ATI Technologies Q46P User manual

O&MManual
ModelQ46P
pH Monitor
HomeOfficeEuropeanOffice
AnalyticalTechnology, Inc.ATI (UK)Limited
6Iron BridgeDriveUnit1& 2Gatehead BusinessPark
Collegeville, PA 19426 DelphNewRoad, Delph
Phone: [phone] SaddleworthOL3 5DE
610-917-0991Phone: [phone]
Fax: [phone]Fax: [phone]
Email: [e-mail] Email: [e-mail]

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Table of Contents
PART1 -INTRODUCTION...........................................4
1.1 General....................................................4
1.2 Features..................................................5
1.3 Q46PSystemSpecifications...................6
1.4 Q46PPerformance Specifications
(Common to all variations)........................7
1.5 General– Q25PpH Sensor....................7
1.6 SensorFeatures......................................8
1.7 Q25PSensorSpecifications...................8
PART2 – ANALYZER MOUNTING............................10
2.1 General..................................................10
2.2 Wall orPipe Mount................................11
2.3 PanelMounting.....................................13
PART3 – SENSOR/FLOWCELL MOUNTING...........14
3.1 General..................................................14
3.2 FlowTee Mounting................................15
3.3 Union Mounting.....................................16
3.4 Submersion Mounting...........................17
3.5 Insertion Mounting.................................18
3.6 ConventionalpH Sensors .....................20
3.61 Sealed Flowcell.....................................21
3.62 FlowTee Adapter..................................22
3.7 Lock-n-Load System.............................23
PART4 – ELECTRICALINSTALLATION..................24
4.1 General..................................................24
4.2 PowerConnection.................................24
4.3 RelayConnection..................................26
4.4 OptionalOutput orRelayConnections...27
4.5 SensorWiring........................................28
4.6 Direct SensorConnection.....................31
4.7 JunctionBoxConnection......................32
4.8 Combination Electrode Connection........33
4.9 ExternalPreamplifier.............................35
PART5 – CONFIGURATION......................................36
5.1 UserInterface........................................36
5.11 Keys......................................................37
5.12 Display...................................................37
5.2 Software................................................38
5.21 Software Navigation.............................39
5.22 MeasureMenu [MEASURE].................41
5.23 Calibration Menu [CAL].........................42
5.24 Configuration Menu[CONFIG]..............42
5.25 ControlMenu [CONTROL]....................47
5.26 Diagnostics Menu [DIAG].....................51
PART6 – CALIBRATION...........................................55
6.1 Overviewand Methods.........................55
6.11 SensorSlope........................................55
6.12 SensorOffset........................................55
6.13 2-Point Calibration Explained...............56
6.14 1-Point Calibration Explained...............56
6.2 Performing a 2-Point Calibration ..........56
6.3 Performing a 1-Point Calibration ..........57
6.4 Temperature Calibration.......................58
PART7 – PID CONTROLLER DETAILS...................60
7.1 PID Description.....................................60
7.2 PID Algorithm........................................60
7.3 ClassicalPID Tuning............................62
7.4 ManualPIDOverride Control...............62
7.5 Common PID Pitfalls............................62
PART8 – MAINTENANCEAND
TROUBLESHOOTING................................................64
8.1 SystemChecks.....................................64
8.2 Instrument Checks................................64
8.3 DisplayMessages.................................65
8.4 Cleaning the Sensor.............................67
8.5 Replacing the Saltbridge and
Reference BufferSolution..............................68
8.6 Troubleshooting....................................69
SPAREPARTS...........................................................71

