ATI Technologies Q46/88 User manual

O & M Manual
Model Q46/88
Suspended Solids 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...............................................6
1.4 Q46/88 System Specifications.............7
1.5 Q46/88 Performance Specifications....8
PART 2 –ANALYZER MOUNTING..................9
2.1 General................................................9
2.2 Wall or Pipe Mount ............................10
2.3 Panel Mount, AC Powered Monitor ...12
PART 3 –SENSOR INSTALLATION..............13
3.1 General..............................................13
3.2 Submersible Installation ....................13
3.3 In-Line Installation..............................15
3.4 Flowcell Mounting..............................17
PART 4 –ELECTRICAL INSTALLATION......19
4.1 General..............................................19
4.2 AC Wiring...........................................19
4.3 Relay Connection ..............................21
4.4 Optional Output/Relay Connection....22
4.5 Direct Sensor Wiring..........................23
4.6 Remote Sensor Wiring.......................24
PART 5 –CONFIGURATION..........................25
5.1 User Interface ....................................25
5.11 Keys ...............................................26
5.12 Display ...........................................26
5.2 Software.............................................27
5.21 Software Navigation......................28
5.22 Measure Menu [MEASURE]..........30
5.23 Calibration Menu [CAL]....................31
5.24 Configuration Menu [CONFIG]......31
5.25 Control Menu [CONTROL]............33
5.26 Diagnostics Menu [DIAG] ...............37
PART 6 –CALIBRATION ...............................41
6.1 Suspended Solids Calibration...........41
6.11 Cal Zero.........................................41
6.12 Cal Span........................................41
6.2 Temperature Calibration....................42
6.3 Check Signal Function ......................43
6.31 Calibrate Check Signal..................43
6.4 External Light Function......................44
PART 7 –SYSTEM MAINTENANCE..............45
7.1 General..............................................45
7.2 Analyzer Maintenance.......................45
7.3 Sensor Maintenance .........................45
PART 8 –TROUBLESHOOTING ...................46
8.1 General..............................................46
8.2 External Sources of Problems...........46
8.3 Analyzer Tests...................................47
8.31 Display Messages .............................48
PART 9 –PID CONTROLLER DETAILS........50
9.1 PID Description .................................50
9.2 PID Algorithm ....................................50
9.3 Classical PID Tuning.........................52
9.4 Manual PID Override Control............52
9.5 Common PID Pitfalls .........................52
SPARE PARTS ...............................................54

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Table of Figures
FIGURE 1-SYSTEM OPTIONS...........................................................................................................................5
FIGURE 2–Q46 ENCLOSURE DIMENSIONS.......................................................................................................9
FIGURE 3-WALL OR PIPE MOUNT BRACKET....................................................................................................10
FIGURE 4-WALL MOUNTING DIAGRAM...........................................................................................................11
FIGURE 5-PIPE MOUNTING DIAGRAM ............................................................................................................11
FIGURE 6-PANEL MOUNT INSTALLATION........................................................................................................12
FIGURE 7-SUBMERSION MOUNTING ASSEMBLY .............................................................................................13
FIGURE 8-SUBMERSIBLE SENSOR ASSEMBLY................................................................................................14
FIGURE 9-11/2" IN-LINE INSTALLATION.........................................................................................................15
FIGURE 10 -FLOW TEE EXPLODED VIEW........................................................................................................16
FIGURE 11 -FLOWCELL DIMENSIONS..............................................................................................................17
FIGURE 12 -SENSOR/FLOWCELL EXPLODED VIEW..........................................................................................18
FIGURE 13 -AC POWER CONNECTIONS .........................................................................................................20
FIGURE 14 -RELAY CONTACTS......................................................................................................................21
FIGURE 15 -OPTIONAL LOW POWER RELAY WIRING.......................................................................................22
FIGURE 16 -OPTIONAL 3RD ANALOG OUTPUT WIRING ....................................................................................22
FIGURE 17 –SUSPENDED SOLIDS SENSOR CONNECTION................................................................................23
FIGURE 18 -REMOTE SENSOR WIRING...........................................................................................................24
FIGURE 19 -USER INTERFACE .......................................................................................................................25
FIGURE 20 -SOFTWARE MAP.........................................................................................................................29
FIGURE 21 -CONTROL RELAY EXAMPLE,HYSTERESIS &PHASE OPTIONS .......................................................35
FIGURE 22 -ALARM RELAY EXAMPLE.............................................................................................................36
FIGURE 23 -DISPLAY MESSAGES...................................................................................................................49
FIGURE 24 -ISA PID EQUATION ....................................................................................................................50

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Part 1 - Introduction
1.1 General
The Model Q46/88 is an on-line monitoring system designed for the continuous measurement of
suspended solids in water. It is intended for continuous monitoring of aeration tank mixed liquor,
clarifier effluent, industrial process water, and other applications containing relatively high levels
of suspended solids.
The system provides measurement over one of 3 selectable operating ranges, 0-100.0 mg/l, 0-
1000 mg/l, or 0-10.00 g/l. The sensing element used for suspended solids measurement is an
optical sensor measuring infrared “backscatter”, a method suitable for high solids levels. For
applications where sensor fouling is frequent, and Auto-Clean version of the system is available
that uses ATI’s Q-Blast air cleaner assembly.
Q46/88 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 (required for Auto-Clean systems). In addition, digital output options are available for
Profibus-DP, Modbus RTU or TCP/IP, or Ethernet-IP.
1.2 Standard System
Q46/88 systems include two components, the Q46 analyzer and an optical sensor with 30 ft.
cable. Sensor mounting options include submersion, submersion with Auto-Clean holder, 1 ½”
flow tee, or flowcell. If possible, the flowcell or flow tee should be used if expected suspended
solids levels are always below 10 mg/l.
For connection of the sensor to the electronics, a 30' cable is supplied. Up to an additional 400
feet of interconnect cable may be added using #07-0100 junction box.

