HACH LANGE RTC103 N-Module, User Manual

Page 1: ...DOC023 52 90448 RTC103 N Module Real Time Control System for Ammonium Removal User manual 07 2013 Edition 1A HACH LANGE GmbH 2013 All rights reserved Printed in Germany ...

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Page 3: ...he sc1000 controller 15 3 3 Connecting the sc 1000 controller 16 3 4 Connection to the automation unit on the plant side 16 Section 4 Parameterization and operation 21 4 1 Operating the sc controller 21 4 2 System setup 21 4 3 Menu structure 21 4 3 1 SENSOR STATUS 21 4 3 2 SYSTEM SETUP 21 4 4 1 Channel RTC103 N Module parameterization on sc1000 controller 21 4 4 1 1 Channel RTC103 N Module 22 4 4 ...

Page 4: ...control 49 4 9 13 Min DO 49 4 9 14 Max DO 49 4 9 15 SMOOTHING 49 4 10 Explanations of DO CONTROL For DO control option only 49 4 10 1 P FAKT O2 For VFD option only 49 4 10 2 DERIVATIVE TIME 49 4 10 3 INT PART 49 4 10 4 DAMPING 49 4 10 5 SUBST AERATION 50 4 10 6 NUMBER OF STAGES 50 4 10 7 VFD P MIN For DO control without VFD option this is fixed to 100 50 4 11 INPUTS 50 4 11 1 MIN INFLOW 50 4 11 2 ...

Page 5: ...ues and variables 52 Section 5 Maintenance 53 5 1 Maintenance schedule 53 Section 6 Troubleshooting 55 6 1 Error messages 55 6 2 Warnings 55 6 3 Wear parts 55 Section 7 Replacement parts and accessories 57 7 1 Replacement Parts 57 Section 8 Contact information 59 Section 9 Warranty and liability 61 Appendix A MODBUS address setting 63 Index 65 ...

Page 6: ...6 Table of Contents ...

Page 7: ...d Power supply Via system bus through power supply module CX1100 0002 Max power loss 6 W including the system interfaces CX1010 N0xx Equipment properties Dimensions L W H 350 mm 120 mm 96 mm 13 78 in 4 72 in 3 78 in Weight Approximately 0 9 kg 1 98 lb Analog input 0 4 to 20 mA for flow rate measurement Internal resistance 80 ohm diode voltage 0 7 V Signal current 0 to 20 mA Common mode voltage UCM...

Page 8: ... the measuring range end value Resolution 12 bit Conversion time Approximately 1 5 ms Electrical isolation 500 Veff K bus field voltage Environmental conditions Working temperature 0 to 50 C 32 to 122 F Storage temperature 25 to 85 C 13 to 185 F Relative humidity 95 non condensing Miscellaneous Pollution degree Protection class Installation category Maximum altitude 3 III I 2000 m 6 562 ft Degree ...

Page 9: ...emphasis This symbol is a warning triangle Follow all safety notes that follow this symbol to prevent possible injuries If this symbol is located on the device it refers to information in the operating and or safety notes of the user manual This symbol can be attached to a housing or a barrier in the product and shows that electric shock risk and or the risk of a death through electric shock exist...

Page 10: ... distributor immediately NOTICE The use of an RTC module Real Time Controller does not release the operator from the responsibility of maintaining the system In particular the operator must make sure that instruments connected to the RTC open closed loop controller are always fully functional To make sure these instruments supply correct reliable measurement values regular maintenance work for exa...

Page 11: ...nection RS485 CX1010 N041 3 Input AVC 100 240 V Input DC 95 250 V 9 Battery compartment 4 PE protective earth 10 CPU base module consisting of Ethernet port with battery compartment CX1010 N000 CPU module with CF card CX1010 0021 and passive aeration element 5 24 V transformer Specifications refer section 3 1 1 page 15 11 Power supply module consisting of bus coupler CX1100 0002 and terminal modul...

Page 12: ...ow rate and the temperature in the aeration tank Optionally the Total Suspended Solids concentration in the aeration tank MLSS can be taken into account Based on that information a DO set point is calculated which is required to reach the desired NH4 N set point at the effluent of the aeration tank In addition to open loop control there is also a closed loop PID based on the NH4 N concentration at...

