ATI Technologies Q46-85 User manual

O&MManual
ModelQ46-85
PeraceticAcidMonitor
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 Standard System....................................... 5
1.3 Features..................................................... 8
1.4 Q46/85 SystemSpecifications.................. 9
1.5 Q46HPerformance Specifications...........10
PART2–ANALYZERMOUNTING.................11
2.1 General.....................................................11
2.2 Wall or PipeMount..................................12
2.3 Panel Mounting........................................14
PART3–SENSOR/FLOWCELLMOUNTING15
3.1 General.....................................................15
3.2 Constant-HeadFlowcell...........................15
3.3 SealedFlowcell........................................16
3.4 SubmersionMounting..............................18
PART4–ELECTRICALINSTALLATION......19
4.1 General.....................................................19
4.2 Power Connection....................................19
4.4 Direct Sensor Connection........................23
4.5 SensorWiring ......................................24
4.6 JunctionBoxConnection.........................25
PART5–SENSORASSEMBLY.........................26
5.1 PAASensor Preparation..........................26
5.2 Optional pHSensor..................................28
PART6–CONFIGURATION.............................29
6.1 User Interface...........................................29
6.11 Keys.........................................................30
6.12 Display.....................................................30
6.2 Software...................................................32
6.21 SoftwareNavigation...............................32
6.22 MeasureMenu [MEASURE]...................35
6.23 CalibrationMenu [CAL].............................36
6.24 ConfigurationMenu[CONFIG]..............36
6.25 ControlMenu[CONTROL]....................41
6.26 DiagnosticsMenu[DIAG].........................45
PART7–CALIBRATION...................................48
7.1 PAACalibration......................................48
7.11 PAAZero Cal..........................................48
7.12 PAASpanCal..........................................49
7.2 TemperatureCalibration..........................50
7.3 pHCalibration..........................................51
7.31 Two-PointpHCal....................................51
7.32 One-PointpHCal.....................................52
PART8–PIDCONTROLLERDETAILS.........53
8.1 PIDDescription.......................................53
8.2 PIDAlgorithm.........................................53
8.3 Classical PIDTuning...............................55
8.4 ManualPIDOverrideControl..................55
8.5 CommonPIDPitfalls...............................55
PART9–SYSTEMMAINTENANCE................57
9.1 General.....................................................57
9.2 Analyzer Maintenance.............................57
9.3 PAASensor Maintenance........................57
9.31 Sensor AcidCleaning..............................58
9.4 FlowCell Maintenance............................58
PART10 –TROUBLESHOOTING....................59
10.1 General.....................................................59
10.2 External SourcesofProblems..................59
10.3 Analyzer Tests.........................................60
10.4 DisplayMessages....................................60
10.5 Sensor Tests.............................................63
SPAREPARTS......................................................65

