Summary of Contents for ATI Technologies Q46H-79PR
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O & M Manual Model Q46H-79PR Total 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: 800-959-0299 Saddleworth OL3 5DE...
Chlorine Zero Cal ......49 Features ..........7 7.12 Chlorine Span Cal ......50 Q46H/79PR System Specifications ..8 Temperature Calibration ....51 Q46H-79PR Performance pH Calibration ........52 Specifications ..........10 7.31 Two-Point pH Cal ......53 7.32 One-Point pH Cal ......53 PART 2 –...
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Table of Figures 1 - T ....................... 5 IGURE YPICAL ONITORING YSTEM 2 - C ............5 IGURE HLORINE YSTEM W PTIONAL P AYONET TYLE ENSOR 3 - S ................ 6 IGURE EALED LOWCELL SSEMBLIES W ONTROL 4 - Q46 E .....................
Part 1 - Introduction General The Model Q46H/79PR is a highly versatile on-line monitoring system designed for the continuous measurement of total chlorine in solution. The full scale operating range of the system may be selected by the user 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 ranging from 0 to 55°C.
Q46H/79PR Chlorine Manual art 1 – Introduction Figure 1 - Typical Monitoring System gure 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.
Q46H/79PR Chlorine Manual art 1 – Introduction 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.
Q46H/79PR Chlorine Manual art 1 – Introduction Features • Standard Q46H/79PR analyzers have fully isolated inputs and outputs. Analog outputs are additionally completely isolated from each other. • Available in either 90-260 VAC or 12-24 VDC power supply systems. All features remain the same in both variations.
Q46H/79PR Chlorine Manual art 1 – Introduction Q46H/79PR System Specifications Displayed Parameters Main input, 0.1 ppb (0.0001 ppm) to 200.0 ppm Sensor temperature, -10.0 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...
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Q46H/79PR Chlorine Manual art 1 – Introduction Sensor Materials Sensor Cable 25 ft. (7.5 meter) cable with 6-pin plug Max. Sensor-to-Analyzer Distance 100 feet (30.5 meters), with junction box Optional pH Input 0-14 pH corresponding to approx. 0.3 – 1.5 VDC Flow Cell Constant head overflow, clear cast acrylic, 7-30 GPH, 15 GPH recommended, inlet is ¼”...
Q46H/79PR Chlorine Manual art 1 – Introduction Q46H-79PR Performance Specifications Accuracy 1.0% of selected range or 0.05 PPM Repeatability 0.5% of selected range or 0.02 PPM Sensitivity 0.1% of selected range Non-linearity 0.1% of selected range Warm-up Time 3 seconds to rated performance (electronics only) Supply Voltage Effects ±...
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.
Q46H/79PR Chlorine Manual art 2 – Analyzer Mounting Wall or Pipe Mount A PVC mounting bracket with attachment screws is supplied with each transmitter (see Figure 5 for dimensions). The multi-purpose bracket is attached to the rear of the enclosure using the four flat head screws.
Q46H/79PR Chlorine Manual art 2 – Analyzer Mounting Panel Mounting Panel mounting uses the panel mounting flange molded into the rear section of the enclosure. Figure 8 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.
Part 3 – Sensor/Flowcell Mounting General Select a location within the maximum sensor cable length for mounting of the sensor flow cell. Constant-Head Flowcell Chlorine sensors are best used in a constant-head overflow chamber because variations in sample flow rate and pressure can cause unstable readings. When monitoring low concentrations (below 0.5 PPM), this method should always be used.
Q46H/79PR Chlorine Manual art 3 – Sensor/Flowcell Mounting 3.3 Sealed Flowcell Applications where the sample inlet flow is well controlled can use a simpler sealed flowcell. Using this flowcell requires that sample flow be controlled externally to about 400 cc/min. using pressure regulators and needle valves.
Q46H/79PR Chlorine Manual art 3 – Sensor/Flowcell Mounting Figure 11 - Sealed pH Flowcell Details Figure 10 - Sealed Chlorine Flowcell Dimensions Submersion Mounting Some applications are much easier done using the submersible sensor. This method can sometimes be used where flow is reasonably constant, and hydraulic head does not vary appreciably.
