Analytical Technology Q46D User Manual

Model Q46D

Optical D.O. Monitor

System

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
Ph: 800-959-0299 Ph: [phone]
610-917-0991
Fax: [phone] Fax: + 44 (0)1457-873-468

Email: [e-mail] Email: [e-mail]

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 start­up, such defective parts will be repaired or replaced free of charge. Inspection and
repairs to products thought to be defective within the warranty period will be completed
at the Manufacturer's facilities in Collegeville, PA. Products on which warranty repairs
are required shall be shipped freight prepaid to the Manufacturer. The product(s) will be
returned freight prepaid and allowed if it is determined by the manufacturer that the
part(s) failed due to defective materials or workmanship.

This warranty does not cover consumable items, batteries, or wear items subject
to periodic replacement including lamps and fuses.

Gas sensors carry a 12 months from date of shipment warranty and are subject
to inspection for evidence of misuse, abuse, alteration, improper storage, or extended
exposure to excessive gas concentrations. Should inspection indicate that sensors
have failed due to any of the above, the warranty shall not apply.

The Manufacturer assumes no liability for consequential damages of any kind,
and the buyer by acceptance of this equipment will assume all liability for the
consequences of its use or misuse by the Customer, his employees, or others. A defect
within the meaning of this warranty is any part of any piece of a Manufacturer's product
which shall, when such part is capable of being renewed, repaired, or replaced, operate
to condemn such piece of equipment.

This warranty is in lieu of all other warranties ( including without limiting the
generality of the foregoing warranties of merchantability and fitness for a particular
purpose), guarantees, obligations or liabilities expressed or implied by the Manufacturer
or its representatives and by statute or rule of law.

This warranty is void if the Manufacturer's product(s) has been subject to misuse
or abuse, or has not been operated or stored in accordance with instructions, or if the
serial number has been removed.

Analytical Technology, Inc. makes no other warranty expressed or implied except
as stated above.

Table of Contents

PART 1 - INTRODUCTION ................................5

1.1 General ................................................ 5

1.2 Standard System ................................. 5

1.3 Features .............................................. 5

1.4 Q46D/60 System Specifications .......... 6

1.5 Q46D Performance Specifications ...... 8

PART 2 – ANALYZER MOUNTING.....................9

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

2.2 Wall or Pipe Mount ........................... 10

2.3 Panel Mount ...................................... 12

PART 3 – OPTICAL D.O. SENSOR .................... 13

3.1 General .................................................. 13

3.2 Optical Sensing ...................................... 14

3.3 Submersion Mounting ...................... 15

PART 4 – ELECTRICAL INSTALLATION ............. 17

4.1 General .............................................. 17

4.2 AC Powered Instrument Wiring ........ 18

4.5 Sensor Wiring .................................... 22

4.5 Junction Box Connection ................... 24

PART 5 – CONFIGURATION ........................... 25

5.1 User Interface ................................... 25

5.11 Keys ................................................... 26

5.12 Display ............................................... 26

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

5.21 Software Navigation ......................... 28

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

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

5.24 Configuration Menu [CONFIG] ......... 33

5.25 Control Menu [CONTROL] ................. 38

5.26 Diagnostics Menu [DIAG] ................... 43

PART 6 – CALIBRATION ................................. 48

6.1 General ................................................. 48

6.11 D.O. Span Cal (1-spl) ......................... 48

6.12 Dissolved Oxygen Air Span Cal (% sat) ..

.......................................................... 50

6.13 Dissolved Oxygen Zero Cal ................ 51

6.2 Temperature Calibration .................. 52

PART 7 – PID CONTROLLER DETAILS .............. 54

7.1 PID Description ................................. 54

7.2 PID Algorithm .................................... 54

7.3 Classical PID Tuning .......................... 56

7.4 Manual PID Override Control ........... 57

7.5 Common PID Pitfalls ......................... 57

PART 8 – SYSTEM MAINTENANCE ................. 59

8.1 General ............................................. 59

8.2 Analyzer Maintenance ...................... 59

8.3 Sensor Maintenance ......................... 59

PART 9 – TROUBLESHOOTING ....................... 60

9.1 General ............................................. 60

9.2 External Sources of Problems ........... 60

9.3 Analyzer Tests ................................... 61

9.31 Display Messages .............................. 62

9.4 Sensor Tests ...................................... 64

SPARE PARTS ............................................... 68

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Table of Figures

FIGURE 1 - Q46 ENCLOSURE DIMENSIONS ..................................................................................... 9

FIGURE 2 - WALL OR PIPE MOUNT BRACKET ................................................................................ 10

FIGURE 3 - WALL MOUNTING DIAGRAM ........................................................................................ 11

FIGURE 4 - PIPE MOUNTING DIAGRAM .......................................................................................... 11

FIGURE 5 - PANEL MOUNT INSTALLATION ..................................................................................... 12

FIGURE 6 - SUBMERSIBLE D.O. SENSOR ASSEMBLY ..................................................................... 13

FIGURE 7 - OPTICAL SENSOR ELEMENT ....................................................................................... 14

FIGURE 8 - SUBMERSIBLE SENSOR MOUNTING ASSY .................................................................... 15

FIGURE 9 - MOUNTING ASSEMBLY DETAIL .................................................................................... 16

FIGURE 10 - LINE POWER CONNECTION ....................................................................................... 19

FIGURE 11 - RELAY CONTACTS ................................................................................................... 20

FIGURE 12 - OPTIONAL RELAY BOARD WIRING ............................................................................. 21

FIGURE 13 - OPTIONAL 3RD ANALOG OUTPUT .............................................................................. 21

FIGURE 14 - SENSOR WIRING ...................................................................................................... 23

FIGURE 15 - JUNCTION BOX INTERCONNECT WIRING .................................................................... 24

FIGURE 16 - USER INTERFACE ..................................................................................................... 25

FIGURE 17 - SOFTWARE MAP ...................................................................................................... 30

FIGURE 18 - CONTROL RELAY HYS & PHASE OPTION ................................................................... 41

FIGURE 19 - ALARM RELAY EXAMPLE .......................................................................................... 42

FIGURE 20 - Q46 ISA (IDEAL) EQUATION ..................................................................................... 55

FIGURE 21 - Q46D DISPLAY MESSAGES ...................................................................................... 63

FIGURE 22 - PT1000 RTD TABLE ................................................................................................ 65

FIGURE 23 - REFERENCE BAROMETRIC PRESSURE CONVERSION .................................................. 66

FIGURE 24 - REFERENCE OXYGEN SOLUBILITY TABLE .................................................................. 67

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Part 1 - Introduction

1.1 General

The Model Q46D is a versatile 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°C.

While the Q46D may be used with either optical oxygen or galvanic membrane
sensors, this manual is specific for systems utilizing ATI’s optical 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. Options are available to add either a third 4-20
mA output or 3 additional low power SPST relays. In addition, a digital output
option for Profibus, Modbus, or Ethernet is available.

1.2 Standard System

The standard model Q46D system includes two components, the Q46D analyzer
and an optical dissolved oxygen (ODO) sensor. For connection of the sensor to
the electronics, a 30' (9 m) cable is supplied. Up to a total length of 200 feet (61
m) of cable may be added using #07-0100 junction box and #31-0038 cable.

1.3 Features

· Q46D monitors are available in either 90-260VAC or 12-24 VDC power supply

systems. All features remain the same in both variations

· High accuracy, high sensitivity system, measures from 0.1 ppm to 40.0 ppm

through 2 internal automatic ranges.

· 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.

· Units provide provides three SPDT relay outputs and two isolated analog

outputs. Software settings for relay control include setpoint, deadband, phase,
delay, and failsafe.

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ATI Q46D-ODO Optical D.O. System Part 1 - Introduction

· Selectable PID controller on main analog output. PID controller can operate with

instrument configured as loop-power transmitter, or as one of the two outputs on
the AC powered instrument. PID includes manual operation feature, and
diagnostic “stuck-controller” timer for relay notification of control problems.

· Selectable Output Fail Alarm feature on Relay B allows system diagnostic

failures to be sent to external monitoring systems.

· 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 D.O. 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.

· High reliability, microprocessor-based system with non-volatile memory back-up

that utilizes no batteries. Low mass, surface mount PCB construction containing
no adjustment potentiometers. All factory calibrations stored in non-volatile
EEPROM.

1.4 Q46D/60 System Specifications

Displayed Parameters Main input, 0.1 ppm to 40.0 ppm

%Saturation, 0 to 999.9%
Sensor temperature, -10.0 to 50.0°C (23 to 122ºF)
Sensor signal, -40 to +2000 mVDC
Analog output current, 4.00 to 20.00 mA
Sensor slope/offset
Model number and software version
PID Controller Status

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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
12-24 VDC, 500 mA max.

Enclosure NEMA 4X, polycarbonate, stainless steel hardware,

Mounting Options Wall, pipe, or panel mount standard. Wall bracket suitable

for either 1.5” or 2” I.D. U-Bolts for pipe mounting.

Conduit Openings Five ½” NPT openings, Adapter can be removed to

provide a 1” NPT opening in the bottom of the enclosure.
Gland seals provided but not installed.

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.

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.

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

oxygen or PID. Output 2 programmable for PPM oxygen,
Temperature, or PID. Max load 450 Ohms for output 1 and
1000 ohms for output 2. Outputs ground isolated and
isolated from each other. An additional 3rd analog option is
available.

Optional Digital Output: Profibus DP available, with Modbus & Ethernet available

soon.

Output Isolation 600 V galvanic isolation

Optional Relays: Three SPST, 1 amp @ 24 VDC. Software selection for

setpoint, phase, delay, deadband, hi-lo alarm, and failsafe.

Ambient Temperature Analyzer Service, -20 to 60 °C (-4 to 140 ºF)
Sensor Service, -5 to 55°C (23 to 131 °F)

Keypad 4-key membrane type with tactile feedback, polycarbonate

Filter Adjustable 0-9.9 minutes additional damping to 90% step

Storage, -30 to 70 °C (-22 to 158 ºF)

with UV coating

input

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ATI Q46D-ODO Optical D.O. System Part 1 - Introduction

Temperature Input Pt1000 RTD with automatic compensation

Ambient Humidity 0 to 95%, indoor/outdoor use, non-condensing to rated

ambient temperature range

Altitude Up to 2000 m (6562 ft)

Electrical Certification Ordinary Location, cCSAus (Certified to both CSA and UL

standards), pollution degree 2, installation category 2

EMI/RFI Influence Designed to EN 61326-1

Weight 2.4 lb. (1.1 Kg.)

