wtw TresCon Operating instructions

OPERATING MANUAL

ba43108e10 05/2017

TresCon

TERMINAL

2 ba43108e10 05/2017

TresCon

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

I1=17 mA

I3= 8 mA

P04-P Zulauf Belebung

NH4-N

K

1

2

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

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wtw TresCon Operating instructions

wtw TresCon Operating instructions

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