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ATI 

Q45D-ODO Optical D.O. System  

 

Part 9– Troubleshooting

 

 

O & M Manual 
Revision C (7/09) 

 63 - 

 

MESSAGE

 

DESCRIPTION

 

 

POSSIBLE CORRECTION

 

D.O. Cal Fail

 

Failure of oxygen calibration.  FAIL icon will 
not  extinguish  until  successful  calibration 
has been performed, 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 
sensor if still failure.

 

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 
pressed.  

 

 

Clean sensor, check cal solution temperature 
and  repeat  sensor  temp  calibration.    TC 
calibration  function  only  allows  adjustments 
of  +/-  6  ºC.    If  still  failure,  perform  sensor 
tests  as  described  in  section  10.4.    Replace 
sensor if still failure.  .

 

EPROM Fail

 

Internal nonvolatile memory failure

 

 

System failure, consult factory.

 

Chcksum Fail

 

Internal software storage error.

 

 

System failure, consult factory.

 

Display Fail

 

Internal display driver fail.

 

 

System failure, consult factory.

 

Range Cal Fail

 

Failure of factory temperature calibration.

 

 

Consult factory.

 

 

Figure 9-1   Q45D Display Messages (continued) 

 
 
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 p200mVDC to 
about +800 mVDC under a wide range of conditions in air.    

Содержание Q45D/60

Страница 1: ...Analytical Technology Inc Analytical Technology 6 Iron Bridge Drive Bank Chambers 33 Stamford St Collegeville PA 19426 Mossley Ashton u Lyne OL50LL Ph 800 959 0299 Ph 0800 018 4020 610 917 0991 44 0 1...

Страница 2: ...exposure to excessive gas concentrations Should inspection indicate that sensors have been expended rather than failed prematurely the warranty shall not apply The Manufacturer assumes no liability f...

Страница 3: ...igure 3 1 Submersible D O Sensor Assembly ATI 0870 15 3 2 Optical Sensing 16 Figure 3 2 Optical Sensing Element 16 3 3 Submersion Mounting 17 Figure 3 3 Submersible Sensor Mounting Assembly ATI 0872 1...

Страница 4: ...7 2 PID Algorithm 53 Figure 7 1 Q45 ISA Ideal PID Equation 54 7 3 Classical PID Tuning 55 7 4 Manual PID Override Control 56 7 5 Common PID Pitfalls 56 PART 8 SYSTEM MAINTENANCE 58 8 1 General 58 8 2...

Страница 5: ...des two components the Q45D analyzer and optical dissolved oxygen ODO sensor For connection of the sensor to the electronics a 30 cable is supplied Up to an additional 100 feet of interconnect cable m...

Страница 6: ...rnal 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 characte...

Страница 7: ...7 6 mm 5x7 dot matrix Integral LED back light for visibility in the dark Keypad 4 key membrane type with tactile feedback polycarbonate with UV coating Weight DC transmitter configuration 1 lb 0 45 kg...

Страница 8: ...cket standard Bracket suitable for either 1 5 or 2 I D U Bolts for pipe mounting Conduit Openings Two PG 9 openings with gland seals DC Cable Type Belden twisted pair shielded 22 gauge or larger Inser...

Страница 9: ...each output Outputs ground isolated and isolated from each other 1 5 Q45D Performance Specifications Common to all variations Accuracy 0 2 of selected range or better Repeatability 0 05 of selected r...

Страница 10: ...ring calibration The sensor to instrument distance should not exceed 100 feet To maximize signal to noise ratio however work with the shortest sensor cable possible The standard cable length of the ox...

Страница 11: ...ATI Q45D ODO Optical D O System Part 2 Analyzer Mounting O M Manual Revision C 7 09 10 Figure 2 1 Q45 Enclosure Dimensions AC Powered Units ATI 0706...

Страница 12: ...ATI Q45D ODO Optical D O System Part 2 Analyzer Mounting O M Manual Revision C 7 09 11 Figure 2 2 Q45 Enclosure Dimensions 2 Wire and Battery Units ATI 0655...

Страница 13: ...ent 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 accomm...

Страница 14: ...ODO Optical D O System Part 2 Analyzer Mounting O M Manual Revision C 7 09 13 Figure 2 4 Wall Mounting Diagram ATI 0709 Figure 2 5 Pipe Mounting Diagram ATI 0710 E N T E R M E N U E S C E N T E R M E...

Страница 15: ...ear 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 fi...

Страница 16: ...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...

Страница 17: ...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 s...

Страница 18: ...e 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 sc...

Страница 19: ...ATI Q45D ODO Optical D O System Part 3 Optical D O Sensor O M Manual Revision C 7 09 18 Figure 3 4 Mounting Assembly Detail ATI 0873 Flexible Air Line applicable for Auto Clean Option Only...

Страница 20: ...in a dedicated conduit to prevent electrical noise from coupling with the instrumentation signals 3 This analyzer must be installed by specifically trained personnel in accordance with relevant local...

