Hach-Lange RTC103 User Manual

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DOC023.52.90448

RTC103 N-Module

Real-Time Control System for Ammonium Removal

User manual

07/2013, Edition 1A

Table of Contents

Section 1 Technical data ........................................................................................................................7

Section 2 General Information............................................................................................................... 9

2.1 Safety information............................................................................................................................... 9

2.1.1 Use of hazard information.......................................................................................................... 9

2.1.2 Precautionary labels .................................................................................................................. 9

2.2 Areas of application .......................................................................................................................... 10

2.3 Scope of delivery .............................................................................................................................. 10

2.4 Instrument overview.......................................................................................................................... 11

2.5 Theory of operation........................................................................................................................... 12

2.5.1 Theory of operation of the RTC103 N-Module......................................................................... 12

Section 3 Installation............................................................................................................................ 15

3.1 Installation of the RTC Module ......................................................................................................... 15

3.1.1 Power supply to the RTC module ............................................................................................15

3.2 Connection of process measuring instruments (for NH

3.2.1 Power supply of the sc sensors and the sc1000 controller...................................................... 15

3.3 Connecting the sc 1000 controller .................................................................................................... 16

3.4 Connection to the automation unit on the plant side.........................................................................16

-N, TSS and O2) ........................................ 15

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

4.4.2 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........................................ 32

4.5.1 2-Channel RTC103 N-Module .................................................................................................33

4.5.2 2-Channel RTC103 N-Module Stages ..................................................................................... 37

4.5.3 2-Channel RTC103 N-Module VFD ......................................................................................... 40

4.6 Select sensors .................................................................................................................................. 45

4.7 Control programs .............................................................................................................................. 47

4.8 Automatic program change............................................................................................................... 47

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. DO FOR MODEL ....................................................................................................48

4.9.9 NH4-N SETPOINT ...................................................................................................................48

4.9.10 P FAKT NH4 (only if NH4-N measurement in effluent is available for feed back control) ......48

4.9.11 INTEGRAL TIME NH4 (only if NH4-N measurement in effluent is available for feed back

control).........................................................................................................................................49

4.9.12 DERIVATIVE TIME NH4 (only if NH4-N measurement in effluent is available for feed back

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 MAX INFLOW.........................................................................................................................50

4.11.3 0/4 to 20mA............................................................................................................................50

4.11.4 MIN RECIRCULATION ..........................................................................................................50

4.11.5 MAX RECIRCULATION .........................................................................................................50

4.11.6 0/4 to 20mA............................................................................................................................50

4.11.7 Q RECI RATIO.......................................................................................................................50

4.11.8 MIN RETURN SLUDGE .........................................................................................................51

4.11.9 MAX RETURN SLUDGE........................................................................................................51

4.11.10 0/4 to 20mA..........................................................................................................................51

4.11.11 Q RETURN RATIO...............................................................................................................51

4.12 OUTPUTS .......................................................................................................................................51

4.12.1 MIN DO SETTING (only for option without DO control) .........................................................51

4.12.2 MAX DO SETTING (only for option without DO control)........................................................51

4.12.3 0/4 to 20mA............................................................................................................................51

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 ................................................................................................................................ 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

Table of Contents

Section 1 Technical data

These are subject to change without notice.

Embedded PC (compact industrial PC)

Processor

Flash memory 2 GB compact flash card

Internal working memory 256 MB DDR-RAM (not expandable)

Interfaces 1× RJ 45 (Ethernet), 10/100 Mbit/s

Diagnostic LED

Expansion slot 1× CompactFlash type II slot with ejector mechanism

Clock

Operating system Microsoft Windows

Control software TwinCAT PLC Runtime or TwinCAT NC PTP Runtime

System bus 16 bit ISA (PC/104 standard)

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)

Weight Approximately 0.9 kg (1.98 lb)

Pentium®1, MMX compatible, 500 MHz clock rate

1× power, 1× LAN speed, 1× LAN activity, TC status,  1× flash access

Internal, battery-buffered clock for time and date (battery can be replaced)

®2

CE or Microsoft Windows Embedded Standard

350 mm × 120 mm × 96 mm (13.78 in. × 4.72 in. × 3.78 in.)