Page 13: ...ol can have up to 6 different aeration stages per channel e g in order to activate blower or activate discrete aeration intensities These aeration stages are activated by a min limit DO concentration and the calculated DO set point Option 3 RTC103 N Module with analog DO controller The RTC103 N Module is equipped with an additional DO controller which using 6 different aeration stages adjusts the ...

Page 14: ...14 General Information ...

Page 15: ...asurement signals of the sc sensors for measuring NH4 N TSS Dissolved Oxygen and Temperature e g AMTAX sc AN ISE sc AISE sc SOLITAX sc LDO2 sc are supplied to the RTC module via the RTC communication card YAB117 in the sc1000 3 2 1 Power supply of the sc sensors and the sc1000 controller See operating instructions of the respective sc sensors and the sc1000 controller DANGER Only qualified experts...

Page 16: ...r Q_RAS The other value has to be calculated C Q_xxx with minimum and maximum values Input signals from sc1000 via RTC communication card to RTC103 N module Common or individual NH4 N concentration inlet aeration Measuring points 1 Inflow 2 Settled Sewage and RAS Mixing Distribution Chamber 3 aeration tank after IRC input Common or individual NH4 N concentrations at the end of each lane DO concent...

Page 17: ...log intput KL3011 1 2 0 4 to 20 mA 1 Flow rate aeration lane 1 1 fold analog input KL3011 1 2 0 4 to 20 mA 2 Flow rate internal recirculation or return sludge lane 1 1 fold analog intput KL3011 1 2 0 4 to 20 mA 1 Flow rate aeration lane 2 1 fold analog input KL3011 1 2 0 4 to 20 mA 2 Flow rate internal recirculation or return sludge lane 2 Bus termination KL9010 Bus termination 1 Ground Connector ...

Page 18: ...aeration lane 1 1 fold analog input KL3011 1 2 0 4 to 20 mA 2 Flow rate internal recirculation or return sludge lane 1 1 fold analog intput KL3011 1 2 0 4 to 20 mA 1 Flow rate aeration lane 2 1 fold analog input KL3011 1 2 0 4 to 20 mA 2 Flow rate internal recirculation or return sludge lane 2 Bus termination KL9010 Bus termination 1 Ground Connector 3 and 7 24 V Connector 6 1 Channel RTC103 N Mod...

Page 19: ...2 ON OFF VFD 12 24 V 0 V 2 Aeration step 3 ON OFF 13 24 V 0 V 2 Aeration step 4 ON OFF 14 24 V 0 V 2 Aeration step 5 ON OFF 15 24 V 0 V 2 Aeration step 6 ON OFF 16 24 V 0 V 2 RTC Channel 2 operating 24V RTC failure 0V 2 fold analog output KL4012 0 4 to 20 mA 1 Output 1 VFD for DO control 0 4 to 20 mA 1 Output 2 VFD for DO control 2 fold analog output KL4012 0 4 to 20 mA 2 Output 1 VFD for DO contr...

Page 20: ...20 Installation ...

Page 21: ... Refer to Section 6 Troubleshooting page 55 for a list of all possible error and warning messages together with a description of all necessary countermeasures to be taken 4 3 2 SYSTEM SETUP The system setup is dependent on the number of channels For 1 channel refer to 4 4 1 Channel RTC103 N Module parameterization on sc1000 controller page 21 For 2 channel refer to 4 5 2 channel RTC103 N Module pa...

Page 22: ...4 N to be incorporated in the bio mass reducing the amount of NH4 N to be nitrified MIN NITRIFERS CONC Based on the amount of NH4 N nitrified during the last SRT the N RTC calculates the concentration of nitrifiers in the activated sludge This concentration is required to determine the DO set point If the calculated concentration is lower than the MIN NITRIFERS CONC the MIN NITRIFERS CONC will be ...

