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Analytical Technology Q45DC Manual

Auto-clean optical d.o. monitor system
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Model Q45D/DC
Optical D.O. Monitor
(Q45D SOFTWARE VERSIONS 4.02 AND HIGHER)
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
Auto-Clean
System
ATI (UK) Limited
Unit 1 & 2 Gatehead Business Park
Delph New Road, Delph
Saddleworth OL3 5DE
Ph: +44 (0)1457-873-318
Fax: + 44 (0)1457-874-468
Email:sales@atiuk.com
European Office

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  • Page 1 Auto-Clean Optical D.O. Monitor System (Q45D SOFTWARE VERSIONS 4.02 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 Saddleworth OL3 5DE...
  • 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

    Table of Contents Part 1 - Introduction ..........3 Part 7 – Sensor Cleaning System ......48 1.1 General ............3 7.1 General ............48 1.2 Standard System .......... 3 7.2 Cleaner Sequence ........49 1.3 Features ............4 7.3 Cleaner Malfunction Alarm (Optional) ..49 1.4 Q45D/60D Optical Auto-Clean System Specifications ............
  • Page 4 Table of Figures Figure 1 - D.O. System w/Auto-Clean Sensor ..............6 Figure 2 - Monitor Assembly Wall Mount Dim..............10 Figure 3 - Handrail Mounting Assembly ................ 11 Figure 4 - Submersible Sensor Mounting Assembly ............12 Figure 5 - Mounting Assembly Detail ................13 Figure 6 - D.O.

  • Page 5: Part 1 - Introduction

    Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction Part 1 - Introduction 1.1 General The Model Q45D is a highly versatile dissolved oxygen instrument designed for the measurement of dissolved oxygen in solution. The full scale operating range of the system is 0-40.0 ppm and the sensing system will operate on water streams with temperatures from 0 to 50°C.

  • Page 6: Features

    Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction Once installed and placed into operation, the Auto-Clean system will provide months of reliable D.O. measurement in almost any application. Sensors should be checked for build-up after the first 3 months to verify that the cleaner is keeping the optical element clean.
  • Page 7 Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction - Large, high contrast, custom Super-Twist display with LED backlight provides excellent readability even in low light conditions. A secondary line of display utilizes 5x7 dot matrix characters for clear message display. Two measured parameters may be on the display simultaneously.

  • Page 8: Figure 1 - D.o. System W/Auto-Clean Sensor

    Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction Series Q45 Auto-Clean Monitor Figure 1 - D.O. System w/Auto-Clean Sensor O&M Manual Rev-B (7/15)

  • Page 9: Q45D/60D Optical Auto-Clean System Specifications

    Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction 1.4 Q45D/60D Optical Auto-Clean System Specifications Displayed Parameters Main input, 0.00 to 40.00 ppm or mg/L. %Saturation, 0 to 999% Sensor temperature, 0 to 50.0 °C (32 to 122 ºF) Sensor Signal -40 to +2000 mVDC Output Values, 4 to 20 mA DC, Out #1/#2 Sensor slope/offset PID controller status...

  • Page 10: Q45D Performance Specifications

    Q45D Optical Auto-Clean D.O. Monitor Part 1 - Introduction Temperature Input Pt1000 RTD for automatic compensation Sensor Optical oxygen sensor with replaceable sensing element. Optical element life 3-5 years. Sensor Materials Sensor Cable 30 ft. (10 meter) cable. Max sensor-transmitter distance 100 feet (30 meters) with j-box.

  • Page 11: Part 2 - Mechanical Installation

    Part 2 – Mechanical Installation 2.1 General The Q45D Auto-Clean Monitor is housed in a NEMA 4X (IP- 65) enclosure. The monitor must be mounted near the measurement point, with a maximum of 60 feet between the monitor and the sensor. The standard system is supplied with a 30 ft.

  • Page 12: Figure 2 - Monitor Assembly Wall Mount Dim

    Q45D/60 Optical Auto-Clean D.O. Monitor Part 2 – Mechanical Installation Series Q45 Auto-Clean Monitor Figure 2 - Monitor Assembly Wall Mount Dim. O&M Manual Rev-B (7/15)

  • Page 13: Railing Mount

    Q45D/60 Optical Auto-Clean D.O. Monitor Part 2 – Mechanical Installation 2.3 Railing Mount Figure 3 shows the mounting assembly used to mount the electronic monitor 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 14: Figure 4 - Submersible Sensor Mounting Assembly

