DOC023.52.90447 RTC112 SD-Module Real Time Control System for Sludge Dewatering User manual 07/2013, Edition 1A © HACH-LANGE GmbH, 2013. 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................
Table of contents 4.7 CONTROL PARAMETER .................................................................................................................30 4.7.1 FACTOR POLYMER DOSING.................................................................................................30 4.7.2 POLYMER CONCENTRATION ...............................................................................................30 4.7.3 MANUAL POLYMER DOSING............................................................................
Table of contents 4.11 Displayed measurement values and variables ............................................................................... 34 Section 5 Maintenance ......................................................................................................................... 37 5.1 Maintenance schedule...................................................................................................................... 37 Section 6 Troubleshooting.............................................
Table of contents 6
Section 1 Technical data These are subject to change without notice.
Technical data 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 Veff (K-bus/field voltage) Equipment properties Dimensions (W × H × D) One-channel: 191 × 120 × 96 mm (7.52 × 4.72 × 3.
Section 2 2.1 General information 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.
General information 2.2 Areas of application The RTC112 SD-Module (Real Time Controller for Sludge Dewatering) is an open and closed-loop control unit for universal applications. It can be used by mechanical sludge dewatering devices, such as centrifuges in wastewater treatment plants.
General information 2.
General information Figure 2 Design of the analog and digital input and output modules 1 2 1 Input- or Output- Module or Bus Termination Module analog or digital 2 LED area with installed LEDs or free LED installation spaces Note: The number of green LEDs indicates the number of channels. 2.5 2.5.
General information NOTICE In a closed-loop circuit, TSS measurement is required in centrate or dewatered sludge. The program of the RTC112 SD-Module has to be adjusted to the type of measurement location that is being used for the closed loop part of the RTC. This is done by executing *.bat files on the CF card of the RTC. Make_Filtrate.bat has to be executed for applications where centrate TSS is measured and Make_Effluent for applications where dewatered/thickened sludge is measured.
General information Figure 3 Adjustment of the polymer dosing rate to the influent TSS load 1 Digester 9 2 Static thickener 10 Pump for open-loop control of the polymer dosing rate 3 Measurement of the feed flow rate 11 Mechanical sludge dewatering device 4 TSS measurement from the influent 12 Dewatered sludge 5 Open-loop control of the polymer dosing rate (feed flow rate measurement value) 13 Centrate 6 Open-loop control of the polymer dosing rate (influent TSS concentration measurement v
General information Figure 4 Adjustment of the feed flow rate to fixed polymer dosing rate 1 Digester 8 Pump for polymer dosing (constant) 2 Static thickener or sludge storage 9 Mechanical sludge dewatering device 3 TSS measurement from the influent 10 Dewatered sludge 4 Open-loop control for the feed flow rate 11 Centrate 5 RTC112 SD-Module 12 Option: Measurement of the TSS concentration in the centrate 6 Pump for open-loop control of the feed flow rate 7 Polymer supply 13 Option: Me
General information 16
Section 3 Installation DANGER Only qualified experts may perform the tasks described in this section of the manual, while adhering to all locally valid safety regulations. CAUTION Always lay cables and hoses so that they are straight and do not pose a tripping hazard. CAUTION Before the power supply is switched on, refer to the instructions in the relevant manuals. 3.1 Installation of the RTC Module Only install the RTC Module on a DIN rail.
Installation 3.4 Connection to the automation unit on the plant side The one-channel and two-channel versions of the RTC112 SD-Module are equipped with various modules that must be connected to the plant automation system. • The feed flow rate must be provided to the RTC112 SD-Module as a 0/4 to 20 mA signal. • The polymer flow rate must be provided (on both versions) to the RTC112 SD-Module as a 0/4 to 20 mA signal. • The polymer pump can be operated in pulse/pause mode (PWM).
Installation Table 4 Connections for the 2-channel RTC112 SD-Module Module Name Connection Signal Channel Function 2x analog output KL4012 1(+) - 3(-) 2 Output of the polymer pump flow rate 5(+) - 7(-) 0/4 to 20 mA 2 Output of the feed flow rate 1x analog input KL3011 1(+) - 2(-) 0/4 to 20 mA 1 Input of the feed flow rate 1x analog input KL3011 1(+) - 2(-) 0/4 to 20 mA 1 Input of the polymer flow rate 1x analog input KL3011 1(+) - 2(-) 0/4 to 20 mA 2 Input of the feed flow rat
Installation Figure 5 Connections and corresponding LEDs for digital output card KL2408 (2 channel option only) a LED a e LED e b LED b f LED f c LED c g LED g d LED d h LED h 1 Connector 1 9 Connector 5 2 Connector 2 10 Connector 6 3 Connector 3 11 Connector 7 4 Connector 4 12 Connector 8 20
Section 4 4.1 Parameterization and operation Operating the sc controller The RTC Module can only be operated via 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 sc1000 setup 1. Open the MAIN MENU. 2. Select RTC MODULES / PROGNOSYS and confirm. 3. Select RTC MODULES and confirm. 4.