Page 23: ...control is available Derivation time for the PID closed loop controller for the NH4 N concentration effluent aeration Note DERIVATIVE TIME NH4 is set to 0 to deactivate the derivative part of the PID controller min LIMITS MIN DO If a calculated DO set point is lower than the MIN DO value the DO set point is set to that value mg L MAX DO If a calculated DO set point is higher than the MIN DO value ...

Page 24: ...low is calculated from the inflow Q RECI Q RECI RATIO INFLOW within the limits of MIN RECIRCULATION and MAX RECIRCULATION MIN RETURN SLUDGE Note 0 4 to20 mA input can be used either for Qreci or for Qras Minimum return sludge flow rate according to measurement signal corresponding to 0 4mA L s MAX RETURN SLUDGE Note 0 4 to20 mA input can be used either for Qreci or for Qras Maximum return sludge f...

Page 25: ...nd switch to adequate fall back strategy SET DEFAULTS Restores the factory settings MAINTENANCE RTC DATA RTC MEASUREMEN Specifies the value measured by the RTC e g the influent measurement RTC ACTUAT VAR Specifies the variable calculated by the RTC e g whether the aeration should be switched on or off DIAG TEST EEPROM Hardware test RTC COMM TO Communication time out RTC CRC Communication check sum...

Page 26: ...t the MLSS concentration in the aeration tank and the aerated volume the SRT is calculated kg d COD TKN RATIO This is the assumed COD TKN ratio The N RTC considers a certain COD related amount of NH4 N to be incorporated in the bio mass reducing the amount of NH4 N to be nitrified MIN NITRIFERS CONC Based on the amount of NH4 N nitrified during the last SRT the N RTC calculates the concentration o...

Page 27: ...N concentration effluent aeration Note DERIVATIVE TIME NH4 is set to 0 to deactivate the derivative part of the PID controller min LIMITS MIN DO If a calculated DO set point is lower than the MIN DO value the DO set point is set to that value mg L MAX DO If a calculated DO set point is higher than the MIN DO value the DO set point is set to that value mg L SMOOTHING Smoothing on the calculated DO ...

Page 28: ...om the inflow Q RECI Q RECI RATIO INFLOW within the limits of MIN RECIRCULATION and MAX RECIRCULATION MIN RETURN SLUDGE Note 0 4 to20 mA input can be used either for Qreci or for Qras Minimum return sludge flow rate according to measurement signal corresponding to 0 4mA L s MAX RETURN SLUDGE Note 0 4 to20 mA input can be used either for Qreci or for Qras Maximum return sludge flow rate of influent...

Page 29: ...to be incorporated in the bio mass reducing the amount of NH4 N to be nitrified MIN NITRIFERS CONC Based on the amount of NH4 N nitrified during the last SRT the N RTC calculates the concentration of nitrifiers in the activated sludge This concentration is required to determine the DO set point If the calculated concentration is lower than the MIN NITRIFERS CONC the MIN NITRIFERS CONC will be used...

Page 30: ...ed DO set point is lower than the MIN DO value the DO set point is set to that value mg L MAX DO If a calculated DO set point is higher than the MIN DO value the DO set point is set to that value mg L SMOOTHING Smoothing on the calculated DO set point min DO CONTROLL P GAIN DO Proportional factor for the PD closed loop controller for the DO concentrtion in the aeration 1 mg L DERIVATIVE TIME Deriv...

Page 31: ...e limits of MIN RECIRCULATION and MAX RECIRCULATION MIN RETURN SLUDGE Note 0 4 to20 mA input can be used either for Qreci or for Qras Minimum return sludge flow rate according to measurement signal corresponding to 0 4mA L s MAX RETURN SLUDGE Note 0 4 to20 mA input can be used either for Qreci or for Qras Maximum return sludge flow rate of influent according to measurement signal corresponding to ...

Page 32: ...t and switch to adequate fall back strategy SET DEFAULTS Restores the factory settings MAINTENANCE RTC DATA RTC MEASUREMEN Specifies the value measured by the RTC e g the influent measurement RTC ACTUAT VAR Specifies the variable calculated by the RTC e g whether the aeration should be switched on or off DIAG TEST EEPROM Hardware test RTC COMM TO Communication time out RTC CRC Communication check ...

