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ATI Technologies Q-Blast Q46D O & M Manual

Auto-clean membrane dissolved oxygen system
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Auto-Clean Membrane
Dissolved Oxygen System
(Q46D Software Versions 2.0 and Higher)
Home Office
Analytical Technology, Inc.
6 Iron Bridge Drive
Collegeville, PA 19426
Phone: 800-959-0299
610-917-0991
Fax:
610-917-0992
Email: sales@analyticaltechnology.com
O & M Manual
European Office
ATI (UK) Limited
Unit 1 & 2 Gatehead Business Park
Delph New Road, Delph
Saddleworth OL3 5DE
Phone: +44 (0)1457-873-318
Fax:
+ 44 (0)1457-874-468
Email: sales@atiuk.com

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Summary of Contents for ATI Technologies Q-Blast Q46D

  • Page 1 O & M Manual Auto-Clean Membrane Dissolved Oxygen System (Q46D Software Versions 2.0 and Higher) 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: 800-959-0299 Saddleworth OL3 5DE 610-917-0991...

  • Page 2: Table Of Contents

    Table of Contents Part 6 - Calibration ........... 43 Part 1 - Introduction........... 4 General ........... 43 General ..........4 D.O. Span Cal (1-spl) ..... 43 Standard System ......4 D.O. Span Air Cal (%-sat) ....44 Features ..........6 D.O.
  • Page 3 Table of Figures Figure 1 – Typical Installation Diagram ......................5 Figure 2 - Wall Mount Bracket........................10 Figure 3 - Enclosure Dimensions ........................ 10 Figure 4 - Cleaner Enclosure Dimensions ....................11 Figure 5 - Handrail Mounting Assembly ...................... 12 Figure 6 -Sensor Mounting Assembly ......................

  • Page 4: Part 1 - Introduction

    Part 1 - Introduction General The Model Q46D is an on-line monitoring system designed for the continuous measurement of dissolved oxygen in solution. The full scale operating range of the system 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 or galvanic membraned sensors, this manual is specific for systems using a membraned D.O.

  • Page 5: Figure 1 - Typical Installation Diagram

    Q46D Membrane D.O. Q-Blast System Part 1 - Introduction (System Diagram Shown on Optional Mounting Plate w/Power Distribution Box) Figure 1 – Typical Installation Diagram O&M Manual (Rev-H, 11/18)

  • Page 6: Features

    Q46D Membrane D.O. Q-Blast System Part 1 - Introduction Features  Standard Q46D electronic transmitters are designed to be fully isolated instruments for operation from either 90-260 VAC or 12-24 VDC power supplies.  High accuracy, high sensitivity system, measures from 0.1 ppm to 40.0 ppm through 2 internal automatic ranges.

  • Page 7: Q46D Auto-Clean System Specifications

    Q46D Membrane D.O. Q-Blast System Part 1 - Introduction Q46D Auto-Clean System Specifications 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 or 12-24 VDC, 500 mA max.

  • Page 8: Q46D Performance Specifications (Includes Sensor)

    Q46D Membrane D.O. Q-Blast System Part 1 - Introduction Max. Sensor Cable Length 1000 feet (300 m), with junction box Q46D Performance Specifications (includes sensor) Accuracy ±0.05 PPM or 0.5% of Span Repeatability 0.05 PPM Sensitivity 0.01 PPM Electronic Stability 0.05% of span per 24 hours, non-cumulative Temperature Drift Span or zero, 0.01% of span/ºC...

  • Page 9: Part 2 - Mechanical Installation

    Part 2 - Mechanical Installation General The Q46D Auto-Clean D.O. System consists of two assemblies housed in NEMA 4X (IP-66) enclosures. The analyzer electronics and the Q-Blast cleaner assembly should both be mounted near the sensor location, with a maximum of 60 feet between the monitor/cleaner and the sensor.

