Analytical Technology Q46H/79PR User manual

ModelQ46H/79PR
Total Chlorine
Measurement
System
HomeOfficeEuropeanOffice
AnalyticalTechnology,Inc.ATI(UK) Limited
6Iron BridgeDriveUnit 1&2GateheadBusiness Park
Collegeville, PA 19426Delph NewRoad, Delph
SaddleworthOL3 5DE
Ph: 800-959-0299Ph: [phone]
610-917-0991
Fax: [phone]Fax: + 44(0) 1457-874-468
Email: [e-mail]:[e-mail]

PRODUCT WARRANTY
AnalyticalTechnology,Inc.(Manufacturer) warrantstothe Customerthatifanypart(s)
ofthe Manufacturer's equipmentprovestobe defectiveinmaterialsorworkmanship
withinthe earlierof18 monthsof the dateof shipmentor12monthsof the dateofstart-
up,suchdefectivepartswillbe repaired orreplacedfreeofcharge.Inspectionand
repairstoproductsthoughttobe defectivewithinthewarrantyperiodwillbe completed
atthe Manufacturer's facilitiesinCollegeville,PA. Productson whichwarrantyrepairs
arerequired shall be shippedfreight prepaidtothe Manufacturer. The product(s)willbe
returnedfreightprepaidandallowed ifitisdeterminedbythe manufacturerthatthe
part(s)failed duetodefectivematerialsorworkmanship.
Thiswarrantydoesnotcoverconsumableitems,batteries,orwearitemssubject
toperiodicreplacement includinglampsandfuses.
Gassensorscarrya12 monthsfromdateofshipmentwarrantyandaresubject
toinspectionforevidenceofmisuse,abuse,alteration,improperstorage,orextended
exposuretoexcessivegasconcentrations.Shouldinspection indicatethatsensors
havefailed duetoanyoftheabove, the warrantyshall notapply.
TheManufacturerassumesnoliabilityforconsequentialdamagesofanykind,
and thebuyerbyacceptanceofthisequipmentwill assumeall liabilityforthe
consequencesofitsuseormisusebythe Customer, hisemployees, orothers. A defect
withinthe meaningofthiswarrantyisanypartofanypieceofaManufacturer's product
whichshall,when suchpartiscapableof beingrenewed,repaired,orreplaced,operate
tocondemnsuchpieceofequipment.
Thiswarrantyisinlieu ofall otherwarranties(includingwithoutlimitingthe
generalityofthe foregoingwarrantiesofmerchantabilityand fitness foraparticular
purpose),guarantees,obligationsorliabilitiesexpressed orimplied bythe Manufacturer
oritsrepresentativesand bystatuteorruleoflaw.
Thiswarrantyisvoidifthe Manufacturer's product(s)hasbeensubjecttomisuse
orabuse,orhasnotbeen operatedorstoredinaccordancewithinstructions,orifthe
serialnumberhasbeenremoved.
AnalyticalTechnology, Inc. makesnootherwarrantyexpressed orimpliedexcept
asstated above

