ATI Technologies Q45S/87 User manual

Fax: [phone] Fax: + 44 (0)1457-874-468
O & M Manual
Model Q45S/87
Wet Hydrogen Sulfide Monitor
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]
Web: www.Analyticaltechnology.com

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Table of Contents
PART 1 - INTRODUCTION..................................4
1.1 General.......................................................4
1.2 Features......................................................5
1.4 Q45S/87 System Specifications.................6
1.5 Q45S/87 Performance Specifications ........7
PART 2 –ANALYZER / AIR PUMP
MOUNTING ............................................................9
2.1 General.......................................................9
2.2 Wall or Pipe Mount .................................11
2.3 Panel Mount, AC Powered Monitor ........13
2.5 Air-Purge Pump Mounting ......................14
PART 3 –SENSOR MOUNTING........................15
3.1 General.....................................................15
3.2 Sensor Duct Assembly.............................15
3.3 Sensor Prefilter Membrane......................17
PART 4 –ELECTRICAL INSTALLATION......18
4.1 General.....................................................18
4.3 115/230 VAC w/Relays...........................18
4.4 Sensor Wiring..........................................21
PART 5 –CONFIGURATION.............................23
5.1 User Interface...........................................23
5.11 Keys.....................................................24
5.12 Display.................................................24
5.2 Software...................................................25
5.21 Software Navigation...........................26
5.22 Measure Menu [MEASURE]...............28
5.23 Calibration Menu [CAL] ........................29
5.24 Configuration Menu [CONFIG] .........29
5.25 Control Menu [CONTROL] ...............31
5.26 Diagnostics Menu [DIAG].........................34
PART 6 –CALIBRATION...................................37
6.1 Calibration ...............................................37
6.11 Zero Cal...............................................37
6.12 Span Cal...............................................38
6.2 Temperature Calibration..........................39
PART 7 –PID CONTROLLER DETAILS.........40
7.1 PID Description .......................................40
7.2 PID Algorithm .........................................40
7.3 Classical PID Tuning...............................42
7.4 Manual PID Override Control .................42
7.5 Common PID Pitfalls...............................42
PART 8 –SYSTEM MAINTENANCE ...............44
8.1 General.....................................................44
8.2 Analyzer Maintenance.............................44
8.3 Sensor Maintenance.................................44
PART 9 –TROUBLESHOOTING ......................45
9.1 General.....................................................45
9.2 External Sources of Problems..................45
9.3 Analyzer Tests .........................................46
9.4 Display Messages ....................................46
SPARE PARTS......................................................48

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Table of Figures
FIGURE 1 - WET H2S TYPICAL SYSTEM DIAGRAM ................................................................................4
FIGURE 2 - Q45 ENCLOSURE DIMENSIONS, AC POWER ......................................................................9
FIGURE 3 - Q45 ENCLOSURE DIMENSIONS, BATTERY UNITS............................................................10
FIGURE 4 - WALL OR PIPE MOUNT BRACKET.......................................................................................11
FIGURE 5 - WALL MOUNTING DIAGRAM................................................................................................12
FIGURE 6 - PIPE MOUNTING DIAGRAM..................................................................................................12
FIGURE 7 - PANEL MOUNT CUT-OUT.....................................................................................................13
FIGURE 8 –AIR PUMP ENCLOSURE SPECIFICATIONS .......................................................................14
FIGURE 9 - DUCT INSERTION SENSOR HOLDER DIMENSIONS .........................................................15
FIGURE 10 - DUCT INSERTION SENSOR HOLDER EXPLODED VIEW ................................................16
FIGURE 11 - LINE POWER CONNECTION ..............................................................................................19
FIGURE 12 - PUMP INTERCONNECT CONNECTION.............................................................................20
FIGURE 13 - RELAY CONTACTS..............................................................................................................20
FIGURE 14 - SENSOR CONNECTION......................................................................................................21
FIGURE 15 - SENSOR CABLE PREPARATION .......................................................................................22
FIGURE 16 - USER INTERFACE...............................................................................................................23
FIGURE 17 - SOFTWARE MAP.................................................................................................................27
FIGURE 18 - CONTROL RELAY EXAMPLE..............................................................................................33
FIGURE 19 - ALARM RELAY EXAMPLE...................................................................................................34
FIGURE 20 - Q45H ISA PID EQUATION ...................................................................................................40
FIGURE 21 - Q45H DISPLAY MESSAGES ...............................................................................................46
FIGURE 22 - Q45H DISPLAY MESSAGES (CONT'D) ..............................................................................47

