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.

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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

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Part 2 – Mechanical Installation
2.1 General
The Q45D Auto-Clean Monitor is housed in a Nema 4X (IP-
65) enclosure. The monitor must be mounted near the
measurement point, with a maximum of 60 feet between the
monitor and the sensor. The standard system is supplied
with a 30 ft. sensor cable and 30 feet of air line tubing.
Monitor enclosure may be mounted to any flat surface like a
wall or plate. A bracket assembly is available (#00-0930) for
mounting the monitor enclosure to aeration handrail
systems. This bracket locates the monitor at a convenient
height for viewing the display and using the controls.
2.2 Wall Mount
Figure 2 shows the dimensions of the electronic assembly
including the hole locations for the enclosure mounting ears.
Note that the enclosure mounting brackets are not installed
at the factory. They are supplied separately and must be
attached using the screws provided. This is done to protect
the brackets against shipping damage.

ATI Q45D/60 Optical Auto-Clean D.O. Monitor Part 2 – Mechanical Installation
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Figure 2 - Monitor Assembly Wall Mount Dim.
Series Q45
Auto-Clean Monitor

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2.3 Railing Mount
Figure 3 shows the mounting assembly used to mount the
electronic monitor to a typical safety handrail that surrounds
many aeration tanks. This bracket assembly consists of
vertical channels attached to the handrail with u-bolts. The
monitor screws to the channels with the 10-32 screws
supplied as part of the kit. U-bolts for 2” diameter handrail
pipe are also supplied.
Figure 3 - Handrail Mounting Assembly
Series Q45
Auto-Clean Monitor

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Figure 4 - Submersible Sensor Mounting Assembly

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Figure 5 - Mounting Assembly Detail

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Part 3 – Electrical Installation
3.1 General
Q45D Auto-Clean D.O. monitors are powered from either
115 or 230 VAC, 50/60 Hz. Monitors can draw up to 3 amps
when the internal air compressor activates as part of the
sensor cleaning system. Normal current draw is less than
0.2 amps when the cleaner is off.
Important Notes:
1. Use wiring practices that conform to all national, state
and local electrical codes. For proper safety as well as
stable measuring performance, it is important that the
earth ground connection be made to a solid ground point
from TB1.
2. Do NOT run sensor cables or instrument 4-20 mA output
wiring in the same conduit that contains AC power wiring.
AC power wiring should be run in a dedicated conduit to
prevent electrical noise from coupling with the
instrumentation signals.
3.2 Connections
All wiring connections are made in the terminal compartment
at the bottom of the monitor. To access the terminal
compartment, loosen the 4 screws holding the cover in place
and set the cover aside. The screws are captive and should
not come completely out of the plastic cover.
AC power should be brought into the enclosure through the
second cordgrip from the left as shown in Figure 6. The left
most cordgrip must remain open as this is the entry used for
the cleaning system air line.
Sensor and 4-20 mA output connections are made to the
terminals in the right side of the terminal compartment as
shown.

ATI Q45D Optical Auto-Clean D.O. Monitor Part 4 – Optical D.O. Sensor
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Figure 6 - D.O. Monitor Electrical Connections
WIRING NOTE: The cable for the optical D.O. sensor contains a “black” wire
that is actually a black shrink tube covering both a blue and
a pink wire. These two wires connect to the same point
designated by black in the above diagram. If the cable is cut
to a shorter length, be sure that both wires are connected to
the terminal marked black.

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A yellow and a grey wire are contained in the cable and
are covered to avoid shorting. If the cable length is
changed, do not strip these two wires.
3.3 Relay Wiring
Relay wiring is done to terminal blocks inside the Q45D
display assembly. This unit actually contains two SPDT
relays, but one of the relays is used to control the activation
of the sensor automatic cleaning system. Relay A is
available for use as either a control relay, an alarm relay, or
as a system failure alarm.
To access the terminals for Relay A, open the front
protective cover of the analyzer. Loosen the 4 corner
screws for the display unit and the front will hinge down. A
terminal block labeled TB3 is accessible. The terminal block
will unplug for wiring convenience, and the circuit board is
screened to indicate the NO, NC and C contacts.
Figure 7 - Relay Contacts

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Part 4 – Optical D.O. Sensor
4.1 General
Optical D.O. sensors are supplied complete and ready to
use. All that’s needed is to make the proper sensor
connections as shown in the previous section.
A rubber boot protects the end of the sensor in transit.
Leave the protective boot in place until the sensor is to be
placed into operation. Removal of the protective boot prior
to submergence may expose the sensing element to
mechanical damage that is not covered by warranty.
Figure 8 - Submersible S.O. Sensor Assembly

ATI Q45D Optical Auto-Clean D.O. Monitor Part 4 – Optical D.O. Sensor
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4.2 Optical Sensing
Optical D.O. measurement employs a technique called
“fluorescence quenching” in order to measure molecular
oxygen. The sensor will respond to oxygen either in the air
or dissolved in water.
A polymer element at the end of the sensor contains an
embedded fluorescent dye. When the element is exposed to
a pulse of light from an internal LED, the material in the
polymer will fluoresce, or emit light at another wavelength.
This light decreases (or is quenched) at a rate proportional
to the amount of oxygen in the polymer. The monitor
measures the rate at which this quenching occurs and
calculates the oxygen concentration based on the
measurement.
Optical oxygen sensors provide the ability to measure
oxygen in stagnant water, and are not affected by certain
kinds of non-biological coatings. However, optical sensors
are affected by biologically active coatings and must be kept
clean. In activated sludge applications, biological films can
have a much lower D.O. concentration on the sensor side of
the film than on the bulk solution side. The automatic air
cleaning system integrated into the Q45D system will
eliminate coating problems by cleaning the sensor on a
regular programmed schedule.
Figure 9 - Optical Sensing Element