Sensor Optical oxygen sensor utilizing fluorescence quenching

technology. Optical element life 3-5 years.

Sensor Materials Noryl, PVC, and stainless steel

Sensor Cable Submersible: 30 ft. (9.1 m)

Max. Sensor Cable Length: 200 feet (61 m), with junction box

1.5 Q46D Performance Specifications

Accuracy 0.5% of selected range or better

Repeatability 0.3% of selected range or better

Sensitivity 0.05% of selected range

Non-linearity 0.1% of selected range

Warm-up Time 3 seconds to rated performance (electronics only)

Supply Voltage Effects ± 0.05% span

Instrument Response Time 120 seconds to 90% of step input at lowest damping

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.

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Part 2 – Analyzer Mounting

2.1 General

All Q46 Series instruments offer maximum mounting flexibility. A bracket is
included with each unit that allows mounting to walls or pipes. In all cases,
choose a location that is readily accessible for calibrations. Also consider that it
may be necessary to utilize a location where solutions can be used during the
calibration process. To take full advantage of the high contrast display, mount
the instrument in a location where the display can be viewed from various angles
and long distances.

Locate the instrument in close proximity to the point of sensor installation - this
will allow easy access during calibration. The sensor-to-instrument distance
should not exceed 200 feet (61 m). To maximize signal-to-noise ratio however,
work with the shortest sensor cable possible. The standard cable length of the
oxygen sensor is 30 feet.

Figure 1 - Q46 Enclosure Dimensions

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ATI Q46D-ODO Optical D.O. System Part 2 – Analyzer Mounting

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 47-0005

Figure 2 - Wall or Pipe Mount Bracket

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ATI Q46D-ODO Optical D.O. System Part 2 – Analyzer Mounting

Note: Analyzer shown with optional
Profibus Connector mounted to side of
enclosure.

Figure 3 - Wall Mounting Diagram

Figure 4 - Pipe Mounting Diagram

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ATI Q46D-ODO Optical D.O. System Part 2 – Analyzer Mounting

2.3 Panel Mount

Panel mounting of the monitor uses the panel mounting flange molded into the
rear section of the enclosure. Figure 5 provides dimensions for the panel cutout
required for mounting.

The panel mounting bracket kit must be ordered separately (part #05-0094).
This kit contains a metal bracket that attaches to the rear of the enclosure, 4
screws for attachment of this bracket, and a sealing gasket to insure that the
panel mounted monitor provides a watertight seal when mounted to a panel.

The sealing gasket must first be attached to the enclosure. The gasket contains
an adhesive on one side so that it remains in place on the enclosure. Remove
the protective paper from the adhesive side of the gasket and slide the gasket
over the back of the enclosure so that the adhesive side lines up with the back of
the enclosure flange. Once in place, you can proceed to mount the monitor in
the panel.

Figure 5 - Panel Mount Installation

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Part 3 – Optical D.O. Sensor

3.1 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. Removal of the
protective boot prior to submergence may expose the sensing element to
mechanical damage that is not covered by warranty.

Figure 6 - Submersible D.O. Sensor Assembly

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ATI Q46D-ODO Optical D.O. System Part 3 – Optical Sensor Mounting

3.2 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. When the element is exposed to a pulse of light from an internal LED, the
material in the polymer will fluoresce, or emit light at another wavelength. This
light decreases (or is quenched) at a rate proportional to the amount of oxygen in
the polymer. The monitor measures the rate at which this quenching occurs and
calculates the oxygen concentration based on the measurement.

Optical oxygen sensors provide the ability to measure oxygen in stagnant water,
and are not affected by certain kinds of non-biological coatings. However, optical
sensors are affected by biologically active coatings and must be kept clean. In
activated sludge applications, biological films can have a much lower D.O.
concentration on the sensor side of the film than on the bulk solution side. The
automatic air cleaning system integrated into the Q46D system will eliminate
coating problems by cleaning the sensor on a regular programmed schedule.

Figure 7 - Optical Sensor Element

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ATI Q46D-ODO Optical D.O. System Part 3 – Optical Sensor Mounting

3.3 Submersion Mounting

Most applications for D.O. monitoring are done using a submersible sensor.
Optical oxygen sensor can be used in stagnant water conditions, as they do not
need sample flow for measurement. Most aeration tank applications in
wastewater treatment plants can for biologically active coatings on the face of the
sensor, resulting in low readings. ATI’s Auto-Clean version of this product is
preferred in these applications. Submersible sensors are mounted to a 1" pipe
using a special sensor adapter that screws to the top of the sensor. The
mounting pipe can be secured to standard 1½” or 2” pipe rail using a mounting
bracket kit available from ATI (part number 00-0624) as shown in Figure 8.
For standard applications, the air line fitting may be removed as it is used only for
Auto-Clean installations.

Flexible Air Line applicable for
Auto-Clean Option Only!

Figure 8 - Submersible Sensor Mounting Assy

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ATI Q46D-ODO Optical D.O. System Part 3 – Optical Sensor Mounting

Flexible Air Line applicable for
Auto-Clean Option Only!

Figure 9 - Mounting Assembly Detail

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Part 4 – Electrical Installation

4.1 General

The Q46 is powered in one of two ways, depending on the version purchased.
The 12-24 VDC powered analyzer requires a customer supplied DC power
supply. The 90-260 VAC version requires line power. Please verify the type of
unit before connecting any power.

WARNING: Do not connect AC line power to the DC version. Severe

damage will result.

Important Notes:

1. Use wiring practices that conform to national, state and local electrical
codes. For proper safety as well as stable measuring performance, it
is important that the earth ground connection be made to a solid
ground point on TB7. The AC power supply in the transmitter contains
a single 630mA slo-blo fuse (Wickmann/Littlefuse #372-0630). The
fuse F1 is located adjacent to TB7 and is easily replaceable.

2. Do NOT run sensor cables or instrument 4-20 mA output wiring in the
same conduit that contains AC power wiring. AC power wiring should
be run in a dedicated conduit to prevent electrical noise from coupling
with the instrumentation signals.

3. This analyzer must be installed by trained personnel in accordance
with local codes and instructions contained in this operating manual.
Observe the analyzer's technical specifications and input ratings.
Proper electrical disconnection means must be provided prior to the
electrical power connected to this instrument, such as a circuit breaker

- rated 250 VAC, 2 A minimum. If one line of the line power mains is
not neutral, use a double-pole mains switch to disconnect the analyzer.

4. Repeated problems with lightning strikes damaging sensitive
instrumentation are often attributed to poorly bonded earth grounds in
the instrument power source. The protection schemes incorporated
into this analyzer cannot operate to maximum efficiency unless the
ground connection is at its’ absolute lowest impedance.

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ATI Q46D-ODO Optical D.O. System Part 4 – Electrical Installation

WARNING

Disconnect line power voltage BEFORE connecting

line power wires to Terminal TB5 of the power supply.

wire

single phase power. The power supply is configured

for 115 VAC or 230 VAC operation at the factory at

time of order, and the power supply is labeled as

such. Do NOT connect voltages other than the

5. There is no standard ground resistance universally recognized. Many
agencies recommend a ground resistance value of 5 ohms or less.
The NEC recommends an impedance to ground of less than 25 ohms,
and less than 5 ohms where sensitive equipment is installed. Power
sources feeding sensitive instruments like the Q46 should have the
lowest possible impedance to ground

4.2 AC Powered Instrument Wiring

Verify the AC power supply requirement before installing. Also verify that power
is fully disconnected before attempting to wire.

Q46 systems are supplied with 5 cable gland fittings for sealing cable entries.

Connect HOT, NEUTRAL, and GROUND to the matching designations on
terminal strip TB7.

The analog outputs from the system are present at terminals TB1 and TB2. The
loop-load limitation in this configuration is 450 Ohms maximum for output 1 and
1000 ohms maximum for output 2. Also note that these two outputs are
completely isolated from each other to insure that ground loops do not result from
the connection of both outputs to the same device such as a PLC or DCS.

A ribbon cable connects the power supply assembly with the microprocessor
assembly located in the front section of the enclosure. This cable may be
unplugged from the front section of the monitor if service is needed, but should
normally be left in place during installation.

The power supply accepts only standard three-

labeled requirement to the input.

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ATI Q46D-ODO Optical D.O. System Part 4 – Electrical Installation

Figure 10 - 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.

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ATI Q46D-ODO Optical D.O. System Part 4 – Electrical Installation

4.3 Relay Connection

Three SPDT relays are provided on the power supply board. None of the relay
contacts are powered. The user must supply the proper power to the contacts.
For applications that require the same switched operating voltage as the Q46
(115 or 230 VAC), power may be jumped from the power input terminals at TB7.
Relay wiring is connected at TB4, TB5, and TB6 as shown below. Note that the
relay contact markings are shown in the NORMAL mode. Programming a relay
for “Failsafe” operation reverses the NO and NC positions in this diagram (Figure

11).

Figure 11 - Relay Contacts

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ATI Q46D-ODO Optical D.O. System Part 4 – Electrical Installation

4.4 Optional Output/Relay Connection

TB2, is used to connect to the optional 3-relay card (Figure 12) OR the optional

third analog output Out#3, (Figure 13). The Q46 can be configured for only one
of these optional features, and the hardware for either option must be factory
installed. Note that the optional 3 relays are for switching LOW POWER DC
ONLY.

Figure 12 - Optional Relay Board Wiring

Figure 13 - Optional 3rd Analog Output

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ATI Q46D-ODO Optical D.O. System Part 4 – Electrical Installation

4.5 Sensor Wiring

The sensor cable can be quickly connected to the Q46 terminal strip by matching

the wire colors on the cable to the color designations on the label in the monitor.
A junction box is also available to provide a break point for long sensor cable
runs. Route signal cable away from AC power lines, adjustable frequency drives,
motors, or other noisy electrical signal lines. Do not run sensor or signal cables
in conduit that contains AC power lines or motor leads.

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.
These two wires connect to the same point designated by black in
Figure 14. If the cable is cut to a shorter length, be sure that both
wires are connected to the terminal marked black.

A yellow and a gray wire are contained in the cable and are

covered to avoid shorting. If the cable length is changed, do
not strip these two wires. If possible, leave sensor cable uncut
to avoid problems.

