ATI Technologies Q46H/63 User manual

O&MManual
ModelQ46H-63
CombinedChlorine Monitor
HomeOfficeEuropeanOffice
AnalyticalTechnology, Inc.ATI (UK)Limited
6Iron BridgeDriveUnit1& 2Gatehead BusinessPark
Collegeville, PA 19426 DelphNewRoad, Delph
Phone: [phone] SaddleworthOL3 5DE
610-917-0991Phone: [phone]
Fax: [phone]Fax: [phone]
Email: [e-mail] Email: [e-mail]

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Table of Contents
PART1-INTRODUCTION........................................4
1.1 GENERAL ....................................................... 4
1.2 STANDARD SYSTEM.......................................... 5
1.3 FEATURES ...................................................... 8
1.4 Q46H/63SYSTEM SPECIFICATIONS.................... 9
1.5 Q46HPERFORMANCE SPECIFICATIONS ............. 11
PART2–ANALYZER MOUNTING..........................12
2.1 GENERAL ..................................................... 12
2.2 WALL OR PIPE MOUNT................................... 13
2.3 PANEL MOUNTING ........................................ 15
PART3–SENSOR/FLOWCELL MOUNTING............16
3.1 GENERAL ..................................................... 16
3.2 CONSTANT-HEAD FLOWCELL ........................... 16
3.3 SEALED FLOWCELL......................................... 17
3.4 SUBMERSION MOUNTING............................... 19
PART4–ELECTRICALINSTALLATION....................20
4.1 GENERAL ..................................................... 20
4.2 POWER CONNECTION..................................... 21
4.3 DIRECT SENSOR CONNECTION.......................... 25
4.4 SENSOR WIRING ........................................... 26
4.5 JUNCTION BOX CONNECTION........................... 27
4.6 OPTIONALPHSENSOR INPUT........................... 28
PART5–SENSOR ASSEMBLY................................30
5.1 CHLORINE SENSOR PREPARATION..................... 30
5.2 OPTIONALPHSENSORS.................................. 32
PART6–CONFIGURATION...................................33
6.1 USER INTERFACE ........................................... 33
6.11 KEYS ...................................................... 34
6.12 DISPLAY.................................................. 34
6.2 SOFTWARE................................................... 35
6.21 SOFTWARE NAVIGATION ........................... 36
6.22 MEASURE MENU [MEASURE]................... 38
6.23 CALIBRATION MENU [CAL].............................. 39
6.24 CONFIGURATION MENU [CONFIG]............ 40
6.25 CONTROL MENU [CONTROL]................... 45
6.26 DIAGNOSTICS MENU [DIAG]........................... 49
PART7–CALIBRATION.........................................52
7.1 CHLORINE CALIBRATION.................................. 52
7.11 CHLORINE ZERO CAL ................................. 52
7.12 CHLORINE SPAN CAL ................................. 53
7.2 TEMPERATURE CALIBRATION ........................... 54
7.3 PHCALIBRATION........................................... 55
7.31 TWO-POINTPHCAL....................................... 56
7.32 ONE-POINTPHCAL ....................................... 57
PART8–PIDCONTROLLERDETAILS.....................58
8.1 PIDDESCRIPTION.......................................... 58
8.2 PIDALGORITHM........................................... 58
8.3 CLASSICAL PIDTUNING.................................. 60
8.4 MANUAL PIDOVERRIDE CONTROL................... 60
8.5 COMMON PIDPITFALLS ................................. 60
PART9–SYSTEMMAINTENANCE........................62
9.1 GENERAL ..................................................... 62
9.2 ANALYZER MAINTENANCE............................... 62
9.3 SENSOR MAINTENANCE.................................. 62
9.4 SENSOR ACID CLEANING................................. 63
9.5 Q22PSENSOR CLEANING ............................... 63
9.6 REPLACING THE SALTBRIDGEAND REFERENCE
BUFFER SOLUTION .................................................. 64
9.7 FLOW CELL MAINTENANCE.............................. 65
PART10 –TROUBLESHOOTING............................66
10.1 GENERAL ................................................ 66
10.2 EXTERNAL SOURCESOF PROBLEMS............... 66
10.3 ANALYZER TESTS....................................... 67
10.4 DISPLAY MESSAGES................................... 68
10.5 SENSOR TESTS.......................................... 70
10.6 TROUBLESHOOTING (Q22PSENSOR)........... 71
SPAREPARTS........................................................72

