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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: 800-959-0299 Saddleworth OL3 5DE...
Table of Contents PART 1 - INTRODUCTION ......... 4 PART 7 – CALIBRATION ........... 47 1.1 G ............4 ENERAL 7.1 C ........47 HLORINE ALIBRATION 1.2 S ..........4 TANDARD YSTEM 7.11 C .......... 47 HLORINE 1.3 F ............7 EATURES 7.12 C ..........
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ABLE OF IGURES 1 - T ............5 IGURE YPICAL HLORINE ONITORING YSTEM 2 - C ........5 IGURE HLORINE YSTEM W ONVENTIONAL P TYLE ENSOR 3 - S ........6 IGURE EALED LOWCELL SSEMBLIES WITH ONTROL 4 - Q46 E .................
Part 1 - Introduction 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 55C.
Q46H/62 Free Chlorine System Part 1 - Introduction 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.
Q46H/62 Free Chlorine System Part 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/62 Free Chlorine System Part 1 - Introduction 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.
Q46H/62 Free Chlorine System Part 1 - Introduction 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...
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.
Part 2 – Analyzer Mounting Q46H/62 Free Chlorine System Figure 7 - Pipe Mounting Diagram Panel Mounting Panel mounting uses the panel mounting flange molded into the rear section of the enclosure. Figure 8provides dimensions for the panel cutout required for mounting. The panel mounting bracket kit must be ordered separately (part number 05-0094).
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 Free 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.
Part 3 – Sensor/Flowcell Mounting Q46H/62 Free Chlorine System 3.3 Sealed Flowcells Applications where the sample inlet flow is well controlled can use a simpler sealed flowcell. Using this flowcell requires that flow be controlled externally to about 400 cc/min. Variable flow rate or variable pressure will cause unstable readings in this flowcell.
Part 4 – Electrical Installation General The Q46 is powered in one of two ways, depending on the version purchased. The 12-24VDC powered analyzer requires a customer supplied DC power supply. The 90-260VAC 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.
Part 4 – Electrical Installation Q46H/62 Free Chlorine System Power Connection Verify the AC power supply requirement before installing. Also verify that power is fully disconnected before attempting to wire. Q46 systems are supplied with 5 cable gland fittings for sealing cable entries. Connect HOT, NEUTRAL, and GROUND to the matching designations on terminal strip TB7.
Part 4 – Electrical Installation Q46H/62 Free Chlorine System Figure 12 - Line Power Connection 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 V), power may be jumpered from the power input terminals at TB7.
Part 4 – Electrical Installation Q46H/62 Free Chlorine System Figure 13 - Optional Relay Board Wiring TB2, is used to connect to the optional 3-relay card (Figures 14) the optional third analog outputOut#3, (Figure 15). The Q46 can be configured for only one of these optional features, and the hardware for either option must be factory installed.
Part 4 – Electrical Installation Q46H/62 Free Chlorine System 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.
Part 4 – Electrical Installation Q46H/62 Free Chlorine System Note: The BLUE wire is NOT used when connecting a Flow Style Probe to the analyzer Note: pH compensation signal may be supplied from a separate isolated voltage input of 0.3-1.5 VDC (75 Ohm resistance across a 4-20 output) Figure 17 –...
Part 4 – Electrical Installation Q46H/62 Free Chlorine System Note: The BLUE wire is NOT used when connecting a Flow or Submersible style Probe to the analyzer Figure 18 - Junction Box Interconnect Wiring O&M Manual Rev-N (11/18)
Part 4 – Electrical Installation Q46H/62 Free Chlorine System Optional pH Compensation Input The Q46H may be configured for pH compensation to maintain excellent accuracy in applications where the pH can vary. To utilize the feature, a pH sensor must be connected to terminals 3 and 5 as shown Figure 17.
Part 4 – Electrical Installation Q46H/62 Free Chlorine System Note: The BLUE wire is NOT used when connecting a Flow Style Probe to the analyzer Figure 19 - Junction Box Wiring w/Optional pH Comp. O&M Manual Rev-N (11/18)
Part 5 – Sensor Assembly Chlorine Sensor Preparation The chlorine sensor supplied with the Q46H is shipped dry. It will not operate until it is prepared by adding electrolyte and a membrane. Preparation of the sensor for operation must be done carefully.
