Hach Lange RTC105 N-Module User Manual
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Hach Lange RTC105 N-Module User Manual

Hach Lange RTC105 N-Module User Manual

Real-time control system for nitrogen removal
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DOC023.52.90217
RTC105 N/DN-Module
Real-Time Control System for Nitrogen Removal
User manual
02/2013, Edition 3A
© HACH-LANGE GmbH 2010, 2011, 2013. All rights reserved. Printed in Germany.

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  • Page 1 DOC023.52.90217 RTC105 N/DN-Module Real-Time Control System for Nitrogen Removal User manual 02/2013, Edition 3A © HACH-LANGE GmbH 2010, 2011, 2013. All rights reserved. Printed in Germany.

  • Page 3: Table Of Contents

    Table of Contents Section 1 Technical data ........................5 Section 2 General Information....................... 7 2.1 Safety information..........................7 2.1.1 Use of hazard information......................7 2.1.2 Precautionary labels ........................7 2.2 Areas of application ..........................8 2.3 Scope of delivery ..........................8 2.4 Instrument overview..........................
  • Page 4 Table of Contents 4.9 Explanations of nitrification/denitrification controller parameters ............28 4.9.1 Target values..........................28 4.9.2 Valuation ratio ..........................28 4.9.3 Time frame ..........................28 4.9.4 Increased biological phosphorous elimination (BIO-P) ............29 4.9.5 Gain factors ..........................29 4.9.6 Derivative times........................30 4.10 Explanations of oxygen controller (O control option) ..............31 4.10.1 General aeration parameters ....................31 4.10.2 Aeration control with stage actuation ..................31...

  • Page 5: Section 1 Technical Data

    Section 1 Technical data These are subject to change without notice. Embedded PC (compact industrial PC) Processor ®1 Pentium , MMX compatible, 500 MHz clock rate Flash memory 2 GB compact flash card Internal working memory 256 MB DDR-RAM (not expandable) Interfaces 1×...
  • Page 6 Technical data Release of aeration control for Digital inputs plants in accumulation operation (SBR, sequencing batch reactor) Number of inputs Nominal voltage 24 V DC (–15 % / +20 %) Signal voltage "0" –3 to +5 V Signal voltage "1" 15 to 30 V Input filter 30 ms...

  • Page 7: Section 2 General Information

    Note: You obtain instructions on the correct disposal of all (marked and not marked) electrical products that were supplied or manufactured by Hach-Lange at your relevant Hach-Lange sales office. C A U T I O N The manufacturer is not responsible for any damages due to misapplication or misuse of this product including, without limitation, direct, incidental and consequential damages, and disclaims such damages to the full extent permitted under applicable law.

  • Page 8: Areas Of Application

    General Information Areas of application The RTC105 N/DN-Module is a universally applicable open-loop and closed-loop controller for setting nitrification and denitrification times at waste water treatment plants, dependent on load. There are several variants available for plants that operate intermittently (non-continuous operation, charging) or in accumulation (SBR, Sequencing-Batch-Reactor).

  • Page 9: Instrument Overview

    General Information Instrument overview Figure 1 Base module RTC 24 V version PE (protective earth) sc 1000 connection: RS485 (CX1010-N031) 24 V Battery compartment CPU base module, consisting of Ethernet port with battery compartment (CX1010-N000), CPU module with CF card (CX1010-0021) and passive aeration element. Automatic circuit breaker (ON/OFF switch for item 7 and Power supply module, consisting of bus coupler 8 without fuse function).
  • Page 10 General Information Figure 2 Base module RTC 100-240 V version L(+) Automatic circuit breaker (ON/OFF switch for item 10 and 11 without fuse function). N(–) sc 1000 connection: RS485 (CX1010-N041) Input AVC 100–240 V / Input DC 95–250 V Battery compartment PE (protective earth) 10 CPU base module, consisting of Ethernet port with battery compartment (CX1010-N000), CPU module with...

  • Page 11: Theory Of Operation

    General Information Figure 3 Design of the analog and digital input and output modules Analog or digital input or output module LED area with installed LEDs or free LED installation or bus termination module spaces. Note: The number of LEDs indicates the number of channels. Theory of operation 2.5.1 Theory of operation of the RTC105 N/DN-Module...

  • Page 12: Controller Behavior With Low Nitrogen Content

    General Information The nitrification phase is complete, if • the deviation of the NH -N concentration and the NO -N concentration from their target values (if applicable, in conjunction with the decay rate of the NH concentration and the slew rate of the NO -N concentration) exceed a specific amount to the detriment of the NO -N concentration.

  • Page 13: Section 3 Installation

    Section 3 Installation D A N G E R Only qualified experts may perform the tasks described in this section of the manual, while adhering to all locally valid safety regulations. C A U T I O N Always lay cables and hoses so that they are straight and do not pose a tripping hazard. C A U T I O N Before switching on the power supply, you must refer to the instructions in the relevant operating manuals.