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 (U

Measurement error (for entire measurement range)

Electrical surge resistance 35 V DC

Electrical isolation 500 V

Digital outputs Aeration and alarm activation

Number of outputs 2 (KL2032), 4 (KL2134), 8 (KL2408), 16 (KL2809)

Nominal load voltage 24 V DC (–15 % / +20 %)

Load type ohmic, inductive lamp load

Max. output current 0.5 A (short-circuit proof) per channel

Reverse polarity protection Yes

Electrical isolation 500 V

  

) 35 V max.

< ± 0.3 % (from measurement range end value)

(K-bus/signal voltage)

eff

(K-bus/field voltage)

eff

Technical data

Analog output Outputs for DO setpoint or VFD control

Number of outputs

Supply voltage

Signal current 0/4 to 20 mA

Working resistance < 500 Ohm

Measurement error

Resolution 12 bit

Conversion time Approximately 1.5 ms

One-channel: 1 (KL4011); 1 (KL4012) VFD control  Two-channel: 1 (KL4012); 2 (KL4012) VFD control

24 V DC via the power contacts (Alternatively, 15 V DC with bus termination KL9515)

± 0.5 LSB linearity error ± 0.5 LSB offset error ± 0.5 % (relative to the measuring range end value)

Electrical isolation 500 V

(K-bus/field voltage)

eff

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 of protection IP20

Installation DIN rail EN 50022 35 × 15

Pentium is a registered trademark of the Intel Corporation.

Microsoft Windows is a brand name for operating systems of the Microsoft Corporation.

Section 2 General Information

2.1 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.

2.1.1 Use of hazard information

DANGER

Indicates a potentially or imminently hazardous situation that, if not avoided, can result in death or serious injury.

WARNING

Indicates a potentially or imminently dangerous situation that, if it is not avoided, can lead to death or to serious injuries.

CAUTION

Indicates a possible dangerous situation that can have minor or moderate injuries as the result.

Indicates a situation that, if it is not avoided, can lead to damage to the device. Information that requires special emphasis.

Note: Information that supplements points in the main text.

2.1.2 Precautionary labels

Read all labels and tags attached to the instrument. Personal injury or damage to the instrument could occur if not observed.

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 exists.

Electrical equipment marked with this symbol may not be disposed of in European domestic or public disposal systems after 12 August 2005. In conformity with European local and national regulations, European electrical equipment users must now return old or end-of life equipment to the manufacturer for disposal at no charge to the user.

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.

NOTICE

CAUTION

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. The user is solely responsible to identify critical application risks and install appropriate mechanisms to protect processes during a possible equipment malfunction.

General Information

2.2 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 module controls one activated sludge tank. The two-channel version controls two activated sludge tanks simultaneously.

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 example, cleaning of the sensors and laboratory comparative measurements) is essential! (Refer to the user manual for the relevant instrument.)

2.3 Scope of delivery

The combination of pre-assembled components supplied by the manufacturer does not represent a standalone functional unit. In accordance with EU guidelines, this combination of pre-assembled components is not supplied with a CE mark, and there is no EU declaration of conformity for the combination.

However, the conformity of the combination of components with the guideline can be proved through technical measurements.

) in the activated sludge tank. The single-channel version of the RTC

NOTICE

Each RTC103 N-Module is supplied with:

• A SUB-D connector (9 pin)

• Ferrite core, foldable

• User manual

Check that the order is complete. All listed components must be present. If anything is missing or damaged, contact the manufacturer or distributor immediately.

2.4 Instrument overview

Figure 1 Base module RTC 100-240 V version

General Information

1 L(+) 7 Automatic circuit breaker (ON/OFF switch for item 10

and 11 without fuse function)

2 N(–) 8 sc 1000 connection: 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)

6 Output DC 24 V, 0.75 A

Note: All components are pre-wired.

11 Power supply module, consisting of bus coupler

(CX1100-0002) and terminal module 24V.

General Information

Figure 2 Design of the analog and digital input and output modules

1 Analog or digital input or output module 

or bus termination module

Note: The number of LEDs indicates the number of channels.

