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Analytical Technology Q25R Manual

Orp monitor/analyzer
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Model Q45R
ORP Monitor/Analyzer
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 Q25R
ORP Sensor
European Office
ATI (UK) Limited
Unit 1 & 2 Gatehead Business Park
Delph New Road, Delph
Saddleworth
Ph: 0800-018-4020
+ 44 (0) 1457-873-318
Fax: + 44 (0) 1457-874-468
Email:sales@atiuk.com

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  • Page 1 Model Q45R ORP Monitor/Analyzer Model Q25R ORP Sensor 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 Ph:(800) 959-0299 Ph: 0800-018-4020...
  • Page 2 PRODUCT WARRANTY Analytical Technology, Inc. (Manufacturer) warrants to the Customer that if any part(s) of the Manufacturer’s products 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

    ....... 45 YSTEM PECIFICATIONS OFTWARE AVIGATION Q45R P ....9 5.22 [MEASURE] ...... 48 ERFORMANCE PECIFICATIONS EASURE (Q25R, ORP S ) ...... 9 5.23 C [CAL] ....... 49 ENERAL ENSOR ALIBRATION ........10 5.24 [CONFIG] ....50 ENSOR EATURES ONFIGURATION ........
  • Page 4 Figure 22 - Relay Contacts ....................... 35 Figure 23 - Cable Description, Model Q25 ................36 Figure 24 - Detachable single Shielded Cable, Q25R ............... 36 Figure 25 - Sensor Cable Preparation ..................37 Figure 26 - Juncion Box Interconnect Wiring ................38 Figure 27 - Sensor Connections, Combination Electrodes ............

  • Page 5: Part 1 - Introduction

    Part 1 - Introduction General (Q45R, ORP Monitor) The Model Q45R ORP monitor/analyzer provides an extremely versatile measurement system for monitoring and control of ORP (oxidation/reduction potential, REDOX) over the range of –1000 mV to +2000 mV. The instrument is offered standard as a loop-powered transmitter for 2-wire DC applications.

  • Page 6: Features

    Q45R ORP Monitor System Part 1 - Introduction Features · Standard Q45R electronic transmitters are designed to be a fully isolated, loop powered instruments for 2-wire DC applications. Optional integral power supply card for 115/230 VAC operation, 12-24 vdc, and optional battery power supply card for portable datalogging applications are available.

  • Page 7: Q45R System Specifications

    Q45R ORP Monitor System Part 1 - Introduction · Selectable Pt1000 or Pt100 temperature inputs. Systems can also be hard-configured for three-wire elements. Temperature element can be user calibrated. · Security lock feature to prevent unauthorized tampering with transmitter settings. All settings can be viewed while locked, but they cannot be changed.
  • Page 8 Q45R ORP Monitor System Part 1 - Introduction EMI/RFI Influence Designed to EN 61326-1 Output Isolation 600 V galvanic isolation Filter Adjustable 0-9.9 minutes additional damping to 90% step input Temperature Input Selectable Pt1000 or Pt100 RTD with automatic compensation Displayed Parameters Main input, -1000 to +2000 mV Sensor temperature, -10.0 to 110.0 °C (14 to 230ºF)

  • Page 9: Q45R Performances

    Distance 30 ft. (9.1 meters) w/o preamp Sensor Types Model Q25R ORP w/ preamp - 5 wire input, or combination style ORP electrode w/ TC - 2 wire input General (Q25R, ORP Sensor) The Model Q25R ORP Sensor measures the oxidation/reduction potential (also known as REDOX) of aqueous solutions in industrial and municipal process applications.

  • Page 10: Sensor Features

    · Pt1000 RTD. The temperature element used in ATI sensors is highly accurate and provides a highly linear output. · The Q25R is fully submersible. Sensor Specifications Measuring Range -1000 to +2000 mV Sensitivity 0.2 mV...