Q46H/79PR Chlorine Manual art 3 – Sensor/Flowcell Mounting SENSOR CABLE 2" HANDRAIL SWIVEL MOUNTING BRACKET WITH HARDWARE, SUPPLIED BY ATI 1" T x T PVC COUPLING 1" ALUMINUM CONDUIT, THREADED SUPPLIED BY ATI ONE END OR 1" SCHED 80 PVC PIPE LENGTH AS REQUIRED (SUPPLIED BY CUSTOMER) SENSOR, TYPICAL...
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. WARNING: Do not connect AC line power to a 12-24 VDC powered unit.
Q46H/79PR Chlorine Manual art 4 – Electrical Installation Power Connection Verify the AC power supply requirement before installing. Also verify that power is fully disconnected before attempting to wire. AC powered Q46 systems are supplied with 5 cable gland fittings. Connect HOT, NEUTRAL, and GROUND to the matching designations on terminal strip TB7.
Q46H/79PR Chlorine Manual art 4 – Electrical Installation Figure 13 - Line Power Connection The power strip, TB7, 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. O&M Manual Rev-E (5/17)
Q46H/79PR Chlorine Manual art 4 – Electrical Installation 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.
Q46H/79PR Chlorine Manual art 4 – Electrical Installation TB2, is used to connect to the optional 3-relay card (See Figure 15) OR the optional third analog output Out#3, (See Figure 16). The Q46 can be configured for only one of these optional features, and the hardware for either option must be factory installed.
Q46H/79PR Chlorine Manual art 4 – Electrical Installation Direct Sensor Connection 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.
Q46H/79PR Chlorine Manual art 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. A junction box is also available to provide a break point for long sensor cable runs.
Q46H/79PR Chlorine Manual art 4 – Electrical Installation Junction Box Connection Installations where the sensor is to be located more than 25 feet from the monitor (max. 100 feet) require the use of a junction box. The junction box is shown in, and is supplied with two cable glands on the bottom of the enclosure.
Q46H/79PR Chlorine Manual art 4 – Electrical Installation Optional pH Sensor Input The Q46H/79PR may be configured for pH sensor input in applications where the pH can vary. To utilize the feature, a pH sensor must be connected to terminals 3 and 5 as shown in Figure 18. Note that jumpers are installed at the factory between terminals 3 and 5, and terminals 6 and 9.
Part 5 – Sensor Assembly Chlorine Sensor Preparation The total chlorine sensor supplied with the Q46H is shipped dry. It will not operate until it is prepared by adding electrolyte. The membrane assembly shipped on the sensor is good and should not be removed at initial start-up.
Q46H/79PR Chlorine Manual art 5 – Sensor Assembly Figure 21 - Submersible Style Sensor Assembly Follow the procedure below to replace a membrane assembly and prepare the chlorine sensor for operation: (It will not always be necessary to replace the membrane assembly. If membrane assembly is not replaced, simply remove the vent screw, empty the electrolyte chamber, rinse thoroughly with D.I.
Q46H/79PR Chlorine Manual art 5 – Sensor Assembly 7. Slowly screw the chamber onto the sensor body. A small amount of electrolyte will run out of the hole from which the vent screw was removed. Place a paper towel around the sensor to absorb the electrolyte overflow.
Part 6 – 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.). Figure 22 - User Interface O&M Manual Rev-E (5/17)
Q46H/79PR Chlorine Manual art 6 – Configuration 6.11 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.
Q46H/79PR Chlorine Manual art 6 – Configuration 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, CONTROL 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.
Q46H/79PR Chlorine Manual art 6 – Configuration 6.21 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.
Q46H/79PR Chlorine Manual art 6 – Configuration MENU MEASURE CONTROL CONFIG DIAG SECTIONS Temperature Entry Lock Cal Cl2 PID 0% #1 Set Hold PI D 100% #1 Fault List Set Delay Cal pH PID % Output PID Setpoint #1 Sim Out Contrast Cal Temp Loop Current (#1)
Q46H/79PR Chlorine Manual art 6 – Configuration 6.22 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.
Q46H/79PR Chlorine Manual art 6 – Configuration Offset =X.X V pH sensor current output at 7 pH input. This value updates after calibration is performed and is useful for resolving sensor problems. Note: A display test (all segments ON) can be actuated by pressing and holding the ENTER key while viewing the model/version number on the lower line of the display.
