Hach-Lange RTC113 User Manual

DOC023.52.90386

RTC113 ST-Module

Real Time Controller – Sludge Thickening-Module

User manual

12/2012, Edition 2A

© HACH-LANGE GmbH, 2012. All rights reserved. Printed in Germany.

Table of contents

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

Section2 General information .................................................................................................................. 9

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

2.1.1 Hazard notices in this manual.................................................................................................... 9

2.1.2 Warning labels ...........................................................................................................................9

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

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

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

2.5 Theory of operation...........................................................................................................................13

2.5.1 Theory of operation of the RTC Module................................................................................... 13

2.5.2 Input signals............................................................................................................................. 13

2.5.3 Parameters for configuration.................................................................................................... 13

2.5.4 Operating modes ..................................................................................................................... 14

Section3 Installation...............................................................................................................................17

3.1 Installation of the RTC Module ......................................................................................................... 17

3.1.1 Supply voltage of the RTC Module ..........................................................................................17

3.2 Connection of process measurement instruments for the TSS concentration of solids ................... 17

3.2.1 Power supply of the sc sensors and the sc1000 controller...................................................... 17

3.3 sc1000 controller connection............................................................................................................ 17

3.4 Connection to the automation unit on the plant side.........................................................................18

Section4 Parameterization and operation ............................................................................................. 21

4.1 Operating the sc controller................................................................................................................21

4.2 sc1000 setup ....................................................................................................................................21

4.3 Menu structure.................................................................................................................................. 21

4.3.1 DIAGNOSIS............................................................................................................................. 21

4.4 Configuration of RTC113 ST-Module parameters on the sc1000 controller..................................... 21

4.4.1 RTC113 ST-Module open and closed-loop controller.............................................................. 21

4.5 Select sensors .................................................................................................................................. 26

4.6 PRESELECT PROG......................................................................................................................... 28

4.6.1 POLYMER DOSING CONTROL.............................................................................................. 28

4.6.2 FEED FLOW CONTROL .........................................................................................................28

4.6.3 CLOSED LOOP EFFLUENT CONTROL................................................................................. 28

3

Table of contents

4.7 CONTROL PARAMETER .................................................................................................................28

4.7.1 FACTOR POLYMER DOSING.................................................................................................28

4.7.2 POLYMER CONCENTRATION ...............................................................................................28

4.7.3 MANUAL POLYMER DOSING.................................................................................................29

4.7.4 MANUAL FEED FLOW ............................................................................................................29

4.7.5 MAX DECREASE CLOSED L ..................................................................................................29

4.7.6 MAX INCREASE CLOSED L ...................................................................................................29

4.7.7 SET-POINT TSS ......................................................................................................................29

4.7.8 P GAIN TSS .............................................................................................................................29

4.7.9 INTEGRAL TIME TSS..............................................................................................................29

4.7.10 DERIVATIVE TIME TSS ........................................................................................................30

4.8 INPUT/OUTPUT LIMITS ...................................................................................................................30

4.8.1 FEED FLOW LOW ...................................................................................................................30

4.8.2 FEED FLOW HIGH ..................................................................................................................30

4.8.3 FEED FLOW SMOOTHING .....................................................................................................30

4.8.4 LIMIT TSS IN LOW ..................................................................................................................30

4.8.5 LIMIT MAX TSS IN HIGH.........................................................................................................30

4.8.6 TSS IN SMOOTHING...............................................................................................................30

4.8.7 LIMIT TSS OUT LOW ..............................................................................................................31

4.8.8 LIMIT TSS OUT HIGH..............................................................................................................31

4.8.9 TSS OUT SMOOTHING...........................................................................................................31

4.8.10 POLYMER DOSING MINIMUM .............................................................................................31

4.8.11 POLYMER DOSING MAXIMUM ............................................................................................31

4.9 INPUTS .............................................................................................................................................31

4.9.1 MIN FEED FLOW.....................................................................................................................31

4.9.2 MAX FEED FLOW....................................................................................................................31

4.9.3 0/4...20 mA...............................................................................................................................31

4.9.4 MIN POLYMER FLOW.............................................................................................................32

4.9.5 MAX POLYMER FLOW............................................................................................................32

4.9.6 0/4...20 mA...............................................................................................................................32

4.10 OUTPUTS .......................................................................................................................................32

4.10.1 MIN FEED FLOW...................................................................................................................32

4.10.2 MAX FEED FLOW..................................................................................................................32

4.10.3 0/4...20 mA.............................................................................................................................32