  • Page 11: Important Notes

    Important Notes The glass electrode must be wetted at all times to ensure proper functionality. Q25R sensors are shipped with a fluid-filled cap over the electrode to enable immediate use (remove cap before installing, save for storage and shipping purposes). Electrodes that have dried out for any reason should be hydrated for 24 hours to restore full functionality.

  • Page 12: Part 2 - Analyzer Mounting

    Part 2 – Analyzer Mounting General All Q45 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 13: Figure 1 - Q45 Enclosure Dim Ac Pwr Units

    Q45R ORP Monitor System Part 2 – Analyzer Mounting MENU ENTER Figure 1 - Q45 Enclosure Dim AC Pwr units O&M Manual Rev-T (3/11)

  • Page 14: Figure 2 - Q45 Enclosure Dim 2-Wire & Batt Units

    Q45R ORP Monitor System Part 2 – Analyzer Mounting 4.38 2.61 (111.2) (66.3) MENU ENTER 4.38 2.61 #10-32 UNF (111.2) (4 PLACES) (66.3) FRONT VIEW BACK VIEW 1" NPT (20.8) 1.23 1.23 PG-9 PORT (31.2) (31.2) (2 PLACES) 1.68 (42.7) 3.45 (87.6) BOTTOM VIEW...

  • Page 15: Wall Or Pipe Mount

    Q45R ORP Monitor System Part 2 – Analyzer Mounting Wall or Pipe Mount A PVC mounting bracket with attachment screws is supplied with each transmitter (see Figure 3 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 16: Figure 4 - Wall Mounting Diagram

    Q45R ORP Monitor System Part 2 – Analyzer Mounting MENU ENTER Figure 4 - Wall Mounting Diagram MENU ENTER Figure 5 - Pipe Mounting Diagram O&M Manual Rev-T (3/11)

  • Page 17: Panel Mount , Ac Powered

    Q45R ORP Monitor System Part 2 – Analyzer Mounting Panel Mount, AC Powered Monitor Panel mounting of an AC powered monitor uses the panel mounting flange molded into the rear section of the enclosure. Figure 6 provides dimensions for the panel cutout required for mounting. The panel mounting bracket kit must be ordered separately (part number 05- 0068).

  • Page 18: Part 3 - Sensor/Flowcell Mounting

    This version may not be submerged and should not be used in unprotected outdoor locations. For special applications, the Q25R is also available in a stainless steel bodied version for insertion type installations, or can be supplied in either 1.5” or 2” sanitary versions.

  • Page 19: Figure 7 - Q25 Sensor Types

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Figure 7 - Q25 Sensor Types O&M Manual Rev-T (3/11)

  • Page 20: Flow Tee Mounting

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 3.2 Flow Tee Mounting Convertible sensors may be used in a 1” flow tee as shown in Figure 8. The flow tee is a modified pipe fitting that accommodates the pipe thread on the front of the sensor.

  • Page 21: Union Mounting

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 3.3 Union Mounting For mounting the sensor in larger pipe and allowing for easy sensor removal, a 1 ½” of 2” union mount adapter system is available. This arrangement allows connection of the sensor to pipe sizes up to 2 inches (using adapters if necessary) while allowing easy removal without twisting sensor wires.

  • Page 22: Figure 10 - 2" Union Mount

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Figure 10 - 2" Union Mount O&M Manual Rev-T (3/11)

  • Page 23: Submersion Mounting

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 3.4 Submersion Mounting When using this sensor for submersion applications, mount the sensor to the end of a 1” mounting pipe using a 1” coupling. ATI’s (00-0628) mounting assembly shown in Figure 11 is available for submersible applications. This assembly is designed to mount to standard handrails and facilitates insertion and removal of the sensor.

  • Page 24: Insertion Mounting

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 3.5 Insertion Mounting Special insertion mounting hardware is available for applications requiring the removal of the sensor from a process line or tank without shutting off the sample flow in the line. Figure 12 & Figure 13 show typical insertion assemblies. Separate manuals are available for the installation and operation of these assemblies.

