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OPERATING MANUAL
ba43108e10 05/2017
TresCon
TERMINAL
2 ba43108e10 05/2017
TresCon
Copyright © 2017 Xylem Analytics Germany GmbH
Printed in Germany.
TresCon List of contents
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TresCon - List of contents
1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 About this operating manual . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.1 Hardware and software components . . . . . . . . . 1-3
1.2.2 Field of application/features . . . . . . . . . . . . . . . . 1-5
1.2.3 Output of measured values . . . . . . . . . . . . . . . . 1-9
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Authorized operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Unauthorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 General safety instructions . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4 Use of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Response after a power failure . . . . . . . . . . . . . . . . . . . 2-4
2.6 Environmental protection/Disposal . . . . . . . . . . . . . . . . 2-4
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Prerequisites for installation . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Installing the TresCon . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Further connections (optional) . . . . . . . . . . . . . . . . . . . 3-18
3.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.4.2 Connecting lines to the terminal strip. . . . . . . . 3-19
3.4.3 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.4.4 Valve control . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.4.5 Recorder outputs . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.4.6 Digital interfaces: General information. . . . . . . 3-24
3.4.7 RS485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.4.8 RS232 (V24) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.4.9 Modem on RS232 . . . . . . . . . . . . . . . . . . . . . . 3-27
3.5 Option: Overflow vessel with controllable valve . . . . . . 3-28
3.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.5.2 Installing the overflow vessel with valve . . . . . 3-30
3.5.3 Maintenance of the overflow vessel with valve 3-37
3.6 Option: Permeate switch . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.6.1 Installing the permeate switch . . . . . . . . . . . . . 3-39
3.7 Connecting the supply of consumables . . . . . . . . . . . . 3-44
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4 Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Checklist for initial commissioning . . . . . . . . . . . . . . . . . 4-1
4.2 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 System settings after initial commissioning . . . . . . . . . . 4-2
4.4 Commissioning after retrofitting . . . . . . . . . . . . . . . . . . .4-3
4.5 Operating structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Basic principles of operation . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Operating elements . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.2 Structure of the display. . . . . . . . . . . . . . . . . . . . 5-4
5.1.3 Menu guidance . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.1.4 The General Parameters menu . . . . . . . . . . . . . 5-7
5.1.5 Selecting an analyzer module. . . . . . . . . . . . . . . 5-9
5.1.6 Calling up the menu list of an analyzer module 5-10
5.1.7 Entering/changing values - Example . . . . . . . . 5-11
5.1.8 Entering alphanumeric characters . . . . . . . . . . 5-14
5.2 Measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5.2.1 Daily/weekly load diagram . . . . . . . . . . . . . . . . 5-15
5.2.2 Composite sample . . . . . . . . . . . . . . . . . . . . . . 5-19
5.2.3 Mean values . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.2.4 Data storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.3 Relay functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30
5.3.1 General information . . . . . . . . . . . . . . . . . . . . . 5-30
5.3.2 Proportional controller: Basic information. . . . . 5-30
5.3.3 Limit indicator: basic information . . . . . . . . . . . 5-37
5.3.4 Setting up a relay . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.3.5 Relays as frequency controllers . . . . . . . . . . . . 5-42
5.3.6 Relays as pulse-width controllers . . . . . . . . . . . 5-43
5.3.7 Relays as limiting value signal . . . . . . . . . . . . . 5-45
5.3.8 Relays as indicator contacts. . . . . . . . . . . . . . . 5-47
5.3.9 Display and recording of relays . . . . . . . . . . . . 5-49
5.4 Recorder function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-50
5.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5.4.2 Setting up the recorder . . . . . . . . . . . . . . . . . . . 5-50
5.4.3 Recorder function, output of measured values. 5-54
5.4.4 Recorder function, regulator . . . . . . . . . . . . . . . 5-55
5.4.5 Recorder function, control. . . . . . . . . . . . . . . . . 5-57
5.4.6 Display of the recorders . . . . . . . . . . . . . . . . . . 5-59
5.5 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-60
5.5.1 RS232 interface parameters. . . . . . . . . . . . . . . 5-61
5.5.2 RS485 (Slave) interface parameters . . . . . . . . 5-63
5.5.3 RS485 (Master) interface parameters . . . . . . . 5-65
5.6 Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-67
5.6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5.6.2 View/change the module-specific parameters . 5-68
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5.6.3 Initializing the modem and setting up a test