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Table of Figures
FIGURE 1–Q46 ENCLOSURE DIMENSIONS .................................................................................................... 10
FIGURE 2-WALL OR PIPE MOUNTING BRACKET............................................................................................. 11
FIGURE 3-WALL MOUNTING DIAGRAM .......................................................................................................... 12
FIGURE 4-PIPE MOUNTING DIAGRAM............................................................................................................ 12
FIGURE 5-115/230 VAC PANEL MOUNT &CUT-OUT..................................................................................... 13
FIGURE 6-Q25 SENSOR TYPES.................................................................................................................... 14
FIGURE 7-FLOW THROUGH TEE MOUNT ....................................................................................................... 15
FIGURE 8-1.5" UNION MOUNT...................................................................................................................... 16
FIGURE 9-SENSOR SUBMERSION MOUNT ..................................................................................................... 17
FIGURE 10 -S.S. SENSOR INSERTION MOUNT................................................................................................ 18
FIGURE 11 -CPVC SENSOR INSERTION MOUNT ............................................................................................ 19
FIGURE 12 -(63-0013) COMBINATIONPHSENSOR,FLOW TYPE..................................................................... 20
FIGURE 13 -(63-0009) COMBINATIONPHSENSOR,SUB.TYPE ...................................................................... 20
FIGURE 14 -SEALED FLOWCELL DETAILS....................................................................................................... 21
FIGURE 15 -TWIST-LOCK FLOW TEE ............................................................................................................. 22
FIGURE 16 -LOCK-N-LOAD SENSOR EXPLODED VIEW..................................................................................... 23
FIGURE 17 –Q46 CONNECTIONS................................................................................................................... 25
FIGURE 18 –Q46 RELAY CONNECTIONS........................................................................................................ 26
FIGURE 19 -OPTIONAL RELAY BOARD WIRING............................................................................................... 27
FIGURE 20 -OPTIONAL ANALOG OUTPUT WIRING........................................................................................... 27
FIGURE 21 -CABLE DESCRIPTION,MODEL Q25P........................................................................................... 28
FIGURE 22 -DETACHABLE SINGLE SHIELDED CABLE,MODEL Q25P................................................................ 29
FIGURE 23 -Q46P SENSOR CONNECTIONS ................................................................................................... 30
FIGURE 24 -SENSOR CABLE PREPARATION ................................................................................................... 31
FIGURE 25 -JUNCTION BOX INTERCONNECT WIRING...................................................................................... 32
FIGURE 26 –OEM SENSOR CONNECTIONS,COMBINATION ELECTRODES........................................................ 33
FIGURE 27 –ATI COMBINATION ELECTRODE CONNECTIONS........................................................................... 34
FIGURE 28 -EXTERNAL PREAMP FOR CONVENTIONAL SENSOR WIRING........................................................... 35
FIGURE 29 -USER INTERFACE....................................................................................................................... 36
FIGURE 30 -SOFTWARE MAP ........................................................................................................................ 40
FIGURE 31 -AUTOMATICPHBUFFER TABLES................................................................................................. 44
FIGURE 32 -AUTOMATICPHBUFFER TABLES (CONT’D).................................................................................. 45
FIGURE 33 -CONTROL RELAY EXAMPLE,HYSTERESISAND OPPOSITE PHASE ................................................. 49
FIGURE 34 -ALARM RELAY EXAMPLE............................................................................................................. 50
FIGURE 35 -Q45H ISA (IDEAL)PID EQUATION.............................................................................................. 60
FIGURE 36 -REPLACINGTHE SALTBRIDGEAND REFERENCE BUFFER .............................................................. 69

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Part 1-Introduction
1.1General
The ModelQ46Pprovidescontinuousmeasurement of pH inaqueoussystems.It issuitablefor
potablewater,wastewater,and awide varietyofprocess waterapplications.Q46Pmonitors
maybeused with Q25P“differential”pH sensors oravarietyofconventional“combination”pH
sensors.
Monitors areavailableintwo electronicversions,auniversalACpoweredmonitorforoperation
from 90-260 VACanda12-24 VDC unit. Both versionsprovidetwo4-20mAanalog outputsand
3SPDTrelays.One analogoutputmaybe configuredforPID controland oneofthe relaysmay
be configured to provide a remote trouble indication.
The Q46Pisavailablewith afewoptionstoexpand the capabilitiesofthe monitor.Users may
selecteitherathirdanalog 4-20 mAoutput oran expansioncardthat providesthree additional
lowvoltage SPSTrelays.The expansion relaysare not isolated fromeach other.
Thismonitoralsoprovidesdigitalcommunicationcapability.Users mayorderQ46systemswith
eitherProfibusDP,ModbusRTU, orEthernet communicationsboardsfactoryinstalled.

