3D TRASAR Technology Installation and Operation Manual · This manual covers the following models: • 3D TRASAR 5500 Series • 3D TRASAR 3500 Series • 3D TRASAR Technology for

This manual covers the following models:

• 3D TRASAR 5500 Series

• 3D TRASAR 3500 Series

• 3D TRASAR Technology for Closed Loop Applications

• 3D TRASAR Technology for High Fouling Applications

• 3D TRASAR Models for the Pacific

3D TRASAR® TechnologyInstallation and Operation Manual

Version 8.0

3D TRASAR 5500 - Installation & Operation Manual

521-OM0108.88Copyright 2009 Nalco Company

iTechnical Help(630) 305-CHEM

TRASAR Technology License

Nalco Company1601 W. Diehl RoadNaperville, IL 60563

TrademarksPRISM, Vantage, 3D TRASAR, STA-BR-EX, ACTI-BROM, Nalco and the logo are RegisteredTrademarks of Nalco Company.

Towerbrom is a registered trademark of Occidental Chemical Corporation.

Nalco has one or more patents and related know-how, which pertain to either TRASAR or 3DTRASAR method of use or practice of technology (“Tracer Technology”). Buyer’s purchase ofequipment, software and chemicals from Nalco conveys to Buyer a non-assignable and non-trans-ferable express license to practice Tracer Technology that correlates with equipment, software andchemicals that Buyer chooses to purchase from Nalco for its water treatment facilities needs for thepractice of Tracer Technology. Such license, however, terminates upon Buyer’s discontinued use ofNalco chemical(s) with Tracer Technology, unless, Buyer negotiates a separate express licenseagreement with Nalco.



TOC-1Technical Help(630) 305-CHEM

Table of ContentsSection 1: Introduction1.1 About the 3D TRASAR® 5500................................................................................ 1-11.2 About this Manual ................................................................................................. 1-11.3 3D TRASAR 3500 and 3D TRASAR 5500 Models and Optional Components .. 1-11.4 3D TRASAR 3500 and 3D TRASAR 5500 Overview ............................................ 1-31.5 How the 3D TRASAR 5500 System Works .......................................................... 1-4

1.5.1 Fluorometer ............................................................................................................... 1-41.5.2 3D TRASAR Scale Control, 3D TRASAR Bio-Control, & NCM Corrosion Technology1-41.5.3 Data Storage / Reporting and Communications ......................................................... 1-5

1.6 Safety .....................................................................................................................1-6

Section 2: Installation and Start-Up2.1 STEP 1 - Unpack and Identify ............................................................................... 2-2

2.1.1 Identify Hardware Model ............................................................................................ 2-22.1.2a Pre-Installed Items (all models) .................................................................................. 2-42.1.2b Pre-Installed Items (3D TRASAR 5500 models only) ................................................. 2-42.1.3a Items Requiring Assembly (all models) ...................................................................... 2-42.1.3b Items Requiring Assembly (3D TRASAR 5500 models only) ...................................... 2-42.1.4 Pellet Feeder Assembly (Optional) ............................................................................. 2-52.1.5 Items Shipped Separately .......................................................................................... 2-52.1.5a 3D TRASAR Starter Upgrades .................................................................................. 2-52.1.5b 3D TRASAR Start-up and Maintenance Kits .............................................................. 2-5

2.2 STEP 2 - Mount the Controller .............................................................................. 2-62.2.1 General Instructions ................................................................................................... 2-62.2.2 3D TRASAR Controller Dimensions .......................................................................... 2-72.2.3 Wall Mounting Templates ......................................................................................... 2-112.2.4 Frame Mount Template ............................................................................................ 2-14

2.3 STEP 3 - Install Bio-reporter Feeder .................................................................. 2-152.3.1 Install Bio-reporter Pellet Feeder .............................................................................. 2-152.3.2 Install Liquid Bio-reporter Pump ............................................................................... 2-17

2.4 STEP 4 – Plumb Controller ................................................................................. 2-182.4.1 Sample Point Selection ............................................................................................ 2-182.4.2 3D TRASAR 5500 Inlet Water Plumbing .................................................................. 2-192.4.3 3D TRASAR 5500 Outlet Water Plumbing ............................................................... 2-202.4.4 Chemical Feed Pumps ............................................................................................ 2-212.4.5 Typical Installation Drawing ...................................................................................... 2-22

2.5 STEP 5 – Plumb Bio-reporter Feeder ................................................................ 2-232.5.1 Pellet Feeder Plumbing ............................................................................................ 2-232.5.2 Pellet Feeder Best Practices .................................................................................... 2-242.5.3 Liquid Bio-reporter Plumbing .................................................................................... 2-24

2.6 STEP 6 – Install Probes ...................................................................................... 2-252.6.1 Fluorometer Installation ............................................................................................ 2-262.6.2 pH Probe Installation ................................................................................................ 2-27




2.6.3 ORP Probe Installation ............................................................................................. 2-282.6.4 Conductivity Probe Installation ................................................................................. 2-292.6.5 NCM Corrosion Probe Installation ............................................................................ 2-30

2.7 STEP 7 - Wiring ................................................................................................... 2-322.7.1 General Information ................................................................................................. 2-322.7.2 Controller Box Layout............................................................................................... 2-332.7.3 Controller Wiring Details .......................................................................................... 2-342.7.4 Junction Box Layout ................................................................................................ 2-362.7.5 Junction Box Details ................................................................................................ 2-372.7.6 System Power Connections ..................................................................................... 2-382.7.7 Internal Power Connections ...................................................................................... 2-382.7.8 Control Relay Connections - Powered (120 VAC fused @ 2.5 amps) ....................... 2-392.7.9 Control Relay Connections - Non-Powered (fused @ 2.5 amps) .............................. 2-402.7.10 Control Relay Connections - Termination Details ..................................................... 2-412.7.11 Pellet Feeder Connections ....................................................................................... 2-432.7.12 System Probe Connections ..................................................................................... 2-432.7.13 Analog I/O Connections ........................................................................................... 2-452.7.14 Factory Wired Digital Inputs ..................................................................................... 2-462.7.15 User Wired Digital Inputs ......................................................................................... 2-462.7.16 Alarm Output Connections ....................................................................................... 2-472.7.17 Phone Line Connections .......................................................................................... 2-472.7.18 Ethernet (Direct Connect to 3D TRASAR 5500) ....................................................... 2-482.7.19 LAN Connections ..................................................................................................... 2-482.7.20 SCADA Connections (Modbus RTU) ....................................................................... 2-482.7.21 Nalco Global Gateway.............................................................................................. 2-48

2.8 STEP 8 – Calibration & System Checkout ........................................................ 2-492.8.1 Establish Sample Flow & Apply Power...................................................................... 2-492.8.2 Calibrate Probes ...................................................................................................... 2-502.8.3 Checkout Control Relays ......................................................................................... 2-51

2.9 STEP 9 - Start-up System ................................................................................... 2-52

Section 3: 3D TRASAR Configurator3.1 PC system requirements ...................................................................................... 3-13.2 Installing the software .......................................................................................... 3-13.3 Configurator support ............................................................................................ 3-2

3.3.1 Sample Help Screen .................................................................................................. 3-23.3.2 Sample Search Screen .............................................................................................. 3-2

Section 4: Controller Settings4.1 3D TRASAR 3500 and 5500 Control Unit Overview ............................................... 4-1

4.1.1 The Display Panel ...................................................................................................... 4-14.1.2 The Keys ................................................................................................................... 4-14.1.3 The Graphical Icons ................................................................................................... 4-2

4.2 Menu, Information, Actions and Alarms Flow Diagram....................................... 4-3




4.3 The Menu Key .......................................................................................................4-44.3.1 Password Screen ....................................................................................................... 4-4

4.4 Control Settings Submenu ................................................................................... 4-44.4.1 Background Correction Screen .................................................................................. 4-54.4.2 TRASAR (Relay 1) Product Screen ........................................................................... 4-64.4.3 Tagged Polymer (Relay 2) Product Screen ................................................................ 4-64.4.4 Oxidizing Biocide Screen ........................................................................................... 4-64.4.5 Blowdown Screen ....................................................................................................... 4-64.4.6 pH Screen.................................................................................................................. 4-6

4.5 Alarm Settings Submenu...................................................................................... 4-74.5.1 System Alarms Screen .............................................................................................. 4-74.5.2 Control Alarms Screens ............................................................................................. 4-74.5.3 Performance Alarms Screen ...................................................................................... 4-74.5.4 Relay Alarms Screens .............................................................................................. 4-84.5.5 4-20 mA Alarm Screen ............................................................................................... 4-8

4.6 Preferences Submenu .......................................................................................... 4-94.7 Network Submenu .............................................................................................. 4-104.8 System Information Submenu ........................................................................... 4-104.9 The Information Key ........................................................................................... 4-11

4.9.1 System Performance Screens................................................................................. 4-114.9.2 Operating Data Screens .......................................................................................... 4-124.9.3 Product Usage Screens ........................................................................................... 4-124.9.4 Water and Energy Screens ...................................................................................... 4-134.9.5 Plot Data Screens .................................................................................................... 4-134.9.6 Control Methods Screens ........................................................................................ 4-144.9.7 Timer Status Screens .............................................................................................. 4-154.9.8 External Inputs Screens ........................................................................................... 4-154.9.9 Product Factors Screen ........................................................................................... 4-154.9.10 Diagnostic Data Screen ........................................................................................... 4-16

4.10 The Actions Key .................................................................................................. 4-174.10.1 Password Screen ..................................................................................................... 4-184.10.2 Clean and Calibrate Screen ..................................................................................... 4-184.10.3 Fluorometer Calibration Screens .............................................................................. 4-194.10.4 pH Calibration Screens ............................................................................................ 4-204.10.5 ORP Calibration Screens ......................................................................................... 4-214.10.6 Conductivity Calibration Screens ............................................................................. 4-224.10.7 Probe Calibration / Maintenance List ........................................................................ 4-254.10.8 Manual Relay Control Screens ................................................................................ 4-264.10.9 Pumping Rates Screens .......................................................................................... 4-274.10.10 Slug Feed Biocide Screens ...................................................................................... 4-284.10.11 System Startup Screens .......................................................................................... 4-294.10.12 Test Email Screen.................................................................................................... 4-294.10.13 Service Email Screen ............................................................................................... 4-29

4.11 The Alarms Key ................................................................................................... 4-304.11.1 Sensor Alarms ......................................................................................................... 4-30




4.11.2 System Alarms ........................................................................................................ 4-304.11.3 Communication Errors ............................................................................................. 4-314.11.4 Performance Alarms ................................................................................................ 4-314.11.5 Control Alarms ......................................................................................................... 4-314.11.6 Relay Timeout Alarms.............................................................................................. 4-324.11.7 Analog Alarms.......................................................................................................... 4-324.11.8 Failsafe Mode .......................................................................................................... 4-324.11.9 Startup Mode ........................................................................................................... 4-32

Section 5: 3D TRASAR Scale Control5.1 Nalco Scale Index (NSI) Measurement ................................................................ 5-1

5.1.1 3D TRASAR Scale Blowdown Control – Uses NSI to Adjust the Blowdown Setpoint ... 5-15.1.2 3D TRASAR Scale Tagged Polymer Control – Uses NSI to Adjust the Tagged Polymer

Setpoint ............................................................................................................................. 5-15.2 3D TRASAR Scale Blowdown Control ................................................................ 5-2

5.2.1 3D TRASAR Scale Blowdown Control: 1-Drum Program Overview ............................ 5-25.2.2 Start-Up Procedure for 1-Drum 3D TRASAR Scale Blowdown Control ...................... 5-35.2.3 3D TRASAR Scale Blowndown Control: 2-Drum Program Overview .......................... 5-55.2.4 Start-up Procedure for 2-Drum 3D TRASAR Scale Blowdown Control ....................... 5-6

5.3 3D TRASAR Scale Tagged Polymer Control ...................................................... 5-95.3.1 3D TRASAR Scale Tagged Polymer Control: 2-Drum Program Overview ................. 5-95.3.2 Start-up Procedure for 2-Drum 3D TRASAR Scale Tagged Polymer Control ........... 5-10

5.4 3D TRASAR Scale Control - Frequently Asked Questions .............................. 5-13

Section 6: 3D TRASAR Bio-Control and 3D TRASAR Bio-Shock Mode6.1 Nalco Bio-Index Measurement (NBI) ................................................................... 6-26.2 Oxidizing Biocide Application and Slug Feeds .................................................. 6-2

6.2.1 3D TRASAR Bio-Control and Overlaid Ox Slugs ........................................................... 6-36.2.2 3D TRASAR Bio-Shock Mode ....................................................................................... 6-46.2.3 Ox-slug/shock control settings ...................................................................................... 6-4

6.3 Bio-reporter Selection .......................................................................................... 6-56.4 3D TRASAR Bio-Control/3D TRASAR Bio-Shock Start-Up Procedure.............. 6-56.5 Pellet Feeder Operation ........................................................................................ 6-86.6 Filling the Pellet Feeder ........................................................................................ 6-96.7 Bio-reporter Initial System Dosing ..................................................................... 6-106.8 Pellet Feeder Cleaning ........................................................................................ 6-116.9 Pellet Feeder Maintenance ................................................................................. 6-11

6.9.1 Cleaning Pellet Feeder Exit Tube ............................................................................. 6-126.9.2 Tighten Valve Seat ................................................................................................... 6-136.9.3 Pellet Shield Replacement ....................................................................................... 6-15

6.10 3D TRASAR Bio-Control & 3D TRASAR Bio-Shock FAQ’s .............................. 6-18

Section 7: Communication and Data Management7.1 3D TRASAR Optimizer .......................................................................................... 7-17.2 3D TRASAR Configurator ..................................................................................... 7-1




7.3 3D TRASAR 5500 Controller ................................................................................ 7-17.4 SCADA Systems .................................................................................................... 7-17.5 3D TRASAR Web ................................................................................................... 7-2

7.5.1 3D TRASAR Web Set Up .......................................................................................... 7-27.5.1a Create/Edit Users ...................................................................................................... 7-37.5.1b Assign Controllers (Data Sources)............................................................................. 7-47.5.1c Manage Controller (Data Source) Setup Information .................................................. 7-57.5.2 3D TRASAR Web Data ............................................................................................. 7-67.5.3 3D TRASAR Reports ................................................................................................. 7-77.5.4 3D TRASAR Web Alarms .......................................................................................... 7-8

7.6 Vantage V100.........................................................................................................7-97.6.1 Import 3D TRASAR Data into Vantage V100 ............................................................. 7-97.6.2 Vantage V100 3D TRASAR EZ Reports .................................................................. 7-117.6.3 Vantage V100 3D TRASAR Specification Limits ...................................................... 7-13

7.7 Nalco Global Gateway......................................................................................... 7-15

Section 8: Maintenance8.1 Maintenance Schedule ......................................................................................... 8-18.2 Clean Fluorometer Flow Cell ................................................................................ 8-28.3 Check/replace Fluorometer Desiccant ................................................................ 8-28.4 Check Sensor Calibration .................................................................................... 8-28.5 Probe Replacement Schedule ............................................................................. 8-38.6 Cleaning Basket / Wye Strainer............................................................................ 8-38.7 Pellet Feeder Maintenance ................................................................................... 8-38.8 Check / Refill Pellet Feeder ................................................................................... 8-3

Section 9: Troubleshooting9.1 General Troubleshooting ...................................................................................... 9-19.2 Alarm Screen Troubleshooting ............................................................................ 9-7




Appendix A: SpecificationsAppendix B: DrawingsAppendix C: Replacement Parts/AccessoriesAppendix D: Air Purging SystemAppendix E: SCADA and LANAppendix F: 3D TRASAR Starter Upgrade ProceduresAppendix G: 3D TRASAR Technology for Closed Loop ApplicationsAppendix H: 3D TRASAR Technology for High Fouling ApplicationsAppendix I: Halogen Analyzer ControlAppendix J: 3D TRASAR Models for the PacificAppendix K: Warranty PolicyGlossary



1-1Technical Help(630) 305-CHEM

!

Section 1: Introduction1.1 About the TRASAR® 3500 and 5500The Nalco 3D TRASAR® 5500 is the most advanced water treatment control system on the markettoday. The design is based on years of field research and a broad base of industry experience andapplication. The introduction and use of the 3D TRASAR 5500 will dramatically change the standardfor cost-efficient and reliable cooling tower control.

The Nalco 3D TRASAR Starter 3500 makes 3D TRASAR technology more accessible. It is customizableto meet specific user needs, yet offers the flexibility for future upgrades to utilize all features of 3DTRASAR.

Both systems are simple to use and feature powerful control algorithms that ensure tighter control,more optimal performance, and requires a minimum of human oversight and testing. The end result isa better, safer, more reliable system that runs more efficiently.

1.2 About this ManualThis manual is a simple, step-by-step description of what you need to do to get your new system upand running in the shortest amount of time.

Keep in mind, as you begin, that your Nalco Technical Representative has already done some of thepreliminary configuration work for you. Don’t hesitate to contact that person if you have a question orproblem, as they are familiar with your situation and can be very helpful in addressing any specificneeds you may have.

Additional help is available at 630-305-CHEM (2436).

1.3 3D TRASAR Starter 3500 and 3D TRASAR 5500 Models andOptional Components

3D TRASAR Starter and3D TRASAR comparison.

3D TRASARStarter

3D TRASAR

3D TRASAR Starter Fluorometer X3D TRASAR 6 channel Fluorometer XModem X XWeb Accessibility X XConductivity Measurement and Control X XpH Measurement and Control XORP Measurement and Control X

Biocide Timers X X3D TRASAR Scale Control X

3D TRASAR Bio-Control X

Nalco Corrosion Measurement X




1.3 3D TRASAR Starter 3500 and 3D TRASAR 5500 Models andOptional Components (con’t)The 3D TRASAR 3500 and 5500 are available in a variety of models. Talk to your Nalcorepresentative about which model is right for your application.

Enclosed Frame Mount unitwith Junction Boxand Pellet Feeder

3D TRASARFrame Mount unit

3D TRASAR StarterWall Mount unit

3D TRASARStarter Models

3D TRASARModels

Description

060-TR3500.88 060-TR5500.88 Wall Mount small b ackboard

060-TR3501.88 060-TR5501.88 Frame Mount small backboard

060-TR3510.88 060-TR5510.88 Wall Mount w/ Junctio n B ox

060-TR3511.88 060-TR5511.88 Frame Mount w/ Juncti on Box

060-TR3520.88 060-TR5520.88 Enclosed Wall Mount w/ Juncti on Box

060-TR3522.88 060-TR5522.88 Enclosed Wall Mount w/J-Box andpre-installed Nalco Global Gateway

060-TR3521.88 060-TR5521.88 Enclosed Frame Mount w/ Juncti on Box

060-TR3523.88 060-TR5523.88 Enclosed Frame Mount w/J-Box andpre-installed Nalco Global Gateway

060-TR3530.88 060-TR5530.88 Air Purged Wall Mount w/ Juncti on Box

060-TR3532.88 060-TR5532.88 Air Purged Wall Mount w/J-Box andpre-installed Nalco Global Gateway

060-TR3531.88 060-TR5531.88 Air Purged Frame Mount w/ Juncti on Box

060-TR3533.88 060-TR5533.88 Air Purged Frame Mount w/J-Box and pre-installed Nalco Global Gateway

3D TRASAR models for High Fouling Applications060-TR5515.88 Wall Mount for Hi gh Fouling Applications060-TR5516.88 Frame Mount for Hi gh Fouling Applications

060-TR5525.88 Enclosed Wall Mount for Hi gh FoulingApplications

060-TR5526.88 Enclosed Frame Mount for Hi gh FoulingApplications

Accessories060-TR5120.88 Bio-Reporter Pellet Feeder, for systems

greater than 12,000 gal141-PJ4035.88 Liquid Bio-Reporter Pump, Iwaki, for

systems 3,000 to 12,000 gal6008505 Liquid Bio-Reporter Pump, Grundfos, for

systems less than 3,000 gal060-TR5540.88 High Pressure Water Reinjection System060-NGG100.88 Nalco Global Gateway US (Domestic) with

1-year contract060-NGG200.88 Nalco Global Gateway International with 1-

year contract500-TSRKITSTR.88 TR3500 Start-Up Calibration Kit500-TSRKIT.88 TR5500 Start-Up Calibration Kit




1.4 3D TRASAR 3500 and 5500 Overview

The 3D TRASAR 5500 utilizes state-of-the-art optical fluorescence sensing to monitor and controlchemical feed. The central component of the system is a rugged 6-channel fluorometer that mea-sures:

• TRASAR Chemical Residuals• Polymer Chemical Residuals• Bio-reporter Chemical Residual• Biological Activity• Instrument Fouling• Background Fluorescence

These measured variables are used in control algorithms that anticipate and respond to systemstresses before costly scaling and fouling can occur.

