ATI Technologies Q-Blast Q46D User manual

O & M Manual
Auto-Clean Membrane
Dissolved Oxygen System
(Q46D Software Versions 2.0 and Higher)
Home Office European Office
Analytical Technology, Inc. ATI (UK) Limited
6 Iron Bridge Drive Unit 1 & 2 Gatehead Business Park
Collegeville, PA 19426 Delph New Road, Delph
Phone: [phone] Saddleworth OL3 5DE
610-917-0991 Phone: [phone]
Fax: [phone] Fax: + 44 (0)1457-874-468
Email: [email protected] Email: [email protected]

Table of Contents
Part 1 - Introduction...........................................4
1.1 General.............................................4
1.2 Standard System ..............................4
1.3 Features............................................6
1.4 Q46D Auto-Clean System Specifications
..........................................................7
1.5 Q46D Performance Specifications
(includes sensor)...................................8
1.6 Q-Blast Assembly.............................8
Part 2 - Mechanical Installation..........................9
2.1 General.............................................9
2.2 Wall or Pipe Mount .........................9
2.3 Wall Mount Dimensions..................10
2.4 Railing Mount..................................12
2.5 Sensor Installation ..........................13
Part 3 - Electrical Installation............................15
3.1 General...........................................15
3.2 Power Connections.........................15
3.3 Sensor Connections .......................18
3.4 Q-Blast to Q46 Connection.............19
3.5 Analog Output Connections............22
3.6 Relay Connections..........................22
Part 4 - Sensor Assembly ................................23
4.1 General...........................................23
4.2 Sensor Module................................24
4.3 Sensor Module................................24
Part 5 - Operation.............................................26
5.1 User Interface .................................26
5.11 Keys............................................27
5.12 Display........................................27
5.2 Software..........................................28
5.21 Software Navigation ...................29
5.22 Measure Menu [MEASURE]...........31
5.23 Calibration Menu [CAL]...................32
5.24 Configuration Menu [CONFIG] .......32
5.25 Control Menu [CONTROL]..............35
5.26 Diagnostics Menu [DIAG]...........39
Part 6 - Calibration...........................................43
6.1 General...........................................43
6.2 D.O. Span Cal (1-spl).....................43
6.3 D.O. Span Air Cal (%-sat) ..............44
6.4 D.O. ZeroCal .................................45
6.5 Temperature Calibration.................46
Part 7 - Sensor Auto-Clean System.................47
7.1 General...........................................47
7.2 Cleaner Sequence..........................47
Part 8 - PID Controller Details .........................49
8.1 PID Description...............................49
8.2 PID Algorithm .................................49
8.3 Classical PID Tuning......................51
8.4 Manual PID Override Control.........51
8.5 Common PID Pitfalls ......................51
Part 9 - System Maintenance ..........................53
9.1 General...........................................53
9.2 Analyzer Maintenance....................53
9.3 Sensor Maintenance.......................53
9.31 Lead Anode Replacement..................53
Part 10 - Troubleshooting ................................55
10.1 General...........................................55
10.2 External Problem Sources..............55
10.3 Analyzer Tests....................................56
Sensor Tests ...............................................59
Spare Parts......................................................61

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Table of Figures
Figure 1 –Typical Installation Diagram.........................................................................................................5
Figure 2 - Wall Mount Bracket.....................................................................................................................10
Figure 3 - Enclosure Dimensions................................................................................................................10
Figure 4 - Cleaner Enclosure Dimensions ..................................................................................................11
Figure 5 - Handrail Mounting Assembly......................................................................................................12
Figure 6 -Sensor Mounting Assembly.........................................................................................................13
Figure 7 - Sensor Mounting Detail ..............................................................................................................14
Figure 8 - Q46D Connections .....................................................................................................................16
Figure 9 - Q-Blast Connections...................................................................................................................17
Figure 10 - Sensor Wiring...........................................................................................................................18
Figure 11 - Standard System Wiring...........................................................................................................20
Figure 12 - Q-Blast Connections w/Optional J-Box ....................................................................................21
Figure 13 - Submersible D.O. Sensor Assy................................................................................................23
Figure 14 - Sensor Module Exploded View.................................................................................................24
Figure 15 - User Interface...........................................................................................................................26
Figure 16 - Software Map............................................................................................................................30
Figure 17 - Control Relay, Hysteresis & Phase Options.............................................................................37
Figure 18 - Alarm Relay Example...............................................................................................................38
Figure 19 - ISA PID Equation......................................................................................................................49
Figure 20 –Q46D Display Messages .........................................................................................................57
Figure 21 –Pt1000 RTD Table...................................................................................................................59
Figure 22 - Reference, Barometric Conversion Table ................................................................................60