Note: If sensor is experiencing Low-Slope or Low-Output conditions, due
To poor Earth Ground Connections, move the Shield connection
from P/S board to alternate location on lid, where indicated with an

“S”.

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ATI Q46D-ODO Optical D.O. System Part 4 – Electrical Installation

Figure 14 - Sensor Wiring

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ATI Q46D-ODO Optical D.O. System Part 4 – Electrical Installation

4.6 Junction Box Connection

For installations where the sensor is to be located more than 25 feet from the
monitor (max. 200 feet/ 61 m), a junction box must be used. The junction box is
shown in Figure 15, and is supplied with a ½" conduit hub on one end and a
sensor cable gland on the other end.

Note: If sensor is experiencing Low-Slope or Low-Output conditions, due
To poor Earth Ground Connections, move the Shield connection
from P/S board to alternate location on lid, where indicated with an

“S”.

Figure 15 - Junction Box Interconnect Wiring

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ENTER

MENU ICONS

12-CHARACTER

Part 5 – Configuration

5.1 User Interface

The user interface for the Q46 Series instrument consists of a custom display
and a membrane keypad. All functions are accessed from this user interface (no
internal jumpers, pots, etc.).

When power is first applied, you may notice that the display does not come on
immediately. This is normal. There is a 5 second start routine that runs before
the display illuminates. In addition, you will notice an occasional “flicker” of the
display, occurring about twice an hour. This is the result of a display processor
refresh program that insures long-term display integrity, and will always occur
during normal operation of the instrument.

SIGN

RELAY/LO-BAT

INDICATOR

4-KEY USER

INTERFACE

MENU/ESCAPE

KEY

UP ARROW

KEY

RELAY

INDICATOR

A

B

MENU

ESC

4-DIGIT

MAIN DISPLAY

MENU ICONS

CAL

UNITS

12-CHARACTER

SECONDARY

DISPLAY

MEMBRANE

KEYPAD

CONF

DIAG
FAIL
HOLD

UNITS

SECONDARY

DISPLAY

MEMBRANE

KEYPAD

ENTER KEY

LEFT ARROW

KEY

Figure 16 - User Interface

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ATI Q46D-ODO Optical D.O. 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.
Using the escape key aborts all changes to the current
screen and backs the user out one level in the software tree.
The manual will refer to this key as either MENU or ESC,
depending upon its particular function.

UP (arrow) To scroll through individual list or display items and to

change number values.

LEFT (arrow) To move the cursor from right to left during changes to a

number value.

ENTER To select a menu section or list item for change and to store

any change.

5.12 Display

The large custom display provides clear information for general measurement
use and user configuration. There are three main areas of the display: the main
parameter display, the secondary message line, and the icon area.

Main Parameter During normal operation, the main parameter display

indicates the present process input with sign and units. This
main display may be configured to display any of the main
measurements that the system provides. During
configuration, this area displays other useful set-up
information to the user.

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ATI Q46D-ODO Optical D.O. 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. During configuration, the
lower line displays menu items and set-up prompts to the
user. Finally, the lower line will display error messages
when necessary. For a description of all display messages,
refer to Section 10.31.

Icon Area The icon area contains display icons that assist the user in

set-up and indicate important states of system functions.
The CAL, CONFIG, and DIAG icons are used to tell the user
what branch of the software tree the user is in while scrolling
through the menu items. This improves software map
navigation dramatically. Upon entry into a menu, the title is
displayed (such as CAL), and then the title disappears to
make way for the actual menu item. However, the icon stays
on.

HOLD The HOLD icon indicates that the current output of the

transmitter has been put into output hold. In this case, the
output is locked to the last input value measured when the
HOLD function was entered. HOLD values are retained
even if the unit power is cycled.

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.

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ATI Q46D-ODO Optical D.O. System Part 5 – Configuration

Relay Area A/B The relay area contains two icons that indicate the state of

the system relays. Relay C is normally configured for FAIL
indication, so it is only displayed on the lower MEASURE
display line.

5.2 Software

The software of the Q46D 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].

Note: The default Measure Menu is display-only and has no menu icon.

5.21 Software Navigation

Within the CAL, CONFIG, CONTROL, and DIAG menu sections is a list of
selectable items. Once a menu section (such as CONFIG) has been selected
with the MENU key, the user can access the item list in this section by pressing
either the ENTER key or the UP arrow key. The list items can then be scrolled
through using the UP arrow key. Once the last item is reached, the list wraps
around and the first list item is shown again. The items in the menu sections are
organized such that more frequently used functions are first, while more
permanent function settings are later in the list. See Figure 17 for a visual
description of the software.

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. In
the multiple variable sequences, variables are changed as the result of some
process. For example, the calibration of oxygen generally requires more than
one piece of information to be entered. The majority of the menu items in the
software consist of the single variable format type.

A

B

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ATI Q46D-ODO Optical D.O. 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. Once the change has been completed, pressing ENTER
again stores the variable and stops the flashing. Pressing ESC aborts the
change and also exits user entry mode.

The starting (default) screen is always the Measure Menu. The UP arrow key is
used to select the desired display. From anywhere in this section the user can
press the MENU key to select one of the four Menu Sections.

The UP arrow icon next to all list items on the display is a reminder to scroll
through the list using the UP arrow key.

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. For
single item type screens, once the user presses the ENTER key, part or all of the
variable will begin to flash, indicating that the user may modify that variable using
the arrow keys. However, if the instrument is locked, the transmitter will display
the message Locked! and will not enter user entry mode. The instrument must
be unlocked by entering the proper code value to allow authorized changes to
user entered values. Once the variable has been reset, pressing the ENTER key
again causes the change to be stored and the flashing to stop. The message
Accepted! will be displayed if the change is within pre-defined variable limits. If
the user decides not to modify the value after it has already been partially
changed, pressing the ESC key aborts the modification and returns the entry to
its original stored value.

In a menu item which is a multiple variable sequence type, once the ENTER key
is pressed there may be several prompts and sequences that are run to complete
the modification. The ESC key can always be used to abort the sequence
without changing any stored variables.

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ATI Q46D-ODO Optical D.O. System Part 5 – Configuration

MENU

SECTIONS

Start

MEASURE

(display only)

Temperature

MV

1

PID % Output

Loop Current (#1)

Loop Current (#2)

2

Loop Current (#3)

3

Aux rly=

Slope

Offset

% Saturation

Model / Version #

PPM or Mg/l

AutoCleaner Status

LIST

ITEMS

Notes:
(1) If Relay A,B,C,D,E,F is set to FAIL mode, relay settings are not
displayed in menu.
(2) The annunciator for Relay C is shown in the MEASURE/
temperature display

1

PID is enabled

2

Optional third 4-20 output installed

3

Optional 3-relay card installed (D,E,F) not displayed if cleaner is enabled

4

If Relay A is set to ALARM mode, the settings are divided into

2 groups of HI and LO points.

5

If Comm Mode is set to a selection other than none,

additional Comm menus will show.

6

For Q-Blast (Autoclean) Systems Only

Figure 17 - Software Map

MENU

ESC

CAL CONFIG DIAG

ENTER

MENU

ESC

ENTER

or

Cal D.O.

Cal Temp

Entry Lock

Set Delay

Contrast

Inst. Type

Zero Filter

Atm. Pressure

Process Conductivity

6

Timer Funcs

5

Com Mode

5

Com Address

I out 1 Mode

I out 2 Mode

4

I out 3 Mode

Relay A Mode

Relay B Mode

Relay C Mode

3

Relay D Mode

3

Relay E Mode

3

Relay F Mode

Temp Units

MENU

CONTROL

ESC

ENTER ENTER

or

1

PID 0% #1 Set Hold

1

PID 100% #1

1

PID Setpoint #1

1

PID Prop #1

1

PID Int #1

1

PID Deriv #1

Set 4mA (#1)

Set 20mA (#1)

Set 4mA (#2)

Set 20mA (#2)

2

Set 4mA (#3)

2

Set 20mA (#3)

4

Setpnt A (or A-HI, A-LO)

4

Hyst A (or A-HI, A-LO)

4

Delay A (or A-HI, A-LO)

MENU

ESC

or or

Fault List

Sim Out

1

PID Timer

Fail Out #1

Fail Val #1

Fail Out #2

Fail Val #2

4

Fail Out #3

4

Fail Val #3

Backlight

Start Delay

6

Cal Check

Failsafe

Set Default

MENU

ESC

Phase A

Setpnt B

Hyst B

Delay B

Phase B

Setpnt C

Hyst C

Delay C

Phase C

3

Setpnt D

3

Hyst D

3

Delay D

3

Phase D

3

Setpnt E

3

Hyst E

3

Delay E

3

Phase E

3

Setpnt F

3

Hyst F

3

Delay F

3

Phase F

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ATI Q46D-ODO Optical D.O. 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. While in the default menu, the UP arrow allows the
user to scroll through the secondary variables on the lower line of the display. A
brief description of the fields in the basic transmitter version is as follows:

TRANSMITTER MEAS SCREENS:

25.7C Temperature display. Can be displayed in C or F,

depending on user selection. A small “m” on the left side of
the screen indicates the transmitter has automatically
jumped to a manual 25C setting due to a failure with the
temperature signal input.

320 mV Raw sensor signal. Useful for diagnosing problems.

100% 20.00 mA PID Status screen (if enabled.) Shows the present controller

output level on left, and actual transmitter current on the
right. The controller can be placed in manual while viewing
this screen by pressing and holding the ENTER key for 5
seconds until a small flashing “m” appears on the screen. At
that point the controller output can be adjusted up or down
using the UP and LEFT arrow keys. To return to automatic
operation, press and hold the ENTER key for 5 seconds and
the “M” will disappear.

#1 4.00 mA Analyzer output current # 1.

#2 12.00 mA Analyzer output current # 2.

#3 20.00 mA Analyzer output current # 3 (if option included.)

Aux relay= D,E,F Auxilliary relay annunciators (if option included.)

Slope = 100% Sensor output response vs. ideal calibration. This value

updates after each calibration. As the sensor ages, the slope
reading will decay indicating sensor aging. Useful for
resolving sensor problems.

Offset = 0.0 mV Sensor output signal at a zero ppm input. This value updates

after a zero-calibration has been performed. Useful for
resolving sensor problems.

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0.00 PPM D.O. Reading in PPM (or mg/L if selected under Instr Type)

% 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. This display
simply indicates the % of oxygen saturation represented by
the current PPM or mg/L display.