  • Page 14: Connecting The Sc 1000 Controller

    Installation Connecting the sc 1000 controller The supplied SUB-D connector is attached to a two-wire, shielded data cable (signal or bus cable). For additional information regarding the data cable connection, refer to the enclosed assembly instructions. Connection to the automation unit on the plant side Depending on the variant and option, the RTC105 N/DN-Module is equipped with various components that can be connected to the automation unit of the plant: •...
  • Page 15 Installation Table 2 Signal assignment of the individual assemblies of the RTC module RTC module options 1 channel 2 channel with with Assembly Designation Terminal Signal Assembly Container 1: +24 V/0 V nitrification/denitrification Container 1: aeration stage 1 +24 V/0 V ON/OFF Container 1: aeration stage 2 +24 V/0 V...
  • Page 16 Installation...

  • Page 17: Section 4 Parameterization And Operation

    Section 4 Parameterization and operation Operating the sc controller The RTC module can only be operated using the sc1000 controller, in conjunction with the RTC communication card. Before the RTC module is used, the user must be familiar with the functionality of the sc1000 controller. Learn how to navigate through the menu and perform the relevant functions.

  • Page 18: 1-Channel Closed-Loop Control

    Parameterization and operation 4.4.1 1-channel closed-loop control RTC MODULES / PROGNOSYS RTC MODULES CONFIGURE Selection list of available, relevant sensors for the RTC module in SELECT SENSOR the sc network (refer to 4.6 Select sensors on page 26). PRESELECT PROG. NH4-N &...

  • Page 19: 1-Channel Closed-Loop Control, Sbr Option

    Parameterization and operation 4.4.1 1-channel closed-loop control (Continued) RTC MODULES / PROGNOSYS RTC MODULES CONFIGURE (Continuation) MODBUS ADDRESS Start address of an RTC within the MODBUS network. Specifies the register order within a double word. Presetting: DATA ORDER NORMAL DATALOG INTRVL Indicates the interval in which the data is saved in the log file.

  • Page 20: 1-Channel Closed-Loop Control, O 2 Closed-Loop Control Option

    Parameterization and operation 4.4.3 1-channel closed-loop control, O closed-loop control option RTC MODULES / PROGNOSYS RTC MODULES CONFIGURE O2 control Maximum O concentration in the nitrification phase. (Refer to MAX O2 4.10.2.1 Maximum value MAX O2, minimum value MIN O2, [mg/L] page Minimum O...
  • Page 21 Parameterization and operation 4.5.1 2-channel closed-loop control (Continued) RTC MODULES / PROGNOSYS RTC MODULES CONFIGURE (continue) N/DN-CONTROL CHANNEL 1 TARGET VALUES (Refer to 4.9.1 Target values, page NH4-N Selected ammonium output value [mg/L] NO3-N Selected nitrate output value [mg/L] NH4/NO3 WEIGHT (Refer to 4.9.2 Valuation ratio, page [none]...
  • Page 22 Parameterization and operation 4.5.1 2-channel closed-loop control (Continued) RTC MODULES / PROGNOSYS RTC MODULES CONFIGURE (Continuation) N/DN-CONTROL (Continuation) CHANNEL 2 TARGET VALUES (Refer to 4.9.1 Target values, page NH4-N Selected ammonium output value [mg/L] NO3-N Selected nitrate output value [mg/L] NH4/NO3 WEIGHT (Refer to 4.9.2 Valuation ratio, page...
  • Page 23 Parameterization and operation 4.5.1 2-channel closed-loop control (Continued) RTC MODULES / PROGNOSYS RTC MODULES MAINTENANCE RTC DATA Specifies the value measured by the RTC, e. g. the influent RTC MEASUREMEN measurement. Specifies the variable calculated by the RTC, e. g. whether the RTC ACTUAT VAR aeration should be switched on or off.

  • Page 24: 2-Channel Closed-Loop Control, Sbr Option

    Parameterization and operation 4.5.2 2-channel closed-loop control, SBR option RTC MODULES / PROGNOSYS RTC MODULES CONFIGURE N/DN-CONTROL CHANNEL 1 TIME FRAME (Refer to 4.9.3 Time frame, page Preselection of phase with which the treatment process is to be START N/DN? started.

  • Page 25: 2-Channel Closed-Loop Control, O 2 Closed-Loop Control Option

    Parameterization and operation 4.5.3 2-channel closed-loop control, O closed-loop control option RTC MODULES / PROGNOSYS RTC MODULES CONFIGURE O2 CONTROL CHANNEL 1 Maximum O concentration in the nitrification phase. (Refer to MAX O2 4.10.2.1 Maximum value MAX O2, minimum value MIN O2, [mg/L] page Minimum O...

  • Page 26: Select Sensors

    Parameterization and operation Select sensors 1. To select sensors and their sequence for the RTC module, press RTC > CONFIGURE > SELECT SENSOR. Figure 4 Select sensor ENTER — Saves the setting and returns to the DELETE — Removes a sensor from the selection. CONFIGURE menu.
  • Page 27 Parameterization and operation 4. The selected sensor is shown in the sensor list. Press (Figure 4, item 3) to open the selection list again. 5. Select the second sensor for the RTC module and confirm by pressing below the selection list. ENTER Note: Previously selected sensors are shown in gray.