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Part 1 - Introduction
1.1 General
The Model Q46D is an on-line monitoring system designed for the continuous measurement of
dissolved oxygen in solution. The full scale operating range of the system 0-40 ppm, and the
sensing system will operate on water streams with temperatures ranging from 0 to 50

C.
While the Q46D may be used with either optical or galvanic membraned sensors, this manual is
specific for systems using a membraned D.O. sensor.
Q46D Monitors are available in two electronic versions, an AC powered monitor with integral
alarm relays and dual 4-20 mA output capability, and a 12-24 VDC unit with dual output and
relays. An optional digital output is available for Profibus-DP, Modbus-RTU, or Ethernet-IP.
1.2 Standard System
The Model Q46D Auto-Clean system includes three main components, a NEMA 4X electronics
unit, the “Q-Blast” NEMA 4X Air-Blast cleaning assembly, and a submersible membraned D.O.
sensor with cleaner nozzle. Sensors are design for direct immersion in an aeration tank or
flowing stream. D.O. sensors come with a standard 30 ft. cable and connect directly to the Q46D
monitor. Sensors with special cable lengths are available. A separate tubing connection located
on the Q-Blast assembly is provided for connection of a 30 foot length of plastic tubing (supplied
with the unit). A typical system is shown in
Figure 1. Note that Figure 1 shows the D.O. Monitor and Q-Blast cleaner mounted on ATI’s
optional panel assembly with power distribution box. The panel and power distribution box are
not part of standard systems, and must be ordered separately using part number (00-1637).
The D.O. sensor assembly is mounted to a 1" pipe using a special mounting adapter supplied as
part of the 00-0624 mounting assembly. The 1" pipe is attached to the tank handrail with a
bracket assembly that holds the sensor at a slight angle in the tank.
Once installed and placed into operation, the Q46D Auto-Clean D.O. system will provide months
of reliable D.O. measurement in almost any application. Sensors should be checked for build-up
after the first month to verify that the cleaner is keeping the membrane clean. However, sensor
maintenance intervals of 3-6 months or more are likely in most aeration tanks.
The sensor automatic 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 frequency of
more than every 2 hours is not recommended. Contact your ATI representative for more
information if an 8-hour cleaning cycle does not keep the membrane clean

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(System Diagram Shown on Optional Mounting Plate w/Power Distribution Box)
Figure 1 –Typical Installation Diagram

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1.3 Features
Standard Q46D electronic transmitters are designed to be fully isolated instruments for operation
from either 90-260 VAC or 12-24 VDC power supplies.
High accuracy, high sensitivity system, measures from 0.1 ppm to 40.0 ppm through 2 internal
automatic ranges.
Two 4-20 mA analog outputs are standard. One output may be configured to track D.O or as a
PID control output, while the other output is programmable to track either D.O. or Temperature.
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 to
avoid system control shocks on analog outputs.
Units provide three SPDT relay outputs and two isolated analog outputs. Software settings for
relay control include setpoint, deadband, phase, delay, and failsafe. An additional bank of three
low-power relays (0-30 VDC) is included for Q-Blast cleaner control.
Large, high contrast, custom LCD display with LED back light provides excellent readability in any
light conditions. The secondary line of display utilizes 5x7 dot matrix characters for clear
message display two of four 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 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 three-wire 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.
Equipment bearing this marking may not be discarded by traditional methods in the
European community after August 12 2005 per EU Directive 2002/96/EC. End
users must return old equipment to the manufacturer for proper disposal.