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Table of Figures
FIGURE 1-TYPICAL SYSTEM DIAGRAM..........................................................................................5
FIGURE 2-MONITORING SYSTEMW/BAYONET STYLE PHSNSOR ....................................................6
FIGURE 3-SEALED FLOWCELL ASSEMBLIES W/FLOW CONTROL......................................................7
FIGURE 4–Q46 ENCLOSURE DIMENSIONS ..................................................................................11
FIGURE 5-WALLOR PIPE MOUNT BRACKET.................................................................................12
FIGURE 6-WALL MOUNTING DIAGRAM........................................................................................13
FIGURE 7-PIPE MOUNTING DIAGRAM..........................................................................................13
FIGURE 8-PANEL MOUNT CUTOUT .............................................................................................14
FIGURE 9-CONSTANT HEAD FLOWCELL DETAILS.........................................................................15
FIGURE 10 -SEALED FLOWCELL DETAILS.....................................................................................16
FIGURE 11 -SEALED PHFLOWCELL DETAILS ...............................................................................17
FIGURE 12 -SUBMERSIBLE SENSOR MOUNTING ASSEMBLY ..........................................................18
FIGURE 13 -LINE POWER CONNECTION.......................................................................................20
FIGURE 14 -OPTIONAL RELAY BOARD WIRING.............................................................................21
FIGURE 15 -OPTIONAL RELAY BOARD WIRING.............................................................................22
FIGURE 16 -OPTIONAL ANALOG OUTPUT WIRING.........................................................................22
FIGURE 17 -SENSOR CABLE PREPARATION .................................................................................23
FIGURE 18 -SENSOR WIRING......................................................................................................24
FIGURE 19 -JUNCTION BOX INTERCONNECT WIRING....................................................................25
FIGURE 20 -PAA SENSOR ASSEMBLY .........................................................................................26
FIGURE 21 -SUBMERSIBLE PAA SENSOR ASSEMBLY ...................................................................27
FIGURE 22 -USER INTERFACE.....................................................................................................29
FIGURE 23 -SOFTWARE MAP......................................................................................................34
FIGURE 24 -AUTOMATIC PHBUFFER TABLES...............................................................................40
FIGURE 25 -CONTROL RELAY EXAMPLE,HYSTERSISAND TWOOPPOSITE PHASE OPTIONS............43
FIGURE 26 -ALARM RELAY EXAMPLE ..........................................................................................44
FIGURE 27 -Q46HISA (IDEAL)EQUATION...................................................................................53
FIGURE 28 -Q46H DSIAPLY MESSAGES ......................................................................................61
FIGURE 29 -DISPLAY MESSAGES (CONTINUED)...........................................................................62
FIGURE 30 -PT100 RTD TABLE..................................................................................................63

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Part 1-Introduction
1.1General
The ModelQ46/85isanon-linemonitoring systemdesigned forthecontinuousmeasurement of
PeraceticAcid(PAA)concentrationinsolution.The fullscaleoperatingrangeof thesystemmay
be selectedbytheuserfor0-20.00 ppm,0-200.0 ppm,or0-2000 ppm,and the sensing system
willoperateon waterstreamswithtemperaturesranging from0to 50°C. The Q46/85PAA
Measurement Systemisengineered forapplicationsinwhichPAAisappliedto waterfor
sterilization purposes
The basicsensing element used inthe PAA monitoris apolarographicmembrane sensorwhich
measuresPAA directly.Watersimplyflowspastthesensorand directlyto drain,withthe flow
rate and pressureacross the sensorcontrolledbyaconstant head flowcell assembly.The PAA
measurement doesnot alterthe sampleoradd anychemicalsto thesamplestream,sothe water
flowcan return to the systemifdesired.
Q46/85Monitors areavailableintwobasicelectronicversions,a90-260 VACpowered monitor,
ora12-24 VDC powered monitor–bothwith three relaysand two 4-20 mAanalogoutputs.Both
versionsallowflexibleoutput optionswhichincludeadditional4-20 mAcurrent outputs,additional
0-30 VDC signalrelays,PID control, and digitalcommunication cards.

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1.2Standard System
The standardmodelQ46/85 systemincludesthree maincomponents,theQ46 analyzer,a
constant head flowcell,and aPAA sensor.Alow-volumeflowcellisalsoavailablefor
applicationswheresampleflowrate and pressurecanbe carefullycontrolled. Figure1showsa
typicalinstallation includingthe optionalpH sensor.
Forconnectionofthesensorto theelectronics,a25' cableissupplied. Anadditional100feet of
interconnectcablemaybe addedusing #07-0100 junction box.All required sparepartsarealso
providedwiththe basicsystem,includingsparemembranes,electrolyte, o-rings,and anyspecial
hardware.
Figure 1 -TypicalSystemDiagram

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Figure2belowshowsthesamestandardflowcellassemblyand PAAsensoralongwiththe
conventionaltype pH sensor.Aspecialadapterisrequiredto holdthe pH sensorinitsproper
location inthe flowcellinlet chamber.
Figure 2 -Monitoring Systemw/BayonetStylepH Snsor

