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HACH LANGE RTC103 N-Module User Manual

Real-time control system for ammonium removal
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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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Summary of Contents for HACH LANGE RTC103 N-Module

  • 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.

  • Page 3: Table Of Contents

    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 4.4.2 1-Channel RTC103 N-Module Stages ..................26 4.4.3 1-Channel RTC103 N-Module VFD ..................29 4.5 2-channel RTC103 N-Module parameterization on the sc1000 controller........
  • Page 4 Table of Contents 4.9 Explanations of nitrification controller parameters................47 4.9.1 SRT MODE ..........................47 4.9.2 SRT (MANUALLY) ........................48 4.9.3 DAILY SURPLUS MASS......................48 4.9.4 COD-TKN RATIO ........................48 4.9.5 MIN NITRIFERS CONC......................48 4.9.6 MAX NITRIFERS CONC......................48 4.9.7 MODEL CORRECTION FACT....................48 4.9.8 SUBSTIT.
  • Page 5 Table of Contents 4.13 Volume............................51 4.13.1 Aerated volume........................51 4.14 MODBUS ............................51 4.14.1 ADDRESS..........................51 4.14.2 DATAORDER ........................51 4.15 Displayed measurement values and variables ................52 Section 5 Maintenance ......................... 53 5.1 Maintenance schedule........................53 Section 6 Troubleshooting........................55 6.1 Error messages ..........................
  • Page 6 Table of Contents...

  • Page 7: 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 8 Technical data Analog output Outputs for DO setpoint or VFD control One-channel: 1 (KL4011); 1 (KL4012) VFD control  Number of outputs Two-channel: 1 (KL4012); 2 (KL4012) VFD control 24 V DC via the power contacts Supply voltage (Alternatively, 15 V DC with bus termination KL9515) Signal current 0/4 to 20 mA Working resistance...

  • Page 9: Section 2 General Information

    Section 2 General Information Safety information Please read this entire manual before unpacking, setting up, or operating this equipment. Pay attention to all danger and caution statements. Failure to do so could result in serious injury to the operator or damage to the equipment. To prevent damage to or impairment of the device's protection equipment, the device may only be used or installed as described in this manual.

  • Page 10: Areas Of Application

    General Information Areas of application The RTC103 N-Module is an universally applicable control unit which optimizes nitrification processes in wastewater treatment plants. In addition, the RTC103 N-Module can optionally be equipped with a closed-loop controller for setting the dissolved oxygen concentration (O ) in the activated sludge tank.

  • Page 11: Instrument Overview

    General Information Instrument overview Figure 1 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...

  • Page 12: Theory Of Operation

    (e.g. plug flow nitrification tanks or pre-denitrification). The RTC103 N-Module consists of an open-loop controller, based on NH -N influent concentration, flow rate, and the temperature in the aeration tank. Optionally, the Total Suspended Solids concentration in the aeration tank (MLSS) can be taken into account.
  • Page 13 PLC. Option 2: RTC103 N-Module with DO aeration stages controller The RTC103 N-Module is equipped with an additional DO controller adjusting the aeration intensity to reach the calculated DO concentration. The DO control can have up to 6 different aeration stages per channel (e.g.
  • Page 14 General Information...

  • Page 15: 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 16: Connecting The Sc 1000 Controller

    Connection to the automation unit on the plant side Depending on the variant (1-channel or 2-channel RTC103 N-Module, with or without DO control) the RTC103 N-Module is equipped with various components that have to be connected to the automation unit of the plant:...
  • Page 17 KL3011 1 - 2 0/4 to 20 mA lane 2 Bus termination KL9010 Bus termination Ground Connector 3 and 7, 24 V Connector 6. 1-Channel RTC103 N-Module DO aeration stages control Module Name Terminal Signal Channel Function +24 V/0 V...
  • Page 18 KL3011 1 - 2 0/4 to 20 mA lane 2 Bus termination KL9010 Bus termination Ground Connector 3 and 7, 24 V Connector 6. 1-Channel RTC103 N-Module connectors DO aeration stages / analog control Module Name Terminal Signal Channel Function +24 V/0 V...
  • Page 19 Installation 2-Channel RTC103 N-Module connectors DO aeration stages / analog control Module Name Terminal Signal Channel Function +24 V/0 V Input Signals ok (24V), Input signal faulty (0V) +24 V/0 V Aeration step 1 ON / OFF (VFD) +24 V/0 V...
  • Page 20 Installation...

