ATI Technologies Q46/84 User manual

O&MManual
ModelQ46/84
Hydrogen PeroxideMonitor
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]

Table of Contents
TABLEOF FIGURES............................................ 3
PART1- INTRODUCTION................................. 4
1.1 General...................................................... 4
1.2 Standard System....................................... 5
1.3 Features..................................................... 6
1.4 Q46/84 SystemSpecifications.................. 7
1.5 Q46 Performance Specifications............... 8
PART2–ANALYZERMOUNTING.................. 9
2.1 General...................................................... 9
2.2 Wall or PipeMount..................................10
2.3 Panel Mounting........................................12
PART3–SENSOR/FLOWCELLMOUNTING13
3.1 General.....................................................13
3.2 Constant-HeadFlowcell...........................13
3.3 SealedFlowcell........................................14
PART4–ELECTRICALINSTALLATION......15
4.1 General.....................................................15
4.4 Direct Sensor Connection........................19
4.6 JunctionBoxConnection.........................21
PART5–SENSORASSEMBLY.........................22
5.1 H2O2Sensor Preparation..........................22
PART6–CONFIGURATION.............................24
6.1 User Interface...........................................24
6.11 Keys.........................................................25
6.12 Display.....................................................25
.....................................................................25
6.2 Software...................................................26
6.21 SoftwareNavigation...............................27
6.22 MeasureMenu [MEASURE]...................29
6.23 CalibrationMenu [CAL].............................30
6.24 ConfigurationMenu[CONFIG].............30
6.25 ControlMenu[CONTROL]...................33
6.26 DiagnosticsMenu[DIAG].........................37
PART7–CALIBRATION...................................40
7.1 HydrogenPeroxideCalibration ...............40
7.11 H2O2Zero Cal..........................................40
7.12 H2O2SpanCal.........................................41
7.2 TemperatureCalibration..........................42
PART8–PIDCONTROLLERDETAILS.........43
8.1 PIDDescription.......................................43
8.2 PIDAlgorithm.........................................43
8.3 Classical PIDTuning...............................45
8.4Manual PIDOverrideControl.......................45
8.5 CommonPIDPitfalls...............................45
PART9–SYSTEMMAINTENANCE................47
9.1 General.....................................................47
9.2 Analyzer Maintenance.............................47
9.3 PeroxideSensor Maintenance..................47
9.31 Sensor AcidCleaning..............................48
9.4 FlowCell Maintenance............................48
PART10 –TROUBLESHOOTING....................49
10.1 General.....................................................49
10.2 External SourcesofProblems..................49
10.3 Analyzer Tests.........................................50
10.4 DisplayMessages....................................50
10.5 Sensor Tests.............................................52
SPAREPARTS......................................................53

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Table of Figures
FIGURE 1-TYPICAL MONITORING SYSTEM....................................................................................................... 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 MOUNTAND CUT-OUT....................................................................................................... 12
FIGURE 7-CONTSTANT HEAD FLOWCELL DETAILS......................................................................................... 13
FIGURE 8-SEALED FLOWCELL DETAILS......................................................................................................... 14
FIGURE 9-LINE POWER CONNECTION........................................................................................................... 16
FIGURE 10 -RELAY CONTACTS...................................................................................................................... 17
FIGURE 11 -OPTIONAL RELAY BOARD WIRING............................................................................................... 18
FIGURE 12 -OPTIONAL ANALOG OUTPUT WIRING........................................................................................... 18
FIGURE 13 -SENSOR CABLE PREPARATION ................................................................................................... 19
FIGURE 14 -SENSOR WIRING........................................................................................................................ 20
FIGURE 15 -JUNCTION BOX INTERCONNECT WIRING...................................................................................... 21
FIGURE 16 -H2O2 SENSOR ASSEMBLY......................................................................................................... 22
FIGURE 17 -USER INTERFACE....................................................................................................................... 24
FIGURE 18 -SOFTWARE MAP ........................................................................................................................ 28
FIGURE 19 -CONTROL RELAY EXAMPLE ........................................................................................................ 35
FIGURE 20 -ALARM RELAY EXAMPLE............................................................................................................. 36
FIGURE 21 -ISA (IDEAL)EQUATION............................................................................................................... 43
FIGURE 22 -DISPLAY MESSAGES .................................................................................................................. 51
FIGURE 23 -PT100 RTD TABLE.................................................................................................................... 52