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1.4 Q46D Auto-Clean System Specifications
Main Parameter Ranges Manual selection of one of the following display ranges,
0.00 to 40.00 ppm or 0.00 to 40.00 mg/L
0.0 to 999.9% Saturation
Power 90-260 VAC, 50/60 Hz., 10 VA Maximum or
12-24 VDC, 500 mA max.
Display 0.75” (19.1 mm) high 4-digit main display with sign
12-digit secondary display, 0.3" (7.6 mm) 5x7 dot matrix.
Integral LED back-light for visibility in the dark.
Enclosure NEMA 4X, IP-66 polycarbonate, stainless steel hardware.
Analog Outputs Two 4-20 mA outputs. Output one programmable for PPM D.O.
or PID. Output 2 programmable for PPM D.O. or Temperature.
Max load 450 Ohms for output 1 and 1000 ohms for output 2.
Outputs ground isolated and isolated from each other.
Output Isolation 600 V galvanic isolation
Optional Digital Output Profibus-DP, Modbus-RTU or Ethernet-IP available.
Relays, Electromechanical Three SPDT, 6 amp @ 250 VAC, 5 amp @ 24 VDC contacts.
Software selection for setpoint, phase, delay, deadband, hi-lo
alarm, and failsafe. A-B indicators on main LCD, and C indicator
on lower display. Three additional low-power (0-30 VDC) relays
are used to control the Q-Blast cleaner functions.
Weight Electronics Assembly: 2.4lbs. (1.1 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, -30 to 70 °C (-22 to 158 ºF)
Ambient Humidity 0 to 95%, non-condensing
Altitude Up to 2000 m (6562 ft.)
Location Designed for hazardous and non-hazardous areas
EMI/RFI Influence Designed to EN 61326-1
Temperature Input Pt1000 RTD for automatic compensation
Sensor Galvanic membrane sensor for direct measurement of dissolved
oxygen, replaceable/rebuildable cartridge.
Sensor Materials Noryl and stainless steel
Sensor Cable Submersible: 30 ft. (9.1 m)

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Max. Sensor Cable Length 1000 feet (300 m), with junction box
1.5 Q46D Performance Specifications (includes sensor)
Accuracy ±0.05 PPM or 0.5% of Span
Repeatability 0.05 PPM
Sensitivity 0.01 PPM
Electronic Stability 0.05% of span per 24 hours, non-cumulative
Temperature Drift Span or zero, 0.01% of span/ºC
Response Time 180 seconds to 90% of step input
1.6 Q-Blast Assembly
Power 90- 260 VAC, 50/60 Hz., 10 VA Maximum
12-24 VDC, 500 mA max.
Enclosure NEMA 4X, IP-66 polycarbonate, stainless steel hardware.
Compressor 12 VDC Diaphragm Type, 28 PSI (1.9 Bar) Maximum
Heater Internal thermostatically controlled.
Ambient Temperature Operating, -40 to 60 °C (-40 to 140 ºF)
Storage, -40 to 70 °C (-40 to 158 ºF)
Air Accumulator Powder coated stainless steel
Weight 3.7 lbs. (1.7 kg)

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Part 2 - Mechanical Installation
2.1 General
The Q46D Auto-Clean D.O. System consists of two assemblies housed in NEMA 4X (IP-66)
enclosures. The analyzer electronics and the Q-Blast cleaner assembly should both be
mounted near the sensor location, with a maximum of 60 feet between the monitor/cleaner and
the sensor. The standard system is supplied with a 30 ft. sensor cable and 30 feet of airline
tubing. Best performance is obtained by keeping sensor cable and air tubing length as short as
practical.
Installation of a complete Q46D Auto-Clean System requires mounting both the analyzer
electronics and the cleaner assembly, mounting the sensor assembly, and running a 3-
conductor interconnect wire between the analyzer and cleaner assemblies. Both the analyzer
and the Q-Blast assembly require power connection. If the system is purchased with optional
mounting plate and power distribution box, interconnect wiring will already be complete and
only one power connection is required at the junction box.
The analyzer enclosure and the cleaner enclosure may be mounted to any flat surface, like a
wall or plate. A bracket assembly is available (#00-0930) for mounting a flat PVC, aluminum, or
stainless steel plate to hold the two enclosures to typical aeration handrail systems. This
bracket locates the monitor at a convenient height for viewing the display and using the
controls.
2.2 Wall or Pipe Mount
A PVC mounting bracket with attachment screws is supplied with each transmitter (see Figure 2
for dimensions). The multi-purpose bracket is attached to the rear of the enclosure using the
four flat head screws. The instrument is then attached to the wall using the four outer mounting
holes in the bracket. These holes are slotted to accommodate two sizes of u-bolt that may be
used to pipe mount the unit. Slots will accommodate u-bolts designed for 1½ “or 2” pipe. The
actual center to center dimensions for the u-bolts are shown in the drawing. Note that these
slots are for u-bolts with ¼-20 threads. The 1½” pipe u-bolt (2” I.D. clearance) is available from
ATI in type 304 stainless steel under part number (47-0004).