2 LED area with installed LEDs or free LED installation

spaces.

2.5 Theory of operation

2.5.1 Theory of operation of the RTC103 N-Module

The RTC103 N-Module (Real-Time Controller for Nitrification) optimises nitrification processes in waste water treatment plants which are continuously aerated (e.g. plug flow nitrification tanks or pre-denitrification).

The RTC103 N-Module consists of an open-loop controller, based on NH 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.

Based on that information, a DO set-point is calculated which is required to reach the desired NH control, there is also a closed-loop PID based on the NH the nitrification zone that can be applied to improve control performance. The PID-output values are combined with the open-loop output to calculate the required DO set point (Figure 3).

-N set-point at the effluent of the aeration tank. In addition to open-loop

-N influent

-N concentration at the end of

Figure 3 Principle operation mode of RTC103 N-Module

General Information

Basic RTC103 N-Module

For each lane the calculated DO set point is delivered either by analog output or via the sc1000 ProfiBus communication card to the PLC. The DO control algorithm has to be implemented on the 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. 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 aeration intensity to reach the calculated DO concentration. This option has two analog outputs per lane, to control up to two variable speed drive blowers per lane.

All the above options for the RTC103 N-Module are available as single-channel (for control of one lane) or dual-channel (for control of two lanes).

General Information

Section 3 Installation

Only qualified experts may perform the tasks described in this section of the manual, while adhering to all locally valid safety regulations.

Always lay cables and hoses so that they are straight and do not pose a tripping hazard.

Before switching on the power supply, you must refer to the instructions in the relevant operating manuals.

3.1 Installation of the RTC Module

Only install the RTC Module on a DIN rail. The module must be attached horizontally, with at least 30 mm (1.2 in.) space at the top and bottom to make sure that the passive aeration element can function correctly.

When used indoors, the RTC Module must be installed in a control cabinet.  When used outdoors, the RTC Module requires a suitable enclosure that supplies the following technical specifications (see Section 1 Technical data, page 7).

DANGER

CAUTION

The RTC Module is only operated via the sc1000 controller (see the user manual for the sc1000 controller).

Note: The software version of the sc1000 controller must be V3.20 or above.

3.1.1 Power supply to the RTC module

WARNING

Alternating current may destroy the direct current system and therefore jeopardize user safety. Never connect an alternating current voltage to the 24 V direct current model.

Table 1 Supply voltage of the RTC Module

Voltage 24 V DC (–15 % / +20 %), max. 25 W Recommended fuse C2 With 110–230 V option 230 V, 50–60 Hz, approximately 25 VA

Note: An external deactivation switch is recommended for all installations.

3.2 Connection of process measuring instruments (for NH4-N, TSS and O

)

The measurement 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.

Installation

3.3 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.

3.4 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:

Output signals from RTC103 N-Module:

Basic For each lane, a single DO set-point 0/4 to 20 mA or ProfiBus / ModBus via

sc1000 communication card

Option 2 For each lane, Aeration intensity (1 to 6 stages) for the aeration system

(0/24 V per stage or ProfiBus / MODBUS) via sc1000 communication card

Option 3 For each lane, 2 additional analog outputs (0/4 to 20 mA or ProfiBus /

MODBUS) via sc1000 communication card

Input signals to RTC103 N-module:

• Flow rate, overall wastewater (Q_in, 0/4 to 20 mA)

• IRC flow rate input (Q_IRC, 0/4 to 20 mA) 

or  IRC flow = C1 * Q_in with minimum and maximum values

• RAS flow rate (Q_RAS 0/4 to 20 mA) or RAS flow = C2 * Q_in with minimum and maximum values

Note: 0/4 to 20 mA input can be used either for Q_IRC or for 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 concentration for each lane

• TSS concentration aeration tank (option)

• Temperature (coming from a connected sensor DO or NH

Main Input parameters:

, or via analog input card)

• Parameters for open-loop control

• Parameters for PID control (closed-loop)

• Min/max DO concentration, max. rate of change

• Control parameters for DO control

Installation

1-Channel RTC103 N-Module

Module Name Terminal Signal Channel Function

2 fold digital output

KL2032

1 fold analog output KL4011 1 - 3 0/4 to 20 mA Output DO set point 1 fold analog intput KL3011 1 - 2 0/4 to 20 mA Flow rate aeration lane 1 fold analog input KL3011 1 - 2 0/4 to 20 mA Flow rate internal recirculation or return sludge Bus termination KL9010 Bus termination

Ground Connector 3 and 7, 24 V Connector 6.