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Part 1 - Introduction
1.1 General
The Q45S/87 Wet H2S Transmitter is a microcomputer-based instrument for monitoring the
concentration of a hydrogen sulfide gas in wet scrubber outlet vents or scrubber inlet ducts
saturated with water vapor.
The system consists of three parts, a Monitor assembly containing an LCD display, analog
outputs, and alarm functions; a special H2S sensor with duct insertion holder designed for
operation in condensing gas streams; and an optional air-purge system to periodically remove
any water droplets that might accumulate on the sensor and cause slow response. When air-
purge system is ordered a system mounting plate is provided for mounting both transmitter and
air purge system in the same location.
The system requires AC power for operation of the monitor and purge pump assembly. Power for
the purge pump is switched on and off through a relay in the monitor. The frequency with which
the purge pump is activated is controlled by the user through a setup routine in the configuration
menu. The purge pump assembly should normally be mounted next to the monitor and both
should be located within 25 feet of the sensor assembly for best results. A 1/8” I.D. tube
connects the outlet of the air-purge pump to the sensor assembly. The basic system is shown in
Figure 1 below.
Figure 1 - Wet H2S Typical System Diagram

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1.2 Features
Standard Q45S/87 electronic transmitters are designed to be a fully isolated instrument
for continuous operation from AC power. An optional battery powered version (without
air-purge system) with an internal data logger is available for short term monitoring use.
High sensitivity system measures from 0.1 ppm to 200.0 ppm with 3 display ranges.
User ranges of 2.000 ppm, 20.00 ppm, or 200.0 ppm may be selected, or the monitor
may operate in Auto-Ranging mode, switching display sensitivity up and down depending
on the measured value.
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.
Two SPDT relays are provided, one normally assigned to the control of the sensor air-
purge pump and the other available for external alarming functions.
Two analog outputs may be configured to track H2S concentration or temperature. Both
analog outputs can be individually programmed to fail to specific values.
Selectable PID controller on main analog output. PID includes manual operation feature,
and diagnostic “stuck-controller” timer feature for relay notification of control problems.
Large, high contrast, custom Super-Twist display provides excellent readability even in
low light conditions. The secondary line of display utilizes 5x7 dot matrix characters for
clear message display
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 and sensor zero-cal. To provide high
accuracy, all calibration methods include stability monitors that check main parameter
stability before accepting data.
Security lock feature to prevent unauthorized tampering with transmitter settings. All
settings can be viewed while locked, but they cannot be changed.

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1.4 Q45S/87 System Specifications
Displayed Parameters Main input, 0.1 ppm to 200.0 ppm
Sensor Current, 0.0 to 999.9 nA, 0.000 to 99.99 uA
Sensor Temperature
Loop current, 4.00 to 20.00 mA
Sensor slope/offset
Model number and software version
PID Controller Status
Main Parameter Ranges Manual selection of one of the following ranges,
0.0 to 2.000 ppm
0.00 to 20.00 ppm
0.00 to 200.0 ppm
Display Large, high-contrast, Super-Twist (STN) LCD;
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
Weight Line powered unit: 1.5 lb. (0.68 Kg)
Battery power unit: 0.8 lbs. (0.36 Kg.)
Ambient Temperature Analyzer Service, -20 to 60 °C (-4 to 140 ºF)
Storage, -5 to 70 °C (-22 to 158 ºF)
Ambient Humidity 0 to 95%, non-condensing.
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
Sensor Electrochemical type for measurement of hydrogen sulfide gas
Sensor Materials Noryl and PVC
Sensor Cable 25 ft. (7.5 meter) cable with 6-pin plug.
Max. Sensor-to-Analyzer 100 feet (30.5 meters), with junction box
Distance
Sensor Holder PVC duct insertion assembly with air-purge nozzle.