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Part 1-Introduction
1.1General
The ModelQ46/84isanon-linemonitoring systemdesigned forthecontinuousmeasurement of
hydrogenperoxide (H2O2)concentration inwater.The full scaleoperating rangeofthe system
maybe selected bytheuserfor0-2.000 ppm,0-20.00 ppm,or0-200.0 ppm,and thesensing
systemwill operateon waterstreamswith temperaturesranging from0to 50°C. The Q46/84
Monitorisengineeredforapplicationsinwhich H2O2isapplied towaterforsterilization purposes.
The basicsensing element used inthe monitorisapolarographicmembraned sensorwhich
measureshydrogen peroxide directly.Watersimplyflowspastthe sensorand directlyto drain,
with theflowrate andpressureacross the sensorcontrolled byaconstanthead flowcell
assembly.The sensormeasurement doesnotalterthesampleoradd anychemicalsto the
sample stream, so the waterflowcan returnto the systemifdesired.
Q46H/64Monitors 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 standardmodelQ46H/84 systemincludesthreemaincomponents,the Q46/84 analyzer,a
constant head flowcell,andan H2O2sensor.Asealed flowcellisalsoavailableforapplications
wheresampleflowrate andpressurecan be carefullycontrolled. Figure1showsatypical
installation.
Forconnectionofthesensorto theelectronics,a25' cableissupplied. Anadditional100feet of
interconnectcablemaybe addedusing #07-0100 junction box.All required sparepartsarealso
providedwiththe basicsystem,includingsparemembranes,electrolyte, o-rings,and anyspecial
hardware.
Note thatstandard25 foot sensorcablesforhydrogenperoxidesensors can becut toashorter
length.Cutting thecableswillnot affectperformance, and eliminationofextracablecan
sometimeseliminate electricalnoise pickup through the cables.
Figure 1 -TypicalMonitoring System

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1.3Features
•StandardQ46Hanalyzers havefullyisolated inputsand outputs.Analog outputsareadditionally
completelyisolated fromeach other.
•Availableineither90-260VACor12-24 VDC powersupplysystems.All featuresremainthe
same in both variations.
•Highaccuracy,high sensitivitysystem,measuresfrom0.1 ppmto 200.0 ppmthrough 4 internal
automaticranges. Userrangesof200.0 ppb,2.000 ppm, 20.00 ppm, or200.0 ppm.
•Output Hold, Output Simulate, Output Alarm, and Output DelayFunctions. All forced changesin
output conditioninclude bumpless transferto providegradualreturn to 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 main analog output. PID controllercan operate withinstrument
configured asloop-powertransmitter, orasone ofthe two outputson the AC powered instrument.
PID includesmanualoperationfeature, and diagnostic“stuck-controller” feature forrelay
notificationofcontrolproblems.
•Two analog outputson the AC powered versionmaybe configured totrackH2O2and
temperature orboth outputscan be setto correspond to H2O2concentration. Both analog
outputscan be individuallyprogrammed to fail tospecificvalues.
•Digitalcommunicationoption forProfibus-DP,Modbus-RTU, orEthernet-IP.See Q46 Digital
CommunicationsManualforSpecifications.
•Diagnosticmessagesprovide a cleardescription ofanyproblemwith no confusing errorcodesto
lookup. Messagesare also included fordiagnosing calibration problems.
•Quickand easyone-point calibration method and sensorzero-cal. To provide high accuracy,all
calibration methodsincludestabilitymonitors that check temperature andmain parameterstability
before accepting data.
•Securitylockfeature to prevent unauthorized tamperingwith transmittersettings. Allsettingscan
be viewed whilelocked, but theycannot be changed.