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TABLEOF FIGURES
FIGURE 1-TYPICAL CHLORINE MONITORING SYSTEM....................................................................................... 5
FIGURE 2-CHLORINE SYSTEMW/CONVENTIONALPHSTYLE SENSOR............................................................... 6
FIGURE 3-SEALED FLOWCELL ASSEMBLIESWITH FLOW CONTROL................................................................... 7
FIGURE 4-Q46 ENCLOSURE DIMENSIONS..................................................................................................... 12
FIGURE 5-WALL OR PIPE MOUNT BRACKET .................................................................................................. 13
FIGURE 6-WALL MOUNTING DIAGRAM .......................................................................................................... 14
FIGURE 7-PIPE MOUNTING DIAGRAM............................................................................................................ 14
FIGURE 8-PANEL MOUNT CUTOUT ............................................................................................................... 15
FIGURE 9-CONSTANT HEAD FLOWCELL DETAILS........................................................................................... 16
FIGURE 10 -SEALED CL2FLOWCELL DETAILS ................................................................................................ 17
FIGURE 11 -SEALEDPHFLOWCELL DETAILS ................................................................................................. 18
FIGURE 12 -SUBMERSIBLE SENSOR MOUNTING ASSEMBLY............................................................................ 19
FIGURE 13 -LINE POWER CONNECTION......................................................................................................... 22
FIGURE 14 -OPTIONAL RELAY BOARD WIRING............................................................................................... 23
FIGURE 15 -OPTIONAL RELAY BOARD WIRING............................................................................................... 24
FIGURE 16 -OPTIONAL ANALOG OUTPUT WIRING........................................................................................... 24
FIGURE 17 -SENSOR CABLE PREPARATION ................................................................................................... 25
FIGURE 18 -DIRECT SENSOR CONNECTION ................................................................................................... 26
FIGURE 19 -JUNCTION BOX INTERCONNECT WIRING...................................................................................... 27
FIGURE 20 -CHLORINE SENSOR ASSEMBLY................................................................................................... 30
FIGURE 21 -SUBMERSIBLE CHLORINE SENSOR ASSEMBLY............................................................................. 31
FIGURE 22 -USER INTERFACE....................................................................................................................... 33
FIGURE 23 -SOFTWARE MAP ........................................................................................................................ 37
FIGURE 24 -AUTOMATICPHBUFFER TABLES................................................................................................. 44
FIGURE 25 -CONTROL RELAY EXAMPLE ........................................................................................................ 47
FIGURE 26 -ALARM RELAY EXAMPLE............................................................................................................. 48
FIGURE 27 -Q46H ISA PID EQUATION.......................................................................................................... 58
FIGURE 28 -REPLACING SALTBRIDGEAND REFERENCE BUFFER..................................................................... 65
FIGURE 29 -Q46H DISPLAY MESSAGES ........................................................................................................ 68
FIGURE 30 -Q46H DISPLAY MESSAGES (CONTINUED)................................................................................... 69
FIGURE 31 -PT100 RTD TABLE.................................................................................................................... 70