  • Page 28: Control Programs

    Parameterization and operation Control programs To adapt to local circumstances and the instruments available, there are 4 different programs available for calculating the time intervals for the nitrification and denitrification Table 3 Control programs to calculate the time intervals for nitrification and denitrification TIME CONTROL FIXED TIME FRAME NH4-N...

  • Page 29: Increased Biological Phosphorous Elimination (Bio-P)

    Parameterization and operation (1 cycle = 1 unaerated phase + 1 aerated phase). The desired cycle time shall lie between 90 and 360 minutes. High NH -N (NO -N) concentrations with low NO -N (NH concentrations require a check of the maximum times NITRI MAX .

  • Page 30: Derivative Times

    Parameterization and operation • only applies if both measurements (NH P GAIN NH4+NO3 and NO -N) are present. • only applies if only the NH -N measurement P GAIN NH4 supplies valid values. • only applies if only the NO -N measurement P GAIN NO3 supplies valid values.

  • Page 31: Explanations Of Oxygen Controller (O Control Option)

    Parameterization and operation 4.10 Explanations of oxygen controller (O control option) 4.10.1 General aeration parameters defines the number of the aeration stages. The NO. OF STAGES RTC105 N/DN-Module with the option for oxygen closed-loop control can actuate between 1 and 6 discrete aeration stages. Table 10 General aeration parameters, default setting NO.

  • Page 32: 4.10.2.3 Absorption

    Parameterization and operation 4.10.2.3 ABSORPTION The closed-loop controller contains an absorption to prevent too frequent switching. A switch procedure is triggered dependent on how much time has past since the last switch and to what extent a limit value has been exceeded or not met. An increase in the parameter causes a decrease in the switch ABSORPTION frequency between the fan stages.

  • Page 33: Section 5 Maintenance

    Section 5 Maintenance Maintenance schedule D A N G E R Multiple hazards Only qualified personnel must conduct the tasks described in this section of the manual. Interval Maintenance task Application-specific Check for contamination and corrosion Visual inspection Replacement by manufacturer's service CF card 2 years department...
  • Page 34 Maintenance...

  • Page 35: Section 6 Troubleshooting

    Section 6 Troubleshooting Error messages Possible RTC errors are displayed by the sc controller. Displayed errors Definition Resolution Supply RTC with voltage No communication between RTC and RTC Test connection cable RTC MISSING communication card Reset the sc1000 and the RTC (switch so it is completely voltage free and switch back on) Make sure +/- connections of the connector Interrupted communication between RTC and...
  • Page 36 Troubleshooting...

  • Page 37: Section 7 Replacement Parts And Accessories

    Section 7 Replacement parts and accessories Replacement Parts Description Cat. No DIN rail NS 35/15, punched according to DIN EN 60715 TH35, made of galvanized steel. LZH165 Length: 35 cm (13.78 in.) Transformer 90–240 V AC/24 V DC 0.75 A, module for top hat rail assembly LZH166 Terminal for 24 V connection without power supply LZH167...
  • Page 38 Replacement parts and accessories...

  • Page 39: Section 8 Contact Information

    HACH Company Repair Service in the Repair Service in Canada: Repair Service in World Headquarters United States: Latin America, the Hach Sales & Service Caribbean, the Far East, P.O. Box 389 HACH Company Canada Ltd. Indian Subcontinent, Africa, Loveland, Colorado...
  • Page 40 Contact information HACH LANGE D.O.O. ΗΑCH LANGE E.Π.Ε. HACH LANGE D.O.O. HACH LANGE MAROC SARLAU Fajfarjeva 15 Αυλίδος 27 Ivana Severa bb SI-1230 Domžale GR-115 27 Αθήνα HR-42 000 Varaždin Villa 14 – Rue 2 Casa Tel. +386 (0)59 051 000 Τηλ.

  • Page 41: Section 9 Warranty And Liability

    Section 9 Warranty and liability The manufacturer warrants that the supplied product is free of material and manufacturing defects, and undertakes to repair or to replace any defective parts without charge. The warranty period is 24 months. If a maintenance contract is taken out within 6 months of purchase, the warranty period is extended to 60 months.
  • Page 42 Warranty and liability...

  • Page 43: Appendix A Modbus Address Setting

    Appendix A MODBUS address setting The same slave address must be set for Modbus communication both on the sc1000 controller display and on the RTC105 N/DN-Module. Since 20 slave numbers are reserved for internal purposes, the following numbers are available for assignment: 1, 21, 41, 61, 81, 101…...
  • Page 44 MODBUS address setting...

  • Page 45: Index

    Index Accumulation operation ........... 12 Maintenance schedule ..........33 Address setting ............43 Maximum value ............31 Aeration element ..........9, 10 Minimum value ............31 Aeration parameters ..........31 Module Base ..............9, 10 Bus termination ............. 11 Base module ............9, 10 Input ..............
  • Page 46 Index...

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