4.10.4 MIN POLYMER FLOW.........................................

4.10.5 MAX POLYMER FLOW..........................................................................................................32

4.10.6 0/4...20 mA.............................................................................................................................32

4.10.7 CONTROL CYCLE.................................................................................................................32

4.10.8 MIN RUNTIME .......................................................................................................................33

4.11 Displayed measurement values and variables................................................................................33

..................................................................32

Section5 Maintenance............................................................................................................................35

5.1 Maintenance schedule ......................................................................................................................35

4

Table of contents

Section6 Troubleshooting...................................................................................................................... 37

6.1 Error messages ................................................................................................................................ 37

6.2 Warnings........................................................................................................................................... 37

6.3 Wear parts ........................................................................................................................................ 37

Section7 Replacement parts and accessories ...................................................................................... 39

7.1 Replacement parts............................................................................................................................39

Section8 Contact information ................................................................................................................ 41

Section9 Warranty and liability .............................................................................................................. 43

AppendixA Modbus address setting ...................................................................................................... 45

AppendixB Configuration of the network modules................................................................................. 47

B.1 RTC113 ST-Module Profibus/Modbus telegram ............................................................................. 47

Index....................................................................................................................................................... 49

5

Table of contents

6

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)

Analog inputs 0/4 to 20 mA for input of the feed flow rate and the polymer flow rate

Number of inputs

Internal resistance 80 ohm + diode voltage 0.7 V

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

One-channel: 2 (KL3011)
Two-channel: 4 (KL3011)

Signal current 0/4 to 20 mA

Common mode voltage (UCM) 35 V max.

Measurement error (for entire measurement
range)

Voltage surge resistance 35 V DC

Electrical isolation 500 V

Digital inputs Enabling of the open-loop control (thickened sludge pump on/off)

Number of inputs 2 (KL1002)

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

Input current 5mA (typ.)

Electrical isolation 500 V

< ± 0.3 % (from end value of measurement range)

(K-bus/signal voltage)

eff

(K-bus/field voltage)

eff

7

Technical data

Analog outputs Output of the polymer dosing, output of the feed flow rate

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: 2 (KL4012)
Two-channel: 4 (KL4012)

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
± 0.1 % (relative to the measuring range end value)

Electrical isolation 500 V

(K-bus/field voltage)

eff

Digital outputs Control of polymer pump: feed flow rate and fault messages

Number of outputs

One-channel: 4 (KL2134)
Two-channel: 8 (KL2408)

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

(K-bus/field voltage)

eff

Equipment properties

Dimensions (W x× H x× D)

One-channel: 191 × 120 × 96 mm (7.52 × 4.72 × 3.78 in)
Two-channel: 227 × 120 × 96 mm (8.94 × 4.72 × 3.78 in)

Mass Approximately 0.9 kg (approximately 1.98 lb)

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

2
1
II
2000 m (6.562 ft.)

Protection class IP20

Installation DIN rail EN 50022 35 × 15.0

1

Pentium is a registered trademark of the Intel Corporation.

2

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

8

Section2 General information

2.1 Safety information

Please read the entire manual carefully before unpacking, assembling or operating the
instrument. Pay attention to all hazard and warning notices. Failure to do so could result in
serious injury to the operator or damage to the instrument.

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 Hazard notices in this manual

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

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

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

DANGER

WARNING

CAUTION

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 Warning labels

Observe all labels and tags attached to the instrument. Failure to do so may result in
personal injury or damage to the instrument.

This symbol may be attached to the device and refers to operation and/or safety notes in the user manual.

This symbol may be found on an enclosure or barrier within the product and indicates a risk of electric shock
and/or death by electrocution.

Electrical equipment marked with this symbol may no longer be disposed of in unsorted domestic or industrial
waste in Europe after August 12, 2005. In conformity with the provisions in force (EU Directive 2002/96/EC),
consumers in the EU must return old electrical devices to the manufacturer for disposal from this date, at no
charge to the consumer.

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

9

General information

2.2 Areas of application

The RTC113 ST-Module (Real Time Controller, Sludge Thickening-Module) is an open
and closed-loop control unit for universal applications. It can be used by mechanical
sludge thickening devices, for example belt thickeners or drum thickeners in wastewater
treatment plants.

