Analytical Technology Q45D User manual

Model Q45D
Auto-Clean
Optical D.O. Monitor
System
(Q45D SOFTWARE VERSIONS 4.02 AND HIGHER)
Home Office EuropeanOffice
Analytical Technology, Inc. ATI (UK) Limited
6 Iron Bridge Drive Unit 1 & 2 Gatehead Business Park
Collegeville, PA 19426 Delph New Road, Delph
Saddleworth OL3 5DE
Ph:[phone] Ph: 0800-018-4020
[phone] + 44 (0) 1457-873-318
Fax: [phone] Fax: + 44 (0) 1457-874-468
Email: [email protected] Email:[email protected]

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PRODUCT WARRANTY
Analytical Technology, Inc. (Manufacturer) warrants to the Customer that if any
part(s) of the Manufacturer's products proves to be defective in materials or
workmanship within the earlier of 18 months of the date of shipment or 12
months of the date of start-up, such defective parts will be repaired or replaced
free of charge. Inspection and repairs to products thought to be defective within
the warranty period will be completed at the Manufacturer's facilities in
Collegeville, PA. Products on which warranty repairs are required shall be
shipped freight prepaid to the Manufacturer. The product(s) will be returned
freight prepaid and allowed if it is determined by the manufacturer that the part(s)
failed due to defective materials or workmanship.
This warranty does not cover consumable items, batteries, or wear items subject
to periodic replacement including lamps and fuses.
Gas sensors, except oxygen sensors, are covered by this warranty, but are
subject to inspection for evidence of extended exposure to excessive gas
concentrations. Should inspection indicate that sensors have been expended
rather than failed prematurely, the warranty shall not apply.
The Manufacturer assumes no liability for consequential damages of any kind,
and the buyer by acceptance of this equipment will assume all liability for the
consequences of its use or misuse by the Customer, his employees, or others. A
defect within the meaning of this warranty is any part of any piece of a
Manufacturer's product which shall, when such part is capable of being renewed,
repaired, or replaced, operate to condemn such piece of equipment.
This warranty is in lieu of all other warranties (including without limiting the
generality of the foregoing warranties of merchantability and fitness for a
particular purpose), guarantees, obligations or liabilities expressed or implied by
the Manufacturer or its representatives and by statute or rule of law.
This warranty is void if the Manufacturer's product(s) has been subject to misuse
or abuse, or has not been operated or stored in accordance with instructions, or if
the serial number has been removed.
Analytical Technology, Inc. makes no other warranty expressed or implied except
as stated above.

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Table of Contents
Part 1 - Introduction..................................................3
1.1 General...........................................................3
1.2 Standard System............................................3
1.3 Features .........................................................4
1.4 Q45D/60D Optical Auto-Clean System
Specifications ........................................................7
1.5 Q45D Performance Specifications .................8
Part 2 – Mechanical Installation ...............................9
2.1 General............................................................9
2.2 Wall Mount .....................................................9
2.3 Railing Mount ................................................11
Part 3 – Electrical Installation.................................14
3.1 General.........................................................14
3.2 Connections .................................................14
3.3 Relay Wiring .................................................16
Part 4 – Optical D.O. Sensor..................................17
4.1 General.........................................................17
4.2 Optical Sensing ............................................18
Part 5 – Operation..................................................19
5.1 User Interface...............................................19
5.11 Keys ...........................................................20
5.12 Display........................................................20
5.2 Software .......................................................22
5.21 Software Navigation ...................................22
5.22 Measure Menu [MEASURE]........................26
5.23 Calibration Menu [CAL] ...............................27
5.25 Control Menu [CONTROL] ..........................31
5.26 Diagnostics Menu [DIAG] ............................38
Part 6 – Calibration ................................................42
6.1 General ........................................................ 42
6.2 D.O. Span Cal (1-spl)................................... 42
6.3 Dissolved Oxygen Span Air Cal (%-sat) ...... 44
6.4 Dissolved oxygen Zero Cal .......................... 45
6.5 Temperature Calibration .............................. 47
Part 7 – Sensor Cleaning System.......................... 48
7.1 General ........................................................ 48
7.2 Cleaner Sequence ....................................... 49
7.3 Cleaner Malfunction Alarm (Optional).......... 49
Part 8 – PID Controller Details............................... 51
8.1 PID Description............................................ 51
8.2 PID Algorithm............................................... 51
8.3 Classical PID Tuning.................................... 54
8.4 Manual PID Override Control........................ 54
8.5 Common PID Pitfalls.................................... 54
Part 9 – System Maintenance................................ 56
9.1 General ......................................................... 56
9.2 Analyzer Maintenance .................................. 56
9.3 Sensor Maintenance..................................... 56
Part 10 – Troubleshooting ..................................... 57
10.1 General ....................................................... 57
10.2 External Sources of Problems .................... 57
10.3 Analyzer Tests ............................................ 58
10.31 Display Messages..................................... 59
10.4 Sensor Tests............................................... 61
Spare Parts............................................................ 65

