Analytical Technology Q45DC User manual

ModelQ45D/DC
Auto-Clean
Optical D.O. Monitor
System
(Q45DSOFTWARE VERSIONS 4.02AND HIGHER)
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] Email:[e-mail]

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PRODUCT WARRANTY
AnalyticalTechnology,Inc.(Manufacturer) warrantstotheCustomerthatifany
part(s)oftheManufacturer's productsprovestobedefectiveinmaterialsor
workmanshipwithinthe earlierof18monthsofthe dateofshipmentor12
monthsofthedateofstart-up,suchdefectivepartswill be repaired orreplaced
freeofcharge.Inspection andrepairstoproductsthoughttobe defectivewithin
the warrantyperiod willbe completed atthe Manufacturer's facilitiesin
Collegeville,PA. Productsonwhichwarrantyrepairsarerequired shall be
shippedfreightprepaidtothe Manufacturer.The product(s)will be returned
freightprepaidandallowed if itisdeterminedbythe manufacturerthatthe part(s)
failed due todefectivematerialsorworkmanship.
Thiswarrantydoesnotcoverconsumableitems,batteries,orwearitemssubject
toperiodicreplacement includinglampsandfuses.
Gassensors,exceptoxygen sensors,arecovered bythiswarranty,butare
subjecttoinspection forevidenceofextended exposuretoexcessivegas
concentrations.Shouldinspectionindicatethatsensorshavebeen expended
ratherthanfailedprematurely, the warrantyshall not apply.
TheManufacturerassumesnoliabilityforconsequentialdamagesofanykind,
and thebuyerbyacceptanceofthisequipmentwillassumeall liabilityforthe
consequencesofitsuseormisusebythe Customer, hisemployees, orothers. A
defectwithinthe meaningofthiswarrantyisanypartofanypieceofa
Manufacturer's productwhichshall,when suchpartiscapableofbeingrenewed,
repaired,orreplaced, operatetocondemnsuchpieceof equipment.
Thiswarrantyisinlieu ofall otherwarranties(includingwithoutlimitingthe
generalityoftheforegoingwarrantiesofmerchantabilityand fitness fora
particularpurpose),guarantees,obligationsorliabilitiesexpressedorimpliedby
the Manufactureroritsrepresentativesandbystatuteorruleof law.
Thiswarrantyisvoidifthe Manufacturer's product(s)hasbeensubjecttomisuse
orabuse, orhasnotbeen operated orstoredinaccordancewithinstructions,orif
the serialnumberhasbeenremoved.
AnalyticalTechnology, Inc. makesnootherwarrantyexpressed orimpliedexcept
asstated above.

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TableofContents
Part 1-Introduction................................................ 3
1.1General......................................................... 3
1.2StandardSystem .......................................... 3
1.3Features........................................................ 4
1.4Q45D/60D OpticalAuto-Clean System
Specifications....................................................... 7
1.5Q45DPerformance Specifications ................ 8
Part 2–MechanicalInstallation.............................. 9
2.1General.......................................................... 9
2.2Wall Mount.................................................... 9
2.3RailingMount............................................... 11
Part 3–Electrical Installation................................ 14
3.1General....................................................... 14
3.2Connections................................................ 14
3.3RelayWiring................................................ 16
Part 4–OpticalD.O.Sensor................................. 17
4.1General....................................................... 17
4.2OpticalSensing........................................... 18
Part 5–Operation................................................ 19
5.1UserInterface............................................. 19
5.11 Keys.......................................................... 20
5.12 Display ...................................................... 20
5.2Software...................................................... 22
5.21 SoftwareNavigation .................................. 22
5.22 MeasureMenu [MEASURE]....................... 26
5.23 Calibration Menu [CAL].............................. 27
5.25 ControlMenu [CONTROL]......................... 31
5.26 DiagnosticsMenu [DIAG]........................... 38
Part 6–Calibration ............................................... 42
6.1General....................................................... 42
6.2D.O.Span Cal (1-spl).................................. 42
6.3Dissolved Oxygen Span Air Cal (%-sat) ...... 44
6.4Dissolved oxygen ZeroCal......................... 45
6.5TemperatureCalibration.............................. 47
Part 7–SensorCleaning System .........................48
7.1General.......................................................48
7.2Cleaner Sequence.......................................49
7.3Cleaner Malfunction Alarm (Optional)..........49
Part 8–PIDController Details..............................50
8.1PIDDescription...........................................51
8.2PIDAlgorithm..............................................51
8.3ClassicalPID Tuning...................................54
8.4ManualPIDOverrideControl........................54
8.5Common PIDPitfalls...................................54
Part 9–System Maintenance ...............................56
9.1General........................................................56
9.2Analyzer Maintenance ..................................56
9.3Sensor Maintenance ....................................56
Part 10–Troubleshooting.....................................57
10.1General......................................................57
10.2ExternalSourcesof Problems....................57
10.3Analyzer Tests............................................58
10.31 DisplayMessages ....................................59
10.4SensorTests..............................................61
SpareParts...........................................................65