The 3D TRASAR Starter 3500 utilizes proven TRASAR technology to monitor and control chemicalfeed. Features of the 3D TRASAR 5500 are available as upgrades to the 3D TRASAR Starter3500.

Scale/Fouling

Corrosion

Microbio

Biocides Inhibitor I Inhibitor II Acid Pump Blowdown Valve

CommunicationsPagerCell phonePalmLaptopDCSWeb

Knowledge ManagementVantage V100

Performance-Based ControlSave energy and waterReduce manpowerIncrease throughputImprove product qualityExtend equipment lifeEnhance safetyPredict cash needs

(3D Bio-Control) (3D Scale Control)

(NCM100)

Scale/Fouling

Corrosion

Microbio

Biocides Inhibitor I Inhibitor II Acid Pump Blowdown Valve

CommunicationsPagerCell phonePalmLaptopDCSWeb

Knowledge ManagementVantage V100

Performance-Based ControlSave energy and waterReduce manpowerIncrease throughputImprove product qualityExtend equipment lifeEnhance safetyPredict cash needs

(3D Bio-Control) (3D Scale Control)

(NCM100)

Stress Management for Cooling Systems




Detector

Emission Filter

Flow Cell

ExcitationFilter

LED Light

Source

Water Water Sample In

Water Sample Out

1.5 How the 3D TRASAR System Works

1.5.1 Fluorometer

TRASAR chemistries contain a uniquely fluorescing molecule that allows the fluorometer to detectexactly how much chemical has been fed in order to determine chemical residual. This informationis used to deliver accurate control of chemical levels in your cooling system.

The patented 3D TRASAR on-line fluorometer consists of a “Flow Cell”, an LED light source, filters,and detectors. The filters and detectors are tuned to specific light frequencies unique to Nalcoproducts and resultant process reactions. The LED light source is extremely bright at the appropri-ate frequencies to reliably and repeatably measure the chemical properties of the flowing water. Asa solid-state device, the fluorometer offers trouble free long life.

1.5.2 3D TRASAR Scale Control, 3D TRASAR Bio-Control, and NCM CorrosionTechnology

3D TRASAR Scale Control, 3D TRASAR Bio-Control and NCM Corrosion Monitoring Technologyare available upgrades for the Starter 3D TRASAR 3500 controller.

Typical cooling water controllers use simple On/Off control schemes and timers to maintain pre-determined set points in hopes to avoid operational upsets. The problem with this approach is that,as system stresses change, scale can form, bio-populations can multiply, and corrosion can occurwithout ever being detected. Pre-determined set points are only good for one set of stress condi-tions!!

The 3D TRASAR 5500 Controller takes a revolutionary proactive approach to managing coolingwater systems. Patented state of the art technology is used to prevent scale formation, control bio-population levels and continuously monitor corrosion rates.




3D TRASAR Scale Control prevents scale formation by continuously monitoring the activity of aninnovative “tagged” high stress dispersant polymer. As scale forming particles increase in thecooling system, the active polymer is consumed. By monitoring this consumption rate and the activepolymer level, 3D TRASAR Scale Control can take corrective action well before the conditionsneeded to produce scale can occur.

Use 3D TRASAR Scale Control to:• Optimize water and chemical use by actively managing the system based on the stresses

placed upon it.• Improve throughput by maintaining equipment at peak efficiency, even as operational

factors vary.• Reduce downtime and maintenance costs by preventing mineral scale, and particulate

fouling.• Increase asset life and maintain asset reliability by preventing degradation during upsets

and process leaks.

3D TRASAR Bio-Control is an entirely new, innovative approach to the control of bio-populations incooling systems. Afluorescent “bio-reporter” is introduced into the cooling system and reactsenzymatically with microbes. The reaction changes the bio-reporter’s fluorescent signature. 3DTRASAR Bio-Control measures the difference between the reacted and unreacted bio-reporter andadjusts biocide feed to optimize control. 3D TRASAR Bio-Control is the only bio-control systemavailable that adjusts system operation in response to changes in bio-activity. This unique Nalcoinnovation delivers comprehensive, continuous control of both sessile and planktonic bio-popula-tions.

Use 3D TRASAR Bio-Control to:• Compensate for variations in makeup bio-populations.• Prevent underdeposit corrosion by controlling sessile bio-populations.• Optimize water and chemical use by actively managing the system based on the actual bio-

activity present.• Reduce downtime and maintenance costs by preventing the corrosion and fouling associ-

ated with bio-activity.• Increase asset life and maintain asset reliability by preventing degradation during upsets

and contamination.

NCM Corrosion Monitoring Technology is also incorporated in the 3D TRASAR 5500. Thispatented technology automatically recognizes the corrosion rates of up to 2 different metallurgies.The available metallurgies include mild steel, galvanized steel, copper, brass, CuNi 90/10, CuNi 70/30, and aluminum. By monitoring corrosion rates continuously (vs. 90-day snapshots) correctiveaction can be taken before the problem becomes serious.

1.5.3 Data Storage / Reporting and Communications

The 3D TRASAR 3500 and 5500 controllers are able to automatically e-mail stored measurementsto a central database that is accessible via the Internet. This allows operational data to be viewedand analyzed remotely, from one or more authorized locations using just a standard web browser.Reports may also be setup and automatically emailed on determined dates or at specified times.




1.6 SafetyAlways follow the safety practices listed below:

• Never perform any installation procedures with electrical power engaged.

• Never perform any repairs with electrical power engaged.

• Never open the 3D TRASAR controller box or junction box with electrical power engaged.

• Never open the pellet feeder hopper with electrical power engaged.

• Maximum water pressure to the 3D TRASAR skid and pellet feeder should never exceed90 psi.

• Maximum water temperature should not exceed 120 deg F.

• Always wear the appropriate Personal Protective Equipment (PPE) when working on a 3DTRASAR system (i.e. gloves, protective eyewear, protective shoes, wearing a mask, etc).

• Always observe local and facility safety practices beyond those listed in this manual.

WARNING: Always turn off power before making any electrical connections, which in-cludes all interconnecting cables, otherwise permanent damage may occur to systemcomponents.

!

NOTE: Both the 3D TRASAR controller and the Bio-reporter Pellet Feeder operate wellbelow an 85 db noise level.!




Section 2: Installation and Start-Up

Introduction

There are 9 steps to installing and starting-up a 3D TRASAR system.

Details Section

2.7

Details Section

2.1

Unpack and identify Mount controller

Install Main Control Panel in well-lit, dry location convenient to points of use. Mount at eye level.

Install Bio-Reporter feeder

Install Bio-Reporter Feeder in well-lit, dry location convenient to points of use.

Plumb bio-reporter feeder

Connect discharge back to recirculating system downstream from supply in basin where possible.

Calibration & checkout

Calibrate probes following instruction on screen.

Wiring

Connect cable between controller box and pellet feeder. Wire pumps using supplied pigtails (or hardwire). Connect

85 to 250 VAC @ 20 amps power using supplied power cord (or hardwiring).

Start-up system

Enter set points.You are up and running!

Install probes

Install probes and attach connectors.

DetailsSection

2.2

DetailsSection

2.3

DetailsSection

2.5

DetailsSection

2.6

DetailsSection

2.8DetailsSection

2.9

Unpack all parts and identify them.

Plumb utilizing ball valves provided. Inlet water from recirculating system must be at 5 GPM or greater.

Outlet ½”

Union0.5

GPM

Plumb controller

DetailsSection

2.4

ORP Probe




2.1 STEP 1 - Unpack and Identify

Wall Mount: Configured for wall attachment, select when floor space is restricted.Frame Mount: Configured for floor-mounted installation, select when wall space is

restricted.Junction Box: Provides convenient access to wiring connections.Enclosure: Provides weather resistant protection. Select for outdoor installations

and dusty environments.Air Purge: Depending on site requirements, may satisfy certain industrial explosion

protection ratings. Select for use in hazardous duty applications.Wireless Gateway: Enables wireless communication of important information such as

alarms and performance indicators.High Fouling Models: Includes automated fluorometer cleaning system to reduce fouling

from solids, oils and debris found in process water.

IMPORTANT: If you do not have all of the itemsneeded for your application, call your Nalcorepresentative before proceeding.!

2.1.1 Identify Hardware Model

Hardware Models Unpack and identify all parts.

Unpack and identify

3D TRASARStarter Model

3D TRASARModel Description

060-TR3500.88 060-TR5500.88 Wall Mount, Small Backboard

060-TR3501.88 060-TR5501.88 Frame Mount, Small Backboard

060-TR3510.88 060-TR5510.88 Wall Mount wi th Junction Box

060-TR3511.88 060-TR5511.88 Frame Mount wi th Junction Box

060-TR3520.88 060-TR5520.88 Enclosed Wall Mount wi th Junction Box

060-TR3522.88 060-TR5522.88 Enclosed Wall Mount wi th Junction Box and Pre-Installed Nalco Global Gateway

060-TR3521.88 060-TR5521.88 Enclosed Frame Mount with Junction Box

060-TR3523.88 060-TR5523.88 Enclosed Frame Mount with Junction Box and Pre-Installed Nalco Global Gateway

060-TR3530.88 060-TR5530.88 Air Purged Wall Mount with Junction Box

060-TR3532.88 060-TR5532.88 Air Purged Wall Mount with Junction Box and Pre-Installed Nalco Global Gateway

060-TR3531.88 060-TR5531.88 Air Purged Frame Mount with Junction Box

060-TR3533.88 060-TR5533.88 Air Purged Frame Mount with Junction Box and Pre-Installed Nalco Global Gateway

N/A 060-TR5515.88 Wall Mount for High Fouling Applications

N/A 060-TR5516.88 Frame Mount for High Fouling Applications

N/A 060-TR5525.88 Enclosed Wall Mount for High Fouli ng Applications

N/A 060-TR5526.88 Enclosed Frame Mount for High Fouling Applications




2.1.1 Identify Hardware Model (con’t)

Small Back PanelPart # 060-TR3500.88,

060-TR5500.88 (wall mount)

Large Back PanelPart # 060-TR3510.88,


Enclosed Part # 060-TR3520.88,060-TR3522.88, 060-TR5520.88,


Air Purged Part # 060-TR3530.88,060-TR3532.88, 060-TR5530.88,


Unpack and identify all parts.

Unpack and identify

Drawings shown with all probesassembled. pH, ORP, and Cor-rosion probes are av ailable asupgrades for 3D TRASAR 3500systems.

Model Number Description Recommended forsystem sizes:

060-TR5120.88 Pellet Feeder Assembly 12,000 gallons and larger141-PJ4035.88 Liquid Bio-reporter pump, Iwaki 3,000 to 12,000 gallons6008505 Liquid Bio-reporter pump, Grundfos Less than 3,000 gallons

!

Bio-reporter Feed Options





Unpack and identify

Conductivity ProbeQty. (1)

Part # 060-TR5432.883/4” Ball Valve

Qty. (2)

Fluorometer CableQty. (1)

Part # 060-TR5221.88

pH Probe CableQty. (1)

Part # 060-TR5412.88

ORP Probe CableQty. (1)

Part # 060-TR5422.88

2.1.2a Pre-Installed Items (all models)

2.1.2b Pre-Installed Items(3D TRASAR 5500 models only)

2.1.3a Items Requiring Assembly (all models)

Pigtail 16/3 SJOWQty. (5)

Part # 991-05053481.88

Service (Power) Cord 12/3 SJOWQty. (1)

Part # 991-01928722.88

Ethernet Crossover Cable (6 ft., orange)Qty. (1)

Part # 991-05047661.88

Additional ItemsReplacement Fuses (4), Part # 991-50473718.88Installation and User Manual, Part # 521-OM0108.88

FluorometerQty. (1)

Part # 060-TR5220.88 (3D)or 060-TR3220.88 (Starter)

Fluorometer Inlet Valveand Tubing Connector

Qty. (1)

Fluorometer OutletAssemblyQty. (1)

2.1.3b Items Requiring Assembly(3D TRASAR 5500 models only)

pH ProbeQty. (1)

Part # 060-TR541 1.88

ORP ProbeQty. (1)

Part # 060-TR5421.88

Corrosion ProbeQty (2) (Steel and Copper std.)Part # 400-NCMP1B.88 (steel)Part # 400-NCMP2B.88 (copper)Part # 400-NCM4B.88 - Cu/Ni 90/10 (optional)Part # 400-NCMP5B.88 - Cu/Ni 70/30 (optional)Part # 400-NCMP7B.88 - 443 Brass (optional)Part # 6016180 - 6061 Aluminum (optional)Part # 6016182 - 1 100 Aluminum (optional)Part # 400-NCMP10.88 Galvanized steel (optional)

Probe Restraint DeviceQty. (2)

Part # 400-NCMAC15.88




Pellet Feeder AssemblyQty. (1)

Part # 060-TR5120.88

PELLETFEEDER

Pellet Feeder Cable (25 ft.)Qty. (1)

Part # 060-TR531 1.88(shipped with pellet feeder only)

25'

2.1.4 Pellet Feeder Assembly (Optional)

Additional ItemsPellet Feeder Brush Part # 500-P2818.88

2.1.5 Items Shipped Separately

3D TRASAR 5500 Start-up Kit(must be ordered separately)

Part # 500-TSRKIT.88Includes:3D TRASAR Cal Soln, 1 L 460-S0940.75pH 7.0 Buffer Soln, 1 L 460-S0407.75pH 10.0 Buffer Soln, 1 L 460-S0408.75ORP 200 mv Buffer Soln, 1 L 460-S0932A.75ORP 600 mv. Buffer Soln, 1 L 460-S0933A.7510% Sulfuric Acid Soln, 1 L 460-S0800.75NCM probe Mild Steel with ferrule 400-NCMP1B.88NCM probe Copper with ferrule 400-NCMP2B.88Fluorometer Probe Brush 500-P2817.88Plastic beakers, qty 3, 500 mL 500-P0116.88Plastic syringe, qty 3, 60 cc 500-P2147.88


Unpack and identify

Part # Upgrade Upgrade Includes

060-TR3200.88 Fluorometer Patented 3D TRASAR technology upgrade procedure, 3D TRASARFluorometer, rebate return instructions and upgrade confirmation sticker.

060-TR3205.88 NCM Patented NCM technology upgrade procedure, 2 probe restraints, 2NCM probe f ittings, and upgrade confirmation sticker (purchase NCMprobes separately, refer to page 2-4 for available metallurgies.)

060-TR3211.88 pH pH probe and cable.

060-TR3221.88 ORP ORP probe and cable.

2.1.5a 3D TRASAR Starter Upgrades

Maintenance Value Package(must be ordered separately , order 2 per year)

Part # 060-TRMNKIT.88Includes all components of the 3D TRASAR 5500Start-up Kit plus:pH probe 060-TR5411.88ORP probe 060-TR5421.88NCM probe, Mild Steel, with ferrule 400-NCMP1B.88NCM probe, Copper, with ferrule 400-NCMP2B.88(includes 2 of each NCM probe)Fluorometer desiccant cannister 060-TR5222.88Fluorometer desiccant indicator 060-TR5223.88

3D TRASAR 3500 Start-up Kit(must be ordered separately)Part # 500-TSRKITSTR.88

Includes:3D TRASAR Cal Soln, 1L 460-S0940.7510% Sulfuric Acid Soln, 1L 460-S0800.75Fluorometer Probe Brush 500-P2817.88Plastic beakers, qty 3, 500 mL 500-P0116.88Plastic syringe, qty 3, 60 cc 500-P2147.88

2.1.5b 3D TRASAR Start-up and Maintenance Kits




2.2 STEP 2 - Mount the Controller

IMPORTANT: The 3D TRASAR controller isdesigned to meet NEMA4X standards for weatherresistance. It is recommended that the unit beinstalled in a sheltered area to minimize thechance of water or debris entering the enclosurewhen the cover is opened for wiring and mainte-nance.

In order to maintain the NEMA4X rating:

• Unused cord grips must remain plugged.• Enclosure cover must be tightly closed at

all times.• Ethernet port cover must also be in place

when this port is not in use.

!

2.2.1 General Instructions

1. Avoid installing the 3D TRASAR controller close to any high voltage source(s), large motors,or any known generator of electrical and strong magnetic noises.

2. The mounting location should be well lit and dry.3. If mounting outside, provisions must be made to protect the controller from direct sunlight

and driving rain.4. In cold weather climates, provisions must be made to prevent piping from freezing.5. The mounting location should be accessible to sample water (5 gpm minimum) and an

electrical power source (20 amp circuit at 85-250 VAC).6. If using the bio-reporter Pellet Feeder, install it on the right hand side of the 3D TRASAR

controller (as you face the controller) within 10 ft.a. The Pellet Feeder is electrically connected to the 3D TRASAR controller with a 25 ft.

pre-configured cable. If necessary, this cable can be spliced in the field to lengthen itto a maximum of 100ft.

b. The Pellet Feeder should be plumbed to the bottom 3/4” sensor outlet piping of the3D TRASAR controller off the right side of the panel (Refer to Section 2.4.3).

7. If using liquid bio-reporter, mount the feed pump in a location convenient to the bio-reportertank and the 3D TRASAR controller.

8. Chemical feed pumps should also be mounted conveniently to the 3D TRASAR controllerand chemical feed tanks.

Mount controller

Install Main Control Panel in well-lit, dry location convenient to points of use. Mount at eye level.




2.2.2 3D TRASAR Controller Dimensions

Wall Mount Small Backboard060-TR3500.88, 060-TR5500.88

Mount controller

Frame Mount Small Backboard060-TR3501.88, 060-TR5501.88




Mount controllerWall Mount with Junction Box060-TR3510.88, 060-TR5510.88

Frame Mount with Junction Box060-TR3511.88, 060-TR5511.88




Mount controllerEnclosed Wall Mount with Junction Box060-TR3520.88, 060-TR3522.88,060-TR5520.88, 060-TR5522.88

Enclosed Frame Mount with Junction Box060-TR3521.88, 060-TR3523.88060-TR5521.88, 060-TR5523.88




Mount controllerAir Purged Wall Mount with Junction Box060-TR3530.88, 060-TR3532.88060-TR5530.88, 060-TR5532.88

Air Purged Frame Mount with Junction Box060-TR3531.88, 060-TR3533.88060-TR5531.88, 060-TR5533.88




2.2.3 Wall Mounting Templates

!

Panels should be mounted on a flat wall so thatthe controller display is at eye level.

Use the template below to locate and drill mountingholes for Model #s 060-TR3500.88 and060-TR5500.88 (approximate weight 75 lbs).

Mount controller

Dimensions shown are in inches

Note: For ease of installation, use 3D TRASAReasy mounting bracket Part # 060-TR5245.88.For models 060-TR3500.88 and 060-TR5500.88 only.




Use the template below to locate and drill mounting holesfor Model #s 060-TR3510.88 and 060-TR5510.88(approximate weight 90 lbs).

Mount controller





Use the template below to determine the space require-ment for Model #’s 060-TR3520.88, 060-TR3522.88,060-TR3530.88, 060-TR3532.88, 060-TR5520.88,060-TR5522.88, 060-TR5530.88, 060-TR5532.88(approximate weight 200 lbs.)

Mount controller


Exact hole locations for these units are not available due to variations in manufacturing runs fromthe enclosure supplier.




2.2.4 Frame Mount Template

For models:060-TR3501.88, 060-TR5501.88060-TR3511.88, 060-TR5511.88060-TR3521.88, 060-TR5521.88060-TR3523.88, 060-TR5523.88060-TR3531.88, 060-TR5531.88060-TR3533.88, 060-TR5533.88

Mount controller





2.3 STEP 3 - Install Bio-reporter FeederThe 3D TRASAR bio-control feature requires the use of abio-reporter feed system. The bio-reporter product comes ineither pellet or liquid form.

• If using bio-reporter pellets refer to 2.3.1• If using bio-reporter liquid refer to 2.3.2

Note: Not all 3D TRASAR installations use the 3D TRASARbio-control feature.

2.3.1 Install Bio-reporter Pellet Feeder

Install bio-reporter feeder


!

!

WARNING: Never install the pellet feeder in an explosion rated atmosphere. Thepellet feeder does not have an explosion proof rating!

