Hach-Lange WTOS P-RTC User Manual
DOC023.52.90202
RTC101 P-Module
Real-Time Control System for Phosphorus Removal
User manual
02/2013, edition 4A
© HACH-LANGE GmbH, 2010, 2011,2013 All rights reserved. Printed in Germany.
Table of Contents
Section 1 Specifications ........................................................................................................................ 5
Section 2 General Information............................................................................................................... 7
2.1 Safety information............................................................................................................................... 7
2.2 Areas of application ............................................................................................................................ 8
2.3 Functional principle............................................................................................................................. 8
2.4 Scope of delivery ................................................................................................................................ 9
2.5 Instrument overview.......................................................................................................................... 10
Section 3 Installation............................................................................................................................ 13
3.1 RTC101 P-Module connection.......................................................................................................... 13
3.2 Dosing pump connection .................................................................................................................. 13
3.3 PHOSPHAX sc analyzer connection ................................................................................................ 13
3.4 sc1000 controller connection ............................................................................................................ 14
3.5 Flow rate signal connection .............................................................................................................. 14
3.6 Connection to the automation unit on the plant side.........................................................................14
Section 4 Parameterization and operation ......................................................................................... 15
4.1 Open-loop control and closed-loop control programs....................................................................... 15
4.2 Program change ............................................................................................................................... 16
4.3 Parameterization on the sc1000....................................................................................................... 18
4.4 Select sensors .................................................................................................................................. 29
4.5 Explanations ..................................................................................................................................... 31
Section 5 Maintenance ......................................................................................................................... 37
5.1 Maintenance schedule...................................................................................................................... 37
Section 6 Troubleshooting................................................................................................................... 39
6.1 Error messages ................................................................................................................................ 39
6.2 Warnings........................................................................................................................................... 39
6.3 Wear parts ........................................................................................................................................ 39
Section 7 Replacement parts and accessories ................................................................................. 41
7.1 Spare parts ....................................................................................................................................... 41
Section 8 Contact information ............................................................................................................ 43
Section 9 Warranty and liability........................................................................................................... 45
Appendix A MODBUS address setting ............................................................................................... 47
3
Table of Contents
4
Section 1 Specifications
Subject to change without notice.
Industrial Personal Computer (IPC), (Embedded PC)
Processor
Flash memory 2 GB compact flash card
Internal working memory 256 MB DDR-RAM (not expandable)
Interface RJ 45 (Ethernet), 10/100 MBit/s
Diagnostic LEDs Power, LAN speed, LAN activity, TC status, flash access
Expansion slot Compact flash type II slot with ejection 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 input 4–20 mA for flow rate measurement
Internal resistance 80 Ohm × diode voltage 0.7 V
Signal current 0–20 mA
Pentium®1, MMX compatible, 500 MHz clock rate
Internal, battery-buffered clock for time and date (battery can be
replaced)
®2
CE or Microsoft Windows Embedded Standard
Common mode voltage (U
Measurement error (for entire measurement
range)
Electrical surge resistance 35 VDC
Electrical isolation 500 V
Analog output 4–20 mA for dosing pump
Number of outputs 1
Power supply
Signal current 0–20 mA
Working resistance < 500 Ω
Measurement error
Resolution 12 bit
Conversion time ~ 1.5 ms
Electrical isolation 500 V
) 35 V max.
CM
< ± 0.3 % (from measurement range end value)
24 V DC via power contacts
(alternatively 15 V DC with bus terminal KL9515)
± 0.5 LSB linearity error
± 0.5 LSB offset error
± 0.1, % (relative to the measuring range end value)
(K-bus/signal voltage)
eff
(K-bus/signal voltage)
eff
5
Specifications
Digital outputs
1-channel: 1 × for dosing pump and 1 × alarm
2-channel: 2 × for dosing pump and 1 × alarm
Nominal load voltage 24 VDC (–15 % / +20 %)
Load type Ohmic, inductive, lamp load
Max. output current 0.5 A (short-circuit proof) per channel
Short-circuit current 0.7 to 1.7 A
Reverse polarity protection Yes
Electrical isolation 500 V
(K-bus/field voltage)
eff
Power contact current consumption 20 mA typ. (for typ. 30 mA 2-channel device)
Equipment properties
Dimensions (L × W × H)
350 mm × 120 mm × 96 mm
(13.78 in. × 4.72 in. × 3.78 in.)