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Power 90 –130 VAC, 50/60 Hz
or
180 –260 VAC, 50/60 Hz
Enclosure, AC Powered NEMA 4X, IP66, polycarbonate, stainless steel hardware,
weatherproof and corrosion resistant,
HWD: 4.9" (124 mm) x 4.9" (124 mm) x 5.5" (139 mm)
Mounting Options Wall or pipe mount bracket standard. Bracket suitable for either
1.5” or 2” I.D. U-Bolts for pipe mounting.
Panel mount adapter optional.
Conduit Openings Three ½” NPT openings. Gland Seals installed
Relays, Electromechanical Two 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.
Analog Outputs Two 4-20 mA outputs. Output one programmable for PPM H2S
or PID. Output 2 programmable for PPM or temperature.
Maximum load 500 Ohms for each output. Outputs ground
isolated and isolated from each other.
Battery Option:
Power: Generic 9 VDC alkaline battery, low battery indication at 6.75 V
DC. Lithium 9 VDC battery recommended for max performance.
Enclosure: NEMA 4X, IP66, polycarbonate, stainless steel hardware,
weatherproof and corrosion resistant,
HWD: 4.4" (112 mm) x 4.4" (112 mm) x 3.5" (89 mm)
Mounting Options Supplied with carrying handle and cable glands installed.
Outputs: Two 0-2.5 VDC isolated outputs are provided on for connection
to data recorders, etc.
Battery Life: Approximately 100 hours with alkaline battery. Use of lithium cell
increases life to approximately 250 hours.
Optional Datalogger Removable data module holds 32,000 points from two user
configured channels, time of logging is user configurable.
Software supplied for data download and display.
1.5 Q45S/87 Performance Specifications
(Common to all variations)
Accuracy 1% of selected range or 0.2 PPM
Repeatability 0.5% of selected range or 0.1 PPM
Sensitivity 0.05% of selected range
Non-linearity 0.1% of selected range

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Warm-up Time 3 seconds to rated performance (electronics only)
Supply Voltage Effects ± 0.05% span
Instrument Response Time 60 seconds to 90% of step input at lowest damping
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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Part 2 – Analyzer / Air Pump Mounting
2.1 General
All Q45 Series instruments offer maximum mounting flexibility. A bracket is included with each
unit that allows mounting to walls or pipes. In all cases, choose a location that is readily
accessible for calibrations. Also consider that it may be necessary to utilize a location where
solutions can be used during the calibration process. To take full advantage of the high contrast
display, mount the instrument in a location where the display can be viewed from various angles
and long distances.
Locate the instrument in close proximity to the point of sensor installation - this will allow easy
access during calibration. The sensor-to-instrument distance should not exceed 100 feet. To
maximize signal-to-noise ratio however, work with the shortest sensor cable possible. The
standard cable length of the sulfide sensor is 25 feet.
Figure 2 - Q45 Enclosure Dimensions, AC Power
ENTER
MENU
ESC

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Figure 3 - Q45 Enclosure Dimensions, Battery Units

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2.2 Wall or Pipe Mount
A PVC mounting bracket with attachment screws is supplied with each transmitter (see Figure 4
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 47-0005
Figure 4 - Wall or Pipe mount Bracket

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Figure 5 - Wall Mounting Diagram
Figure 6 - Pipe Mounting Diagram

