Analytical Technology Q46R User manual

ModelQ46R
ORPMonitor
HomeOfficeEuropeanOffice
AnalyticalTechnology,Inc.ATI(UK) Limited
6Iron BridgeDriveUnit 1&2GateheadBusiness Park
Collegeville, PA 19426DelORP NewRoad, DelORP
SaddleworthOL3 5DE
ORP:[phone]ORP: 0800-018-4020
[phone]+ 44(0) 1457-873-318
Fax: [phone]Fax: + 44(0) 1457-874-468
Email: [e-mail] Email:[e-mail]

PRODUCT WARRANTY
AnalyticalTechnology,Inc.(Manufacturer) warrantstothe Customerthatifanypart(s)
ofthe Manufacturer'sproductsprovestobe 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,orwearitemssubjectto
periodicreplacement includinglampsand fuses.
Gassensors,exceptoxygen sensors,arecovered bythiswarranty,butaresubjectto
inspectionforevidenceofextended exposuretoexcessivegasconcentrations.Should
inspectionindicatethatsensorshavebeen expended ratherthan failed prematurely,the
warrantyshall not apply.
TheManufacturerassumesno liabilityforconsequentialdamagesofanykind,and the
buyerbyacceptanceofthisequipmentwill assumeall liabilityforthe consequencesof
itsuseormisusebytheCustomer,hisemployees,orothers.Adefectwithinthe
meaningofthiswarrantyisanypartofanypieceofaManufacturer's productwhich
shall,when suchpartiscapableofbeingrenewed,repaired,orreplaced,operateto
condemnsuchpieceofequipment.
Thiswarrantyisinlieu ofall otherwarranties(includingwithoutlimitingthe generalityof
the foregoingwarrantiesofmerchantabilityand fitness foraparticularpurpose),
guarantees,obligationsorliabilitiesexpressed orimpliedbythe Manufacturerorits
representativesandbystatuteorruleof law.
Thiswarrantyisvoidifthe Manufacturer's product(s)hasbeen subjecttomisuseor
abuse,orhasnotbeen operated orstoredinaccordancewithinstructions,orifthe
serialnumberhasbeenremoved.
AnalyticalTechnology,Inc.makesnootherwarrantyexpressed orimpliedexceptas
statedabove.

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O&M Manual
Rev-B(10/13)
Table of Contents
PART1- INTRODUCTION.................................. 4
1.1 General............................................ 4
1.2 Features.......................................... 5
1.3 Q46RSystemSpecifications............ 6
1.4 Q46RPerformanceSpecifications
(Common toall variations)........................ 7
1.5 General–Q25R ORP Sensor.......... 8
1.6 Sensor Features.............................. 8
1.7 Q25RSensor Specifications ............ 9
PART2–ANALYZER MOUNTING................... 11
2.1 General.......................................... 11
2.2 Wall or Pipe Mount......................... 12
2.3 PanelMounting.............................. 14
PART3–SENSOR/FLOWCELL MOUNTING.. 15
3.1 General.......................................... 15
3.2 FlowTeeMounting........................ 16
3.3 Union Mounting.............................. 17
3.4 Submersion Mounting .................... 18
3.5 Insertion Mounting ......................... 19
3.6 ConventionalORP Sensors........... 21
3.61 Sealed Flowcell.............................. 22
3.62 FlowTeeAdapter........................... 23
3.7 Lock-n-LoadSystem...................... 24
PART4–ELECTRICALINSTALLATION......... 25
4.1 General.......................................... 25
4.2 Power Connection.......................... 26
4.3 RelayConnection........................... 28
4.4 Optional Output or Relay
Connections ........................................... 29
4.5 SensorWiring ................................ 30
4.6 Direct Sensor Connection .............. 33
4.7 Junction BoxConnection............... 34
4.8 Combination Electrode
Connection ............................................. 35
4.9 ExternalPreamplifier...................... 37
PART5–CONFIGURATION.............................38
5.1 UserInterface.................................38
5.11 Keys...............................................39
5.12 Display...........................................39
5.2 Software.........................................41
5.21 SoftwareNavigation......................41
5.22 MeasureMenu [MEASURE]...........44
5.23 Calibration Menu [CAL]..................45
5.24 Configuration Menu [CONFIG] .......46
5.25 ControlMenu [CONTROL].............51
5.26 DiagnosticsMenu [DIAG]..............58
PART6–CALIBRATION..................................63
6.1 Overviewand Methods...................63
6.11 Sensor Slope..................................63
6.12 SensorOffset.................................64
6.13 2-Point Calibration Explained .........64
6.14 1-Point Calibration Explained .........65
6.2 Performinga2-PointCalibration.....65
6.3 Performinga1-PointCalibration.....67
6.4 TemperatureCalibration.................68
PART7–PIDCONTROLLERDETAILS...........70
7.1 PIDDescription..............................70
7.2 PIDAlgorithm.................................70
7.3 ClassicalPIDTuning......................72
7.4 ManualPIDOverrideControl.........73
7.5 CommonPIDPitfalls......................73
PART8–MAINTENANCE AND
TROUBLESHOOTING.......................................75
8.1 System Checks..............................75
8.2 Instrument Checks.........................75
8.3 DisplayMessages ..........................76
8.4 CleaningtheSensor.......................80
8.5 ReplacingtheSaltbridgeand
ReferenceBufferSolution.......................81
8.6 Troubleshooting.............................82
SPAREPARTS..................................................84