    Q45D/60 Optical Auto-Clean D.O. Monitor Part 2 – Mechanical Installation Figure 4 - Submersible Sensor Mounting Assembly O&M Manual Rev-B (7/15)

  • Page 15: Figure 5 - Mounting Assembly Detail

    Q45D/60 Optical Auto-Clean D.O. Monitor Part 2 – Mechanical Installation Figure 5 - Mounting Assembly Detail O&M Manual Rev-B (7/15)

  • Page 16: Part 3 - Electrical Installation

    Part 3 – Electrical Installation 3.1 General Q45D/DC Auto-Clean D.O. monitors are powered from 24 VDC. Monitors can draw up to 3 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 17: Figure 6 - D.o. Monitor Electrical Connections

    Q45D Optical Auto-Clean D.O. Monitor Part 4 – Optical D.O. Sensor Figure 6 - D.O. Monitor Electrical Connections WIRING NOTE: The cable for the optical D.O. sensor contains a “black” wire that is actually a black shrink tube covering both a blue and a pink wire.

  • Page 18: Relay Wiring

    Q45D Optical Auto-Clean D.O. Monitor Part 4 – Optical D.O. Sensor 3.3 Relay Wiring Relay wiring is done to terminal blocks inside the Q45D display assembly. This unit actually contains two SPDT relays, but one of the relays is used to control the activation of the sensor automatic cleaning system.

  • Page 19: Part 4 - Optical D.o. Sensor

    Part 4 – Optical D.O. Sensor 4.1 General Optical D.O. sensors are supplied complete and ready to use. All that’s needed is to make the proper sensor connections as shown in the previous section. A rubber boot protects the end of the sensor in transit. Leave the protective boot in place until the sensor is to be placed into operation.

  • Page 20: Optical Sensing

    Q45D Optical Auto-Clean D.O. Monitor Part 4 – Optical D.O. Sensor 4.2 Optical Sensing Optical D.O. measurement employs a technique called “fluorescence quenching” in order to measure molecular oxygen. The sensor will respond to oxygen either in the air or dissolved in water. A polymer element at the end of the sensor contains an embedded fluorescent dye.

  • Page 21: Part 5 - Operation

    Part 5 – Operation 5.1 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...

  • Page 22: Keys

    Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation 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 23 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation 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 24: Software

    Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation FAIL The FAIL icon indicates that the system diagnostic function has detected a problem that requires immediate attention. This icon is automatically cleared once the problem has been resolved. Relay Area A/B The relay area contains two icons that indicate the state of the system relays (if the relay card is installed).
  • Page 25 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation Each list item allows a change to a stored system variable. List items are designed in one of two forms: simple single variable, or multiple variable sequences. In the single variable format, the user can quickly modify one parameter - for example, changing temperature display units from °F to °C.

  • Page 26: Figure 11 - Software Map

    Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation Start MENU MEASURE CONFIG CONTROL DIAG SECTIONS (display only) Temperature *PID 0% #1 Cal D.O. Entry Lock Set Hold Sensor mV *PID 100% #1 Cal Temp Set Delay Fault List *PID Setpoint #1 * PID Status Contrast Sim Out...
  • Page 27 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation To select a list item for modification, first select the proper menu with the MENU key. Scroll to the list item with the UP arrow key and then press the ENTER key. This tells the system that the user wishes to perform a change on that item.

  • Page 28: Measure Menu [Measure]

    Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation 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 29: Calibration Menu [Cal]

    Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation % Saturation The most common display of D.O. in water is either PPM or mg/L units. However, the same PPM value at different water temperatures can represent quite different concentrations of oxygen in terms of the percent of saturation.
  • Page 30 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation 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 31 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation 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”.
  • Page 32 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation theoretical ppm value during a saturation calibration. This value is only required to be entered during initial installation - it does not need to be modified at every calibration. Press ENTER to initiate user entry mode and the value will flash.

  • Page 33: Control Menu [Control]

    Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation The AL setting allows two setpoints to be selected for the same relay, producing a HI-LO alarm band. In this mode, Relay A will trip inside or outside of the band, depending upon the Phase selected. Figure 13 for further details.
  • Page 34 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation Set PID 0% Set PID 100% [Out1=PID] If the PID is enabled, this function sets the minimum and maximum controller end points. Unlike the standard 4-20 mA output, the controller does not “scale”...
  • Page 35 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation PID Int [Out1=PID] Integral is the number of “repeats-per-minute” of the action of the controller. It is the number of times per minute that the controller acts on the input error. At a setting of 2.0 rpm, there are two repeats every minute.
  • Page 36 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation A Setpoint This function establishes the dissolved oxygen trip point for relay A. The entry value is limited to a value within the range of 0 to 40.00 ppm. Use the LEFT arrow key to select the first digit to be modified.