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TableofFigures
Figure1- D.O. Systemw/Auto-Clean Sensor................................................................. 6
Figure2- Monitor AssemblyWall MountDim................................................................ 10
Figure3- Handrail Mounting Assembly........................................................................ 11
Figure4- SubmersibleSensor MountingAssembly...................................................... 12
Figure5- MountingAssemblyDetail............................................................................. 13
Figure6- D.O. MonitorElectricalConnections.............................................................. 15
Figure7- Relay Contacts............................................................................................. 16
Figure8- SubmersibleS.O. Sensor Assembly............................................................. 17
Figure9-OpticalSensingElement............................................................................... 18
Figure10 - UserInterface............................................................................................. 19
Figure11 - SoftwareMap.............................................................................................. 24
Figure12 - ControlRelayExample............................................................................... 35
Figure13 - Alarm RelayExample.................................................................................. 36
Figure14 - CleanerFailure&Jumper Map Config........................................................ 50
Figure15 -Q45D ISA (Ideal) PIDEquation................................................................... 52
Figure16 -Q45DDisplayMessages............................................................................. 60
Figure17 - Pt1000 RTD Table...................................................................................... 62
Figure18 - Reference- BarometricPressureConversion ............................................. 63
Figure19 - Reference- OxygenSolubilityTable........................................................... 64

ATI Q45D OpticalAuto-Clean D.O. MonitorPart 1-Introduction
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Part1 - Introduction
1.1General
TheModelQ45Disahighlyversatiledissolved oxygen
instrumentdesigned forthe measurementofdissolved
oxygen insolution.Thefull scaleoperatingrangeofthe
systemis0-40.0ppmand the sensingsystemwill operate
on waterstreamswithtemperaturesfrom0to50°C.
TheQ45Dmonitorisdesigned touseeithera galvanic
membranesensor oran opticaloxygensensor.While
the sensortechnologyisdifferentforeachtype,thebasic
monitoringsystemremainsthesame.Thismanualrelates
specificallytothe operation ofaD.O. systemutilizingthe
opticalsensorequipped withan automaticair blastsensor
cleaningsystem.Asthe majorityofapplicationsforD.O.
measurementareinwastewateraerationsystems,this
cleaningsystemisthekeyelementthatinsureslong-term
reliablemeasurement.Figure1showsatypicalAuto-Clean
D.O. systemwithnecessaryinterconnections.
1.2Standard System
TheModelQ45D/60DAuto-Cleansystemincludestwomain
components,aNEMA4Xelectronics unitandasubmersible
D.O. sensorassemblywithcleanernozzle.Forspecial
applications,thecleanersystemcanbesuppliedseparate
fromtheD.O monitorelectronics toallowthe D.O. readoutto
be mountedremotefromthesensorandcleaner.
Submersiblesensorsaredesignfordirectimmersion inan
aerationtankorflowingstream.A25ft.cableispottedinto
the topsectionofthe sensorassembly,andconnects
directlytothe D.O. monitor,ortoan intermediatejunction
boxifrequired.Aseparatetubingconnectionlocatedatthe
top ofthe sensorassemblyisprovided forconnection ofa
30-footlengthofplastictubing(supplied withthe unit)
between thesensorand the monitor.Atypicalsystemis
showninFigure1.
TheD.O.sensorassemblyismountedtoa1"pipeusinga
specialmountingadaptersupplied withthesystem.The1"
pipe isattachedtothetankhandrail withabracketassembly
thatholdsthesensorat aslight angleinthetank.