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Q46H/79PR Chlorine Manual art 6 – Configuration Set Delay The delay function sets the amount of damping on the instrument. This function allows the user to apply a first order time delay function to the chlorine measurements being made. Both the display and the output value are affected by the degree of damping.
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Q46H/79PR Chlorine Manual art 6 – Configuration Iout#1 Mode This function sets analog output #1 to either track chlorine (default) or enables the PID controller to operate on the chlorine input. Press ENTER to initiate user entry mode, and the entire value will flash. Use the UP arrow key to modify the desired value;...
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Q46H/79PR Chlorine Manual art 6 – Configuration *Relay D Mode *Relay E Mode *Relay F Mode OPTIONAL. Relays D,E,and F can be used in two ways: as a setpoint control, or as an alarm. The two settings for Relay B Mode are CON and FAIL.
Q46H/79PR Chlorine Manual art 6 – Configuration Once the buffer set is selected, press ENTER and the message Accepted! will be displayed on the lower line. Table 1 Table 2 4.00 pH 7.00 pH 9.18 pH 7.00 pH 10.00 pH 4.00 pH ºC °C...
Q46H/79PR Chlorine Manual art 6 – Configuration 6.25 Control Menu [CONTROL] The Control Menu contains all of the output control user settings: Set PID 0% Set PID 100% [Iout1=PID] If the PID is enabled, this function sets the minimum and maximum controller end points.
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Q46H/79PR Chlorine Manual art 6 – Configuration Set 4 mA #1 Set 20 mA #1 [Iout1=chlorine These functions set the main 4 and 20 mA current loop output points for the transmitter. The units displayed depend on the selection made in the CONFIG menu for Iout #1 Mode.
Q46H/79PR Chlorine Manual art 6 – Configuration A Setpoint This function establishes the chlorine trip point for relay A. The entry value is limited to a value within the range specified in “Set Range”. Use the LEFT arrow key to select the first digit to be modified. Then use the UP and LEFT arrow keys to select the desired numerical value.
Q46H/79PR Chlorine Manual art 6 – Configuration If Relay A Mode is set to Alarm Mode, AL, then the following settings will *Setpnt A-HI appear in the Config Menu list automatically. In this mode, two setpoints *Hyst A-HI can be selected on the same relay, to create an alarm band. Phase HI *Delay A-HI selection causes the relay to energize outside of the band, and Phase *Setpnt A-LO...
Q46H/79PR Chlorine Manual art 6 – Configuration 6.26 Diagnostics Menu [DIAG] The diagnostics menu contains all of the user settings that are specific to the system diagnostic functions, as well as functions that aid in troubleshooting application problems. Set Hold The Set Hold function locks the current loop output values on the present process value, and halts operation of the PID controller.
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Q46H/79PR Chlorine Manual art 6 – Configuration PID Timer This function sets a timer to monitor the amount of time the PID controller remains at 0% or 100%. This function only appears if the PID controller is enabled. If the timer is set to 0000, the feature is effectively disabled.
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Q46H/79PR Chlorine Manual art 6 – Configuration Fail Out #2 This function sets the fail-mode of current loop output #2 under a FAIL condition. The settings and operation are identical to Fail Out for output Fail Val #2 This function sets the value of current loop output #2 under a FAIL condition.
Part 7 – Calibration Chlorine Calibration Once power is applied, the sensor must be given time to stabilize. This is best done by following the zeroing procedure below. Establishing a stable zero is critical to the proper operation of the monitor.
Q46H/79PR Chlorine Manual 7 – Calibration Part in calibration failures, review the Service section of this manual, and then contact the service dept. at ATI for further assistance. The sensor zero offset value in nA from the last zero calibration is displayed on the lower line of the Default Menus for information purposes.
Q46H/79PR Chlorine Manual 7 – Calibration Part 8. The screen will display the last measured ppm value and a message will be displayed prompting the user for the lab value. The user must then modify the screen value with the arrow keys and press ENTER.
Q46H/79PR Chlorine Manual 7 – Calibration Part pH Calibration The pH calibration menus will not be seen unless the optional pH sensor input is turned ON and a special pH sensor is connected to the input of the instrument. See section 6.23 Calibration Menu [CAL] pH Input for more details.
