ATI Technologies Q46 Series User manual

O & M Manual
Model Q46D/60
Dissolved Oxygen 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]

Table of Contents
PART 1 - INTRODUCTION................................4
1.1 General................................................4
1.2 Standard System.................................4
1.3 Features...............................................4
5
1.4 Q46D/60 System Specifications..........6
1.5 Q46D Performance Specifications ......7
PART 2 –ANALYZER MOUNTING..................8
2.1 General................................................8
2.2 Wall or Pipe Mount ..............................9
2.3 Panel Mount, AC Powered Monitor ...11
PART 3 –SENSOR MOUNTING ....................12
3.1 General..............................................12
3.2 Submersion Mounting........................12
3.3 Flowcell Mounting..............................13
3.4 Sealed Flowcell..................................14
PART 4 –ELECTRICAL INSTALLATION......15
4.1 General..............................................15
4.2 AC Powered Instrument Wiring .........15
4.3 Relay Connection ..............................17
4.4 Optional Output/Relay Connection....18
4.5 Sensor Wiring....................................19
4.6 Direct Sensor Connection..................20
4.7 Junction Box Connection...................21
PART 5 –SENSOR ASSEMBLY....................22
5.1 Oxygen Sensor Preparation ..............22
5.2 Flow Type D.O. Sensor .....................24
PART 6 –CONFIGURATION..........................25
6.1 User Interface ....................................25
6.11 Keys...............................................26
6.12 Display ...........................................26
6.2 Software.............................................27
6.21 Software Navigation......................28
6.22 Measure Menu [MEASURE] ..........30
6.23 Calibration Menu [CAL]....................31
6.24 Configuration Menu [CONFIG]......31
6.25 Control Menu [CONTROL]............34
6.26 Diagnostics Menu [DIAG] ...............39
PART 7 –CALIBRATION ...............................43
7.1 Oxygen Calibration............................43
7.11 Oxygen Span Cal...........................43
7.12 D.O. Span Cal (1-spl) ...................43
7.13 D.O. Air Span Cal (% sat).............44
7.14 Dissolved Oxygen Zero Cal...........45
7.2 Temperature Calibration....................46
PART 8 –PID CONTROLLER DETAILS........47
8.1 PID Description .................................47
8.2 PID Algorithm ....................................47
8.3 Classical PID Tuning.........................49
8.4 Manual PID Override Control............49
8.5 Common PID Pitfalls .........................49
PART 9 –SYSTEM MAINTENANCE..............51
9.1 General..............................................51
9.2 Analyzer Maintenance.......................51
9.3 Sensor Maintenance .........................51
9.31 Lead Anode Replacement.............51
9.32 Pressure Compensator Rebuild ....52
PART 10 –TROUBLESHOOTING .................53
10.1 General..............................................53
10.2 External .............................................53
10.3 Analyzer.............................................54
10.31 Display...............................................55
10.4 Sensor...............................................56
SPARE PARTS ...............................................60

