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Analytical Technology Q45R Instruction Manual

2-wire orp transmitter
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Model Q45R
2-Wire ORP Transmitter
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
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 2-Wire ORP Transmitter 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 (610) 917-0991...

  • Page 2: Product Warranty

    PRODUCT WARRANTY Analytical Technology, Inc. (Manufacturer) warrants to the Customer that if any part(s) of the Manufacturer's equipment proves to be defective in materials or workmanship within the earlier of 18 months of the date of shipment or 12 months of the date of start- up, such defective parts will be repaired or replaced free of charge.

  • Page 3: Table Of Contents

    Table of Contents PART 1 - INTRODUCTION ........5 PART 6 – CALIBRATION......... 53 (Q45R, ORP M ) ....5 ......53 ENERAL ONITOR VERVIEW AND ETHODS ............. 6 6.11 ..........54 EATURES ENSOR LOPE Q45R S ......6 6.12 ...........
  • Page 4 Table of Figures Figure 1 - Q45 Enclosure Dimensions ..................12 Figure 2 - Wall or Pipe Mount Bracket ..................13 Figure 3 - Wall Mounting Diagram .................... 14 Figure 4 - Pipe Mounting Diagram .................... 14 Figure 5 - Q25 Sensor Types ....................16 Figure 6 - Flow Through Tee Mount ..................

  • Page 5: Part 1 - Introduction

    5-17 VDC Externally powered unit with two voltage outputs. This manual refers to the Loop-Powered 2-wire transmitter version. In all configurations, the Q45R displays mV, sensor temperature, and output loop current on the secondary line of the custom display. The instrument may be used with either the high performance Q25 series sensors or with combination- style electrodes.

  • 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. · Output Hold, Output Simulate, Output Alarm, and Output Delay Functions. All forced changes in output condition include bumpless transfer to provide gradual return to on-line signal levels and to avoid system control shocks on both analog outputs.
  • Page 7 Q45R ORP Monitor System Part 1 - Introduction Display 0.75” (19.1 mm) high 4-digit main display with sign 12-digit secondary display, 0.3" (7.6 mm) 5x7 dot matrix. Keypad 4-key membrane type with tactile feedback, polycarbonate with UV coating, integral EMI/static shield and conductively...

  • Page 8: Q45R Performances

    REDOX) of aqueous solutions in industrial and municipal process applications. It is designed to perform in the harshest of environments, including applications that poison conventional ORP sensors. All seals are dual o-ring using multiple sealing materials. The sensor is designed for use with the Q45R Monitor/Analyzer. Sensor Features ·...

  • Page 9: Sensor Specifications

    Q45R ORP Monitor System Part 1 - Introduction · An integral preamplifier is encapsulated in the body of the sensor. This creates a low impedance signal output which ensures stable readings in noisy environments and increases the maximum possible distance between sensor and transmitter to 3,000 feet (914 meters).

  • Page 10: Important Notes

    Q45R ORP Monitor System Part 1 - Introduction 2. The maximum flow rate specification is lower for process solutions with low ionic conductivity or high suspended solids concentration. High flow rates in low ionic conductivity processes may cause a measurement error due to static electrical discharge.

  • Page 11: 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 12: Figure 1 - Q45 Enclosure Dimensions

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 4.38 2.61 (111.2) (66.3) MENU ENTER 4.38 #10-32 UNF 2.61 (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...

  • Page 13: Wall Or Pipe Mount

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Wall or Pipe Mount A PVC mounting bracket with attachment screws is supplied with each transmitter (see Figure 2 - Wall or Pipe Mount Bracket 2 for dimensions). The multi-purpose bracket is attached to the rear of the enclosure using the four flat head screws.