Q46H/79PR Chlorine Manual 7 – Calibration Part 7.31 Two-Point pH Cal Thoroughly clean the pH sensor and place it into the first pH calibration buffer, stirring is several times before letting it rest in the beaker. Allow sensor to sit in solution long enough to achieve temperature equilibrium with the pH buffer (maybe 5 minutes.) It is important that both pH buffers be fresh and at room temperature.
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Q46H/79PR Chlorine Manual 7 – Calibration Part Press the ENTER key. The display will begin to flash. Using the UP arrow key, adjust the displayed number to a 1 pt calibration type. This will allow the user to offset-adjust the sensor input for one pH point.
Part 8 – 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.
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Q46H/79PR Chlorine Manual 8 – PID Controller Details Part 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. Be careful of this, as many times the units are the reciprocals of each other (i.e.
Q46H/79PR Chlorine Manual 8 – PID Controller Details Part 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. In fact, the risk of instability is far greater with overly tuned PID control schemes.
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Q46H/79PR Chlorine Manual 8 – PID Controller Details Part The easiest processes 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.
Part 9 – System Maintenance General The Q46H/79PR Total chlorine 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.
Q46H/79PR Chlorine Manual 10 – Troubleshooting Part Sensor Acid Cleaning Over an extended operating period, chlorine sensors can slowly accumulate deposits on the surface of the platinum electrode. Typically, this type of buildup occurs over years of operation, but can sometimes occur more quickly in high levels of manganese, iron, or other metals are dissolved in the water.
Q46H/79PR Chlorine Manual 10 – Troubleshooting Part Soak the sensor for several minutes in the soap solution. Use a small, extra-soft bristle brush (such as a mushroom brush) to thoroughly clean the electrode and saltbridge surfaces. If surface deposits are not completely removed after performing this step, use a dilute acid to dissolve the deposits.
Q46H/79PR Chlorine Manual 10 – Troubleshooting Part Figure 28 - Replacing the Saltbridge and Reference Buffer Flow Cell Maintenance The maintenance on the flow cell is simple cleaning. The flow cell is clear to make examination of the condition of the sensor easier without interfering with operations. The flow cell may be cleaned by wiping or by washing with detergents or dilute acids.
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.
Q46H/79PR Chlorine Manual 10 – Troubleshooting Part interference for other devices. This can be quickly resolved by moving wiring, or by adding very inexpensive snubbers (such As Quencharcs) to the load. 8. Carefully examine any junction box connections for loose wiring or bad wire stripping. If possible, connect the sensor directly to the analyzer for testing.
Q46H/79PR Chlorine Manual 10 – Troubleshooting Part 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...
Q46H/79PR Chlorine Manual 10 – Troubleshooting Part MESSAGE DESCRIPTION POSSIBLE CORRECTION Chlor Cal Fail Failure of chlorine 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 25% or greater than 250%.
Q46H/79PR Chlorine Manual 10 – Troubleshooting Part 10.5 Sensor Tests 1. 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. 2. Residual chlorine sensors can be tested with a digital voltmeter (DVM) to determine if a major sensor problem exists.
Q46H/79PR Chlorine Manual 10 – Troubleshooting Part If you suspect that water has gotten into a cable connection on a flow type sensor 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.
Q46H-79PR Front Lid Assembly 07-0373 Q46H-79PR Monitor, 100-240 VAC 07-0374 Q46H-79PR Monitor, 12-24 VDC 07-0375 Q46H-79PR Monitor, 100-240 VAC with Profibus 07-0376 Q46H-79PR Monitor, 12-24 VDC with Profibus 03-0407 Q46 P/S Assy, 100-240VAC 03-0408 Q46 P/S Assy, 100-240VAC with 3...
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Q46H/79PR Chlorine Manual 10 – Troubleshooting Part 00-1522 Sealed Cl2 Flowcell Assy 00-1527 Sealed pH Flowcell Assy 05-0101 Sealed Cl2 Flowcell Vacuum Breaker Note: Instrument is supplied with sufficient spare parts for 6-12 months of operation. For 2 year spare parts inventory, 3 each of the items marked with an asterisk are required.
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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.
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