  • Page 10: Wall Mount Dimensions

    Part 2 – Mechanical Installation Q46D Membrane D.O. Q-Blast System Figure 2 - Wall Mount Bracket Wall Mount Dimensions Figure 3 shows the dimensions of the analyzer dimensions. Note that the enclosure mounting brackets are not installed at the factory. They are supplied separately and must be attached using the screws provided.

  • Page 11: Figure 4 - Cleaner Enclosure Dimensions

    Part 2 – Mechanical Installation Q46D Membrane D.O. Q-Blast System Figure 4 shows the dimensions of the Q-Blast assembly. This enclosure should be mounted beside the analyzer enclosure as shown in Figure 1. If the optional mounting plate and power junction box were purchased, the analyzer and cleaner will be supplied mounted to the plate.

  • Page 12: Railing Mount

    Part 2 – Mechanical Installation Q46D Membrane D.O. Q-Blast System Railing Mount Figure 5 shows the optional mounting assembly (on system mounting plate) used to mount the analyzer and cleaner assembly to a typical safety handrail that surrounds many aeration tanks. This bracket assembly consists of vertical channels attached to the handrail with u-bolts.

  • Page 13: Sensor Installation

    Part 2 – Mechanical Installation Q46D Membrane D.O. Q-Blast System Sensor Installation Most applications for D.O. monitoring are done using a submersible sensor. This method can be used where flow is reasonably constant, and hydraulic head does not vary more than about 10 feet.

  • Page 14: Figure 7 - Sensor Mounting Detail

    Part 2 – Mechanical Installation Q46D Membrane D.O. Q-Blast System Figure 7 - Sensor Mounting Detail O&M Manual (Rev-H, 11/18)

  • Page 15: Part 3 - Electrical Installation

    Part 3 - Electrical Installation General Q46D/60 Auto-Clean D.O. monitors and Q-Blast cleaners are powered from 90-260 VAC, 50/60 Hz. or 12-24 VDC. Systems can draw up to 0.5 amps when the internal air compressor activates as part of the sensor cleaning system. Normal current draw is less than 0.2 amps when the cleaner is off.

  • Page 16: Figure 8 - Q46D Connections

    Part 3 – Electrical Installation Q46D Membrane D.O. Q-Blast System Figure 8 - Q46D Connections O&M Manual (Rev-H, 11/18)

  • Page 17: Figure 9 - Q-Blast Connections

    Part 3 – Electrical Installation Q46D Membrane D.O. Q-Blast System Figure 9 - Q-Blast Connections O&M Manual (Rev-H, 11/18)

  • Page 18: Sensor Connections

    Part 3 – Electrical Installation Q46D Membrane D.O. Q-Blast System Sensor Connections Prior to making any sensor connections, the sensor wire and the cleaner air tube must be run up inside the mounting pipe as shown in the previous section, Figure 6 & Figure 7. The sensor cable is connected to the Q46 terminal strip on the front lid of the assembly as shown in Figure 10.

  • Page 19: Q-Blast To Q46 Connection

    Part 3 – Electrical Installation Q46D Membrane D.O. Q-Blast System Q-Blast to Q46 Connection Connections inside the Q-Blast enclosure include power and an interconnect cable running to the Q46 monitor. To access the terminal compartment, loosen the 4 screws holding the cover in place and set the cover aside.

  • Page 20: Figure 11 - Standard System Wiring

    Part 3 – Electrical Installation Q46D Membrane D.O. Q-Blast System Figure 11 - Standard System Wiring O&M Manual (Rev-H, 11/18)

  • Page 21: Figure 12 - Q-Blast Connections W/Optional J-Box

    Part 3 – Electrical Installation Q46D Membrane D.O. Q-Blast System Figure 12 - Q-Blast Connections w/Optional J-Box O&M Manual (Rev-H, 11/18)

  • Page 22: Analog Output Connections

    Part 3 – Electrical Installation Q46D Membrane D.O. Q-Blast System Analog Output Connections Q46 Auto-Clean systems provide two 4-20 mA outputs. Output connections are made to terminal TB1 as shown in Figure 8. Relay Connections Relay wiring is done to terminal blocks inside the Q46 display assembly. This unit actually contains three SPDT relays, and a bank of three low-power relays that is used to control the activation of the sensor automatic cleaning system.