Part 5 – Sensor Assembly Q46H/62 Free Chlorine System 6. 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.). RELAY 4-DIGIT INDICATOR MAIN DISPLAY MENU ICONS MENU ICONS SIGN...
Part 6 – Configuration Q46H/62 Free Chlorine System 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.
Part 6 – Configuration Q46H/62 Free Chlorine 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, 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.
Part 6 – Configuration Q46H/62 Free Chlorine System 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.
Part 6 – Configuration Q46H/62 Free Chlorine System MENU MEASURE CONFIG CONTROL DIAG SECTIONS Temperature Entry Lock Cal Cl2 Set Hold PID 0% #1 PID 100% #1 Fault List Cal pH Set Delay PID % Output Sim Out PID Setpoint #1 Cal Temp Contrast Loop Current (#1)
Part 6 – Configuration Q46H/62 Free Chlorine System 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.
Part 6 – Configuration Q46H/62 Free Chlorine System Offset = X.X mV 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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Part 6 – Configuration Q46H/62 Free Chlorine System 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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Part 6 – Configuration Q46H/62 Free Chlorine System Iout#2 Mode This function sets analog output #2 for temperature (default), chlorine, or pH. 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, 2-ppm for chlorine, or 3-pH for pH.
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Part 6 – Configuration Q46H/62 Free Chlorine System 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. Press ENTER to store the new value.
Part 6 – Configuration Q46H/62 Free Chlorine System pH Comp Enables pH compensation of free chlorine measurements using a built in comp table. An optional pH sensor is required for this compensation method, and “pH Input” menu item above must be selected to be ON. pH type must also be selected.
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Part 6 – Configuration Q46H/62 Free Chlorine System PID Deriv [Iout1=PID] Derivative is a second order implementation of Integral, used to suppress “second-order” effects from process variables. These variables may include items like pumps or mixers that may have minor impacts on the measured value. The derivative factor is rarely used in water treatment process, and therefore, it is best in most cases to leave it at the default value.
Part 6 – Configuration Q46H/62 Free Chlorine System 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 “SetRange”. 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.
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Part 6 – Configuration Q46H/62 Free Chlorine System 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 set points Hyst A-HI can be selected on the same relay, to create an alarm band.
Part 6 – Configuration Q46H/62 Free Chlorine System 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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Part 6 – Configuration Q46H/62 Free Chlorine System controller remains at 0% or 100% for the timer value. If one of the relays is set to FAIL mode, this failure condition can be signaled by a changing relay contact. Press ENTER to initiate user entry mode, and the entire value will flash. Use the UP arrow key to modify desired value;...
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Part 6 – Configuration Q46H/62 Free Chlorine System This function has three options. ON – On all the time, OFF – Off all the time, AL Backlight – Alarm (Default). This function flashes the backlight on and off whenever the Fail icon is displayed.
Part 7 – Calibration Chlorine Calibration After 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.
Part 7 – Calibration Q46H/62 Free Chlorine System value remain high and result 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.
Part 7 – Calibration Q46H/62 Free Chlorine System remains unstable for 10 minutes, the calibration will fail and the message CalUnstable will be displayed. 8. The screen will display the last measured ppm value and a message will be displayed prompting the user for the lab value.
Part 7 – Calibration Q46H/62 Free Chlorine System Once completed, the display will indicate PASS or FAIL. If the unit fails, the temperature adjustment may be out of range, the sensor may not have achieved complete temperature equilibrium, or there may be a problem with the temperature element. In the event of calibration failure, it is recommended to attempt the calibration again immediately.
Part 7 – Calibration Q46H/62 Free Chlorine System Press the ENTER key. The display will begin to flash. Using the UP arrow key, adjust the displayed number to a 2pt calibration type. This will allow the user to offset+slope adjust the sensor input for two separate pH point.