connection . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5.6.4 Deactivating the modem . . . . . . . . . . . . . . . . . 5-75
5.7 Controller settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5.7.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5.7.2 Record printout . . . . . . . . . . . . . . . . . . . . . . . . 5-78
5.7.3 Designation of the analyzer module. . . . . . . . . 5-83
5.7.4 Selection of the display language . . . . . . . . . . 5-86
5.7.5 Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5.7.6 TresCon Info . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5.7.7 Date and time. . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5.8 Valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
5.9 Permeate switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5.10 N balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Calling up the service menu . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1 Testing the recorders . . . . . . . . . . . . . . . . . . . . . 6-3
6.1.2 Test of the relays and valves . . . . . . . . . . . . . . . 6-4
6.1.3 Testing the interfaces. . . . . . . . . . . . . . . . . . . . . 6-6
6.1.4 Service records . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.1.5 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.1.6 Display test . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.1.7 Keyboard test. . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Modem on RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 RS485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3.1 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.3.3 Master operation . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.3.4 Slave operation . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4 Interface commands . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.4.1 General RS commands . . . . . . . . . . . . . . . . . . 8-11
8.4.2 RS commands for modem . . . . . . . . . . . . . . . . 8-15
8.4.3 Commands for PROFIBUS . . . . . . . . . . . . . . . 8-20
8.5 Accessories and consumables . . . . . . . . . . . . . . . . . . . 8-24
9 Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
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TresCon Overview
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1Overview
The first chapter contains the following information:
Structure and contents of this operating manual
Structure and function of TresCon
Please read the following section 1.1 A
BOUT THIS OPERATING MANUAL
before starting to work with the TresCon. You will discover how to
rapidly find the information that you require.
1.1 About this operating manual
This operating manual has a modular structure. It contains a separate
operating manual for each individual component of the analyzer (see
Fig. 1-1). Part 1, T
ERMINAL is always available; the other parts depend
on the configuration of the analyzer.
Structure
Fig. 1-1 Structure of the operating manual
Terminal
TresCon
Module 1
TresCon
Module 2
TresCon
Module 3
TresCon Analyzer
Part 1
TresCon
Terminal
Part 3
TresCon
Module 2
Part 4
TresCon
Module 3
Part 2
TresCon
Module 1
Operating
manual of
the
TresCon
analyzer
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Lists Each part of the operating manual contains the following lists:
List of contents
Index
The present section additionally contains the
list of abbreviations.
These lists enable you to quickly find the correct information.
Note
The screen dialog and menu guide are described in section B
ASIC
PRINCIPLES OF OPERATION on page 5-1.
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1.2 General information
1.2.1 Hardware and software components
The analyzer is made up of the following components:
Terminal
1 to 3 analyzer modules of the following types:
– TresCon NH4-N for measuring ammonium - nitrogen
– TresCon NO2-N for measuring nitrite - nitrogen
– TresCon NOx-N for measuring nitrate/nitrite - nitrogen
– TresCon NOx-N/SAK for measuring nitrate/nitrite - nitrogen and
the spectral absorption coefficient
– TresCon PO4-P for measuring orthophosphate
– TresCon Pges for measuring total phosphate
The modular structure of the analyzer enables individual adaptation to
your specific requirements. Up to three different analyzer modules can
be installed at the same time.
Hardware The individual components of the analyzer have their own
microprocessors (with specific software routines).
The controller of the terminal and the analyzer modules communicate
with each other via a data bus. The processor in the controller
administrates and controls the individual analyzer modules.
This involves the use of the CAN bus that is particularly suitable for
harsh environmental conditions.
The operation and programming of the entire instrument is carried out
on the controller.
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Software The software-related task distribution of controller and analyzer
modules is reflected in the menu structure:
Fig. 1-2 Software structure
Task distribution All the processes that are involved in the data exchange with the
individual components run in the background and have no significance
for the user.
Menu
Menu of the
central unit
(controller)
Measuring
mode
Module 1
Module 2
Menu
Selected
module
(here 1)
4
42
3
4
Software Task
Controller Administration of all functions and parameters that
are independent of the type and number of the
individual analyzer modules, e.g. data storage,
recorder output, relay output, RS interfaces.
Modules
1 ... 3
Administration of all the functions and parameters
that involve a specific analyzer module ("parameter-
specific" settings), e.g. AutoCal parameters or
AutoClean parameters.
