Analytical Technology Q45 User manual

ModelQ45/85
2-WirePeraceticAcid
Transmitter
HomeOfficeEuropeanOffice
AnalyticalTechnology,Inc.ATI(UK) Limited
6Iron BridgeDriveUnit 1&2GateheadBusiness Park
Collegeville, PA 19426Delph NewRoad, Delph
SaddleworthOL3 5DE
Ph:[phone]Ph: 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'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.

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Table of Contents
PART1- INTRODUCTION................................. 4
1.1 General...................................................... 4
1.2 Standard System....................................... 5
1.3 Features..................................................... 8
1.4 Q45/85 SystemSpecifications.................. 9
1.5 Q45HPerformance Specifications...........10
PART2–ANALYZERMOUNTING.................11
2.1 General.....................................................11
2.2 Wall or PipeMount..................................13
PART3–SENSOR/FLOWCELLMOUNTING15
3.1 General.....................................................15
3.2 Constant-HeadFlowcell...........................15
3.3 SealedFlowcell........................................17
3.4 SubmersionMounting..............................19
PART4–ELECTRICALINSTALLATION......20
4.1 General.....................................................20
4.2 Two-Wire.................................................20
4.21 LoadDrive...............................................22
4.3 Sensor Wiring ..........................................23
4.4 Direct Sensor Connection ........................23
4.5 JunctionBoxConnection.........................24
4.6 Optional pHSensor Input........................25
PART5–SENSORASSEMBLY.........................28
5.1 PAASensor Preparation..........................28
5.2 Optional pHSensor..................................30
PART6–CONFIGURATION.............................31
6.1 User Interface...........................................31
6.11 Keys.........................................................32
6.12 Display.....................................................32
6.2 Software...................................................34
6.21 SoftwareNavigation...............................34
6.22 MeasureMenu [MEASURE]...................37
6.23 CalibrationMenu [CAL].............................38
6.24 ConfigurationMenu[CONFIG]..............39
6.25 ControlMenu[CONTROL]....................43
6.26 DiagnosticsMenu[DIAG].........................45
PART7–CALIBRATION...................................48
7.1 PAACalibration......................................48
7.11 PAAZero Cal..........................................48
7.12 PAASpanCal..........................................49
7.2 TemperatureCalibration ..........................51
7.3 pHCalibration..........................................52
7.31 Two-PointpHCal....................................52
7.32 One-PointpHCal.....................................53
PART8–PIDCONTROLLERDETAILS.........55
8.1 PIDDescription.......................................55
8.2 PIDAlgorithm.........................................55
8.3 Classical PIDTuning ...............................57
8.4 ManualPIDOverrideControl..................58
8.5 CommonPIDPitfalls...............................58
PART9–SYSTEMMAINTENANCE................60
9.1 General.....................................................60
9.2 Analyzer Maintenance.............................60
9.3 PAASensor Maintenance........................60
9.31 Sensor AcidCleaning..............................61
9.5 Q22PSensor Cleaning.............................62
9.6 ReplacingtheSaltbridgeandReference
Buffer Solution....................................................63
9.4 FlowCell Maintenance............................64
PART10 –TROUBLESHOOTING....................65
10.1 General.....................................................65
10.2 External SourcesofProblems..................65
10.3 Analyzer Tests.........................................66
10.4 DisplayMessages....................................66
10.5 Sensor Tests.............................................69
SPAREPARTS......................................................71