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2.3 Panel Mount, AC Powered Monitor
Panel mounting of an AC powered monitor uses the panel mounting flange molded into the rear
section of the enclosure. Figure 7 provides dimensions for the panel cutout required for
mounting.
The panel mounting bracket kit must be ordered separately (part number 05-0068). This kit
contains a metal retainer bracket that attaches to the rear of the enclosure, 4 screws for
attachment of this bracket, and a sealing gasket to insure that the panel mounted monitor
provides a water tight seal when mounted to a panel.
The sealing gasket must first be attached to the enclosure. The gasket contains an adhesive on
one side so that it remains in place on the enclosure. Remove the protective paper from the
adhesive side of the gasket and slide the gasket over the back of the enclosure so that the
adhesive side lines up with the back of the enclosure flange. Once in place, you can proceed to
mount the monitor in the panel.
Figure 7 - Panel Mount Cut-Out
ENTER
MENU
ESC

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2.5 Air-Purge Pump Mounting
The Air Pump is mounted in a Junction Box, which is a NEMA 4X enclosure. The air pump
comes with 25 ft. of tubing that should be cut to the desired length. A 5 ft. piece of 2 conductor
cable is also supplied to interconnect the pump with the relay control in the Q45S/87 monitor.
See Figure 8 for Junction Box dimensions. The junction box comes complete with mounting
hardware for pipe or wall mounting identical to that used for the monitor enclosure.
Figure 8 –Air Pump Enclosure Specifications
Inches (mm)

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Part 3 – Sensor Mounting
3.1 General
Select a location for the sensor on the side of the scrubber inlet or outlet duct. Do not mount the
sensor on the bottom of a horizontal duct section. If the duct is horizontal, mount the sensor at about
45-60 degrees off of vertical. The preferred location for mounting the sensor is on a VERTICAL
section of duct. Always select a location that allows for easy access to the sensor for maintenance
purposes. Placing the sensor in an inacessible location generally leads to a lack of maintenance and
ultimate failure of the system.
3.2 Sensor Duct Assembly
Figure 9 shows the dimensions of the duct mount assembly used to insert the wet hydrogen sulfide
sensor into a scrubber duct. This assembly is designed to be screwed into a 1½” NPT female
adapter on the duct. The female adapter attached to the duct must be supplied by the user.
Figure 9 - Duct Insertion Sensor Holder Dimensions

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Figure 10 shows an exploded view of the duct insertion assembly with the hydrogen sulfide sensor
and cable assembly.
To facilitate installation, disassemble the sensor system so that the front half of the holder can be
screwed into the duct separately. Note that the front section of the holder contains a small barb fitting
on the side. This fitting is for connection of the optional air purge pump. The air purge system blows
air through the sensing chamber to blow out accumulated water that may condense inside the air
chamber. The outlet hole is 180 degrees opposite this barb fitting. When installing the holder in
the duct, align the air connection fitting to insure that water can be discharged from the
chamber. On a vertical duct mount, this means orienting the air connection barb so that it is on top
of the holder.
The front section of the sensor holder assembly is screwed to the duct, and it will need to be removed
periodically to replace the prefilter membrane. Apply teflon tape to the threads prior to installation
and screw this part in “hand tight” to allow for easy removal.
When taking the sensor assembly apart, first loosen the cable gland at the back of the adapter so that
cable can slide freely. Then unscrew the adapter from the front holder. The sensor can be pulled out
from the holder using the cable. When inserting the sensor, connect the sensor cable first and use
the connector to press the sensor firmly into place. An o-ring at the front of the holder seals the
compartment. A small amount of o-ring lubricant on the side of the front section of the sensor will
make insertion and removal much easier. Screw the adapter back in and then tighten the cable gland
to seal the cable against water intrusion.
Figure 10 - Duct Insertion Sensor Holder Exploded View