  • Page 21: Section 4 Parameterization And Operation

    4.4 1-Channel RTC103 N-Module parameterization on sc1000 controller, page For 2-channel:  refer to 4.5 2-channel RTC103 N-Module parameterization on the sc1000 controller, page 32 1-Channel RTC103 N-Module parameterization on sc1000 controller The following menu entries can be found in the MAIN MENU.

  • Page 22: 1-Channel Rtc103 N-Module

    SRT MODE • SRT-RTC: The SRT is provided by a separate SRT-RTC and forwarded to the RTC103 N-Module • TSS mL: The SRT is calculated based on the TSS concentration and the amount of TSS daily removed. SRT (MANUALLY)
  • Page 23 Parameterization and operation 4.4.1 1-Channel RTC103 N-Module (Continued) RTC MODULES / PROGNOSYS RTC MODULES Note: These settings are only necessary if NH -N measurement in effluent for feed back control is available! P FACT NH4 [1/mg/L] Proportional factor for the PID closed loop controller for the NH4-N concentration effluent aeration.
  • Page 24 Parameterization and operation 4.4.1 1-Channel RTC103 N-Module (Continued) RTC MODULES / PROGNOSYS RTC MODULES Note: 0/4 to20 mA input can be used either for Qreci or for Qras. MIN RECIRCULATION [L/s] Minimum recirculation flow rate according to measurement signal corresponding to 0/4mA Note: 0/4 to20 mA input can be used either for Qreci or for Qras.
  • Page 25 Parameterization and operation 4.4.1 1-Channel RTC103 N-Module (Continued) RTC MODULES / PROGNOSYS RTC MODULES OUTPUTS MIN DO SETTING Minimum DO set point corresponding to 0/4mA [mg/L] MAX DO SETTING Maximum DO set point corresponding to 20mA [mg/L] Transfer range of 0/4 to 20 mA current loop as set in connected flow 0/4 to 20 mA measuring instrument.

  • Page 26: 1-Channel Rtc103 N-Module Stages

    SRT MODE • SRT-RTC: The SRT is provided by a separate SRT-RTC and forwarded to the RTC103 N-Module • TSS mL: The SRT is calculated based on the TSS concentration and the amount of TSS daily removed. SRT (MANUALLY)
  • Page 27 Parameterization and operation 4.4.2 1-Channel RTC103 N-Module Stages (Continued) RTC MODULES / PROGNOSYS RTC MODULES This factor can be used on order to fine tune the DO concentration MODEL CORRECTION FACT. calculated by the model (feed forward part of the N-RTC).
  • Page 28 Parameterization and operation 4.4.2 1-Channel RTC103 N-Module Stages (Continued) RTC MODULES / PROGNOSYS RTC MODULES Note: 0/4 to20 mA input can be used either for Qreci or for Qras. MIN RECIRCULATION [L/s] Minimum recirculation flow rate according to measurement signal corresponding to 0/4mA Note: 0/4 to20 mA input can be used either for Qreci or for Qras.

  • Page 29: 1-Channel Rtc103 N-Module Vfd

    SRT MODE • SRT-RTC: The SRT is provided by a separate SRT-RTC and forwarded to the RTC103 N-Module • TSS mL: The SRT is calculated based on the TSS concentration and the amount of TSS daily removed. SRT (MANUALLY)
  • Page 30 Parameterization and operation 4.4.3 1-Channel RTC103 N-Module VFD (Continued) RTC MODULES / PROGNOSYS RTC MODULES Note: These settings are only necessary if NH -N measurement in effluent for feed back control is available! P FACT NH4 [1/mg/L] Proportional factor for the PID closed loop controller for the NH4-N concentration effluent aeration.
  • Page 31 Parameterization and operation 4.4.3 1-Channel RTC103 N-Module VFD (Continued) RTC MODULES / PROGNOSYS RTC MODULES Note: 0/4 to20 mA input can be used either for Qreci or for Qras. MIN RECIRCULATION [L/s] Minimum recirculation flow rate according to measurement signal corresponding to 0/4mA Note: 0/4 to20 mA input can be used either for Qreci or for Qras.

  • Page 32: 2-Channel Rtc103 N-Module Parameterization On The Sc1000 Controller

    RTC VERSION Shows the software version of the RTC module. 2-channel RTC103 N-Module parameterization on the sc1000 controller In addition to the 1-channel version, there is also a 2-channel version that can control two activated sludge tanks. The relevant parameters therefore appear twice and are identified as channel 1 and channel 2.

