ATI Technologies Q46H/62 User manual

O & M Manual
Model Q46H-62
Free Chlorine 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]
Web: www.Analyticaltechnology.com

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Table of Contents
PART 1 - INTRODUCTION ......................................... 4
1.1 GENERAL ..........................................................4
1.2 STANDARD SYSTEM.............................................4
1.3 FEATURES .........................................................7
1.4 Q46H/62 SYSTEM SPECIFICATIONS.......................8
1.5 Q46H PERFORMANCE SPECIFICATIONS ..................9
PART 2 –ANALYZER MOUNTING.............................10
2.1 GENERAL ........................................................10
2.2 WALL OR PIPE MOUNT .....................................10
2.3 PANEL MOUNTING ...........................................12
PART 3 –SENSOR/FLOWCELL MOUNTING ..............14
3.1 GENERAL ........................................................14
3.2 CONSTANT-HEAD FLOWCELL ..............................14
3.3 SEALED FLOWCELLS ..........................................15
PART 4 –ELECTRICAL INSTALLATION.......................17
4.1 GENERAL ........................................................17
4.2 POWER CONNECTION........................................18
4.3 DIRECT SENSOR CONNECTION.............................22
4.4 SENSOR WIRING ..............................................22
4.5 JUNCTION BOX CONNECTION..............................23
4.6 OPTIONAL PHCOMPENSATION INPUT ..................25
PART 5 –SENSOR ASSEMBLY ..................................27
5.1 CHLORINE SENSOR PREPARATION........................27
5.2 OPTIONAL PHSENSORS.....................................28
PART 6 –CONFIGURATION .....................................29
6.1 USER INTERFACE ..............................................29
6.11 KEYS ..............................................................30
6.12 DISPLAY..........................................................30
6.2 SOFTWARE......................................................31
6.21 SOFTWARE NAVIGATION ...................................32
6.22 MEASURE MENU [MEASURE] ..........................34
6.23 CALIBRATION MENU [CAL] ................................35
6.24 CONFIGURATION MENU [CONFIG]....................35
6.25 CONTROL MENU [CONTROL] ..........................40
6.26 DIAGNOSTICS MENU [DIAG].............................44
PART 7 –CALIBRATION...........................................47
7.1 CHLORINE CALIBRATION ....................................47
7.11 CHLORINE ZEROCAL..........................................47
7.12 CHLORINE SPANCAL..........................................48
7.2 TEMPERATURE CALIBRATION ..............................49
7.3 PHCALIBRATION..............................................50
7.31 TWO-POINT PHCAL .........................................50
7.32 ONE-POINT PHCAL..........................................51
7.4 ADJUSTING PHCOMPENSATION CURVE ................52
7.41 MODIFYING PHCORRECTION VALUES ..................52
7.42 PHCORRECTION –TABLE MODIFICATION EXAMPLE54
7.43 STORING MODIFIED TABLE.................................55
PART 8 –PID CONTROLLER DETAILS .......................56
8.1 PID DESCRIPTION.............................................56
8.2 PID ALGORITHM..............................................56
8.3 CLASSICAL PID TUNING.....................................58
8.4 MANUAL PID OVERRIDE CONTROL......................58
8.5 COMMON PID PITFALLS ....................................59
PART 9 –SYSTEM MAINTENANCE...........................60
9.1 GENERAL ........................................................60
9.2 ANALYZER MAINTENANCE..................................60
9.3 SENSOR MAINTENANCE.....................................60
9.4 SENSOR ACID CLEANING....................................61
9.5 Q22P SENSOR CLEANING ..................................61
9.6 REPLACING THE SALTBRIDGE AND REFERENCE
BUFFER SOLUTION.....................................................62
9.7 FLOW CELL MAINTENANCE ................................63
PART 10 –TROUBLESHOOTING ..............................64
10.1 GENERAL ........................................................64
10.2 EXTERNAL SOURCES OF PROBLEMS ......................64
10.3 ANALYZER TESTS ..............................................65
10.4 DISPLAY MESSAGES ..........................................65
10.5 SENSOR TESTS .................................................67
10.6 TROUBLESHOOTING (Q22P SENSOR)...................68
SPARE PARTS..........................................................69