2-Channel RTC103 N-Module

Module Name Terminal Signal Channel Function

4 fold digital output1KL2134

2 fold analog output KL4012

1 fold analog 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

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

Bus termination KL9010 Bus termination

1 +24 V/0 V Input Signals ok (24V), Input signal faulty (0V) 5 +24 V/0 V RTC operating (24V), RTC failure (0V)

1 +24 V/0 V 1 Input Signals ok (24V), Input signal faulty (0V) 5 +24 V/0 V 1 RTC operating (24V), RTC failure (0V) 4 +24 V/0 V 2 Input Signals ok (24V), Input signal faulty (0V) 8 +24 V/0 V 2 RTC operating (24V), RTC failure (0V) 1 - 3 0/4 to 20 mA 1 Output DO set point lane 1 5 - 7 0/4 to 20 mA 2 Output DO set point lane 2

Flow rate internal recirculation or return sludge lane 1

Flow rate internal recirculation or return sludge lane 2

Ground Connector 3 and 7, 24 V Connector 6.

1-Channel RTC103 N-Module DO aeration stages control

Module Name Terminal Signal Channel Function

1 +24 V/0 V Input Signals ok (24V), Input signal faulty (0V) 2 +24 V/0 V Aeration step 1 ON / OFF 3 +24 V/0 V Aeration step 2 ON / OFF

8 fold digital output

KL2408

4 +24 V/0 V Aeration step 3 ON / OFF 5 +24 V/0 V Aeration step 4 ON / OFF 6 +24 V/0 V Aeration step 5 ON / OFF 7 +24 V/0 V Aeration step 6 ON / OFF

8 +24 V/0 V RTC operating (24V), RTC failure (0V) 1 fold analog output KL4011 1 - 3 0/4 to 20 mA Output DO set point 1 fold analog intput KL3011 1 - 2 0/4 to 20 mA Flow rate aeration lane 1 fold analog input KL3011 1 - 2 0/4 to 20 mA Flow rate internal recirculation or return sludge Bus termination KL9010 Bus termination

Ground Connector 3 and 7, 24 V Connector 6.

Installation

2-Channel RTC103 N-Module DO aeration stages control

Module Name Terminal Signal Channel Function

1 +24 V/0 V 1 Input Signals ok (24V), Input signal faulty (0V) 2 +24 V/0 V 1 Aeration step 1 ON / OFF 3 +24 V/0 V 1 Aeration step 2 ON / OFF 4 +24 V/0 V 1 Aeration step 3 ON / OFF 5 +24 V/0 V 1 Aeration step 4 ON / OFF 6 +24 V/0 V 1 Aeration step 5 ON / OFF 7 +24 V/0 V Aeration step 6 ON / OFF

16 fold digital output1KL2809

2 fold analog output KL4012

1 fold analog 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

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

Bus termination KL9010 Bus termination

8 +24 V/0 V RTC Channel 1 operating (24V), RTC failure (0V) 9 +24 V/0 V 2 Input Signals ok (24V), Input signal faulty (0V) 10 +24 V/0 V 2 Aeration step 1 ON / OFF 11 +24 V/0 V 2 Aeration step 2 ON / OFF 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 Aeration step 6 ON / OFF 16 +24 V/0 V RTC Channel 2 operating (24V), RTC failure (0V) 1 - 3 0/4 to 20 mA 1 Output DO set point lane 1 5 - 7 0/4 to 20 mA 2 Output DO set point lane 2