Q46D vX.XX Transmitter software version number.

Tcyc 24.0 hr Automatic sensor cleaning frequency (displayed only when

enabled by programming relay B for Cln1 or Cln2).

Note: A display test (all segments ON) can be actuated by pressing and

holding the ENTER key while viewing the model/version number on
the lower line of the display.

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.
There are four items in this list: Cal D.O., Cal Temp, Set Range, and Cal Zero.

Cal D.O. The oxygen calibration function allows the user to adjust the

transmitter span reading to match a reference solution, or to
set the sensor zero point. See Part 6 - Calibration for more
details.

Cal Temp The temperature calibration function allows the user to

adjust the offset of the temperature response by a small
factor of ± 5°C. The temperature input is factory calibrated
to very high accuracy. However, long cable lengths and
junction boxes may degrade the accuracy of the temperature
measurement in some extreme situations. Therefore, this
feature is provided as an adjustment. See Part 6 ­Calibration for more details.

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ATI Q46D-ODO Optical D.O. 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. The Entry Lock feature is a toggle-type setting;
that is, entering the correct code will lock the transmitter and
entering the correct code again will unlock it. The code is
preset at a fixed value. Press ENTER to initiate user entry
mode and the first digit will flash. Use arrow keys to modify
value. See Spare Parts List at the end of this manual for
the Q46D lock/unlock code. Press ENTER to toggle lock
setting once code is correct. Incorrect codes do not change
state of lock condition.

Set Delay The delay function sets the amount of damping on the

instrument. This function allows the user to apply a first
order time delay function to the oxygen measurements being
made. Both the display and the output value are affected by
the degree of damping. Functions such as calibration are
not affected by this parameter. The calibration routines
contain their own filtering and stability monitoring functions to
minimize the calibration timing. Press ENTER to initiate user
entry mode, and the value will flash. Use the arrow keys to
modify value; range is 0.1 to 9.9 minutes. Press ENTER to
store the new value.

Contrast This function sets the contrast level for the display. The

custom display is designed with a wide temperature range
and contains an LED back light so that the display is can be
seen in the dark.

Press ENTER to initiate user entry mode, and the value will

flash. Use arrow keys to modify the value; range is 0 to 8 (0
being lightest). Press ENTER to update and store the new
value.

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”. There
is not a great deal of difference between type 1 and 2
settings as PPM and mg/L measurement units are pretty
close to the same.

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ATI Q46D-ODO Optical D.O. System Part 5 – Configuration

Programming for type 3 percent saturation changes the
measured parameter to read a dissolved oxygen value that
represents the percent of oxygen saturation at a given
temperature. When this unit of measurement is selected,
the main analog output and all alarm and control functions
will relate to this measurement. While a PPM measurement
is displayed on the lower line, it is no longer the primary
variable being measured by the system. Press ENTER to
initiate user entry mode, and the selected value will flash.
Use the UP arrow key to modify the desired display value.
Press ENTER to store the new value.

Zero Filter The Q46D allows the user to program a value near zero

below which the monitor will read zero. Because sensors
rarely have a perfect zero stability, this zero filter eliminates
occasional displays of numbers that are not meaningful. For
instance, setting a zero filter at 0.03 PPM D.O. will cause
any measured values of 0.01 or 0.02 PPM to be displayed
as 0.00 PPM.

Atm Pres The Q46D instrument utilizes the atmospheric pressure

value as an input for the calculation of a theoretical ppm
value during a saturation calibration. The input default units
are inHg (inches Mercury) since these units are easy to
obtain from most local weather services or from the general
chart located on page 66 of this manual. This value is only
entered during initial installation – it does not need to be
modified at every calibration. Press ENTER to initiate user
entry mode and the entire value will flash. Use the arrow
keys to modify the value; range is 20.00 to 31.50 inHg.

The reference table on page 66 is provided to convert inHg

from several other common air pressure units. Press ENTER
to store the new value.

Proc Cond The Q46 instrument also utilizes the process conductivity

value as an input for the calculation of a 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. Use the
arrow keys to modify the value; range is 0.00 to 76.00
mS/cm. Press ENTER to store the new value.

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ATI Q46D-ODO Optical D.O. System Part 5 – Configuration

Note: If the user will not be changing solution conductivity

dramatically during the calibration process, leave a default
setting of 00.50 mS/cm. For ultrapure water applications, set
this value to 0.00. For sea water applications, set this value
to 53.00.

Com Mode Sets digital communication mode of analyzer. Optional

digital communication card must be plugged into the power
supply slot for this function to work. Press ENTER to initiate
user entry mode, and the entire value will flash. Use the UP
arrow key to modify the desired value; selections include 1­None, 2- P-DP for Profibus DP, 3 – Modbus, 4 – Ethernet IP.
Press ENTER to store the new value.

Com Address Sets bus address for digital communication mode of

analyzer. Optional digital communication card must be
plugged into the power supply slot for this function to work.

Press ENTER to initiate user entry mode, and the entire

value will flash. Use the UP arrow key to modify the desired
value. Range is 1-125. Press ENTER to store the new
value.

Iout#1 Mode This function sets analog output #1 to either track PPM or

mg/L oxygen (default), % Saturation, or enables the PID
controller to operate on the oxygen input in either PPM,
mg/L, or % Saturation. Press ENTER to initiate user entry
mode, and the entire value will flash. Use the UP arrow key
to modify the desired value; selections include 1- for oxygen
tracking or 2-PID for oxygen PID control. Press ENTER to
store the new value.

*Iout#2 Mode This function sets analog output #2 for either temperature

(default) or oxygen. Press ENTER to initiate user entry
mode, and the entire value will flash. Use the UP arrow key
to modify the desired value; selections include 1-C/F for
temperature, or 2-ppm for oxygen, or 3-% Saturation. Press
ENTER to store the new value.

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ATI Q46D-ODO Optical D.O. System Part 5 – Configuration

*Iout#3 Mode OPTIONAL. This function sets analog output #3 for either

temperature (default) or D.O. Press ENTER to initiate user
entry mode, and the entire value will flash. Use the UP
arrow key to modify the desired value; selections include 1­C/F for temperature or 2-ppm for oxygen. Press ENTER to
store the new value.

*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.

The CON setting enables normal control operation for Relay

A, with settings for setpoint, hysteresis, delay and phasing
appearing in the CONFIG menu automatically. See Figure
18 for further details.

The FAIL setting enables the fail alarm mode for Relay A.

Relay A will then trip on any condition that causes the FAIL
icon to be displayed on the LCD. Using this mode allows the
User to send alarm indications to other remote devices.

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. See Figure 19 for further details.

*Relay B Mode Relay B can be used in a number of ways: as a setpoint

control, as an alarm, or as the control logic for an automatic
sensor cleaning system. The settings for Relay B Mode are
CON, FAIL, CLn1 and CLn2. The first two modes function
identically to the corresponding modes on Relay A.

The CLn1 and CLn2 modes of operation enable the timer

feature for the automatic sensor cleaner. Once enabled, a
periodic automatic cleaning cycle will occur where a jet of air
is blown past the sensor membrane to dislodge any
contaminants which may have accumulated. During the
cleaning cycle, the outputs of the system are held (analog
outputs and relays) so that the cleaning cycle is invisible to
recording instrumentation, which may be connected. These
outputs are released in a “bumpless” manner once the
system automatically returns to the monitoring mode. The
timer consists of three menu items which will appear in the
CNTRL menu: Timer B CLEAN, Timer B CYCLE, and Timer
B HOLD. The CLEAN function engages the relay B contact

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ATI Q46D-ODO Optical D.O. System Part 5 – Configuration

for a set time to operate the cleaning pump. The CYCLE
function sets the time until the next CLEAN cycle. The
HOLD setting sets the amount of delay that occurs after a
cleaning cycle to let the outputs return to normal. See these
specific function descriptions listed below for more detail.

NOTE: When CLn1 is enabled, the setting for Timer

Clean defaults to 1 minute and this value is locked.
When CLn2 is enabled, the setting for Timer Clean can
be changed. CLn1 should be selected when the ATI
Auto-Clean system is used, and CLn2 should be
selected if an alternate cleaning system is used.

Relay C Mode Relay C can be used in two ways: as a setpoint control, or

as an alarm. The two settings for Relay C Mode are CON
and FAIL.

The CON setting enables normal setpoint operation for

Relay B/C. Relay B/C then operates identically to Relay A,
with settings for setpoint, hysteresis, delay and phasing
appearing in the CONFIG menu automatically. See Figure
18 for details.

The FAIL setting enables the fail alarm mode for Relay B/C.

Relay B/C will then trip on any condition that causes the
FAIL icon to be displayed on the LCD. Note that the Relay C
indicator shows up only on the lower screen of the display
next to the temperature reading. This is because the default
setting for relay C is the FAIL setting. Using this mode
allows the User to send alarm indications to other remote
devices. See Figure 19 for details.

*Relay D Mode
*Relay E Mode
*Relay F Mode OPTIONAL. Relays D,E, and F can be used in two ways: as

a setpoint control, or as an alarm. The two settings for Relay
B Mode are CON and FAIL.

The CON setting enables normal setpoint operation for

Relay B. Relay B then operates identically to Relay A, with
settings for setpoint, hysteresis, delay and phasing
appearing in the CONFIG menu automatically. See Error!
Reference source not found. for details.

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Temp Units This function sets the display units for temperature

measurement. Press ENTER to initiate user entry mode,
and the entire value will flash. Use the UP arrow key to
modify the desired display value. The choices are °F and

°C. Press ENTER to store the new value.

5.25 Control Menu [CONTROL]

The Control Menu contains all of the output control user settings. Note that PID

menu items will not appear unless output 1 is configured for PID mode in the
CONFIG menu.

Set PID 0%
Set PID 100%

[Iout1=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” output values
across the endpoints. Rather, the endpoints determine
where the controller would normally force minimum or
maximum output in an attempt to recover the setpoint (even
though the controller can achieve 0% or 100% anywhere
within the range.)

If the 0% point is lower than the 100% point, then the

controller action will be “reverse” acting. That is, the output
of the controller will increase if the measured value is less
than the setpoint, and the output will decrease if the
measured value is larger than the setpoint. Flipping the
stored values in these points will reverse the action of the
controller to “direct” mode.

The entry value is limited to a value within the range

specified in “Set Range”, and the 0% and the 100% point
must be separated by at least 1% of this range Use the
LEFT arrow key to select the first digit to be modified. Then
use the UP and LEFT arrow keys to select the desired
numerical value. Press ENTER to store the new value.

