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Analytical Technology Q46D Manual

Optical d.o. monitor system
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Optical D.O. Monitor
Home Office
Analytical Technology, Inc.
6 Iron Bridge Drive
Collegeville, PA 19426
Ph: 800-959-0299
610-917-0991
Fax: 610-917-0992
Email: sales@analyticaltechnology.com
Model Q46D
System
European Office
ATI (UK) Limited
Unit 1 & 2 Gatehead Business Park
Delph New Road, Delph
Saddleworth OL3 5DE
Ph: +44 (0)1457-873-318
Fax: + 44 (0)1457-873-468
Email: sales@atiuk.com

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  • Page 1 Model Q46D Optical D.O. Monitor System 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 Saddleworth OL3 5DE Ph: 800-959-0299 Ph: +44 (0)1457-873-318...
  • Page 2 PRODUCT WARRANTY Analytical Technology, Inc. (Manufacturer) warrants to the Customer that if any part(s) of the Manufacturer's equipment proves to be defective in materials or workmanship within the earlier of 18 months of the date of shipment or 12 months of the date of start- up, such defective parts will be repaired or replaced free of charge.

  • Page 3: Table Of Contents

    Standard System ......... 5 6.11 D.O. Span Cal (1-spl) ......48 Features ..........5 6.12 Dissolved Oxygen Air Span Cal (% sat) .. Q46D/60 System Specifications ..6 ............50 Q46D Performance Specifications ..8 6.13 Dissolved Oxygen Zero Cal ....51 PART 2 –...
  • Page 4 19 - A ..................42 IGURE LARM ELAY XAMPLE 20 - Q46 ISA (I ..................55 IGURE DEAL QUATION 21 - Q46D D ..................63 IGURE ISPLAY ESSAGES 22 - P 1000 RTD T ....................65 IGURE ABLE 23 - R ..........

  • Page 5: Part 1 - Introduction

    0-40 ppm, and the sensing system will operate on water streams with temperatures ranging from 0 to 50°C. While the Q46D may be used with either optical oxygen or galvanic membrane sensors, this manual is specific for systems utilizing ATI’s optical D.O. sensor.

  • Page 6: Q46D/60 System Specifications

    Q46D-ODO Optical D.O. System Part 1 - Introduction · Selectable PID controller on main analog output. PID controller can operate with instrument configured as loop-power transmitter, or as one of the two outputs on the AC powered instrument. PID includes manual operation feature, and diagnostic “stuck-controller”...
  • Page 7 Q46D-ODO Optical D.O. System Part 1 - Introduction Main Parameter Ranges Manual selection of one of the following display ranges, 0.00 to 40.00 ppm or 0.00 to 40.00 mg/l 0.0 to 999.9% Saturation Power 90- 260 VAC, 50/60 Hz., 10 VA Maximum 12-24 VDC, 500 mA max.

  • Page 8: Q46D Performance Specifications

    Q46D-ODO Optical D.O. System Part 1 - Introduction Temperature Input Pt1000 RTD with automatic compensation Ambient Humidity 0 to 95%, indoor/outdoor use, non-condensing to rated ambient temperature range Altitude Up to 2000 m (6562 ft) Electrical Certification Ordinary Location, cCSAus (Certified to both CSA and UL...

  • Page 9: Part 2 - Analyzer Mounting

    Part 2 – Analyzer Mounting 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.

  • Page 10: Wall Or Pipe Mount

    Q46D-ODO Optical D.O. System Part 2 – Analyzer Mounting 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.

  • Page 11: Figure 3 - Wall Mounting Diagram

    Q46D-ODO Optical D.O. System Part 2 – Analyzer Mounting Note: Analyzer shown with optional Profibus Connector mounted to side of enclosure. Figure 3 - Wall Mounting Diagram Figure 4 - Pipe Mounting Diagram O&M Manual Rev-J (8/17)

  • Page 12: Panel Mount

    Q46D-ODO Optical D.O. System Part 2 – Analyzer Mounting Panel Mount Panel mounting of the 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.

  • Page 13: Part 3 - Optical D.o. Sensor

    Part 3 – Optical D.O. Sensor 3.1 General Optical D.O. sensors are supplied complete and ready to use. All that’s needed is to make the proper sensor connections as shown in the previous section. A rubber boot protects the end of the sensor in transit. Leave the protective boot in place until the sensor is to be placed into operation.