ATIQ46H/79PRChlorine Manual TableOf Contents
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Table of Contents
PART1- INTRODUCTION................................. 5
1.1 General...................................................... 5
1.2 Standard System....................................... 5
1.3 Features..................................................... 9
1.4 Q46H/79PRSystemSpecifications.........11
1.5 Q46H-79PRPerformance Specifications.13
PART2–ANALYZERMOUNTING.................14
2.1 General.....................................................14
2.2 Wall or PipeMount..................................15
2.3 Panel Mounting........................................17
PART3–SENSOR/FLOWCELLMOUNTING18
3.1 General.....................................................18
3.2 Constant-HeadFlowcell...........................18
3.3 SealedFlowcell........................................19
3.4 SubmersionMounting..............................21
PART4–ELECTRICALINSTALLATION......22
4.1 General.....................................................22
4.2 Power Connection....................................23
4.3 Direct Sensor Connection ........................27
4.4 Sensor Wiring ..........................................28
4.5 JunctionBoxConnection.........................29
4.6 Optional pHSensor Input........................30
PART5–SENSORASSEMBLY.........................31
5.1 ChlorineSensor Preparation....................31
5.2 Optional pHSensor..................................33
PART6–CONFIGURATION.............................34
6.1 User Interface...........................................34
6.11 Keys.........................................................35
6.12 Display.....................................................35
6.2 Software...................................................37
6.21 SoftwareNavigation...............................37
6.22 MeasureMenu [MEASURE]...................40
6.23 CalibrationMenu [CAL].............................41
6.24 ConfigurationMenu[CONFIG]..............42
6.25 ControlMenu[CONTROL]....................48
6.26 DiagnosticsMenu[DIAG].........................54
PART7–CALIBRATION...................................59
7.1 ChlorineCalibration.................................59
7.11 ChlorineZero Cal....................................59
7.12 ChlorineSpanCal....................................60
7.2 TemperatureCalibration ..........................62
7.3 pHCalibration..........................................63
7.31 Two-PointpHCal....................................64
7.32 One-PointpHCal.....................................65
PART8–PIDCONTROLLERDETAILS.........66
8.1 PIDDescription.......................................66
8.2 PIDAlgorithm.........................................66
8.3 Classical PIDTuning ...............................68
8.4 ManualPIDOverrideControl..................69
8.5 CommonPIDPitfalls...............................69
PART9–SYSTEMMAINTENANCE................71
9.1 General.....................................................71
9.2 Analyzer Maintenance.............................71
9.3 Sensor Maintenance.................................71
9.4 Sensor AcidCleaning..............................72
9.5 Q22PSensor Cleaning.............................73
9.6 ReplacingtheSaltbridgeandReference
Buffer Solution..........................................74
9.7 FlowCell Maintenance............................75
PART10 –TROUBLESHOOTING....................76
10.1 General.....................................................76
10.2 External SourcesofProblems..................76
10.3 Analyzer Tests.........................................78
10.4 DisplayMessages....................................79
10.5 Sensor Tests.............................................81
10.6 Troubleshooting(Q22PSensor)...............83
SPAREPARTS......................................................84

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Table of Figures
FIGURE 1-TYPICAL MONITORING SYSTEM.....................................................................................6
FIGURE 2-CHLORINE SYSTEMW/OPTIONALPHBAYONET STYLE SENSOR ......................................7
FIGURE 3-SEALED FLOWCELL ASSEMBLIES W/FLOW CONTROL......................................................8
FIGURE 4-Q46 ENCLOSURE DIMENSIONS ...................................................................................14
FIGURE 5-WALLOR PIPE MOUNT BRACKET ................................................................................15
FIGURE 6-WALL MOUNTING DIAGRAM ........................................................................................16
FIGURE 7-PIPE MOUNTING DIAGRAM..........................................................................................16
FIGURE 8-PANEL MOUNT CUTOUT &DIAGRAM ...........................................................................17
FIGURE 9-CONSTANT HEAD FLOWCELL DETAILS.........................................................................18
FIGURE 10 -SEALED CHLORINE FLOWCELL DIMENSIONS ..............................................................19
FIGURE 11 -SEALED PHFLOWCELL DETAILS ...............................................................................20
FIGURE 12 -SUBMERSIBLE SENSOR MOUNTING ...........................................................................21
FIGURE 13 -LINE POWER CONNECTION .......................................................................................24
FIGURE 14 -OPTIONAL RELAY BOARD WIRING .............................................................................25
FIGURE 15 -OPTIONAL RELAY BOARD WIRING .............................................................................26
FIGURE 16 -OPTIONAL ANALOG OUTPUT WIRING.........................................................................26
FIGURE 17 -SENSOR CABLE PREPARATION .................................................................................27
FIGURE 18 -DIRECT SENSOR CONNECTION .................................................................................28
FIGURE 19 -JUNCTION BOX INTERCONNECT WIRING ....................................................................29
FIGURE 20 -FLOW STYLE SENSOR ASSEMBLY .............................................................................31
FIGURE 21 -SUBMERSIBLE STYLE SENSOR ASSEMBLY .................................................................32
FIGURE 22 -USER INTERFACE.....................................................................................................34
FIGURE 23 -SOFTWARE MAP ......................................................................................................39
FIGURE 24 -AUTOMATIC PHBUFFER TABLES...............................................................................47
FIGURE 25 -CONTROL RELAY EXAMPLE ......................................................................................52
FIGURE 26 -ALARM RELAY EXAMPLE ..........................................................................................53
FIGURE 27 -ISA (IDEAL)PID EQUATION ......................................................................................67
FIGURE 28 -REPLACINGTHE SALTBRIDGE AND REFERENCE BUFFER ............................................74
FIGURE 29 -DISPLAY MESSAGES ................................................................................................79
FIGURE 30 -DISPLAY MESSAGES (CONT'D)..................................................................................80
FIGURE 31 -PT100 RTD TABLE ..................................................................................................82