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Table of Figures
FIGURE 1–Q46 ENCLOSURE DIMENSIONS..........................................................................8
FIGURE 2-WALL OR PIPE MOUNT BRACKET.........................................................................9
FIGURE 3-WALL MOUNTING DIAGRAM..............................................................................10
FIGURE 4-PIPE MOUNTING DIAGRAM ...............................................................................10
FIGURE 5-PANEL MOUNT INSTALLATION...........................................................................11
FIGURE 6-SUBMERSIBLE SENSOR MOUNTING...................................................................12
FIGURE 7-CONSTANT HEAD FLOWCELL DIMENSIONS ........................................................13
FIGURE 8-SEALED FLOWCELL DIMENSIONS......................................................................14
FIGURE 9-AC POWER CONNECTIONS ..............................................................................16
FIGURE 10 -RELAY CONTACTS.........................................................................................17
FIGURE 11 -OPTIONAL LOW POWER RELAY WIRING ..........................................................18
FIGURE 12 -OPTIONAL 3RD ANALOG OUTPUT WIRING........................................................18
FIGURE 13 -SUBMERSIBLE SENSOR CONNECTION .............................................................19
FIGURE 14 -SENSOR CABLE PREPARATION.......................................................................20
FIGURE 15 -JUNCTION BOX INTERCONNECT WIRING..........................................................21
FIGURE 16 -SUBMERSIBLE SENSOR ASSEMBLY.................................................................22
FIGURE 17 -SUBMERSIBLE SENSOR MODULE EXPLODED VIEW...........................................23
FIGURE 18 -FLOW TYPE D.O. SENSOR ASSEMBLY ............................................................24
FIGURE 19 -USER INTERFACE..........................................................................................25
FIGURE 20 -SOFTWARE MAP ...........................................................................................29
FIGURE 21 -CONTROL RELAY EXAMPLE,HYSTERESIS &PHASE OPTIONS ...........................37
FIGURE 22 -ALARM RELAY EXAMPLE................................................................................38
FIGURE 23 -ISA PID EQUATION.......................................................................................47
FIGURE 24 -DISPLAY MESSAGES......................................................................................55
FIGURE 25 -PT1000 RTD RESISTANCE TABLE..................................................................57
FIGURE 26 -REFERENCE,BAROMETRIC CONVERSION TABLE..............................................58

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Part 1 - Introduction
1.1 General
The Model Q46D is a versatile 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.
The basic sensing element used in the dissolved oxygen monitor is a galvanic membrane sensor
which measures oxygen directly.
Q46/60 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. Options are available to add either a third 4-20 mA output or 3 additional low power SPST
relays. In addition, a digital output option for Profibus, Modbus, or Ethernet is available.
1.2 Standard System
The standard model Q46D/60 system includes two components, the Q46D analyzer and a
dissolved oxygen sensor. For connection of the sensor to the electronics, a 25' cable is supplied.
Up to an additional 1000 feet of interconnect cable may be added using #07-0100 junction box.
All required spare parts are also provided with the basic system, including spare membranes,
electrolyte, o-rings, and any special hardware.
1.3 Features
•Standard Q46D electronic transmitters are designed to be a 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, and a third analog output is available as an option.
One output may be configured for PID control, while other outputs are programmable to track
either D.O. or Temperature.
•Selectable PID controller on main analog output. PID includes manual operation feature, and
diagnostic “stuck-controller” timer feature for relay notification of control problems.
•Digital communication option for Profibus-DP, Modbus-RTU. More versions pending. See Q46
Digital Communications Manual for Specifications.
•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.

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•Units provide provides three SPDT relay outputs and two isolated analog outputs. Software
settings for relay control include setpoint, deadband, phase, delay, and failsafe.
•Selectable Output Fail Alarm feature on Relay C allows system diagnostic failures to be sent to
external monitoring systems.
•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 Pt100 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/60 System Specifications
Displayed Parameters Main input, 0.1 ppm to 40.0 ppm
%Saturation, 0 to 999.9%
Sensor temperature, -10.0 to 50.0°C (23 to 122ºF)
Sensor signal, -40 to +2000 mVDC
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 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
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, polycarbonate, stainless steel hardware,
Mounting Options Wall, pipe, or panel mount standard. Wall bracket suitable for
either 1.5” or 2” I.D. U-Bolts for pipe mounting.
Conduit Openings Five ½” NPT openings, Adapter can be removed to provide a 1”
NPT opening in the bottom of the enclosure. Gland seals
provided but not installed.
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.
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. An
additional 3rd analog option is available.
Output Isolation 600 V galvanic isolation
Optional Relays: Three SPST, 1 amp @ 24 VDC. Software selection for setpoint,
phase, delay, deadband, hi-lo alarm, and failsafe.
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)
Keypad 4-key membrane type with tactile feedback, polycarbonate with
UV coating