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Rev-B(10/13)
Table of Figures
FIGURE 1–Q46 ENCLOSURE DIMENSIONS ........................................................................11
FIGURE 2-WALL OR PIPE MOUNTING BRACKET .................................................................12
FIGURE 3-WALL MOUNTING DIAGRAM ..............................................................................13
FIGURE 4-PIPE MOUNTING DIAGRAM................................................................................13
FIGURE 5-115/230 VAC PANEL MOUNT &CUT-OUT .........................................................14
FIGURE 6-Q25 SENSOR TYPES .......................................................................................15
FIGURE 7-FLOW THROUGH TEE MOUNT ...........................................................................16
FIGURE 8-1.5" UNION MOUNT .........................................................................................17
FIGURE 9-SENSOR SUBMERSION MOUNT .........................................................................18
FIGURE 10 -S.S. SENSOR INSERTION MOUNT....................................................................19
FIGURE 11 -CPVC SENSOR INSERTION MOUNT ................................................................20
FIGURE 12 -(63-0008) COMBINATION ORP SENSOR,FLOW TYPE ......................................21
FIGURE 13 -(63-0023) COMBINATION ORP SENSOR,SUB.TYPE........................................21
FIGURE 14 -SEALED FLOWCELL DETAILS...........................................................................22
FIGURE 15 -TWIST-LOCK FLOW TEE .................................................................................23
FIGURE 16 -LOCK-N-LOAD SENSOR EXPLODED VIEW.........................................................24
FIGURE 17 –Q46 CONNECTIONS ......................................................................................27
FIGURE 18 –Q46 RELAY CONNECTIONS ...........................................................................28
FIGURE 19 -OPTIONAL RELAY BOARD WIRING ...................................................................29
FIGURE 20 -OPTIONAL ANALOG OUTPUT WIRING ...............................................................29
FIGURE 21 -CABLE DESCRIPTION,MODEL Q25R...............................................................30
FIGURE 22 -DETACHABLE SINGLE SHIELDED CABLE,MODEL Q25R....................................31
FIGURE 23 -Q46R SENSOR CONNECTIONS .......................................................................32
FIGURE 24 -SENSOR CABLE PREPARATION .......................................................................33
FIGURE 25 -JUNCTION BOX INTERCONNECT WIRING ..........................................................34
FIGURE 26 –OEM SENSOR CONNECTIONS,COMBINATION ELECTRODES.............................35
FIGURE 27 –ATI COMBINATION ELECTRODE CONNECTIONS ...............................................36
FIGURE 28 -EXTERNAL PREAMPFOR CONVENTIONAL SENSOR WIRING................................37
FIGURE 29 -USER INTERFACE ..........................................................................................38
FIGURE 30 -SOFTWARE MAP............................................................................................43
FIGURE 31 -CONTROL RELAY EXAMPLE,HYSTERESISAND OPPOSITE PHASE.......................55
FIGURE 32 -ALARM RELAY EXAMPLE ................................................................................56
FIGURE 33 -Q45H ISA (IDEAL)PID EQUATION ..................................................................71
FIGURE 34 -REPLACINGTHE SALTBRIDGEAND REFERENCE BUFFER ...................................81

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O&M Manual
Rev-B(10/13)
Part 1-Introduction
1.1General
TheModelQ46RprovidescontinuousmeasurementofORPinaqueous
systems.It issuitableforpotablewater,wastewater,and awide varietyof
process waterapplications. Q46Rmonitorsmaybe used withQ25R“differential”
ORP sensorsoravarietyof conventional“combination”ORP sensors.
Monitorsareavailableintwoelectronicversions,auniversalACpowered
monitorforoperationfrom90-260VACanda12-24VDC unit. Both versions
provide two4-20 mA analogoutputsand3SPDTrelays. One analogoutputmay
be configuredforPIDcontrolandoneoftherelaysmaybe configured toprovide
aremotetroubleindication.
TheQ46Risavailablewithafewoptionstoexpand the capabilitiesofthe
monitor.Usersmayselecteitherathirdanalog4-20 mAoutputoran expansion
cardthatprovidesthree additionallowvoltageSPSTrelays.The expansion
relaysarenot isolatedfromeachother.
Thismonitoralsoprovidesdigitalcommunication capability.Usersmayorder
Q46 systemswitheitherProfibusDP, ModbusRTU,orEthernetcommunications
boardsfactoryinstalled.

