ATI Technologies Q-Blast Q46D Manual de usuario

O & M Manual

Auto-Clean Membrane

Dissolved Oxygen System

(Q46D Software Versions 2.0 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

Phone: 800-959-0299 Saddleworth OL3 5DE

610-917-0991 Phone: +44 (0)1457-873-318

Fax: 610-917-0992 Fax: + 44 (0)1457-874-468

Email: [email protected] Email: [email protected]

Table of Contents

Part 1 - Introduction...........................................4

1.1 General.............................................4

1.2 Standard System ..............................4

1.3 Features............................................6

1.4 Q46D Auto-Clean System Specifications

..........................................................7

1.5 Q46D Performance Specifications

(includes sensor)...................................8

1.6 Q-Blast Assembly.............................8

Part 2 - Mechanical Installation..........................9

2.1 General.............................................9

2.2 Wall or Pipe Mount .........................9

2.3 Wall Mount Dimensions..................10

2.4 Railing Mount..................................12

2.5 Sensor Installation ..........................13

Part 3 - Electrical Installation............................15

3.1 General...........................................15

3.2 Power Connections.........................15

3.3 Sensor Connections .......................18

3.4 Q-Blast to Q46 Connection.............19

3.5 Analog Output Connections............22

3.6 Relay Connections..........................22

Part 4 - Sensor Assembly ................................23

4.1 General...........................................23

4.2 Sensor Module................................24

4.3 Sensor Module................................24

Part 5 - Operation.............................................26

5.1 User Interface .................................26

5.11 Keys............................................27

5.12 Display........................................27

5.2 Software..........................................28

5.21 Software Navigation ...................29

5.22 Measure Menu [MEASURE]...........31

5.23 Calibration Menu [CAL]...................32

5.24 Configuration Menu [CONFIG] .......32

5.25 Control Menu [CONTROL]..............35

5.26 Diagnostics Menu [DIAG]...........39

Part 6 - Calibration...........................................43

6.1 General...........................................43

6.2 D.O. Span Cal (1-spl).....................43

6.3 D.O. Span Air Cal (%-sat) ..............44

6.4 D.O. ZeroCal .................................45

6.5 Temperature Calibration.................46

Part 7 - Sensor Auto-Clean System.................47

7.1 General...........................................47

7.2 Cleaner Sequence..........................47

Part 8 - PID Controller Details .........................49

8.1 PID Description...............................49

8.2 PID Algorithm .................................49

8.3 Classical PID Tuning......................51

8.4 Manual PID Override Control.........51

8.5 Common PID Pitfalls ......................51

Part 9 - System Maintenance ..........................53

9.1 General...........................................53

9.2 Analyzer Maintenance....................53

9.3 Sensor Maintenance.......................53

9.31 Lead Anode Replacement..................53

Part 10 - Troubleshooting ................................55

10.1 General...........................................55

10.2 External Problem Sources..............55

10.3 Analyzer Tests....................................56

Sensor Tests ...............................................59

Spare Parts......................................................61

O&M Manual

(Rev-H, 11/18)

Table of Figures

Figure 1 –Typical Installation Diagram.........................................................................................................5

Figure 2 - Wall Mount Bracket.....................................................................................................................10

Figure 3 - Enclosure Dimensions................................................................................................................10

Figure 4 - Cleaner Enclosure Dimensions ..................................................................................................11

Figure 5 - Handrail Mounting Assembly......................................................................................................12

Figure 6 -Sensor Mounting Assembly.........................................................................................................13

Figure 7 - Sensor Mounting Detail ..............................................................................................................14

Figure 8 - Q46D Connections .....................................................................................................................16

Figure 9 - Q-Blast Connections...................................................................................................................17

Figure 10 - Sensor Wiring...........................................................................................................................18

Figure 11 - Standard System Wiring...........................................................................................................20

Figure 12 - Q-Blast Connections w/Optional J-Box ....................................................................................21

Figure 13 - Submersible D.O. Sensor Assy................................................................................................23

Figure 14 - Sensor Module Exploded View.................................................................................................24

Figure 15 - User Interface...........................................................................................................................26

Figure 16 - Software Map............................................................................................................................30

Figure 17 - Control Relay, Hysteresis & Phase Options.............................................................................37

Figure 18 - Alarm Relay Example...............................................................................................................38

Figure 19 - ISA PID Equation......................................................................................................................49

Figure 20 –Q46D Display Messages .........................................................................................................57

Figure 21 –Pt1000 RTD Table...................................................................................................................59

Figure 22 - Reference, Barometric Conversion Table ................................................................................60

O&M Manual

(Rev-H, 11/18)

Part 1 - Introduction

1.1 General

The Model Q46D is an on-line monitoring system designed for the continuous measurement of

dissolved oxygen in solution. The full scale operating range of the system 0-40 ppm, and the

sensing system will operate on water streams with temperatures ranging from 0 to 50



While the Q46D may be used with either optical or galvanic membraned sensors, this manual is

specific for systems using a membraned D.O. sensor.