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Table of Figures
FIGURE 1-TYPICAL MONITORING SYSTEM.....................................................................................5
FIGURE 2-SYSTEMW/BAYONET STYLE PHSENSOR ......................................................................6
FIGURE 3-SEALED FLOWCELL ASSY W/FLOW CONTROL ................................................................7
FIGURE 4-Q45 ENCLOSURE DIMENSIONS ...................................................................................12
FIGURE 5-WALLOR PIPE MOUNT BRACKET.................................................................................13
FIGURE 6-WALL MOUNTING DIAGRAM ........................................................................................14
FIGURE 7-PIPE MOUNTING DIAGRAM..........................................................................................14
FIGURE 8-CONSTANT HEAD FLOWCELL DETAILS.........................................................................15
FIGURE 9-SEALED FLOWCELL DETAILS.......................................................................................17
FIGURE 10 -SEALED PHFLOWCELL DETAILS ...............................................................................18
FIGURE 11 -SUBMERSIBLE SENSOR MOUNTING ASSEMBLY ..........................................................19
FIGURE 12 -LOOP POWER SENSOR CONNECTION ........................................................................21
FIGURE 13 -SENSOR CABLE PREPARATION .................................................................................23
FIGURE 14 -JUNCTION BOX INTERCONNECT WIRING ....................................................................24
FIGURE 15 -OPTIONALPHSENSOR CONNECTION ........................................................................25
FIGURE 16 -OPTIONALPHSENSOR CONNECTION W/JUNCTION BOX .............................................27
FIGURE 17 -PAA SENSOR ASSEMBLY .........................................................................................28
FIGURE 18 -SUBMERSIBLE PAA SENSOR ASSEMBLY ...................................................................29
FIGURE 19 -USER INTERFACE.....................................................................................................31
FIGURE 20 -SOFTWARE MAP ......................................................................................................36
FIGURE 21 -AUTOMATIC PHBUFFER TABLES...............................................................................42
FIGURE 22 -Q45H ISA (IDEAL)EQUATION...................................................................................56
FIGURE 23 -REPLACING SALT BRIDGE /REFERENCE BUFFER........................................................63
FIGURE 24 -Q45H DSIAPLY MESSAGES ......................................................................................67
FIGURE 25 -DISPLAY MESSAGES (CONTINUED)...........................................................................68
FIGURE 26 -PT100 RTD TABLE ..................................................................................................70

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Part 1-Introduction
1.1General
TheModelQ45/85isahighlyversatileon-line monitoringsystemdesigned for
the continuousmeasurementofPeraceticAcid(PAA)concentrationinsolution.
Thefull scaleoperating rangeofthesystemmaybe selected bythe userfor0-
20.00,0-200.0ppm,or0-2000 ppm,and the sensingsystemwill operateon
waterstreamswithtemperaturesrangingfrom0to50°C.TheQ45/85 PAA
MeasurementSystemisengineeredforapplicationsinwhichPAAisappliedto
waterforsterilization purposes
Thebasicsensingelementused inthePAA monitorisapolarographic
membrane sensorwhichmeasuresPAAdirectly.Watersimplyflowspastthe
sensorand directlytodrain,withthe flowrateandpressureacross the sensor
controlledbyaconstantheadflowcell assembly.ThePAAmeasurementdoes
notalterthe sampleoradd anychemicalstothe samplestream,sothe water
flowcan returntothe systemif desired.
Q45/85 Monitorsareavailableinthree electronicversions, aloop-powered 2-wire
transmitter,adual“AA”batteryoperated portableunitwithtwovoltageoutputs,
and a5-17VDC Externallypowered unitwithtwovoltageoutputs.Thismanual
referstotheLoop-Powered 2-wiretransmitterversion.
Inadditiontonormalchlorine measurement, the Q45/85 isalsoavailablewithan
optionalpHinputwhichprovidesatwo-parametermonitoringsystem.BothPAA
and pHaredisplayed simultaneously,andthePAAvalue isautomatically
compensatedforpHchanges.Onbatteryoperatedunits,analog outputsare
availableforBOTHPAA andpH.

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1.2Standard System
ThestandardmodelQ45/85 systemincludesthreemaincomponents,theQ45
analyzer,aconstanthead flowcell,and aPAA sensor.Alow-volumeflowcell is
alsoavailableforapplicationswheresampleflowrateand pressurecan be
carefullycontrolled.Error!Reference source notfound. showsatypical
installationincludingtheoptionalpHsensor.
Forconnectionofthe sensortotheelectronics,a25'cableissupplied.An
additional100feetofinterconnectcablemaybe added using#07-0100junction
box.All required sparepartsarealsoprovided withthe basicsystem,including
sparemembranes,electrolyte, o-rings, and anyspecialhardware.
Notethatstandard25ft. sensorcablesforbothPAAand optionalpHsensors
can be cut toashorterlength. Cuttingthecableswill not affect performance, and
elimination ofextracablecan sometimeseliminateelectricalnoisepickup
throughthe cables.
ESC
MENU ENTER
Figure 1 -Typical Monitoring System

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Error!Reference source notfound. belowshowsthe samestandardflowcell
assemblyand PAA sensoralongwiththe conventionaltype pHsensor. A special
adapterisrequired toholdthepHsensorinitsproperlocationintheflowcell inlet
chamber.
ESC
MENU ENTER
Figure 2 -Systemw/BayonetStylepH Sensor