  • Page 14: 3.2 Optical Sensing

    D.O. concentration on the sensor side of the film than on the bulk solution side. The automatic air cleaning system integrated into the Q46D system will eliminate coating problems by cleaning the sensor on a regular programmed schedule.

  • Page 15: Submersion Mounting

    Q46D-ODO Optical D.O. System Part 3 – Optical Sensor Mounting Submersion Mounting Most applications for D.O. monitoring are done using a submersible sensor. Optical oxygen sensor can be used in stagnant water conditions, as they do not need sample flow for measurement.

  • Page 16: Figure 9 - Mounting Assembly Detail

    Q46D-ODO Optical D.O. System Part 3 – Optical Sensor Mounting Flexible Air Line applicable for Auto-Clean Option Only! Figure 9 - Mounting Assembly Detail O&M Manual Rev-J (8/17)

  • Page 17: Part 4 - Electrical Installation

    Part 4 – Electrical Installation 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.

  • Page 18: Ac Powered Instrument Wiring

    Q46D-ODO Optical D.O. System Part 4 – Electrical Installation 5. 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.

  • Page 19: Figure 10 - Line Power Connection

    Q46D-ODO Optical D.O. System Part 4 – Electrical Installation Figure 10 - Line Power Connection The power strip, TB5, allows up to 12 AWG wire. A wire gauge of 16 AWG is recommended to allow for an easy pass-through into the ½” NPT ports when wiring.

  • Page 20: Figure 11 - Relay Contacts

    Q46D-ODO Optical D.O. System Part 4 – Electrical Installation 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 VAC), power may be jumped from the power input terminals at TB7.

  • Page 21: Figure 12 - Optional Relay Board Wiring

    Q46D-ODO Optical D.O. System Part 4 – Electrical Installation Optional Output/Relay Connection TB2, is used to connect to the optional 3-relay card (Figure 12) OR the optional third analog output Out#3, (Figure 13). The Q46 can be configured for only one of these optional features, and the hardware for either option must be factory installed.

  • Page 22: Sensor Wiring

    Q46D-ODO Optical D.O. System Part 4 – Electrical Installation 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.

  • Page 23: Figure 14 - Sensor Wiring

    Q46D-ODO Optical D.O. System Part 4 – Electrical Installation Figure 14 - Sensor Wiring O&M Manual Rev-J (8/17)

  • Page 24: Junction Box Connection

    Q46D-ODO Optical D.O. System Part 4 – Electrical Installation Junction Box Connection For installations where the sensor is to be located more than 25 feet from the monitor (max. 200 feet/ 61 m), a junction box must be used. The junction box is shown in Figure 15, and is supplied with a ½"...

  • Page 25: Part 5 - Configuration

    Part 5 – Configuration User Interface The user interface for the Q46 Series instrument consists of a custom display and a membrane keypad. All functions are accessed from this user interface (no internal jumpers, pots, etc.). When power is first applied, you may notice that the display does not come on immediately.

  • Page 26: 5.11 Keys

    Q46D-ODO Optical D.O. System Part 5 – Configuration 5.11 Keys All user configurations occur through the use of four membrane keys. These keys are used as follows: MENU/ESC To scroll through the menu section headers or to escape from anywhere in software. The escape sequence allows the user to back out of any changes in a logical manner.
  • Page 27 Q46D-ODO Optical D.O. System Part 5 – Configuration Lower Line During normal operation, the lower line of the display indicates user-selected secondary measurements that the system is making. This also includes calibration data from the last calibration sequence and the transmitter model number and software version.

  • Page 28: Software

    MEASURE display line. Software The software of the Q46D is organized in an easy to follow menu-based system. All user settings are organized under five menu sections: Measure, Calibration [CAL], Configuration [CONFIG], Control [CONTROL] and Diagnostics [DIAG].
  • Page 29 Q46D-ODO Optical D.O. System Part 5 – Configuration Any data that may be changed will be flashing. This flashing indicates user entry mode and is initiated by pressing the ENTER key. The UP arrow key will increase a flashing digit from 0 to 9. The LEFT arrow key moves the flashing digit from right to left.