PID Setpnt

[Iout1=PID] The measured value which the controller is attempting to

maintain by adjusting output value. It is the nature of the
PID controller that it never actually gets to the exact value
and stops. The controller is continually making smaller and
smaller adjustments as the measured value gets near the
setpoint.

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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.

PID Int

[Iout1=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. If the integral is set to
zero, a fixed offset value is added to the controller (manual
reset.) Increasing this value will make the controller more
responsive.

PID Deriv

[Iout1=PID] Derivative is a second order implementation of Integral, used

to suppress “second-order” effects from process variables.
These variables may include items like pumps or mixers that
may have minor impacts on the measured value. The
derivative factor is rarely used in water treatment process,
and therefore, it is best in most cases to leave it at the
default value. Increasing this value will make the controller
more responsive.

Set 4 mA

Set 20 mA
[Iout1=D.O.] These functions set the main 4 and 20 mA current loop

output points for the transmitter. The units displayed depend
on the selection made in the CONFIG menu for Iout #1
Mode. Also, when the Relay Option Board is installed, the
units will also display #1 or #2 – since there are actually two
analog outputs present in this version.

The value stored for the 4 mA point may be higher or lower

than the value stored for the 20 mA point. The entry values
are limited to values within the range specified in “Set
Range”, and the 4 mA and the 20 mA point must be
separated by at least 1% of this range Use the LEFT arrow
key to select the first digit to be modified. Then use the UP
and LEFT arrow keys to select the desired numerical value.
Press ENTER to store the new value.

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ATI Q46D-ODO Optical D.O. System Part 5 – Configuration

*Set 4 mA #2
*Set 20 mA #2
[temp/D.O.] 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), PPM oxygen, or % Saturation.
The values stored for the 4 mA point may be higher or lower
than the value stored for the 20 mA point.

The entry value is limited to a value between 0 and 50 °C if it

is set for temperature. The 4 mA and the 20 mA point must
be at least 20 units away from each other. Press ENTER to
initiate user entry mode, and the value will flash. Use arrow
keys to modify value. Press ENTER to store the new value.

NOTE: If the temperature units are changed between °C and

°F (see Temp Units in this section), the default settings for
this output will be stored (present data is not converted.)

*Set 4 mA #3
*Set 20 mA #3
[temp/D.O.] OPTIONAL. These functions set the optional third 4 mA and

20 mA current loop output points for the analyzer. The
output may be set to track temperature (default) or D.O. The
values stored for the 4 mA point may be higher or lower than
the value stored for the 20 mA point.

The entry value is limited to a value between 0 and 55 °C if it

is set for temperature. The 4 mA and the 20 mA point must
be at least 20 units away from each other. Press ENTER to
initiate user entry mode, and the value will flash. Use arrow
keys to modify value. Press ENTER to store the new value.

*A Setpoint This function establishes the oxygen trip point for relay A.

The entry value is limited to a value within the range
specified in “Set Range”. Use the LEFT arrow key to select
the first digit to be modified. Then use the UP and LEFT
arrow keys to select the desired numerical value. Press
ENTER to store the new value.

*A Hysteresis This function establishes the hysteresis, or “deadband”, for

Relay A. Hysteresis is most often used to control relay
chattering; however, it may also be used in control schemes
to separate the ON/OFF trip points of the relay. Press
ENTER to initiate user entry mode, and the value will flash.

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ON

}

1.050 ppm

1.000 ppm

PHASE: LO

OFF

HYSTERESIS

“DEAD BAND”

X

ON

}

1.050 ppm

1.000 ppm

PHASE: LO

OFF

HYSTERESIS

“DEAD BAND”

X

Use the arrow keys to modify value. Press ENTER to store
the new value.

*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. Press ENTER to initiate
user entry mode, and the value will flash. Use arrow keys to
modify value; range is 0 to 999 seconds. Press ENTER to
store the new value.

*A Phasing This function establishes the direction of the relay trip.

When phase is HI, the relay operates in a direct mode.
Therefore, the relay energizes and the LCD indicator
illuminates when the oxygen value exceeds the setpoint.
When the phase is LO, the relay energizes and the LCD
indicator illuminates when the oxygen level drops below the
setpoint. The failsafe setting does have an impact on this
logic. The description here assumes the failsafe setting is
OFF. Press ENTER to initiate user entry mode, and the
entire value will flash. Use the UP arrow key to modify the
desired value; selections include HI for direct operation or
LO for reverse operation. Press ENTER to store the new
value.

See Figure 18 below for a visual description of a typical
control relay application.

When value rises to ≥ 1.000 ppm, relay closes.

When value rises to ≥ 1.050 ppm, relay opens.

1.000 ppm

1.000 ppm

PHASE: HI

PHASE: HI

0.950 ppm

0.950 ppm

When value falls to ≤ 0.950 ppm, relay opens.

Figure 18 - Control Relay Hys & Phase Option

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OFF

OFF

X

X

HYSTERESIS

HYSTERESIS

OR

}

}

OR

“DEAD BAND”

“DEAD BAND”

Settings:

Setpoint: 1.000 ppm
Hyst: 0.050
Delay: 000
Failsafe: OFF

ON

ON

When value falls to ≤ 1.000 ppm, relay closes.

41

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OR

ATI Q46D-ODO Optical D.O. System Part 5 – Configuration

*Setpnt A

-

HI

*B Setpoint

ON

ON

}

}

1.050 ppm

1.000 ppm

0.500 ppm

0.450 ppm

PHASE: LO

OFF

HYST - HI

HYST - LO

OFF

X

X

If Relay A Mode is set to Alarm Mode, AL, then the following

*Hyst A-HI
*Delay A-HI
*Setpnt A-LO
*Hyst A-LO
*Delay A-LO

Figure 19 is a visual description of a typical alarm relay

When value rises to ≥ 1.000 ppm, relay
closes, until value falls back to < 0.950 ppm.

settings will appear in the Config Menu list automatically. In
this mode, two setpoints can be selected on the same relay,
to create an alarm band. Phase HI selection causes the
relay to energize outside of the band, and Phase LO causes
the relay to energize inside of the band. This feature
enables one relay to be used as a control relay while the
other is used as a HI-LO Alarm relay at the same time.
Setpoint A-LO must be set lower than Setpoint A-HI. When
AL mode is first selected, Setpoint A-LO is defaulted to 0.

application.

When value falls to < 1.000 ppm, relay
closes, until rises back to > 1.050 ppm.

1.000 ppm

0.950 ppm

PHASE: HI

0.550 ppm

0.500 ppm

When value falls to < 0.500 ppm, relay
closes, until rises back to > 0.550 ppm.

Figure 19 - Alarm Relay Example

Setpoint A-HI: 1.000 ppm Setpoint A-LO: .500 ppm
Hyst A-HI: 0.050 Hyst A-LO: .0.050
Delay A-HI: 000 Delay A-LO: 000

X

OFF

X

Settings:

HYST - HI

}

HYST - LO

}

ON

When value rises to ≥ 0.500 ppm, relay
closes, until value falls back to < 0.450 ppm.

If Relay B Mode is set to CON, then Relay B will function

*B Hysteresis
*B Delay
*B Phasing

identically to Relay A. Relay B settings appear in the
CONFIG menu list automatically.

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C Setpoint

C Setpoint

If Relay C Mode is set to CON (see Relay C Mode), then

C Hysteresis

C Hysteresis
C Delay

C Delay
C Phasing

C Phasing

If Relay D, E, or F Mode is set to CON (see Relay D,E,F

D,E,F Setpoint
D,E,F Hyster
D,E,F Delay
D,E,F Phasing

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

The Set Hold function can also hold at an output value

Relay C will function identically to Relay A. Relay C settings
appear in the CONFIG menu list automatically.

Modes), then the Relay will function identically to Relay A.
Relay settings appear in the CONFIG menu list
automatically.

on the present process value and holds relays in current
status. This function can be used prior to calibration, or
when removing the sensor from the process, to hold the
output in a known state. Once HOLD is released, the
outputs return to their normal state of following the process
input. The transfer out of HOLD is bumpless on the both
analog outputs - that is, the transfer occurs in a smooth
manner rather than as an abrupt change. An icon on the
display indicates the HOLD state, and the HOLD state is
retained even if power is cycled. Press ENTER to initiate
user entry mode, and entire value will flash. Use the UP
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.

specified by the user. To customize the hold value, first turn
the HOLD function on. Press the ESC key to go to the DIAG
Menu and scroll to Sim Output using the UP arrow key.
Press ENTER. Follow the instructions under Sim Output
(see following page).

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Fault List The Fault List screen is a read-only screen that allows the

user to display the cause of the highest priority failure. The
screen indicates the number of faults present in the system
and a message detailing the highest priority fault present.
Note that some faults can result in multiple displayed failures
due to the 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 them. The
exception to this rule is the calibration failure. When a
calibration fails, no corrupt data is stored. Therefore, the
system continues to function normally on the data that was
present before the calibration was attempted.

After 30 minutes or if power to the transmitter is cycled, the

failure for calibration will be cleared until calibration is
attempted again. If the problem still exists, the calibration
failure will re-occur. Press ENTER to initiate view of the
highest priority failure. The display will automatically return
to normal after a few seconds.

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. If the timer value is
set to any number other zero, a FAIL condition will occur if
the PID controller remains at 0% or 100% for the timer value.
If one of the relays are set to FAIL mode, this failure
condition can be signaled by a changing relay contact.

Press ENTER to initiate user entry mode, and the entire

value will flash. Use the UP arrow key to modify desired
value; range of value is 0-9999 seconds. Press ENTER to
store the new value.

Sim Out The Sim Out function allows the user to simulate the oxygen

level of the instrument in the user selected display range.
The user enters a ppm value directly onto the screen, and
the output responds as if it were actually receiving the signal
from the sensor. This allows the user to check the function
of attached monitoring equipment during set-up or

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troubleshooting. Escaping this screen returns the unit to
normal operation. Press ENTER to initiate the user entry
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.

Note: If the HOLD function is engaged before the Sim Output

function is engaged, the simulated output will remain the
same even when the ESC key is pressed. Disengage the
HOLD function to return to normal output.