Flow rate internal recirculation or return sludge lane 1

Flow rate internal recirculation or return sludge lane 2

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

1 +24 V/0 V Input Signals ok (24V), Input signal faulty (0V) 2 +24 V/0 V Aeration step 1 ON / OFF (VFD) 3 +24 V/0 V Aeration step 2 ON / OFF (VFD)

8 fold digital output

KL2408

4 +24 V/0 V Aeration step 3 ON / OFF 5 +24 V/0 V Aeration step 4 ON / OFF 6 +24 V/0 V Aeration step 5 ON / OFF 7 +24 V/0 V Aeration step 6 ON / OFF 8 +24 V/0 V RTC operating (24V), RTC failure (0V)

2 fold analog output KL4012

1 - 3 0/4 to 20 mA Output 1 VFD for DO control

5 - 7 0/4 to 20 mA Output 2 VFD for DO control 1 fold analog intput KL3011 1 - 2 0/4 to 20 mA Flow rate aeration lane 1 fold analog input KL3011 1 - 2 0/4 to 20 mA Flow rate internal recirculation Bus termination KL9010 Bus termination

Ground Connector 3 and 7, 24 V Connector 6.

2-Channel RTC103 N-Module connectors DO aeration stages / analog control

Module Name Terminal Signal Channel Function

1 +24 V/0 V 1 Input Signals ok (24V), Input signal faulty (0V) 2 +24 V/0 V 1 Aeration step 1 ON / OFF (VFD) 3 +24 V/0 V 1 Aeration step 2 ON / OFF (VFD) 4 +24 V/0 V 1 Aeration step 3 ON / OFF 5 +24 V/0 V 1 Aeration step 4 ON / OFF 6 +24 V/0 V 1 Aeration step 5 ON / OFF 7 +24 V/0 V 1 Aeration step 6 ON / OFF

16 fold digital output1KL2809

2 fold analog output KL4012

1 fold analog intput KL3011 1 - 2 0/4 to 20 mA 1 Flow rate aeration lane 1 fold analog input KL3011 1 - 2 0/4 to 20 mA 1 Flow rate internal recirculation 1 fold analog intput KL3011 1 - 2 0/4 to 20 mA 2 Flow rate aeration lane 1 fold analog input KL3011 1 - 2 0/4 to 20 mA 2 Flow rate internal recirculation Bus termination KL9010 Bus termination

8 +24 V/0 V 1 RTC Channel 1 operating (24V), RTC failure (0V) 9 +24 V/0 V 2 Input Signals ok (24V), Input signal faulty (0V) 10 +24 V/0 V 2 Aeration step 1 ON / OFF (VFD) 11 +24 V/0 V 2 Aeration step 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)

0/4 to 20 mA 1 Output 1 VFD for DO control 0/4 to 20 mA 1 Output 2 VFD for DO control 0/4 to 20 mA 2 Output 1 VFD for DO control 0/4 to 20 mA 2 Output 2 VFD for DO control

Installation

Ground Connector 3 and 7, 24 V Connector 6.

Installation

Section 4 Parameterization and operation

4.1 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.

4.2 System setup

1. Open the MAIN MENU.

4.3 Menu structure

4.3.1 SENSOR STATUS

SENSOR STATUS

RTC

ERROR

WARNINGS

4.3.2 SYSTEM SETUP

2. Select

3. Select the

4. Select the RTC module and confirm.

Possible error messages: 

RTC MISSING, RTC CRC, CHECK KONFIG, RTC FAILURE

Possible warning messages: 

MODBUS ADDRESS, PROBE SERVICE

Note: 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.

The system setup is dependent on the number of channels.

RTC MODULES / PROGNOSYS and confirm.

RTC MODULES menu and confirm.

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 parameterization on the

sc1000 controller, page 32

4.4 1-Channel RTC103 N-Module parameterization on sc1000 controller

The following menu entries can be found in the MAIN MENU.

Parameterization and operation

4.4.1 1-Channel RTC103 N-Module

RTC MODULES / PROGNOSYS

RTC MODULES

RTC

CONFIGURE

SELECT SENSOR

N CONTROL

SRT MODE

SRT (MANUALLY) Manual input for the SRT (also used as fallback value) [days]

DAILY SURPLUS MASS

COD-TKN RATIO

MIN NITRIFERS CONC.