  • Page 25: Figure 13 - Cpvc Sensor Insertion Mount

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Figure 13 - CPVC Sensor Insertion Mount O&M Manual Rev-T (3/11)

  • Page 26: Conventional Orp Sensors

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 3.7 Conventional ORP Sensors As indicated previously, Model Q45R transmitters may be used with standard combination ORP sensors available from a variety of manufacturers. For simple clean water applications, these lower cost sensors may be all that’s needed for reliable monitoring.

  • Page 27: Sealed Flowcell

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 3.71 Sealed Flowcell For applications where a flowcell is desired, a sealed flowcell (00-1527) shown in Figure 16 is available. This flowcell is used only with sensor (63-0008) and may be used for sample pressures up to 75 PSIG. The sample flow should be controlled to 300-800 cc/min.

  • Page 28: Flow Tee Adapter

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 3.72 Flow Tee Adapter When using the (63-0008) sensor in a flow application, a 1” or ¾” pipe tee adapter is required. Figure 17 shows a detail of that arrangement. Figure 17 - Twist-Lock Tee O&M Manual Rev-T (3/11)

  • Page 29: Lock-N-Load System

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Lock-n-Load System A special sensor/flowcell system is available that allows insertion and removal of an ORP sensor under flow conditions. Called a Lock-n-Load system, this assembly uses a 2” flow tee and special sensor holder that retracts the sensor from a flowing sample for maintenance and cleaning.

  • Page 30: Part 4 - Electrical Installation

    Part 4 – Electrical Installation General The Q45 is powered in one of two ways, depending on the version purchased. The 2-wire version is a 16-35 VDC powered transmitter. The integral 115/230 VAC version requires line power. DC powered units with relays may be powered from either 12 or 24 VDC regulated power supplies (customer supplied).

  • Page 31: Figure 19 - Dc/Loop Power Wiring Diagram

    Q45R ORP Monitor System Part 4 – Electrical Installation Figure 19 - DC/Loop Power Wiring Diagram Notes: 1. Voltage between Terminals 9 and 10 MUST be between 16 and 35 VDC. 2. Earth ground into Terminal 12 is STRONGLY recommended. This connection can greatly improve stability in electrically noisy environments.

  • Page 32: Load Drive

    Q45R ORP Monitor System Part 4 – Electrical Installation 4.21 Load Drive The amount of resistance that the analog output can drive in the 115/230 VAC version is fixed. However, in the two-wire configuration, the load-drive level is dependant on the DC supply voltage provided to the controller. The two-wire instrument can operate on a power supply voltage of between 16 and 35 VDC.
  • Page 33 Q45R ORP Monitor System Part 4 – Electrical Installation AC powered Q45 systems are supplied with 3 ½” NPT cable gland fittings Glands fittings will screw into any of the three threaded holes on the bottom of the enclosure. Connect HOT, NEUTRAL, and GROUND to the matching designations on terminal strip TB5.

  • Page 34: Figure 20 - Line Power Connection

    Q45R ORP Monitor System Part 4 – Electrical Installation Figure 20 - 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 35: Sensor Wiring

    Q45R ORP Monitor System Part 4 – Electrical Installation Two sets of SPDT relay contacts 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 Q45 (115 or 230 V), power may be jumpered from the power input terminals at TB5.

  • Page 36: Figure 23 - Cable Description, Model Q25

    ORANGE - TEMPERATURE COMPENSATION WHITE - SENSE ELECTRODE BLUE - NOT USED CABLE SHIELD - EARTH GROUND Figure 24 - Detachable single Shielded Cable, Q25R DANGER: DO NOT connect sensor cable to power lines. Serious injury may result. Take care to route sensor cable away from AC power lines, adjustable frequency drives, motors, or other noisy electrical signal lines.