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TABLE OF FIGURES
FIGURE 1-TYPICAL CHLORINE MONITORING SYSTEM...........................................................5
FIGURE 2-CHLORINE SYSTEM W/CONVENTIONAL PHSTYLE SENSOR ...................................5
FIGURE 3-SEALED FLOWCELL ASSEMBLIES WITH FLOW CONTROL........................................6
FIGURE 4-Q46 ENCLOSURE DIMENSIONS.........................................................................10
FIGURE 5-WALL OR PIPE MOUNT BRACKET......................................................................11
FIGURE 6-WALL MOUNTING DIAGRAM..............................................................................11
FIGURE 7-PIPE MOUNTING DIAGRAM ...............................................................................12
FIGURE 8-PANEL MOUNT CUTOUT...................................................................................13
FIGURE 9-CONSTANT HEAD FLOWCELL DETAILS...............................................................14
FIGURE 10 -SEALED CL2FLOWCELL DETAILS.....................................................................15
FIGURE 11 -SEALED PHFLOWCELL DETAILS.....................................................................16
FIGURE 12 -LINE POWER CONNECTION ............................................................................19
FIGURE 13 -OPTIONAL RELAY BOARD WIRING...................................................................20
FIGURE 14 -OPTIONAL RELAY BOARD WIRING...................................................................21
FIGURE 15 -OPTIONAL ANALOG OUTPUT WIRING ..............................................................21
FIGURE 16 -SENSOR CABLE PREPARATION.......................................................................22
FIGURE 17 –DIRECT SENSOR CONNECTION......................................................................23
FIGURE 18 -JUNCTION BOX INTERCONNECT WIRING..........................................................24
FIGURE 19 -JUNCTION BOX WIRING W/OPTIONAL PHCOMP...............................................26
FIGURE 20 -CHLORINE SENSOR ASSEMBLY.......................................................................27
FIGURE 21 -USER INTERFACE..........................................................................................29
FIGURE 22 -SOFTWARE MAP ...........................................................................................33
FIGURE 23 -AUTOMATIC PHBUFFER TABLES ....................................................................39
FIGURE 24 -CONTROL RELAY EXAMPLE............................................................................42
FIGURE 26 -ALARM RELAY EXAMPLE................................................................................43
FIGURE 27 -TYPICAL FREE CHLORINE RESPONSE TO CHANGE IN PH...................................54
FIGURE 28 -Q46H ISA PID EQUATION.............................................................................56
FIGURE 29 -REPLACING SALTBRIDGE AND REFERENCE BUFFER .........................................63
FIGURE 30 -Q46H DISPLAY MESSAGES............................................................................66
FIGURE 32 -PT100 RTD TABLE.......................................................................................67

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Part 1 - Introduction
1.1 General
The Model Q46H/62 is a versatile on-line monitoring system designed for the continuous
measurement of free chlorine in solution. The full scale operating range of the system is user
selectable for 0-200.0 ppb, 0-2.000 ppm, 0-20.00 PPM, or 0-200.0 ppm, and the sensing system
will operate on water streams with temperatures from 0 to 55C. The Q46H/62 Free Chlorine
Measurement System is well suited for potable water treatment, cooling water, sea water,
produce wash water, reverse osmosis membrane protection, or activated carbon filter break-
through detection.
The basic sensing element used in the free chlorine monitor is a polarographic membrane sensor
which measures chlorine directly. Water simply flows past the sensor and directly to drain, with
the flow rate and pressure across the sensor controlled by a constant head flow cell assembly.
The chlorine measurement does not alter the sample or add any chemicals to the sample stream,
so the water flow can return to the system if desired. Sensors will operate on all kinds of samples
from very low conductivity water up to sea water and brine solutions.
Q46H/62 Monitors are available in two basic electronic versions, a 90-260VAC powered monitor,
or a 12-24VDC powered monitor –both with three relays and two 4-20 mA analog outputs. Both
versions allow flexible output options which include additional 4-20 mA current outputs, additional
0-30V signal relays, PID control, and digital communication cards.
In addition to normal chlorine measurement, the Q46H/62 is also available with an optional pH
input which provides a two-parameter monitoring system. Both free chlorine and pH are
displayed simultaneously, and the free chlorine value is automatically compensated for pH
changes.
1.2 Standard System
The standard model Q46H/62 system includes three main components, the Q46H analyzer, a
constant head flow cell, and a free chlorine sensor. A sealed flowcell is also available for
applications where sample flow rate and pressure can be carefully controlled. Figure 1 shows a
typical installation including the optional 07-0096 pH sensor.
For connection of the sensor to the electronics, a 25 foot cable is supplied. An additional 100 feet
of interconnect cable may be added using #07-0100 junction box. All required spare parts are
also provided with the basic system, including spare membranes, electrolyte, o-rings, and any
special hardware.
Note that standard 25 foot sensor cables for both chlorine and optional pH sensors can be cut to
a shorter length. Cutting the cables will not affect performance, and elimination of extra cable can
sometimes eliminate electrical noise pickup through the cables.