Page 33: ...he MLSS concentration in the aeration tank and the aerated volume the SRT is calculated kg d COD TKN RATIO This is the assumed COD TKN ratio The N RTC considers a certain COD related amount of NH4 N to be incorporated in the bio mass reducing the amount of NH4 N to be nitrified MIN NITRIFERS CONC Based on the amount of NH4 N nitrified during the last SRT the N RTC calculates the concentration of n...

Page 34: ...GRAL TIME NH4 is set to 0 to deactivate the integral part of the PID controller min DERIVATIVE TIME NH4 Note These settings are only necessary if NH4 N measurement in effluent for feed back control is available Derivation time for the PID closed loop controller for the NH4 N concentration effluent aeration Note DERIVATIVE TIME NH4 is set to 0 to deactivate the derivative part of the PID controller...

Page 35: ...ted from the inflow Q RECI Q RECI RATIO INFLOW within the limits of MIN RECIRCULATION and MAX RECIRCULATION MIN RETURN SLUDGE Note 0 4 to20 mA input can be used either for Qreci or for Qras Minimum return sludge flow rate according to measurement signal corresponding to 0 4mA L s MAX RETURN SLUDGE Note 0 4 to20 mA input can be used either for Qreci or for Qras Maximum return sludge flow rate of in...

Page 36: ... control do not use this measurement and switch to adequate fall back strategy SET DEFAULTS Restores the factory settings MAINTENANCE RTC DATA RTC MEASUREMEN Specifies the value measured by the RTC e g the influent measurement RTC ACTUAT VAR Specifies the variable calculated by the RTC e g whether the aeration should be switched on or off DIAG TEST EEPROM Hardware test RTC COMM TO Communication ti...

Page 37: ...t the MLSS concentration in the aeration tank and the aerated volume the SRT is calculated kg d COD TKN RATIO This is the assumed COD TKN ratio The N RTC considers a certain COD related amount of NH4 N to be incorporated in the bio mass reducing the amount of NH4 N to be nitrified MIN NITRIFERS CONC Based on the amount of NH4 N nitrified during the last SRT the N RTC calculates the concentration o...

Page 38: ...EGRAL TIME NH4 is set to 0 to deactivate the integral part of the PID controller min DERIVATIVE TIME NH4 Note These settings are only necessary if NH4 N measurement in effluent for feed back control is available Derivation time for the PID closed loop controller for the NH4 N concentration effluent aeration Note DERIVATIVE TIME NH4 is set to 0 to deactivate the derivative part of the PID controlle...

Page 39: ...w measuring instrument Note The input is not connected to the 0 4 to 20 mA has to be calculated in ratio to Qinflow Q RECI RATIO Note 0 4 to20 mA input can be used either for Qreci or for Qras If the value Q RECI RATIO is 0 the RECI flow is calculated bases on the mA input signal If the value is different from 0 the RECI flow is calculated from the inflow Q RECI Q RECI RATIO INFLOW within the limi...

Page 40: ...TURN RATIO INFLOW within the limits of MIN RETURN SLUDGE and MAX RETURN SLUDGE CHANNEL 2 same as CHANNEL 1 VOLUME CHANNEL 1 VOLUME Aerated volume m3 CHANNEL 2 same as CHANNEL 1 4 5 2 2 Channel RTC103 N Module Stages Continued RTC MODULES PROGNOSYS RTC MODULES RTC 4 5 3 2 Channel RTC103 N Module VFD RTC MODULES PROGNOSYS RTC MODULES RTC CONFIGURE SELECT SENSOR Selection list of available relevant s...

Page 41: ...iders a certain COD related amount of NH4 N to be incorporated in the bio mass reducing the amount of NH4 N to be nitrified MIN NITRIFERS CONC Based on the amount of NH4 N nitrified during the last SRT the N RTC calculates the concentration of nitrifiers in the activated sludge This concentration is required to determine the DO set point If the calculated concentration is lower than the MIN NITRIF...

Page 42: ...TIME NH4 Note These settings are only necessary if NH4 N measurement in effluent for feed back control is available Derivation time for the PID closed loop controller for the NH4 N concentration effluent aeration Note DERIVATIVE TIME NH4 is set to 0 to deactivate the derivative part of the PID controller min LIMITS MIN DO If a calculated DO set point is lower than the MIN DO value the DO set point...