WARNING: Always shut-off power before opening the pellet feeder lid and placing yourhands inside the hopper. NEVER insert your fingers in the pellet drop holes at thebottom of the hopper!

1. Attach the pellet hopper and plumbing assembly to thestand as shown on the next page.

2. Locate the pellet feeder to the right of the 3D TRASARcontroller (as you face the controller) within 10 ft.

3. It is recommended that the Pellet Feeder be installed in asheltered area to minimize the chance of water or debrisentering the hopper when the lid is open.

4. The Pellet Feeder is electrically connected to the3D TRASAR controller with a 25 ft. pre-configured cable.If necessary this cable can be spliced in the field tolengthen it to a maximum of 100 ft.

5. The Pellet Feeder should be anchored by either (1) theinstalled plumbing or (2) by removing the base feet andbolting to the floor.

! WARNING: Never attempt to lift the pellet feeder with a mechanical device, i.e. forklift!

Note: The Overflow Container (P/N060-TR5350.88) shown in the photomust be ordered separately.







2.3.2 Install Liquid Bio-reporter Pump

Install the liquid bio-reporter feed pump in a loca-tion convenient to the bio-reporter tank and the 3DTRASAR controller.

Install bio-reporter feeder


! IMPORTANT: Ensure that the suction sideof the bio-reporter pump is always flooded!

For cooling systems withvolumes between 3,000 and12,000 gallons, use Iwaki pump(P/N 141-PJ4035.88).

For cooling systems with volumesless than 3,000 gallons, useGrundfos pump (P/N 6008505).




2.4 STEP 4 – Plumb ControllerThe 3D TRASAR system has one sample water inletplumbing connection and two sample water outletplumbing connections. Refer to the Typical InstallationDrawing in Section 2.4.5 for a general installationoverview.

2.4.1 Sample Point Selection

! IMPORTANT: Sample water flow must be aminimum of 5 gpm.

It is very important to select the appropriate sampling point for your cooling system. Sample pointsare system dependent and should be taken from one of the following two locations:

1. Recirculating Pump Discharge - Sample points from the recirculating pump dischargeprovide the maximum pressure opportunity for achieving the 5 gpm flow requirement ofthe 3D TRASAR system and the Pellet Feeder.

2. Return Header to Cooling Tower - Sample points from the return header give the bestrepresentation of corrosion rate measurements due to system heat loads.

In either case, it is important to understand the impact of the sample point in relation to control lagtimes of the chemical feed (lag time is the time it takes the chemical to travel from point of injectionto the controller). In general, the shorter the lag time, the better the control (provided good mixinghas been achieved and recirculation rates are nominal). However, in cooling systems, the effects oflong lag times can be compensated for by decreasing the feed rate of the chemical pump, whichwill reduce set-point overshoot.

Consult your Nalco representative for the appropriate sample point location for your system.

Plumb using ball valves provided. Inlet water from recirculating system must be at 5 GPM or greater.

Outlet ½”

Union0.5

GPM

Plumb controller




2.4.2 3D TRASAR System Inlet Water Plumbing

!


Outlet ½”

Union0.5

GPM

Plumb controller

• Required flow rate through the sample piping is 5gpm total (>0.5 gpm is routed through the Fluorom-eter and up to 4.5 gpm goes through the sensors).

• Plumb the 5 gpm sample water to the inlet ball valve(¾” female NPT).

• Maximum inlet water pressure should not exceed 90psig.

• Inlet water temperature should be between 40 and120 deg F.

Note: If the required 5 gpm flow cannot be achieved through normal system operatingpressures, a booster pump may be needed to increase the flow rate.

IMPORTANT: If a booster pump is used, it is important to make provisions to Interlock the3D TRASAR system with the operation of the cooling system. In the event that the coolingsystem SHUTS DOWN the booster pump may continue to supply sample water to the 3DTRASAR system. In this case, all controlling relays will continue to function causing anoverfeed of chemical or excessive blowdown. Refer to Section 2.7.14 for System Interlockwiring details.

Inlet Ball Valve




2.4.3 3D TRASAR System Outlet Water Plumbing

!IMPORTANT: Do not connect the sensor outlet plumbing to the fluorometer outlet plumb-ing – this may impair the flow through the fluorometer when inlet flow pressure varies.


Outlet ½”

Union0.5

GPM

Plumb controller

• There are two outlet connections on the 3D TRASAR system.a. The top ½” fluorometer outlet must have a minimum flow rate of 0.5 gpm.b. The bottom ¾” sensor outlet must have a minimum flow rate of 4.5 gpm.

• Plumb the ½” female NPT fluorometer outlet to one of the following:a. Cooling tower basinb. Drainc. Lower pressure point in the system (minimum differential of 20 psig)

• Plumb the 4.5 gpm sensor outlet (3/4” female NPT) to one of the following:a. Inlet of the Pellet Feeder (preferred if Pellet Feeder is being used)b. Cooling tower basinc. Lower pressure point in system (minimum differential of 20 psig)d. Drain (not recommended)

Outlets




2.4.4 Chemical Feed Pumps

• Install the chemical feed pumps (inhibitors, dispers-ants and biocides) as conveniently to the 3DTRASAR system and chemical tanks as possible.

• Use pumps that are properly sized for the applica-tion.

o Oversized pumps can result in productoverfeeds, which can damage the coolingsystem.

o Undersized pumps can result in repeatedtimeout alarms, which are triggered when arelay is energized for longer than a userspecified time.

• Do not inject chemicals immediately upstream of the3D TRASAR sampling point. Chemical injectionpoints should allow for good mixing prior to reachingthe sampling point.

• Avoid feeding biocides near the injection point of the bio-reporter• Ensure that the suction side of the pump is always flooded.

Note: Acomplete line of chemical feed pumps is available through the Nalco Global EquipmentSolutions Group (NGES). Please call (800)323-8483 or (630) 848-3387 for assistance withselecting the right pump for your application.


Outlet ½”

Union0.5

GPM

Plumb controller

Chemical feed pumps available through NGES




2.4.5 Typical Installation Drawing




2.5 STEP 5 – Plumb Bio-reporter FeederThe 3D TRASAR bio-control feature requires the use of abio-reporter feed system. The bio-reporter product comesin either pellet or liquid form.

• If using bio-reporter pellets refer to 2.5.1• If using bio-reporter liquid refer to 2.5.3

Note: Not all 3D TRASAR installations use the 3D TRASARbio-control feature.

2.5.1 Pellet Feeder Plumbing

!

1. Plumb the pellet feeder inlet water to the ¾” ball valve on the left side of the unit.2. Plumb the pellet feeder outlet to the ¾” ball valve on the right side of the unit.3. Outlet water must go to a point of good circulation in the cooling system for maximum

and even distribution. Avoid close proximity to any biocide injection points.4. Connect pellet feeder overflow to tubing and route to drain, or attach the Bio-reporter

Liquid Overflow Container (P/N 060-TR5350.88) as shown below. The OverflowContainer must be ordered separately.

!


Pellet Feeder requires 4 to 5 gpm flow

To Recirc.Water

5 GPM

Plumb bio-reportersm feeder

IMPORTANT: The Bio-reporter pellet feeder requires a minimum sample water flow of 4.5GPM. The sensor outlet from the 3D TRASAR system or a separate water source can beused as long as it is returned to the cooling system.

WARNING: Always shut-off power before openingthe pellet feeder lid and placing your hands insidethe hopper. NEVER insert your fingers in thepellet drop holes at the bottom of the hopper!

WARNING: Maximum inlet water pressure should not exceed 90 psig.!




2.5.2 Pellet Feeder Best Practices

• The pellet feeder hopper must be maintained withan adequate supply of pellets at all times.

• Insert the pellet desiccant into the holdermounted inside the hopper cover.

• Replacement desiccants are included in eachnew bottle of pellets and should replace olddesiccants whenever the hopper is refilled.

• The hopper lid must remain tightly closed exceptwhen refilling.

• It is recommended that the feeder be installed ina sheltered area to minimize the chance of wateror debris entering the hopper when the cover isopened for refilling and maintenance.

• When the Pellet Feeder is not in use (especiallywhen temperatures are near freezing), it isstrongly recommended to drain the plumbing manifold. Simply close off the inlet andoutlet ball valves and open the strainer.

2.5.3 Liquid Bio-reporter Plumbing

Bio-reporter liquid is fed via a small diaphragm pump. Plumb the discharge of the bio-reporterpump to a point of good circulation (mixing) sufficiently away from any biocide feed points.


Pellet Feeder requires 4 to 5 gpm flow

To Recirc.Water

5 GPM

Plumb bio-reportersm feeder

For system volumes be-tween 3,000 and 12,000gallons, use Iwaki pump(P/N 141-PJ4035.88).

For system volumesless than 3000 gallons,use Grundfos pump(P/N 6008505).




2.6 STEP 6 – Install ProbesThe table below indicates the types of probes includedwith the 3D TRASAR Starter and 3D TRASAR systems.

IMPORTANT: Corrosion Probe #1 must be mildsteel if mild steel is one of the two metallurgies.Refer to the chart below for the order of optimalcorrosion probe locations.

!

Install probes

Install probes and attach connectors as shown. Tighten swage fitting fully.

ORP Probe

Install probes


Corrosion Probe #1

Corrosion Probe #2

pH Probe ORP Probe

Fluorometer

Conductivity Probe

WARNING: Always turn off power before making any electrical connections, which in-cludes all interconnecting cables, otherwise permanent damage may occur to systemcomponents.

!

Refer to the drawing onthe left for the installa-tion location of eachprobe.

3D TRASARStarter

3D TRASAR

3D TRASAR StarterFluorometer

Included N/A

3D TRASAR 6 channelFluorometer

Upgrade Included

Conductivity Included Included

pH Upgrade Included

ORP Upgrade Included

Corrosion NCM100 Upgrade Included

Probe #1 Probe #2

Mild S

teel

Galv S

teel

Alum

inum

Cu/N

i

Adm

Bra

ss

Copp

er




2.6.1 Fluorometer Installation

The fluorometer is shipped unattached to prevent damage.Install as follows:

STEP 1 - Locate and unpack the fluorometer,fluorometer inlet valve, tubing connector, andfluorometer outlet assembly (comprised of aflow switch housing and three-way ball valve).

STEP 2 - Attach the inlet valve and tubing connector tothe fluorometer inlet using teflon tape(Do not over tighten).

STEP 3 - Thread the fluorometer outlet assembly tooutlet of the fluorometer (do not overtighten).

STEP 4 - Remove the end cap from the sample supply tubing. Connect the supply tubing tothe fluorometer inlet tubing connector.

STEP 5 - Mount the fluorometer (and outlet assembly) to the back panel with the screwsprovided. DO NOT FORCE!

Install probes


ORP Probe

Install probes


IMPORTANT: The length of the sample supply tubing may need to be adjusted to attainproper alignment of the mounting screws with the back panel. DO NOT BEND sampletubing. Excessive force may break fluorometer inlet fitting and internals. A broken inletfitting will necessitate the purchase of a new fluorometer which will not be covered underwarranty.

!

STEP 6 - Connect the flow switch shuttle (pre-wired to the controller) to the flow switch hous-ing. Adjust the position of the ball valve as needed to maintain proper alignment withthe flow switch assembly (slotted holes are provided on the three-way valve bracketfor adjustments.)

STEP 7 - Connect the pre-installed fluorometer cable to the fluorometer.




2.6.2 pH Probe Installation

Install the pH probe as follows:

STEP 1 - Carefully unpack the pH probe.

STEP 2 - Apply 5 revolutions of Teflon tape tothe pH probe threads.

STEP 3 - Hand tighten the probe in thethreaded tee location indicated inSection 2.6

STEP 4 - Connect pH probe to pH cable (cableis labeled pH.)

Install probes


ORP Probe

Install probes





2.6.3 ORP Probe Installation

Install the ORP probe as follows:

STEP 1 - Carefully unpack the ORP probe.

STEP 2 - Apply 5 revolutions of Teflon tape tothe ORP probe threads.

STEP 3 - Hand tighten the probe in thethreaded tee location indicated inSection 2.6.

STEP 4 - Connect the ORP probe to ORPcable (cable is labeled ORP).

Install probes


ORP Probe

Install probes





2.6.4 Conductivity Probe Installation

The Conductivity probe is shipped installed.Verify probe is hand tight in the tee and thecable is firmly connected to the controller andprobe.

Install probes


ORP Probe

Install probes





2.6.5 NCM Corrosion Probe Installation

The 3D TRASAR 5500 system is shipped with 1 mildsteel corrosion probe and 1 copper corrosion probe.

Corrosion monitoring is an available upgrade for 3DTRASAR Starter 3500 systems.

IMPORTANT: Brass, CuNi 90/10, CuNi70/30, aluminum, and galvanized steelprobes can be ordered separately. Referto the Appendix for part numbers.

!

Install the corrosion probes as follows:

STEP 1 - Carefully unpack both corrosion probes andlocate the two probe restraints.

Install probes


ORP Probe

Install probes


NCM Probe RestraintP/N 400-NCMAC15.88

STEP 2 - Attach the probe restraints to each probe. The ring portion of the restraint is installedbetween the hex nut and the threaded portion of the swage fitting as shown below.

WARNING: The probe restraint must be installed on all 3D TRASAR units at all times.!




2.6.5 NCM Corrosion Probe Installation (con’t)

STEP 3 - Insert the mild steel probe in location #1as indicated in Section 2.6. Probe tipsmust be parallel to the ground. Tworaised dots on the probe end cap can beused to orient the tips.

Install probes


ORP Probe

Install probes


STEP 4 - Insert the copper probe in location #2 as indicated in Section 2.6. Probe tips must beparallel to the ground. Two raised dots on the probe end cap can be used to orientthe tips.

STEP 5 - Tighten the swage fittings fully (finger tight plus 1¼ turn)

STEP 6 - Connect the corrosion probe cables to either of the two controller inputs (there is oneinput connection on each side of the controller). The 3D TRASAR controllerautomatically recognizes the probe metallurgy – no calibration is required.




2.7 STEP 7 - Wiring

WARNING: Always turn off power beforemaking any electrical connections, whichincludes all interconnecting cables, other-wise permanent damage may occur tosystem components.

!

Wiring

Connect cable between controller box and pellet feeder. Wire pumps using supplied pigtails (or hardwire). Connect 85 to 250 VAC @ 20 amps power using supplied power cord (or hardwiring).

Electrical connections to the 3D TRASAR are either madedirectly to the controller box or a junction box depending onwhich model you have:

2.7.1 General Information

• All electrical connections must conform to applicable state and local codes.• Supply power must be 85-250VAC @ 20 amps on separate GFCI protected circuit.• A power cord without termination has been provided. A proper plug for 20-amp service

must be provided or the unit may be hard wired (using 12 AWG. wire).• Failure to provide 20-amp service could result in intermittent operations, caused by circuit

breaker overload• Probe connections are made through coaxial cables with waterproof connectors at the

probe.• Pump connections can be made via supplied “pigtails” with receptacles, or hardwired (using

14 AWG. wire) directly to the terminals inside the control box as appropriate.• There are 7 control relays individually fused at 2.5 amps (designed to operate at 2 amps).

In cases where more amperage is required, the control relays can be wired as dry contactsfor motor starters.

• Alarm outputs are fused at 1 amp.• Refer to the following diagrams and charts for details on wiring connections.

3D TRASAR electrical connections are madedirectly in the controller for models060-TR3500.88, 060-TR3501.88,060-TR5500.88, and 060-TR5501.88

3D TRASAR electrical connections are madein the junction box for all other models.

Junction Box




2.7.2ControllerBox Layout

pH and ORP cables are not pre-wired on 3D TRASAR Starter models.




2.7.3 Controller Wiring Details

pH and ORP cables are not pre-wired on 3D TRASAR Starter models.




2.7.3 Controller Wiring Details (con’t)

Notes:1. Relay voltage jumpers (terminals 4 & 5) -

Remove for non-powered output. Refer 2.7.8and 2.7.9 for control relay details.

2. Control relays fused at 2.5 amps.3. Alarm relay fused at 1.0 amps.5. Board traces and contacts rated at 5 amps

(85-250 VAC).6. For motor driven pumps a separate motor

starter must be used.

Wiring




2.7.4 Junction Box Layout




2.7.6 System Power Connections

(User Wired in Controller Box or Junction Box)

For models 060-TR3500.88, 060-TR3501.88, 060-TR5500.88 and 060-TR5501.88, the incomingpower connections are made in the controller box. Power connections are made in the junction boxfor all other models.

ConnectionDescription

Controller BoxBoard Reference

Controller BoxTerminal

Junction BoxTerminal Wire Color

Ground TB9-4 Gnd Not used Not usedGround TB9-3 Gnd Gnd GreenNeutral TB9-2 N T2 White

Line Power TB9-1 L T1 Black

2.7.7 Internal Power Connections

(Factory Wired in Controller Box)ConnectionDescription


Controller BoxTerminal Wire Color

Power Switch Neutral E1 N Black-1Power Switch Line E2 L Black-2

Switched AC Neutral E3 N Black-3Switched AC Line E4 L Black-4

Wiring




2.7.8 Control Relay Connections - Powered(120 VAC fused @ 2.5 amps)


There are 7 pre-defined control relays in the 3D TRASAR controller that can be wired for poweredor non-powered operation. Follow the wiring diagrams below to connect metering pumps andvalves for powered control relay outputs (120 VAC, fused @ 2.5 amps).

Typical Powered Relayfrom Controller Box

Typical Powered Relayfrom Junction Box

Wiring

NO N L COM

1 2 3 4 5

Fuse

BLK

WH

T

GR

N

ControllerBox

Typical Powered RelayOutput from Controller Box

Contact

In order to power the relay with 120 VAC, a jumper must be placed acrosscontrol relay terminals 4 & 5 in the controller box, or the Line & COM terminals inthe junction box.

!

LINE

BLKJumper

COM NO N

NO N L COM

1 2 3 4 5

Fuse

ControllerBox

Ear

th G

roun

d B

us

WH

T

GR

N

JunctionBox

Typical Powered RelayOutput from Junction Box

Controller Box suppliesLine, Neutral, & Earth Gnd

Contact




2.7.9 Control Relay Connections - Non-Powered(fused @ 2.5 amps)


There are 7 pre-defined control relays in the 3D TRASAR controller that can be wired for poweredor non-powered operation. Follow the diagrams below to connect motor starters and/or solenoidsfor non-powered control relay outputs (fused @ 2.5 amps).

Typical Non-Powered Relayfrom Controller Box

NO N L COM

1 2 3 4 5

Fuse

ControllerBox

Contact

NO N L COM

1 2 3 4 5

Fuse

ControllerBox

Contact

External MotorStarter Power (+)

MotorStarter

External MotorStarter Neutral (-)

2.5 amp

Typical Non-Powered Relayfrom Junction Box

LINE COM NO N

NO N L COM

3 4 5

Fuse

Controller

Earth Ground Bus

JunctionController Box supplies

Contact

External Motor

Starter

External Motor

Box

Box

1 2

Starter Power (+) Starter Neutral (-)

Line, Neutral, & Earth

Motor

Gnd

Ear

th G

roun

d B

us

Fuse

2.5 amp

Wiring

!The factory wired jumper must be removed from control relay terminals 4 & 5in the controller box, or the Line & COM terminals in the junction box, in orderto remove power from the relay output.




2.7.10 Control Relay Connections -Termination Details

The table below lists the different control relays and theirassociated terminal connections in the controller box andjunction box.