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1.2.2 Field of application/features
The analyzer is a continuously measuring precision analyzing system
for the control and optimization of biological waste water purification
processes. The instrument performs numerous monitoring tasks in
water/waste water treatment, especially within the sewage treatment
plant.
ATV specification M269 The TresCon fulfills all the points of the guidelines specified in the
"Requirements of on-line process analysis instruments for N and P" in
the ATV specification, M269:
High availability of the systems to ensure continuous operation of
the wastewater treatment plant,
Fast response time of the analyzing instruments to changes in
concentration to ensure efficient control,
Automatic calibration with minimum interruption of the measuring
operation.
Features TresCon combines the proven features of the WTW analyzers with the
additional new developments:
AutoThermControl: Adjusting the temperature of the plant.
AutoFlowControl: Pressure measurement for the identification of
clogging, leakage and levels of reagents.
AutoClean system: Self cleaning.
AutoCal system: Automatic calibration.
AutoRead system: Automatic evaluation of the measured values
when measuring absorbance.
AutoAdapt system: Minimum reagent consumption by automatically
adapting the measuring intervals to any change in concentration.
Maintenance: User guidance for service activities via display texts
and inputs (interactive menu guidance). TresCon provides
information on the maintenance activities that are due.
Controller functions for the regulated phosphate precipitation or
denitrification and nitrification:
– P, PI, PD, PID controller of the mA outputs,
– Frequency controller or pulse-width controller of the relay
outputs.
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Controller The controller is the operating unit of the instrument. It is equipped with
a planar display that also enables the graphical representation of
measured values such as daily and weekly load diagrams. The
operation of all the components is menu-driven via the display and keys
in the dialog system. The individual components of the analyzer
communicate internally via a data bus.
Fig. 1-3 Controller
Configuration The voltage supply is provided by an integrated power unit located in
the mounting stand. All the analyzer modules and the controller are fed
with protective low voltage (24 V).
The analyzer modules are separated from the controller (operating and
electronic parts) by a partition and can be accessed individually
(service-friendly).
TresCon
<<Stop
>19.2
NH4-N Zulauf Belebung
I2=18 mA
mg/l
mg/l
mg/l
I1=17 mA
I3= 8 mA
P04-P Zulauf Belebung
NH4-N
K
K
K
K
K
K
K
K
K
K
1
2
4
4
6
7
4
10
11
12
N03-N
N03-N Ablauf Kläranlage
1.23
26.32
23.04.2000 07:24
M
C
P04-P
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Fig. 1-4 Single analyzer module, e.g. TresCon NOx-N
Reagents The reagent containers and standards stand on a tray. The containers
are color coded. The colors correspond to the color of the individual
analyzer modules. This enables the containers to be uniquely
identified.
The fittings are also color coded so that the tubing can be connected
without any problem.
All the components can be combined to form a distinct and compact
unit. As a result of the modular conception of the instrument, the
analyzer modules can be operated completely independently of one
another. This ensures that, during the maintenance of an analyzing
module, the remaining analyzing modules can be operated without any
problem.
TresCon N0x-N
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View of the instrument
Fig. 1-5 Overall view of the analyzer
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1.2.3 Output of measured values
Altogether, the analyzer provides the following options to record, store
and output the measured values and messages:
In addition, the measured values can be forwarded to external devices
(e.g. recorder, PC) via the interfaces (RS 232, RS 485, modem, 20 mA
recorder output).
Display Display
Measuring mode In normal operation, the current measured
values of the individual analyzer modules
are displayed on the screen of the controller.
Daily/weekly load
diagram
The display mode allows you to display one
or more measured values for daily, weekly or
monthly periods of time as graphs on the
display or to output them via an external
printer.
Data storage The display of one or more measured values
for the last four weeks in the form of a list.
The values can also be output to an external
printer.
Record The comprehensive record functions enable
data records to be compiled (analyzer
module-related, time-dependent, etc...) and
the corresponding interval to be individually
optimized.
Report The report function enables the limiting
conditions and operating states to be traced
in case of malfunction or performance
problems. This simplifies maintenance work;
the instrument configuration can be
optimally adapted to individual operating
conditions.
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TresCon Safety
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2 Safety
This chapter contains basic instructions that you must follow during the
commissioning, operation and maintenance of the instrument.
Consequently, the user must read this chapter before working with the
instrument. The operating manual must always be available within the
vicinity of the instrument.
