ATI Technologies Q46C2 User manual

O & M Manual
Model Q46C2
2-Electrode Conductivity/Resistivity
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]

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Table of Contents
TABLE OF FIGURES ........................................3
PART 1 - INTRODUCTION................................4
1.1 General................................................4
1.2 Features...............................................5
1.3 Q46C2 System Specifications.............6
1.4 Q46C2 Performance Specs.................7
PART 2 –ANALYZER MOUNTING..................9
2.1 General................................................9
2.2 Wall or Pipe Mount ............................10
2.3 Panel Mount.......................................12
PART 3 –SENSOR MECHANICALS .............13
3.1 General..............................................13
PART 4 –ELECTRICAL INSTALLATION......15
4.1 General..............................................15
4.2 Power Connection .............................15
4.3 Relay Connection ..............................17
4.4 Optional Output or Relay Connections..
...........................................................18
4.5 Sensor Wiring....................................19
4.6 Direct Sensor Connection..................20
4.7 Junction Box Connection...................21
4.8 In-Line Sensor Connection................22
4.9 OEM Sensor Connection...................23
4.10 Sanitary Sensor Connection ..........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] .......................30
5.24 Configuration Menu [CONFIG]......31
PART 6 - CONTROL .......................................35
PART - 7 DIAGNOSTICS MENU [DIAG]........39
PART 8 –CALIBRATION ...............................42
8.1 Overview and Methods......................42
8.11 1-Point Calibration Explained ........42
8.12 Cell Constant Calibration Explained..
.......................................................42
8.13 Zero Calibration Explained ............42
8.2 Performing a 1-Point Calibration.......43
8.3 Performing a Cell Constant Calibration.
...........................................................44
8.4 Performing a Sensor Zero Calibration...
...........................................................45
8.5 Temperature Calibration....................45
8.6 TC Factor Calibration........................46
PART 9 –PID CONTROLLER DETAILS........47
9.1 PID Description .................................47
9.2 PID Algorithm ....................................47
9.3 Classical PID Tuning.........................49
9.4 Manual PID Override Control............49
9.5 Common PID Pitfalls .........................49
PART 10 –SYSTEM MAINTENANCE............51
10.1 System Checks..............................51
10.2 Instrument Checks.........................51
10.4 Cleaning the Sensor......................54
10.5 Sensor Testing...............................54
SPARE PARTS ...............................................56

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Table of Figures
FIGURE 1-ENCLOSURE DIMENSIONS,AC POWERED UNITS..............................................................................9
FIGURE 2-WALL OR PIPE MOUNT BRACKET...................................................................................................10
FIGURE 3-WALL MOUNTING DIMENSIONS......................................................................................................11
FIGURE 4-PIPE MOUNTING DIAGRAM ............................................................................................................11
FIGURE 5-PANEL CUTOUT AND MOUNTING....................................................................................................12
FIGURE 6–INSERTION/SUBMERSIBLE STYLE SENSOR DIMENSIONS.................................................................13
FIGURE 7-SANITARY STYLE PROBE DIMENSIONS...........................................................................................14
FIGURE 8-Q46 CONNECTION LAYOUT...........................................................................................................16
FIGURE 9-RELAY CONNECTIONS...................................................................................................................17
FIGURE 10 -OPTIONAL RELAY BOARD WIRING ...............................................................................................18
FIGURE 11 -OPTIONAL ANALOG OUTPUT WIRING ...........................................................................................18
FIGURE 12 -CABLE DESCRIPTION,MODEL Q25C2.........................................................................................19
FIGURE 13 -SENSOR CABLE PREPARATION....................................................................................................20
FIGURE 14 -JUNCTION BOX INTERCONNECT WIRING.......................................................................................21
FIGURE 15 -IN-LINE SENSOR CONNECTION....................................................................................................22
FIGURE 16 -OEM SENSOR CONNECTIONS.....................................................................................................23
FIGURE 17 -SANITARY SENSOR WIRING.........................................................................................................24
FIGURE 18 -USER INTERFACE .......................................................................................................................25
FIGURE 19 -SOFTWARE MAP.........................................................................................................................29
FIGURE 20 -CONTROL RELAY EXAMPLE.........................................................................................................37
FIGURE 21 -ALARM RELAY EXAMPLE.............................................................................................................38
FIGURE 22 -NACL REFERENCE SOLUTION FOR CALIBRATION..........................................................................43
FIGURE 23 -Q46 ISA (IDEAL)EQUATION........................................................................................................47
FIGURE 24 -PT1000 RESISTANCE TABLE.......................................................................................................55