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Table of Figures
Figure 1 - D.O. System w/Auto-Clean Sensor ..................................................................6
Figure 2 - Monitor Assembly Wall Mount Dim.................................................................10
Figure 3 - Handrail Mounting Assembly..........................................................................11
Figure 4 - Submersible Sensor Mounting Assembly.......................................................12
Figure 5 - Mounting Assembly Detail..............................................................................13
Figure 6 - D.O. Monitor Electrical Connections...............................................................15
Figure 7 - Relay Contacts ...............................................................................................16
Figure 8 - Submersible S.O. Sensor Assembly...............................................................17
Figure 9 - Optical Sensing Element ................................................................................18
Figure 10 - User Interface...............................................................................................19
Figure 11 - Software Map................................................................................................24
Figure 12 - Control Relay Example.................................................................................35
Figure 13 - Alarm Relay Example...................................................................................36
Figure 14 - Cleaner Failure & Jumper Map Config .........................................................50
Figure 15 - Q45D ISA (Ideal) PID Equation....................................................................52
Figure 16 - Q45D Display Messages..............................................................................60
Figure 17 - Pt1000 RTD Table........................................................................................62
Figure 18 - Reference - Barometric Pressure Conversion..............................................63
Figure 19 - Reference - Oxygen Solubility Table............................................................64

ATI Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction
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Part 1 - Introduction
1.1 General
The Model Q45D is a highly versatile dissolved oxygen
instrument designed for the measurement of dissolved
oxygen in solution. The full scale operating range of the
system is 0-40.0 ppm and the sensing system will operate
on water streams with temperatures from 0 to 50°C.
The Q45D monitor is designed to use either a galvanic
membrane sensor or an optical oxygen sensor. While
the sensor technology is different for each type, the basic
monitoring system remains the same. This manual relates
specifically to the operation of a D.O. system utilizing the
optical sensor equipped with an automatic air blast sensor
cleaning system. As the majority of applications for D.O.
measurement are in wastewater aeration systems, this
cleaning system is the key element that insures long-term
reliable measurement. Figure 1 shows a typical Auto-Clean
D.O. system with necessary interconnections.
1.2 Standard System
The Model Q45D/60D Auto-Clean system includes two main
components, a NEMA 4X electronics unit and a submersible
D.O. sensor assembly with cleaner nozzle. For special
applications, the cleaner system can be supplied separate
from the D.O monitor electronics to allow the D.O. readout to
be mounted remote from the sensor and cleaner.
Submersible sensors are design for direct immersion in an
aeration tank or flowing stream. A 25 ft. cable is potted into
the top section of the sensor assembly, and connects
directly to the D.O. monitor, or to an intermediate junction
box if required. A separate tubing connection located at the
top of the sensor assembly is provided for connection of a
30-foot length of plastic tubing (supplied with the unit)
between the sensor and the monitor. A typical system is
shown in Figure 1.
The D.O. sensor assembly is mounted to a 1" pipe using a
special mounting adapter supplied with the system. The 1"
pipe is attached to the tank handrail with a bracket assembly
that holds the sensor at a slight angle in the tank.

ATI Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction
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Once installed and placed into operation, the Auto-Clean
system will provide months of reliable D.O. measurement in
almost any application. Sensors should be checked for
build-up after the first 3 months to verify that the cleaner is
keeping the optical element clean. Optical D.O. sensors
require virtually no maintenance other than cleaning, so a
quick visual inspection every 6 months or so should be all
that’s needed.
The automatic sensor cleaning frequency is programmable,
and units are shipped with a default cleaning frequency of
once every 24 hours. This frequency has proven sufficient
for most aeration applications, but can be increased if
needed for a specific application. A cleaning frequency of
more than every 2 hours is not recommended. Contact your
ATI representative for more information if a 2-hour cleaning
cycle does not keep the sensor clean
1.3 Features
- Standard main module is designed to be a fully isolated, line
powered instrument. Protected from surge and brownout.
-High accuracy, high sensitivity system, measures from 0.01
ppm to 40.0 ppm through 2 internal automatic ranges.
- Output Hold, Output Simulate, Output Alarm, and Output
Delay Functions. All forced changes in output condition
include bumpless transfer to provide gradual return to on-line
signal levels and to avoid system control shocks on both
analog outputs.
- One SPDT relay and two isolated analog outputs. Software
settings for relay control include setpoint, deadband, phase,
delay, and failsafe.
- Selectable PID controller on main analog output. PID
includes manual operation feature, and diagnostic “stuck-
controller” timer feature for relay notification of control
problems.
- Two analog outputs may be configured to track dissolved
oxygen and temperature, or dissolved oxygen and dissolved
oxygen. Both analog outputs can be individually
programmed to fail to specific values.