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Part 1 - Introduction
1.1General
TheModelQ46H/79PRisahighlyversatileon-line monitoringsystemdesigned
forthecontinuousmeasurementoftotalchlorine insolution.Thefull scale
operatingrangeofthe systemmaybe selected bythe userfor0-200.0ppb,0-
2.000ppm,0-20.00ppm,or0-200.0ppm,and the sensingsystemwilloperate
on waterstreamswithtemperaturesrangingfrom0to55°C.TheQ46H/79PR
TotalChlorineMeasurementSystemiswellsuitedforpotablewatersystems,
activated carbonfilterbreak-throughdetection,and formonitoring wastewater
treatment effluents.
Thebasicsensingelementusedinthetotalchlorine monitorisa3electrode
amperometricmembrane sensorwhichmeasureschlorine directly.Watersimply
flowspastthesensorand directlytodrain,withthe flowrateand pressureacross
the sensorcontrolledbyaconstanthead flowcell assembly.The chlorine
measurementdoesnotalterthe sampleoraddanychemicalstothesample
stream, sothewaterflowcan returntothe systemif desired.
Q46H/79PRMonitorsareavailableintwobasicelectronicversions,a90-260
VACpowered monitor,ora12-24VDC powered monitor–bothwiththreerelays
and two4-20 mAanalogoutputs.Bothversionsallowflexibleoutputoptions
whichinclude additional4-20 mAcurrentoutputs,additional0-30VDC signal
relays, PIDcontrol,anddigitalcommunicationcards.
Inaddition tonormalchlorine measurement,the Q46H/79PRisalsoavailable
withan optionalpHinputwhichprovidesatwo-parametermonitoringsystem.
Bothcombinedchlorine andpHaredisplayed simultaneously.
1.2Standard System
ThestandardmodelQ46H/79PRsystemincludesthree maincomponents,the
Q46Hanalyzer,aconstantheadflowcell,and atotalchlorinesensor.Alow-
volumeflowcell isalsoavailableforapplicationswheresampleflowrateand
pressurecanbecarefullycontrolled.Figure2showsatypicalinstallation
includingtheoptionalpHsensor.
Forconnectionofthe sensortotheelectronics,a25'cableissupplied.An
additional100feetofinterconnectcablemaybe added using#07-0100junction
box.All required sparepartsarealsoprovided withthe basicsystem,including
sparemembranes,electrolyte, o-rings, and anyspecialhardware.

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Notethatstandard25footsensorcablesforbothchlorineandoptionalpH
sensorscanbe cuttoashorterlength.Cuttingthe cableswill notaffect
performance,andelimination ofextracablecan sometimeseliminateelectrical
noisepickup throughthe cables.
Figure1-Typical MonitoringSystem

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Figure2belowshowsthe samestandardflowcell assemblyand chlorine sensor
alongwiththe conventionaltype pHsensor.A specialadapterisrequired tohold
the pHsensorinitsproperlocationinthe flowcell inlet chamber.
Figure2-ChlorineSystemw/Optional pH Bayonet StyleSensor

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Figure3belowshowsan installationusinga00-1522sealed flowcell forthechlorine
sensorand a00-1527sealedflowcell forthe pHsensor.Thistype ofinstallation
requirescarefulflowcontrol.Werecommend theuseofour03-0372flowcontrol
assemblywhen usingsealed flowcells.Thisassemblyconsistsofanin-line filteranda
fixed-flowregulatorwhichwill maintainaconstant400 cc/minflowratethroughthe
system.Thisflowwill be maintained solongasinletpressuresarebetween 5and 125
PSIG. The in-line filterisused mainlytoprotectthe flowcontrolelementagainstlarger
particlesthatmight causepluggingofthedevice.
Figure3-Sealed Flowcell Assemblies w/FlowControl