  • Page 23: Part 4 - Sensor Assembly

    Part 4 - Sensor Assembly General Auto-Clean D.O. sensors are actually made up of a number of parts as shown in Figure 13. A holder with 30 feet of cable provides the support for the sensor and cleaner nozzle. The sensing element screws into the bottom of the holder, as does the cleaner nozzle.

  • Page 24: Sensor Module

    Part 4 – Sensor Assembly Q46D Membrane D.O. Q-Blast System Sensor Module The D.O. sensing module unscrews from the holder. However, in order to remove the sensing module, the cleaner nozzle must be rotated 180 degrees so that the module does not hit the machined step on the nozzle.
  • Page 25 Part 4 – Sensor Assembly Q46D Membrane D.O. Q-Blast System From the package of membranes supplied with the sensor, place a new membrane into the front nut. The membrane is clear and is separated from other membranes by a blue paper spacer. Screw the membrane cap onto the canister until you feel the o-ring compress.

  • Page 26: Part 5 - Operation

    Part 5 - Operation 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.). RELAY 4-DIGIT INDICATOR MAIN DISPLAY MENU ICONS MENU ICONS SIGN...

  • Page 27: 5.11 Keys

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System 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.

  • Page 28: Software

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System Icon Area The icon area contains display icons that assist the user in set-up and indicate important states of system functions. The CAL, CONFIG, CTRL, and DIAG icons are used to tell the user what branch of the software tree the user is in while scrolling through the menu items.

  • Page 29: 5.21 Software Navigation

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System 5.21 Software Navigation Within the CAL, CONFIG, CONTROL, and DIAG menu sections is a list of selectable items. Once a menu section (such as CONFIG) has been selected with the MENU key, the user can access the item list in this section by pressing either the ENTER key or the UP arrow key.

  • Page 30: Figure 16 - Software Map

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System MENU MEASURE CONFIG CONTROL DIAG SECTIONS Temperature Entry Lock Cal D.O. Set Hold PID 0% #1 Fault List PID 100% #1 Set Delay Cal Temp PID % Output PID Setpoint #1 Sim Out Contrast Loop Current (#1)

  • Page 31: Measure Menu [Measure]

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System 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]

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System The MEASURE screens are intended to be used as a very quick means of looking up critical values during operation or troubleshooting. 5.23 Calibration Menu [CAL] The calibration menu contains items for frequent calibration of user parameters. There are two items in this list: Cal D.O., Cal Temp.
  • Page 33 Part 5 – Operation Q46D Membrane D.O. Q-Blast System Instr Type This function allows the user to change the type of measurement to be displayed in the primary display area. The user may select “1 PPM”¸ “2 mg/L, or “3 %Sat”. There is not a great deal of difference between type 1 and 2 settings as PPM and mg/L measurement units are pretty close to the same.
  • Page 34 Part 5 – Operation Q46D Membrane D.O. Q-Blast System When enabled, the D, E and F relay settings are not displayed in the CONFIG or CNTRL menus. Com Mode Sets digital communication mode of analyzer. Optional digital communication card must be plugged into the power supply slot for this function to work.

  • Page 35: Control Menu [Control]

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System Relay C Mode Relay C can be used in two ways: as a setpoint control, or as an alarm. The two settings for Relay C Mode are CON and FAIL. The CON setting enables normal setpoint operation for Relay B/C. Relay B/C then operates identically to Relay A, with settings for setpoint, hysteresis, delay and phasing appearing in the CONFIG menu automatically.
  • Page 36 Part 5 – Operation Q46D Membrane D.O. Q-Blast System PID Prop Proportional gain factor. The proportional gain value is a multiplier on [Iout1=PID] the controller error (difference between measured value and setpoint value.) Increasing this value will make the controller more responsive. Integral is the number of “repeats-per-minute”...