Fail Out #1 This function enables the user to define a specified value

that the main current output will go to under fault conditions.
When the Relay Option Board is installed, the display will
read Fail Out #1. When enabled to ON, the output may be
forced to the current value set in Fail Val (next item.) With
the Fail Out setting of ON, and a Fail Val setting of 6.5 mA,
any alarm condition will cause the current loop output to drop
outside the normal operating range to exactly 6.5 mA,
indicating a system failure that requires attention.

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 #1 Sets the output failure value for Iout#1. When Fail Out

above is set to ON, this function sets value of the current
loop under a FAIL condition. When the Relay Option Board
is installed, the display will read Fail Out #1. The output
may be forced to any current value between 4-20 mA.

Press ENTER to initiate user entry mode, and the entire

value will flash. Use the UP arrow key to 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.

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Fail Val #2 This function sets the value of current loop output #2 under a

FAIL condition. The settings and operation are identical to
Fail Out for output #1.

*Fail Out #3 OPTIONAL. This function sets the fail-mode of current loop

output #3 under a FAIL condition. The settings and
operation are identical to Fail Out for output #1.

*Fail Val #3 OPTIONAL. This function sets the value of current loop

output #3 under a FAIL condition. The settings and
operation are identical to Fail Out for output #1.

Backlight This function has three options. ON – On all the time, OFF –

Off all the time, AL – Alarm (Default). This function flashes
the backlight on and off whenever the Fail icon is displayed.

Start Delay This function is designed to minimize control or alarm issues

arising from temporary power loss. When power goes down,
the monitor records the analog output values and the status
of relays and PID functions. When power is restored, the
analog values and relays will be held at the pre-power loss
values for a defined period of time. This “start delay” may be
programmed for periods from 0-9.9 minutes. This function is
set to 0.0 minutes by default and must be activated by the
user if desired by setting a positive time value.

*Failsafe This function allows the user to set the optional system

relays to a failsafe condition. In a failsafe condition, the relay
logic is reversed so that the relay is electrically energized in
a normal operating state. By doing this, the relay will not
only change state when, for example, an oxygen limit is
exceeded, but also when power is lost to the controller.

When failsafe is selected to be ON, the normally-open

contacts of the relay will be closed during normal operation.
In an attempt to make this configuration less confusing, the
LCD icon logic is reversed with this setting, and the icon is
OFF under this normal condition. Therefore, when the trip
condition occurs, the closed N.O. contacts will be opened
(relay de-energized), and the LCD icon will illuminate. In
addition, a power fail would also cause the same contacts to
open.

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Set Default The Set Default function allows the user to return the

instrument back to factory default data for all user settings or
for just the calibration default. It is intended to be used as a
last resort troubleshooting procedure. All user settings or
the calibration settings are returned to the original factory
values. Hidden factory calibration data remains unchanged.
Press ENTER to initiate user entry mode and select either
CAL or ALL with the UP arrow key. The default CAL routine
will reset the zero offset to 0.0 nA and reset the slope to
100%. The default ALL routine will reset all program
variables to factory default and should be used with care
since it will change any user settings that were programmed
in the field.

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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, but it should be done during the initial installation.

The output of the optical dissolved oxygen sensor will degrade very slowly
over the lifetime of the optical element, which is normally 3-5 years. To
account for this degradation, the Q46D system should be re-calibrated
about every 6 months. The 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 operating at more ambient levels. It is important for the user to
establish a periodic calibration schedule for a particular application. Before
calibrating with a new sensor for the first time, or whenever a sensor has
been left unpowered for 10 days or more, first connect the sensor to the
transmitter and allow the system to operate for at least 2 hours to allow for
sensor stabilization and hydration of the optical element. Once the sensor
has been properly conditioned, the user must select the proper operating
parameters, including atmospheric pressure and solution conductivity.

The system provides three methods of D.O. calibration: 1-Point (sample),
% Saturation (air cal), and Zero. These three methods are significantly
different.

6.11 D.O. Span Cal (1-spl)

The 1-Point (sample or comparison) method is intended to be primarily
used as an on-line calibration; however, the sensor can be removed,
cleaned and then calibrated in a bucket of clean water if necessary.
During calibration, the system will display the current ppm reading and the
user can manually enter a reference value from a lab sample or
comparative reference instrument. In the Q46D system, the 1-Point
calibration adjusts the slope of the sensor output response.

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.

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2. If the sensor has been removed and placed into a bucket of water,
allow sensor to temperature equilibrate with the solution as much as
possible. With the sensor coming from an application which differs
greatly in temperature, the user may have to wait as much as 20
minutes. If the sensor is on-line, the user may want to set the output
HOLD feature prior to calibration to lock out any output fluctuations.

3. Scroll to the CAL menu section using the MENU key and press ENTER
or the UP arrow key. Cal DO will then be displayed.

4. Press the ENTER key. The screen will display a flashing 1-spl for 1­point, a 2-%sat for Saturation calibration, or a 3-zer for zero
calibration. Using the UP arrow key, set for a 1-spl calibration and
press ENTER.

5. 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. The calibration
data point acquisition will stop only when the data remains stable for a
pre-determined amount of time. This can be overridden by pressing
ENTER.

6. If the data remains unstable for 10 minutes, the calibration will fail and
the message Cal Unstable will be displayed.

7. The screen will display the last measured ppm value and a message
will be displayed prompting the user for the lab value. The user must
then modify the screen value with the arrow keys and press ENTER.
The system then performs the proper checks.

8. If accepted, the screen will display the message PASS with the new
slope 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.

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6.12 Dissolved Oxygen Air Span Cal (% sat)

This is the recommended method for air temperatures greater than about
10C; 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. As the sensor temperature equilibrates, the
transmitter automatically calculates the new 100% saturation point utilizing
the temperature readings and the barometric pressure user data located
on page 71. This method therefore requires no user input during
calibration. Note: It is very important to allow enough time for the

sensor to completely temperature equilibrate with the surrounding
air. This time is at least 10 minutes.

This method requires that the sensor be removed from the process,
cleaned, and Covered, shielding the sensor from direct sunlight. The
sensor membrane must be dry for this procedure, and not submerged in
liquid. This method requires no user input during calibration; however, if
this is the first time the system is being installed and calibrated, make sure
to enter the proper atmospheric pressure data and process conductivity
data prior to calibration.

1. Remove the sensor from the process. Clean and rinse if necessary

with water, paying particular attention to cleaning the membrane.

2. Cover the sensor, if necessary, to shield it from the direct rays of the
sun. Remember, the membrane must not be submerged - it must be in
the air letting the sensor hang, membrane downward, while powered.

3. Allow the system to operate undisturbed for at least 20 minutes. If the

system is stable, the value on the display will increase to some PPM
value and remain at that level. At that point, calibration can continue.

4. Scroll to the CAL menu section using the MENU key and press ENTER

or the UP arrow key. Cal D.O. will then be displayed.

5. Press the ENTER key. The screen will display a flashing 1-spl for 1­point, a 2-%sat for Saturation air calibration, or a 3-zer for zero
calibration. Using the UP arrow key, set for a 2-sat span calibration
and press ENTER.

6. The display will prompt the user to hold the sensor in air and press
ENTER. If the sensor has already been removed from the process
and reached temperature equilibrium, press the ENTER key.

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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. The calibration data point acquisition will stop only when the data
remains stable for a pre-determined amount of time (approximately 15­20 seconds.) This can be overridden by pressing ENTER. If the data
remains unstable for 10 minutes, the calibration will fail and the
message Cal Unstable will be displayed.

9. If accepted, the screen will display the message PASS with the new
sensor slope 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.

10. The range of acceptable values for sensor slope is 20% to 500%. It
may be necessary to rebuild the sensor as described in section 5,
Dissolved Oxygen Sensor Assembly.

Should the slope value remain out of range and result in calibration
failures, review the Service Section of this manual, then contact the
Service Dept. at ATI for further assistance.

6.13 Dissolved Oxygen Zero Cal

Dissolved oxygen sensors have extremely low offset outputs at zero. For
this reason, it is normally sufficient to simply leave the zero at the factory
default of 0 mV unless longer cable lengths are added to the sensor. As
an alternative if non-standard cable lengths are added, a zero can be set
by sensor from the performing the steps below.

For total cable length of: Off-set Zero
30 m (98 ft) 0.96 mV
50 m (164 ft) 1.39 mV
60 m (200 ft) 1.90 mV

These steps below assume that the sensor has been connected to the
monitor with the monitor powered for 2 hours. During this period, the
sensor should be wet.

1. Remove the sensor from the application if necessary. Clean and rinse
if required.

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2. Place about an inch of zero solution in a small beaker or other
convenient container and immerse the tip of the sensor. Allow the
sensor to sit undisturbed for at least 15 minutes. Suspend sensor, DO
NOT LET SENSOR SIT ON TIP.

3. Scroll to the CAL menu section using the MENU key and press ENTER
or the UP arrow key. Cal D.O. will then be displayed.

4. Press the ENTER key. The screen will display a flashing 1-spl for 1­point, a 2-%sat for Saturation air calibration, or a 3-zer for zero
calibration. Using the UP arrow key, set for a 3-Zer zero calibration
and press ENTER.

5. The system now begins acquiring data for the sensor zero calibration
value. As data is gathered, the units for sensor millivolts (mV) and
temperature may flash. Flashing units indicate that this parameter is
unstable. The calibration data point acquisition will stop only when the
data remains stable for a pre-determined amount of time. This can be
overridden by pressing ENTER.

6. If the data remains unstable for 10 minutes, the calibration will fail and
the message Cal Unstable will be displayed.

7. If accepted, the screen will display the message PASS with the new
sensor zero reading (offset), 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. The range of acceptable value for sensor offset is -40 mV to +40
mV. Review the Service section of this manual, and then contact the
service dept. at ATI for further assistance.

The sensor offset value in mV from the last zero calibration is displayed on
the lower line of the Default Menus for information purposes.

6.2 Temperature Calibration

The temperature calibration sequence is essentially a 1-point offset
calibration that allows adjustments of approximately ± 5°C. If sensor cable
lengths beyond the standard cable length are being used the resistance of
this added cable will affect the temperature accuracy and will have to be
off-set to compensate for this added resistance.

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Cable length Temperature off-set
30 m (98 ft) -1.09º C
50 m (164 ft) -1.82º C
61 m (200 ft) -1.90º 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. In any case, it is critical that the sensor be allowed to reach
temperature equilibrium with the solution in order to provide the highest
accuracy. When moving the sensor between widely different temperature
conditions, it may be necessary to allow the sensor to stabilize as much as
one hour before the calibration sequence is initiated. If the sensor is on­line, the user may want to set the output HOLD feature prior to calibration
to lock out any output fluctuations.