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Figure3belowshowsaninstallation using a(00-1522)sealed flowcell forthe PAAsensorand a(00-
1527)sealed flowcell forthe pHsensor.Thistype ofinstallationrequirescarefulflow control.We
recommend the useofour(03-0371)flowcontrolassemblywhen using sealed flowcells.Thisassembly
consistsofan in-line filterand afixed-flowregulatorwhichwillmaintainaconstant 400 cc/minflowrate
throughthesystem.Thisflowwillbe maintained solong asinlet pressuresare between5and 125PSIG.
The in-linefilterisused mainlytoprotecttheflowcontrolelement againstlargerparticlesthat might cause
plugging ofthe device.
Figure 3 -SealedFlowcellAssembliesw/Flow Control

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1.3Features
•StandardQ46HAnalyzershavefullyinputsand outputs.Analogoutputsareadditionally
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 transferto provide gradualreturnto on-line signallevelsand to
avoid systemcontrolshocks on both analog outputs.
•Three 6ampSPDTrelayoutputsandtwoanalog 4-20 mAoutputsarestandard. Software
settingsforrelaycontrolinclude setpoint, deadband, phase, delay,and failsafe. Anoptional3-
relaycard forlow voltagesignalsisavailable tobring the totalto 6 relays.
•SelectablePID controlleron mainanalogoutput. PID controllercan operate withinstrument
configured asloop-powertransmitter, orasone ofthetwo outputson the ACpowered instrument.
PID includesmanualoperationfeature, and diagnostic“stuck-controller” timerfeatureforrelay
notificationofcontrolproblems.
•TwoanalogoutputsontherelayversionmaybeconfiguredtotrackPAAand temperature, PAA
and PAA,orPAAand pH. Both analog outputscan be individuallyprogrammed to fail to specific
values.
•Digitalcommunicationoption forProfibus-DP,Modbus-RTU, orEthernet-IP.See Q46 Digital
CommunicationsManualforSpecifications.
•Diagnosticmessagesprovide acleardescription ofanyproblemwith no confusingerrorcodesto
lookup. Messagesare also included fordiagnosing calibration problems.
•Quickand easyone-point calibration method andsensorzero-cal.Toprovide high accuracy,all
calibration methodsincludestabilitymonitors that check temperature and main parameterstability
before accepting data.
•Securitylockfeatureto preventunauthorized tamperingwithtransmittersettings.Allsettingscan
be viewed whilelocked, but theycannot be changed.

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1.4Q46/85 SystemSpecifications
DisplayedParameters Main input, 0.01 ppmto 2000 ppm
Sensortemperature, -10.0 to 55.0 °C(23 to 131 ºF)
SensorCurrent, 0.0–999.9 nA, 0.000 to 99.99 uA
Loopcurrent, 4.00to 20.00 mA
Sensorslope/offset
Modelnumberand software version
PID ControllerStatus
OptionalpH Input value. 0.00 to14.00 pH
MainParameterRanges Manualselectionofone ofthe following ranges,
0.00 to 20.00 ppm
0.0 to 200.0 ppm
0 to 2000 ppm
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.
Weight Approximately5 lbs. (2.3 Kg)withsensor&flowcell
Ambient Temperature AnalyzerService,-20 to 60 °C (-4 to 140 ºF)
SensorService, -5 to 55°C(23 to 131 °F)
Storage, -5to 70 °C(-22 to 158 ºF)
Ambient Humidity 0 to 95%,non-condensing
EMI/RFIInfluence Designed toEN 61326-1, CEMarked
OutputIsolation 600 Vgalvanicisolation
Filter Adjustable0-9.9 minutesadditionaldamping to 90%step input
TemperatureInput Pt100 RTDwith automaticcompensation
Sensor 2-electrode polarographicmembrane sensorfordirect
measurement ofPAA,
SensorMaterials PVCand PEEK
ElectricalCertification OrdinaryLocation, cCSAus(CSA and UL standards-both CSA
approved), pollution degree 2, installation category2
SensorCable 25 ft. (7.5 meter) cable with 6-pinplug.
Max.Sensor-to-Analyzer 100 feet (30.5 meters), withjunctionbox
Distance
FlowCell Constant head overflow, clearcast acrylic, 7-30 GPH, 15 GPH
recommended, inlet is¼”hose barbat 1/8”MNPT, outlet is½”
hose barb at 3/8”MNPT