  • Page 33: 2-Channel Rtc103 N-Module

    SRT MODE • SRT-RTC: The SRT is provided by a separate SRT-RTC and forwarded to the RTC103 N-Module • TSS mL: The SRT is calculated based on the TSS concentration and the amount of TSS daily removed. SRT (MANUALLY)
  • Page 34 Parameterization and operation 4.5.1 2-Channel RTC103 N-Module (Continued) RTC MODULES / PROGNOSYS RTC MODULES This factor can be used to fine tune the DO concentration calculated MODEL CORRECTION FACT. by the model (feed forward part of the N-RTC). If there is a failure in any of the input signals (NH4-N, TSS, Flow) the SUBSTIT.
  • Page 35 Parameterization and operation 4.5.1 2-Channel RTC103 N-Module (Continued) RTC MODULES / PROGNOSYS RTC MODULES Note: 0/4 to20 mA input can be used either for Qreci or for Qras. MIN RECIRCULATION [L/s] Minimum recirculation flow rate according to measurement signal corresponding to 0/4mA Note: 0/4 to20 mA input can be used either for Qreci or for Qras.
  • Page 36 Parameterization and operation 4.5.1 2-Channel RTC103 N-Module (Continued) RTC MODULES / PROGNOSYS RTC MODULES OUTPUTS CHANNEL 1 MIN DO SETTING Minimum DO set point corresponding to 0/4mA [mg/L] MAX DO SETTING Maximum DO set point corresponding to 20mA [mg/L] Transfer range of 0/4 to 20 mA current loop as set in connected flow 0/4 to 20 mA measuring instrument.

  • Page 37: 2-Channel Rtc103 N-Module Stages

    SRT MODE • SRT-RTC: The SRT is provided by a separate SRT-RTC and forwarded to the RTC103 N-Module • TSS mL: The SRT is calculated based on the TSS concentration and the amount of TSS daily removed. SRT (MANUALLY)
  • Page 38 Parameterization and operation 4.5.2 2-Channel RTC103 N-Module Stages (Continued) RTC MODULES / PROGNOSYS RTC MODULES This factor can be used on order to fine tune the DO concentration MODEL CORRECTION FACT. calculated by the model (feed forward part of the N-RTC).
  • Page 39 Parameterization and operation 4.5.2 2-Channel RTC103 N-Module Stages (Continued) RTC MODULES / PROGNOSYS RTC MODULES INPUTS CHANNEL 1 Minimum flow rate of influent according to measurement signal MIN INFLOW [L/s] corresponding to 0/4mA Maximum flow rate of influent according to measurement signal...

  • Page 40: 2-Channel Rtc103 N-Module Vfd

    Parameterization and operation 4.5.2 2-Channel RTC103 N-Module Stages (Continued) RTC MODULES / PROGNOSYS RTC MODULES Note: 0/4 to20 mA input can be used either for Qreci or for Qras. If the value Q RETURN RATIO is “0” the RAS flow is calculated bases on the mA input signal.
  • Page 41 Parameterization and operation 4.5.3 2-Channel RTC103 N-Module VFD (Continued) RTC MODULES / PROGNOSYS RTC MODULES Three different types of operation regarding the aerobic Sludge Retention Time (SRT) can be selected: • Manually: The SRT is provided as a manual input to the...
  • Page 42 Parameterization and operation 4.5.3 2-Channel RTC103 N-Module VFD (Continued) RTC MODULES / PROGNOSYS RTC MODULES This factor can be used on order to fine tune the DO concentration MODEL CORRECTION FACT. calculated by the model (feed forward part of the N-RTC).
  • Page 43 Parameterization and operation 4.5.3 2-Channel RTC103 N-Module VFD (Continued) RTC MODULES / PROGNOSYS RTC MODULES INPUTS CHANNEL 1 Minimum flow rate of influent according to measurement signal MIN INFLOW [L/s] corresponding to 0/4mA Maximum flow rate of influent according to measurement signal...
  • Page 44 Parameterization and operation 4.5.3 2-Channel RTC103 N-Module VFD (Continued) RTC MODULES / PROGNOSYS RTC MODULES Note: 0/4 to20 mA input can be used either for Qreci or for Qras. If the value Q RETURN RATIO is “0” the RAS flow is calculated bases on the mA input signal.