The RTC113 ST-Module

• Optimizes polymer consumption and

• Uniformly manages the concentration of solids in the thick sludge

1-channel Open/closed-loop controller for one thickener
2-channel Open/closed-loop controller for two thickeners

The use of an RTC Module does not release the operator from the duty of care to the system. No
guarantees as to the functionality or operational safety of 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 sensor and laboratory comparative
measurements) is essential! (Refer to the user manual for the relevant instrument.)

Table1 Versions of the RTC113 ST-Module

NOTICE

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 guidelines can be proved
through technical measurements.

Each RTC Module is supplied with:

• SUB-D connector (9 pin)

• user manual

• ferrite core
Check that the order is complete. All listed components must be present. If anything is

missing or damaged, contact the manufacturer or distributor immediately.

NOTICE

10

2.4 Instrument overview

Figure1 Base module RTC 24 V version .

General information

1 PE (protective earth) 5 sc 1000 connection: RS485 (CX1010-N031)
2 24 V 6 Battery compartment
3 0 V 7 CPU base module, consisting of Ethernet port with

battery compartment (CX1010-N000), CPU module with
CF card (CX1010-0021) and passive aeration element.

4 Automatic circuit breaker (ON/OFF switch for item 7 and

8 without fuse function).

Note: All components are pre-wired.

8 Power supply module, consisting of bus coupler

(CX1 100-0002) and terminal module 24V.

11

General information

Abbildung 2 Base module RTC 100-240 V version

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 AC 100–240 V / Input DC 95 V–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 (Specification section 3.1.1, page 17) 11 Power supply module, consisting of bus coupler
6 Output DC 24 V, 0,75 A

(CX1100-0002) and terminal module 24V.

Note: All components are pre-wired.

12

Figure3 Design of the analog and digital input and output modules

2

1

General information

1 Input- or Output- Module or Bus Termination Module

analog or digital

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

2.5 Theory of operation

2.5.1 Theory of operation of the RTC Module

The RTC113 RTC Module outputs analog (0/4–20 mA) and digital (0/24 V) signals for the
polymer dosing rate or the feed flow rate of mechanical sludge thickening devices. Digital
fieldbus signals from sc1000 communication cards can also be used.

2.5.2 Input signals

The most important input signals are:

• Sludge influent TSS concentration (concentration of solids)

• Feed flow rate of the machine-controlled sludge thickening

2.5.3 Parameters for configuration

• Thickened sludge TSS concentration (optional)

• Status of the thickened sludge pump (on/off)

The most important parameters for configuration are:

2 LED area with installed LEDs or free LED installation

spaces

• The required specific polymer dosing [g polymer/kg TSS]

• The target TSS concentration in thickened sludge

Note: In a closed-loop circuit, TSS measurement is required in thickened sludge.

13

General information

2.5.4 Operating modes

The RTC113 ST-Module can be operated as a combined open-loop and closed-loop
controller. Several variants can be configured.

1. Configuration of a specified polymer rate [L/h] with a specified feed flow rate [m

2. Configuration of a specified specific polymer dosing rate [g polymer/kg TSS]. One of
the following settings is adjusted:

a. The polymer flow rate according to the TSS concentration and the feed flow rate

• Based on the actual feed flow rate [L/h] and TSS concentration [g/L] in the feed

Or:
b. The feed flow rate according to the specified polymer dosing rate and the

3

/h].

(Figure4).

flow, the polymer dosing rate [L/h] is calculated for the required specific dosing
rate.

measured TSS concentration of the influent (Figure5).

• Based on the measurement value of the TSS concentration from the influent [g/L]

and the configurable specified polymer dosing rate [L/h], the feed flow rate [m
is calculated such that it corresponds to the pre-defined specific polymer dosing
rate [g/kg].

3. Both variants 2a and 2b can be combined with the closed-loop controller described
below:

a. Closed-loop control of the TSS concentration in the thickened sludge

• The specific polymer dosing rate is adjusted according to the difference between

the target and actual TSS concentration in the outlet.

3

/h]

14

Figure4 Adjustment of the polymer dosing rate to the feed flow rate

General information

1 Static thickener 8 Pump for open-loop control of the polymer dosing rate
2 Measurement of the feed flow rate 9 Pump for the feed flow rate
3 Open-loop control of the polymer dosing rate (feed flow

rate measurement value)
4 TSS measurement from the influent 11 TSS measurement in the thickened sludge outlet
5 Open-loop control of the polymer dosing rate (influent

TSS concentration measurement value)
6 RTC113 ST-Module 13 Thickened sludge pump
7 Polymer supply 14 Digester

10 Mechanical sludge thickener

12 Closed-loop control of the polymer dosing rate

15