  • Page 30: Figure 17 - Software Map

    Q46D-ODO Optical D.O. System Part 5 – Configuration Start MENU MENU MENU MENU MENU MENU MEASURE CONFIG CONTROL DIAG SECTIONS (display only) ENTER ENTER ENTER ENTER Temperature Entry Lock Cal D.O. PID 0% #1 Set Hold PID 100% #1 Fault List...

  • Page 31: Measure Menu [Measure]

    Q46D-ODO Optical D.O. System Part 5 – Configuration 5.22 Measure Menu [MEASURE] The default menu for the system is the display-only menu MEASURE. This menu is a display-only measurement menu, and has no changeable list items. When left alone, the instrument will automatically return to this menu after approximately 30 minutes.

  • Page 32: Calibration Menu [Cal]

    Q46D-ODO Optical D.O. System Part 5 – Configuration 0.00 PPM D.O. Reading in PPM (or mg/L if selected under Instr Type) % Saturation The most common display of D.O. in water is either PPM or mg/L units. However, the same PPM value at different water temperatures can represent quite different concentrations of oxygen in terms of the percent of saturation.

  • Page 33: Configuration Menu [Config]

    Use arrow keys to modify value. See Spare Parts List at the end of this manual for the Q46D lock/unlock code. Press ENTER to toggle lock setting once code is correct. Incorrect codes do not change state of lock condition.
  • Page 34 Use the UP arrow key to modify the desired display value. Press ENTER to store the new value. Zero Filter The Q46D allows the user to program a value near zero below which the monitor will read zero. Because sensors rarely have a perfect zero stability, this zero filter eliminates occasional displays of numbers that are not meaningful.
  • Page 35 Q46D-ODO Optical D.O. System Part 5 – Configuration Note: If the user will not be changing solution conductivity dramatically during the calibration process, leave a default setting of 00.50 mS/cm. For ultrapure water applications, set this value to 0.00. For sea water applications, set this value to 53.00.
  • Page 36 Q46D-ODO Optical D.O. System Part 5 – Configuration *Iout#3 Mode OPTIONAL. This function sets analog output #3 for either temperature (default) or D.O. Press ENTER to initiate user entry mode, and the entire value will flash. Use the UP arrow key to modify the desired value; selections include 1- C/F for temperature or 2-ppm for oxygen.
  • Page 37 Q46D-ODO Optical D.O. System Part 5 – Configuration for a set time to operate the cleaning pump. The CYCLE function sets the time until the next CLEAN cycle. HOLD setting sets the amount of delay that occurs after a cleaning cycle to let the outputs return to normal. See these specific function descriptions listed below for more detail.

  • Page 38: Control Menu [Control]

    Q46D-ODO Optical D.O. System Part 5 – Configuration Temp Units This function sets the display units for temperature measurement. Press ENTER to initiate user entry mode, and the entire value will flash. Use the UP arrow key to modify the desired display value. The choices are °F and °C.
  • Page 39 Q46D-ODO Optical D.O. System Part 5 – Configuration PID Prop [Iout1=PID] Proportional gain factor. The proportional gain value is a multiplier on the controller error (difference between measured value and setpoint value.) Increasing this value will make the controller more responsive.
  • Page 40 Q46D-ODO Optical D.O. System Part 5 – Configuration *Set 4 mA #2 *Set 20 mA #2 [temp/D.O.] These functions set the second 4 mA and 20 mA current loop output points for the transmitter. The output may be set to track temperature (default), PPM oxygen, or % Saturation.

  • Page 41: Figure 18 - Control Relay Hys & Phase Option

    Q46D-ODO Optical D.O. System Part 5 – Configuration Use the arrow keys to modify value. Press ENTER to store the new value. *A Delay This function places an additional amount of time delay on the trip point for relay A. This delay is in addition to the main delay setting for the controller.

  • Page 42: Figure 19 - Alarm Relay Example

    Q46D-ODO Optical D.O. System Part 5 – Configuration If Relay A Mode is set to Alarm Mode, AL, then the following *Setpnt A-HI settings will appear in the Config Menu list automatically. In *Hyst A-HI this mode, two setpoints can be selected on the same relay, *Delay A-HI to create an alarm band.

  • Page 43: Diagnostics Menu [Diag]

    Q46D-ODO Optical D.O. System Part 5 – Configuration If Relay C Mode is set to CON (see Relay C Mode), then C Setpoint C Setpoint Relay C will function identically to Relay A. Relay C settings C Hysteresis C Hysteresis appear in the CONFIG menu list automatically.