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Part 1 - Introduction
1.1 General
The Model Q46C2 Conductivity monitor/analyzer provides an extremely versatile measurement
system for monitoring and control of resistivity/conductivity over the range of 0.056 µS/cm to
2000 µS/cm. The instrument display range is programmable for conductivity ranges of 0-2.000, 0-
20.00, 0-200.0, and 0-2000 microsiemens and for resistivity ranges of 0-20.00 MΩor 0-200 kΩ. In
addition, the monitor can be programmed to display TDS (Total Dissolved Solids) or percent
concentration. If data is available, a customized concentration table can be created.
Monitors are available in two electronic versions, a universal AC powered monitor for operation
from 90-260 VAC and a 12-24 VDC unit. Both versions provide two 4-20 mA analog outputs and
3 SPDT relays. One analog output may be configured for PID control and one of the relays may
be configured to provide a remote trouble indication.
In all configurations, the Q46C2 displays conductivity, sensor temperature, TDS, and output loop
current on the secondary line of the custom display. The instrument is used with the Q25C2
sensors or other compatible 2-electrode sensors. Q25C2 sensors are available in either 0.05K or
0.5K cell constants and in submersible, in-line, or 1 ½” sanitary versions.
WARNING: Not following operating instructions may impair safety.

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1.2 Features
Power options for either AC or low voltage DC operation.
Two analog outputs on the relay version may be configured to track conductivity and
temperature. Both analog outputs can be individually programmed to fail to specific values.
A third 4-20 mA output is available as an option.
Three 6 amp SPDT relay outputs and two analog 4-20 mA outputs are standard. Software
settings for relay control include setpoint, deadband, phase, delay, and failsafe. An
optional 3-relay card, for 0-30 V signals, is available to bring the total to 6 relays.
Digital communication option for Profibus-DP, Modbus-RTU, and Ethernet-IP. See Q46
Digital Communications Manual for Specifications.
Output Hold, Output Simulate, Output Alarm, and Output Delay Functions. All forced
changes in output condition include bumpless transfer to provide gradual return to on-line
signal levels and to avoid system control shocks on both analog outputs.
Selectable PID controller on main analog output. PID includes manual operation feature,
and diagnostic “stuck-controller” timer feature for relay notification of control problems.
Large, high contrast, custom LCD display with LED back light provides excellentreadability
in any light conditions. The second line of display utilizes 5x7 dot matrix characters for
clear message display.
Diagnostic messages provide a clear description of any problem with no confusing error
codes to look up. Messages are also included for diagnosing calibration problems.
Quick and easy one-point calibration method and sensor zero-cal. To provide high
accuracy, all calibration methods include stability monitors that check temperature and
main parameter stability before accepting data.
Selectable Pt1000 or Pt100 temperature inputs. Systems can also be hard-configured for
three-wire elements. Temperature element can be user calibrated.
Security lock feature to prevent unauthorized tampering with transmitter settings. All
settings can be viewed while locked, but they cannot be changed.

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1.3 Q46C2 System Specifications
Main Parameter Ranges Automatic or manual selection of the following:
0.00 to 20.00 M/ with 0.05K cell constant
0.0 to 200.0 k/ with 0.05K cell constant
0.000 to 2.000 μS/ with 0.05K cell constant
0.00 to 20.00 μS/ with 0.05K or 0.5K cell constant
0.0 to 200.0 μS/ with 0.05K or 0.5K cell constant
0.0 to 2000 μS with 0.5K cell constant
Power 90 - 260 VAC, 50-60 Hz, 10 VA max. or
12-24 VDC, 500 mA max.
Analog Outputs Two 4-20 mA outputs. Output one programmable for
conductivity or PID. Output 2 programmable for conductivity or
Temperature. Max load 500 Ohms for each output. Outputs
ground isolated and isolated from each other. An additional 3rd
analog option is available.
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. Three additional low power relays optional.
Enclosure NEMA 4X, polycarbonate, stainless steel hardware,
weatherproof and corrosion resistant,
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.
Mounting Options Wall or pipe mount bracket standard. Bracket suitable for either
1.5” or 2” I.D. U-Bolts for pipe mounting.
Panel mount bracket optional.
Weight 2 lb. (0.9 kg)
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.
Ambient Temperature Service, -20 to 60 °C (-4 to 140 ºF)
Storage, -30 to 70 °C (-22 to 158 ºF)
Ambient Humidity 0 to 95%, indoor/outdoor use, non-condensing to rated ambient
temperature range
Altitude 2000 m (6562 Ft.)
Electrical Certification Ordinary Location, cCSAus (CSA and UL standards- both CSA
approved), pollution degree 2, installation category 2
EMI/RFI Influence Designed to EN 61326-1, CE Certified