Страница 21: ...evision C 7 09 20 Figure 4 1 Loop Power Sensor Connections ATI 0874 Notes 1 Voltage between Terminals 7 and 8 MUST be between 16 and 35 VDC 2 Earth ground into Terminal 12 is HIGHLY recommended This c...

Страница 22: ...the 16 VDC represents insertion loss For example if a 24 VDC power supply is being used the load drive voltage is 8 VDC The maximum loop current of the two wire Q45 is always 20 00 mA or 02 A Therefo...

Страница 23: ...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 In the line powered unit a ribbon...

Страница 24: ...ectrical Installation O M Manual Revision C 7 09 23 Figure 4 2 Line Power Connection ATI 0761 The power strip TB5 allows up to 12 AWG wire A wire gauge of 16 AWG is recommended to allow for an easy pa...

Страница 25: ...al 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 signa...

Страница 26: ...ction For installations where the sensor is to be located more than 25 feet from the monitor max 100 feet a junction box must be used The junction box is shown in Figure 4 5 and is supplied with a con...

Страница 27: ...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 int...

Страница 28: ...Q45 this is also the ON button 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 valu...

Страница 29: ...d 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 impr...

Страница 30: ...he 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...

Страница 31: ...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...

Страница 32: ...lay A LO Phase A Hyst A LO Saturation CONTROL Fail Out 2 Failsafe If PID is enabled on I out 1 If Relay B set to Cln1 or Cln2 Note Some menu items are dependant on specifications in other menus Theref...

Страница 33: ...o 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 ac...

Страница 34: ...ry powered version of the transmitter the screens are basically the same with additions to show two analog outputs instead of one 1 and 2 The MEASURE screens are intended to be used as a very quick me...

Страница 35: ...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 initiat...

Страница 36: ...s of 0 01 or 0 02 PPM to be displayed as 0 00 PPM Atm Pres The Q45D instrument utilizes the atmospheric pressure value as an input for the calculation of a theoretical ppm value during a saturation ca...

Страница 37: ...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 Saturtion Press EN...

Страница 38: ...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 fu...

Страница 39: ...select the desired numerical value Press ENTER to store the new value 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...

Страница 40: ...mber 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 cont...

Страница 41: ...d 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...

Страница 42: ...red value selections include HI for direct operation or LO for reverse operation Press ENTER to store the new value See Figure 6 3 below for a visual description of a typical control relay application...

Страница 43: ...a typical alarm relay application Figure 5 4 Alarm Relay Example If Relay B Mode is set to CON then Relay B will function identically to Relay A Relay B settings appear in the CONFIG menu list automa...

Страница 44: ...ons are ON for engaging the HOLD function and OFF to disengage the function Press ENTER to store the new value Note When the Relay Option Board is installed the Set Hold function holds BOTH current le...

Страница 45: ...00 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 fl...

Страница 46: ...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...

Страница 47: ...cts to open 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 us...

Страница 48: ...r 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 op...

Страница 49: ...on 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 unsta...

Страница 50: ...he 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 proce...

Страница 51: ...ry 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 man...

Страница 52: ...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 displa...

Страница 53: ...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 mov...

Страница 54: ...ose 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 pr...

Страница 55: ...nput 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...

Страница 56: ...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 t...

Страница 57: ...ontrol 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 s...

Страница 58: ...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 t...

Страница 59: ...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 enclosu...

Страница 60: ...e 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 groun...

Страница 61: ...nductive solenoids motor starters large aux relays note that the contact rating will be de rated to a lower level Also due to the large amount of energy present in circuits driving these types of load...

Страница 62: ...ensor 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 w...

Страница 63: ...isplayed just after security code has been entered Offset High The sensor zero offset point is out of the acceptable range of 40 to 40 mV Check wiring connections to sensor Allow sensor to operate pow...

Страница 64: ...PROM Fail Internal nonvolatile memory failure System failure consult factory Chcksum Fail Internal software storage error System failure consult factory Display Fail Internal display driver fail Syste...

Страница 65: ...values for various temperatures Reading resistance between the red and green wires should give exactly the same values as between red and black Temperature C Resistance 0 1000 5 1019 10 1039 15 1058 2...

Страница 66: ...Sea Level 22 00 558 8 8790 22 50 571 5 8053 23 00 584 2 7347 23 50 596 9 6671 24 00 609 6 6023 24 50 622 3 5402 25 00 635 0 4806 25 50 647 7 4233 26 00 660 4 3682 26 50 673 1 3156 27 00 685 5 2653 27...

Страница 67: ...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...

Страница 68: ...ersible O D O Sensor with 30 cable 01 0242 Power supply circuit board assembly specify 115 or 230 VAC 07 0100 Junction box 31 0038 Interconnect cable for junction box to monitor wiring 23 0018 Fuse 10...

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