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1.3Features
·StandardQ46H/79PRanalyzershavefullyisolatedinputsandoutputs.Analog
outputsareadditionallycompletelyisolatedfromeachother.
·Availableineither90-260 VACor12-24 VDC powersupplysystems.All features
remainthesameinbothvariations.
·Highaccuracy,highsensitivitysystem,measuresfrom0.1ppb to200.0ppm
through4internalautomaticranges.Userrangesof200.0ppb,2.000ppm,
20.00ppm, or200.0ppm.
·OutputHold,OutputSimulate,OutputAlarm,andOutputDelayFunctions.All
forced changesinoutputconditioninclude bumpless transfertoprovide gradual
returntoon-line signallevelsand toavoidsystemcontrolshocks onbothanalog
outputs.
·Three6ampSPDTrelayoutputsandtwoanalog4-20 mAoutputsarestandard.
Softwaresettingsforrelaycontrolincludesetpoint,deadband,phase,delay,and
failsafe.An optional3-relaycard,for0-30VDC signals,isavailabletobringthe
totalto6relays.
·SelectablePIDcontrolleron mainanalogoutput. PIDcontrollercanoperatewith
instrumentconfigured asloop-powertransmitter,orasone ofthe twooutputson
the ACpowered instrument. PIDincludesmanualoperation feature,and
diagnostic“stuck-controller” timerfeatureforrelaynotificationofcontrol
problems.
·Digitalcommunication optionsforProfibus-DP, ModbusRTU.Moreversions
pending. SeeQ46DigitalCommunicationsManualforSpecifications.
·OptionalpHsensorfeatureenablesactivepHmeasurement withthe Q46H/79PR
monitor.The pHreadingcan alsobe senttoone oftheanalog outputsfor
completepH+chlorinemonitoring.
·Twoanalogoutputsonthe relayversion maybe configured totrackchlorine and
temperature,chlorine and chlorine,orchlorine and pH.Bothanalogoutputscan
be individuallyprogrammed tofail tospecificvalues.
·SelectableOutputFail AlarmfeatureonRelayBallowssystemdiagnostic
failurestobesent toexternalmonitoringsystems.

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·Large,highcontrast, customSuper-Twistdisplayprovidesexcellentreadability
even inlowlightconditions.Thesecondaryline ofdisplayutilizes5x7dotmatrix
charactersforclearmessagedisplaytwooffourmeasured parametersmaybe
on the displaysimultaneously.
·Diagnosticmessagesprovide acleardescription ofanyproblemwithno
confusingerrorcodestolookup.Messagesarealsoincluded fordiagnosing
calibration problems.
·Quick and easyone-pointcalibrationmethodand sensorzero-cal.Toprovide
highaccuracy,all calibration methodsinclude stabilitymonitorsthatcheck
temperatureand mainparameterstabilitybeforeacceptingdata.
·Highaccuracythree-wirePt100temperatureinput.Temperatureelementcanbe
usercalibrated.
·Securitylock featuretopreventunauthorized tamperingwithtransmittersettings.
All settingscanbeviewed whilelocked,buttheycannot bechanged.

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1.4Q46H/79PRSystemSpecifications
DisplayedParameters Maininput, 0.1ppb(0.0001 ppm)to200.0ppm
Sensortemperature,-10.0to55.0°C (23 to131 ºF)
Sensor Current, 0.0–999.9nA, 0.000to99.99uA
Loop current, 4.00 to20.00 mA
Sensor slope/offset
Modelnumberand softwareversion
PIDController Status
OptionalpH Input value.0.00 to14.00 pH
MainParameterRanges Manualselection of one ofthe followingranges,
0.000 to200.0ppb
0.0to2.000 ppm
0.00 to20.00 ppm
0.00 to200.0ppm
Display 0.75”(19.1mm)high4-digit maindisplaywithsign
12-digitsecondarydisplay,0.3"(7.6mm)5x7dot
matrix. IntegralLEDback-light forvisibilityinthe dark.
Keypad 4-keymembranetype withtactilefeedback, polycarbonate
withUV coating
Weight DC transmitterconfiguration:1lb.(0.45kg)
Line powered unit:1.5lb.(0.68 kg)
Ambient Temperature Analyzer Service, -20 to60 °C (-4to140 ºF)
Sensor Service,-5to55°C(23 to131°F)
Storage,-5to70°C (-22to158 ºF)
Ambient Humidity 0to95%,indoor/outdooruse,non-condensingtorated
ambienttemperaturerange
Altitude Upto2000m(6562 Ft.)
ElectricalCertification OrdinaryLocation,cCSAus (CSA and ULstandards -both
approved byCSA), pollution degree 2,installation category
2
EMI/RFIInfluence Designed toEN 61326-1
OutputIsolation 600 Vgalvanicisolation
Filter Adjustable0-9.9minutesadditionaldamping to90%step
input