2.1 Authorized operation
The authorized operation of this automatic analyzer consists of
the measuring of components according to the parameters of the
analyzer modules,
the regulation and control of biological waste water-purification
processes in the sewage treatment plant and in selected industrial
applications,
measuring of surface water.
Only the operation and running of the automatic analyzers according to
the instructions in this operating manual is authorized.
2.2 Unauthorized use
Unauthorized use includes all the types of handling and operation that
exceed the operation of the analyzer and individual components as
documented in this operating manual.
2.3 General safety instructions
Function and operating
safety
The analyzer left the factory in a safe and secure condition. The smooth
functioning and operational safety of the instrument can only be
guaranteed under the environmental and electrical operating
conditions that are specified in chapter 7 T
ECHNICAL DATA.
The smooth functioning and operational safety of the instrument can
only be guaranteed if the generally applicable
safety measures and the specific safety instructions in this operating
manual are followed during operation.
Caution
Noncompliance with the operating instructions and safety instructions
in this operating manual can endanger the safety of the operating
personnel!
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Caution
Opening the instrument or adjustment, maintenance and repair work
that exceed the activities described in chapter 6 M
AINTENANCE must
only be performed by specialist personnel authorized by the company,
WTW.
Technical condition It is the responsibility of the operator to continuously observe the
overall technical condition (externally recognizable deficits and
damage as well as alterations to the operational behavior) of the
analyzer.
Safe operation If safe operation is no longer possible, the instrument must be taken out
of service and secured against inadvertent operation!
Safe operation is no longer possible if, e.g.
the instrument has been damaged in transport,
the instrument has been stored under adverse conditions,
the instrument is visibly damaged, or
the instrument no longer operates correctly.
If you are in any doubt, please contact the supplier of the instrument.
Operating personnel TresCon was developed for use in wastewater treatment plants. We
assume that, as a result of their professional training and experience,
the operators will know the necessary safety precautions to take when
handling chemicals.
Personal
protective equipment
During all maintenance activities on the wet chemistry section of the
modules, and when renewing consumables, the following protective
equipment must be used:
Obligations of the
purchaser
The purchaser of this automatic analyzer must ensure that the following
laws and guidelines are observed when using dangerous substances:
EEC directives for protective labor legislation
National protective labor legislation
Safety regulations
Safety datasheets of the chemicals and consumable materials used
(see appendix of the operating manual of the individual modules).
Wear protective
goggles
Wear protective
gloves
Wear protective
clothing
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2.4 Use of symbols
Warning
This symbol indicates danger to life and limb.
It is essential to read and follow these instructions!
Caution
This symbol indicates danger of material damage that could occur as a
result of faulty operation. It is essential to read and follow these
instructions!
Warning
This symbol indicates danger to life and limb in connection with
electricity. It is essential to read and follow these instructions!
Note
This symbol indicates instructions that describe special features
and simplify your work with the instrument.
Note
This symbol indicates information in other sections of this operating
manual and other documents.
Corrosive
Indicates danger by corrosive substances when dealing with reagent or
cleaning solutions in certain analyzer modules (see operating manual
of the analyzer module).
Irritating
Indicates danger by irritating substances when dealing with reagent or
cleaning solutions in certain analyzer modules (see operating manual
of the analyzer module).
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Wear protective goggles
This symbol indicates that you must wear protective goggles.
Activities that endanger health, especially the eyes, are indicated in the
operating manual with this symbol.
Wear protective gloves
This symbol indicates that you must wear protective gloves.
Activities that endanger health, especially the hands, are indicated in
the operating manual with this symbol.
Wear protective clothing
This symbol indicates that you must wear protective clothing.
Activities that endanger health are indicated in the operating manual
with this symbol.
2.5 Response after a power failure
After a power failure, the status before the power failure is
automatically restored. If necessary, the blocks are heated up first.
2.6 Environmental protection/Disposal
WTW products are designed to take into account the recycling and
disposal of the product at the end of its lifetime as a constituent part of
product development. Our factory standards lay down stringent
requirements.
Mode before a power failure Mode after a power failure
Measure Measuring mode ( after
AutoTherm) or AutoClean or
AutoCal if the AutoClean interval or
the AutoCal interval has expired
AutoCal AutoCal or AutoClean, if the
AutoClean interval has expired
AutoClean AutoClean
Stop, Service,
Parameterization
Stop
/