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Power 90 -260VAC,50-60 Hz, 10 VAmaxor
12-24 VDC,500 mAmax.
Enclosure NEMA4X(IP-66), polycarbonate, stainless steelhardware,
weatherproofand corrosion resistant,
Mounting Options Wall orpipe mount bracketstandard. Bracket suitableforeither
1.5”or2”I.D. U-Boltsforpipe mounting.
Panelmount adapteroptional.
Conduit Openings 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.
OptionalRelays: Three additionalnon-isolated lowpowerrelaysavailable.SPST,
1 Amp @30VDC.
Analog Outputs Two 4-20mAoutputs.Output one programmable forPPM PAA
orPID. Output 2 programmable forPPMPAAorTemperature.
Maxload 500Ohmsforeach output. Outputsground isolated
and isolatedfromeach other. An additional3rd analog option is
available.
1.5Q46HPerformanceSpecifications
Accuracy 0.5%ofselected rangeor0.02 PPM
Repeatability 0.3%ofselected rangeor0.01 PPM
Sensitivity 0.05%ofselected range
Non-linearity 0.1%ofselected range
Warm-up Time 3 secondsto rated performance (electronics only)
SupplyVoltageEffects ±0.05%span
InstrumentResponse Time 60 secondsto 90%ofstep input atlowest damping
Equipment bearing thismarking maynot be discarded bytraditionalmethods
inthe EuropeancommunityafterAugust122005 perEUDirective
2002/96/EC. End users mustreturnoldequipment to the manufacturerfor
properdisposal.

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Part 2–AnalyzerMounting
2.1General
AllQ46 Seriesinstrumentsoffermaximummounting flexibility.Abracket isincluded with each
unitthat allowsmountingto wallsorpipes.In allcases,choosealocationthat isreadily
accessibleforcalibrations.Alsoconsiderthat itmaybe necessaryto utilizealocation where
solutionscan be usedduring thecalibration process.Totakefull advantage ofthe high contrast
display,mount the instrument inalocation wherethedisplaycan beviewedfromvariousangles
and long distances.
Locatetheinstrument incloseproximityto thepointofsensorinstallation -thiswill alloweasy
access duringcalibration. The sensor-to-instrument distanceshouldnotexceed100feet.To
maximizesignal-to-noiseratiohowever,workwiththe shortestsensorcablepossible. The
standard cable length ofthe PAA sensoris25 feet.
Due to the flexibilityoftheinstrument design, someofthe mounting featureschangebasedon
the configurationthat wasordered. Forexample, the2-wiretransmitterversion isdifferent forthe
115/230 VACcontrollerbecausethe rearofthe enclosureismuchdeeperwhenthe ACpowered
unitisused.Inaddition,the ACpowered unithasanintegratedpanelmount flangerequiringa
single cutout forflush mounting.
Figure 4 – Q46 EnclosureDimensions

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2.2Wallor PipeMount
APVCmounting bracket with attachment screwsissuppliedwitheachtransmitterasshown in
Figure5. The multi-purposebracket isattached to the rearofthe enclosureusing thefourflat
head screws.The instrument isthen attached tothe wallusingthe fouroutermounting holesin
the bracket. Theseholesareslotted toaccommodate twosizesofu-boltthat maybe used to
pipemount the unit. Slotswill accommodate u-boltsdesigned for1½“or2”pipe. The actual
centertocenterdimensionsforthe u-boltsare shownin the drawing. Note that these slotsare for
u-boltswith¼-20threads.The 1½”pipe u-bolt(2”I.D. clearance)isavailablefromATIintype
304 stainless steelunderpart number(47-0005).
Figure 5 -Wall orPipe mount Bracket