  • Page 37: Figure 12 - Control Relay Example

    Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation See Figure 12 below for a visual description of a typical control relay application. When value rises to ≥ 1.000 ppm, relay When value rises to ≥ 1.050 ppm, closes. relay opens. When value falls to ≤...

  • Page 38: Figure 13 - Alarm Relay Example

    Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation Figure 13 is a visual description of a typical alarm relay application. When value rises to ≥ 1.000 ppm, When value falls to < 1.000 ppm, relay relay closes, until value falls back to < closes, until rises back to >...
  • Page 39 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation The timer HOLD setting allows an output hold time to be entered into the cleaning cycle. This hold time allows the outputs to stabilize back to normal readings before the outputs are released from their “hold” state. Using this feature properly avoids disturbing any instruments connected to the outputs during the cleaning cycle –...

  • Page 40: Diagnostics Menu [Diag]

    Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation If the B mode selection is changed while the sensor wash timer is in mid-cycle (and the HOLD is enabled), the HOLD must be turned off manually to return all of the outputs to normal operation.
  • Page 41 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation high number of internal tests occurring. As faults are corrected, they are immediately cleared. 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...
  • Page 42 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation 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.
  • Page 43 Q45D Optical Auto-Clean D.O. Monitor Part 5 – Operation modify desired value; selections are between 4mA, and 20mA. Press ENTER to store the new value. 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 #1.

  • Page 44: Part 6 - Calibration

    Part 6 – Calibration 6.1 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, however, it should be done during the initial installation.
  • Page 45 Q45D Optical Auto-Clean D.O. Monitor Part 6 – Calibration 1. Determine whether the calibration will be done on-line or with the sensor removed and placed into a bucket of clean water. If the sensor is removed from the application, rinse and clean if necessary.

  • Page 46: Dissolved Oxygen Span Air Cal (%-Sat)

    Q45D Optical Auto-Clean D.O. Monitor Part 6 – Calibration 6.3 Dissolved Oxygen Span Air Cal (%-sat) This is the recommended method for air temperatures greater than about 5 C; however, it requires that the sensor be removed from the process and cleaned. Once cleaned, the sensor is held in air and allowed time to adjust to the air temperature.

  • Page 47: Dissolved Oxygen Zero Cal

    Q45D Optical Auto-Clean D.O. Monitor Part 6 – Calibration 7. The system now begins acquiring data for the calibration value. As data is gathered, the units for ppm and temperature may flash. Flashing units indicate that this parameter is unstable. 8.
  • Page 48 Q45D Optical Auto-Clean D.O. Monitor Part 6 – Calibration 2. Place about an 3 inches of zero solution in a container large enough to immerse the end of the sensor. You can make a zero solution by adding about 2 teaspoons of powdered sodium sulfite to up to 1 gallon of water.

  • Page 49: Temperature Calibration

    Q45D Optical Auto-Clean D.O. Monitor Part 6 – Calibration 6.5 Temperature Calibration Calibration of the temperature circuit is rarely ever required. The temperature calibration sequence is essentially a 1-point offset calibration that allows adjustments of approximately ±5 °C. The sensor temperature may be calibrated on line, or the sensor can be removed from the process and placed into a known solution temperature reference.

  • Page 50: Part 7 - Sensor Cleaning System

    Part 7 – Sensor Cleaning System 7.1 General The cleaner control system located in the D.O. system 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 AC powered...

  • Page 51: Cleaner Sequence

    Q45D Optical Auto-Clean D.O. Monitor Part 8 – PID Controller 7.2 Cleaner Sequence The cleaner control system is designed to provide four 3-second pulses of pressurized air through a nozzle located within 1 inch of the sensing element. The nozzle directs the air blast at the center of this component, effectively blasting away accumulated coatings on the surface.

  • Page 52: Part 8 - Pid Controller Details

    Q45D Optical Auto-Clean D.O. Monitor Part 8 – PID Controller The relay associated with this alarm is a SPST relay that can be configured with a jumper to operate either as a normally open (NO) or normally closed (NC) contact. The jumper is located inside the protective circuit cover in the terminal compartment of the monitor.