  • Page 14: Figure 3 - Wall Mounting Diagram

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting MENU ENTER Figure 3 - Wall Mounting Diagram MENU ENTER Figure 4 - Pipe Mounting Diagram O&M Manual Rev-U (2/14)

  • Page 15: Part 3 - Sensor/Flowcell Mounting

    Part 3 – Sensor/Flowcell Mounting General The Q25R ORP Sensor mounting options include flow-through, submersion, insertion (special hardware required), or sanitary mount depending on the type of sensor purchased. Q25R Differential ORP Sensors are available in 4 different versions as shown in Figure 5 - Q25 Sensor Types 5.

  • Page 16: Figure 5 - Q25 Sensor Types

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Figure 5 - Q25 Sensor Types O&M Manual Rev-U (2/14)

  • Page 17: Flow Tee Mounting

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Flow Tee Mounting Convertible sensors may be used in a 1” flow tee as shown in Figure 6 - Flow Through Tee Mount . The flow tee is a modified pipe fitting that accommodates the pipe thread on the front of the sensor.

  • Page 18: Union Mounting

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 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 19: Figure 8 - 2" Union Mount

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Figure 8 - 2" Union Mount O&M Manual Rev-U (2/14)

  • Page 20: Submersion Mounting

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting 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 9 - Sensor Submersion Mount 9 is available for submersible applications.

  • Page 21: 3.5 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 10 - S.S.
  • Page 22 Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Figure 11 - CPVC Sensor Insertion Mount O&M Manual Rev-U (2/14)

  • Page 23: 3.6 Conventional Orp Sensors

    2 and Figure 13 - (63-0023) Combination ORP Sensor - Submersion 3 below show the dimensions of two ORP sensors frequently used with the Q45R. The (63-0008) sensor is suitable for use with either a pipe tee adapter or a special clear acrylic sealed flowcell.
  • Page 24 Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting O&M Manual Rev-U (2/14)

  • Page 25: Sealed Flowcell

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Sealed Flowcell For applications where a flowcell is desired, a sealed flowcell (00-1527) shown in Figure 14 - Sealed Flowcell Details 4 is available. This flowcell is used only with sensor (63-0008) and may be used for sample pressures up to 75 PSIG.

  • Page 26: Flow Tee Adapter

    Q45R ORP Monitor System Part 3 – Sensor/Flowcell Mounting Flow Tee Adapter When using the (63-0008) sensor in a flow application, a 1” or ¾” pipe tee adapter is required. Figure 15 - Twist-Lock Tee 5 shows a detail of that arrangement.

  • Page 27: 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 28: Part 4 - Electrical Installation

    Part 4 – Electrical Installation General The Q45 is powered in one of 3 ways, depending on the version purchased. The 2-wire version is a 16-35 VDC powered transmitter. The battery powered unit is supplied with 2-“C” cell batteries. The 5-17 VDC Externally Powered Transmitter is designed for low power operation for solar power applications.

  • Page 29: Figure 17 - Loop Power Wiring Diagram

    Q45R ORP Monitor System Part 5 – Configuration Figure 17 - 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 30: 4.21 Load Drive

    Q45R ORP Monitor System Part 5 – Configuration 4.21 Load Drive In the two-wire configuration, the load-drive level is dependent 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 31: Sensor Wiring

    Q45R ORP Monitor System Part 5 – Configuration Sensor Wiring The sensor cable can be quickly connected to the Q45 terminal strip by matching the wire colors on the cable to the color designations on the label in the monitor.

  • Page 32: Direct Sensor Connection

    Q45R ORP Monitor System Part 5 – Configuration Figure 19 - 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 33: Figure 20 - Sensor Cable Preparation

    Q45R ORP Monitor System Part 5 – Configuration Figure 20 - Sensor Cable Preparation O&M Manual Rev-U (2/14)

  • Page 34: Junction Box Connection

    Q45R ORP Monitor System Part 5 – Configuration 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...

  • Page 35: Combination Electrodec

    Q45R ORP Monitor System Part 5 – Configuration Combination Electrode Connection The Q45P may also be used with non-amplified simple combination electrodes (see Figure 22 - Sensor Connections, Combination Electrodes 2). 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 36: Figure 23 - Combination Electrode Connection

    Q45R ORP Monitor System Part 5 – Configuration 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 37: External Temperaturec

    Q45R ORP Monitor System Part 5 – Configuration 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 24...