Q46D Monitors are available in two electronic versions, an AC powered monitor with integral

alarm relays and dual 4-20 mA output capability, and a 12-24 VDC unit with dual output and

relays. An optional digital output is available for Profibus-DP, Modbus-RTU, or Ethernet-IP.

1.2 Standard System

The Model Q46D Auto-Clean system includes three main components, a NEMA 4X electronics

unit, the “Q-Blast” NEMA 4X Air-Blast cleaning assembly, and a submersible membraned D.O.

sensor with cleaner nozzle. Sensors are design for direct immersion in an aeration tank or

flowing stream. D.O. sensors come with a standard 30 ft. cable and connect directly to the Q46D

monitor. Sensors with special cable lengths are available. A separate tubing connection located

on the Q-Blast assembly is provided for connection of a 30 foot length of plastic tubing (supplied

with the unit). A typical system is shown in

Figure 1. Note that Figure 1 shows the D.O. Monitor and Q-Blast cleaner mounted on ATI’s

optional panel assembly with power distribution box. The panel and power distribution box are

not part of standard systems, and must be ordered separately using part number (00-1637).

The D.O. sensor assembly is mounted to a 1" pipe using a special mounting adapter supplied as

part of the 00-0624 mounting assembly. The 1" pipe is attached to the tank handrail with a

bracket assembly that holds the sensor at a slight angle in the tank.

Once installed and placed into operation, the Q46D Auto-Clean D.O. system will provide months

of reliable D.O. measurement in almost any application. Sensors should be checked for build-up

after the first month to verify that the cleaner is keeping the membrane clean. However, sensor

maintenance intervals of 3-6 months or more are likely in most aeration tanks.

The sensor automatic cleaning frequency is programmable, and units are shipped with a default

cleaning frequency of once every 24 hours. This frequency has proven sufficient for most

aeration applications, but can be increased if needed for a specific application. A frequency of

more than every 2 hours is not recommended. Contact your ATI representative for more

information if an 8-hour cleaning cycle does not keep the membrane clean

ATI Q46D Membrane D.O. Q-Blast System Part 1 - Introduction

O&M Manual

(Rev-H, 11/18)

(System Diagram Shown on Optional Mounting Plate w/Power Distribution Box)

Figure 1 –Typical Installation Diagram

ATI Q46D Membrane D.O. Q-Blast System Part 1 - Introduction

O&M Manual

(Rev-H, 11/18)

1.3 Features

Standard Q46D electronic transmitters are designed to be fully isolated instruments for operation

from either 90-260 VAC or 12-24 VDC power supplies.

High accuracy, high sensitivity system, measures from 0.1 ppm to 40.0 ppm through 2 internal

automatic ranges.

Two 4-20 mA analog outputs are standard. One output may be configured to track D.O or as a

PID control output, while the other output is programmable to track either D.O. or Temperature.

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 to

avoid system control shocks on analog outputs.

Units provide three SPDT relay outputs and two isolated analog outputs. Software settings for

relay control include setpoint, deadband, phase, delay, and failsafe. An additional bank of three

low-power relays (0-30 VDC) is included for Q-Blast cleaner control.

Large, high contrast, custom LCD display with LED back light provides excellent readability in any

light conditions. The secondary line of display utilizes 5x7 dot matrix characters for clear

message display two of four measured parameters may be on the display simultaneously.

Diagnostic messages provide a clear description of any problem with no confusing error codes to

look up. Messages are also included for diagnosing calibration problems.

Quick and easy one-point calibration method, air calibration method, and sensor zero-cal. To

provide high accuracy, all calibration methods include stability monitors that check temperature

and main parameter stability before accepting data.

High accuracy three-wire Pt1000 temperature input. 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.

Equipment bearing this marking may not be discarded by traditional methods in the

European community after August 12 2005 per EU Directive 2002/96/EC. End

users must return old equipment to the manufacturer for proper disposal.

ATI Q46D Membrane D.O. Q-Blast System Part 1 - Introduction

O&M Manual

(Rev-H, 11/18)

1.4 Q46D Auto-Clean System Specifications

Main Parameter Ranges Manual selection of one of the following display ranges,

0.00 to 40.00 ppm or 0.00 to 40.00 mg/L

0.0 to 999.9% Saturation

Power 90-260 VAC, 50/60 Hz., 10 VA Maximum or

12-24 VDC, 500 mA max.

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.

Integral LED back-light for visibility in the dark.

Enclosure NEMA 4X, IP-66 polycarbonate, stainless steel hardware.

Analog Outputs Two 4-20 mA outputs. Output one programmable for PPM D.O.

or PID. Output 2 programmable for PPM D.O. or Temperature.

Max load 450 Ohms for output 1 and 1000 ohms for output 2.

Outputs ground isolated and isolated from each other.