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1.4Q46/84 SystemSpecifications
DisplayedParameters Main input, 0.001ppmto 200.0 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
MainParameterRanges Manualselectionofone ofthe following ranges,
0.0 to 2.000 ppm
0.00 to 20.00 ppm
0.00 to 200.0 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.
SystemWeight 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/RFI Influence Designed toEN 61326-1
Output Isolation 600 Vgalvanicisolation
Filter Adjustable0-9.9 minutesdamping to 90%step input
Temperature Input Pt100 RTDwith automaticcompensation
Sensor 3-electrode polarographicmembraned sensorfordirect
measurement ofH2O2,
SensorMaterials PVCand PEEK
Electrical Certification 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,polycarbonate, stainless steelhardware,
weatherproofand corrosion resistant,
Mounting Options Wall orpipe mount bracketstandard. Bracket suitableforeither
1.5”or2”I.D. U-Boltsforpipe mounting.
Panelmount adapteroptional.
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.
Optional Relays: Three additionalnon-isolated lowpowerrelaysavailable.SPST,
1 Amp @30VDC.
Analog Outputs Two 4-20mAoutputs.Output one programmable forPPM
peroxide orPID. Output 2 programmable forPPMperoxide or
Temperature. Maxload 500 Ohmsforeach output. Outputs
ground isolated and isolated fromeach other.An additional3rd
analog optionisavailable.
1.5Q46 PerformanceSpecifications
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
Instrument Response 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 H2O2sensoris25 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 2 -Q46 EnclosureDimensions

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2.2Wallor PipeMount
APVCmounting bracket with attachment screwsissupplied with eachtransmitter(see Figure3
belowfordimensions).The multi-purposebracket isattachedto therearofthe enclosureusing
the fourflat head screws.The instrument isthen attachedto thewallusing the fourouter
mounting holesinthe bracket. Theseholesareslotted toaccommodate two sizesofu-boltthat
maybe usedto pipemount the unit. Slotswill accommodate u-boltsdesigned for1½“or2”pipe.
The actualcenterto centerdimensionsforthe u-boltsareshowninthe drawing. Note that these
slotsareforu-boltswith ¼-20 threads.The 1½”pipeu-bolt(2”I.D. clearance)is availablefrom
ATI in type304 stainless steelunderpartnumber47-0005
Figure 3 -Wall orPipe Mount Bracket

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Figure 4 -Wall Mounting Diagram
Figure 5 -Pipe Mounting Diagram

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2.3Panel Mounting
Panelmountingofan ACpoweredmonitorusesthe panelmountingflange molded into therear
section ofthe enclosure.Figure6providesdimensionsforthe panelcutout requiredfor
mounting. Loop-powered instrumentsarenormallynot panelmounted, butmaybepanel
mounted ifordered specificallyforthispurpose. Panelmounted 2-wiresystemsrequirethe use
ofthe “deep back”enclosure normallyused forAC powered systems.
The panelmounting bracketkitmustbe ordered separately(part#05-0068).This kitcontainsa
metalretainerbracket thatattachestothe rearoftheenclosure,4screwsforattachment ofthis
bracket, and asealing gasket to insurethat the monitorprovidesawatertight sealwhen mounted
to a panel.
The sealinggasket mustfirstbe attached tothe enclosure. The gasket containsan adhesiveon
one side to remainsinplaceontheenclosure.Removethe protectivepaperfromthe adhesive
side ofthe gasket and slidethe gasket overthe backofthe enclosuresothat theadhesiveside
linesup withthe backofthe enclosureflange.Onceinplace, proceedto mount the monitorin
the panel.
Figure 6 -Panel Mount andCut-Out

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Part 3–Sensor/Flowcell Mounting
3.1General
Select a locationwithin themaximumsensorcablelength formounting ofthe sensorflowcell.
3.2Constant-HeadFlowcell
H
2
O
2
sensors arebestused inaconstant-headoverflowchamberbecausevariationsinsample
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 platewillaccommodate a 2"U-bolt formountingthe plate to a2"pipe.Figure7
showsthe dimensionsand mounting hole locationsforthe flowcell. Be sure to allowenough
clearanceon the left side ofthe flow cellforinsertion and removalofthe sensor.About 12 inches
clearanceisrecommended.
Figure 7 -Constant HeadFlowcell Details

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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.
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 8 -SealedFlowcellDetails