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Figure 1 - Typical Chlorine Monitoring System
Figure 2 below shows the same standard flowcell assembly and chlorine sensor along with the
conventional type pH sensor. A special adapter is required to hold the pH sensor in its proper
location in the flowcell inlet chamber.
Figure 2 - Chlorine System w/Conventional pH Style Sensor

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Figure 3 below shows an installation using a 00-1522 sealed flowcell for the chlorine sensor and
a 00-1527 sealed flowcell for the pH sensor. This type of installation requires careful flow control.
We recommend the use of our 03-0372 flow control assembly when using sealed flowcells. This
assembly consists of an in-line filter and a fixed-flow regulator which will maintain a constant 400
cc/min flow rate through the system. This flow will be maintained so long as inlet pressures are
between 5 and 125 PSIG. The in-line filter is used mainly to protect the flow control element
against larger particles that might cause plugging of the device.
Figure 3 - Sealed Flowcell Assemblies with Flow Control

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1.3 Features
•Available in either 90-260VAC or 12-24 VDC power supply systems. All features remain the
same in both variations.
•High accuracy, high sensitivity system, measures from 20 ppb to 200.0 ppm through 4 internal
automatic ranges. User ranges of 200.0 ppb, 2.000 ppm, 20.00 ppm, or 200.0 ppm.
•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.
•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.
•Selectable PID controller on main analog output. PID controller can operate with instrument
configured as loop-power analyzer or as one of the two outputs on the AC powered instrument.
PID includes manual operation feature, and diagnostic “stuck-controller” timer feature for alarm
output of control problems.
•Digital communication option for Profibus-DP, Modbus-RTU. More versions pending. See Q46
Digital Communications Manual for Specifications.
•Two analog outputs may be configured to track chlorine and temperature, chlorine and chlorine,
or chlorine and pH. Both analog outputs can be individually programmed to fail to specific values.
An optional third analog output is available, providing separate outputs for chlorine, pH, and
temperature.
•Selectable automatic pH compensation feature. Enables active pH compensation of free chlorine
readings –requiring no pumps or buffers to maintain a constant pH level. The pH reading can
also be sent to one of the analog outputs for complete pH + chlorine monitoring. The pH
correction can be done using ATI’s optional pH sensor or using an input signal of 0.4-2.0 VDC (4-
20 mA across a 100 ohm resistor) from another pH monitor. Input from another monitor requires
the use of a loop isolator.
•Selectable Output Fail Alarm feature allows system diagnostic failures to be sent to external
monitoring systems.
•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.
•High accuracy three-wire Pt100 temperature input. Temperature element can be user calibrated.
•Security lock feature to prevent unauthorized tampering with analyzer settings. All settings can
be viewed while locked, but they cannot be changed.