Output Isolation 600 V galvanic isolation

Optional Digital Output Profibus-DP, Modbus-RTU or Ethernet-IP available.

Relays, Electromechanical Three SPDT, 6 amp @ 250 VAC, 5 amp @ 24 VDC contacts.

Software selection for setpoint, phase, delay, deadband, hi-lo

alarm, and failsafe. A-B indicators on main LCD, and C indicator

on lower display. Three additional low-power (0-30 VDC) relays

are used to control the Q-Blast cleaner functions.

Weight Electronics Assembly: 2.4lbs. (1.1 kg)

Sensor Assembly: 3.5 lbs. (1.58 kg.)

Ambient Temperature Analyzer Service, -20 to 60 °C (-4 to 140 ºF)

Sensor Service, -5 to 55°C (23 to 131 °F)

Storage, -30 to 70 °C (-22 to 158 ºF)

Ambient Humidity 0 to 95%, non-condensing

Altitude Up to 2000 m (6562 ft.)

Location Designed for hazardous and non-hazardous areas

EMI/RFI Influence Designed to EN 61326-1

Temperature Input Pt1000 RTD for automatic compensation

Sensor Galvanic membrane sensor for direct measurement of dissolved

oxygen, replaceable/rebuildable cartridge.

Sensor Materials Noryl and stainless steel

Sensor Cable Submersible: 30 ft. (9.1 m)

ATI Q46D Membrane D.O. Q-Blast System Part 1 - Introduction

O&M Manual

(Rev-H, 11/18)

Max. Sensor Cable Length 1000 feet (300 m), with junction box

1.5 Q46D Performance Specifications (includes sensor)

Accuracy ±0.05 PPM or 0.5% of Span

Repeatability 0.05 PPM

Sensitivity 0.01 PPM

Electronic Stability 0.05% of span per 24 hours, non-cumulative

Temperature Drift Span or zero, 0.01% of span/ºC

Response Time 180 seconds to 90% of step input

1.6 Q-Blast Assembly

Power 90- 260 VAC, 50/60 Hz., 10 VA Maximum

12-24 VDC, 500 mA max.

Enclosure NEMA 4X, IP-66 polycarbonate, stainless steel hardware.

Compressor 12 VDC Diaphragm Type, 28 PSI (1.9 Bar) Maximum

Heater Internal thermostatically controlled.

Ambient Temperature Operating, -40 to 60 °C (-40 to 140 ºF)

Storage, -40 to 70 °C (-40 to 158 ºF)

Air Accumulator Powder coated stainless steel

Weight 3.7 lbs. (1.7 kg)

O&M Manual

(Rev-H, 11/18)

Part 2 - Mechanical Installation

2.1 General

The Q46D Auto-Clean D.O. System consists of two assemblies housed in NEMA 4X (IP-66)

enclosures. The analyzer electronics and the Q-Blast cleaner assembly should both be

mounted near the sensor location, with a maximum of 60 feet between the monitor/cleaner and

the sensor. The standard system is supplied with a 30 ft. sensor cable and 30 feet of airline

tubing. Best performance is obtained by keeping sensor cable and air tubing length as short as

practical.

Installation of a complete Q46D Auto-Clean System requires mounting both the analyzer

electronics and the cleaner assembly, mounting the sensor assembly, and running a 3-

conductor interconnect wire between the analyzer and cleaner assemblies. Both the analyzer

and the Q-Blast assembly require power connection. If the system is purchased with optional

mounting plate and power distribution box, interconnect wiring will already be complete and

only one power connection is required at the junction box.

The analyzer enclosure and the cleaner enclosure may be mounted to any flat surface, like a

wall or plate. A bracket assembly is available (#00-0930) for mounting a flat PVC, aluminum, or

stainless steel plate to hold the two enclosures to typical aeration handrail systems. This

bracket locates the monitor at a convenient height for viewing the display and using the

controls.

2.2 Wall or Pipe Mount

A PVC mounting bracket with attachment screws is supplied with each transmitter (see Figure 2

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. These holes are slotted to accommodate two sizes of u-bolt that may be

used to pipe mount the unit. Slots will accommodate u-bolts designed for 1½ “or 2” pipe. The

actual center to center dimensions for the u-bolts are shown in the drawing. Note that these

slots are for u-bolts with ¼-20 threads. The 1½” pipe u-bolt (2” I.D. clearance) is available from

ATI in type 304 stainless steel under part number (47-0004).

ATI Q46D Membrane D.O. Q-Blast System Part 2 –Mechanical Installation

O&M Manual

(Rev-H, 11/18)

Figure 2 - Wall Mount Bracket

2.3 Wall Mount Dimensions

Figure 3 shows the dimensions of the analyzer dimensions. Note that the enclosure mounting

brackets are not installed at the factory. They are supplied separately and must be attached

using the screws provided. This is done to protect the brackets against shipping damage.

Figure 3 - Enclosure Dimensions

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