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Part 1-Introduction
1.1General
The ModelQ46H/63isaversatileon-line monitoring systemdesignedforthe continuous
measurement ofcombinedchlorineinsolution. The full scaleoperating range ofthe systemis
userselectablefor0-200.0 ppb,0-2.000ppm,0-20.00PPM,or0-200.0ppm,and the sensing
systemwill operateon waterstreamswith temperaturesfrom-5to 55°C. The Q46H/63
Combined ChlorineMeasurement System is wellsuitedforchloraminated potablewatersystems,
activatedcarbon filterbreak-through detection,andformonitoring wastewatertreatment effluents
wheresufficientammoniaispresent toinsurethat themajorityofthechlorineresidualis
monochloramine.
The basicsensing elementused inthe combined chlorine monitorisapolarographicmembrane
sensorwhichmeasureschlorine directly.Watersimplyflowspastthesensorand directlyto
drain, with the flowrate andpressureacross the sensorcontrolled byaconstant headflowcell
assembly.The chlorine measurement doesnot alterthe sampleoradd anychemicalsto the
sample stream, so the waterflowcan returnto the systemifdesired.
Q46H/63Monitors 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.
In addition tonormalchlorine measurement, the Q46H/63 isalsoavailablewithan optionalpH
input whichprovidesatwo-parametermonitoringsystem.Both combined chlorine andpH are
displayed simultaneously.

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1.2Standard System
The standardmodelQ46H/63 systemincludesthreemaincomponents,theQ46H analyzer,a
constant head flowcell,andacombined chlorine sensor.Asealedflowcellisalsoavailablefor
applicationswheresampleflowrate and pressurecanbe carefullycontrolled. Figure1showsa
typicalinstallation includingthe optional07-0096 pH sensor.
Forconnection ofthe sensorto theelectronics, a25foot cable issupplied.Anadditional100 feet
ofinterconnectcablemaybe added using#07-0100junctionbox.Allrequired sparepartsare
alsoprovided with the basicsystem,including sparemembranes,electrolyte, o-rings,and any
specialhardware.
Note thatstandard25foot sensorcablesforboth chlorine andoptionalpH sensors can becut to
a shorterlength.Cutting the cableswillnotaffect performance, and elimination of extra cable can
sometimeseliminate electricalnoise pickup through the cables.
Figure 1 -TypicalChlorineMonitoring System

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Figure2belowshowsthesamestandardflowcellassemblyandchlorinesensoralong withthe
conventionaltype pH sensor.Aspecialadapterisrequiredto holdthe pH sensorinitsproper
location inthe flowcellinlet chamber.
Figure 2 -ChlorineSystemw/Conventional pHStyle Sensor

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Figure3belowshowsan installation using a00-1522sealed flowcellforthe chlorine sensorand
a00-1527 sealed flowcell forthe pHsensor.Thistypeof installationrequirescarefulflowcontrol.
Werecommend the useofour03-0372 flowcontrolassemblywhenusingsealed flowcells.This
assemblyconsistsofan in-linefilterandafixed-flowregulatorwhichwillmaintainaconstant400
cc/minflowrate through thesystem.Thisflowwill be maintained solong asinletpressuresare
between 5and 125 PSIG.The in-linefilterisusedmainlytoprotecttheflowcontrolelement
against largerparticlesthat might cause plugging ofthe device.
Figure 3 -SealedFlowcellAssemblieswith Flow Control