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Onceinstalledandplaced intooperation,the Auto-Clean
systemwillprovide monthsofreliableD.O. measurementin
almostanyapplication.Sensorsshouldbe checkedfor
build-up afterthe first3monthstoverifythatthe cleaneris
keepingtheopticalelementclean.OpticalD.O. sensors
requirevirtuallyno maintenanceotherthan cleaning,soa
quick visualinspectionevery6monthsorsoshouldbe all
that’sneeded.
Theautomaticsensorcleaningfrequencyisprogrammable,
and unitsareshippedwithadefaultcleaningfrequencyof
onceevery24 hours.Thisfrequencyhasproven sufficient
formostaerationapplications,butcan beincreased if
neededforaspecificapplication.Acleaning frequencyof
morethanevery2hoursisnotrecommended.Contactyour
ATIrepresentativeformoreinformation ifa2-hourcleaning
cycledoesnot keep thesensorclean
1.3Features
- Standardmainmoduleisdesigned tobeafullyisolated,line
powered instrument. Protected fromsurgeand brownout.
-Highaccuracy,highsensitivitysystem,measuresfrom0.01
ppmto40.0ppmthrough2internalautomaticranges.
-OutputHold,OutputSimulate,OutputAlarm,andOutput
DelayFunctions.Allforcedchangesinoutputcondition
include bumpless transfertoprovide gradualreturntoon-line
signallevelsand toavoidsystemcontrolshocks on both
analogoutputs.
-One SPDTrelayand twoisolated analogoutputs.Software
settingsforrelaycontrolinclude setpoint,deadband,phase,
delay, andfailsafe.
-SelectablePIDcontrolleron mainanalog output. PID
includesmanualoperation feature,anddiagnostic“stuck-
controller” timerfeatureforrelaynotification ofcontrol
problems.
-Twoanalogoutputsmaybe configured totrack dissolved
oxygen and temperature,ordissolved oxygenand dissolved
oxygen.Bothanalogoutputscan be individually
programmed tofail tospecificvalues.

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-Large,highcontrast, customSuper-TwistdisplaywithLED
backlightprovidesexcellentreadabilityeven inlowlight
conditions.Asecondaryline ofdisplayutilizes5x7dot
matrixcharactersforclearmessagedisplay.Twomeasured
parametersmaybeonthe displaysimultaneously.
-Diagnosticmessagesprovide acleardescription ofany
problemwithno confusingerrorcodestolookup. Messages
arealsoincluded fordiagnosingcalibrationproblems.
-Quick andeasyone-pointsamplecalibration method,air
calibration method,and sensorzero-cal.Toprovide high
accuracy,all calibration methodsincludestabilitymonitors
thatcheck temperatureand mainparameterstabilitybefore
acceptingdata.
-HighaccuracyPt1000 temperatureinput. Temperature
element can be usercalibrated.
-Securitylock featuretopreventunauthorized tamperingwith
transmittersettings.All settingscan be viewed whilelocked,
but theycannotbe changed.
-Highreliability,microprocessor-basedsystemwithnon-
volatilememory. Lowmass, surfacemount PCB construction
containingnoadjustmentpotentiometers.All factory
calibrationsstoredinnon-volatileEEPROM.

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Series Q45
Auto-CleanMonitor
Figure 1 -D.O. Systemw/Auto-CleanSensor

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1.4 Q45D/60DOpticalAuto-CleanSystemSpecifications
DisplayedParameters Maininput, 0.00 to40.00ppmormg/L.
%Saturation,0to999%
Sensortemperature,0to50.0°C (32 to122ºF)
Sensor Signal-40to+2000 mVDC
Output Values, 4to20 mADC,Out#1/#2
Sensor slope/offset
PIDcontroller status
Modelnumberand softwareversion
Display Large,high-contrast,Super-Twist withbacklight;
4-digit maindisplaywithsign,0.75"(19.1mm)
seven-segmentcharacters;
12-digitsecondarydisplay,0.3"(7.6mm)5x7dot
matrixcharacters
Keypad 4-keymembranetype withtactilefeedback,
polycarbonatewithUV coating, integralEMI/static
shieldand conductivelycoated window
Enclosure NEMA4X,IP65noryl, stainless steelhardware,
weatherproofandcorrosion resistant.
Mounting Options Wall mounted electronicenclosure,Optional
handrail mounting brackets.
Conduit Openings Fivecordgripcableentries provided.
Weight Electronics Assembly: 15lbs.(6.8kg)
Sensor Assembly: 3.5lbs.(1.58kg.)
AmbientTemperature AnalyzerService, -20 to60°C(-4to140ºF)
Sensor Service,-5to55°C(23 to131°F)
Storage,-5to70°C (-22to158 ºF)
Ambient Humidity 0to95%, non-condensing
Altitude Upto2000m(6562 ft.)
Location Designed fornon-hazardous areas
EMI/RFIInfluence Designed toEN 61326-1
OutputIsolation 600 Vgalvanicisolation
Filter Adjustable0-9.9minutes additionaldampingto
90%step input