Mass approx. 0.9 kg
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
1
Pentium is a registered trademark of the Intel Corporation.
2
Microsoft Windows is a brand name for operating systems of the Microsoft Corporation.
6
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 Warning signs
Read all labels and tags attached to the instrument. Non-observance may result in
personal injury or damage to the equipment..
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 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
7
General Information
2.2 Areas of application
The RTC101 P-Module is a universal open-loop control and closed-loop control unit in
waste water treatment plants for automatic precipitant metering for phosphate
precipitation.
Depending on the operating situation, the precipitant dosage can be based on measured
values in the influent or effluent or based on profiles. The system automatically selects the
best possible strategy. The user is able to make restrictions manually.
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.)
2.3 Functional principle
In the following, a distinction is made between the open-loop control and the
closed-loop control of the precipitant concentration.
NOTICE
For the open-loop control of the precipitant dosing, the measuring point for the
phosphate concentration is upstream of the precipitant dosing point.
For the closed-loop control of the precipitant dosing, the measuring point for the
phosphate concentration is downstream of the precipitant dosing point.
The measuring point for the flow rate is usually located in the influent of the waste water
treatment plant. At the measuring point, the actual flow rate (influent quantity and
recirculation - e.g. RAS, MLR, etc) is determined via further entries in the RTC module.
If the measured values for the flow rate quantity and/or phosphate concentration are
temporarily not available (e.g. due to a malfunction), the system automatically refers back
to saved profiles.
Connect the following input signals on the control unit in order to make optimum use of all
system functions:
• Flow rate, measurement signal 4–20 mA
• Fault indicator signal of the flow rate measurement (230 V AC or 24 V DC)
In the event that measured value failures are not signaled according to NAMUR 43, as
the values are below the 4
Note: If these signals are not available, the equipment operates with limited functionality.
• sc1000 controller with PO4P PHOSPHAX sc analyzer.
The measured value is adopted directly.
• Dosing pump for the precipitant
The dosing pump is continuously actuated via a 0–20 mA or 4–20 mA current loop
signal as well as via a changeover contact. If the dosing rate is below the minimum
precipitant flow rate of the pump, the system automatically switches to pulse/pause
mode.
mA threshold.
8
2.4 Scope of delivery
Each RTC101 P-Module is supplied with:
• SUB-D connector (9 pin)
• Ferrite core, folding
• Manual
Check that the order is complete. If anything is missing or damaged, please contact the
manufacturer or distributor.
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.
General Information
NOTICE
9
General Information
2.5 Instrument overview
Figure1 Base module RTC 24 V version .
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
(CX1100-0002) and terminal module 24V.
10
Abbildung 2 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 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 13) 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.
11
General Information
12
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 the power supply is switched on, refer to the instructions in the relevant manuals!
3.1 RTC101 P-Module connection
The RTC module must be installed on a DIN rail/standard rail.
Install the module horizontally, with at least 30 mm clearance at the top and bottom, in
order to guarantee the functionality of the passive ventilation element. The RTC module is
operated solely via the sc1000 controller (see sc1000 controller operating instructions).
When used indoors, the RTC module can be installed in a control cabinet.
When used outdoors, the RTC module requires its own housing that follows the technical
specifications.
DANGER
CAUTION
CAUTION
3.1.1 Power supply to the RTC module
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.
Table1 Supply voltage of the RTC Module
Voltage 24 V DC (–15 % / +20 %), max. 25 W
Recommended fuse C2
With 110–230 V option 110–230 VAC, 50-60 Hz, approximately 25 VA
Note: An external deactivation switch is recommended for all installations.
3.2 Dosing pump connection
There are two connections for the dosing pump:
• Current loop signal 0/4 to 20 mA for analog actuation of pumps with frequency
converters.
• 24 V output for the actuation of pumps without frequency converters or below the
analog adjustment range in pulse/pause mode.
Note: It must also be possible to switch the pump off via the digital output in the case of analog
actuation!