  • Page 37: Direct Sensor Connection

    Part 4 – Electrical Installation Only ATi’s custom 6-wire shielded interconnect cable should be used when connecting the Model Q25R sensor to the analyzer. This high-performance, double shielded, polyethylene jacketed cable is specially designed to provide the proper signal shielding for the sensor used in this system. Substituted cables...

  • Page 38: Junction Box Connection

    Q45R ORP Monitor System Part 4 – Electrical Installation Junction Box Connection For installations where the sensor is to be located more than 30 feet from the monitor (max. 100 feet), a junction box must be used. The junction box is shown in Figure 26, and is supplied with Pg 9 gland seals for sensor and interconnect wiring installation.

  • Page 39: Figure 27 - Sensor Connections, Combination Electrodes

    Q45R ORP Monitor System Part 4 – Electrical Installation Combination Electrode Connection The Q45P may also be used with non-amplified simple combination electrodes (see Figure 27). Note that a wire jumper must be installed from Terminal 3 to Terminal 8. The user must also select Sensor Type 2 within the Config Menu (see Section 5.24).

  • Page 40: Figure 28 - Combination Electrode Connection

    Q45R ORP Monitor System Part 4 – Electrical Installation Flow ORP Probe (63-0008) Submersible ORP Probe (63-0023) For other combination Electrodes, connect as follows: Terminal 1- Metal Electrode 3 - Reference Electrode 7 - PT100 or PT1000 Temp. Element 8 - PT100 or PT1000 Temp Element NOTES: 1.

  • Page 41: Ompensation

    Q45R ORP Monitor System Part 4 – Electrical Installation External Temperature Compensation All Q25R sensors include an integral Pt1000 RTD. The Q45 series instruments also allow user-supplied external Pt1000 or Pt100 elements to be connected to the temperature input, as shown in Figure 29.

  • Page 42: Part 5 - Configuration

    Part 5 – Configuration User Interface The user interface for the Q45 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 43: Keys

    Q45R ORP Monitor 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 44 Q45R ORP Monitor 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 45: Software

    Q45R ORP Monitor System Part 5 – Configuration Relay Area A/B The relay area contains two icons that indicate the state of the system relays (if the relay card is installed). If the battery board is installed instead, the B icon indicates that the battery voltage is at a low level.
  • Page 46 Q45R ORP Monitor 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 47: Figure 31 - Software Map

    Q45R ORP Monitor System Part 5 – Configuration Start MENU MEASURE CONFIG CONTROL DIAG SECTIONS (display only) *PID 0% #1 Entry Lock Cal ORP Set Hold Temperature *PID 100% #1 Cal Temp Set Delay Fault List Sensor mV *PID Setpoint #1 Contrast Sim Out * PID Output...

  • Page 48: Measure Menu [Measure]

    Q45R ORP Monitor 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 49: Alibration Menu [Cal]

    Q45R ORP Monitor System Part 5 – Configuration 5.23 Calibration Menu [CAL] The calibration menu contains items for frequent calibration of user parameters. There are three items in this list: Cal ORP, Cal Temp, and Cal TC Factor. Cal ORP The ORP calibration function allows the user to adjust the transmitter offset and span reading to match reference buffers, or to adjust the sensor offset to match the sample...

  • Page 50: Configuration Menu [Config]

    Q45R ORP Monitor System Part 5 – Configuration 5.24 Configuration Menu [CONFIG] The Configuration Menu contains all of the general user settings: Entry Lock This function allows the user to lock out unauthorized tampering with instrument settings. All settings may be viewed while the instrument is locked, but they cannot be modified.
  • Page 51 Press ENTER to initiate user entry mode, and the entire value will flash. Use the UP arrow key to modify the desired value. Selections are 1 for Q25R sensor, 2 for combination electrode. Press ENTER to store the new value.
  • Page 52 Q45R ORP Monitor System Part 5 – Configuration (AC Powered Units Only) *Rly A Mode Relay A can be used in three different ways: as a setpoint control, as a fail alarm, or as a HI-LO alarm band. The three settings for Rly A Mode are CON, FAIL and AL.