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1.2Features
•Standard Q46PAnalyzers have fullyisolatedinputsand outputs. Analog outputsare additionally
completelyisolated fromeach other.
•Availableineither90-260VACor12-24 VDC powersupplysystems.All featuresremainthe
same in both variations.
•Output Hold,OutputSimulate, Output Alarm,and Output DelayFunctions.All forced changesin
output condition include bumpless transferforgradualreturnto on-line signallevelstoavoid
systemcontrolshockson both analog outputs.
•Three 6ampSPDTrelayoutputsandtwoanalog4-20 mAoutputsarestandard. Software
settingsforrelaycontrolinclude setpoint,deadband, phase, delay,and failsafe.Anoptional3-
relaycard, for0-30Vsignals, isavailableto bringthetotalto 6 relays.
•SelectablePID controlleron mainanalog output. PID controllercan operate with instrument
configured asloop-poweranalyzerorasone ofthe two outputsonthe ACpowered instrument.
PID includesmanualoperationfeature, and diagnostic“stuck-controller” timerfeatureforalarm
output ofcontrolproblems.
•Digitalcommunication option forProfibus-DP,Modbus-RTU. Moreversionspending. See Q46
DigitalCommunicationsManualforSpecifications.
•Twoanalog outputsmaybeconfigured totrackpH andtemperature. Both analogoutputscanbe
individuallyprogrammed to fail tospecificvalues.Anoptionalthirdoutputisavailable,providing
separate outputsforpH orTemperature.
•Lowvoltage relayexpansionboardprovidesforanalyzercontrolofthe optional“airblast”sensor
cleaningsystemavailable forsubmersion applications.
•Sensordiagnostics monitorglass breakage, sensorleaks,and RTDcondition. Diagnostic
messagesprovide a cleardescription ofproblems.
•Two-point andsamplecalibrationmethodsincludeauto-bufferrecognitionfrom13built-inbuffer
tables,with stabilitychecksduring calibration.
•SelectablePt1000orPt100 temperature inputs.
•Securitylockfeature to prevent unauthorized tampering.

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1.3Q46P SystemSpecifications
DisplayedParameters Main input, 0.00 to 14.00pH
Sensortemperature, -10.0 to 110.0 °C (14 to 230ºF)
Loopcurrent, 4.00to 20.00 mA
Sensorslope/offset
Modelnumberand software version
Enclosure NEMA4X,polycarbonate, stainless steelhardware,
weatherproofand corrosion resistant.
Mounting Options Wall orpipe mount bracketstandard. Bracket suitableforeither
1.5”or2”I.D. U-Boltsforpipe mounting. Panelmounting bracket
optional.
Weight 2 lb. (0.9 kg)
Display 0.75”(19.1 mm)high 4-digit main displaywith sign
12-digit secondarydisplay,0.3"(7.6 mm)5x7 dot matrix.
IntegralLEDback-light forvisibilityin the dark.
Keypad 4-keymembrane type, polycarbonate
Ambient Temperature Service, -20 to 60 °C (-4 to140 ºF)
Storage, -30 to 70 °C (-22 to 158 ºF)
Ambient Humidity 0 to 95%,indoor/outdooruse, non-condensing.
Altitude Up to 2000 m(6562 Ft.)
Electrical Certification OrdinaryLocation, cCSAus(CSA andUL standards-both
approved byCSA),pollution degree 2, installation category2
EMI/RFI Influence Designed toEN 61326-1
Output Isolation 600 Vgalvanicisolation
Filter(Damping) Adjustable0-9.9 minutesdamping to 90%step input change.
Temperature Input SelectablePt1000orPt100 RTD with automaticcompensation
Power 90 -260VAC,50-60 Hz, 10 VAmax
12-24 VDC,500 mAmax.
Enclosure NEMA4X,polycarbonate, stainless steelhardware,
weatherproofand corrosion resistant.
Mounting Options Wall orpipe mount bracketstandard. Bracket suitableforeither
1.5”or2”I.D. U-Boltsforpipe mounting.
Panelmount adapteroptional.