WARNING
3.3 PHOSPHAX sc analyzer connection
The measuring signal of the PHOSPHAX sc analyzer is transmitted to the RTC101
P-Module from the sc-system via the RTC communication card.
Previous designs of the analyzer (e.g. PHOSPHAX inter) can be connected to an analog
input card (YAB018).
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Installation
3.3.1 PHOSPHAX sc analyzer power supply
Refer to the PHOSPHAX sc manual.
3.4 sc1000 controller connection
Connect the SUB-D plug supplied to a dual-core, sheathed data cable (signal or bus
cable). For further information regarding the data cable connection, refer to the enclosed
assembly instructions.
3.5 Flow rate signal connection
If a flow rate measurement signal of 4 to 20 mA is available, connect it to the analog input
of the RTC module.
3.6 Connection to the automation unit on the plant side
Depending on the variant and option, the RTC101 P-Module is equipped with various
components that must be connected to the plant's automation unit.
• The volumetric flow rate is provided to the RTC module as a 0/4 to 20 mA signal for all
variants and options.
• The precipitant volume to be metered is delivered by the RTC module as a 0/4 to
20
mA signal for all variants and options.
Alternatively, the precipitant volume can also be output by the fieldbus variants
provided by the sc1000 (see sc1000 operating instructions).
• The RTC module supplies the digital output signal for activating the precipitant pump
at 0
V or 24 V.
• The RTC module supplies a collective fault message at 0 V (fault) or 24 V (device
functional).
Table 2 Signal allocation of individual components of the RTC module
RTC module options
Component Name Connection Signal Function 1-channel 2-channel
1
1
KL2032
KL2134
2-fold digital output
4-fold digital output
Single analog output KL4011 1(+) 3(-) +24 V/0 V Precipitant pump dosing rate X
2-fold analog output KL4012
1-fold analog input KL3011 1(+) – 2(-) 0/4 to 20 mA Feed volume flow Channel 1 X X
2-fold analog input KL3011 1(+) – 2(-) 0/4 to 20 mA Feed volume flow Channel 2 X
1
Ground to connections 3 and 7 or equal to voltage supply
1 +24 V/0 V Precipitant pump on/off X
5 +24 V/0 V No fault/fault X
1 +24 V/0 V Precipitant pump 1 on/off X
5 +24 V/0 V No fault/fault in channel 1 X
4 +24 V/0 V Precipitant pump 2 on/off X
8 +24 V/0 V No fault/fault in channel 2 X
1(+) 3(-) +24 V/0 V Precipitant pump 1 dosing rate X
5(+) 7(-) +24 V/0 V Precipitant pump 2 dosing rate X
14
Section 4 Parameterization and operation
4.1 Open-loop control and closed-loop control programs
Four different programs are provided to enable optimal
adaptation to local conditions and to the available measurement
signals.
Programs 3 and 4 have various functions depending on whether
open-loop control or closed-loop control is selected.
4.1.1 Open-loop control
For the open-loop control of precipitant dosing, the measuring
point for phosphate concentration is upstream of the precipitant
dosing point.
4.1.1.1 Open-loop control according to phosphate concentration profiles
Program 1
Load-proportional open-loop control:
• Specified profile of the phosphate concentration in the reactor
inlet
• Specified profile for the flow rate
Program 2
Load-proportional open-loop control:
• Specified profile of the phosphate concentration in the reactor
inlet
• Flow rate measured value
Note: The prerequisite for this program is that the flow rate
measurement signal is valid. "Valid" means that the signal is present at
the relevant input.
4.1.1.2 Open-loop control according to measured phosphate values
Program 3
Load-proportional open-loop control:
• Measured value of the phosphate concentration in the reactor
inlet
• Specified profile for the flow rate
Note: The prerequisite for this program is that the PO4-P measurement
signal is valid. "Valid" means that the signal is present at the relevant
input.
Program 4
Load-proportional open-loop control:
• Measured value of the phosphate concentration in the reactor
inlet
• Flow rate measurement
Note: The prerequisite for this program is that both measurement signals
are valid. "Valid" means that the signal is present at the relevant input.
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