Controller BoxTerminal Junction Box Terminal

TRASAR Feed -Relay 1 TB1-1 NO1 TRASAR - NO1

TB1-2 N TRASAR - NTB1-3 Gnd Ground BarTB1-4 L TRASAR - LTB1-5 COM1 TRASAR - COM1

Tag Polymer Feed -Relay 2 TB2-1 NO2 TAG POLYMER - NO2

TB2-2 N TAG POLYMER - NTB2-3 Gnd Ground BarTB2-4 L TAG POLYMER - LTB2-5 COM2 TAG POLYMER - COM2

Bio-reporter LiquidFeed - Relay 3 TB3-1 NO3 BIO-REPORTER - NO3

TB3-2 N BIO-REPORTER - NTB3-3 Gnd Ground BarTB3-4 L BIO-REPORTER - LTB3-5 COM3 BIO-REPORTER - COM3

Oxidizing BiocideFeed - Relay 4 TB4-1 NO4 OXIDE BIOCIDE - NO4

TB4-2 N OXIDE BIOCIDE - NTB4-3 Gnd Ground BarTB4-4 L OXIDE BIOCIDE - LTB4-5 COM4 OXIDE BIOCIDE - COM4

Wiring






Controller BoxTerminal Junction Box Terminal

Non-OxidixingBiocide Feed -

Relay 5TB5-1 NO5 NONOX BIOCIDE - NO5

TB5-2 N NONOX BIOCIDE - NTB5-3 Gnd Ground BarTB5-4 L NONOX BIOCIDE - LTB5-5 COM5 NONOX BIOCIDE - COM5

Blowdown Valve -Relay 6 TB6-1 NO6 BLOWDOWN - NO6

TB6-2 N BLOWDOWN - NTB6-3 Gnd Ground BarTB6-4 L BLOWDOWN - LTB6-5 COM6 BLOWDOWN - COM6

pH Control Feed -Relay 7 TB7-1 NO7 pH CONTROL - NO7

TB7-2 N pH CONTROL - NO7TB7-3 Gnd Ground BarTB7-4 L pH CONTROL - LTB7-5 COM7 pH CONTROL - C OM7

2.7.10 Control Relay Connections - TerminationDetails (con’t) Wiring




2.7.11 Pellet Feeder Connections

(User wired in Controller Box or Junction Box)

The pellet feeder is wired using the supplied pellet feedercable (P/N 060-TR5311.88). The cable needs to be hardwired at the controller and connected tothe pellet feeder via the cable connector. The pellet feeder operates on 24 VDC, 0.5 amp, power.

Wiring

2.7.12 System Probe Connections

(Factory wired in Controller Box)

Probe wiring for the Fluorometer and Conductivity probe is done at the factory.




(RemovableConnector)

Junction BoxTerminal Wire Color

Pellet Feeder TB11 ISO Gnd Gnd Blue with White stripeTB11 B B Orange with White stripeTB11 A A White with Orange stripeTB11 ISO Gnd Gnd BlackTB11 24V 24V White with Blue stripe

ProbeDescription


Controller Box Terminal(Removable Connector) Wire Color

Fluorometer TB15 A White with Orange stripeTB15 B Orange with White stripeTB15 Gnd Blue with White stripeTB15 6V White with Blue stripe

Conductivity J7-1 Wht WhiteJ7-2 Blk BlackJ7-3 Gnd ShieldJ7-4 Red RedJ7-5 Blk BlackJ7-6 Gnd ShieldJ7-7 Grn GreenJ7-8 Blk BlackJ7-9 Gnd Shield

!Important: Pay close attention to orientation and placement of terminal blockfor Pellet Feeder. Miswiring, or improperly placing the terminal on thecontroller board could damage both pellet feeder and controller, which is notcoveed under warranty.




2.7.12 System Probe Connections (con’t)

(pH, ORP and Corrosion cables are factory wired in theController Box for 3D TRASAR 5500 models.Corrosion cables are factory wired, and pH and ORPcables are user wired in the Controller Box for upgraded3D TRASAR Starter 3500 Models.)

The pH, ORP, and corrosion probes must be installed and connected using the quick disconnects.

! IMPORTANT: Make sure the pH and ORP probes are connected to the appropriateterminals as they look very similar and will display a reading even if connected improperly.

ProbeDescription


Controller Box Terminal(Removable Connector) Wire Color

pH J4 + BlackJ4 Gnd Shield

ORP J5 + BlackJ5 Gnd Shield

Corrosion 1 J2 Removable Connector Not UsedJ2 Removable Connector Not UsedJ2 Removable Connector BlackJ2 Removable Connector BlueJ2 Removable Connector GreenJ2 Removable Connector Not UsedJ2 Removable Connector BrownJ2 Removable Connector Orange

Corrosion 2 J1 Removable Connector Not UsedJ1 Removable Connector Not UsedJ1 Removable Connector BlackJ1 Removable Connector BlueJ1 Removable Connector GreenJ1 Removable Connector Not UsedJ1 Removable Connector BrownJ1 Removable Connector Orange

Wiring




2.7.13 Analog I/O Connections


There are (2) 4-20ma inputs and (8) 4-20ma outputsavailable in the 3D TRASAR controller. Both are non-isolated.

The analog inputs must be externally powered. They can be used to control conductivity, pH, andORP. Refer to Appendix I for information on the halogen analyzer.

The analog outputs are internally powered for a max. load of 600 ohms. The analog outputs can beused to transmit any of the following variables: TRASAR product dosage, Tag Polymer productdosage, Cell Fouling, Nalco Scale Index, Nalco Bio-Index, Conductivity, pH, ORP, Corrosion#1, Corrosion #2, and Sample Water Temperature.



Controller Box Terminal(RemovableConnector)

Junction BoxTerminal

4-20ma Input 1 TB16 1+ AI1 (+)TB16 1- AI1 (-)

4-20ma Input 2 TB16 2+ AI2 (+)TB16 2- AI2 (-)

4-20ma Output 1 TB17 1+ AO1 (+)TB17 1- AO1 (-)






4-20ma Ouput 7 TB17 7+ AO7 (+)TB17 7- AO7 (-)


Wiring




2.7.14 Factory Wired Digital Inputs

(Factory Wired in Controller Box or Junction Box)

There are two factory wired digital inputs. The first is thefluorometer flow switch, which is used to suspend control of any relay associated with the fluorom-eter upon loss of sample flow.

The second digital input is the system interlock, which is intended for use on cooling systems thatoperate intermittently. Afactory installed jumper wire is placed across the terminals of this input(leave in place under normal operation). Removal of this jumper will suspend operation of ALLcontrol relays and initiate an alarm.

2.7.15 User Wired Digital Inputs


There are two user wired digital inputs that can be used to log and/or alarm the state of anunpowered contact or totalize the counts from a low frequency pulse water meter. Note: Please call630-305-CHEM for wiring assistance with “hall-effect sensor” transistor output water meters.

For water meter inputs, each pulse represents a pre-defined amount of water usage (i.e., 10 gal-lons/pulse, 100 gallons/pulse, etc.). The gallon scaling factor is user-defined in the 3D TRASARConfigurator. Note: The minimum on-time and off-time pulse width is 5 milliseconds for a validpulse. The maximum number of pulse counts is 10 per second.





Digital Input 3 TB10 3 (+) DI3 (+)TB10 3 (-) DI3 (-)

Digital Input 4 TB10 4 (+) DI4 (+)TB10 4 (-) DI4 (-)

Wiring




(RemovableConnector)

Junction Box Terminal

Digital Input 1Fluorometer Flow

SwitchTB10 Flow (+) N/A

TB10 Flow (-) N/ADigital Input 2

System Interlock TB10 INTERLOCK (+) INT (+)

TB10 INTERLOCK (-) INT (-)




2.7.16 Alarm Output Connections


There are two different alarm outputs. The first is ageneral alarm (fused @ 1.0 amp) that is initiated by anyof the alarms described in Section 4.11.

The second alarm output is a float switch alarm that is only used with 3D TRASAR models that arefully enclosed. This alarm is initiated if water starts accumulating in the enclosure. This alarmshould be sent to a location where it can be responded to as quickly as possible to avoid damagingthe electronics.




Junction Box Terminal

General SystemAlarm TB8-1 COM ALARM - COM

TB8-2 NO ALARM - NOTB8-3 NC ALARM - NC

Float SwitchAlarm

Terminations madeat float swi tch N/A N/A

2.7.17 Phone Line Connections

A phone line can be connected to the 3D TRASAR controller. Through this modem connection youcan upload/download configurations, download history, and view live data. The phone line is alsorequired to transmit email alarms to users.

The phone line connection is located inside the controller box and can be connected through theRJ11 analog phone jack or hardwired to terminals 1 and 2.

Wiring

1

2

RJ11 AnalogPhone Jack

Hard Wire AnalogPhone Connection*



Controller Box Terminal(or Phone Jack)


Modem(Phone Line) TB-1 1 AP 1

TB-2 2 AP 2

Note: Connect the analog “Tip” and “Ring” phone wires from thetelephone company to pins 1 and 2. The modem input is not polaritysensitive, so it does not matter which order the wires are connected.




2.7.18 Ethernet (Direct Connect)

The ethernet port is primarily used for direct connectionswith a laptop. Through the port you can upload/downloadconfigurations, download history, view live data, andupgrade firmware. The ethernet port is located on the left-hand side of the box in a connector with awaterproof cap. The cap must be in place whenever the port is not in use. Use the suppliedEthernet Crossover Cable (P/N 991-05047661.88)for PC connections.

2.7.19 LAN Connections

The 3D TRASAR controller can be connected to a LAN system, however, it is required that a Router(P/N 060-TR5270.88) be used to isolate the controller from the rest of the LAN system. Processingextraneous broadcast messages will significantly impact controller operation. Refer to Appendix Efor more details or call 630-305-CHEM for assistance.

2.7.20 SCADA Connections (Modbus RTU)

The 3D TRASAR controller is equipped to handle either a single RS-232 or RS-485 modbusconnection. Refer to Appendix E for more details.

Wiring



Controller Box Terminal(Removable Connector)


SCADA TB12-1 A Rx/ATB12-2 B Tx/BTB12-3 Gnd Gnd

Call 630-305-CHEM for assistance.

2.7.21 Nalco Global Gateway

See Section 7.7 for details.




2.8 STEP 8 – Calibration & SystemCheckoutBefore starting up the 3D TRASAR system, it is important toverify probe calibration and test the plumbing and electricalconnections.

2.8.1 Establish Sample Flow & Apply Power

1. Check all unions and probe connections for tightness.

2. Double check all cables to ensure correct and tight electricalconnections.

3. Slowly open the inlet and outlet ball valves on the 3DTRASAR system and Pellet Feeder (if installed).

4. Check for leaks and tighten where necessary.

5. Verify that a minimum of 5 gpm is flowing through the unit as indicated by the rotometer.

6. Verify that the circuit breaker in the appropriate electrical service box is switched on.

7. Flip the 3D TRASAR controller power switch to “ON”.

8. Flip the Pellet Feeder power switch to “ON” (if installed).

9. Adjust the water flow through the fluorometer to a minimum of 0.5 gpm as indicated by theflowswitch.

10. Verify that a “No Flow Alarm” does not exist on the 3D TRASAR controller display. No flow isindicated by a flashing “F”.

11. Verify that a “System Interlock” alarm does not exist on the 3D TRASAR controller display.System Interlock alarms are indicated by a flashing “I”.






2.8.2 Calibrate Probes Calibration & checkout


IMPORTANT: Make sure you have the appropriateStart-up Kit (P/N 500-TSRKIT.88 for 3D TRASAR5500 systems, or P/N 500-TSRKITSTR.88 for 3DTRASAR Starter systems) with a sufficient supply ofreagents on hand before proceeding.

!

• The calibrations required for the 3D TRASAR 5500system are Fluorometer, pH, ORP, and Conductivity.

• The calibrations required for the 3D TRASAR 3500system are Fluorometer and Conductivity.

• Corrosion probes never require calibration.• Calibrations are performed through the 3D TRASAR

control panel.• Make sure to close off inlet and outlet ball valves before

proceeding.

Fluorometer Calibration1. Press Actions key on control panel.2. Select Clean & Calibrate.3. Enter PASSWORD 12345 if requested.4. Select Fluorometer and follow directions

on screen.5. Refer to Section 4.10.3 for details.

pH Calibration1. Press Actions key on control panel.2. Select Clean & Calibrate.3. Enter PASSWORD 12345 if requested.4. Select pH.5. Select 2-Point/standards and follow

directions on screen.6. Refer to Section 4.10.4 for details.

Note: 1-point calibration can be used after theinitial 2-point calibration has been performed.

ORP Calibration1. Press Actions key on control panel.2. Select Clean & Calibrate.3. Enter PASSWORD 12345 if requested.4. Select ORP.5. Select 2-Point/standards and follow



Conductivity Calibration1. Press Actions key on control panel.2. Select Clean & Calibrate.3. Enter PASSWORD 12345 if requested.4. Select Conductivity.5. Select 2-Point/Process and follow



2-point calibration should be performed when-ever a replacement conductivity probe isinstalled.




2.8.3 Checkout Control Relays

Before start-up of the 3D TRASAR controller it is important tocheck the functional operation of all pumps and valves. Followthe procedure below for each control device (There is amaximum of 7 control relays).

Control Relay Test Procedure1. Press Actions key on control panel.2. Select Manual Relay Control.3. Enter PASSWORD 12345 if requested.4. Use arrow keys to highlight device to be tested and

press Select.5. Use arrow keys to highlight Current State ....6. Press Edit.7. Use arrow keys to toggle to Man-On.8. Press Accept.9. Verify pump or valve has been activated (NOTE: when testing Pellet Feeder make sure

feeder is switched “ON” before verifying the feed of a pellet).10. Use arrow keys to highlight Current State Man-On.11. Press Edit.12. Use arrow keys to toggle to Man-Off.13. Press Accept.14. Verify pump or valve has turned off.15. Use arrow keys to highlight Current State Man-Off.16. Press Edit.17. Use arrow keys to toggle to Auto.18. Press Accept.19. Press Back key to test the next device in the list until you have tested each device.



!IMPORTANT: Make sure all relays are in “Auto” mode after checkout. Pumps or valvesleft in “Man-On” mode will result in excessive waste of chemical and water which maycause damage to the cooling system.




Start-up system

Enter Set PointsYou are up and running!!

2.9 STEP 9 - Start-up System

The following is an overview of the steps required to start upyour 3D TRASAR system. The remainder of the manual pro-vides details for each step listed below.

STEP 1 - Upload configuration (refer to help screens (F1) inConfigurator program).

IMPORTANT: Every 3D TRASAR controller isconfigured uniquely for each application throughNalco’s “Configurator” software. Your Nalcorepresentative will have created your systemconfiguration prior to installation.

STEP 2 - Verify control settings, setpoints and alarms.

• Through the controller keypad, verify that all of the new settings from the “Configurator”have been accepted into the controller.

STEP 3 - Activate “System Start-up” mode (refer to Section 4.10.11).

• The “System Start-up” mode allows you to temporarily suppress alarms for a user definedperiod of time. This prevents false alarming and relay time-outs from occurring until thecooling system has reached chemical equilibrium.

STEP 4 - Initiate 3D TRASAR scale control (refer to Section 5).• 3D TRASAR scale control is an available upgrade for 3D TRASAR Starter systems.

STEP 5 - Initiate 3D TRASAR bio-control (refer to Section 6).• 3D TRASAR bio-control is an available upgrade for 3D TRASAR Starter systems.




Section 3: 3D TRASAR ConfiguratorThe configurator program is used to:

• Configure the controller• Establish direct and modem connections to the 3D TRASAR controller• Download data from the 3D TRASAR controller• Update controller firmware

!NOTE: Although many settings can be changed through the 3D TRASAR controllerkeypad, the configurator must be used for initial controller setup and to makechanges to control methods.

3.1 PC System Requirements• The 3D TRASAR controller configurator software requires a PC running the Windows 2000

or Windows XP operating system (it is not supported on other versions of Windows at thistime).

NOTE: The configurator software operates optimally when Lotus Notes is installed onyour PC. Lotus Notes is used as a means of obtaining the most recent data for use in theconfigurator. The configurator also has the capability of generating email messages (withthe user’s consent), which are sent via the user’s Notes mailbox at the next replication.However, the program has been designed to operate in the absence of Notes with a morelimited capability.

• For direct connection to a 3D TRASAR controller an Ethernet adapter is required.• For remote dialup access to a 3D TRASAR controller a modem is required.

3.2 Installing the SoftwareFor Windows 2000 users, insert the CD and double click on the Setup.exe icon. Followthe on screen steps to complete the installation.

For Nalco Windows XP users, the configurator program should be pre-installed. To openclick Start, Programs, Nalco Software, 3D TRASAR, 3DT Configurator.

If the program is not pre-installed, it can be downloaded from SMS. To download, clickStart, Programs, System Manager. Scroll through programs, locate Nalco 3D TRASARConfigurator.

A second program, 3Cdaemon, will also be installed. This is a TFTP server program usedonly for controller software upgrades.

!




3.3 Configurator SupportImportant configurator information can be located in the help screen by pressing the F1 functionkey. A keyword search can also be performed to locate information on a specific topic.

3.3.1 Sample Help Screen

3.3.2 Sample Search Screen




4.1 3D TRASAR 3500 and 5500Control Unit OverviewThe keypad and display on thecontrol panel is shown to theright. Through this panel you canperform many basic operationsquickly and conveniently, includingsetting control ranges, performingcalibrations, manual relay operation,and biocide slug feeds.

4.1.1 The Display Panel

The display panel is a 6-line,backlit LCD graphical display.

The display panel is used toedit numeric data and showstatus information for the varioussystem parameters, alarms and pumps.

4.1.2 The Keys

The function of the 20 keys on the controlpanel's key pad are summarized to the right:

Pressing any of these keys will change theinformation shown on the display and let youquickly check the status of the unit orchange its configuration.

Info...................

Actions.............

Alarms..............Numbers 0-9....Menu................Help..................Up/Down..........Back.................Soft Keys..........

Indicates system performance, operatingdata, product inventory, water and energyAllows user to clean and calibrate, updateinventory, feed biocideShows active alarmsProvides for the entry of numerical listingsProvides complete main menu listProvides contact information helpUsed for menu navigationReturns to previous screenUsed to make selections shown on thedisplay panel

Section 4: Controller Settings

NumberKeys

Up/Down

BackSoft Keys

Help

Info

Action

Alarms

Menu

Display Panel




4.1.3 The Graphical Icons

The graphical icons that will appear in the display are listed below with a brief explanation of theirmeaning.

The screen on the left has several ICONS thatindicate a particular function. Refer to thesymbols below for more details.

• Relay is “ON” in Auto mode (no icon indicates Auto “OFF”)

• Move to next/previous screen (use arrow keys)

• Relay is “OFF” in Manual mode

• Relay is “ON” in Manual mode

• Relay is “OFF” in Failsafe mode

• Relay is “ON” in Failsafe mode

• Scroll through list of choices (use arrow keys)

• One or more alarms is active (press Alarms to view)

• Modem connection is established (incoming or outgoing)

• No flow condition exists (delay for alarm)

• Interlock contact is opened (immediate alarm)




4.2 Menu, Information, Actions and Alarms Flow DiagramThe flow diagram below shows all of the different screens that can be accessed through the control-ler display panel. The remainder of Section 4 gives detail on each of these screens.

Control Settings

Alarm Settings Preferences Network System Info

Background System Alarms Time DHCP System

Volume

Relay 1 Product

Control Alarms Date IP Address Makeup

Cond.

Relay 2 Product

Performance Alarms Date Format Subnet Delta T

Oxidizing Biocide

Relay Alarms Password Gateway

Blowdown Analog Alarms Contrast

pH SCADA Address

SCADA Mode

SCADA Baud

Menu

Control Settings

Alarm Settings Preferences Network System InfoControl

SettingsAlarm

Settings Preferences Network System Info

Background System Alarms Time DHCP System

VolumeBackground System Alarms Time DHCP System

Volume

Relay 1 Product


Cond.Relay 1 Product


Cond.

Relay 2 Product

Performance Alarms Date Format Subnet Delta TRelay 2

ProductPerformance

Alarms Date Format Subnet Delta T

Oxidizing Biocide

Relay Alarms Password GatewayOxidizing

BiocideRelay Alarms Password Gateway

Blowdown Analog Alarms ContrastBlowdown Analog Alarms Contrast

pH SCADA AddresspH SCADA Address

SCADA Mode

SCADA Baud

Menu

Information Actions Alarms

System Performance

Clean and Calibrate

Current Alarms

Operating Data

Manual Relay Control

Product Usage

Pumping Rates

Water & Energy

Slug Feed Biocide

Plot Data System Startup

Timer Status

External Inputs

Product Factors

Diagnostic Data

Control Methods Test Email

Information Actions AlarmsInformation Actions Alarms

System Performance

Clean and Calibrate

Current Alarms

System Performance

Clean and Calibrate

Current Alarms

Operating Data


Operating Data


Product Usage

Pumping Rates

Product Usage

Pumping Rates

Water & Energy

Slug Feed Biocide

Water & Energy

Slug Feed Biocide

Plot Data System StartupPlot Data System Startup

Timer Status

External Inputs

Product Factors

Diagnostic Data

Control Methods Test EmailControl Methods Test Email

Service Response

Email


System Performance

Clean and Calibrate

Current Alarms

System Performance

Clean and Calibrate

Current Alarms

Operating Data


Operating Data


Product Usage

Pumping Rates

Product Usage

Pumping Rates

Water & Energy

Slug Feed Biocide

Water & Energy

Slug Feed Biocide


Timer Status

External Inputs

Product Factors

Diagnostic Data

Control Methods Test EmailControl Methods Test Email


System Performance

Clean and Calibrate

Current Alarms

System Performance

Clean and Calibrate

Current Alarms

Operating Data


Operating Data


Product Usage

Pumping Rates

Product Usage

Pumping Rates

Water & Energy

Slug Feed Biocide

Water & Energy

Slug Feed Biocide


Timer Status

External Inputs

Product Factors

Diagnostic Data

Control Methods Test EmailControl Methods Test EmailControl Methods Test EmailControl Methods Test Email

Service Response

Email




4.3 The Menu Key

Plot Data ControlSettings

AlarmSettings

Preferences SystemInfo

NetworkInformation

ManualRelay

Actions Alarms

Menu

The Menu Key provides access to 5 submenus.• Control Settings - Set control parameters.• Alarm Settings - Set alarm parameters.• Preferences - Set time, date, password, SCADAand display

options.• Network - Network settings• System Info - System volume, make-up conductivity and

delta-t.