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Figure 2 - Wall Mount Bracket
2.3 Wall Mount Dimensions
Figure 3 shows the dimensions of the analyzer dimensions. 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.
Figure 3 - Enclosure Dimensions

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Figure 4 shows the dimensions of the Q-Blast assembly. This enclosure should be mounted
beside the analyzer enclosure as shown in Figure 1. If the optional mounting plate and power
junction box were purchased, the analyzer and cleaner will be supplied mounted to the plate.
Figure 4 - Cleaner Enclosure Dimensions

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2.4 Railing Mount
Figure 5 shows the optional mounting assembly (on system mounting plate) used to mount the
analyzer and cleaner assembly 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 5 - Handrail Mounting Assembly

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2.5Sensor Installation
Most applications for D.O. monitoring are done using a submersible sensor. This method can be
used where flow is reasonably constant, and hydraulic head does not vary more than about 10
feet. Oxygen sensors can never be used in completely stagnant conditions. A flow velocity of at
least 0.3 feet per second is normally required for measurement.
Submersible sensors are mounted to a 1" pipe using a standard 1" PVC thread by thread pipe
coupling. The mounting pipe can be secured to standard 1½” or 2” pipe rail using a mounting
bracket kit available from ATI (part number 00-0628) as shown in Figure 6 & Figure 7.
Figure 6 -Sensor Mounting Assembly

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Figure 7 - Sensor Mounting Detail

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Part 3 - Electrical Installation
3.1 General
Q46D/60 Auto-Clean D.O. monitors and Q-Blast cleaners are powered from 90-260 VAC, 50/60
Hz. or 12-24 VDC. Systems can draw up to 0.5 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 Power Connections
Auto-Clean D.O. systems are generally AC powered, although a DC powered system is available.
Power connections are made to terminal TB7 in the Q46D D.O. monitor (Figure 8) and to TB1 in
the Q-Blast assembly (Figure 9).
AC or DC power should be brought into the enclosures through the bottom gland seal on the right
side of the enclosure. This entry is directly above the power terminal blocks. Terminal blocks are
pluggable, and can be removed for easy wire connection.

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Figure 8 - Q46D Connections

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Figure 9 - Q-Blast Connections

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3.3 Sensor Connections
Prior to making any sensor connections, the sensor wire and the cleaner air tube must be run up
inside the mounting pipe as shown in the previous section, Figure 6 & Figure 7. The sensor cable
is connected to the Q46 terminal strip on the front lid of the assembly as shown in Figure 10. The
sensor wire color code is marked on the inside label. Route sensor cable away from AC power
lines, adjustable frequency drives, motors, or other noisy electrical signal lines. Do not run
sensor or signal cables in conduit that contains AC power lines or motor leads.
Figure 10 - Sensor Wiring

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3.4Q-Blast to Q46 Connection
Connections inside the Q-Blast enclosure include power and an interconnect cable running to the
Q46 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.
As previously mentioned, power for the Q-Blast connects to TB1. An additional 3-conductor
cable must be connected between the Q46 analyzer and the Q-Blast cleaner as shown in Figure
11.The sequencing of the compressor and solenoid are controlled by the Q46, with control
signals carried by this cable.
Auto-Clean systems must be installed with the Q-Blast assembly no more than 60 ft. from the
sensor, and preferably much closer. However, the Q46 analyzer can be installed up to 500 ft.
from the cleaner assembly. This allows the display to be located at a convenient spot somewhat
remote from the sensor/cleaner location. When a remote cleaner installation is required,
interconnect the analyzer and the cleaner unit with 3-conductor, 22 AWG shielded cable as
shown in Figure 12. Do not run the interconnect cable in the same conduit with AC wiring. Note
also that a separate junction box is required for the sensor wiring if a remote monitor is to be
used. The 3-conductor control wire and the sensor signal wire may be run in the same conduit.

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Figure 11 - Standard System Wiring