  • Page 44: Rev-J (8/17

    Q46D-ODO Optical D.O. System Part 5 – Configuration Fault List The Fault List screen is a read-only screen that allows the user to display the cause of the highest priority failure. The screen indicates the number of faults present in the system and a message detailing the highest priority fault present.

  • Page 45: Rev-J (8/17

    Q46D-ODO Optical D.O. System Part 5 – Configuration troubleshooting. Escaping this screen returns the unit to normal operation. Press ENTER to initiate the user entry mode, and the right-most digit of the value will flash. Use arrow keys to modify desired value.

  • Page 46: Rev-J (8/17

    Q46D-ODO Optical D.O. System Part 5 – Configuration Fail Val #2 This function sets the value of current loop output #2 under a FAIL condition. The settings and operation are identical to Fail Out for output #1. *Fail Out #3 OPTIONAL.

  • Page 47: Rev-J (8/17

    Q46D-ODO Optical D.O. System Part 5 – Configuration Set Default The Set Default function allows the user to return the instrument back to factory default data for all user settings or for just the calibration default. It is intended to be used as a last resort troubleshooting procedure.

  • Page 48: Part 6 - Calibration

    The output of the optical dissolved oxygen sensor will degrade very slowly over the lifetime of the optical element, which is normally 3-5 years. To account for this degradation, the Q46D system should be re-calibrated about every 6 months. The frequency of calibration must be determined by the application.
  • Page 49 Q46D-ODO Optical D.O. System Part 6 - Calibration 2. If the sensor has been removed and placed into a bucket of water, allow sensor to temperature equilibrate with the solution as much as possible. With the sensor coming from an application which differs greatly in temperature, the user may have to wait as much as 20 minutes.

  • Page 50: Dissolved Oxygen Air Span Cal (% Sat)

    Q46D-ODO Optical D.O. System Part 6 - Calibration 6.12 Dissolved Oxygen Air Span Cal (% sat) This is the recommended method for air temperatures greater than about 10C; however, it requires that the sensor be removed from the process and cleaned. Once cleaned, the sensor is held in air and allowed time to adjust to the air temperature.

  • Page 51: 6.13 Dissolved Oxygen Zero Cal

    Q46D-ODO Optical D.O. System Part 6 - Calibration The system now begins acquiring data for the calibration value. As data is gathered, the units for ppm and temperature may flash. Flashing units indicate that this parameter is unstable. 8. The calibration data point acquisition will stop only when the data remains stable for a pre-determined amount of time (approximately 15- 20 seconds.) This can be overridden by pressing ENTER.

  • Page 52: Temperature Calibration

    Q46D-ODO Optical D.O. System Part 6 - Calibration 2. Place about an inch of zero solution in a small beaker or other convenient container and immerse the tip of the sensor. Allow the sensor to sit undisturbed for at least 15 minutes. Suspend sensor, DO NOT LET SENSOR SIT ON TIP.
  • Page 53 Q46D-ODO Optical D.O. System Part 6 - Calibration Cable length Temperature off-set 30 m (98 ft) -1.09º C 50 m (164 ft) -1.82º C 61 m (200 ft) -1.90º C The sensor temperature may be calibrated on line, or the sensor can be removed from the process and placed into a known solution temperature reference.

  • Page 54: Part 7 - Pid Controller Details

    Part 7 – PID Controller Details PID Description PID control, like many other control schemes, are used in chemical control to improve the efficiency of chemical addition or control. By properly tuning the control loop that controls chemical addition, only the amount of chemical that is truly required is added to the system, saving money.
  • Page 55 Q46D-ODO Optical D.O. System Part 7 –PID Controller Details é ù ò output ê ë ú û Where: output = controller output proportional gain integral gain derivative gain time e(t) = controller error (e=measured variable – setpoint) Figure 20 - Q46 ISA (Ideal) Equation The most notable feature of the algorithm is the fact the proportional gain term affects all components directly (unlike some other algorithms - like the “series”...

  • Page 56: Classical Pid Tuning

    The P value is then reduced to ½ of the oscillatory value, and the I term is increased to give the desired response. This can be done with the Q46D controller, with the exception that the I term should start no lower than 1.0.