  • Page 53: Control Menu [Control]

    Q45R ORP Monitor System Part 5 – Configuration this relay without first consulting ATI or your ATI representative 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.
  • Page 54 Q45R ORP Monitor System Part 5 – Configuration smaller adjustments as the measured value gets near the setpoint. 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 55 Q45R ORP Monitor System Part 5 – Configuration AC POWERED UNITS ONLY *Set 4 mA #2 *Set 20 mA #2 [temp/ORP] 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) or ORP.

  • Page 56: Figure 32 - Control Relay Example, Hysteresis & Two Phase Options

    Q45R ORP Monitor System Part 5 – Configuration *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. The entry value is limited to a value between 0 and 999 seconds.

  • Page 57: Figure 33 - Alarm Relay Example

    Q45R ORP Monitor 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 58 Q45R ORP Monitor System Part 5 – Configuration *Timer B ON *Timer B OFF *Timer B HOLD If Relay B Mode is set to CLn1 (see Relay B Mode), then these timer settings appear in the CNTRL menu list automatically. Relay B will toggle ON and OFF based on the time settings entered by the user.

  • Page 59: Iagnostics Menu [Diag]

    Q45R ORP Monitor System Part 5 – Configuration 5.26 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.
  • Page 60 Q45R ORP Monitor System Part 5 – Configuration 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 61 Q45R ORP Monitor System Part 5 – Configuration Glass Diags This function allows the user to shut off the glass breakage/leak diagnostics. It does not affect the state of the remaining system diagnostics. This capability is provided to eliminate nuisance trips in electrically noisy applications, such as some plating operations.
  • Page 62 Q45R ORP Monitor System Part 5 – Configuration Press ENTER to initiate user entry mode, and the entire value will flash. Use the UP arrow key to modify desired value; selections are ON, OFF. Press ENTER to store the new value. Fail Val Sets the output failure value for Iout#1.
  • Page 63 Q45R ORP Monitor System Part 5 – Configuration Default All The Set Default function allows the user to return the instrument back to factory default data for all user settings. It is intended to be used as a last resort troubleshooting procedure.

  • Page 64: Part 6 - Calibration

    Part 6 – Calibration Overview and Methods The instrument must be calibrated periodically to maintain a high degree of measurement accuracy. Frequency of calibration must be determined by the application. High temperature applications or applications involving other extreme operating conditions may require more frequent calibration than those that operate at more ambient level temperatures.

  • Page 65: Sensor Slope

    Q45R ORP Monitor System Part 6 – Calibration 6.11 Sensor Slope The sensor slope is a number (expressed as a percentage) which represents the current condition of the sensor electrodes. The slope display is updated after every calibration. When new, the sensor slope should be between 90% and 110%.

  • Page 66: 1-Point Calibration Explained

    Q45R ORP Monitor System Part 6 – Calibration IMPORTANT: the 2-point calibration mode MUST be performed when a new sensor is first put into operation so that accurate calibration data is available for possible later 1-point calibrations. 6.14 1-Point Calibration Explained The 1-point calibration method is generally known as the “grab sample”...
  • Page 67 Q45R ORP Monitor System Part 6 – Calibration 6. The present ORP value will be displayed and the secondary line of the display will flash Wait for approximately 10-15 seconds. 7. The screen will display the measured mV value. If the user chooses to change this value, the arrow keys can be used to modify the value.

  • Page 68: Performing A 1-Point Calibration

    Q45R ORP Monitor System Part 6 – Calibration Performing a 1-Point Calibration The 1-point, or sample calibration method is intended to be used as an on-line calibration method. However, the sensor can be removed and calibrated in a separate solution. During calibration, the system will display the current mV reading and the user can manually enter a reference value from a lab grab- sample or a comparative reference instrument.