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Filter Adjustable 0-9.9 minutes to 90% input step change
Temperature Input Pt1000 RTD with automatic compensation
Ambient Humidity 0 to 95%, indoor/outdoor use, non-condensing to rated ambient
temperature range
Altitude Up to 2000 m (6562 ft)
Electrical Certification Ordinary Location, cCSAus (Certified to both CSA and UL
standards), pollution degree 2, installation category 2
EMI/RFI Influence Designed to EN 61326-1
Weight 2.4 lb. (1.1 Kg.)
Sensor 2-electrode galvanic membraned sensor for direct measurement
of oxygen,
Sensor Materials Noryl, PVC, and stainless steel
Sensor Cable Submersible: 30 ft. (9.1 m)
Max. Sensor Cable Length:1000 feet (300 m), with junction box
1.5 Q46D Performance Specifications
Accuracy 0.5% of selected range or better
Repeatability 0.3% of selected range or better
Sensitivity 0.05% of selected range
Non-linearity 0.1% of selected range
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

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Part 2 – Analyzer Mounting
2.1 General
All Q46 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 200 feet (61 m).
To maximize signal-to-noise ratio however, work with the shortest sensor cable possible. The
standard cable length of the oxygen sensor is 30 feet.
Figure 1 –Q46 Enclosure Dimensions

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2.2 Wall or Pipe Mount
A PVC mounting bracket with attachment screws is supplied with each transmitter (see
Figure 2for 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 2 - Wall or Pipe mount bracket

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Figure 3 - Wall Mounting Diagram
Figure 4 - Pipe Mounting Diagram
ENTER
MENU
ESC

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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 5 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 ensure that the panel mounted monitor
provides a watertight 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 5 - Panel Mount Installation

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Part 3 – Sensor Mounting
3.1 General
Select a location within the maximum sensor cable length for mounting of the sensor. Locating
the sensor within 25 ft. of the transmitter is generally preferred for ease of operation and
calibration.
3.2 Submersion Mounting
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 - Submersible Sensor
Mounting.
SENSOR CABLE
2" HANDRAIL
1" ALUMINUMCONDUIT, THREADED1" T x T PVC COUPLING ONE END OR 1" SCHED 80 PVC PIPE
LENGTHAS REQUIRED
(SUPPLIED BYCUSTOMER)
SWIVEL MOUNTING BRACKET WITH
HARDWARE, SUPPLIED BY ATI
SUPPLIED BYATI
SENSOR, TYPICAL
2 - 3 FT. SUBMERGENCE
Figure 6 - Submersible Sensor Mounting

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3.3 Flowcell Mounting
For applications requiring measurement in a flowing water line, a flowcell assembly and a flow-
type sensor should be used. Two types of flowcell are available. Applications that allow an open
flow system can best be satisfied using the 00-0043 constant-head flowcell. This flowcell is open
to atmosphere and the drain is a gravity drain that must go to waste.
For applications where in-line measurement is required, flowcell no. (00-1522) should be used.
This flowcell allows pressurized sample to flow to the sensor, but provision must be made for
controlling the flow at 300-500 cc/min. Sample pressure can be variable provided pressure
changes are relatively slow. Rapid pressure changes will cause a spike in the measured D.O.
value.
Figure 7 - Constant Head Flowcell Dimensions

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3.4 Sealed Flowcell
Applications where the sample inlet flow is well controlled can use a simpler sealed flowcell.
Using this flowcell requires that flow be controlled externally to about 400 cc/min. Variable flow
rate or variable pressure will cause unstable readings in this flowcell. ATI offers a special flow
control element that can be used ahead of this flowcell on the incoming sample line. The flow
control is part no. (55-0048). It will control the inlet flowrate at 400 cc/min. with inlet pressure
variations from 5-150 PSIG. A 50 micron y-strainer ahead of the flow control element is
recommended. The sealed flowcell provides a drain vent with check valve to avoid pulling a
vacuum on the flow chamber.
Figure 8 - Sealed Flowcell Dimensions