Part 7 – Calibration Q46H/62 Free Chlorine System 6. The message Accepted! will be displayed, or an error describing the cause the failure. The system is now two-point calibrated for pH. 7.4 Adjusting pH Compensation Curve If the pH input is ON and the pH Comp feature is enabled (see section 6.23 Calibration Menu [CAL]), then the chlorine reading will be automatically adjusted for changes in the pH measurement.
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Part 7 – Calibration Q46H/62 Free Chlorine System To access the table editing routines, first go to the CONFIG menu and use the Up arrow to move down to the “pH Comp” selection screen. With the display indicating pH COMP on the bottom line, press and hold the left arrow key for approximately 5 seconds.
Part 7 – Calibration Q46H/62 Free Chlorine System Free Chlorine Sensor Output vs. pH (1.61 PPM Cl2) 110% 100% 7.27 7.60 8.28 8.72 9.05 9.30 9.88 Figure 26 - Typical Free Chlorine Response to change in pH 7.42 pH Correction – Table Modification Example In unusual applications where sample pH can vary widely, and especially when pH values can run in the 8-10 range, default pH correction factors may not fit every application.
Part 7 – Calibration Q46H/62 Free Chlorine System The new multiplier then is 4.850 x 1.15 = 5.577. With the original 4.850 multiplier on the display, press enter and the value will flash. Use the up key to change each digit and the left key to move from digit to digit. When done, press enter. In this example, you have now changed your 9.55 multiplier, but the multipliers at 8.55 and 9.05 are still unchanged.
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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Part 8 – PID Controller Details Q46H/62 Free Chlorine 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.
Part 8 – PID Controller Details Q46H/62 Free Chlorine System Derivative gain. The addition of derivative control can be problematic in many applications, because it greatly contributes to oscillatory behavior. In inherently slow chemical control process’, differential control is generally added in very small amounts to suppress erratic actions in the process that are non-continuous, such as pumps and valves clicking on and off.
Part 8 – PID Controller Details Q46H/62 Free Chlorine System Common PID Pitfalls The most common problem occurring in PID control applications involves the false belief that proper settings on only the PID controller can balance any process to an efficient level. Close-loop control can only be effective if all elements in the loop are properly selected for the application, and the process behavior is properly understood.
Part 9 – System Maintenance General The Q46H/62 Free 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. 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.
Part 9 – Sensor Maintenance Q46H/62 Free Chlorine System 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 if high levels of manganese, iron, or other metals are dissolved in the water.
Part 9 – Sensor Maintenance Q46H/62 Free Chlorine System NOTE: DO NOT use a soap containing any oils (such as lanolin). Oils can coat the glass electrode and harm sensor performance. 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.
Part 9 – Sensor Maintenance Q46H/62 Free Chlorine System NOTE: Every ATI Q25P Sensor includes a spare bottle of Reference Buffer Solution, 7.0 pH. This is NOT typical pH 7 buffer, it is a special “high- capacity” buffer developed to ensure the highest possible stability of the reference portion of the pH measurement.
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.
Part 10 – Troubleshooting Q46H/62 Free Chlorine System 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.
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Part 10 – Troubleshooting Q46H/62 Free Chlorine System MESSAGE DESCRIPTION POSSIBLE CORRECTION Reduce value to ≤ 200 Max is 200 Entry failed, maximum user value allowed is 200. Increase value to ≥ 20 Min is 20 Entry failed, minimum value allowed is 20. Cal Unstable Calibration problem, data...
Part 10 – Troubleshooting Q46H/62 Free Chlorine System 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.
Part 10 – Troubleshooting Q46H/62 Free Chlorine System 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.
Spare Parts Part No. Description 03-0407 P/S Assy, 100-240 VAC 03-0408 P/S Assy, 100-240 VAC with 3 4-20mA output 03-0409 P/S Assy, 100-240 VAC with 3 relay exp. Board 03-0410 P/S Assy, 12-24 VDC 03-0411 P/S Assy, 12-24 VDC with 3 4-20mA output 03-0412 P/S Assy, 12-24 VDC with 3 relay exp.
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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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