  • Page 69: Temperature Calibration

    Q45R ORP Monitor System Part 6 – Calibration 7. If accepted, the screen will display the message PASS with the new offset reading, and then it will return to the main measurement display. If the calibration fails, a message indicating the cause of the failure will be displayed and the FAIL icon will be turned on.
  • Page 70 Q45R ORP Monitor System Part 6 – Calibration 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.

  • Page 71: 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 72: Figure 34 - Q45H Isa (Ideal) Equation

    Q45R ORP Monitor System Part 7 – PID Controller 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 34 - Q45H 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 73: Classical Pid Tuning

    Q45R ORP Monitor System Part 7 – PID Controller 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.

  • Page 74: Manual Pid Override Control

    Q45R ORP Monitor System Part 7 – PID Controller Manual PID Override Control The Q45 PID output function allows the user to take manual control of the PID control signal. 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 75 Q45R ORP Monitor System Part 7 – PID Controller 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.

  • Page 76: Part 8 -Maintenance And Troubleshooting

    Part 8 –Maintenance and Troubleshooting System Checks 1. If the FAIL icon is flashing on the display, check the Fault List to determine the cause of the failure. To access the Fault List, press the MENU/ESC key until the DIAG menu appears. Then press the UP arrow key until the Fault List appears. Press the ENTER key to access the Fault List, and the highest priority fault message will be displayed.

  • Page 77: Instrument Checks

    Q45R ORP Monitor System Part 8 – Maintenance & Troubleshooting Instrument Checks 1. Remove sensor completely and connect 1100 Ohms from the yellow to black sensor input leads. Make sure the unit is configured for a Pt1000 thermal element and that the temperature is not in manual locked mode.
  • Page 78 Q45R ORP Monitor System Part 8 – Maintenance & Troubleshooting Slope LOW Sensor slope from calibration is Clean sensor, get fresh cal solutions, allow less than 80%. temperature and readings to fully stabilize, check for correct buffer values. Offset HIGH Sensor offset from calibration is Clean or replace saltbridge, replace reference less than –90 mV or greater than...
  • Page 79 Q45R ORP Monitor System Part 8 – Maintenance & Troubleshooting Meas Break Leakage detected on measuring Measuring electrode glass may be cracked electrode of sensor. or broken. Electrical noise may falsely trip this diagnostic. Turn off glass diagnostic feature sensor operates correctly.

  • Page 80: Cleaning The Sensor

    Q45R ORP Monitor System Part 8 – Maintenance & Troubleshooting Cleaning the Sensor Keep the sensor as clean as possible for optimum measurement accuracy - this includes both the saltbridge and the measuring electrode. Frequency of cleaning depends upon the process solution. Carefully wipe the measuring end of the sensor with a clean soft cloth.

  • Page 81: Replacing The Saltbridge And Reference Solution

    NOTE: Every ATI Q25R 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 ORP measurement.

  • Page 82: Troubleshooting

    Q45R ORP Monitor System Part 8 – Maintenance & Troubleshooting 8.6 Troubleshooting The first step in resolving any measurement problem is to determine whether the trouble lies in the sensor or the transmitter. Since measurement problems can often be traced to dirty sensor electrode glass and/or saltbridge, cleaning the sensor using the method outlined in Section 8.4 should always be the first step in any troubleshooting.
  • Page 83 Q45R ORP Monitor System Part 8 – Maintenance & Troubleshooting 5. Reconnect the yellow and white wires. 6. Connect the multimeter’s positive (+) lead to the red wire and its negative (-) lead to the green wire. With the sensor in the first mV solution at approximately 20-30 ºC, measure the DC millivolts.

  • Page 84: Spare Parts

    Spare Parts Part No. Description 07-0005 Q45R ORP transmitter, 2-Wire 07-0007 Q45R ORP monitor, 115 VAC /Relays 07-0119 Q45R ORP monitor, 230 VAC / Relays 07-0239 Q45R ORP monitor, 12-24VDC w/Relays 01-0242 Power Supply PCB (115 or 230VAC please specify) 01-0289 Power Supply PCB (12-24VDC) 07-0065...

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