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Part 4 – Electrical Installation
4.1 General
The Q46 is powered in one of two ways, depending on the version purchased. The 12-24 VDC
powered analyzer requires a customer supplied DC power supply. The 90-260 VAC version
requires line power. Please verify the type of unit before connecting any power.
WARNING: Do not connect AC line power to the DC version. Severe damage will
result.
Important Notes:
1. Use wiring practices that conform to 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 on TB7. The AC power supply in
the transmitter contains a single 630mA slo-blo fuse (Wickmann/Littlefuse #372-
0630). The fuse F1 is located adjacent to TB7 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.
3. This analyzer must be installed by specifically trained personnel in accordance with
relevant local codes and instructions contained in this operating manual. Observe
the analyzer's technical specifications and input ratings. Proper electrical
disconnection means must be provided prior to the electrical power connected to this
instrument, such as a circuit breaker - rated 250 VAC, 2 A minimum. If one line of
the line power mains is not neutral, use a double-pole main switch to disconnect the
analyzer.
4. Repeated problems with lightning strikes damaging sensitive instrumentation are
often attributed to poorly bonded earth grounds in the instrument power source. The
protection schemes incorporated into this analyzer cannot operate to maximum
efficiency unless the ground connection is at its’ absolute lowest impedance.
5. There is no standard ground resistance universally recognized. Many agencies
recommend a ground resistance value of 5 ohms or less. The NEC recommends an
impedance to ground of less than 25 ohms, and less than 5 ohms where sensitive
equipment is installed. Power sources feeding sensitive instruments like the Q46
should have the lowest possible impedance to ground
4.2 AC Powered Instrument Wiring
Verify the AC power supply requirement before installing. Also verify that power is fully
disconnected before attempting to wire.
Q46 systems are supplied with 5 cable gland fittings for sealing cable entries.
Connect HOT, NEUTRAL, and GROUND to the matching designations on terminal strip TB7.

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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 450 Ohms maximum for output 1 and 1000 ohms maximum for
output 2. Also note that these two outputs are completely isolated from each other to ensure 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 may be unplugged from the front section of the
monitor if service is needed but should normally be left in place during installation.
Figure 9 - AC Power Connections
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.
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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4.3 Relay Connection
Three SPDT relays 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 Q46 (115 or 230 V), power may be jumped from the
power input terminals at TB7. Relay wiring is connected at TB4, TB5, and TB6 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 10).
Figure 10 - Relay Contacts

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4.4 Optional Output/Relay Connection
TB2, is used to connect to the optional 3-relay card (Figure 11) OR the optional third analog
output Out#3, (Figure 13). The Q46 can be configured for only one of these optional features,
and the hardware for either option must be factory installed. Note that the optional 3 relays are for
switching LOW POWER DC ONLY.
Figure 11 - Optional Low Power Relay Wiring
Figure 12 - Optional 3rd Analog Output Wiring

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4.5 Sensor Wiring
The sensor cable can be quickly connected to the Q46 terminal strip by matching the wire colors
on the cable to the color designations on the label in the monitor. A junction box is also available
to provide a break point for long sensor cable runs. Route signal 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.
Note: If sensor is experiencing Low-Slope or Low-Output conditions, due to poor Earth
Ground Connections, move the Shield connection from P/S board to alternate
location on lid, where indicated with an “S”.
Figure 13 - Submersible Sensor Connection

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4.6 Direct Sensor Connection
The sensor cable can be routed into the enclosure through one of cord-grips supplied with the
unit. Routing sensor wiring through conduit is only recommended if a junction box is to be used.
Some loose cable is needed near the installation point so that the sensor can be inserted and
removed easily from the flowcell.
Cord-grips used for sealing the cable should be snugly tightened after electrical connections have
been made to prevent moisture incursion. When stripping cables, leave adequate length for
connections in the analyzer enclosure as shown below. The standard 25 ft. sensor cable
normally supplied with the system is already stripped and ready for wiring. This cable can be cut
to a shorter length if desired to remove extra cable in a given installation. Do not cut the cable so
short as to make installation and removal of the sensor difficult.
.
Figure 14 - Sensor Cable Preparation