  • Page 37: Figure 17 - Control Relay, Hysteresis & Phase Options

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System This function establishes the hysteresis, or “deadband”, for Relay A. *A Hysteresis Hysteresis is most often used to control relay chattering; however, it may also be used in control schemes to separate the ON/OFF trip points of the relay.

  • Page 38: Figure 18 - Alarm Relay Example

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System Figure 18 is a visual description of a typical alarm relay application. When value rises to ≥ 1.000 ppm, relay When value falls to < 1.000 ppm, relay closes, until rises back to > 1.050 ppm. closes, until value falls back to <...

  • Page 39: Diagnostics Menu [Diag]

    Part 5 – Operation Q46D Membrane D.O. Q-Blast System UP arrow key to modify the desired value. Selections for each variable are: CLEAN 1-10 minutes, CYCLE 1-999 hours, HOLD 0-999 minutes. Press ENTER to store the new value. Example: If the timer-CYCLE setting is 24 hours, the timer CLEAN setting is 3 pulses, and the timer-HOLD setting is 1 minutes, the following sequence will occur: At the instant the timer is enabled, the time period begins.
  • Page 40 Part 5 – Operation Q46D Membrane D.O. Q-Blast System Faults are not stored; therefore, they are immediately removed if power is cycled. If the problem causing the faults still exists, however, faults will be displayed again after power is re-applied and a period of time elapses during which the diagnostic system re-detects them.
  • Page 41 Part 5 – Operation Q46D Membrane D.O. Q-Blast System Fail Val #1 Sets the output failure value for Iout#1. When Fail Out above is set to ON, this function sets value of the current loop under a FAIL condition. When the Relay Option Board is installed, the display will read Fail Out #1.
  • Page 42 Part 5 – Operation Q46D Membrane D.O. Q-Blast System (relay de-energized), and the LCD icon will illuminate. In addition, a power fail would also cause the same contacts to open. 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.

  • Page 43: Part 6 - Calibration

    Part 6 - Calibration General The instrument must be calibrated periodically to maintain a high degree of measurement accuracy. A complete calibration will include zeroing and spanning the sensor. It is generally unnecessary to set the zero at every calibration, but it should be done during the initial installation.

  • Page 44: Span Air Cal (%-Sat)

    Part 7 – Sensor Auto-Clean System Q46D Membrane D.O. Q-Blast System Press the ENTER key. The screen will display a flashing 1-spl for 1-point, a %-sat for Saturation air calibration, or a 3-zer for zero calibration. Using the UP arrow key, set for a 1-spl calibration and press ENTER.

  • Page 45: 6.4 D.o. Zerocal

    Part 7 – Sensor Auto-Clean System Q46D Membrane D.O. Q-Blast System 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. 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 46: Temperature Calibration

    Part 7 – Sensor Auto-Clean System Q46D Membrane D.O. Q-Blast System 6. If the data remains unstable for 10 minutes, the calibration will fail and the message CalUnstable will be displayed. 7. If accepted, the screen will display the message PASS with the new sensor zero reading (offset), then it will return to the main measurement display.

  • Page 47: Part 7 - Sensor Auto-Clean System

    Part 7 - Sensor Auto-Clean System General The cleaner control system located in the cleaner enclosure contains a number of components designed to supply pulses of high pressure air to the tip of the sensor. The main components and their function are as follows: Compressor: The air compressor is a small DC powered diaphragm type compressor that delivers air at up to 30 PSI to the accumulator cylinder which is part...
  • Page 48 Part 7 – Sensor Auto-Clean System Q46D Membrane D.O. Q-Blast System Once the air cleaning system has run through a cycle, it will remain in standby while waiting for the next activation signal from the D.O. monitor. This will normally occur every 24 hours, but can be activated manually at any time as explained previously.