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ConduitOpenings Five½”NPTopenings, Adaptercanbe removed toprovide a 1”
NPTopeninginthebottomofthe enclosure. Gland seals
provided but not installed.
Relays, Electromechanical: Three SPDT, 6 amp @250VAC, 5 amp @24 VDC contacts.
Software selection forsetpoint, phase, delay,deadband, hi-lo
alarm, and failsafe.A-Bindicators on main LCD, and Cindicator
on lowerdisplay.
Expansion Relays: Optionalrelayboardwith 3 SPSTlowpowerrelays. Relays
rated 2A@30 VDC. Relaysare not isolated.
Analog Outputs Two 4-20mAoutputs.Output one programmable forpH orPID.
Output 2 programmable forpH orTemperature. Maxload 500
Ohmsforeach output. Outputsground isolated and isolated
fromeach other. Anadditional3rd analog option isavailable.
1.4Q46P Performance Specifications(Common toall variations)
Accuracy 0.1%ofspanorbetter(± 0.01 pH)
Repeatability 0.1%ofspanorbetter(± 0.01 pH)
Sensitivity 0.05%ofspan (± 0.01 pH)
Stability 0.05%ofspan per24 hours, non-cumulative
SupplyVoltageEffects ±0.05%span
Instrument Response Time 6 secondsto 90%ofstep input at lowest setting
Temperature Drift Span orzero, 0.02%ofspan/°C
Max. Sensor-Instrument 3,000 ft. (914 meters) w/preamp,
Distance 30 ft. (9.1 meters) w/o preamp
SensorTypes ModelQ25PpH w/ preamp-5wireinput, orcombinationstyle
pH electrodew/ TC
1.5General –Q25P pHSensor
ModelQ25P“differential”pH sensors arethemostcommonlyused sensors withtheQ46P
monitor.The differentialdesignutilizesasecond glass measuring electrodecontainedinan
internalbufferasthe referenceelement. Thiseliminatesthe needforasilver/silverchloride
referenceused inconventionalpH sensordesigns.Itisdesignedto performinthe harshestof
environments,includingapplicationsthat poisonconventionalpH sensors.Allsealsaredualo-
ring usingmultiple sealing materials.
Q25Psensors areavailablewith achoiceoftwoglasstypes.Forthe mostdemanding industrial
applications,P1glass shouldbe used. Thisglass isthickerand will lastlongerinhigher
temperatureand pressureapplications.Onthe otherhand,P1glass hasaveryhighimpedance
and isnot suggestedforuseinverycoldapplications.P2glass isagoodgeneralpurposeglass
that isbetterfordrinking water,wastewater,andlowtemperatureindustrialapplications.This
glass issomewhatthinnerwithlowerimpendenceandcanhandlecoldwatermoreeasily.Note
that the salt bridge isdifferent forthesetwo sensors.

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1.6Sensor Features
•Ahighvolume, dualjunctionsaltbridge tomaximizethein-servicelifetimeofthe sensor.The
annularjunctionprovidesalarge surfaceareatominimizethechanceoffouling.Large
electrolytevolumeand dualreferencejunctionsminimizecontamination.The saltbridgeis
replaceable.
•Anintegralpreamplifierencapsulatedprovidesalowimpedancesignaloutputwhichensures
stablereadingsinnoisyenvironments.Sensortotransmitterseparation canbe up to 3,000
feet (914 meters).
•Pt1000RTD. The temperatureelement usedinATIsensors ishighlyaccurate and provides
a highlylinearoutput.
•Availableinvariousconfigurationsincluding submersible, flowtype with quickdisconnect,
sanitary, and insertion.
1.7Q25P SensorSpecifications
Measuring Range 0 to 14.00 pH
Sensitivity 0.01 pH
Stability 0.02 pH per24hours, non-cumulative
WettedMaterials PEEK, ceramic, titanium, glass, Viton, EDPM
(optional: 316 stainless steelbody)
Temperature Compensation Pt1000 RTD
SensorCable 6 Conductor(5are used)plus2 shields,
15 feet (4.6 meters) standard length
Temperature Range -5 to +95 °C (23 to 203°F)
Pressure Range 0 to 100 psig
Maximum FlowRate 10 feet (3 meters) persecond
Sensorto AnalyzerDistance 3,000 feet (914 meters) maximum
Options 1”NPTconvertible, 1¼”insertion, 1½”or2”sanitary-style
Weight 1 lb. (0.45 kg)
Notes: 1. The typeofhardwareusedtomount thesensormaylimitthemaximumtemperatureand
pressureratings.Pleaseconsultthehardwaremanufacturer’sspecificationstoobtainthe
relevanttemperature and pressure rating information.
2. The maximumflowrate specificationislowerforprocess solutionswithlowionicconductivity
orhighsuspendedsolidsconcentration.High flowratesinlowionicconductivityprocesses
maycauseameasurement errordue to staticelectricaldischarge.Highflowratesin
processeswithhigh suspended solidsconcentration maydecreasethe functionallifeofthe
sensorbyerodingthepH-sensitive glass electrode.