  • Page 53: Pid Description

    Q45D Optical Auto-Clean D.O. Monitor Part 8 – PID Controller 8.1 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 54: Figure 15 - Q45D Isa (Ideal) Pid Equation

    Q45D Optical Auto-Clean D.O. Monitor Part 8 – 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 15 - Q45D ISA (Ideal) PID 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 55 Q45D Optical Auto-Clean D.O. Monitor Part 8 – PID Controller Integral gain. Integral gain is what allows the controller to eventually drive the input error to zero – providing accuracy to the control loop. It must be used to affect the accuracy in the servo action of the controller.

  • Page 56: Classical Pid Tuning

    Q45D Optical Auto-Clean D.O. Monitor Part 8 – PID Controller 8.3 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 57 Q45D Optical Auto-Clean D.O. Monitor Part 8 – PID Controller Closed-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. Luckily, the nature of simple chemical control process are generally slow in nature.

  • Page 58: Part 9 - System Maintenance

    Part 9 – System Maintenance 9.1 General The Q45D/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 59: 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 60: Analyzer Tests

    Q45D/60 Dissolved Oxygen System Part 10– Troubleshooting 5. If rigid conduit has been run directly to the Q45D enclosure, check for signs that moisture has followed conduit into the enclosure. 6. Check for ground loops. Although the sensor is electrically isolated from the process water, high frequency sources of electrical noise may still cause erratic behavior in extreme conditions.

  • Page 61: Display Messages

    Q45D/60 Dissolved Oxygen System Part 10– Troubleshooting FIRST, disconnect any wiring going to I-out#1. Then, verify voltage across these wires is about 16-18 VDC when still connected to the terminal strip on the front half of the enclosure. If the BLUE and WHITE wires are not connected to the terminal strip on the front half of the enclosure, the voltage across them should measure about 29 VDC.

  • Page 62: Figure 16 - Q45D Display Messages

    Q45D/60 Dissolved Oxygen System Part 10– Troubleshooting MESSAGE DESCRIPTION POSSIBLE CORRECTION Max is 200 Entry failed, maximum user value Reduce value to ≤ allowed is 200. Min is 200 Entry failed, minimum value allowed is Increase value to ≥ 200. Calibration problem, data too unstable to Clean sensor.

  • Page 63: Sensor Tests

    Q45D/60 Dissolved Oxygen System Part 10– Troubleshooting MESSAGE DESCRIPTION POSSIBLE CORRECTION D.O. Cal Fail Failure of oxygen calibration. FAIL Clean sensor redo span icon will extinguish until calibration. If still failure, sensor successful calibration been slope may be less than 20% or performed, or 30 minutes passes greater than 500%.

  • Page 64: Figure 17 - Pt1000 Rtd Table

    Q45D/60 Dissolved Oxygen System Part 10– Troubleshooting 2. Prior to disconnecting the sensor, measure the sensor output voltage at the analyzer terminal strip with a DVM while the sensor is hanging in air. If the sensor has been connected to a powered analyzer for at least 12 hours, the nominal output of the sensor will be about +400mVDC when measured in air at 25C (100% saturation) from BLACK (-) to RED (+) on the analyzer terminal strips.

  • Page 65: Figure 18 - Reference - Barometric Pressure Conversion

    Q45D/60 Dissolved Oxygen System Part 10– Troubleshooting Barometric Pressure Conversion Inches of Millimeters of Feet Above Mercury(inHg) Mercury (mmHg) Sea Level 22.00 558.8 +8790 22.50 571.5 +8053 23.00 584.2 +7347 23.50 596.9 +6671 24.00 609.6 +6023 24.50 622.3 +5402 25.00 635.0 +4806 25.50...

  • Page 66: Figure 19 - Reference - Oxygen Solubility Table

    Q45D/60 Dissolved Oxygen System Part 10– Troubleshooting Oxygen Solubility vs. Temperature Temperature Temperature °F °C °F °C 14.6 23.3 14.1 24.4 13.7 25.6 13.3 26.7 12.9 27.8 12.6 28.9 12.2 30.0 11.9 31.1 11.6 32.2 10.0 11.3 33.3 11.1 11.0 34.4 12.2 10.7...

  • Page 67: Spare Parts

    Spare Parts PART NO. DESCRIPTION 03-0337 Front Lid electronics assembly 07-0011 D.O. Display Assembly, 115 VAC 07-0030 D.O. Display Assembly, 230 VAC 01-0242 Power supply assembly (specify 115 or 230 VAC) 01-0317 Universal Autoclean PCB Assy 63-0100 Submersible D.O. Sensor with 30’ cable 36-0040 Compression Pump, 12VDC 36-0041...

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