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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 connectAC line powerto the DC version. Severe damage will result.
Important Notes:
1. Usewiring practicesthat conformto all national,stateand localelectricalcodes.
Forpropersafetyaswellasstablemeasuring performance, itisimportant thatthe
earth groundconnection be made to a solidground point fromTB7. The AC power
supplycontainsasingle250mAslo-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. Repeatedproblemswith lightning strikesdamaging sensitive
instrumentationareoftenattributed to poorlybonded earth groundsinthe
instrument powersource. The protectionschemesincorporated intothisanalyzer
cannot operateto maximumefficiencyunless the groundconnection isat its’
absolute lowest impedance.
Thereisnostandardgroundresistanceuniversallyrecognized.Manyagencies
recommend agroundresistancevalueof5ohmsorless.The NECrecommendsan
impedanceto ground ofless than 25 ohms,and less than 5ohmswheresensitive
equipment isinstalled. Powersourcesfeedingsensitiveinstrumentslikethe Q46H/84
should havethelowest possibleimpedanceto ground.
4.2PowerConnection
VerifytheACpowersupplyrequirement beforeinstalling.Alsoverifythat powerisfully
disconnected before attempting to wire.
Q46 systemsare supplied with 5 cablegland fittingsforsealingcable entries.

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Connect HOT, NEUTRAL, and GROUND to the matching designationson terminalstrip TB7.
The two analogoutputsforthe standardsystemarepresentatterminalTB1.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 9 -Line PowerConnection
The powerstrip, TB7,allowsup to 12AWGwire. Awiregauge of16 AWGisrecommended to
allowforan easypass-through into the ½”NPTportswhen wiring.
WARNING
DisconnectlinepowervoltageBEFOREconnecting linepower
wires to Terminal TB7 ofthepowersu
pply.Thepowersupply
acceptsonlystandardthree-wiresinglephasepower.ACpower
supplies areconfiguredfor90-
260VACoperationatthefactory
attimeof order,and thepowersupplyis labeledas such.Do
NOTconnectvoltages otherthanthelabele
drequirement to the
input.

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4.3RelayConnection
Three SPDTrelaysareprovidedon thepowersupplyboard. None ofthe relaycontactsare
powered. The usermustsupplytheproperpowertothe contacts.Forapplicationsthat require
the sameswitchedoperating voltageastheQ46 (115or230 V),powermaybejumpered from
the powerinput terminalsat TB7. Relaywiringisconnectedat TB4, TB5, and TB6 asshown
below.Note that the relaycontactmarkingsareshown inthe NORMALmode. Programming a
relayfor“Failsafe”operation reversesthe NOandNC positionsin thisdiagram(Figure 10).
Figure 10 -RelayContacts

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TB2, isused toconnecttotheoptional3-relaycard(Figures11)OR theoptionalthirdanalog output,
Out#3, (Figure12).The Q46 can be configured foronlyone oftheseoptionalfeatures,and thehardware
foreitheroption must be factoryinstalled.
Figure 11 -Optional Relay BoardWiring
Figure 12 -Optional Analog Output Wiring

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4.4DirectSensor Connection
The sensorcablecanbe routedinto the enclosurethrough one ofcord-gripssuppliedwiththe
unit.Routing sensorwiring through conduitisonlyrecommended ifajunction boxisto be used.
Someloosecableisneeded nearthe installation point sothat thesensorcanbe insertedand
removed easilyfromthe flowcell.
Cord-gripsusedforsealing the cableshouldbe snuglytightenedafterelectricalconnectionshave
been made to prevent moistureincursion. When stripping cables,leaveadequate length for
connectionsintheanalyzerenclosureasshownbelow. The standard25ft. sensorcable
normallysupplied with the systemis alreadystripped and readyforwiring.Thiscablecan becut
to a shorterlength if desiredto removeextracableinagiven installation. Do not cut thecable so
short asto make installation and removalofthe sensordifficult.
.
Figure 13 -SensorCable Preparation

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4.5Sensor Wiring
The sensorcablecan be quicklyconnectedto the Q46terminalstripbymatchingthe wirecolors
on the cableto thecolordesignationson thelabelinthemonitor.Ajunctionboxis alsoavailable
to provide abreakpoint forlong sensorcableruns.Route signalcableawayfromACpower
lines,adjustablefrequencydrives,motors,orothernoisyelectricalsignallines.Donot run
sensororsignalcablesinconduit that containsAC powerlinesormotorleads.
NOTE:Ifsensoris experiencing Low-SlopeorLow-Outputconditions, dueto poorEarth
Ground Connections, movetheShieldconnection from P/SBoardto alternatelocation on
lid, where indicatedwith an“S”
Figure 14 -SensorWiring