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Figure 6 -WallMounting Diagram
Figure 7 -PipeMounting Diagram

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2.3Panel Mounting
Panelmountingusesthe panelmountingflange molded into therearsectionof the enclosure.
Figure8 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 8 -PanelMount Cutout

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Part 3–Sensor/Flowcell Mounting
3.1General
Select a locationwithin themaximumsensorcablelength formounting ofthe sensorflowcell.
3.2Constant-HeadFlowcell
PAAsensors arebestusedinaconstant-head overflowchamberbecausevariationsinsample
flowrateandpressurecan causeunstablereadings.When monitoringlowconcentrations(below
0.5 PPM),thismethod shouldalwaysbeused. Mechanicalinstallationofthe flowcell requires
that itbe mounted to awall orotherconvenient flat surface. Alternatively,the mounting holeson
the plate willaccommodatea2"U-boltformountingthe plate toa2"pipe. Figure9showsthe
dimensionsand mounting holelocationsforthe flowcell.Besureto allowenough clearanceon
the leftsideoftheflowcellforinsertionand removalofthesensor.About12inchesclearanceis
recommended.
Figure 9 -Constant HeadFlowcell Details
Oncemounted,inletand drainconnectionsmustbe made. The flowcellcontainsa1/8"MNPT
inlet connectionanda3/8"MNPTdrainconnection. Hosebarbsfortheinletand drain
connectionsaresuppliedwith the flowcell forusewith flexibletubing. The inlet hosebarbis
used with ¼"I.D. tubingand thedrain hose barb isused with ½"I.D. tubing.

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3.3SealedFlowcell
Applicationswherethesampleinletflowiswellcontrolled canuseasimplersealedflowcell.
Using thisflowcell requiresthat flowbecontrolled externallyto about 400 cc/min. Variableflow
rate orvariablepressurewillcauseunstablereadingsinthisflowcell.ATIoffersaspecialflow
controlelement that canbeused ahead ofthisflowcellon theincoming sampleline. The flow
controlispartno. (55-0048).It will controlthe inlet flowrateat 400 cc/min. withinlet pressure
variationsfrom5-150 PSIG.A50 micron y-strainerahead ofthe flowcontrolelement is
recommended. The sealedflowcell providesadrainvent withcheckvalvetoavoidpullinga
vacuumon the flowchamber.
Figure 10 -SealedFlowcell Details

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Figure 11 -SealedpH Flowcell Details

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3.4Submersion Mounting
Someapplicationsaremucheasierdoneusing thesubmersiblesensor.Thismethod can
sometimesbe used whereflowisreasonablyconstant, and hydraulicheaddoesnot vary
appreciably.PAA sensors can neverbe used incompletelystagnant conditions.Aflowvelocity
ofat least0.3 feet persecond isnormallyrequiredformeasurement. Anyapplicationsfora
submersiblePAAsensorshouldfirstbediscussed withATI. Atrialofsuchinstallationsmaybe
necessary.
Submersible sensors are mounted to a 1"pipe using astandard1"PVC threadbythread pipe
coupling. The mounting pipe can be secured tostandard 1½"pipe rail usinga mountingbracket
kit availablefromATI (part number00-0628)asshownin Figure12 -Submersible Sensor Mounting
Assembly
.
SENSOR CABLE
2"HANDRAIL
1"ALUMINUM CONDUIT, THREADED1"T xT PVC COUPLING ONE END OR 1"SCHED 80 PVC PIPE
LENGTH AS REQUIRED
(SUPPLIED BYCUSTOMER)
SWIVEL MOUNTING BRACKET WITH
HARDWARE, SUPPLIED BYATI
SUPPLIED BYATI
SENSOR, TYPICAL
2 - 3 FT. SUBMERGENCE
Figure 12 -SubmersibleSensorMounting Assembly