1. Scroll to the CAL menu section using the MENU key and press ENTER
or the UP arrow key.

2. Press the UP arrow key until Cal Temp is displayed.

3. Press the ENTER key. The message Place sensor in solution then
press ENTER will be displayed. Move the sensor into the calibration
reference (if it hasn’t been moved already) and wait for temperature
equilibrium to be achieved. Press ENTER to begin the calibration
sequence.

4. The calibration data gathering process will begin. The message Wait
will flash as data is accumulated and analyzed. The °C or °F symbol
may flash periodically if the reading is too unstable.

5. The message Adjust value - press ENTER will be displayed, and the
right-most digit will begin to flash, indicating that the value can be
modified. Using the UP and LEFT arrow keys, modify the value to the
known ref solution temperature. Adjustments up to ± 5°C from the
factory calibrated temperature are allowed. Press ENTER.

Once completed, the display will indicate PASS or FAIL. If the unit fails,
the temperature adjustment may be out of range, the sensor may not have
achieved complete temperature equilibrium, or there may be a problem
with the temperature element. In the event of calibration failure, it is
recommended to attempt the calibration again immediately.

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Part 7 – PID Controller Details

7.1 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. The savings can be
substantial when compared to a system which may be simply adding chemical at
a constant rate to maintain some minimal addition under even the worst case
conditions. The PID output controller is highly advantageous over simple control
schemes that just utilize direct (proportional only) 4-20 mA output connections for
control, since the PID controller can automatically adjust the “rate” of recovery
based on the error between the setpoint and the measured value – which can be
a substantial efficiency improvement..

The PID controller is basically designed to provide a “servo” action on the 4-20
mA output to control a process. If the user requires that a measured process
stay as close as possible to a specific setpoint value, the controller output will
change from 0% to 100% in an effort to keep the process at the setpoint. To
affect this control, the controller must be used with properly selected control
elements (valves, proper chemicals, etc.) that enable the controller to add or
subtract chemical rapidly enough. This is not only specific to pumps and valves,
but also to line sizes, delays in the system, etc.

This section is included to give a brief description of tuning details for the PID
controller, and is not intended to be an exhaustive analysis of the complexities of
PID loop tuning. Numerous sources are available for specialized methods of
tuning that are appropriate for a specific application.

7.2 PID Algorithm

As most users of PID controllers realize, the terminology for the actual algorithm
terms and even the algorithms themselves can vary between different
manufacturers. This is important to recognize as early as possible, since just
plugging in similar values from one controller into another can result in
dramatically different results. There are various basic forms of PID algorithms
that are commonly seen, and the implementation here is the most common
version; The ISA algorithm (commonly referred to as the “ideal” algorithm.)

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tde

dt

)(

ù
ú

û

é
ê

ë

1

tePoutput

)(

ò

I

)()(

Where:

output = controller output
P = proportional gain
I = integral gain
D = derivative gain
t = time
e(t) = controller error (e=measured variable – setpoint)

Figure 20 - Q46 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”
form.) If a pre-existing controller utilizes the same form of the algorithm shown
above, it is likely similar settings can for made if the units on the settings are
exactly the same. Be careful of this, as many times the units are the reciprocals
of each other (i.e. reps-per-min, sec-per-rep.)

PID stands for “proportional, integral, derivative.” These terms describe the three
elements of the complete controller action, and each contributes a specific
reaction in the control process. The PID controller is designed to be primarily
used in a “closed-loop” control scheme, where the output of the controller directly
affects the input through some control device, such as a pump, valve, etc.

Although the three components of the PID are described in the setting area
(section 6.25), here are more general descriptions of what each of the PID
elements contribute to the overall action of the controller.

P Proportional gain. With no “I” or “D” contribution, the controller output is

simply a factor of the proportional gain multiplied by the input error
(difference between the measured input and the controller setpoint.)
Because a typical chemical control loop cannot react instantaneously to a
correction signal, proportional gain is typically not efficient by itself – it
must be combined with some integral action to be useful. Set the P term to
a number between 2-4 to start. Higher numbers will cause the controller
action to be quicker.

I 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. Like
proportional gain, increasing integral gain results in the control action
happening quicker. Set the I term to a number between 3-5 to start (1-2
more than P). Like proportional gain, increasing the integral term will
cause the controller action to be quicker.

++=

Dtdte

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D 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. However, as a starting point for chemical process control, its best
to leave the “D” term set to 0.

Based on these descriptions, the focus on tuning for chemical applications really
only involves adjustment of “P” and “I” in most cases. However, increasing both
increases the response of the controller. The difference is in the time of recovery.
Although combinations of high “P’s” and low “I” will appear to operate the same
as combinations of low “P’s” and high “I’s”, there will be a difference in rate of
recovery and stability. Because of the way the algorithm is structured, large “P’s”
can have a larger impact to instability, because the proportional gain term
impacts all the other terms directly. Therefore, keep proportional gain lower to
start and increase integral gain to achieve the effect required.

Many of the classical tuning techniques have the user start with all values at 0,
and then increase the P term until oscillations occur. The P value is then
reduced to ½ of the oscillatory value, and the I term is increased to give the
desired response. This can be done with the Q46D controller, with the exception
that the I term should start no lower than 1.0.

If it appears that even large amounts of integral gain (>20) don’t appreciably
increase the desired response, drop I back to about 1.0, and increase P by 1.00,
and start increasing I again. In most chemical control schemes, I will be
approximately 3 times the value of P.

7.3 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. In
fact, the risk of instability is far greater with overly tuned PID control schemes. In
addition, many of the classical mathematical exercises can be damaging or
wasteful in the use of chemicals when the process is bumped with large amounts
of input error to seek a response curve. Because of this, the general adjustment
guidelines described in section 7.2 are sufficient for almost all application tuning
for this instrument. Beyond this, many sources are available for classical tuning
methods.

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ATI Q46D-ODO Optical D.O. System Part 7 –PID Controller Details

7.4 Manual PID Override Control

The Q46 electronics is equipped designed to allow the user to take manual
control of the PID output. 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.

To access the manual PID control, you must be in the MEASURE mode of
operation and you must have the PID output displayed on the lower line. This
line will indicate “XX.X% XX.X mA” with the X values simply indicating the
current values. With this display on the screen, press and hold the ENTER key
for about 5 seconds. You will see a small “m” show up between the % value and
the mA value. This indicates you are now in manual mode.

Once in manual, you may increase the PID output by pressing the UP arrow or
you may decrease the output by pressing the LEFT arrow. This will allow you to
drive the PID output to any desired setting.

To revert to normal PID control, press and hold the ENTER key again until the
“m” indicator disappears.

7.5 Common PID Pitfalls

The most common problem occurring in PID control applications involves the
false belief that proper settings on only the PID controller can balance any
process to an efficient level.

Close-loop control can only be effective if all elements in the loop are properly
selected for the application, and the process behavior is properly understood.
Luckily, the nature of simple chemical control process’ are generally slow in
nature. Therefore, even a de-tuned controller (one that responds somewhat
slowly) can still provide substantial improvements to setpoint control. In fact,
damaging oscillatory behavior is far more likely in tightly tuned controllers where
the user attempted to increase response too much.

When deciding on a PID control scheme, it is important to initially review all
elements of the process. Sticking valves, undersized pumps, or delays in
reaction times associated with chemical addition can have a dramatic effect on
the stability of the control loop. When controlling a chemical mix or reaction, the
sensor should be placed in a location that ensures proper mixing or reaction time
has occurred.

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The easiest process’ 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. Chemical control process’ can be more problematic when the
nature of the setpoint value is non-linear relative to the input of chemical added.
For example, D.O. control of a process may appear linear only in a certain range
of operation, and become highly exponential at the extreme ranges of the
measuring scale. In addition, if a chemical process is not symmetrical, that
means it responds differentially to the addition and subtraction of chemical. It is
important in these applications to study steady-state impact as well as step­change impact to process changes. In other words, once the process has
apparently been tuned under normal operating conditions, the user should
attempt to force a dramatic change to the input to study how the output reacts. If
this is difficult to do with the actual process input (the recommended method), the
user can place the control in manual at an extreme control point such as 5% or
95%, and release it in manual. The recovery should not be overly oscillatory. If
so, the loop needs to be de-tuned to deal with that condition (reduce P and/or I.)

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Part 8 – System Maintenance

8.1 General

The Q46D/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. Keep in mind
that preventive maintenance on a regular schedule is much less troublesome
than emergency maintenance that always seems to come at the wrong time.

8.2 Analyzer Maintenance

No unusual maintenance of the analyzer is required if installed according to the
guidelines of this operating manual. If the enclosure door is frequently opened
and closed, it would be wise to periodically inspect the enclosure sealing gasket
for breaks or tears.

8.3 Sensor Maintenance

Very little sensor maintenance is required for an optical D.O. system. The
primary requirement is simply to keep the sensing area clean. The photo in
section 3 of this manual shows the sensitive area. Inspect the sensor every few
weeks visually just to verify that this area is clean. Wipe with a soft cloth if
necessary.

The life of the optical element is likely to be greater than 2 years but less than 5
years. When the optical sensing element is expended, a new one can easily be
installed.

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Part 9 – Troubleshooting

9.1 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. Therefore, this section
is organized from the approach of excluding any likely external
sources, isolating the analyzer, and finally isolating the sensor. If
these procedures still do not resolve the operational problems, any
results the operator may have noted here will be very helpful when
discussing the problem with the factory technical support group.

9.2 External Sources of Problems

To begin this process, review the connections of the system to all

external connections.

1. Verify the analyzer is earth grounded. For all configurations of
the analyzer, an earth ground connection MUST be present for
the shielding systems in the electronics to be active. Grounded
conduit provides no earth connection to the plastic enclosure, so
an earth ground wiring connection must be made at the power
input terminal strip. Use the special “shield terminal” stub on the
power supply board for optimum sensor cable shield grounding.

2. Verify the proper power input is present (115/230 VAC.)

3. Verify the loads on any 4-20 mA outputs do not exceed the
limits in the Instrument Specifications (500 Ohms each for
analyzer.) During troubleshooting, it is many times helpful to
disconnect all these outputs and place wire-shorts across the
terminals in the instrument to isolate the system and evaluate
any problems which may be coming down the analog output
connections.