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- Large, high contrast, custom Super-Twist display with LED
backlight provides excellent readability even in low light
conditions. A secondary line of display utilizes 5x7 dot
matrix characters for clear message display. Two measured
parameters may be on the display simultaneously.
- Diagnostic messages provide a clear description of any
problem with no confusing error codes to look up. Messages
are also included for diagnosing calibration problems.
- Quick and easy one-point sample calibration method, air
calibration method, and sensor zero-cal. To provide high
accuracy, all calibration methods include stability monitors
that check temperature and main parameter stability before
accepting data.
- High accuracy Pt1000 temperature input. Temperature
element can be user calibrated.
- Security lock feature to prevent unauthorized tampering with
transmitter settings. All settings can be viewed while locked,
but they cannot be changed.
- High reliability, microprocessor-based system with non-
volatile memory. Low mass, surface mount PCB construction
containing no adjustment potentiometers. All factory
calibrations stored in non-volatile EEPROM.

ATI Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction
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Series Q45
Auto-Clean Monitor
Figure 1 - D.O. System w/Auto-Clean Sensor

ATI Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction
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1.4 Q45D/60D Optical Auto-Clean System Specifications
Displayed Parameters Main input, 0.00 to 40.00 ppm or mg/L.
%Saturation, 0 to 999%
Sensor temperature, 0 to 50.0 °C (32 to 122 ºF)
Sensor Signal -40 to +2000 mVDC
Output Values, 4 to 20 mA DC, Out #1/#2
Sensor slope/offset
PID controller status
Model number and software version
Display Large, high-contrast, Super-Twist with backlight;
4-digit main display with sign, 0.75" (19.1 mm)
seven-segment characters;
12-digit secondary display, 0.3" (7.6 mm) 5x7 dot
matrix characters
Keypad 4-key membrane type with tactile feedback,
polycarbonate with UV coating, integral EMI/static
shield and conductively coated window
Enclosure NEMA 4X, IP65 noryl, stainless steel hardware,
weatherproof and corrosion resistant.
Mounting Options Wall mounted electronic enclosure, Optional
handrail mounting brackets.
Conduit Openings Five cordgrip cable entries provided.
Weight Electronics Assembly: 15 lbs. (6.8 kg)
Sensor Assembly: 3.5 lbs. (1.58 kg.)
Ambient Temperature Analyzer Service, -20 to 60 °C (-4 to 140 ºF)
Sensor Service, -5 to 55°C (23 to 131 °F)
Storage, -5 to 70 °C (-22 to 158 ºF)
Ambient Humidity 0 to 95%, non-condensing
Altitude Up to 2000 m (6562 ft.)
Location Designed for non-hazardous areas
EMI/RFI Influence Designed to EN 61326-1
Output Isolation 600 V galvanic isolation
Filter Adjustable 0-9.9 minutes additional damping to
90% step input

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Temperature Input Pt1000 RTD for automatic compensation
Sensor Optical oxygen sensor with replaceable sensing
element. Optical element life 3-5 years.
Sensor Materials PVC
Sensor Cable 30 ft. (10 meter) cable. Max sensor-transmitter
distance 100 feet (30 meters) with j-box.
Power 115 or 230 VAC ± 10%, 50/60 Hz, 300 VA Max.
Fuse 6A slow-blow
Relays One SPDT, 6-Amp @250VAC, 5-Amp @24
VDC Software selection for setpoint, phase,
delay, deadband, hi-lo alarm, and failsafe.
Indicators on main LCD.
Analog Outputs Dual 4-20 mA current loops, 500 Ohms max
Cleaner Air Supply Internal diaphragm compressor with accumulator
Cleaner Fail Relay Optional relay to indicate that cleaner has not
operated for 24 hours
1.5 Q45D Performance Specifications
Accuracy 0.5% of span or better
Repeatability 0.5% of span or better
Sensitivity 0.01 PPM
Non-linearity 0.1% of span
Stability 0.1% of span per 24 hours, non-cumulative
Temperature Drift Span or zero, 0.01% of span/ºC
Warm-up Time 5 minutes to rated performance
Response Time 60 seconds to 90% of step change at lowest
damping setting