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TemperatureInput Pt100 RTDwithautomaticcompensation
Sensor 3-electrodeamperometricmembranesensorfordirect
measurement of chlorine
SensorMaterials PVC
SensorCable 25 ft.(7.5meter)cablewith6-pinplug.
Max.Sensor-to-Analyzer
Distance 100 feet(30.5meters), withjunction box
OptionalpH Input 0-14 pH corresponding toapprox. 0.3–1.5VDC
FlowCell Constanthead overflow,clear cast acrylic, 7-30GPH, 15
GPH recommended,inlet is¼”hosebarbat1/8”MNPT,
outlet is½” hosebarbat 3/8”MNPT
Power 90 -260 VAC,50-60Hz, 10 VA max
12-24 VDC,500 mAmax.
Enclosure NEMA4X,polycarbonate, stainless steelhardware,
weatherproofandcorrosion resistant,
HWD:4.9"(124 mm)x4.9"(124mm)x5.5"(139 mm)
Mounting Options Wall orpipe mountbracketstandard.Bracketsuitablefor
either 1.5”or2”I.D. U-Boltsfor pipemounting.
Panelmountadapter optional.
Conduit Openings Five½” NPTopenings, Adaptercan beremoved to
provide a1” NPTopening inthebottom ofthe enclosure.
Gland sealsprovided butnotinstalled.
Relays, Electromechanical: Three SPDT,6amp@250 VAC, 5amp@24VDC
contacts.Softwareselection for setpoint, phase, delay,
deadband, hi-loalarm, and failsafe.A-Bindicatorson
mainLCD,and Cindicator onlower display.
OptionalRelays: Three additionalnon-isolated lowpower relaysavailable.
SPST,1amp@30 VDC
Analog Outputs Two4-20 mAoutputs.Outputone programmablefor PPM
chlorine orPID. Output 2programmableforPPMchlorine,
Temperature, or pH.Maxload 500 Ohmsfor eachoutput.
Outputsgroundisolated and isolated from each other.An
additional3rd analogoption isavailable.

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1.5Q46H-79PRPerformance Specifications
Accuracy 1.0%of selectedrangeor 0.05 PPM
Repeatability 0.5%of selectedrangeor 0.02 PPM
Sensitivity 0.1%of selectedrange
Non-linearity 0.1%of selectedrange
Warm-up Time 3secondstorated performance (electronics only)
SupplyVoltageEffects ± 0.05%span
InstrumentResponse Time 60 secondsto90%of step input at lowest damping
Equipmentbearingthismarkingmaynotbe discardedbytraditional
methodsintheEuropeancommunityafterAugust12 2005 perEU
Directive2002/96/EC.End usersmustreturnoldequipmenttothe
manufacturerforproperdisposal.

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Part 2 – AnalyzerMounting
2.1General
All Q46 Seriesinstrumentsoffermaximummountingflexibility.Abracketis
includedwitheachunitthatallowsmountingtowallsorpipes.Inall cases,
choosealocation thatisreadilyaccessibleforcalibrations.Alsoconsiderthatit
maybe necessarytoutilizealocation wheresolutionscanbeused duringthe
calibration process.Totakefull advantageofthe highcontrastdisplay,mount
the instrumentinalocation wherethe displaycan be viewed fromvariousangles
and longdistances.
Locatethe instrumentincloseproximitytothe pointofsensorinstallation -this
will alloweasy access duringcalibration.Thesensor-to-instrumentdistance
shouldnotexceed 100feet.Tomaximizesignal-to-noiseratio,however,work
withthe shortestsensorcablepossible.Thestandardcablelengthofthe
chlorine sensoris25feet.
Figure4-Q46 EnclosureDimensions