ATI Q46RORPSystemPart 1–Introduction
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1.2Features
·StandardQ46Ranalyzershavefullyisolatedinputsandoutputs.Analogoutputs
areadditionallycompletelyisolated fromeachother.
·Availableineither90-260 VACor12-24VDC powersupplysystems.All features
remainthesameinbothvariations.
·OutputHold,OutputSimulate,OutputAlarm,andOutputDelayFunctions.All
forced changesinoutput condition include bumpless transferforgradualreturnto
on-line signallevelstoavoidsystemcontrolshocks onbothanalogoutputs.
·Three6ampSPDTrelayoutputsandtwoanalog4-20 mAoutputsarestandard.
Softwaresettingsforrelaycontrolincludesetpoint,deadband,phase,delay,and
failsafe.An optional3-relaycard,for0-30Vsignals,isavailabletobringthe total
to6relays.
·SelectablePIDcontrolleron mainanalogoutput. PIDcontrollercanoperatewith
instrument configuredasloop-poweranalyzerorasone ofthe twooutputson the
ACpowered instrument. PIDincludesmanualoperationfeature,and diagnostic
“stuck-controller” timerfeatureforalarm output ofcontrolproblems.
·Digitalcommunicationoption forProfibus-DP, Modbus-RTU.Moreversions
pending. SeeQ46DigitalCommunicationsManualforSpecifications.
·Twoanalogoutputsmaybeconfiguredtotrack ORPandtemperature.Both
analogoutputscanbeindividuallyprogrammed tofail tospecificvalues.An
optionalthirdanalogoutputisavailable,providingseparateoutputsforORPand
temperature.
·Lowvoltagerelayexpansion boardprovidesforanalyzercontrolofthe optional
“air blast”sensorcleaningsystemavailableforsubmersion applications.
·Sensordiagnostics monitorglass breakage,sensorleaks,and RTDcondition.
Diagnosticmessagesprovide acleardescription of problems.
·Two-pointand samplecalibration methodsinclude auto-bufferrecognition from
13 built-inbuffertables, withstabilitychecks duringcalibration.
·SelectablePt1000 orPt100temperatureinputs.
·Securitylock featuretoprevent unauthorized tampering.

ATI Q46RORPSystemPart 1–Introduction
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Rev-B(10/13)
1.3Q46RSystemSpecifications
DisplayedParameters Maininput, -1000 to+2000 mV
Sensortemperature,-10.0to110.0°C (14 to230ºF)
Loop current, 4.00 to20.00 mA
Sensor slope/offset
Modelnumberand softwareversion
Enclosure NEMA4X,polycarbonate,stainless steelhardware,
weatherproofandcorrosion resistant.
Mounting Options Wall orpipe mountbracketstandard.Bracketsuitablefor
either1.5”or2”I.D.U-Boltsforpipe mounting.Panel
mountingbracket optional.
Weight 2lb.(0.9kg)
Display 0.75”(19.1mm) high4-digitmaindisplaywithsign
12-digit secondarydisplay, 0.3"(7.6mm)5x7dotmatrix.
IntegralLED back-lightfor visibilityinthe dark.
Keypad 4-keymembranetype,polycarbonate
Ambient Temperature Service, -20 to60°C(-4to140ºF)
Storage,-30to70°C (-22to158 ºF)
Ambient Humidity 0to95%, indoor/outdooruse,non-condensing.
AltitudeUpto2000m(6562 Ft.)
ElectricalCertification OrdinaryLocation,cCSAus (CSA and ULstandards -both
approved byCSA), pollution degree 2, installation category2
EMI/RFIInfluence Designed toEN 61326-1
OutputIsolation 600 Vgalvanicisolation
Filter(Damping) Adjustable0-9.9minutes dampingto90%step input
change.
TemperatureInput SelectablePt1000 or Pt100 RTDwithautomaticcompensation
Power 90 -260 VAC,50-60Hz, 10 VA max
12-24 VDC,500 mAmax.