  • Page 38: 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 39: 5.11 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 40 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 41: Software

    Q45R ORP Monitor System Part 5 – Configuration Software The software of the Q45R is organized in an easy to follow menu-based system. All user settings are organized under five menu sections: Measure, Calibration [CAL], Configuration [CONFIG], Control [CONTROL] and Diagnostics [DIAG].
  • Page 42 Q45R ORP Monitor System Part 5 – Configuration 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.
  • Page 43 Q45R ORP Monitor System Part 5 – Configuration Start MENU ME NU M E NU M E NU ME NU ME NU MEASUR E C A L CON FIG CONTROL DIA G SECTIONS E SC E SC E SC E SC...

  • Page 44: [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 45: Calibration Menu [Cal]

    Q45R ORP Monitor System Part 5 – Configuration The MEASURE screens are intended to be used as a very quick means of looking up critical values during operation or troubleshooting. 5.23 Calibration Menu [CAL] The calibration menu contains items for frequent calibration of user parameters.

  • Page 46: [Config]

    Press ENTER to initiate user entry mode and the first digit will flash. Use arrow keys to modify value. See End of Manual for the Q45R lock/unlock code. Press ENTER to toggle lock setting once code is correct.
  • Page 47 Q45R ORP Monitor System Part 5 – Configuration Main This function allows the user to change the measurement in Display the primary display area. The user may select between ORP, sensor temperature, or output current. Using this function, the user may choose to put temperature in the main display area and ORP on the secondary, lower line of the display.

  • Page 48: [Control]

    Q45R ORP Monitor System Part 5 – Configuration 5.25 Control Menu [CONTROL] The Control Menu contains all of the output control user settings: Set PID 0% If the PID is enabled, this function sets the minimum and Set PID 100% maximum controller end points.

  • Page 49: Diagnostics Menu [Diag]

    Q45R ORP Monitor System Part 5 – Configuration reset.) Increasing this value will make the controller more responsive. PID Deriv Derivative is a second order implementation of Integral, used [Iout1=PID] 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.
  • Page 50 Q45R ORP Monitor System Part 5 – Configuration arrow key to modify the desired value, selections are ON for engaging the HOLD function, and OFF to disengage the function. Press ENTER to store the new value. The Set Hold function can also hold at an output value specified by the user.
  • Page 51 Q45R ORP Monitor System Part 5 – Configuration mode, and the right-most digit of the value will flash. Use arrow keys to modify desired value. The starting display value will be the last read value of the input. The output will be under control of the SIM screen until the ESC key is pressed.
  • Page 52 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.

  • Page 53: 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 54: 6.11 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 55: 6.14 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 56 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 57: 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 58: 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 59 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 60: 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 61: Figure 27 - 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 27 - 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 62: 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 63: 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 64 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 65: Part 8 -Maintenance And Troubleshooting

    Part 8 –Maintenance and Troubleshooting System Checks 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.

  • Page 66: 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 67 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...
  • Page 68 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 69: 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.

  • Page 70: Replacing The Saltbridge And Reference Solution

    Q45R ORP Monitor System Part 8 – Maintenance & Troubleshooting Replacing the Saltbridge and Reference Buffer Solution · Hold the sensor with the process electrode pointing up. Place a cloth or towel around the saltbridge. Turn the saltbridge counterclockwise (by hand) to loosen and remove the saltbridge.

  • Page 71: 8.6 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...
  • Page 72 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 73: Spare Parts

    Spare Parts Part No. Description Spare Electronics 07-0005 Q45R ORP transmitter, 2-Wire 03-0341 Q45R OPR Front Lid Assy 31-0173 20 Pos. Ribbon Cable Spare Sensors 07-0065 Q25R1 ORP Sensor 30’ Pt 07-0066 Q45R1 ORP Sensor 30’ Au 63-0008 Twist-Lock probe ORP Sensor, 25’...

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