Parameterization and operation 4.4.1 RTC112 SD-Module open and closed-loop controller (Continued) RTC MODULES / PROGNOSYS RTC MODULES RTC PRESELECT PROG. CHANNEL 1 POLYMER DOSING CONTROL Based on the feed flow rate [m³/h] and measured TSS concentration [g/L] from the influent, the polymer dosing rate [L/h] is calculated such that it corresponds to the target specific polymer dosing rate [g/kg].
Parameterization and operation 4.4.1 RTC112 SD-Module open and closed-loop controller (Continued) RTC MODULES / PROGNOSYS RTC MODULES RTC MAX DECREASE CLOSED L This value defines the maximum decrease of the specific polymer dosing rate FACTOR POLYMER DOSING [g/kg] if CLOSED-LOOP EFFLUENT CONTROL is selected. g/kg MAX INCREASE CLOSED L This value defines the maximum increase of the specific polymer dosing rate FACTOR POLYMER DOSING [g/kg] if CLOSED-LOOP EFFLUENT CONTROL is selected.
Parameterization and operation 4.4.1 RTC112 SD-Module open and closed-loop controller (Continued) RTC MODULES / PROGNOSYS RTC MODULES RTC DERIVATIVE TIME FILT CHANNEL 2 Derivative time for the PID closed-loop controller for the TSS concentration in the centrate/filtrate. Note: This parameter is only considered if CLOSED-LOOP FILTRATE CONTROL is activated.
Parameterization and operation 4.4.1 RTC112 SD-Module open and closed-loop controller (Continued) RTC MODULES / PROGNOSYS RTC MODULES RTC INPUTS CHANNEL 1 MIN FEED FLOW Minimum flow rate [m³/h] from the influent in accordance with the 0/4 mA measurement signal. m³/h MAX FEED FLOW Maximum flow rate [m³/h] from the influent in accordance with the 20 mA measurement signal. m³/h 0/4...20mA Transfer range of 0/4 to 20 mA current loop (as set in connected flow measuring instrument).
Parameterization and operation 4.4.1 RTC112 SD-Module open and closed-loop controller (Continued) RTC MODULES / PROGNOSYS RTC MODULES RTC MODBUS ADDRESS Start address of an RTC within the MODBUS network. Default setting: 41–61 DATA ORDER Specifies the register order within a double word. Presetting: NORMAL DATALOG INTRVL Indicates the interval in which the data is saved in the log file. SET DEFAULTS Restores the factory settings.
Parameterization and operation Figure 6 Select sensor 1 ENTER — Saves the setting and returns to the CONFIGURE menu. 4 DELETE — Removes a sensor from the selection. 2 CANCEL — Returns to the CONFIGURE menu without saving. 5 UP/DOWN — Moves the sensors up or down. 3 ADD — Adds a new sensor to the selection. 2. Press ADD (Figure 6, item 3). A selection list of all subscribers to the sc1000 network opens. 3.
Parameterization and operation 4. The selected sensor is shown in the sensor list. Press ADD (Figure 6, item 3) to open the selection list again. 5. Select the second sensor for the RTC Module and confirm by pressing ENTER below the selection list. Note: Previously selected sensors are shown in gray. The selected sensors are shown in the sensor list. 6. To sort the sensors in the order specified for the RTC Module, press the sensor and use the arrow keys to move it (Figure 6, item 5).
Parameterization and operation 4.6 4.6.1 PRESELECT PROG POLYMER DOSING CONTROL Based on the measured feed flow rate [m³/h] and the measured TSS concentration [g/L] from the influent, the polymer dosing rate [L/h] is calculated such that the setpoint corresponds to the specific polymer dosing rate [g/kg]. Note: This open-loop control mode can only be activated if FEED FLOW CONTROL is deactivated. Note: The polymer flow rate is controlled via the RTC. 4.6.
Parameterization and operation 4.7 4.7.1 CONTROL PARAMETER FACTOR POLYMER DOSING Required specific polymer dosing [g/kg]. This parameter determines how many grams of polymer per kilogram of TSS are fed by the system. 4.7.2 POLYMER CONCENTRATION Polymer concentration [g/L] fed via the polymer pump. 4.7.3 MANUAL POLYMER DOSING The RTC outputs the polymer dosing rate [L/h] if 4.7.4 • FEED FLOW CONTROL is activated • No open-loop control mode (section 4.6.1 to section 4.6.
Parameterization and operation 4.7.8 P GAIN TSS Proportional gain for the PID closed-loop controller for the TSS concentration in the dewatered sludge. Note: P GAIN TSS [L/g] is divided by 100 before it is multiplied by the deviation of the actual TSS concentration from the required TSS setpoint. 4.7.9 INTEGRAL TIME TSS Integral time for the PID closed-loop controller for the TSS concentration in the dewatered sludge.