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1.8ImportantSensor Notes
•The glass electrodemustbe wetted at alltimesto ensureproperfunctionality. Q25Psensors
areshipped with afluid-filled cap overthe electrodeto enableimmediate use(removecap
beforeinstalling, saveforstorage and shipping purposes).Electrodesthat havedried out for
anyreason shouldbe hydrated for24hours to restorefull functionality.
•Hydrofluoricacid(HF) will dissolveconventionalglass electrodes.Forapplicationsinvolving
hydrofluoricacid, apH sensorwith antimonyelectrodeisrecommended.
NOTE: The standardQ25Pprocesselectrodeismade ofglassand canbreakifnot handled
properly.Shouldthe electrode everbreak,USECAUTIONwhenhandlingthesensor
to avoid seriouscuts.
Equipment bearing thismarking maynot be discardedbytraditionalmethodsinthe
European communityafterAugust122005perEUDirective2002/96/EC. End
users must return old equipment to the manufacturerforproperdisposal.

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Part 2–AnalyzerMounting
2.1General
AllQ46 Seriesinstrumentsprovide formounting flexibility.Abracket isincluded that allows
mounting to wallsorpipes.In all cases,choosealocation that isreadilyaccessiblefor
calibrations.Alsoconsiderthatitmaybe necessarytoutilizealocation wheresolutionscan be
used during the calibration process.Totakefull advantage ofthe high contrastdisplay,mount
the instrument inalocation wherethedisplaycanbe viewed fromvariousanglesandlong
distances.
Locatetheinstrument incloseproximityto thepointofsensorinstallation -thiswill alloweasy
access during calibration. The standardcablelengthofthe pHsensoris15 feet. Forsensor
cableslongerthan30 feet, usethe optionaljunction box(07-0100)and sensorinterconnectcable
(31-0057).
Figure 1 – Q46 EnclosureDimensions

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2.2Wallor PipeMount
APVCmountingbracket withattachment screwsissupplied witheachtransmitter.The multi-
purposebracket isattachedtotherearofthe enclosureusing thefourflat headscrews.The
instrument isthen attachedto the wallusingthefouroutermounting holesinthe bracket. These
holesareslotted to accommodate two sizesofu-boltthat maybe usedto pipe mount the unit.
Slotswillaccommodate u-boltsdesigned for1½“or2”pipe. The actualcenterto center
dimensionsforthe u-boltsareshown inthe drawing. Note thattheseslotsareforu-boltswith¼-
20 threads.The 1½”pipeu-bolt(2”I.D. clearance)is availablefromATIintype304 stainless
steelunderpartnumber(47-0005).
Figure 2 -Wall orPipeMounting Bracket

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Figure 3 -WallMounting Diagram
Figure 4 -PipeMounting Diagram
Note: Analyzershown with optional
ProfibusConnectormounted to
side ofenclosure.

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2.3Panel Mounting
Panelmountingusesthe panelmountingflange molded into therearsectionof the enclosure.
Figure5 providesdimensionsforthe panelcutout required formounting.
The panelmounting bracket kitmustbe ordered separately(partnumber05-0094).Thiskit
containsametalretainerbracket that attachesto the rearoftheenclosure, 4screwsfor
attachment ofthisbracket, and asealinggasket to insurethat the panelmounted monitor
providesawatertight sealwhen mounted toa panel.
The sealing gasket must first be attached to the enclosure. The gasket containsan adhesiveon
one side sothatit remainsin place on the enclosure. Remove the protective paperfromthe
adhesive side ofthe gasket and slide the gasket overthe backofthe enclosure sothat the
adhesive side linesup with the backofthe enclosure flange. Onceinplace,you can proceed to
mount the monitorin the panel.
Figure 5 -115/230VAC Panel Mount & Cut-out