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Part 4–Electrical Installation
4.1General
The Q46 ispoweredinoneoftwoways,dependingon the version purchased. The 12-24 VDC
poweredanalyzerrequiresacustomersuppliedDC powersupply.The 90-260VACversion
requiresline power.Please verifythe type ofunitbefore connecting anypower.
WARNING: Donot connectAClinepowerto aDC poweredunit.Severedamagewill
result.
ImportantNotes:
1. Usewiring practicesthat conformto all national,stateand localelectricalcodes.
Forpropersafetyaswellasstablemeasuring performance, itisimportant thatthe
earth groundconnection be made to a solidground point fromTB7. The AC power
supplycontainsasingle630mAslo-blofuse(Wickmann/Littlefuse#372-0630).The
fuse F1 islocated adjacent to TB7 and iseasilyreplaceable.
2. Do NOTrun sensorcablesorinstrument 4-20 mAoutput wiring inthe same
conduitthat containsACpowerwiring. ACpowerwiringshouldberun ina
dedicated conduitto prevent electricalnoisefrom coupling with theinstrumentation
signals.
3. Thisanalyzermustbe installedbyspecificallytrainedpersonnelinaccordancewith
relevantlocalcodesandinstructionscontained inthisoperatingmanual.Observe
the analyzer'stechnicalspecificationsand input ratings.Properelectrical
disconnectionmeansmustbe provided priorto the electricalpowerconnectedto
thisinstrument, suchasacircuitbreaker-rated 250 VAC,2Aminimum.Ifone
lineofthe linepowermainsisnot neutral,useadouble-polemainsswitchto
disconnect theanalyzer.
4. Repeated problemswith lightning strikesdamagingsensitiveinstrumentation are
often attributedto poorlybondedearthgroundsinthe instrument powersource. The
protection schemesincorporatedintothisanalyzercannotoperatetomaximum
efficiencyunless theground connection isat its’absolute lowestimpedance.
Thereisnostandardground resistanceuniversallyrecognized.Manyagencies
recommend aground resistancevalue of5ohmsorless.The NECrecommendsan
impedanceto ground ofless than 25 ohms,and less than 5ohmswheresensitive
equipment isinstalled.Powersourcesfeedingsensitiveinstrumentslikethe
Q46H/79PR shouldhave the lowest possible impedance to ground.
4.2PowerConnection
VerifytheACpowersupplyrequirement beforeinstalling.Alsoverifythat powerisfully
disconnected before attempting to wire.
Q46 systemsare supplied with 5 cablegland fittingsforsealingcable entries.
Connect HOT, NEUTRAL, and GROUND to the matching designationson terminalstrip TB7.

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The twoanalogoutputsforthe standardsystemarepresent at terminalTB1. The loop-load
limitationinthisconfiguration is500Ohmsmaximumforeachoutput.Alsonotethat thesetwo
outputsarecompletelyisolated fromeachotherto insurethat ground loopsdo not resultfrom the
connection ofboth outputsto the same device such asa PLC orDCS.
Aribbon cableconnectsthepowersupplyassemblywith the microprocessorassemblylocatedin
the front section ofthe enclosure. Thiscablemaybe unpluggedfromthe front section ofthe
monitorifserviceisneeded, but should normallybeleft inplaceduring installation.
Figure 13 -LinePowerConnection
The powerstrip, TB7,allowsup to 12AWGwire. Awiregauge of16 AWGisrecommended to
allowforan easypass-through into the ½”NPTportswhen wiring.
WARNING
DisconnectlinepowervoltageBEFOREconnecting
linepowerwires toTerminalTB7ofthepowersupply.
Thepowersupplyacceptsonlystandard three-
wire
singlephasepower.ACpowersuppl
ies are
configuredfor 90-
260VACoperation atthefactoryat
timeoforder,and thepowersupplyislabeledas
such.DoNOTconnectvoltages otherthanthe
labeledrequirementtotheinput.