4.3.1 Password Screen

A password must be entered to access all submenus.

Enter Password….12345 (Default Password)

The password has to be re-entered after 10 minutes of inactivity.

4.4 Control Settings Submenu


AlarmSettings


NetworkInformation

ManualRelay

Actions Alarms

Menu

This submenu is used to access the system control settings. Only items that have beenconfigured as “controlling” will display.




4.4.1 Background Correction Screen

Displays the 3D TRASAR background correction data from a TOWER water sample.


AlarmSettings


NetworkInformation

ManualRelay

Actions Alarms

Menu

TRA Background Shows the TRASAR background fluorescence value. Note: Do not useTRASAR Control or 3D TRASAR scale control if TRABackground is > 15%.

TAG Background Shows the tagged polymer background fluorescence value. Note: Do notuse TAG Polymer Control if TAG Background is > 75%. Do not use 3DTRASAR scale control if TAG Background is > 30%.

TAG Ratio Shows the ratio for tagged polymer background fluorescence correction.

TAG Method Toggles between Fixed offset correction and Online background correctionfor tagged polymer control. Note: The preferred Online TAG Method can onlybe used if TAG Ratio is between 1.41 and 1.71. Fixed TAG Method can beused for any TAG Ratio value.

!IMPORTANT: Periodically check the Tagged Polymer level on the controller against thelevel determined by the Nalco DR/2800 or DR/890 Active Polymer Test (Reagent P/N460-S0811.75). The results from the Active Polymer Test must be multiplied by (ProductFactor divided by 10) to convert to ppm of product for accurate comparisons.

Example: 3DT265-a = 160 ppm (as product) at the controller.3DT265-a Product Factor = 133.Active Polymer Test = 9 ppm (as actives) * (133/10) = 119.7 ppm (asproduct).

% Difference = ((160-119.7)/(160)) * 100 = 25%.

Select Fixed for TAG Method and enter 25% for TAG Bkgd

Note: Tagged polymer products must be fed for a minimum of 5 HTI’s before Active Polymer Testresults can be used for comparison.




4.4.2 TRASAR (Relay 1) Product Screen

Displays the dosage set point and control range for theTRASAR product controlled by Relay 1.


AlarmSettings


NetworkInformation

ManualRelay

Actions Alarms

Menu

!NOTE: Control ranges will only be displayed if applicable. Control range is notdisplayed if 3D Scale Index schemes are used. In these cases, the ranges aredetermined by the control algorithm.

4.4.3 Tagged Polymer (Relay 2) Product Screen

Displays the dosage set point and control range for theTagged Polymer product controlled by Relay 2.

4.4.4 Oxidizing Biocide Screen

Displays the ORP set point and control range. This is used only ifthe system has been configured to control the oxidizing biocidebased on the ORP probe reading.

4.4.5 Blowdown Screen

Displays the conductivity set point and control range.

4.4.6 pH Screen

Displays the pH set point and control range.




4.5 Alarm Settings Submenu

ControlSettings

AlarmSettings


NetworkInformation

ManualRelay

Actions Alarms

Menu

This submenu displays the following options for alarm settings.

! IMPORTANT: Whenever any alarm condition occurs, a specific alarm email issent (i.e., “pH High 7.9”) and the general system alarm relay is activated.

4.5.1 System Alarms Screen

High and low alarm thresholds for temperature and cell fouling.To change these set points, press Edit, arrow down to the settingto change, type in the new value and press Accept.

4.5.2 Control Alarms Screens

High and low alarm thresholds for product levels, ORP, pH, andconductivity. To change, arrow down to the parameter and pressSelect.

! NOTE: The duty cycle percentages for high and low alarmscan be set to different values if needed via the Configurator.

4.5.3 Performance Alarms Screen

Corrosion 1, Corrosion 2, Nalco Bio-Index, and Nalco Scale Index highalarm thresholds. To change, arrow down and press Edit.




4.5.4 Relay Alarms Screens

Each relay output can be timed to prevent overfeed. Should a relayenergize continuously for a time exceeding the Relay Timeout setting,an alarm condition will occur and the relay will operate in a FailsafeDuty cycle for that parameter.

Startup Factor allows you to extend the relay time-out period duringstartup. Chemical residuals may be extremely low at startup andrequire an extended period to equilibrate. The Startup Factor (select-able between 1 and 99) multiplies this initial time out period for allrelays (i.e. if the Relay Timeout is set for 60 minutes and the StartupFactor is set for 5, the timeout period will be 300 minutes for startup).

Relay Timeout - Maximum time for continuous relay operation before an alarm is initiated and theFailsafe Duty mode begins.

Failsafe Duty - When any alarm condition exists for the parameter associated with a relay, the relayreverts to the Failsafe Duty mode. Failsafe Duty can be set as “Fixed” or “Smart”.

The Failsafe Duty set as "Fixed" is the percentage of a 15-minute period that the relay isactivated. For example, if the failsafe duty is set at 20%, the relay will be activated for 3minutes and deactivated for 12 minutes. This pattern repeats as long as the alarm conditionexists. Set these carefully as improperly set failsafe modes can cause under or overfeedconditions during "alarm" conditions.

! Note: Make sure all alarm parameters have been set prior to startup. Impropersettings will adversely affect performance of controller and cooling system.

Pump timeout alarms will be cleared automatically if the related parameter concentration is withinthe defined control range or can be cleared manually at the controller via the keypad.

!Note: “Fixed” Failsafe Duty can be set via both the Configurator and the Key-pad, which is used for Pump Timeout and NoFlow alarm conditions. Level alarmFailsafe Duty can be set to different values for high or low level alarm conditionsONLY through the Configurator .

The Failsafe Duty set as "Smart" is the average run time of that relay for the last 7 days.Selecting this mode allows the system to continue to operate under average conditionsbased on past performance during failsafe operation. The Failsafe Duty median is used forall alarm conditions with the “Smart” setting

4.5.5 4-20 mAAlarm Screen

High and low alarm thresholds for 4-20mA input signals.

Press Edit to modify.




4.6 Preferences Submenu

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This submenu is used to display and edit general settings. The arrow keys can be used to navigatebetween fields with more than one setting (i.e., the time field has both hours and minutes).

Time…………………………………

Date…………………………………

Date Format………………………..

Password…………………………..

Contrast…………………………….

SCADA Address…………………..

SCADA Mode………………………

SCADA Baud………………………

Displays the clock setting in hours and minutes (24-hourformat).

Shows the date setting in the format configured through the PC.

Selects the date format (M/D/Y, D/M/Y, Y/M/D).

Displays the current system password. Changing the passwordsis not recommended under normal circumstances. A lost orforgotten password may result in a service visit or return of yoursystem to the factory for reset.

Adjust display contrast.

The Modbus address for the controller. This information needsto be supplied by the customer only if SCADA is used.

The SCADA communication mode (RS-232 or RS-485).

Selects the SCADABaud rate (1200, 2400, 4800, 9600, 19200).




4.7 Network Submenu

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The Network submenu screen accesses the network settings of the ethernet port.

Before making changes to the network settings check with your local Network Administrator or ISPprovider. Any changes made must also be made in the configuration program!

DHCP………………………..

IP Addr..…………………….

Subnet………………………

Gateway…………………….

Enables/disables the assignment of the controller IP address foruse on a network. In most cases, this should be disabled.

Displays the current controller IP address.

Indicates the controller subnet address

Indicates the controller default gateway address.

4.8 System Information Submenu

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This submenu is used to display the start-up system parameters as entered by the user. This is thestarting point for the water and energy calculations.

System Volume………………………..

Makeup Conductivity..…………….….

Delta T………...................…………….

Estimate of system volume in gallons.

Measured (microsiemens)

Temperature drop across cooling towers.




4.9 The Information Key

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The information key accesses general performance information. There are no adjustments orchangeable settings accessible through these screens.

4.9.1 System Performance Screens

The System Performance screens display measurements for corrosion, scale, and microbial foul-ing. The values that appear here depend on the configured control modes (i.e. Nalco Bio-Index willonly appear if the controller is set in 3D TRASAR bio-control mode).

Nalco Scale Index - Reports the status of the Nalco Scale Index calculations. This is aunit-less measure of the scaling tendencies of the system water. It is used for trendingand is not to be viewed as a direct indication of scaling as each system will trenduniquely.

Nalco Bio-Index - Reports the status of the Nalco Bio-Index calculations. This is a unit-less measure of biological activity. It is used for trending as each system will readuniquely based on operating characteristics.

Corrosion Probe #1 - Reports the corrosion rate for Corrosion probe # 1 (Note: Corro-sion shown in screen display above indicates a mild steel (stl) probe is installed).

Corrosion Probe #2 - Reports the corrosion rate for Corrosion probe # 2 (Note: Corro-sion shown in screen display above indicates a Copper (Cu) probe is installed).

Consumption - Reports the actual consumption of the Tag Polymer. It indicates thedifference between the quantity fed and the active quantity remaining in the system. (Inthe screen display above, 18% consumption means 82% of active polymer remains.)




4.9.2 Operating Data Screens

These screens display basic cooling water measurements. The values that appear here depend onthe configuration.

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3DT265-i………………….

3DT265-a..…………….….

Conductivity…………….

pH……….........................

ORP..................................

Temp................................

Turbidity...........................

HTI....................................

Real time measurement of inert TRASAR level in one drumprograms.

Real time measurement of active Tagged Polymer level in onedrum programs.

Real time measurement from system conductivity probe.

Real time measurement from system pH probe.

Real time measurement from system ORP probe.

Real time measurement from the RTD in the conductivity probe.

Relative measurement of NTU’s by the fluorometer.

Holding Time Index - half life of treatment chemicals in system.

4.9.3 Product Usage Screens

These screens indicate chemical feed rates in gallons per day calculated from pump run time andpumping rate. Pumping rates should be based on actual pump draw down.




4.9.4 Water and Energy Screens

These screens display calculated water and energy usage derived from the calculated averageHolding Time Index.

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Blowdown - Calculated blowdown rate in gallons per day based on mass balance equations.

Makeup - Calculated make-up rate to the system based on mass balance equations.

Heat Rejection - Calculated heat rejection in BTU based on mass balance equations.

Recirculation Rate - Calculated water recirculating rate based on mass balance equations.

System Volume - Calculated system volume based on feed rates and residuals.

4.9.5 Plot Data Screens

These screens are used to display stored data in a graphical form. All of the data shown below canbe plotted:




4.9.5 Plot Data Screens (con’t)

Plot data is a quick and easy way to view trends over time.

The plots can show a time scale of either 1, 7, or 30 days. Time scale is changed by pressing thesoft key labeled X Zoom.

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The plots can also be changed to show 1X or 2X by pressing the soft key labeled Y Zoom.

For Example:In the 30-day view, the graph spans 1-week time periods. The average value for the week is dis-played next to the y axis. Likewise, in the 7-day view, the graph spans 1-day. The average valuefor the day is displayed.

In the 1-day view, the cursor is a line and corresponds to a single point whose value is displayed.

In each view, the cursor can be moved left or right using the arrow keys. Scrolling off the screenwill display data from the next or previous period of time. The previous 90-days of data may bedisplayed.

4.9.6 Control Methods Screens

These screens display the control configurations for each controlled variable. Refer to theConfigurator help screens for more details.




4.9.7 Timer Status Screens

Press View to show the schedule for a given timer. Schedules are View Only and cannot be setfrom the keypad/display. Current state of Biocide Timers (Prebleed, Feed, Lockout, Off) and forGeneric Timers (Feed, Off) is displayed for each scheduled timer.

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4.9.8 External Inputs Screens

Displays the values for the external inputs. Only items that have been configured will appear.

4-20 mA inputs shows scaled values. Digital Input 1 shows the System Sample Flow On/Off status.Digital Input 2 shows the System Interlock On/Off status. Digital Inputs 3 and 4 may be configuredto show On/Off status of a non-powered contact (see DI3 in figure below) or as low frequency watermeter counter to show current and previous day’s total usage (see DI4 in figure below).External inputs can be used as a control signal for pH, ORP, and Conductivity. Refer to page 2-45.

4.9.9 Product Factors Screen

Displays TRASAR and Tagged Polymer product factors.




4.9.10 Diagnostic Data Screens

The Diagnostic screens are used primarily by Nalco Service Technicians to ascertain the status ofraw signals from the sensors.

! NOTE: The NDM is not yet a commercial option.




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4.10 The Actions Key

Pressing the Actions key allows access to the following options.

Clean and Calibrate - Accesses the calibration for the fluorometer, pH, conductivity, and ORP.

Manual Relay Control - Selects control relay mode (Manual - Off - Auto).

Pumping Rates - Enter pump feed rates based on pump calibration information.

Slug Feed Biocide - Use this submenu to manually slug feed biocides.

System Startup - Activates the Controller "Startup" mode which delays alarms.

Test Email - Sends a test data e-mail and alarm e-mail to the 3D TRASAR Web.

Service Response Email - Sends one of ten service e-mails to the 3D TRASAR Web.




Enter Password….12345 (Default Password)

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A password must be entered to access all Actions submenus.

The password has to be re-entered after 10 minutes of inactivity.

4.10.2 Clean and Calibrate Screen

To calibrate or clean the sensor probes, follow the menu selections on the display panel. Calibrationis necessary for proper balance in the system. The need for cleaning or calibration is usually indi-cated by a drift in readings or an error between test results and readings.

4.10.1 Password Screen




4.10.3 Fluorometer Calibration Screens

Select Fluorometer and follow screen directions to perform calibration:

STEP 1Close fluorometer inlet valve and turn 3-way fluorometer discharge valve tosample position.

IMPORTANT: Bubbles trapped in fluorometer during injection can cause instru-ment error. With the syringe (P/N 500-P2147.88) in a vertical position, tap thesyringe against a solid object to move the bubbles to the needle end of thesyringe. Then, force the bubbles out by pushing a small amount of solutionthrough the needle end of the syringe.

STEP 2Clean the fluorometer by injecting acid with a syringe into the flow cell. Fill thesyringe with 60 ml of dilute acid. 10% Sulfuric Acid (P/N 460-S0800.75) is rec-ommended. If iron fouling exists, use 1:1 HCl (P/N 460-S0726.75) for cleaning.Screw the syringe onto the fitting, inject the dilute acid at a slow, steady rate intothe flow cell, and allow it to stand for 2 minutes. Rinse well with water. Using theflow cell brush (P/N 500-P2817.88), gently push the brush down through theopening and scrub the full length of the flowswitch and fluorometer tube.

IMPORTANT: If using 1:1 HCl, do not leave the acid in the flow cell for more thanfive minutes.

STEP 3Following the screen prompts, use a second clean 60 ml syringe and slowlyflush the flow cell with 180 ml of blank solution. Then slowly inject another 180 mlblank solution and allow it to remain in the flow cell by leaving the syringe at-tached. Press Continue.

STEP 4Following the screen prompts, use a third clean 60 ml syringe and slowly injectthe flow cell with 180 ml of calibration solution (P/N 460-S0940.75) and allow itto remain in the flow cell by leaving the syringe attached. Press Continue.

STEP 5Successful calibration will be indicated and must be “accepted”. Controller willautomatically re-boot after accepting calibration. Turn valves back to operatingpositions.

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!A failed calibration is most likely caused by insufficient flush-ing, contaminated/incorrect standards, introduction of airbubbles, excessive cell fouling, or a bad probe connection.




4.10.4 pH Calibration Screens

Select pH from the Calibration menu and follow screen directions toperform calibration:

A 1-point calibration utilizes the system water as the calibration point.It is best used to fine-tune your calibration to compensate for minor drifting.

A 2-point calibration is best utilized when installing a new probe or if amajor error has developed due to excessive fouling or probe degradation.

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For a 1-point calibrationSTEP 1 - Leave probe in tee with water flowing. Select 1-point calibration.

STEP 2 - Using a handheld instrument of known accuracy andcalibration, sample the process water and determine the pHvalue.

STEP 3 - Enter this value.

For a 2-point calibrationSTEP 1 - Select 2-point calibration.

STEP 2 - Close the sample inlet, lower sensor outlet, and 3-way valves.

STEP 3 - Remove the pH probe from the tee.

STEP 4 - Swirl the probe in a beaker of clean, fresh pH 7.0 buffersolution (P/N 460-S0407.75). Press Continue.

STEP 5 - After prompt, rinse probe well in clean DI water and wipe clean.

STEP 6 - Swirl probe in a beaker of clean, fresh pH 10.0 buffer solution (P/N 460-S0408.75). Press Continue.

STEP 7 - After successful calibration reinstall probe and open valves.

!If probe calibration is unsuccessful, check standards, wiringconnections, or handheld pH meter for accuracy. Soak probein standard extra 5-10 min or clean probe tip and recalibrate.




4.10.5 ORP Calibration Screens

Select ORP from the Calibration menu and follow screen directions to per-form calibration.

A 1-point calibration utilizes the system water as the calibration point.It is best used to fine-tune your calibration to compensate for minor drift-ing.

A 2-point calibration is best utilized when installing a new probe or if amajor error has developed due to excessive fouling or probe degradation.

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For a 1-point calibrationSTEP 1 - Leave probe in tee with water flowing. Select 1-point calibration.

STEP 2 - Using a handheld instrument of known accuracy and calibration,sample the process water and determine the ORP value.


For a 2-point calibrationSTEP 1 - Select a 2-point calibration.

STEP 2 - Close the sample inlet, lower sensor outlet, and 3-way valves.

STEP 3 - Remove the ORP probe the tee.

STEP 4 - Swirl the probe in a beaker of clean, fresh ORP 200 mV buffersolution (P/N 460-S0932A.75). Press Continue.

STEP 5 - After prompt, rinse probe well in clean DI water and wipe clean.

STEP 6 - Swirl probe in a beaker of clean, fresh 600 mV buffer solution (P/N 460-S0933A.75). Press Continue.

STEP 7 - After successful calibration reinstall probe and open valves.

!If probe calibration is unsuccessful, check standards, wiringconnections, or handheld ORP meter for accuracy. Clean theORP probe tip and recalibrate.




4.10.6 Conductivity Calibration Screens

Select Conductivity and follow the screen directions to perform calibration:

A 2-point calibration is best utilized when installing a new probe or if a majorerror has developed due to excessive fouling or probe degradation.

A 1-point calibration utilizes the system water as the calibration point. It is bestused to fine-tune your calibration to compensate for minor drifting. Leave theprobe in the process water. The 1-point calibration range is +/-10% of thesecond point value of the previous 2-point calibration.

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For a 2-point calibration

Tips√ Conduct the 2-point conductivity calibration after completing other cali-

brations (pH, ORP, etc.).√ A calibrated conductivity meter with correct temperature coefficient for

the process water is required.√ Measure the water sample and obtain an accurate conductivity value.√ Follow the instructions on the screen.√ Standard solution for the probe calibration is not required. If using a

standard solution for the calibration, choose a solution close to thevalue of the process water conductivity value.

STEP 1 - Select a 2-point calibration.STEP 2 - Close the sample inlet, lower sensor outlet, and 3-way valves.STEP 3 - Remove the conductivity probe from the Tee and dry it.STEP 4 - Hold the probe in the air. Press Continue.STEP 5 - Wait two minutesSTEP 6 - Reinstall the probe into the Tee and open all valves to let the

process water flow. Press Continue.STEP 7 - Press Edit and use the keypad to enter the accurate value of

the process water. Press Accept.STEP 8 - Wait six minutes. Accept the new value if successful, or Retry

if failed.