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1.4 Q46H/62 System Specifications
Displayed Parameters Main input, 0.1 ppb (0.0001 ppm) to 200.0 ppm
Sensor temperature, -5.0 to 55.0 °C (23 to 131 ºF)
Sensor Current, 0.0–999.9 nA, 0.000 to 99.99 uA
Loop current, 4.00 to 20.00 mA
Sensor slope/offset
Model number and software version
PID Controller Status
Optional pH Input value.0.00 to 14.00 pH
Main Parameter Ranges Manual selection of one of the following ranges,
0.000 to 200.0 ppb
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 display with sign
12-digit secondary display, 0.3" (7.6 mm) 5x7 dot matrix.
Integral LED back-light for visibility in the dark.
Keypad 4-key membrane type with tactile feedback, polycarbonate with UV
coating
Weight 2 lb. (0.9 kg)
Ambient Temperature Analyzer Service, -20 to 60 °C (-4 to 140 ºF)
Sensor Service, -5 to 55°C (23 to 131 °F)
Storage, -5 to 70 °C (-22 to 158 ºF)
Ambient Humidity 0 to 95%, indoor/outdoor use, non-condensing to rated ambient
temperature range
Altitude Maximum 2000 m (6562 ft.)
Electrical Certification Ordinary Location, cCSAus (CSA and UL standards - both approved by
CSA), pollution degree 2, installation category 2
EMI/RFI Influence Designed to EN 61326-1
Output Isolation 600 V galvanic isolation
Filter Adjustable 0-9.9 minutes additional damping to 90% step input
Temperature Input Pt100 RTD, 3-wire type
Sensor 2-electrode polarographic membraned sensor for direct measurement of
chlorine
Sensor Materials Noryl and stainless steel
Sensor Cable 25 ft. (7.5 meter) cable with 6-pin plug

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Max. Sensor-to-Analyzer
Distance 100 feet (30.5 meters), with junction box
Optional pH Comp Input Accepts standard combination or Q22P pH Sensors
Flow Cell Constant head overflow, clear cast acrylic, 7-30 GPH, 15 GPH
recommended, inlet is ¼” hose barb at 1/8” MNPT, outlet is ½” hose barb
at 3/8” MNPT
Power 90 - 260 VAC, 50-60 Hz, 10 VA max
12-24 VDC, 500 mA max.
Enclosure NEMA 4X, polycarbonate, stainless steel hardware,
HWD: 4.9" (124 mm) x 4.9" (124 mm) x 5.5" (139 mm)
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 adapter optional.
Conduit Openings Five ½” NPT openings, Adapter can be removed to provide a 1” NPT
opening in the bottom of the enclosure. Gland seals provided but not
installed.
Relays, Electromechanical: Three SPDT, 6 amp @ 250 VAC, 5 amp @ 24 VDC contacts. Software
selection for setpoint, phase, delay, deadband, hi-lo alarm, and
failsafe.A-B indicators on main LCD, and C indicator on lower display.
Analog Outputs Two 4-20 mA outputs. Output one programmable for PPM chlorine or
PID. Output 2 programmable for PPM chlorine, Temperature, or pH.
Max load 500 Ohms for each output. Outputs ground isolated and
isolated from each other. An additional 3rd analog option is available.
1.5 Q46H Performance Specifications
Accuracy 0.5% of selected range or 0.02 PPM
Repeatability 0.3% of selected range or 0.01 PPM
Sensitivity 0.05% of selected range
Non-linearity 0.1% of selected range
Warm-up Time 3 seconds to rated performance (electronics only)
Supply Voltage Effects ± 0.05% span
Instrument Response Time 60 seconds to 90% of step input at lowest damping
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 sensor-to-instrument distance should not exceed 100 feet. To
maximize signal-to-noise ratio however, work with the shortest sensor cable possible. The
standard cable length of the chlorine sensor is 25 feet.
Refer to Figure 4for overall dimensions of the Q46 monitor.
Figure 4 - Q46 Enclosure Dimensions
2.2 Wall or Pipe Mount
A PVC mounting bracket with attachment screws is supplied with each analyzer (see Figure 5 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 (Figure 6) 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 (Figure 7). Slots will accommodate u-bolts designed for 1½“ or 2”
pipe. The actual center to center dimensions for the u-bolts are shown in the drawing. Note that
these slots are for u-bolts with ¼-20 threads. The 1½” pipe u-bolt (2” I.D. clearance) is available
from ATI in type 304 stainless steel under part number 47-0005