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TemperatureInput Pt1000 RTD forautomaticcompensation
Sensor Opticaloxygen sensorwithreplaceablesensing
element.Opticalelement life3-5years.
SensorMaterials PVC
SensorCable 30 ft.(10meter)cable.Maxsensor-transmitter
distance 100feet(30 meters) withj-box.
Power 24 VDC
Fuse 6Aslow-blow
Relays One SPDT,6-Amp@250VAC,5-Amp@24
VDC Softwareselection forsetpoint, phase,
delay,deadband,hi-loalarm,andfailsafe.
IndicatorsonmainLCD.
Analog Outputs Dual4-20mA current loops,500Ohmsmax
CleanerAirSupply Internaldiaphragm compressorwithaccumulator
CleanerFailRelay Optional relaytoindicatethat cleanerhasnot
operatedfor 24hours
1.5Q45DPerformance 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 24hours,non-cumulative
TemperatureDrift Span or zero, 0.01%of span/ºC
Warm-up Time 5minutestoratedperformance
Response Time 60 secondsto90%of step changeat lowest
damping setting
Equipmentbearing thismarking maynotbediscarded bytraditional
methodsintheEuropeancommunityafterAugust12 2005perEU Directive
2002/96/EC.End usersmustreturnoldequipmenttothe manufacturerfor
properdisposal.

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Part2 – Mechanical Installation
2.1General
TheQ45DAuto-Clean MonitorishousedinaNEMA4X(IP-
65)enclosure.Themonitormustbemountednearthe
measurementpoint, withamaximumof60 feetbetween the
monitorandthesensor.Thestandardsystemissupplied
witha30 ft. sensorcableand 30feetofair line tubing.
Monitorenclosuremaybe mounted toanyflatsurfacelikea
wallorplate.Abracketassemblyisavailable(#00-0930)for
mountingthemonitorenclosuretoaeration handrail
systems.Thisbracketlocatesthemonitorataconvenient
heightforviewingthe displayand usingthecontrols.
2.2Wall Mount
Figure2showsthe dimensionsoftheelectronicassembly
includingthe holelocationsforthe enclosuremountingears.
Notethattheenclosuremountingbracketsarenotinstalled
atthe factory.Theyaresupplied separatelyand mustbe
attached usingthe screwsprovided.Thisisdonetoprotect
the bracketsagainst shippingdamage.

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Figure 2 -MonitorAssembly Wall Mount Dim.
SeriesQ45
Auto-CleanMonitor

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2.3 Railing Mount
Figure3showsthe mountingassemblyused tomountthe
electronicmonitortoatypicalsafetyhandrail thatsurrounds
manyaerationtanks.Thisbracketassemblyconsistsof
verticalchannelsattached tothe handrail withu-bolts.The
monitorscrewstothechannelswiththe10-32screws
supplied aspartofthekit. U-boltsfor2”diameterhandrail
pipe arealsosupplied.
Figure 3 -Handrail Mounting Assembly
SeriesQ45
Auto-CleanMonitor

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Figure 4 -SubmersibleSensorMounting Assembly

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Figure 5 -Mounting Assembly Detail