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3.3 Sensor Prefilter Membrane
On the front of the sensor holder is a membrane that serves as a sample prefilter to protect the
sensor from deposits that could cause premature sensor failure. This membrane is held in place with
a screw-on cap, and the membrane should be changed every 2 or 3 months to insure proper
operation of the system. A package of 10 prefilter membranes are supplied with the unit.
The membrane material used as a prefilter IS NOT the same on both sides. Look carefully at one of
the membrane disks and you will see a mesh pattern on one side. You can also feel the difference
between the two sides. The mesh side is fairly smooth while the opposite side is slightly sticky,
feeling a little like a latex glove. When installing the prefilter on the sensor holder, the mesh side
of the membrane must face out toward the measured air stream.
Prefilters are available in packages of 10. The part number is listed on the spare parts page of this
manual.

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Part 4 – Electrical Installation
4.1 General
The Q45 is powered from either 115 or 230 VAC, 50/60 cycle power. Please verify the type of
unit before connecting any power. The power supply voltage is marked on the circuit board near
the AC power connection terminals. Connection of 230 VAC power to a 115 VAC unit will
result in damage to the power supply assembly.
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 terminal 12 (Figure 11). The AC
power supply contains a single 100mA (115V) or 50mA (230V) slo-blo fuse. The fuse F1
is located adjacent to TB5 and is easily replaceable.
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.
4.3 115/230 VAC w/Relays
In the 115/230 VAC configuration, a DC power supply is mounted into the inside rear of the
enclosure. The power supply must be ordered with the proper operating voltage. Verify that the
unit requires either 115 VAC or 230 VAC before installing. Also verify that power is fully
disconnected before attempting to wire. Units marked for 115 VAC operation may be safely
operated between 90 and 130 VAC. Units marked for 230 VAC operation may be safely operated
with input voltages from 180 to 260 VAC.
AC powered Q45 systems are supplied with 3 cable gland fittings and two ½” conduit adapters.
One of the cable glands has a larger hole in the rubber gland and should be used for the power
cord entry if a flexible power cord will be used for installation. One of the cable glands with the
smaller gland opening should normally be used for the sensor cable. Cable glands and conduit
hubs will screw into any of the three threaded holes on the bottom of the enclosure.
Connect HOT, NEUTRAL, and GROUND to the matching designations on terminal strip TB5.
WARNING
Disconnect line power voltage BEFORE connecting line power
wires to Terminal TB5 of the power supply. The power supply
accepts only standard three-wire single phase power. The power
supply is configured for 115 VAC or 230 VAC operation at the
factory at time of order, and the power supply is labeled as such.
Do NOT connect voltages other than the labeled requirement to
the input.

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The analog outputs from the system are present at terminals TB1 and TB2. The loop-load
limitation in this configuration is 500 Ohms maximum for each output. Also note that these two
outputs are completely isolated from each other to insure that ground loops do not result from the
connection of both outputs to the same device such as a PLC or DCS.
A ribbon cable connects the power supply assembly with the microprocessor assembly located in
the front section of the enclosure. This cable can be removed during installation to facilitate
wiring if desired. It is best to unplug only one end. The ribbon cable has a marking stripe on one
edge that is used to indicate proper orientation. The indicator stripe should be on the bottom
edge of the cable when installed as shown in Figure 11
Figure 11 - Line Power Connection
The power strip, TB5, allows up to 12 AWG wire. A wire gauge of 16 AWG is recommended to
allow for an easy pass-through into the M16 ports when wiring.

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Figure 12 - Pump Interconnect Connection
Two sets of SPDT relay contacts are provided on the power supply board. None of the relay
contacts are powered. The user must supply the proper power to the contacts. For applications
that require the same switched operating voltage as the Q45 (115 or 230 V), power may be
jumpered from the power input terminals at TB5. Relay wiring is connected at TB3 as shown
below. Note that the relay contact markings are shown in the NORMAL mode. Programming a
relay for “Failsafe” operation reverses the NO and NC positions in this diagram.
Figure 13 - Relay Contacts