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Part 3–Sensor/Flowcell Mounting
3.1General
The Q25PpH Sensormounting optionsinclude flow-through, submersion, insertion (special
hardwarerequired),orsanitarymount depending on the typeofsensorpurchased.
Q25PDifferentialpH Sensors areavailablein4different versionsasshowninFigure6. The
convertiblestyleisthemostcommon and can be used foreitherflow-throughorsubmersion
applications.Aconvertiblesensorwith aquick-disconnectreceptacleisavailable. Thisversion
maynot be submerged andshouldnot be usedinunprotectedoutdoorlocations.Forspecial
applications,theQ25Pisalsoavailableinastainless steelbodiedversionforinsertiontype
installations, orcanbe supplied ineither1.5”or2”sanitaryversions.
Figure 6 -Q25 SensorTypes

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3.2FlowTee Mounting
Convertiblesensors maybe used ina1”flowteeasshown inFigure7. The flowtee isa
modified pipefitting that accommodatesthe pipethreadon the front ofthesensor.Samplemust
flowdirectlyagainstthefaceofthe sensorasshown.The sensormaybemounted horizontally
providedthat the outletflowispointeduptoavoid“airlocking”inthetee. Notethat standard1”
tee fittingswillnot workwithout modification due to clearance problemsinmostmolded tees.
Figure 7 -Flow Through Tee Mount

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3.3Union Mounting
Formounting the sensorinlargerpipeand allowing foreasysensorremoval,a1½”or2”union
mount adaptersystemisavailable. Thisarrangement allowsconnectionofthesensortopipe
sizesupto2inches(usingadapters ifnecessary)whileallowingeasyremovalwithouttwisting
sensorwires.ContactATIforpartnumbers and pricesforunionmount assembliesand
associatedpipe tees. The 1 ½”assemblyisshownbelow.The 2”teeassemblyis similar.
Figure 8 -1.5"Union Mount
Q45P
SENSOR
1½UNION
1½NIPPLE
1½TEE
(CUSTOMER
SUPPLIED)
1½UNION
1½NIPPLE
1½TEE
(CUSTOMER
SUPPLIED)

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3.4Submersion Mounting
When using thissensorforsubmersion applications,mount the sensorto the end ofa1”
mounting pipe using a1”coupling.ATI’s(00-0628)mountingassemblyshown inFigure9is
availableforsubmersibleapplications.Thisassemblyisdesignedto mount to standardhandrails
and facilitatesinsertion andremovalofthe sensor.
Figure 9 -SensorSubmersion Mount

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3.5Insertion Mounting
Specialinsertionmountinghardwareisavailableforapplicationsrequiringthe removalofthe
sensorfromaprocess line ortankwithoutshuttingoff the sampleflowinthe line. Figure10&
Figure11 showtypicalinsertion assemblies.
Figure 10 -S.S.SensorInsertion Mount

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Figure 11 -CPVCSensorInsertion Mount

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3.6Conventional pHSensors
Asindicatedpreviously,ModelQ46Ptransmitters maybe usedwithstandardcombinationpH
sensors availablefromavarietyofmanufacturers.Forsimpleclean waterapplications,these
lowercostsensors maybeallthat’sneeded forreliablemonitoring. ATIoffersafewofthese
typesofsensors asstandarditemsand can assistwith the selection ofspecialsensors should
the needarise.
Figure 12 belowshowthedimensionsof two pH sensors frequentlyused withtheQ46P.The 63-
0013sensorissuitableforusewitheitherapipeteeadapteroraspecialclearacrylicsealed
flowcell.
The 63-0009 pH sensorwithflat glass tipissuitableforsubmersion use,orforscrewingdirectly
into a pipe tee.If using inatee, be carefulto allowforenough slackcable sothatthe cable does
not twist excessively.
Figure 12 -(63-0013)Combination pH Sensor, Flow Type
Figure 13 -(63-0009)Combination pH Sensor,Sub.Type