!If probe calibration failed, clean the probe, check wiring con-nections, or handheld conductivity meter for accuracy andrecalibrate.




For a 1-point calibration

Tip√ A 1-point conductivity calibration can be performed when conductivityhas drifted, or changed <+/- 10% of the second point value of the previ-ous 2-point calibration

STEP 1 - Leave probe in the Tee with water flowing (probe should have beeninstalled at least 15 minutes for equilibrium.) Select 1-pointcalibration.

STEP 2 - Using a handheld instrument of known accuracy, locally sample theprocess water and determine the conductivity value.


4.10.6 Conductivity Calibration Screens (con’t)

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Firmware Version 8.0 Firmware Version's 6.0 and prior

Curve Setting Calibration 2-Point 3-point1-point calibration offset Yes Yes

Standard Solutions No(Need true conductivity value) Yes

TemCoEff Access Yes NoData Weighted Filter Yes NoRecommended Range 500-99,999 uS/cm 500-15,000 uS/cmBuilt-in Instructions Yes Yes

Comparison of Conductivity Calibrations




Adjusting the conductivity temperature coefficient (TempCoEff)Calibrated conductivity systems will use a default temperature coefficient to compensate the tem-perature effect on conductivity. The default temperature coefficient may not fit for your processwater perfectly and may need to be adjusted.

Diagnose the TempCoEff Problem

During operations, you may have an inaccurate temperature coefficient for the system if the follow-ing are true:• The output conductivity is accurate after the calibration, and becomes deviated from the true value

as temperature changes, and• The changes between conductivity and temperature are consistently correlated (i.e. conductivity

always changes in the same manner as temperature increases and vice versa).

!NOTE: Conductivity fluctuations that do not consistently correlate with tempera-ture changes may indicate other issues such as probe malfunction, loose wireconnections, etc. Call the Nalco Help Desk for assistance.

Adjust the TempCoEff value

To adjust the temperature coefficient of your conductivity detection system:• Connect your Configurator with the 3D Controller.• Using the pull down Menu, choose Controller – Tools – Adjust Cond Probe Temp Coeff.• In the dialogue box, choose “Get Values” button, then fill in the accurate conductivity value obtained

from a calibrated conductivity meter.• Choose “Calculate” button, the new Temp coefficient should be in the field.• Choose Upload

! NOTE: To make an accurate temperature coefficient change, make sure thetemperature of the process water is less than 71oF (22 oC) or greater than 83 oF(28 oC).

The best time to perform this adjustment is when the process water temperature is in a stable stateat which the temperature is different from the temperature when a 2-point calibration was performed(avoid performing a temperature coefficient adjustment if process water temperature is quicklychanging).




4.10.7 Probe Calibration / Maintenance List

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P a ra m e te r R e p la c e m e n tP ro b e P a r t #

M a in te n a n c eIn d ic a tio n

C a lib ra tio nS ta n d a rd sR e q u ire d

T y p ic a lM a in te n a n c e

S c h e d u le *

T y p ic a lP ro b e

L ife

C o n d u c tiv i ty 0 6 0 -T R 5 4 4 1 .8 8 C o nd u c tiv i tyd r i f t

U s e s ys te m w a te ra nd p e rfo rm a "1 "

p o in t c a lib ra tio n

C le a n a ndc a lib ra tem o nth ly

Ind e fin i te

F luo ro m e te r 0 6 0 -T R 5 2 2 0 .8 8 C e ll fo u linga la rm

C a lib ra t io n S o lu tio n(4 6 0 -S 0 9 4 0 .7 5 )


Ind e fin i te

p H 0 6 0 -T R 5 4 11 .8 8 p H d rif t

p H 7 .0 B uffe r(4 6 0 -S 0 4 0 7 .8 8 )

p H 1 0 .0 B uffe r(4 6 0 -S 0 4 0 8 .8 8 )


U p to 1 yr.

O R P 0 6 0 -T R 5 4 2 1 .8 8 O R P d rif t

2 0 0 m V(4 6 0 -S 0 9 3 2 A .7 5 )

6 0 0 m V(4 6 0 -S 0 9 3 3 A .7 5 )


U p to 1 yr.

C o rro s io n

4 0 0 -N C M P 1 B .8 8S te e l

4 0 0 -N C M P 2 B .8 8C o p p e r

4 0 0 -N C M P 4 B .8 8C uN i 9 0 /1 0

4 0 0 -N C M P 5 B .8 8C u N i 7 0 /3 0

4 0 0 -N C M P 7 B .8 8B ra s s 4 4 3

6 0 1 6 1 8 06 0 6 1 A lum inum

6 0 1 6 1 8 211 0 0 A lum inum

4 0 0 -N C M P 1 0 .8 8G a lva n ize d S te e l

S tu d yc o m p le te d N o t re q u i re d Ins p e c t p ro b e

m o nth lyU p to 6m o n ths

* For a detailed maintenance schedule, see Section 8.




4.10.8 Manual Relay Control Screens

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All configured control relays can be placed in Manual On, Manual Off, or Auto through these screens.

STEP 1 - After selecting desired relay, highlight Current Mode and press Edit.

STEP 2 - Use arrow keys to select desired mode (Manual Off, Manual On, Auto) and pressAccept.

STEP 3 - After selecting desired mode, highlight Auto After and press Edit (Auto After isthe amount of time the relay will remain in the selected mode before reverting backto auto).

STEP 4 - Enter the Auto After value in hours and minutes using the keypad (0-4-2-5 equals 4hours 25 minutes). Entering 00:00 will put the relay in the selected mode continu-ously.

STEP 1 STEP 3

STEP 2 STEP 4




4.10.9 Pumping Rates Screens

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Chemical feed pumping rates are used to monitor and report on chemical usage and several calcu-lations of water and energy use. The inert TRASAR product pumping rate is used to determinesystem volume. The accuracy of this reporting is dependant on the accuracy of the pumping ratesinput here.

For specific directions on proper calibration techniques, refer to the pump manufacturers instruc-tions supplied with the pumps. The calibrated cylinder draw-down method is suggested for greatestaccuracy.




4.10.10 Slug Feed Biocide Screens

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There are three options for slug feeding biocides. Each choice will follow the pre-bleed and lockoutconditions setup in the configuration.

1. Use Hand Feed Nonox to physically add a non-oxidizer by an operator to the cooling system.Note: If feeding Glutaraldehyde the configured oxidizing feed will be suspended for 8 hours.

2. Use Hand Feed Oxidizer to physically add an oxidizer by an operator to the cooling system.

3. Use Relay Feed Oxidizer to energize the oxidizer relay.




4.10.11 System Startup Screens

This screen allows the user to “Activate” a special startup mode in which the alarms are temporarilysuppressed, preventing false alarming until the system has reached a balanced equilibrium. Thestartup period is equal to the Relay Timeout Limit multiplied by the Startup Factor (Referto section 4.5.4 for Startup Factor details).

4.10.12 Test Email Screen

This will send both a test alarm email and a data email to the indicated respective addresses.

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4.10.13 Service Email Screens

Sends an email to the 3D TRASAR Web alarm mailbox. Use this function to indicate one of theroutine maintenance functions listed below have been performed. Service emails will be sent tothe users who are specified to receive alarms.

Change ID (identification code) by selecting ID and pressing Edit.

Select Routine Maintenance to view list of service emails.• Fluor Cal Check Pass• Fluor Cal Check Fail• pH Cal Check Pass• pH Cal Check Fail• ORP Cal Check Pass• ORP Cal Check Fail• Cond Cal Check Pass• Cond Cal Check Fail• Routine Service Performed• Site Audit Completed




4.11 The Alarms Key

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4.11.1 Sensor Alarms

Sensor Alarms are activated when an error is detected in the sensor probes. These alarms aretypically the result of improper or loose wiring, or faulty probes.

• Conductivity Sensor Error• RTD Sensor Error• pH Sensor Error*• ORP Sensor Error*

!NOTE: pH and ORP are high impedance measurements, and it is difficult to detectmissing or miswired probes. Therefore, the pH and ORP Sensor Errors are notalways triggered. Inaccurate or fluctuating readings are another indication of amiswired or faulty probe.

4.11.2 System Alarms

System Alarms are related to cooling system parameters that are not controlled by the 3D TRASARsystem. Interlock and No Flow alarms supercede all other alarms, such that the other alarms in allcategories are disabled during Interlock and No Flow alarms. Likewise, the Interlock alarmsupercedes the No Flow alarm.

• Turbidity High• Temperature High• Temperature Low• Cell Fouling High• No Flow• Interlock

Interlock - The Interlock digital input provides the ability to use a signal, for example, from therecirculation pumps to enable or disable the 3D TRASAR control relays. If the recirculation pumpsare turned off, the contact is opened, and the Interlock alarm occurs immediately, disabling allcontrol relays. Control is restored when the recirculation pumps are turned back on and the contactis closed, which clears the Interlock alarm. If this feature is not needed, the Interlock input must beshorted with a wire jumper so the contact is always closed.




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4.11.3 Communication Errors

Communication Errors result from problems that the controller encounters in attempting to commu-nicate with the other components. They do not indicate whether the problem is with the controller orthe component, although the presence of multiple Comm Errors suggests a problem with thecontroller.

• Fluorometer Comm Error• Multiprobe Comm Error• Pellet Feeder Comm Error

4.11.4 Performance Alarms

Performance Alarms are related to the parameters that comprise the Cooling Water Triangle (scal-ing, corrosion, microbio). The 3D TRASAR bio-control "Failsafe" alarms are so named to indicatethat the oxidizing biocide is fed in failsafe mode when those alarms are activated, and the relay mustbe reset at the controller display by clearing the popup window. The bio-reporter is never fed infailsafe mode.

• System Stress High• Corrosion #1 High• Corrosion #2 High• Nalco Bio-Index High• Biocide Pump Rate High• Biocide Pump Rate Low• Bio-reporter High• Bio-reporter High Failsafe• Bio-reporter Low

• Bio-reporter Low Failsafe• Bio-product High• Bio-product High Failsafe• Bio-product Low• Bio-product Low Failsafe• Bio Data Noise High• Bio Data Noise High Failsafe• Pellet Rotor Current High• Pellet Supply Low

4.11.5 Control Alarms

Control Alarms are related to the parameters that may be controlled by the 3D TRASAR controller,even when the parameters are only being monitored.

• TRASAR High• TRASAR Low• Tagged Polymer High• Tagged Polymer Low• Conductivity High

• Conductivity Low• pH High• pH Low• ORP High• ORP Low

Control Alarms in this category are related to Failsafe Duty and can be set to different values for Highand Low alarms via the configurator. In monitoring mode, the parameter monitored may be sepa-rated from the relay that is on timer control for a different product.




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4.11.6 Relay Timeout Alarms

Relay Timeout Alarms are safety alarms activated when a relay has been energized for longer thanthe entered Pump Timeout Limit. In Startup Mode, the Pump Timeout Limit is extended by theStartup Factor.

• TRASAR Relay Timeout• Tagged Polymer Relay Timeout• Bio-reporter Relay Timeout• Oxidizing Biocide Relay Timeout

• Blowdown Relay Timeout• pH Relay Timeout• Pellet Feeder Timeout

4.11.7 Analog and Digital Alarms

Analog Alarms are for the 4-20 mAinputs. The high and low limits are settable in scaled units (ratherthan mA values). Digital input alarms are dry contacts that can be set by the user in theConfigurator. These alarms do not affect any of the control relays and are for information only.

• Analog #1 High• Analog #1 Low• Analog #2 High• Analog #2 Low

4.11.8 Failsafe Mode

When alarms are activated, the affected control relays will operate in Failsafe Mode. In FailsafeMode, the relay is operated in a cycle of on-time and off-time as determined by the failsafe duty.For each relay, the user can select "Fixed Failsafe" and input the desired relay failsafe duty. The 3DTRASAR controller also offers the option of "Smart Failsafe", in which the failsafe duty is calculatedfrom the actual relay operation under normal conditions. With this option, the calculated failsafe dutycan vary as relay usage changes. On initial startup or after erasing the datalog, the Smart FailsafeDuty must be learned by the controller, which it does automatically after the first 7 days. The first 7days' values are ignored to avoid skewed values as a result of extreme startup conditions. Duringthe first 7 days, each relay will use an initial fixed failsafe duty. This fixed failsafe duty is also loggedas the actual relay duty to indicate that the learning is in progress. The Smart Failsafe Duty iscalculated as the median of the previous 7 days' relay duty values.

4.11.9 Startup Mode

When a system is first started up with a new product, it is often desirable to suppress alarms for aperiod to allow the 3D TRASAR controller to bring the system under control. See section 4.5.4.

• Digital #3 On or Off• Digital #4 On or Off




Section 5: 3D TRASAR Scale Control

High Stress>30

Moderate Stress10 – 30

Low Stress<10

Performance LevelNalco Scale Index (NSI)

3D TRASAR Scale Control is a revolutionary way to manage scale stress in cooling systems. The3D TRASAR 5500 coupled with an innovative “tagged” high stress polymer (essentially a barcodeattached to the polymer molecule) monitors the actual performance of the polymer as system scalestress changes. 3D TRASAR Scale Control then takes corrective action through blowdown orchemical inhibitor feed adjustments. For 3D TRASAR Starter controllers, 3D TRASAR ScaleControl is available through the 3D TRASAR Fluorometer upgrade P/N 060-TR3200.88.

WARNING: DO NOT use 3D TRASAR Scale Control if the TRASAR Background is > 15%or TAG Background is > 30%. DO NOT use Tagged Polymer Control if TAG Background is> 75%. Refer to Section 4.4.1 for more details.

!5.1 Nalco Scale Index (NSI) MeasurementThe Nalco Scale Index (NSI) is a calculated variable that compares the current rate of polymerconsumption against the learned average rate of polymer consumption. The NSI number has adirect correlation to cooling system stress level as shown in the table below.

3D TRASAR Scale Control uses NSI to make setpoint adjustments in response to both high andlow stress conditions. There are two different control methods to choose from, either 3D TRASARScale Blowdown Control, or 3D TRASAR Scale Tagged Polymer Control.

5.1.1 3D TRASAR Scale Blowdown Control – Uses NSI to Adjust the BlowdownSetpoint

• If NSI < 0: the blowdown setpoint is increased.(e.g. NSI = – 20; blowdown setpoint adjusted by + 2.0%)

• If NSI = 0: no blowdown setpoint adjustment is made.• If NSI > 0: the blowdown setpoint is decreased.

(e.g. NSI = + 20; blowdown setpoint adjusted by - 2.0%)

5.1.2 3D TRASAR Scale Tagged Polymer Control – Uses NSI to Adjust the TaggedPolymer Setpoint

• If NSI < 0: the Tagged Polymer setpoint is decreased.(e.g. NSI = – 20; Tagged Polymer setpoint adjusted by - 2.0%)

• If NSI = 0: no Tagged Polymer setpoint adjustment is made.• If NSI > 0: the Tagged Polymer setpoint is increased.

(e.g. NSI = + 20; Tagged Polymer setpoint adjusted by + 2.0%)




5.2 3D TRASAR Scale Blowdown ControlThe start-up procedure for 3D TRASAR Scale Blowdown Control depends on your chemical treat-ment program. Your system will operate on either a 1-Drum (Sections 5.2.1 & 5.2.2) or 2-Drum(Sections 5.2.3 & 5.2.4) program.

5.2.1 3D TRASAR Scale Blowdown Control: 1-Drum Program Overview

Start-up for 1-Drum programs is a 4-Step process. This process is necessary for product transitionand for the 3D TRASAR controller to learn the average scaling stress of your cooling system anddevelop the appropriate control responses to optimize the treatment program:

Before - Make sure to baseline your system performance data before initiating the 4-Step process. Bydoing this you will be able to clearly see the added value provided by 3D TRASAR Scale Control.

Step 1 TRASAR Control Mode – The goal of this step is to determine the Tagged Polymer setpointto be used in Step 2. The 1-Drum product is controlled by traditional TRASAR while the TaggedPolymer level is monitored. Blowdown is controlled based on conductivity during this period. It willtake approximately 5 HTI’s to complete Step 1.

Step 2 3D TRASAR Scale Blowdown Monitoring Mode – In this step the 3D TRASAR controllerlearns the typical rate of polymer consumption needed to calculate NSI. The 1-Drum productcontrol is switched to Tagged Polymer Control using the setpoint determined in Step 1. TheTRASAR level will now only be monitored and blowdown will still be controlled by conductivity. Afterthe learning period is complete you can move to Step 3.

Step 3 3D TRASAR Scale Blowdown Control Mode – This step switches the blowdown controlfrom conductivity-based to 3D TRASAR Scale Control. The controller will now respond to highsystem scale stresses by reducing the blowdown setpoint.

Step 4 Advanced 3D TRASAR Scale Blowdown Control Mode – This step adds to 3D TRASARScale Blowdown Control the feature of increasing the blowdown setpoint during low scale stressconditions to maximize system water and chemical efficiencies.

3D Scale Blowdown Control1-Drum Program Start-Up Overview

Time

Before

•TRASARControl

•TRASARControl

•MonitorTaggedPolymer

•Monitor TRASAR

•Control Tagged Polymer

•Monitor Nalco Scale Index

•Monitor TRASAR


•Control Nalco Scale Index

Conductivity

Step 1 Step 2 Steps 3 & 4

TRASAR

Tagged Polymer

0

100

ppm




5.2.2 Start-Up Procedure for 1-Drum 3D TRASAR Scale Blowdown Control

STEP 1 - TRASAR Control Mode• Connect the product feed pump to TRASAR control Relay # 1.• Connect the blowdown valve to BLOWDOWN control Relay #6.• At the controller, activate the “System Start-up” mode (Refer to Section 4.10.11).• Launch the Configurator on your laptop PC and select the configuration for this system.• In the Configurator Alarm Settings window:

1. Click the Failsafe Relay Settings tab, set the Blowdown Valve Timeout Limit to a mini-mum of 240 minutes (If the blowdown valve is not being controlled by the 3D TRASARcontroller, set the Blowdown Valve Timeout Limit to zero).

2. Click OK.• In the Configurator Control Settings window:

1. Under Installed Sensors set the Conductivity Probe to Controlling.2. Click the Blowdown/pH tab, set the Blowdown Control Method to Conductivity

Setpoint, enter the desired Blowdown Setpoint, and accept the default control range.3. Click the Inhibitor tab, set the Number of Inhibitor Products to 1, choose the Product

Name, set the Control Method to TRASAR Control, enter the Inhibitor 1 Set Point valuerecommended by the 3D TRASAR Optimizer, and accept the default control range.

4. Click OK.• Upload the new configuration to the 3D TRASAR controller.• The Configurator program should request an automatic “REBOOT” of the controller.

If not – reboot manually either by using the power switch or through the Configurator: go to “Con-troller” —> “Tools” —> “Reboot Controller”.

• Operate the cooling system under TRASAR control for > 5 HTI’s.

Note: On the controller LCD, “Product-i” reading indicates the inert TRASAR level and “Product-a”reading indicates the active Tagged Polymer level, as ppm product.

STEP 2 - 3D TRASAR Scale Blowdown Monitoring Mode• At the controller, determine the Tagged Polymer setpoint by reading the average Tagged polymer

level over the last month of TRASAR control (see Section 4.9.5 for plot data instructions).Note: Make sure to plot the data for the product indicated by “-a” (TAG) reading.

!STOP! The “-i” (TRASAR) reading should be greater than the “-a” (TAG) reading.IF NOT – call 630-305-CHEM before proceeding and remain in TRASAR control.

• Change the product feed pump electrical connections to TAG POLYMER control Relay # 2.• Leave the blowdown valve connected to BLOWDOWN control Relay # 6.• In the Configurator Control Settings window:

1. Click the Blowdown/pH tab, set the Blowdown Control Method to 3D TRASAR ScaleControl.

2. Under 3D TRASAR Scale Control Settings, check the Monitor Only (Setpoint does notchange) box. By checking this box, no blowdown setpoint adjustments will be made.

3. Click the Inhibitor tab, change the Product Control Method to Tagged Polymer Control,enter the last month average Tagged Polymer level as the Inhibitor 1 Set Point, and acceptthe default control range.

• Do NOT change any other settings.




5.2.2 Start-Up Procedure for 1-Drum 3D TRASAR Scale Blowdown Control (con’t)

Upload the new configuration to the 3D TRASAR controller.• The Configurator program should request an automatic “REBOOT” of the controller.