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1.3Features
•StandardQ46H/63analyzers havefullyisolated inputsand outputs.Analogoutputsare
additionallycompletelyisolated fromeach other.
•Availableineither90-260VACor12-24VDC powersupplysystems.All featuresremainthe
same in both variations.
•High accuracy,high sensitivitysystem,measuresfrom20 ppb to 200.0ppmthrough 4internal
automaticranges. Userrangesof200.0 ppb,2.000 ppm, 20.00 ppm, or200.0 ppm.
•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, for0-30VDC signals, isavailable to bring the totalto 6 relays.
•SelectablePID controlleron mainanalogoutput. PID controllercan operate withinstrument
configured asloop-poweranalyzerorasone ofthe two outputsonthe ACpowered instrument.
PID includesmanualoperationfeature, and diagnostic“stuck-controller” timerfeatureforalarm
output ofcontrolproblems.
•Digitalcommunication optionsforProfibus-DP,ModbusRTU. Moreversionspending. SeeQ46
DigitalCommunicationsManualforSpecifications.
•OptionalpH sensorfeatureenablesactivepH measurement with theQ46H/63monitor.The pH
reading can also besent to one ofthe analog outputsforcomplete pH and chlorine monitoring.
•Twoanalog outputsmaybeconfiguredtotrackchlorine and temperature, chlorine and chlorine,
orchlorineand pH.Both analog outputscan beindividuallyprogrammed to failto specificvalues.
Anoptionalthirdanalog output isavailable, providingseparateoutputsforchlorine, pH, and
temperature.
•SelectableOutput FailAlarmfeatureallowssystemdiagnosticfailuresto be sent toexternal
monitoring systems.
•Large, high contrast, customLCD displaywith LED backlightprovidesexcellent readabilityinany
light conditions. The secondaryline ofdisplayutilizes5x7 dotmatrixcharacters forclear
message display. Two offourmeasured parameters maybe on the displaysimultaneously.
•Diagnosticmessagesprovide acleardescription ofanyproblemwith no confusingerrorcodesto
lookup. Messagesare also included fordiagnosing calibration problems.
•Quickand easyone-point calibration method and sensorzero-cal.Toprovide high accuracy,all
calibration methodsincludestabilitymonitors that check temperature and main parameterstability
before accepting data.
•Highaccuracythree-wire Pt100 temperature input. Temperature element can be usercalibrated.

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•Securitylockfeatureto preventunauthorizedtampering with analyzersettings.Allsettingscan
be viewed whilelocked, but theycannot be changed.
1.4Q46H/63SystemSpecifications
DisplayedParameters Main input, 0.1 ppb (0.0001 ppm)to 200.0ppm
Sensortemperature, -5.0to55.0°C (23 to 131ºF)
SensorCurrent, 0.0 to 99.9nA,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,
0.000 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 displaywith sign
12-digit secondarydisplay,0.3"(7.6 mm)5x7 dot matrix.
IntegralLEDback-light forvisibilityin the dark.
Keypad 4-keymembrane typewith tactile feedback, polycarbonate with
UVcoating
SystemWeight Approximately5 lbs(2.3 kg)with sensor&flowcell
Ambient Temperature AnalyzerService,-20 to 60 °C (-4 to 140 ºF)
SensorService, -5 to 55°C(23 to 131 °F)
Storage, -30 to 70 °C (-22 to 158 ºF)
Ambient Humidity 0to 95%,indoor/outdooruse, non-condensingtoratedambient
temperature range
Altitude Maximum2000 m(6562 ft.)
Electrical Certification OrdinaryLocation, cCSAus(CSA and UL standards-both
approved byCSA),pollution degree 2, installation category2
EMI/RFI Influence Designed toEN 61326-1
Output Isolation 600 Vgalvanicisolation
Filter Adjustable0-9.9 minutesadditionaldamping to 90%step input
Temperature Input Pt100 RTD, 3-wiretype

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Sensor 2-electrode polarographicmembraned sensorfordirect
measurement ofchlorine
SensorMaterials PVCand stainless steel
SensorCable 25 ft. (7.5 meter) cable with 6-pinplug
Max. Sensor-to-Analyzer
Distance 100 feet (30.5 meters), withjunctionbox
Optional pH Compensation
Input Acceptsstandard combination orQ22PpHSensors
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
Power 90 -260VAC,50-60 Hz, 10 VAmax
12-24 VDC,500 mAmax.
Enclosure NEMA4X,polycarbonate, stainless steelhardware,
weatherproofand corrosion resistant,
HWD: 4.9"(124 mm)x4.9"(124 mm)x5.5"(139 mm)
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,andC indicator
on lowerdisplay.
Optional Relays:Three additionalnon-isolated lowpowerrelaysavailable.
SPST, 1 amp @30 VDC
Analog Outputs Two 4-20mAoutputs.Output one programmable forPPM
chlorine orPID. Output 2 programmable forPPM chlorine,
Temperature, orpH. Maxload 500 Ohmsforeach output.
Outputsground isolated and isolated fromeach other.An
additional3rd analog option isavailable.