ATI Q46RORPSystemPart 1–Introduction
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Enclosure NEMA4X,polycarbonate,stainless steelhardware,
weatherproofandcorrosion resistant.
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 main
LCD, and Cindicatoron lower display.
Expansion Relays: Optional relayboardwith3SPSTlowpower relays.
Relaysrated 2A@30 VDC. Relaysarenotisolated.
Analog Outputs Two4-20 mAoutputs.Outputone programmableforORP
or PID.Output 2programmablefor ORP or Temperature.
Maxload 500 Ohmsfor each output.Outputsground
isolated and isolatedfrom eachother. Anadditional3rd
analogoption isavailable.
1.4Q46RPerformanceSpecifications(Common toall variations)
Accuracy 0.1%of span or better(± 2mV)
Repeatability 0.1%of span or better(±2mV)
Sensitivity 0.05%of span (±2mV)
Stability 0.05%of span per 24hours,non-cumulative
SupplyVoltageEffects ± 0.05%span
InstrumentResponse Time 6secondsto90%of stepinput at lowest setting
TemperatureDrift Span or zero, 0.02%of span/°C
Max.Sensor-Instrument 3,000 ft.(914 meters) w/preamp,
Distance 30 ft.(9.1meters) w/opreamp
SensorTypes ModelQ25RORP w/ preamp- 5wireinput, or combination
styleORP electrode w/TC

ATI Q46RORPSystemPart 1–Introduction
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Rev-B(10/13)
1.5General –Q25RORPSensor
ModelQ25R“differential” ORPsensorsarethe mostcommonlyused sensors
withthe Q46Rmonitor.The differentialdesignutilizesaglass measuring
electrodecontainedinaninternalbufferasthereferenceelement. This
eliminatesthe needforasilver/silverchloride referenceusedinconventional
ORPsensordesigns.It isdesignedtoperformintheharshestofenvironments,
includingapplicationsthatpoison conventionalORPsensors.All sealsaredual
o-ringusingmultiplesealingmaterials.
Q25Rsensorsareavailablewithachoiceoftwoelectrode types.Formost
applications,R1shouldbeused.Thisplatinumelectrodecanbeusedinall
applications,exceptthosecontainingZinc,Nickel,Cadmium,Tin,and Lead.The
R2goldelectrodeshouldbe used intheseapplications.The platinumelectrode
shouldalsobe usedinapplicationscontainingCyanide
1.6Sensor Features
·Ahighvolume,dualjunction saltbridgetomaximizethe in-servicelifetimeof
the sensor.The annularjunction providesalargesurfaceareatominimize
the chanceoffouling.Largeelectrolytevolumeand dualreferencejunctions
minimizecontamination. Thesaltbridgeisreplaceable.
·An integralpreamplifierencapsulatedprovidesalowimpedancesignaloutput
whichensuresstablereadingsinnoisyenvironments.Sensortotransmitter
separation can be up to3,000feet (914meters).
·Pt1000RTD.ThetemperatureelementusedinATIsensorsishighly
accurateandprovidesahighlylinearoutput.
·Availableinvariousconfigurationsincludingsubmersible,flowtype withquick
disconnect, sanitary, and insertion.

ATI Q46RORPSystemPart 1–Introduction
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1.7Q25RSensor Specifications
Measuring Range -1000 to+2000 mV
Sensitivity 0.2mV
Stability 2mVper 24hours, non-cumulative
WettedMaterials PEEK, ceramic,titanium,Viton,EDPM
(optional: 316stainless steelbody)
TemperatureCompensation Pt1000 RTD
SensorCable 6Conductor(5areused)plus 2shields,
15 feet(4.6meters)standardlength
TemperatureRange -5to+95 °C(23to203 °F)
PressureRange 0to100 psig
MaximumFlowRate 10 feet(3meters) per second
SensortoAnalyzerDistance 3,000 feet(914meters) maximum
SensorBodyOptions 1” NPTconvertible, 1¼” insertion, 1½” or2”sanitary-style
Weight 1lb.(0.45kg)
Notes:1.Thetype ofhardwareusedtomountthe sensormaylimitthemaximum
temperatureand pressureratings.Pleaseconsultthe hardware
manufacturer’sspecificationstoobtainthe relevanttemperatureand pressure
ratinginformation.
2.Themaximumflowratespecificationislowerforprocess solutionswithlow
ionicconductivityorhighsuspendedsolidsconcentration.Highflowratesin
lowionicconductivityprocessesmaycauseameasurementerrorduetostatic
electricaldischarge.Highflowratesinprocesseswithhighsuspendedsolids
concentrationmaydecreasethefunctionallifeofthesensorbyerodingthe
metalelectrode.