• After the controller reboots – go to the Configurator Control Settings window, under theBlowdown/pH tab, click the RELEARN NOW button to perform a Relearn. This will clear thememory of learned scaling stresses and start the new Learning Period.

• The number of cycles in the “Learning Period” is automatically calculated and varies based on theuser input HTI.

• The system is now under 3D TRASAR Scale Blowdown Monitoring Mode. Note: The blowdownset point will NOT be adjusted based on NSI until Step 3.

Note: The controller LCD will show dashes (- - -) for NSI, and the data log will show a value of –999for NSI until the required “Learning Period” is completed. The “Learning Period” will last between 7to 8 HTI’s if the system HTI is < 72 hours, and 22 days if the HTI is > 72 hours. The “LearningPeriod” is over when NSI values start to appear.

STEP 3 - Switch to 3D TRASAR Scale Blowdown Control Mode• Product feed pump remains connected to TAG POLYMER control Relay # 2.• Blowdown valve remains connected to BLOWDOWN control Relay # 6.• In the Configurator Control Settings window:

1. Click the Blowdown/pH tab, leave the Blowdown Control Method in 3D Scale Control.2. Under 3D TRASAR Scale Control Settings, click the Setpoint Limits button.3. Enter 0% for Setpoint Increase Limit, 30% for Setpoint Decrease Limit, and click OK.4. After returning to the Blowdown/pH page, uncheck the Monitor Only (Setpoint does not

change) box.• Do NOT change any other settings.• Upload the modifications to the 3D TRASAR controller.• The system is now under 3D TRASAR Scale Blowdown Control.

IMPORTANT: The blowdown set point will now be decreased by as much as 30% inresponse to high system stress but will NOT be allowed to go above the user-entered setpoint since the “Set Point Increase Limit” is 0%.

!STEP 4 - Advanced 3D TRASAR Scale Blowdown Control Mode• In the Configurator Control Settings window:

1. Click the Blowdown/pH tab, leave the Blowdown Control Method in 3D Scale Control.2. Under 3D TRASAR Scale Control Settings, click the Setpoint Limits button.3. Enter 10% for Setpoint Increase Limit, 30% for Setpoint Decrease Limit, and click OK.4. After returning to the Blowdown/pH page, uncheck the Monitor Only (Setpoint does not

change) box.• Do NOT change any other settings.• Upload the modifications to the 3D TRASAR controller.• The system is now under Advanced 3D TRASAR Scale Blowdown Control mode.

IMPORTANT: The blowdown set point will now be decreased by as much as 30% inresponse to high system stress AND will be allowed to go above the user-entered set pointby as much as 10% in response to low system stress.!




5.2.3 3D TRASAR Scale Blowdown Control: 2-Drum Program Overview

Initial start-up for 2-Drum 3D TRASAR Scale Blowdown Control is a 4-Step process. This process isnecessary for product transition and for the 3D TRASAR controller to learn the average scaling stressof your cooling system and develop the appropriate control responses to optimize the treatment pro-gram.

3D Scale Blowdown Control2-Drum Program Start-Up Overview

Time

Before

•TRASARControl

•TRASARControl


•TRASAR Control



•TRASAR Control



Conductivity


TRASAR

Tagged Polymer

0

100

ppm

Before - Make sure to baseline your system performance data before initiating the 4-Step process.By doing this you will be able to clearly see the added value provided by 3D TRASAR ScaleControl.

Step 1 TRASAR Control Mode - The purpose of this step is to gradually replace any oldUNTAGGED polymer product with the new, TAGGED polymer product. The TRASAR Product iscontrolled based on TRASAR while the Tagged Polymer Product is slaved to the TRASAR Product.Blowdown is controlled based on conductivity during this period.

Step 2 3D TRASAR Scale Blowdown Monitoring Mode - In this step the 3D TRASAR controllerlearns the typical rate of polymer consumption needed to calculate NSI. The Tagged Polymerproduct will now be controlled based on the setpoint recommended by the 3D TRASAR Optimizer.The TRASAR product will still be under TRASAR control mode. Blowdown is controlled at the sameconductivity setpoint, while in Scale Monitoring mode with no blowdown setpoint adjustments.

Step 3 3D TRASAR Scale Blowdown Control Mode - This step switches the blowdown controlfrom conductivity-based to 3D TRASAR Scale Control. The controller will now respond to highsystem scale stresses by reducing the blowdown setpoint.

Step 4 Advanced 3D TRASAR Scale Blowdown Control Mode - This step adds to 3D TRASARScale Blowdown Control the feature of increasing the blowdown setpoint during low scale stressconditions to maximize system water and chemical efficiencies.




5.2.4 Start-up Procedure for 2-Drum 3D TRASAR Scale Blowdown Control

STEP 1 - TRASAR Control Mode• Connect the TRASAR product feed pump to TRASAR control Relay # 1.• Connect the Tagged Polymer product feed pump to TAG POLYMER control Relay # 2.• Connect the blowdown valve to BLOWDOWN control Relay # 6.• At the controller, activate the “System Start-up” mode (Refer to Section 4.10.11).• Launch the Configurator on your laptop PC and select the configuration for this system.• In the Configurator Alarm Settings window:




Setpoint, enter the desired Blowdown Set Point, and accept the default control range.3. Click the Inhibitor tab, set the Number of Inhibitor Products to 2 or more, choose the

Product Names, set the Control Method of the TRASAR Product to TRASAR Control,enter the TRASAR Product Set Point value recommended by the 3D TRASAR Optimizer,accept the default control range, and set the Control Method of the Tagged Polymer Prod-uct to Slaved.

4. Still under the Inhibitor tab, enter the TRASAR product Pumping Rate (R1) and the TAGPolymer product Pumping Rate (R2) according to the following equation. Note: Make sureto match the calibration of the TRASAR product pump and the TAG polymer product pumpto the feed rates entered.

R2/R1 = (d1/d2) * (SP2/SP1) * 1.25Where, R2 = TAG polymer product pump feed rate

R1 = TRASAR product pump feed rated1 = density of TRASAR productd2 = density of TAG polymer productSP2 = setpoint of TAG polymer productSP1 = setpoint of TRASAR product

Example: If, SP1= 20 ppm, SP2 = 80 ppm, d1=10.35, d2=9.35:Then, R2/R1 = (10.35/9.35) * (80/20) * 1.25 = 5.53

This example shows that the Tagged Polymer product Pumping Rate should be 5.53 times theTRASAR product Pumping Rate (i.e. TRASAR Pumping Rate = 1 gpm; Tagged Polymer PumpingRate = 5.53 gpm).

5. Click OK.




5.2.4 Start-up Procedure for 2-Drum 3D TRASAR Scale Blowdown Control (con’t)

• Upload the new configuration to the 3D TRASAR controller.• The Configurator program should request an automatic “REBOOT” of the controller.


• Operate the cooling system under TRASAR Control and slaved Tagged Polymer Control forapproximately 5 HTI’s. The Tagged Polymer product level should reach steady state after 5 HTI’s,while any old untagged polymer will be reduced to zero.

• Once the Tagged Polymer product level reaches steady state move to Step 2.

NOTE: If the steady state Tagged polymer product level needs to be achieved in a shorterperiod of time, it is OK to slug feed the product. It is still necessary to run for approxi-mately 5 HTI’s to replace untagged polymer with Tagged polymer.

!

STEP 2 - 3D TRASAR Scale Blowdown Monitoring Mode• In the Configurator Control Settings window:

1. Click the Blowdown/pH tab, set the Blowdown Control Method to 3D TRASAR ScaleControl.

2. Under 3D TRASAR Scale Control Settings, check the Monitor Only (Setpoint does notchange) box. By checking this box, no blowdown setpoint adjustments will be made.

3. Click the Inhibitor tab, change the Tagged Polymer Product Control Method to TaggedPolymer Control, enter the Tagged Polymer Set Point as recommended by the 3DTRASAR Optimizer, and accept the default control range.

4. Leave the TRASAR product Pumping Rate and the TAG Polymer product Pumping Ratethe same as entered in Step 1.

• Upload the new configuration to the 3D TRASAR controller.• The Configurator program should request an automatic “REBOOT” of the controller. If not – reboot

manually either by using the power switch or through the Configurator: go to “Controller” —>“Tools” —> “Reboot Controller”.

• After the controller reboots – go to the Configurator Control Settings window, under theBlowdown/pH tab, click the RELEARN NOW button to perform a Relearn. This will clear thememory of learned scaling stresses and start the new Learning Period.

• The number of cycles for the “Learning Period” is automatically calculated and varies based on theuser input HTI.

• The system is now in 3D TRASAR Scale Blowdown Monitoring Mode. Note: The blowdown setpoint will NOT be adjusted based on NSI until Step 3.





5.2.4 Start-up Procedure for 2-Drum 3D TRASAR Scale Blowdown Control (con’t)

STEP 3 - 3D TRASAR Scale Blowdown Control Mode• In the Configurator Control Settings window:

1. Click the Blowdown/pH tab, leave the Blowdown Control Method in 3D TRASAR ScaleControl.

2. Under 3D TRASAR Scale Control Settings, click the Setpoint Limits button.3. Enter 0% for Setpoint Increase Limit, 30% for Setpoint Decrease Limit, and click OK.4. After returning to the Blowdown/pH page, uncheck the Monitor Only (Setpoint does not

change) box.• Do NOT change any other settings.• Upload the modifications to the 3D TRASAR controller.• The system is now under 3D TRASAR Scale Blowdown Control.

IMPORTANT: The blowdown set point will now be decreased by as much as 30% inresponse to high system stress AND will be allowed to go above the user-entered set pointby as much as 10% in response to low system stress.!

IMPORTANT: The blowdown set point will now be decreased by as much as 30% inresponse to high system stress but will NOT be allowed to go above the user-entered setpoint since the “Set Point Increase Limit” is 0%.!

STEP 4 - Advanced 3D TRASAR Scale Blowdown Control• In the Configurator Control Settings window:

1. Click the Blowdown/pH tab, leave the Blowdown Control Method in 3D TRASAR ScaleControl.

2. Under 3D TRASAR Scale Control Settings, click the Setpoint Limits button.3. Enter 10% for Setpoint Increase Limit, 30% for Setpoint Decrease Limit, and click OK.4. After returning to the Blowdown/pH page, uncheck the Monitor Only (Setpoint does not

change) box.• Do NOT change any other settings.• Upload the modifications to the 3D TRASAR controller.• The system is now under Advanced 3D TRASAR Scale Blowdown Control mode.




5.3 3D TRASAR Scale Tagged Polymer Control3D TRASAR Scale Tagged Polymer Control can only be used with 2-Drum programs.

5.3.1 3D TRASAR Scale Tagged Polymer Control: 2-Drum Program Overview

Initial start-up for 3D TRASAR Scale Tagged Polymer Control: 2-Drum program is a 4-Step process.This process is necessary for product transition and for the 3D TRASAR controller to learn theaverage scaling stress of your cooling system and develop the appropriate control responses tooptimize the treatment program:

Before - Make sure to baseline your system performance data before initiating the 4-Step process. Bydoing this you will be able to clearly see the added value provided by 3D TRASAR Scale Control.

Step 1 TRASAR Control Mode - The purpose of this step is to gradually replace any oldUNTAGGED polymer product with the new, TAGGED polymer product. The TRASAR Product iscontrolled based on TRASAR while the Tagged Polymer Product is slaved to the TRASAR Product.Blowdown is controlled based on conductivity during this period.

Step 2 3D TRASAR Scale Tagged Polymer Monitoring Mode - In this step the 3D TRASAR control-ler learns the typical rate of polymer consumption needed to calculate NSI. The T agged Polymerproduct will now be controlled based on the setpoint recommended by the 3D TRASAR Optimizer .The TRASAR product will still be under TRASAR control mode. Blowdown is controlled at the sameconductivity setpoint. No Tagged Polymer setpoint adjustments will be made until Step 3.

Step 3 3D TRASAR Scale Tagged Polymer Control Mode - This step switches the TaggedPolymer control to Scale Index Control. The controller will now respond to high system scalestresses by increasing the Tagged Polymer setpoint.

Step 4 Advanced 3D TRASAR Scale Tagged Polymer Control Mode - This step adds to 3DTRASAR Scale Tagged Polymer Control the feature of decreasing the Tagged Polymer setpointduring low scale stress conditions to maximize chemical efficiency.

3D Scale Tagged Polymer Control2-Drum Program Start-Up Overview

Time

Before

•TRASARControl

•TRASARControl


•TRASAR Control

•Control Conductivity


•TRASAR Control

•Control Conductivity


Tagged Polymer


TRASAR

Conductivity

0

100

ppm




5.3.2 Start-up Procedure for 2-Drum 3D TRASAR Scale Tagged Polymer Control

STEP 1 - TRASAR Control Mode• Connect the TRASAR product feed pump to TRASAR control Relay # 1.• Connect the Tagged Polymer product feed pump to TAG POLYMER control Relay # 2.• Connect the blowdown valve to BLOWDOWN control Relay # 6.• At the controller, activate the “System Start-up” mode (Refer to Section 4.10.11).• Launch the Configurator on your laptop PC and select the configuration for this system.• In the Configurator Alarm Settings window:




Setpoint, enter the desired Blowdown Set Point, and accept the default control range.3. Click the Inhibitor tab, set the Number of Inhibitor Products to 2 or more, choose the

Product Names, set the Control Method of the TRASAR Product to TRASAR Control,enter the TRASAR Product Set Point value recommended by the 3D TRASAR Optimizer,accept the default control range, and set the Control Method of the Tagged Polymer Prod-uct to Slaved.

4. Still under the Inhibitor tab, enter the TRASAR product Pumping Rate (R1) and the TAGPolymer product Pumping Rate (R2) according to the following equation. Note: Make sureto match the calibration of the TRASAR product pump and the TAG polymer product pumpto the feed rates entered.

R2/R1 = (d1/d2) * (SP2/SP1) * 1.25Where, R2 = TAG polymer product pump feed rate

R1 = TRASAR product pump feed rated1 = density of TRASAR productd2 = density of TAG polymer productSP2 = setpoint of TAG polymer productSP1 = setpoint of TRASAR product

Example: If, SP1= 20 ppm, SP2 = 80 ppm, d1=10.35, d2=9.35:Then, R2/R1 = (10.35/9.35) * (80/20) * 1.25 = 5.53

This example shows that the Tagged Polymer product Pumping Rate should be 5.53 times theTRASAR product Pumping Rate (i.e. TRASAR Pumping Rate = 1 gpm; Tagged Polymer PumpingRate = 5.53 gpm).

5. Click OK.




5.3.2 Start-up Procedure for 2-Drum 3D TRASAR Scale Tagged Polymer Control(con’t)



• Operate the cooling system under TRASAR Control and slaved Tagged Polymer Control forapproximately 5 HTI’s. The Tagged Polymer product level should reach steady state after 5 HTI’s,while any old untagged polymer will be reduced to zero.

• Once the Tagged Polymer product level reaches steady state move to Step 2.

NOTE: If the steady state Tagged polymer product level needs to be achieved in a shorterperiod of time, it is OK to slug feed the product. It is still necessary to run for approxi-mately 5 HTI’s to replace untagged polymer with Tagged polymer.

!

STEP 2 - 3D TRASAR Scale Tagged Polymer Monitoring Mode• In the Configurator Control Settings window:

1. Click the Inhibitor tab, leave the TRASAR Control Method to TRASAR Control.2. Under 3D TRASAR Scale Control Settings, check the Monitor Only (Setpoint does not

change) box. By checking this box, no blowdown setpoint adjustments will be made.3. Change the Tagged Polymer Product Control Method to Scale Index Control, enter the

Tagged Polymer Set Point as recommended by the 3D TRASAR Optimizer, and accept thedefault control range.

4. Leave the TRASAR product Pumping Rate and the TAG Polymer product Pumping Ratethe same as entered in Step 1.



• After the controller reboots – go to the Configurator Control Settings window, under the Inhibitortab, click the “RELEARN NOW” button to perform a Relearn. This will clear the memory oflearned scaling stresses and start the new Learning Period.

• The number of cycles for the “Learning Period” is automatically calculated and varies based on theuser input HTI.

• The system is now in 3D TRASAR Scale Tagged Polymer Monitoring Mode. Note: The TaggedPolymer set point will NOT be adjusted based on NSI until Step 3.





5.3.2 Start-up Procedure for 2-Drum 3D TRASAR Scale Tagged Polymer Control(con’t)

STEP 3 - 3D TRASAR Scale Tagged Polymer Control Mode• In the Configurator Control Settings window:

1. Click the Inhibitor tab, leave the Tagged Polymer Control Method in Scale Index Control.2. Under 3D TRASAR Scale Control Settings, click the Setpoint Limits button.3. Enter 30% for Setpoint Increase Limit, 0% for Setpoint Decrease Limit, and click OK.4. After returning to the Inhibitor page, uncheck the Monitor Only (Setpoint does not

change) box.• Do NOT change any other settings.• Upload the modifications to the 3D TRASAR controller.• The system is now under 3D TRASAR Scale Tagged Polymer Control.

IMPORTANT: The Tagged Polymer set point will now be increased by as much as 30% inresponse to high system stress AND will be allowed to go below the user-entered set pointby as much as 10% in response to low system stress.

!

STEP 4 - Advanced 3D TRASAR Scale Tagged Polymer Control Mode• In the Configurator Control Settings window:

1. Click the Inhibitor tab, leave the Tagged Polymer Control Method in Scale Index Control.2. Under 3D TRASAR Scale Control Settings, click the Setpoint Limits button.3. Enter 30% for Setpoint Increase Limit, 10% for Setpoint Decrease Limit, and click OK.4. After returning to the Inhibitor page, uncheck the Monitor Only (Setpoint does not

change) box.• Do NOT change any other settings.• Upload the modifications to the 3D TRASAR controller.• The system is now under Advanced 3D TRASAR Scale Tagged Polymer Control mode.

IMPORTANT: The Tagged Polymer set point will now be increased by as much as 30% inresponse to high system stress but will NOT be allowed to go below the user-entered setpoint since the “Set Point Decrease Limit” is 0%.

!




5.4 3D TRASAR Scale Control - Frequently Asked Questions

1. What is 3D TRASAR Scale Control?

3D TRASAR Scale Control is a revolutionary way to manage scale stress in cooling systems. The3D TRASAR 5500 coupled with an innovative "tagged" high stress polymer (essentially a barcodeattached to the polymer molecule) monitors the actual performance of the polymer as system stresschanges. 3D TRASAR Scale Control then takes corrective action through blowdown or chemicalinhibitor feed adjustments.

2. How does 3D TRASAR Scale Control measure the Scaling Stress in a coolingsystem?

Relative Rate of Polymer Consumption, K

K = Rate of (Tagged Polymer Decay / TRASAR Decay)

TRASAR Decay:Hydraulic Loss

Tagged Polymer Decay:Hydraulic loss and scaling/dispersion

Inert TRASAR

Tagged Polymer

TRA

SA

R o

r Tag

ged

Pol

ymer

Lev

el (p

pm)

After the product(s) is(are) fed to the system and the pump(s) is(are) turned off, the concentrationsof inert TRASAR (also known as PTSA) and tagged polymer will decrease due to hydraulic loss,such as blowdown and system leaks. The hydraulic loss impacts the inert TRASAR level andtagged polymer level equally. When scaling stress increases in a cooling system, the polymerdecay rate will be faster than the inert TRASAR decay rate. Therefore, the Relative Rate of Poly-mer Consumption, or the rate of polymer decay compared to the inert TRASAR decay, will beincreased. 3D TRASAR Scale Control measures the Relative Rate of Polymer Consumption, K, asan indication of the scaling stress.

It should be noted that the cooling system is usually operated under some level of scaling stress.The key is to know when the scaling stress is changed, the magnitude of the change in scalingstress (upsets) compared to the normal operating conditions and the timely corrective actions thatneed to be taken to prevent scaling.




3. I'm already using TRASAR, why should I switch to 3D TRASAR Scale Control?

3D TRASAR Scale Control not only monitors product feed but also provides a superior level ofcontrol by monitoring the active polymer level in the system and determining the scaling tendency ofthe cooling tower. With 3D TRASAR Scale Control, scaling stress is automatically reduced bymaintaining the desired active polymer level in the system or by automatically blowing down thesystem when needed.

• TRASAR provides only product feed set point control. It does not measure any scaling tendencyor system performance of the cooling tower.

• 3D TRASAR Scale Control employs a new improved Fluorometer with better accuracy for betterproduct feed control.

• 3D TRASAR Scale Control can maintain the desired residual tagged polymer level to minimize/avoid scaling.