Page 43: ...ow measuring instrument Note The input is not connected to the 0 4 to 20 mA has to be calculated in ratio to Qinflow Q RECI RATIO Note 0 4 to20 mA input can be used either for Qreci or for Qras If the value Q RECI RATIO is 0 the RECI flow is calculated bases on the mA input signal If the value is different from 0 the RECI flow is calculated from the inflow Q RECI Q RECI RATIO INFLOW within the lim...

Page 44: ... Indicates the interval in which the data is saved in the log file min PROGNOSYS Activate or deactivate PROGNOSYS for RTC control Activate means if Measurement Indicator from relevant sensor decrease to 50 or lower RTC control do not use this measurement and switch to adequate fall back strategy SET DEFAULTS Restores the factory settings MAINTENANCE RTC DATA RTC MEASUREMEN Specifies the value meas...

Page 45: ...e RTC communication card YAB117 in the sc1000 RTC MODE Shows the installed RTC module variant e g 1 channel closed loop control RTC VERSION Shows the software version of the RTC module 4 5 3 2 Channel RTC103 N Module VFD Continued RTC MODULES PROGNOSYS RTC MODULES RTC 1 ENTER Saves the setting and returns to the CONFIGURE menu 4 DELETE Removes a sensor from the selection 2 CANCEL Returns to the CO...

Page 46: ...le refer to the PROGNOSYS user manual 4 The selected sensor is shown in the sensor list Press ADD Figure 4 item 3 to open the selection list again 5 Select the second sensor for the RTC module and confirm by pressing ENTER below the selection list Note Previously selected sensors are shown in gray The selected sensors are shown in the sensor list 6 To sort the sensors in the order specified for th...

Page 47: ... between programs occurs with a delay of 5 minutes 4 9 Explanations of nitrification controller parameters 4 9 1 SRT MODE Three different types of operation regarding the Sludge Retention Time SRT can be selected MANUALLY The SRT is provided as a manual input to the controller if no TSS measurement is available in aeration tank SRT RTC The SRT is provided by a separate SRT RTC and forwarded to the...

Page 48: ... used to determine the DO set point 4 9 6 MAX NITRIFERS CONC Based on the amount of NH4 N nitrified during the last SRT the RTC103 N Module calculates the concentration of nitrifiers in the activated sludge This concentration is required to determine the DO set point If the calculated concentration is higher than the MAX NITRIFERS CONC the MAX NITRIFERS CONC will be used to determine the DO set po...

Page 49: ...t is set to that value 4 9 14 Max DO If a calculated DO set point is higher than the MIN DO value the DO set point is set to that value 4 9 15 SMOOTHING Smooth this calculated DO set point for more economical blower control 4 10 Explanations of DO CONTROL For DO control option only Note The configuration for DO control different kind of blowers aeration stages has to be carefully pre configured fr...

Page 50: ...fluent according to measurement signal corresponding to 0 4mA 4 11 2 MAX INFLOW Maximum flow rate of influent according to measurement signal corresponding to 20mA 4 11 3 0 4 to 20mA Transfer range of 0 4 to 20mA current loop as set in connected flow measuring instrument 4 11 4 MIN RECIRCULATION Minimum recirculation flow rate according to measurement signal corresponding to 0 4mA 4 11 5 MAX RECIR...

Page 51: ...he RAS flow is calculated from the inflow Q RETURN Q RETURN RATIO INFLOW within the limits of MIN RETURN SLUDGE and MAX RETURN SLUDGE 4 12 OUTPUTS 4 12 1 MIN DO SETTING only for option without DO control Minimum DO set point corresponding to 0 4mA 4 12 2 MAX DO SETTING only for option without DO control Maximum DO set point corresponding to 20mA 4 12 3 0 4 to 20mA Transfer range of 0 4 to 20mA cur...