MAX NITRIFERS CONC.

MODEL CORRECTION FACT.

SUBSTIT. DO FOR MODEL

NH4-N SETPOINT Desired set point of the NH4-N concentration effluent aeration. [mg/L]

Selection list of available, relevant sensors for the RTC module in the sc network (refer to 4.6 Select sensors on page 45).

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 controller

•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.

The amount of sludge daily removed from the process. Based on that amount, the MLSS concentration in the aeration tank and the aerated volume the SRT is calculated.

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.

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 to determine the DO set point.

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 higher than the MAX NITRIFERS CONC., the MAX NITRIFERS CONC.. will be used to determine the DO set point.

This factor can be used to fine tune the DO concentration calculated 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 N-RTC will apply this DO feed forward set point for all further calculations.

[kg/d]

[%]

]%]

[mg/L]

4.4.1 1-Channel RTC103 N-Module (Continued)

RTC MODULES / PROGNOSYS

RTC MODULES

RTC

Note: These settings are only necessary if NH effluent for feed back control is available!

P FACT NH4

Proportional factor for the PID closed loop controller for the NH4-N concentration effluent aeration.

Note: These settings are only necessary if NH effluent for feed back control is available!

Parameterization and operation

-N measurement in

[1/mg/L]

-N measurement in

INTEGRAL TIME NH4

DERIVATIVE TIME NH4

LIMITS

MIN DO

MAX DO

SMOOTHING Smoothing on the calculated DO set point [min]

INPUTS

MIN INFLOW

MAX INFLOW

0/4 to 20 mA

Integral time for the PID closed loop controller for the NH4-N concentration in the thickened sludge.

Note: INTEGRAL TIME NH4 is set to “0” to deactivate the integral part of the PID controller.

Note: These settings are only necessary if NH 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.

If a calculated DO set point is lower than the MIN DO value, the DO set point is set to that value

If a calculated DO set point is higher than the MIN DO value, the DO set point is set to that value

Minimum flow rate of influent according to measurement signal corresponding to 0/4mA

Maximum flow rate of influent according to measurement signal corresponding to 20mA

Transfer range of 0/4 to 20 mA current loop as set in connected flow measuring instrument.

-N measurement in

[min]

[mg/L]

[L/s]

Parameterization and operation

4.4.1 1-Channel RTC103 N-Module (Continued)

RTC MODULES / PROGNOSYS

RTC MODULES

RTC

Note: 0/4 to20 mA input can be used either for Qreci or for Qras.

MIN RECIRCULATION

MAX RECIRCULATION

0/4 to 20 mA

Q RECI RATIO

MIN RETURN SLUDGE

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.

Maximum recirculation flow rate of influent according to measurement signal corresponding to 20mA

Note: 0/4 to20 mA input can be used either for Qreci or for Qras.

Transfer range of 0/4 to 20 mA current loop as set in connected flow measuring instrument.

Note: The input is not connected to the 0/4 to 20 mA has to be calculated in ratio to Qinflow.

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 limits of MIN RECIRCULATION and MAX

RECIRCULATION.

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

Note: 0/4 to20 mA input can be used either for Qreci or for Qras.

[L/s]

[%]

[L/s]

MAX RETURN SLUDGE

0/4 to 20 mA

Q RETURN RATIO

Maximum return sludge flow rate of influent according to measurement signal corresponding to 20mA

Note: 0/4 to20 mA input can be used either for Qreci or for Qras.

Transfer range of 0/4 to 20 mA current loop as set in connected flow measuring instrument.

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.

If the value is different from “0” the RAS flow is calculated from the inflow:

Q RETURN = Q RETURN RATIO * INFLOW within the limits of MIN RETURN SLUDGE and MAX RETURN

SLUDGE.

[L/s]

[%]

Parameterization and operation

4.4.1 1-Channel RTC103 N-Module (Continued)

RTC MODULES / PROGNOSYS

RTC MODULES

RTC

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]

0/4 to 20 mA

VOLUME

VOLUME Aerated volume [m

MODBUS

ADDRESS Start address of an RTC within the MODBUS network.