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Output Isolation 600 V galvanic isolation
Filter Adjustable 0-9.9 minutes additional damping to 90% step input
Temperature Input Selectable Pt1000 or Pt100 RTD
Displayed Parameters Main input, 0.0 μS to 2000 μS, 0-20.00 M, 0-200.0K
(depending on cell constant selected)
TDS
Sensor temperature, -10.0 to 110.0 °C (14 to 230ºF)
Loop current, 4.00 to 20.00 mA
Q25C2 Conductivity sensors
Cell Constant 0.05K or 0.5K
` Measuring Range 0.05K: 0-2, 0-20 uS, 0-20 MΩ, 0-200 kΩ
0.5K: 0-20, 0-200, 0-2000 μS
Temperature Element Pt1000 RTD with automatic compensation
Wetted Materials Titanium, PEEK, 316 Stainless steel
Temperature Compensation Pt1000 RTD
Sensor Cable 6 Conductor plus 2 shields,
Temperature Range -10° to +125° C
Pressure Range 0-100 PSIG
Maximum Flow Rate 10 feet (3 meters) per second
1.4 Q46C2 Performance Specs.
Accuracy 0.1% of span or better
Repeatability 0.1% of span or better
Sensitivity 0.05% of span
Stability 0.05% of span per 24 hours, non-cumulative
Warm-up Time 7 seconds to rated performance
Supply Voltage Effects ± 0.05% span
Instrument Response Time 2 seconds to 90% of step input at lowest setting
Temperature Drift Span or zero, 0.03% of span/°C

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Max. Sensor-Instrument 60 ft. (18.2 meters)
Distance
Sensor Types Model Q25C2 - 4 wire input or equal
Accuracy Note:
The Q46C2 is designed to allow measurements over a broad conductivity range using sensors with
either 0.05K or 0.5K cell constants. However, extending the measurements made with various cell
constants can result in some non-linearity at the high end of operating ranges. This can reduce
accuracy from 0.1% to 1-2% in some cases. When high accuracy is critical, the following provides
a list of the preferred cell constant to be used for various operating ranges in order to maintain the
highest accuracy.
0.05K Sensor –Use for all resistivity ranges (20 Mor 200 K)
0.05K Sensor –Use for 0-2.000 or 0-20.00 uS ranges.
0.5K Sensor –Use for 0-20.00, 0-200.0, 0-2000 uS ranges.
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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Part 2 – Analyzer Mounting
2.1 General
All Q46 Series instruments offer maximum mounting flexibility. A bracket is included with each unit that
allows mounting to walls or pipes. In all cases, choose a location that is readily accessible for calibrations.
Also consider that it may be necessary to utilize a location where solutions can be used during the calibration
process. To take full advantage of the high contrast display, mount the instrument in a location where the
display can be viewed from various angles and long distances.
Locate the instrument in close proximity to the point of sensor installation - this will allow easy access during
calibration. The standard cable length of the conductivity sensor is 20 feet. For sensor cables longer than
20 feet, use the optional junction box (07-0100) and sensor interconnect cable (31-0057).
Figure 1 - Enclosure Dimensions, AC Powered Units

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2.2 Wall or Pipe Mount
A PVC mounting bracket with attachment screws is supplied with each transmitter (see Figure 2 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 (47-0005).
Figure 2 - Wall or Pipe Mount Bracket

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Figure 3 - Wall Mounting Dimensions
Figure 4 - Pipe Mounting Diagram
Note: Analyzer shown with optional
Profibus Connector mounted to
side of enclosure.

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2.3 Panel Mount
Panel mounting of an AC powered monitor uses the panel mounting flange molded into the rear
section of the enclosure. Figure 5 provides dimensions for the panel cutout required for mounting.
The panel mounting bracket kit must be ordered separately (part number 05-0094). 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 panel mounted monitor 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 on the enclosure. Remove the protective paper from the
adhesive side of the gasket and slide the gasket over the back of the enclosure so that the adhesive
side lines up with the back of the enclosure flange. Once in place, you can proceed to mount the
monitor in the panel.
Figure 5 - Panel Cutout and Mounting

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Part 3 – Sensor Mechanicals
3.1 General
The Q25C2 Conductivity Sensors are designed for industrial and municipal process applications.
Mounting options include flow-through, submersion, or sanitary mount depending on the type of
sensor purchased. The sensor-to-analyzer distance must not exceed 60 feet (18.2 meters).
Calibrate the sensor before placing it into the process. See Part 8 of this manual for detailed
calibration instructions.
.
Figure 6 –Insertion/Submersible Style Sensor Dimensions

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Figure 7 - Sanitary Style Probe Dimensions