  • Page 57: Manual Pid Override Control

    Q46D-ODO Optical D.O. System Part 7 –PID Controller Details Manual PID Override Control The Q46 electronics is equipped designed to allow the user to take manual control of the PID output. This is often useful when starting up a control loop, or in the event that you wish to bump the system manually to measure system response time.
  • Page 58 Q46D-ODO Optical D.O. System Part 7 –PID Controller Details The easiest process’ to control with closed-loop schemes are generally linear, and symmetrical, in nature. For example, controlling level in tank where the opening of valve for a fixed period of time corresponds linearly to the amount that flows into a tank.

  • Page 59: Part 8 - System Maintenance

    Part 8 – System Maintenance General The Q46D/60 Dissolved Oxygen System will generally provide unattended operation over long periods of time. With proper care, the system should continue to provide measurements indefinitely. For reliable operation, maintenance on the system must be done on a regular schedule. Keep in mind that preventive maintenance on a regular schedule is much less troublesome than emergency maintenance that always seems to come at the wrong time.

  • Page 60: Part 9 - Troubleshooting

    Part 9 – Troubleshooting General The information included in this section is intended to be used in an attempt to quickly resolve an operational problem with the system. During any troubleshooting process, it will save the most time if the operator can first determine if the problem is related to the analyzer, sensor, or some external source.

  • Page 61: Analyzer Tests

    Q46D-ODO Optical D.O. System Part 9 – Troubleshooting 5. If rigid conduit has been run directly to the Q46 enclosure, check for signs that moisture has followed conduit into the enclosure. 6. Check for ground loops. Although the sensor is electrically...

  • Page 62: 9.31 Display Messages

    Q46D-ODO Optical D.O. System Part 9 – Troubleshooting 2. If analyzer does not appear to power up (no display), remove power and check removable fuse for continuity with a DVM. 3. Using a DVM, check the voltage across the BLUE and WHITE wires coming from the power supply board in the base of the enclosure.
  • Page 63 The temperature reading is < -10 ºC Same as “Temp High” above. TC Error TC may be open or shorted. Check sensor wiring and perform RTD test as described in sensor manual. Check j-box connections. Figure 21 - Q46D Display Messages O&M Manual Rev-J (8/17)

  • Page 64: Sensor Tests

    Q46D-ODO Optical D.O. System Part 9 – Troubleshooting MESSAGE DESCRIPTION POSSIBLE CORRECTION D.O. Cal Fail Failure of oxygen calibration. FAIL icon will Clean sensor redo zero and span calibration. not extinguish until successful calibration If still failure, sensor slope may be less than has been performed, or 30 minutes passes 20% or greater than 500%.

  • Page 65: Figure 22 - Pt1000 Rtd Table

    Q46D-ODO Optical D.O. System Part 9 – Troubleshooting 3. Disconnect the five sensor wires from the oxygen monitor. Those wires are color coded red, white, blue, green, brown, and black. Note: the brown wire may be replaced by an orange wire in some cables. Connect the DVM between the brown and black wires.

  • Page 66: Figure 23 - Reference Barometric Pressure Conversion

    Q46D-ODO Optical D.O. System Part 9 – Troubleshooting Barometric Pressure Conversion Inches of Millimeters of Feet Above Mercury(inHg) Mercury (mmHg) Sea Level 22.00 558.8 +8790 22.50 571.5 +8053 23.00 584.2 +7347 23.50 596.9 +6671 24.00 609.6 +6023 24.50 622.3 +5402 25.00...

  • Page 67: Figure 24 - Reference Oxygen Solubility Table

    Q46D-ODO Optical D.O. System Part 9 – Troubleshooting Oxygen Solubility vs. Temperature Temperature Temperature °F °C °F °C 14.6 23.3 14.1 24.4 13.7 25.6 13.3 26.7 12.9 27.8 12.6 28.9 12.2 30.0 11.9 31.1 11.6 32.2 10.0 11.3 33.3 11.1 11.0...

  • Page 68: Spare Parts

    Spare Parts Model Q46D Optical D.O. System Part No. Description 03-0393 Q46D Front Lid electronics assembly 07-0320 AC Powered monitor electronics assembly, 100-240 VAC 07-0321 DC Powered monitor electronics assembly 12-24 VDC 07-0322 AC Powered monitor electronics assembly w/Profibus, 100-240 VAC...

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