4. Do not run sensor cables or analog output wiring in the same
conduits as power wiring. If low voltage signal cables must
come near power wiring, cross them at 90° to minimize
coupling.

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ATI Q46D-ODO Optical D.O. System Part 9 – Troubleshooting

5. If rigid conduit has been run directly to the Q46 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. If readings are very erratic after wiring has been
checked, check for a possible AC ground loop by temporarily
placing the sensor into a bucket of water. The reading should
be initially stable and then fall very slowly in a smooth fashion
as the powered sensor depletes oxygen in the static sample
directly at the sensor face.

7. On relay based systems, check the load that is connected to the
relay contacts. Verify the load is within the contact rating of the
relays. Relay contacts which have been used for higher power
AC current loads may become unsuitable for very low signal DC
loads later on because a small amount of pitting can form on the
contacts. If the load is highly inductive (solenoids, motor
starters, large aux relays), note that the contact rating will be de­rated to a lower level. Also, due to the large amount of energy
present in circuits driving these types of loads when they are
switched on an off, the relay wiring placement can result in
electrical interference for other devices. This can be quickly
resolved by moving wiring, or by adding very inexpensive
snubbers (such As Quencharcs) to the load.

8. Carefully examine any junction box connections for loose wiring
or bad wire stripping. If possible, connect the sensor directly to
the analyzer for testing.

9. Check sensor for fouling. Look closely for signs of grease or oil
which may be present.

9.3 Analyzer Tests

1. Disconnect power and completely disconnect all output wiring

coming from the analyzer. Remove sensor wiring, relay wiring,
and analog output wiring. Re-apply power to the analyzer.
Verify proper voltage (115 or 230 VAC) is present on the
incoming power strip of the analyzer, and that the analyzer
power label matches the proper voltage value.

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ATI Q46D-ODO Optical D.O. System Part 9 – Troubleshooting

2. If analyzer does not appear to power up (no display), remove
power and check removable fuse for continuity with a DVM.

3. Using a DVM, check the voltage across the BLUE and WHITE
wires coming from the power supply board in the base of the
enclosure. FIRST, disconnect any wiring going to Iout#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.

4. If analyzer does power up with a display, use the “Simulate”
feature to check operation of the analog outputs (and relays
contacts with a DVM.)

5. Check sensor power circuits. With a DVM, verify between -4.5
and -5.5 VDC from sensor connection terminals WHITE (+) to
BLACK (-). Then verify between +4.5 and +5.5VDC from
GREEN (+) to BLACK (-).

6. Check TC drive circuit. Place a wire-short between the RED
and BLACK sensor terminals. With a DVM, measure the
voltage between the BLACK (-) and BROWN (+) sensor
terminals to verify that the TC drive circuit is producing about -

4.6 to -5.5 VDC open-circuit. Remove DVM completely and
connect a 1000 Ohm resistor across the BLACK to BROWN
terminals. The temperature reading on the front LCD should
display approximately 0°C and the dissolved oxygen reading
should display approximately 0 ppm.

9.31 Display Messages

The Q46 Series instruments provide a number of diagnostic

messages which indicate problems during normal operation and
calibration. These messages appear as prompts on the secondary
line of the display or as items on the Fault List.

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ATI Q46D-ODO Optical D.O. System Part 9 – Troubleshooting

MESSAGE

DESCRIPTION

POSSIBLE CORRECTION

Max is 200

Min is 200

Cal Unstable

Calibration problem, data too unstable to

calibrate. Icons will not stop flashing if data is too

or, get fresh cal solutions, allow

temperature and conductivity readings to fully

stabilize, do not handle sensor or cable during

Out of Range

Input value is outside selected range of the

limits of the function to be

Locked!

Enter security code to allow modifications to

Unlocked!

Displayed just after security code has been

Offset High

The sensor zero offset point is out of the

Check wiring connections to sensor. Allow

sensor to operate powered a minimum of 2

Sensor High

too high and

Sensor Low

D.O. High

The oxygen reading is greater than the maximum

he oxygen reading is over operating limits.

Temp High

The temperature reading is over operating

limits. Check wiring and expected temp level.

ed in sensor

manual. Recalibrate sensor temperature

Temp Low

TC Error

Check sensor wiring and perform RTD test as

box

Entry failed, maximum user value allowed is 200.

Entry failed, minimum value allowed is 200.

unstable. User can bypass by pressing ENTER.

specific list item being configured.

Transmitter security setting is locked.

Transmitter security has just been unlocked.

acceptable range of -40 to +40 mV.

The raw signal from the sensor is
out of instrument range.

The raw signal from the sensor is too low.

of the User-selected range.

Reduce value to ≤ 200

Increase value to ≥ 200

Clean sens

calibration.

Check manual for
configured.

settings.

entered.

hours prior to first zero cal.

Check wiring connections to sensor.

Check wiring connections to sensor.

T
Set measuring range to the next highest level.

The temperature reading is > 55ºC.

Perform RTD test as describ

element if necessary.

The temperature reading is < -10 ºC

TC may be open or shorted.

Same as “Temp High” above.

described in sensor manual. Check j­connections.

Figure 21 - Q46D Display Messages

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ATI Q46D-ODO Optical D.O. System Part 9 – Troubleshooting

MESSAGE

DESCRIPTION

POSSIBLE CORRECTION

D.O. Cal Fail

Failure of oxygen calibration. FAIL icon will

not extinguish until successful calibration

d, or 30 minutes passes

with no keys being pressed.

Clean sensor redo zero and span calibration.

If still failure, sensor slope may be less than

20% or greater than 500%. Perform sensor

tests as described in section 10.4. Replace

TC Cal Fail

Failure of temperature calibration. FAIL icon

will not extinguish until successful

calibration has been performed, or 30

minutes passes with no keys being

Clean sensor, check cal solution temperature

ibration. TC

calibration function only allows adjustments

C. If still failure, perform sensor

tests as described in section 10.4. Replace

EPROM Fail

Chcksum Fail

Display Fail

Range Cal Fail

has been performe

sensor if still failure.

and repeat sensor temp cal

of +/- 6 º

pressed.

sensor if still failure. .

Internal nonvolatile memory failure

Internal software storage error.

Internal display driver fail.

Failure of factory temperature calibration.

9.4 Sensor Tests

1. Check the condition of the optical sensing element. Mechanical damage to
the black covering over the optical element is an indication that sensor
problems are likely.

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 2 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. This value is affected by temperature, pressure, and age of the sensor
so it’s possible to see a typical value that ranges from perhaps +200mVDC to
about +800 mVDC under a wide range of conditions in air.

System failure, consult factory.

System failure, consult factory.

System failure, consult factory.

Consult factory.

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ATI Q46D-ODO Optical D.O. System Part 9 – Troubleshooting

3. Disconnect the five sensor wires from the oxygen monitor. Those wires are
color coded red, white, blue, green, brown, and black. Note: the brown wire
may be replaced by an orange wire in some cables. Connect the DVM
between the brown and black wires. These are the RTD leads, and you
should find a resistance value that depends on the temperature. The table
below lists the resistance values for various temperatures.

Temperature
°C
0 1000
5 1019
10 1039
15 1058
20 1078
25 1097
30 1117
35 1136
40 1155
45 1175
50 1194

Resistance
W

Figure 22 - Pt1000 RTD Table

If you suspect that water has gotten into a cable connection or into

the plug connection of a submersible sensor, disconnect the cable
and allow the parts of the sensor to sit in a warm place for 24
hours. If water in the connector is the problem, it should dry out
sufficiently to allow normal sensor operation.

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Barometric Pressure Conversion

Inches of

Mercury(inHg)

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

25.50 647.7 +4233

26.00 660.4 +3682

26.50 673.1 +3156

27.00 685.5 +2653

27.50 698.5 +2150

28.00 711.2 +1675

28.50 723.9 +1217

Millimeters of

Mercury (mmHg)

Feet Above

Sea Level

29.00 736.6 +776

29.50 749.3 +349

30.00 762.0 -64

30.50 774.7 -463

31.00 784.4 -759

Figure 23 - Reference Barometric Pressure Conversion

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Oxygen Solubility vs. Temperature

Temperature

°F °C

32 0.0 14.6 74 23.3 8.5

34 1.1 14.1 76 24.4 8.3

36 2.2 13.7 78 25.6 8.2

38 3.3 13.3 80 26.7 8.0

40 4.4 12.9 82 27.8 7.8

42 5.6 12.6 84 28.9 7.7

44 6.7 12.2 86 30.0 7.5

46 7.8 11.9 88 31.1 7.4

48 8.9 11.6 90 32.2 7.3

50 10.0 11.3 92 33.3 7.1

52 11.1 11.0 94 34.4 7.0

54 12.2 10.7 96 35.6 6.9

56 13.3 10.4 98 36.7 6.8

58 14.2 10.2 100 37.8 6.6

PPM

Temperature

°F °C

PPM

60 15.6 9.9 102 38.9 6.5

62 16.7 9.7 104 40.0 6.4

64 17.8 9.5 106 41.1 6.3

66 18.9 9.3 108 42.2 6.2

68 20.0 9.1 110 43.3 6.1

70 21.1 8.9 112 44.4 6.0

72 22.2 8.7 114 45.6 5.9

Figure 24 - Reference Oxygen Solubility Table

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Spare Parts

Model Q46D Optical D.O. System

Part No. Description

03-0393 Q46D Front Lid electronics assembly
07-0320 AC Powered monitor electronics assembly, 100-240 VAC
07-0321 DC Powered monitor electronics assembly 12-24 VDC
07-0322 AC Powered monitor electronics assembly w/Profibus, 100-240 VAC
07-0323 DC Powered monitor electronics assembly w/Profibus, 12-24 VDC
63-0100 Submersible O.D.O. Sensor with 30’ cable
63-0103 Replacement optical element for 63-0100 sensor
03-0387 Optional 3-relay PCB Assy
03-0388 Optional 4-20 mA PCB Assy
07-0100 Junction box
31-0038 Interconnect cable for junction box to monitor wiring
23-0029 Fuse, 630mA, 250V, TR-5 (for AC and DC Analyzers)
38-0072 Terminal block plug, 3 position (Relays)
38-0073 Terminal block plug, 4 position (Outputs)
38-0074 Terminal block plug, 3 position (Cable Shields)
38-0081 Terminal block plug, 3 position (Power)

Lock/Unlock Code: 1463

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