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Part 4 – Electrical Installation
4.1 General
The Q46 is powered in one of two ways, depending on the version purchased. The 12-24 VDC
powered analyzer requires a customer supplied DC power supply. The 90-260 VAC version
requires line power. Please verify the type of unit before connecting any power.
WARNING: Do not connect AC line power to the DC version. Severe damage will result.
Important Notes:
1. Use wiring practices that conform to all 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 from TB7. The AC power supply
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.
There is no standard ground resistance universally recognized. Many agencies recommend a
ground resistance value of 5 ohms or less. The NEC recommends an impedance to ground of less
than 25 ohms, and less than 5 ohms where sensitive equipment is installed. Power sources feeding
sensitive instruments like the Q46 should have the lowest possible impedance to ground.
4.2 Power Connection
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 two analog outputs for the standard system are present at terminalTB1. The loop-load
limitation in this configuration is 500 Ohms maximum for each output. 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 8 - Q46 Connection Layout
WARNING
Disconnect line power voltage BEFORE connecting line power
wires to Terminal TB7 of the power supply. The power supply
accepts only standard three-wire single phase power. AC power
supplies are configured for 90-260 VAC operation at the factory
at time of order, and the power supply is labeled as such. Do
NOT connect voltages other than the labeled requirement to the
input.

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4.3 Relay Connection
Three SPDT relays are provided on the power supply board. None of the relay contacts are
powered. The user must supply the proper power to the contacts. For applications that require the
same switched operating voltage as the Q46 (115 or 230 V), power may be jumpered from the
power input terminals at TB7. Relay wiring is connected at TB4, TB5, and TB6 as shown below.
Note that the relay contact markings are shown in the NORMAL mode. Programming a relay for
“Failsafe” operation reverses the NO and NC positions as shown in diagram below.
Figure 9 - Relay Connections

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4.4 Optional Output or Relay Connections
TB2, is used to connect to the optional 3-relay card (Figure 10) OR the optional third analog output,
Out#3, (Figure 11). The Q46 can be configured for only one of these optional features, and the
hardware for either option must be factory installed.
Figure 10 - Optional Relay Board Wiring
Figure 11 - Optional Analog Output Wiring

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4.5 Sensor Wiring
The sensor cable can be quickly connected to the Q46 terminal strip by matching the wire colors
on the cable to the color designations on the label in the monitor. A junction box is also available
to provide a break point for long sensor cable runs. Route signal cable away from AC power lines,
adjustable frequency drives, motors, or other noisy electrical signal lines. Do not run sensor or
signal cables in conduit that contains AC power lines or motor leads.
When installing conductivity monitors and sensors, we recommend keeping the sensor
cable as short as is practical. This will minimize potential noise problems.
Standard convertible sensors, insertion sensors, and sanitary sensors have cable permanently
attached to the sensor. This cable contains double shielded conductors to minimize noise problems
in heavy industrial environments. Convertible sensors with connectors and flow type sensors use
a slightly different cable assembly with only a single shield. This assembly is sufficient for many
applications where EMI/RFI problems are not severe.
DANGER: DO NOT connect sensor cable to power lines. Serious injury may result.
Refer to Cable Description and Figure 14, Wiring Diagram for illustrative details on electrical
installation.
Figure 12 - Cable Description, Model Q25C2
Take care to route sensor cable away from AC power lines, adjustable frequency drives, motors,
or other noisy electrical signal lines. Do not run signal lines in the same conduit as AC power lines.
Run signal cable in dedicated metal conduit if possible. For optimum electrical noise protection,
run an earth ground wire to the ground terminal in the transmitter.
Only ATI’s custom 6-wire shielded interconnect cable must be used when connecting the Model
Q25C2 sensor to the analyzer. This high-performance, double shielded, polyethylene jacketed
cable is specially designed to provide the proper signal shielding for the sensor used in this system.
No substitutions can be made. Substituted cables may cause problems with system performance.
Note: If sensor is experiencing Low-Slope or Low-Output conditions, due to poor Earth
Ground Connections, move the Shield connection from P/S board to alternate
location on lid, where indicated with an “S”.

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4.6 Direct Sensor Connection
Sensor connections are made in accordance with Figure 14. The sensor cable can be routed into
the enclosure through one of cord-grips supplied with the unit. Routing sensor wiring through
conduit is only recommended if a junction box is to be used. Some loose cable is needed near the
installation point so that the sensor can be inserted and removed easily from the flowcell.
Cord-grips used for sealing the cable should be snugly tightened after electrical connections
have been made to prevent moisture incursion. When stripping cables, leave adequate length for
connections in the transmitter enclosure as shown below. The standard 15 ft. sensor cable
normally supplied with the system is already stripped and ready for wiring. This cable can be cut
to a shorter length if desired to remove extra cable in a given installation. Do not cut the cable so
short as to make installation and removal of the sensor difficult.
.
Figure 13 - Sensor Cable Preparation