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Part 3–Electrical Installation
3.1General
Q45D/DC Auto-CleanD.O. monitorsarepowered from24
VDC.Monitorscan drawup to3ampswhenthe internalair
compressoractivatesaspartofthe sensorcleaningsystem.
Normalcurrentdrawisless than0.2ampswhenthecleaner
isoff.
ImportantNotes:
1. Usewiringpracticesthatconform toall national,state
and localelectricalcodes.Forpropersafetyaswell as
stablemeasuringperformance,itisimportantthatthe
earthgroundconnection be madetoasolidground point
from TB1.
2.DoNOTrunsensorcablesorinstrument4-20mAoutput
wiringinthe sameconduitthatcontainsACpowerwiring.
ACpowerwiring shouldbe run inadedicatedconduitto
preventelectricalnoisefromcouplingwiththe
instrumentation signals.
3.2Connections
All wiringconnectionsaremade inthe terminalcompartment
atthe bottomofthemonitor.Toaccesstheterminal
compartment,loosen the 4screwsholdingthecoverinplace
and setthe coveraside.The screwsarecaptiveand should
not comecompletelyout of theplasticcover.
ACpowershouldbe broughtintotheenclosurethroughthe
secondcordgripfromthe leftasshowninFigure6.The left
mostcordgripmustremainopen asthisistheentryused for
the cleaningsystemair line.
Sensorand4-20mA output connectionsaremadetothe
terminalsintheright side of theterminalcompartmentas
shown.

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Figure 6 -D.O.MonitorElectrical Connections
WIRING NOTE:ThecablefortheopticalD.O. sensorcontainsa“black”wire
that isactuallyablack shrinktubecoveringbothablueand
apinkwire. Thesetwowiresconnect tothesamepoint
designatedbyblack inthe abovediagram. If the cableiscut
toashorterlength,be surethat bothwiresareconnected to
the terminalmarked black.
Ayellowand agreywirearecontainedinthecableand
arecoveredtoavoidshorting. Ifthecablelengthis
changed, do notstripthese twowires.

ATI Q45D OpticalAuto-Clean D.O. MonitorPart 4– OpticalD.O.Sensor
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3.3 RelayWiring
Relaywiringisdone toterminalblocks inside theQ45D
displayassembly.ThisunitactuallycontainstwoSPDT
relays,butone ofthe relaysisused tocontrolthe activation
ofthe sensorautomaticcleaningsystem.RelayAis
availableforuseaseitheracontrolrelay,analarmrelay,or
asasystemfailurealarm.
ToaccesstheterminalsforRelayA, open thefront
protectivecoverofthe analyzer.Loosenthe 4corner
screwsforthe displayunitand the frontwillhingedown.A
terminalblock labeledTB3isaccessible.Theterminalblock
will unplugforwiringconvenience,and thecircuitboardis
screenedtoindicatetheNO, NC and Ccontacts.
Figure 7 -Relay Contacts

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Part4 – Optical D.O. Sensor
4.1General
OpticalD.O. sensorsaresuppliedcompleteand readyto
use.All that’sneeded istomakethepropersensor
connectionsasshownintheprevioussection.
Arubberbootprotectstheendofthesensorintransit.
Leavethe protectivebootinplaceuntil thesensoristobe
placed intooperation.Removalofthe protectivebootprior
tosubmergencemayexposethe sensingelementto
mechanicaldamagethat isnot covered bywarranty.
Figure 8 -SubmersibleS.O. SensorAssembly

ATI Q45D OpticalAuto-Clean D.O. MonitorPart 4– OpticalD.O.Sensor
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4.2 OpticalSensing
OpticalD.O.measurementemploysatechnique called
“fluorescencequenching”inordertomeasuremolecular
oxygen.The sensorwill respond tooxygen eitherintheair
ordissolved inwater.
Apolymerelementattheendofthe sensorcontainsan
embeddedfluorescent dye.Whenthe elementisexposedto
apulseoflightfroman internalLED,the materialinthe
polymerwill fluoresce,oremitlightatanotherwavelength.
Thislightdecreases(orisquenched)atarateproportional
tothe amountofoxygen inthe polymer.The monitor
measurestherateatwhichthisquenchingoccursand
calculatestheoxygen concentrationbased on the
measurement.
Opticaloxygen sensorsprovide the abilitytomeasure
oxygen instagnantwater,and arenotaffected bycertain
kindsofnon-biologicalcoatings.However,opticalsensors
areaffectedbybiologicallyactivecoatingsand mustbe kept
clean.Inactivated sludgeapplications,biologicalfilmscan
haveamuchlowerD.O. concentration onthesensorsideof
the filmthan on the bulksolution side.The automaticair
cleaningsystemintegrated intothe Q45Dsystemwill
eliminatecoatingproblemsbycleaningthesensoron a
regularprogrammed schedule.
Figure 9 -Optical SensingElement