  • Page 49: Part 8 - Pid Controller Details

    Part 8 - PID Controller Details PID Description PID control, like many other control schemes, is 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. The savings can be substantial when compared to a system which may be simply adding chemical at a constant rate to maintain some minimal addition under even the worst case conditions.
  • Page 50 Part 8 – PID Controller Details Q46D Membrane D.O. Q-Blast System 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” form.) If a pre-existing controller utilizes the same form of the algorithm shown above, it is likely similar settings can for made if the units on the settings are exactly the same.

  • Page 51: Classical Pid Tuning

    Part 8 – PID Controller Details Q46D Membrane D.O. Q-Blast System Classical PID Tuning Unlike many high speed position applications where PID loops are commonly used, the chemical feed application employed by this instrument does not require intense mathematical exercise to determine tuning parameters for the PID.
  • Page 52 Part 8 – PID Controller Details Q46D Membrane D.O. Q-Blast System 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 53: Part 9 - System Maintenance

    Part 9 - 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.
  • Page 54 Part 9 – System Maintenance Q46D Membrane D.O. Q-Blast System electrode, remove the nut and washer and unwrap the old lead. Loop the end of a new lead electrode around the post and replace the nut and washer. Tighten the nut firmly but do not over tighten as damage to the sensing module can result.

  • Page 55: Part 10 - Troubleshooting

    Part 10 - Troubleshooting 10.1 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 56: 10.3 Analyzer Tests

    Part 10 – Troubleshooting Q46D Membrane D.O. Q-Blast System the large amount of energy present in circuits driving these types of loads when they are switched on an off, the relay wiring placement can result in electrical interference for other devices. This can be quickly resolved by moving wiring, or by adding very inexpensive snubbers (such As Quencharcs) to the load.

  • Page 57: Figure 20 - Q46D Display Messages

    Part 10 – Troubleshooting Q46D Membrane D.O. Q-Blast System 10.4 Display Messages The Q46 Series instruments provide a number of diagnostic messages which indicate problems during normal operation and calibration. These messages appear as prompts on the secondary line of the display or as items on the Fault List. MESSAGE DESCRIPTION POSSIBLE CORRECTION...
  • Page 58 Part 10 – Troubleshooting Q46D Membrane D.O. Q-Blast System 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 59: Sensor Tests

    Part 10 – Troubleshooting Q46D Membrane D.O. Q-Blast System Sensor Tests Check the membrane condition. A membrane that is not stretched smoothly across the tip of the sensor will cause unstable measurements. If necessary, change membrane and electrolyte. Dissolved oxygen sensors can be tested with a digital voltmeter (DVM) to determine if a major sensor problem exists.

  • Page 60: Figure 22 - Reference, Barometric Conversion Table

    Part 10 – Troubleshooting Q46D Membrane D.O. Q-Blast System If you suspect that water has gotten into a cable connection or into the plug connection of a submersible sensor, disconnect the cable and allow the parts of the sensor to sit in a warm place for 24 hours.

  • Page 61: Spare Parts

    Spare Parts PART NO. DESCRIPTION 03-0393 Q46D Front Lid Assembly 07-0320 AC Powered Analyzer Electronics Assembly, 90-260 VAC 07-0321 DC Powered Analyzer Electronics Assembly, 12-24 VDC 07-0322 AC Powered Analyzer Electronics Assembly, w/Profibus 07-0323 DC Powered Analyzer Electronics Assembly, w/Profibus 03-0407 Q46 P/S Assy, 100-240VAC 03-0408...
  • Page 62 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 63 WATER QUALITY MONITORS GAS DETECTION PRODUCTS Dissolved Oxygen Ammonia Carbon Monoxide Free Chlorine Hydrogen Combined Chlorine Nitric Oxide Total Chlorine Oxygen Residual Chlorine Dioxide Cl2 Phosgene Potassium Permanganate Bromine Chlorine Dissolved Ozone Chlorine Dioxide pH/ORP Fluorine Conductivity Iodine Hydrogen Peroxide Acid Gases Peracetic Acid O Ethylene Oxide...

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