DATA ORDER

DATALOG INTRVAL Indicates the interval in which the data is saved in the log file. [min]

PROGNOSYS

SET DEFAULTS Restores the factory settings.

MAINTENANCE

RTC DATA

RTC MEASUREMEN

RTC ACTUAT VAR

DIAG/TEST

EEPROM Hardware test RTC COMM TO Communication time-out RTC CRC Communication check sum

MODBUS ADDRESS

LOCATION

SOFT-VERSION

RTC MODE

RTC VERSION Shows the software version of the RTC module.

Transfer range of 0/4 to 20 mA current loop as set in connected flow measuring instrument.

Specifies the register order within a double word. Presetting: NORMAL

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.

Specifies the value measured by the RTC, e. g. the influent measurement.

Specifies the variable calculated by the RTC, e. g. whether the aeration should be switched on or off.

Here, the address is displayed where the communication actually takes place. Presetting: 41

Here, a location name can be assigned for better identification of the RTC module, e.g. activation 2.

Shows the software version of the RTC communication card (YAB117) in the sc1000.

Shows the installed RTC module variant, e.g. 1-channel closed-loop control.

]

Parameterization and operation

4.4.2 1-Channel RTC103 N-Module Stages

RTC MODULES / PROGNOSYS

RTC MODULES

RTC

CONFIGURE

SELECT SENSOR

N CONTROL

SRT MODE

SRT (MANUALLY) Manual input for the SRT (also used as fallback value) [days]

DAILY SURPLUS MASS

COD-TKN RATIO

MIN NITRIFERS CONC.

MAX NITRIFERS CONC.

Selection list of available, relevant sensors for the RTC module in the sc network (refer to 4.6 Select sensors on page 45).

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 controller

•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.

The amount of sludge daily removed from the process. Based on that amount, the MLSS concentration in the aeration tank and the aerated volume the SRT is calculated.

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.

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 higher than the MAX NITRIFERS CONC., the MAX NITRIFERS CONC.. will be used to determine the DO set point.

[kg/d]

[%]

]%]

4.4.2 1-Channel RTC103 N-Module Stages (Continued)

RTC MODULES / PROGNOSYS

RTC MODULES

RTC

MODEL CORRECTION FACT.

SUBSTIT. DO FOR MODEL

NH4-N SETPOINT

P FACT NH4

INTEGRAL TIME NH4

DERIVATIVE TIME NH4

LIMITS

MIN DO

MAX DO

SMOOTHING Smoothing on the calculated DO set point [min]

DO CONTROL

DERIVATIVE TIME Derivative Time of DO controller [min] DAMPING Damping of DO control [min]

SUBST AERATION

NO. OF STAGES Number of controlled aeration stages (maximun 6) [Stage] VFD P MIN fixed to 100% [%]

INPUTS

MIN INFLOW

MAX INFLOW

0/4 to 20 mA

This factor can be used on order to fine tune the DO concentration calculated 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 N-RTC will apply the this DO feed forward set point for all further calculation

Desired set point of the NH4-N concentration effluent aeration

Note: These settings are only necessary if NH4-N measurement in effluent for feed back control is available!

Proportional factor for the PID closed loop controller for the NH4-N concentration effluent aeration.

Integral time for the PID closed loop controller for the NH4-N concentration in the thickened sludge.

Note: INTEGRAL TIME NH4 is set to “0” to deactivate the integral part of the PID controller.

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.

If a calculated DO set point is lower than the MIN DO value, the DO set point is set to that value

If a calculated DO set point is higher than the MIN DO value, the DO set point is set to that value

If the DO sensor (e.g. LDO) signals a fault, the set aeration stage is selected

Minimum flow rate of influent according to measurement signal corresponding to 0/4mA

Maximum flow rate of influent according to measurement signal corresponding to 20mA

Transfer range of 0/4 to 20 mA current loop as set in connected flow measuring instrument.

Note: 0/4 to 20 mA input can be used either for Qreci or for Qras!

Parameterization and operation

[mg/L]

[1/mg/L]

[min]

[mg/L]

[Stage]

[L/s]