Parameterization and operation 4.8.2 FEED FLOW HIGH Feed flow rate input signals above this value [m3/h] are set to this value. This avoids load peaks. 4.8.3 FEED FLOW SMOOTHING Feed flow measurement values are smoothed in line with this parameter. SMOOTHING = 1: The signal for the flow rate measurement is not smoothed. SMOOTHING = 2: Smoothing is performed over 3 minutes. SMOOTHING = 3: Smoothing is performed over 5 minutes. SMOOTHING = 5: Smoothing is performed over 12 minutes.
Parameterization and operation 4.8.9 TSS OUT SMOOTHING TSS measurement values from the effluent are smoothed in line with this parameter. SMOOTHING = 1: The signal is not smoothed. SMOOTHING = 2: Smoothing is performed over 3 minutes. SMOOTHING = 3: Smoothing is performed over 5 minutes. SMOOTHING = 5: Smoothing is performed over 12 minutes. SMOOTHING = 10: Smoothing is performed over 25 minutes. 4.8.
Parameterization and operation 4.9.6 0/4...20 mA Transfer range of the 0/4 to 20 mA current loop (as set in connected flow measuring instrument). 4.10 OUTPUTS 4.10.1 MIN FEED FLOW Minimum feed flow rate [m³/h] in accordance with 0/4 mA. 4.10.2 MAX FEED FLOW Maximum feed flow rate [m³/h] in accordance with 20 mA. 4.10.3 0/4...20 mA Transfer range of 0/4 to 20 mA current loop (as set in connected flow measuring instrument). 4.10.
Parameterization and operation RTC112 SD-Module, one-channel Parameter Unit Description Measurement 1 Qin 1 m3/h Flow rate from the influent Measurement 2 Qavg 1 m3/h Average flow rate Measurement 3 Qdos1 L/h Polymer flow rate Measurement 4 TSin 1 g/L TSS concentration from the influent Measurement 5 TSef 1 g/L TSS concentration from the effluent Actuat var 6 Pdos1 L/h Polymer dosing Actuat var 7 Fact 1 g/kg Specific polymer dosing Feed 1 m3/h Feed flow rate Actuat var 8
Parameterization and operation 36
Section 5 Maintenance DANGER Multiple hazards Only qualified personnel must conduct the tasks described in this section of the manual. 5.
Maintenance 38
Section 6 6.1 Troubleshooting Error messages Possible RTC errors are displayed by the sc controller.
Troubleshooting 40
Section 7 7.1 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. Length: 35 cm (13.78 in.) LZH165 Transformer 90–240 V AC/24 V DC 0.75 A, module for DIN rail assembly LZH166 Terminal for 24 V connection without power supply LZH167 Terminal for protective earth LZH168 SUB-D connector LZH169 C2 circuit breaker LZH170 CPU base module with Ethernet port, passive ventilation element.
Replacement parts and accessories 42
Section 8 Contact information HACH Company World Headquarters P.O. Box 389 Loveland, Colorado 80539-0389 U.S.A. Tel (800) 227-HACH (800) -227-4224 (U.S.A. only) Fax (970) 669-2932 orders@hach.com www.hach.com Repair Service in the United States: HACH Company Ames Service 100 Dayton Avenue Ames, Iowa 50010 Tel (800) 227-4224 (U.S.A. only) Fax (515) 232-3835 Repair Service in Canada: Hach Sales & Service Canada Ltd.
Contact information HACH LANGE D.O.O. Fajfarjeva 15 SI-1230 Domžale Tel. +386 (0)59 051 000 Fax +386 (0)59 051 010 info@hach-lange.si www.hach-lange.si HACH LANGE OOO Finlyandsky prospekt, 4A Business Zentrum “Petrovsky fort”, R.803 RU-194044, Sankt-Petersburg Tel. +7 (812) 458 56 00 Fax. +7 (812) 458 56 00 info.russia@hach-lange.com www.hach-lange.com 44 ΗΑCH LANGE E.Π.Ε. Αυλίδος 27 GR-115 27 Αθήνα Τηλ. +30 210 7777038 Fax +30 210 7777976 info@hach-lange.gr www.hach-lange.gr HACH LANGE D.O.O.
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.
Warranty and liability 46
Appendix A MODBUS address setting The same slave address must be set for MODBUS communication on the sc1000 controller display and in the RTC module. Since 20 slave numbers are reserved for internal purposes, the following numbers are available for assignment: 1, 21, 41, 61, 81, 101… The start address 41 is preset at the factory.
Appendix B Configuration of the network modules B.
Index Numerics 1-channel version ..................................................... 18 2-channel version ..................................................... 18 A Address setting ........................................................ 47 aeration element ...................................................... 11 B Battery compartment ................................................ 11 C Closed-loop controller behavior ............................... 12 Concentration of solids SOLITAX sc .............
Index 52