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Figure3 -SealedFlowcell Assyw/FlowControl
belowshowsan installation usinga(00-1522)sealed flowcell forthePAA sensor
and a(00-1527)sealed flowcell forthe pHsensor.Thistypeofinstallation
requirescarefulflowcontrol.Werecommend theuseofour(03-0371)flow
controlassemblywhen usingsealed flowcells.Thisassemblyconsistsofan in-
line filterand afixed-flowregulatorwhichwill maintainaconstant400cc/min
flowratethroughthe system.Thisflowwill be maintainedsolongasinlet
pressuresarebetween5and 125PSIG. Thein-line filterisused mainlyto
protecttheflowcontrolelementagainstlargerparticlesthat mightcauseplugging
ofthedevice.
MENU
ESC
ENTER
Figure 3 -SealedFlowcellAssyw/Flow Control

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1.3Features
·StandardQ45/85transmittersarefullyisolated,looppowered instrumentsfor2-
wireDC applications.
·Highaccuracy,highsensitivitysystem,measuresfrom0.01 ppmto2000ppm
through4internalautomaticranges.Userrangesof0-20.00 ppm,0-200.0ppm,
or0-2000 ppm.
·OutputHold,OutputSimulate,OutputAlarm,andOutputDelayFunctions.All
forced changesinoutputconditioninclude bumpless transfertoprovide gradual
returntoon-line signallevelsand toavoidsystemcontrolshocks onbothanalog
outputs.
·SelectablePIDcontrolleron mainanalogoutput. PIDcontrollercanoperatewith
instrumentconfigured asloop-powertransmitter,orasone ofthe twooutputson
the ACpowered instrument. PIDincludesmanualoperation feature,and
diagnostic“stuck-controller” timerfeatureforrelaynotificationofcontrol
problems. NotapplicabletobatteryorexternalDC powered units.
·OptionalpHsensorfeatureenablesactivepHmeasurementwiththe Q45/85
monitor.The pHreadingcan alsobe senttoone oftheanalog outputsfor
completepH+PAAmonitoring.
·Large,highcontrast, customSuper-Twistdisplayprovidesexcellentreadability
even inlowlightconditions.Thesecondaryline ofdisplayutilizes5x7dotmatrix
charactersforclearmessagedisplayTwooffourmeasuredparametersmaybe
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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1.4Q45/85 SystemSpecifications
DisplayedParameters Maininput, 0.01 ppmto2000 ppm
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,
0.00 to20.00 ppm
0.0to200.0ppm
0to2000 ppm
Display 0.75”(19.1mm) high4-digitmaindisplaywithsign
12-digit secondarydisplay, 0.3"(7.6mm)5x7dotmatrix.
Keypad 4-keymembranetype withtactilefeedback, polycarbonate
withUV coating
Weight 1lb.(0.45kg)
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 Maximum 2000m(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
TemperatureInput Pt100 RTDwithautomaticcompensation
Sensor 2-electrodepolarographicmembranesensorfordirect
measurement of PAA,

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SensorMaterials Noryland Kynar
SensorCable 25 ft.(7.5meter)cablewith6-pinplug.
Max.Sensor-to-Analyzer 100 feet(30.5meters), withjunction box
Distance
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 16-35 VDC (2-wiredevice)
Enclosure: NEMA4X,polycarbonate, stainless steelhardware,
weatherproofandcorrosion resistant,
HWD:4.4"(112 mm)x4.4"(112mm)x3.5"(89 mm)
Mounting Options Wall orpipe mountbracketstandard.Bracketsuitablefor
either 1.5”or2”I.D. U-Boltsfor pipemounting.
Conduit Openings TwoPG-9openingswithgland seals
DC CableType Belden twisted-pair, shielded, 22gaugeor larger
Insertion Loss 16 VDC
1.5Q45HPerformanceSpecifications
Accuracy 0.5%of selectedrangeor 0.02 PPM
Repeatability 0.3%of selectedrangeor 0.01 PPM
Sensitivity 0.05%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
Equipmentbearingthismarkingmaynotbediscarded bytraditional
methodsinthe European communityafterAugust12 2005perEU
Directive2002/96/EC.Endusersmustreturnoldequipmenttothe
manufacturerforproperdisposal.