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Figure 1 - System Options

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1.3 Features
Q46 electronic transmitters are designed to be a fully isolated instruments for operation
from either 90-260 VAC or 12-24 VDC power supplies.
Two 4-20 mA analog outputs are standard, and a third analog output is available as an
option. Output #1 may be configured for PID control. Outputs 2 (and 3 if added) are
programmable to track Suspended Solids, Temperature, or sensor signal strength.
Selectable PID controller on main analog output.
Communication options for Profibus-DP, Modbus-RTU or TCP/IP, or Ethernet-IP.
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.
oThree SPDT relay outputs for on-off control. Software settings for relay control include
setpoint, deadband, phase, delay, and failsafe.
oSelectable 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.
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 Q46/88 System Specifications
Displayed Parameters Main input, 0.1 mg/l to 10.00 g/l
Sensor temperature, -5.0 to 50.0°C (23 to 122ºF)
Loop current, 4.00 to 20.00 mA
Sensor slope/offset
Check Signal Level
% Light Level
Model number and software version
PID Controller Status
Main Parameter Ranges Manual selection of one of the following display ranges,
0-100.0 mg/l, 0-1000 mg/l, or 0-10.00 g/l.
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 NTU
Suspended Solids or PID. Output 2 programmable for NTU 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, 0 to 55°C (23 to 131 °F)
Storage, -30 to 70 °C (-22 to 158 ºF)
Ambient Humidity 0 to 95%, indoor/outdoor use, non-condensing to rated ambient
temperature range

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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 Optical backscatter
Sensor Materials PVC and acrylic
Sensor Cable Submersible: 30 ft. (10 m)
Max. Sensor Cable Length: 400 feet (123 m), with junction box
1.5 Q46/88 Performance Specifications
Accuracy 0.5% of range or 0.5 mg/l
Repeatability 0.3% of range or 0.3 mg/l
Sensitivity 0.1% of selected range
Warm-up Time 30 seconds to rated performance (electronics only)
Supply Voltage Effects ± 0.1% span
Instrument Response Time 120 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. Choose a location that is readily accessible for
calibrations and keep in mind that it will be necessary to use solutions 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 (30 m).
To maximize signal-to-noise ratio however, work with the shortest sensor cable possible. The
standard cable length of the Suspended Solids sensor is 15 feet.
Figure 2 –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 3
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 3 - Wall or Pipe mount bracket

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Figure 4 - Wall Mounting Diagram
Figure 5 - 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 6 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 monitor flange 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. 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 6 - Panel Mount Installation

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Part 3 – Sensor Installation
3.1 General
The majority of suspended solids applications use a submersible sensor mounted on a pipe and
submerged in aeration tanks, effluent channels, or other open tanks. For monitoring very low
suspended solids levels, it is often better to use a flowcell or flow tee for measurement, which
means the sample must be pumped to the measuring point. A flowcell or flow tee eliminates all
ambient light which might interfere at low solids levels. If a flowcell or tee is used, insure that air
is not entrained in the pumped sample. Air bubbles will cause high SS values do to optical
reflections off the bubbles.
3.2 Submersible Installation
The standard Suspended Solids sensor may also be used for submersion installations. A special
adapter is available for mounting the Suspended Solids sensor to a 1” pipe. Figure 11 below
shows a typical submersion mounting using ATI’s 00-1690 submersion mounting kit. This
complete kit adapts to typical handrails. The pipe adapter only is part no. 00-1689 and is
available separately when the handrail mounting kit is not required.
Figure 7 - Submersion Mounting Assembly

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Figure 8 - Submersible Sensor Assembly

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3.3 In-Line Installation
Suspended Solids sensors may be installed directly into a flowing pipe system provided that the
water does not contain a lot of entrained air. A 1 ½” flow tee assembly is available for this
purpose. It is best to install the sensor in a vertical pipe section with water flowing upward. This
assures that air pockets cannot develop at the sensor. If installed in a horizontal run of pipe,
place the sensor at the 3 or 9 o’clock position. Never mount the sensor on the top or bottom of
the pipe. It is also good practice to install a bypass system around the sensor for maintenance
and calibration purposes.
Figure 9 - 1 1/2" In-Line Installation

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Figure 10 - Flow Tee Exploded View

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3.4 Flowcell Mounting
Flowcells are used only for low suspended solids applications. The flowcell contains a needle
valve for flow adjustment that can easily plug in high solids applications. I expected suspended
solids will always be below 10 mg/l, the flowcell is a good choice. Figure 11 provides flowcell
dimensions. Note that the flowcell should always be mounted horizontally with the inlet on
the bottom and outlet on the top.
Select a flowcell location with sufficient clearance below to allow installation of the inlet calibration
valve to facilitate adjustment of the system after installation. See figure 8 for the suggested
tubing arrangement.
Figure 11 - Flowcell Dimensions
Figure 12 below provides a detail of how the Suspended Solids sensor is installed in the flowcell
assembly. During installation of the sensor, be sure that the O-ring is seated properly in the
groove at the end of the flowcell assembly. Proper seating of that O-ring is critical to avoiding
water leakage.

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Figure 12 - Sensor/Flowcell Exploded View

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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 mains 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
Q46H/79PR should have the lowest possible impedance to ground.
4.2 AC 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 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 may be unplugged from the front section of the
monitor if service is needed, but should normally be left in place during installation.
Figure 13 - 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 ½” NPT 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.