  • Page 45: Select Sensors

    Parameterization and operation 4.5.3 2-Channel RTC103 N-Module VFD (Continued) RTC MODULES / PROGNOSYS RTC MODULES Shows the software version of the RTC communication card SOFT-VERSION (YAB117) in the sc1000. Shows the installed RTC module variant, e.g. 1-channel closed-loop RTC MODE control.
  • Page 46 Parameterization and operation 3. Press the required sensor for the RTC module and confirm by pressing below the selection list. ENTER Sensors in black type are available for the RTC module. Sensors in red type are not available for the RTC module. Note: For sensors marked (p), PROGNOSYS is available if these sensors have been selected in conjunction with an RTC module (refer to the PROGNOSYS user manual).

  • Page 47: Control Programs

    4, item 1) to confirm the list once it is finished. Note: The order of selected sensors has to be defined and pre-configured by Service of Supplier on CF-card of RTC103 N-Module. Control programs To adapt to local circumstances and the instruments available,...
  • Page 48 SRT is calculated. 4.9.4 COD-TKN RATIO This is the assumed COD / TKN ratio. The RTC103 N-Module considers a certain COD-related amount of NH -N to be incorporated in the bio mass, reducing the amount of NH -N to be nitrified.
  • Page 49 Note: The configuration for DO control, different kind of blowers, aeration stages has to be carefully pre-configured from service of supplier on CF-card of RTC103 N-Module. 4.10.1 P FAKT O2 (For VFD option only) Proportional factor for the PD closed loop controller for the DO concentration in the aeration.
  • Page 50 Parameterization and operation 4.10.5 SUBST AERATION If the oxygen sensor (e.g. LDO) signals a fault, the set aeration stage is selected (stages 1 to 6). 4.10.6 NUMBER OF STAGES Number of controlled aeration stages (maximum 6). 4.10.7 VFD P MIN (For DO control without VFD option this is fixed to 100%) Set minimum speed [%] for VFD controlled blowers.

  • Page 51: Volume

    Parameterization and operation 4.11.8 MIN RETURN SLUDGE Minimum return sludge flow rate according to measurement signal corresponding to 0/4mA. 4.11.9 MAX RETURN SLUDGE Maximum return sludge flow rate of influent according to measurement signal corresponding to 20mA. 4.11.10 0/4 to 20mA Transfer range of 0/4 to 20mA current loop as set in connected flow measuring instrument.

  • Page 52: 4.15 Displayed Measurement Values And Variables

    4.15 Displayed measurement values and variables The following measurement values and variables are shown on the SC1000 display and transferred via fieldbus. Parameter Unit Description Note RTC103 N-Module, 1-channel MEASUREMEN 1 Qin 1 Flow rate aeration lane Flow rate internal recirculation or return MEASUREMEN 2...

  • Page 53: 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 54 Maintenance...

  • Page 55: 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 56 Troubleshooting...

  • Page 57: 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 58 Replacement parts and accessories...

  • Page 59: Section 8 Contact Information

    Fax +33 (0)1 69 67 34 99 www.hach-lange.nl info@hach-lange.fr www.hach-lange.fr HACH LANGE APS HACH LANGE AB HACH LANGE S.R.L. HACH LANGE SPAIN S.L.U. Åkandevej 21 Vinthundsvägen 159A Via Rossini, 1/A Edificio Seminario DK-2700 Brønshøj SE-128 62 Sköndal I-20020 Lainate (MI)...
  • Page 60 Contact information HACH LANGE D.O.O. ΗΑCH LANGE E.Π.Ε. HACH LANGE D.O.O. HACH LANGE MAROC SARLAU Fajfarjeva 15 Ηρακλείτου 3 Ivana Severa bb SI-1230 Domžale GR-15235 Χαλάνδρι HR-42 000 Varaždin Villa 14 – Rue 2 Casa Tel. +386 (0)59 051 000...

  • Page 61: 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 62 Warranty and liability...

  • Page 63: 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 RTC103 N-Module. Since 20 slave numbers are reserved for internal purposes, the following numbers are available for assignment: 1, 21, 41, 61, 81, 101…...
  • Page 64 MODBUS address setting...

  • Page 65: Index

    Index Module Base ..............11 Address setting ............63 Bus termination ............. 12 Aeration element ............11 Input ..............12 Output ..............12 Terminal ..............11 Base module ............11 Battery compartment ..........11 Bus coupler .............. 11 Operating system ............7 Output digital ..............
  • Page 66 Index...

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