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Part 2–AnalyzerMounting
2.1General
All Q45 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-noiseratiohowever,work
withthe shortestsensorcablepossible.Thestandardcablelengthofthe PAA
sensoris25feet.
Referto Error!Reference source notfound.6and Error!Reference source
notfound.7fordetaileddimensionsof eachtype ofsystem.

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Figure 4 -Q45 EnclosureDimensions

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2.2Wallor PipeMount
APVCmountingbracketwithattachmentscrewsissuppliedwitheach
transmitter(seeFigure55fordimensions).Themulti-purposebracketis
attached totherearoftheenclosureusing the fourflathead screws.The
instrumentisthen attachedtothewall usingthe fouroutermounting holesinthe
bracket. Theseholesareslottedtoaccommodatetwosizesofu-bolt that maybe
used topipe mountthe unit. Slotswill accommodateu-boltsdesigned for1½“or
2”pipe.Theactualcentertocenterdimensionsfortheu-boltsareshowninthe
drawing.Notethattheseslotsareforu-boltswith¼-20 threads.The1½” pipe
u-bolt(2”I.D.clearance)isavailablefromATIintype 304stainlesssteelunder
part number(47-0005).
Figure 5 -Wall orPipe mount Bracket

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ENTER
MENU
ESC
Figure 6 -WallMounting Diagram
ENTER
MENU
ESC
Figure 7 -PipeMounting Diagram

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Part 3–Sensor/Flowcell Mounting
3.1General
Selectalocation withinthe maximumsensorcablelengthformountingofthe
sensorflowcell.
3.2Constant-HeadFlowcell
PAA sensorsarebestused inaconstant-head overflowchamberbecause
variationsinsampleflowrateand pressurecan causeunstablereadings.When
monitoringlowconcentrations(below0.5PPM),thismethodshouldalwaysbe
used.
Mechanical installation of the flow cell requires thatitbe mountedto a wall orotherconvenient
flatsurface. Alternatively, the mounting holes on the plate willaccommodate a 2"U-boltfor
mounting the plate to a 2"pipe.
Figure8showsthe dimensionsand mounting holelocationsfortheflowcell.Be
suretoallowenoughclearanceonthe leftside oftheflowcell forinsertion and
removalofthesensor.About 12inchesclearanceisrecommended.
Figure 8 -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.Using thisflowcell requiresthatflowbe controlled externallyto
about400 cc/min.Variableflowrateorvariablepressurewill causeunstable
readingsinthisflowcell.ATIoffersaspecialflowcontrolelementthatcanbe
used aheadofthisflowcellon the incomingsampleline.The flowcontrolispart
no.(55-0048).It will controltheinletflowrateat400cc/min.withinletpressure
variationsfrom5-150PSIG. A50 micron y-straineraheadofthe flowcontrol
elementisrecommended.The sealedflowcell providesadrainventwithcheck
valvetoavoidpullingavacuumon the flowchamber.
Figure 9 -SealedFlowcellDetails

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Figure 10 -SealedpH Flowcell Details

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3.4Submersion Mounting
Someapplicationsaremucheasierdoneusingthe submersiblesensor.This
method can sometimesbe usedwhereflowisreasonablyconstant, and hydraulic
headdoesnotvaryappreciably.PAA sensorscan neverbe used incompletely
stagnantconditions.Aflowvelocityofatleast0.3feetpersecondisnormally
required formeasurement. AnyapplicationsforasubmersiblePAAsensor
shouldfirst bediscussed withATI. A trialofsuchinstallationsmaybe necessary.
Submersiblesensorsaremountedtoa1"pipe usingastandard1"PVCthread
bythread pipecoupling.The mountingpipe can be secured tostandard1½"
pipe rail usingamountingbracketkitavailablefromATI(partnumber00-0628)
asshowninFigure11.
SENSOR CABLE
2"HANDRAIL
1"ALUMINUM CONDUIT, THREADED1"T xT PVC COUPLING
ONE END OR 1"SCHED 80 PVC PIPE
LENGTH AS REQUIRED
(SUPPLIED BYCUSTOMER)
SWIVEL MOUNTING BRACKET WITH
HARDWARE, SUPPLIED BYATI
SUPPLIED BYATI
SENSOR, TYPICAL
2 - 3 FT. SUBMERGENCE
Figure 11 -SubmersibleSensorMounting Assembly