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2.2Wallor PipeMount
APVCmountingbracketwithattachmentscrewsissuppliedwitheach
transmitter(seeFigure5fordimensions).Themulti-purposebracketisattached
tothe rearoftheenclosureusingthe fourflathead screws.The instrumentis
then attachedtothewall using the fouroutermountingholesinthe bracket.
Theseholesareslottedtoaccommodatetwosizesofu-boltthatmaybe used to
pipe mount the unit. Slotswill accommodateu-boltsdesigned for1½“or2”pipe.
Theactualcentertocenterdimensionsforthe u-boltsareshowninthe drawing.
Notethattheseslotsareforu-boltswith¼-20 threads.The1½” pipe u-bolt(2”
I.D.clearance)isavailablefromATIintype 304 stainlesssteelunderpart
number(47-0005). SeeFigures6and 7formountingdiagrams.
Figure5-WallorPipe Mount Bracket

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Figure6-WallMounting Diagram
Figure7-Pipe Mounting Diagram

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2.3Panel Mounting
Panelmountingusesthe panelmountingflangemoldedintothe rearsection of
the enclosure.Figure8providesdimensionsforthepanelcutoutrequired for
mounting.
Thepanelmountingbracketkitmustbe ordered separately(partnumber05-
0094).Thiskitcontainsametalretainerbracketthatattachestothe rearofthe
enclosure,4screwsforattachmentofthisbracket, and asealinggaskettoinsure
thatthe panelmountedmonitorprovidesawatertightsealwhen mountedtoa
panel.
Thesealinggasket mustfirst beattachedtothe enclosure. Thegasket contains
an adhesiveonone side sothat it remainsinplaceon theenclosure. Remove
the protectivepaperfromthe adhesiveside ofthegasketandslidethe gasket
overthe back of theenclosuresothat theadhesiveside linesupwiththe back of
the enclosureflange. Onceinplace, you can proceedtomount the monitorin
the panel.
Figure8-PanelMount Cutout & Diagram

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Part 3–Sensor/Flowcell Mounting
3.1General
Selectalocation withinthe maximumsensorcablelengthformountingofthe
sensorflowcell.
3.2Constant-HeadFlowcell
Chlorine sensorsarebestused inaconstant-headoverflowchamberbecause
variationsinsampleflowrateand pressurecan causeunstablereadings.When
monitoringlowconcentrations(below0.5PPM),thismethodshouldalwaysbe
used.
Mechanicalinstallation ofthe flowcell requiresthatit bemountedtoawall or
otherconvenientflatsurface.Alternatively, the mountingholesonthe platewill
accommodatea2"U-boltformountingtheplatetoa2" pipe.Figure9 -Constant
HeadFlowcell Details
showsthe dimensionsand mountingholelocationsfortheflowcell.Besureto
allowenoughclearanceontheleftside oftheflowcell forinsertion and removal
ofthesensor. About12inchesclearanceisrecommended.
Figure9-Constant HeadFlowcell Details

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Oncemounted,inletand drainconnectionsmustbe made.The flowcell
containsa1/8"MNPTinletconnection anda3/8"MNPTdrainconnection.Hose
barbsfortheinletanddrainconnectionsaresupplied withthe flowcellforuse
withflexibletubing.The inlethosebarbisused with¼"I.D.tubingand the drain
hosebarbisusedwith½"I.D. tubing.
3.3SealedFlowcell
Applicationswherethesampleinletflowiswell controlled can useasimpler
sealed flowcell.Usingthisflowcell requiresthatsampleflowbe controlled
externallytoabout400 cc/min.usingpressureregulatorsand needlevalves.
Variableflowrateorvariablepressurewill causeunstablereadingsinthis
flowcell.ATIoffersaspecialflowcontrolelementthatcanbe used ahead ofthis
flowcell ontheincoming sampleline.Theflowcontrolassyispartno.(03-0372).
It will controlthe inlet flowrateat 400 cc/min.withinlet pressurevariationsfrom5-
150PSIG. A50micron y-strainerahead oftheflowcontrolelementis
recommended.
Figure10- Sealed Chlorine Flowcell Dimensions

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Figure11- Sealed pHFlowcell Details