Page 52: ...L s Flow rate internal recirculation or return sludge lane 1 MEASUREMEN 3 Qin 2 L s Flow rate aeration lane 2 MEASUREMEN 4 Qrec 2 L s Flow rate internal recirculation or return sludge lane 2 ACTUAT VAR 5 NffO 1 mg L DO demand calc from influent load NffO 1 ACTUAT VAR 6 NfbO 1 mg L Additional DO demand calculated from NH4 N effluent concentration always 0 if no effluent NH4 N measurement available ...

Page 53: ...t conduct the tasks described in this section of the manual Interval Maintenance task Visual inspection Application specific Check for contamination and corrosion CF card 2 years Replacement by manufacturer s service department Section 8 page 59 Battery type CR2032 Panasonic or Sanyo 5 years Replacement ...

Page 54: ...54 Maintenance ...

Page 55: ...on of a new sc1000 participant From MAIN MENU RTC MODULES PROGNOSYS RTC MODULES RTC CONFIGURE SELECT SENSOR select the correct sensor for the RTC again and confirm RTC FAILURE Brief general read write error on the CF card mostly caused by a brief interruption to the power supply Acknowledge error If this message is shown frequently eliminate the cause of the power disruptions If necessary inform t...

Page 56: ...56 Troubleshooting ...

Page 57: ...lement CX1010 0021 and RS422 485 connection module CX1010 N031 LZH171 Power supply module consisting of a bus coupler and a 24 V terminal module CX1100 0002 LZH172 Digital output module 24 V DC 2 outputs KL2032 LZH173 Digital output module 24 V DC 4 outputs KL2134 LZH174 Analog output module 1 output KL4011 LZH175 Analog output module 2 outputs KL4012 LZH176 Analog input module 1 input KL3011 LZH1...

Page 58: ...58 Replacement parts and accessories ...

Page 59: ...0 15 41 61 20 info hach lange be www hach lange be DR LANGE NEDERLAND B V Laan van Westroijen 2a NL 4003 AZ Tiel Tel 31 0 344 63 11 30 Fax 31 0 344 63 11 50 info hach lange nl www hach lange nl HACH LANGE APS Åkandevej 21 DK 2700 Brønshøj Tel 45 36 77 29 11 Fax 45 36 77 49 11 info hach lange dk www hach lange dk HACH LANGE AB Vinthundsvägen 159A SE 128 62 Sköndal Tel 46 0 8 7 98 05 00 Fax 46 0 8 7...

Page 60: ...vana Severa bb HR 42 000 Varaždin Tel 385 0 42 305 086 Fax 385 0 42 305 087 info hach lange hr www hach lange hr HACH LANGE MAROC SARLAU Villa 14 Rue 2 Casa Plaisance Quartier Racine Extension MA Casablanca 20000 Tél 212 0 522 97 95 75 Fax 212 0 522 36 89 34 info maroc hach lange com www hach lange ma HACH LANGE OOO Finlyandsky prospekt 4A Business Zentrum Petrovsky fort R 803 RU 194044 Sankt Pete...

Page 61: ...iscovery of the fault If the customer fails to notify the supplier the product is considered approved despite the defect Further liability for indirect or direct damages is not accepted If device specific maintenance or inspection work prescribed by the supplier is to be performed within the guarantee period by the customer maintenance or by the supplier inspection and these requirements are not m...

Page 62: ...62 Warranty and liability ...

Page 63: ...urposes the following numbers are available for assignment 1 21 41 61 81 101 The start address 41 is preset at the factory N O T I C E If this address is to be or must be changed because for example it has already been allocated for another RTC module the changes must be made both on the sc1000 controller and on the CF card of the RTC module This can only be done by the manufacturer service depart...

Page 64: ...64 MODBUS address setting ...

Page 65: ...ansion slot 7 F Flash memory 7 I Input analog 7 Input module 12 Interfaces 7 M Maintenance schedule 53 Module Base 11 Bus termination 12 Input 12 Output 12 Terminal 11 O Operating system 7 Output digital 7 Output module 12 P Precautionary labels 9 S Safety information 9 Slave address 63 Supply voltage 15 T Technical data 7 Terminal module 11 Theory of operation 12 W Warnings 55 Warranty and liabil...

Page 66: ...66 Index ...