• 3D TRASAR Scale Control also allows one to determine if deviations from the learned normalnon-scaling operating condition is occurring in real time, so that corrective actions can be takenautomatically (blowdown or feed more scale inhibitor when needed) to minimize and/or preventscaling of critical heat exchanger surfaces.

4. What differences will I see when I run 3D TRASAR Scale Control compared to whatI do now?

• Polymer feed level will be constant while the TRASAR level may vary.• Conductivity set point may automatically be adjusted in response to changes in scaling stress

(one-drum programs).• Conductivity set point or tagged polymer product set point may automatically be adjusted in

response to changes in scaling stress (two-drum programs).

5. What are the unique benefits of 3D TRASAR Scale Control?

• Optimize water and chemical use by actively managing the system based on the stresses placedupon it.

• Improve throughput by maintaining equipment at peak efficiency, even as operational factors vary.• Reduce downtime and maintenance costs by preventing mineral scale and particulate fouling.• Increase asset life and maintain asset reliability by preventing degradation during upsets and

process leaks.

6. Is 3D TRASAR Scale Control compatible with other components (Bio andCorrosion inhibitors) of the cooling water treatment program?

Yes. 3D TRASAR Scale Control can be run with 3D TRASAR Bio and Corrosion Inhibitor pro-grams.Note: Nalco 90005 for algae may cause interference with 3D TRASAR Scale Control due to foam-ing. The interference can be avoided/minimized by using antifoams.




7. What are the operating limits for 3D TRASAR Scale Control?

1Applies to operation with 10 ppm active polymer- operation with less polymer requirescommensurately lower background level limits.2Inhibitor chemical stability should be considered as a potential limiting factor in long HTI(e.g. >~200 hr) operation.3Status may change; Look in Optimizer or call 630-305-CHEM.4If foaming occurs on application, loss of TRASAR 2 (PTSA) or polymer may be observed.Follow 90005 use recommendations to avoid foaming.5Corresponds to a 10% loss of fluorescence when exposed to halogen for 24 hrs.

System Parameters

Turbidity (NTU) <150Background Fluorescence Correction1

Fixed offset 30%Online real-time 30%

HTI (hrs) Minimum of 142

Volume (gal) No limitBlowdown Rate (gpm) No limitSystem Volume/Recirc Rate Ratio (min) <20Biocide Compatibility

Bleach CompatibleSTA-BR-EX CompatibleACTI-BROM CompatibleTowerbrom 960 See Bromine limitsTowerbrom 991 See Bromine limitsCI2 Gas CompatibleCl02 Not Compatible3

BCDMH with EASIBROM Feeder See Bromine limitsStabilized Bleach CompatibleIsothiazolinone CompatibleGlutaraldehyde Compatible90005 Compatible at 160 ppm4

DBNPA CompatibleUpper limit of halogen concentration-impact on polymer/TRASAR fluorescence

Chlorine (FRC)5 <1.5Bromine (TRO)5 <5

Other VariablesIron (ppm) <10SO2 NoneSulfides (ppm) NoneCopper (ppm) <40




8. What 3D TRASAR Products are required for 3D TRASAR Scale Control to work?

3D TRASAR Scale control programs require both an inert TRASAR product and a Tagged Polymerproduct. Two different programs are available:• One-drum programs:

The product contains both TRASAR (also known as PTSA) and Tagged polymer.• Two-drum programs:

Product 1 contains TRASAR (also known as PTSA).Product 2 contains Tagged Polymer

For a complete list of available 3D TRASAR products, please refer to the 3D TRASAR productselection guide.

9. What is Nalco Scale Index (NSI)?

The Nalco Scale Index (NSI) is a calculated variable that compares the current rate of polymerconsumption against the learned average rate of polymer consumption. NSI has a direct correla-tion to the cooling system stress level. 3D TRASAR Scale control uses NSI to make set pointadjustments in response to both high and low stress conditions.

10. How does the 3D TRASAR 5500 controller detect "active" polymer?

A new component of 3D TRASAR products is a "tagged" polymer, either Nalco's tagged PRISMpolymer or tagged High Stress Polymer (HSP). The 3D TRASAR 5500 controller measures thefluorescent intensity of the "tag" to determine the concentration of residual dispersant polymer.

11. What is Background Fluorescence?

Most waters can contain humic and fulvic acids naturally, which when excited by ultraviolet or nearultraviolet can be moderately fluorescent. The fluorescence intensity arising from such species isknown as background fluorescence, and, if uncorrected, may cause a significant error in fluores-cence measurements. 3D TRASAR provide automatic background corrections for accurate mea-surements of TRASAR and tagged polymer levels.

12. I don't feel comfortable allowing the 3D TRASAR controller to adjust theconductivity setpoint. Must I allow 3D TRASAR to do this, or can I simply establish aset point as I always have?

It is acceptable to control system Conductivity based on a user-defined Conductivity setpoint.Setpoints can be selected during configuration and changed at any time. However, to realize thebenefits of 3D TRASAR Scale Control, the controller should be allowed to automatically adjust thesetpoint in order to effectively maximize cycles of concentration to minimize operating cost, orreduce the cycles as necessary to prevent scale, corrosion and fouling.




13. Can 3D TRASAR Scale Control be operated in Monitoring Mode only (monitoringNalco Scale Index, but without Setpoint adjustments)?

Yes. 3D TRASAR Scale Control can be operated in the Monitoring Mode to monitor the NalcoScale Index (NSI) without setpoint adjustments.

For 3D TRASAR Scale Monitoring Mode, the NSI will be calculated upon the completion of theLearning Period. The setpoint adjustment limits are set to zero.

14. Can I compare the Relative Rate of Polymer Consumption with other commonlyused indices, such as Calcite Saturation Ratio?

Yes. The scaling stress or the Relative Rate of Polymer Consumption, K, can be compared to othercommonly used indices, such as Langelier Saturation Index (LSI), the Ryznar Stability Index (RSI)and the Pukorius (Practical) Scale Index (PSI) as practical predictors of calcium carbonate forma-tion. The scaling stress or the Relative Rate of Polymer Consumption, K, can also be compared tocomputer saturation models such as the French Creek Water Cycle or the Calcite Saturation Ratio.

In addition, the scaling stress or the Relative Rate of Polymer Consumption, K, correlates veryclosely with the difference between the magnesium and calcium cycles (or Mg-Ca cycle split).

However, unlike the "snap shots" provided by grab sample analyses for obtaining LSI, RSI, PSI,Calcite Saturation Ratio, and Mg-Ca cycle split, 3D TRASAR Scale Control evaluates the scale-forming tendency of a cooling system continuously by measuring the scaling stress or the RelativeRate of Polymer Consumption and takes corrective actions in a timely manner before scale can foulthe system.

0

20

40

60

80

100

120

140

160

180

20 30 40 50 60 70 80 90 100 110 120 130 140

Calcite Saturation Ratio

Rel

ativ

e R

ate

of P

olym

er C

onsu

mpt

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ress




15. How long does it take to complete the Learning Period?

It depends on Learning Cycles or the number of product decay cycles in the Learning Period.• If HTI < = 72 hours: The Learning Period consists of 50 decay cycles and will take approximately 7

to 8 HTI's to complete.• If HTI > 72 hours: The number of Learning Cycles will be less and it will take approximately 22

days to complete the Learning Period.

16. How do I know if I have completed the Learning Period?

• Check the 3D TRASAR controller display.Press Information key, select System Performance. If a numerical value appears after NalcoScale Index, the learning period has completed. If "------" appears, the system is still in LearningMode.Note: After a Power Reset, the LCD also shows "-----" for NSI. NSI will be re-displayed at the endof the first cycle after a Power Reset if the Learning Period has been completed.

• Check 3D Scale Data File, Column under "NSI Cycle."Download 3D Scale Data File through the configurator. If numerical values other than -999 appearin the NSI log, the learning period has completed. If -999 appears, the system is still in LearningMode.

17. 3D TRASAR Scale Control has been operational for a while. Why is there no NSIvalue appearing on the 3D TRASAR controller display?

• 3D TRASAR Scale Control may still be in the Learning Period.-After a Power Cycle, both the Polymer Consumption and NSI will display as "-----".-After a Power Cycle, the Polymer consumption reading will be redisplayed at the end of thenext cycle whether or not the Learning Period has been completed.-After a Power Cycle, the NSI reading will be redisplayed at the end of the next cycle only ifthe Learning Period has been completed.

18. The LCD was showing polymer consumption. Why is it now showing "-----" onLCD?

• After a Power Cycle, the Polymer Consumption (and NSI) will display as "-----". The PolymerConsumption reading will be redisplayed at the end of next cycle.

• If you just performed a Relearn, during the very first cycle the polymer consumption will be dis-played as "-----". The polymer consumption will be displayed/recorded at the end of each cycle.




19. How is Polymer Consumption TP% calculated?

For One-Drum, the difference between the TRASAR level and tagged polymer level is an indicationof polymer consumption, TP%.

For one-drum programs, the polymer consumption, TP%, is calculated as follows:

TP%(cycle) = 100 * {TRASAR(cycle) - TP(cycle)} / TRASAR(cycle)

Where TRASAR(cycle) = TRASAR level at the end of a decay cycle, andTP(cycle) = Tagged polymer level at the end of a decay cycle.

For Two-Drum, the polymer consumption, TP%, is calculated by integrating the Relative Rate ofPolymer Consumption with respect to time.

20. I was feeding 23265 and now feed 3DT265. What are 3DT265-i and 3DT265-areadings on the LCD display ?

When feeding one-drum 3D TRASAR Product, in this example, 3DT265:• 3DT265-i is the concentration of the inert component or TRASAR, as ppm of product.• 3DT265-a is the concentration of the active polymer, as ppm of product.

21. For one-drum programs, why does the -a reading not vary with polymerconsumption during tagged polymer control?

The TRASAR concentration will vary with time depending on the stress level. As the polymerconsumption changes, the product feed compensates to maintain the tagged polymer at thesetpoint (Product-a). Only the polymer consumption number, and the TRASAR level will vary withsystem stress changes when the product feed is controlled by tagged polymer (Product-a).

22. (For one-drum program) My "-a reading" is higher than my "-i reading". Is thiscorrect?

The cooling system is usually operated under some level of scaling stress. As a result, there will besome polymer consumption (TP% > 0) and the "-a reading" should be lower than the "-i reading".However, when the system stress is very low, sometimes the "-a reading" can be slightly greaterthan the "-i reading".

If the "-a reading" is significantly greater than the "-i reading", it is also possible that:

1. Fluorometer requires recalibration, and/or2. Background correction settings (TRA, TAG) and/or TAG ratio factor and TAG correction method

are incorrect.




22. (For one-drum program) My "-a reading" is higher than my "-i reading". Is thiscorrect? (con’t)

To determine the root cause, perform the following S0940 Check - it verifies fluorometer operationand helps determine if recalibration is required:

S0940 Diagnostic Data Check (for one-drum and two-drum programs):

Steps to run an S0940 calibration check:1. Turn off Fluorometer inlet shutoff valve and rotate 3-way Fluorometer discharge valve to

sample position.2. Slowly flush the flow cell with 180 ml of blank solution (DI water.)

Note: To avoid creating bubbles which affect the accuracy of fluorescence readings,SLOWLY draw blank solution into the syringe and SLOWLY inject blank solution into theflow cell.

3. Using a clean syringe, slowly inject the flow cell with 180 ml of calibration solution (P/N 460-S0940.75) and allow it to remain in the flow cell by leaving the syringe attached.Note: To avoid creating bubbles which affect the accuracy of fluorescence readings,SLOWLY draw S0940 standard into the syringe and SLOWLY inject S0940 standard into thecell.

4. Go to the controller keypad and select INFORMATION, Diagnostic Data, FluorometerData.

5. Record the values displayed for Prod1, Prod2, Rz, Rs, and Bkgd.

• Prod 1 should equal PFtra - (PFtra * %TRA bkgd)

• If 'on-line' tag correction is being usedProd 2 should equal Pftag-Where PFtra is the TRASAR product factor, PFtag is the Polymer product factor and%TRA bkgd is the background TRASAR correction %.

• If 'on-line' tag correction is not being usedProd2 should equal PFtag - (PFtag * %TAG bkgd),-Where %TAG bkgd is the background TAG correction %.

• Rz should equal 20

• Rs should equal 40

• Bkgd should equal PFtag

6. If recorded values are close to the results obtained above, the Fluorometer is workingcorrectly and the calibration is good. Otherwise - recalibrate.

7. Use only DI water for calibration. Do not use make-up or other water source for calibration,as this will result in an erroneous calibration curve.

If Calibration check is okay, check if the entered background fluorescence is correct. Collect/sendwater samples for background analyses if necessary.




23. When should I perform a Relearn?

You should perform a Relearn to clear the learned data when you change any of the following:• Conductivity set point• Blowdown control method• Product 2 set point• Product 2 control method• Product 1 set point• Product 1 control method• Number of products• pH setpoint• Change any product or Product Factor (TRASAR or Tagged Polymer) (This also needs a product

transition period)

24. My conductivity is over the upper deadband. Why is there no blowdown?

• After the product pump off event(s), there is a wait interval (25 minutes by default) to allow forsystem mixing. During this wait interval, the blowdown is shut off.

• After a power cycle or after the power is turned on, if Product level(s) > lower deadband, there is await interval during which the blowdown is shut off.

• In case of running NSI control, the set point may have been adjusted to a higher value.

25. Where can I call for help?

Call (630) 305-CHEM for help/questions.




Section 6: 3D TRASAR Bio-Control and3D TRASAR Bio-Shock Mode3D TRASAR Bio-Control and 3D TRASAR Bio-Shock are unique and highly effective controlschemes for the addition of oxidizing biocide to the cooling system. Patented bio-reporter chemistryis fed to the cooling system and reacts enzymatically with living microbes in the system. This reac-tion is measured by the 3D TRASAR controller and is used to determine biological activity levels inthe system. The controller then feeds biocide at the correct time to maintain control.

3D TRASAR bio-reporter technology can be operated in two modes:• 3D TRASAR Bio-Control mode: the bio-reporter ratio determines when and whatamount of biocide is to be added into the system to continuously control the microbiologicalactivity.• 3D TRASAR Bio-Shock mode: the bio-reporter determines the time at which thesystem is to be shocked with oxidizing biocide. The oxidizing biocide is then fed by timer orORP control according to user set parameters. When the oxidizing biocide concentrationdissipates, bio-reporter is added to the system and the microbiological activity is measured.

3D TRASAR Bio-Control ONLY works with the following oxidizing biocides:• STA-BR-EX• Bleach• ACTI-BROM• Chlorine Gas• Towerbrom (Towerbrom 991 Lil’ & Mini-Slugger; Towerbrom 960 in 3D TRASAR Bio-Shock

Mode )• BCDMH (use Easibrom feeder)

Note: Stabilized Chlorine, aka N-2818 and N-7345 CANNOT be used. If using Chlorine Dioxide,call 630-305-CHEM.




6.1 Nalco Bio-Index Measurement (NBI)The Nalco Bio-Index measurement is a calculated variable used to measure the historical systemresponse to biocide feed. It is NOT used to control the feed of oxidizing biocide. The table belowshows the correlation between cooling system biological stress level and the Nalco Bio-Indexnumber. Please note that the NBI can be negative during normal operation.

!NOTE: 3D TRASAR Bio-Control cannot be run in ‘Monitoring Mode’. For NBI numbers tobe meaningful, 3D TRASAR Bio-Control MUST be in control of the oxidant feed pump (e.g.no external ‘slug feed’ or external control of oxidant feed). During controller based slugfeed of oxidizing biocide the NBI reverts to –999 since the bio-reporter is not in control ofthe Oxidant during that period.

6.2 Oxidizing Biocide Application and Slug FeedsFor most normally operating systems, 3D TRASAR Bio-Control applies the necessary biocide tomaintain microbiological control. In some systems, additional dosing of biocide may be desired fora variety of reasons, including:

1. System has recirculation problems (with zones which have stagnant or slow-moving water)

2. System is struggling with algae control

3. Good BioManage™ practices stipulate a need to vary the stresses experienced by themicrobial population.

4. Positive Legionella counts require a slug dose of Oxidizing biocide into the system

5. Routine oxidant slugs are a part of the water hygiene response plan

6. System needs to respond to a process leak

Nalco Bio-Index Reading System Biological Stress Level

<-20 Often seen within 48 hours of startup. Ifpersistent, call help desk.

-20 to +10 Low10 to 30 Mild30 to 80 High

> 80 Very High

Nalco Bio-Index Reading System Biological Stress Level

-999 or --- Bio-reporter is not in control of Oxidizing Biocide

-250 to 0Bio-reporter is measuring microbiological activity.Increasing Nalco Bio-Index indicates increased

microbiological activity0 System is about to slug Oxi dizing Biocide

Table 6.1a Nalco Bio-Index Reading for 3D TRASAR Bio-Control.

Table 6.1b Nalco Bio-Index Reading for 3D TRASAR Bio-Shock mode.




6.2 Oxidizing Biocide Application and Slug Feeds (con’t)There are two options available to increase the amount of oxidizing biocide applied under bio-reporter control:

A. Slug Oxidizing Biocide: Oxidizing Biocide Slugs are periodically overlaid on top of stan-dard 3D TRASAR Bio-Control. The amount of biocide applied under standard 3D TRASARBio-Control cannot be externally adjusted. Oxidant slugs with user set durations and ORPsetpoints can be used to increase the amount of oxidizing biocide applied to the system.

B. Bio Shock Mode: This is an all shock method of applying oxidizing biocide. The bio-reporter monitors microbiological activity and when it reaches a preset value oxidizingbiocide is slugged into the system. The duration of the slug can be set from 10 minutes to35 hours and the ORP setpoint for the slug is also selectable by the user. This mode allowsthe user to actively control the dosage of the oxidizing biocide.

During the slug feed period under 3D TRASAR Bio-Control or 3D TRASAR Bio-Shock mode, bio-reporter feed is suspended and oxidizing biocide is applied based on timer control or system ORPmeasurement. A functional ORP probe is required to resume bio-reporter feed (with both timer andORP based slugs). For timer based slugs, the oxidant relay is on continuously for the preset time.For ORP based slugs, the oxidant is dosed to the specified ORP level and then maintained at thatORP level for the preset time. Bio-reporter feed restarts after the system water has returned topre-slug ORP values.

6.2.1 3D TRASAR Bio-Control and Overlaid Ox Slugs

Slug feeds can be set to occur on regular schedule or they can be individually initiated.

Scheduled Slug Feeds: Use the 3D TRASAR Configurator slug feed screen to define theschedule for feed. We do not recommend more than one slug feed per week. If morefrequent slugs are desired, use the 3D TRASAR Bio-Shock mode.

Manual Slug Feeds: There are two methods of manually initiating slug feeds to thesystem:

1. Controller Configurator: Initiate slug from the OxBio Slug Feed screen afterconnecting to the controller either directly or via a phone line.

2. Controller Keypad: To initiate a manual slug feed from the controller keypadpress <Actions> and then <Slug Feed Biocide>. Choose:

<Hand Feed Ox> If biocide is applied with pumps or means not controlled bythe controller

<Relay Feed Oxidizing Biocide> In the relay feed option, the controllerapplies the oxidizing biocide for the slug.




6.2.2 3D TRASAR Bio-Shock Mode

In 3D TRASAR Bio-Shock mode the timing of the Oxidant slug is determined by the bio-reporterratio (and therefore cannot be scheduled). The four segments of an Ox Slug (Prebleed, Feed,Post-Feed and Recovery) are used and the parameters determining them must be set by the user.If Towerbrom 960 is the oxidizing biocide, standard 3D TRASAR Bio-Control cannot be used, and3D TRASAR Bio-Shock mode is the only option for bio-reporter based Oxidizing biocide control.

3D TRASAR Bio-Shock Mode can be used with any 3D TRASAR Bio-Control approved oxidant.Under 3D TRASAR Bio-Shock Mode, the Nalco Bio-Index will give an indication of how close thesystem is to an oxidant slug. When the bio-reporter dye is first dosed, the Nalco Bio-Index will bevery negative (-100 to -70). As the bio-reporter reacts with microbes, the Nalco Bio-Index numberwill slowly (dependent on the overall microbial activity within the system) increase. As the NalcoBio-Index approaches 0, this is an indication that the system will soon be slugged.

6.2.3 Ox-slug/shock control settings

Using the 3D TRASAR Configurator, set up the four sequential segments of the ox-slug/shockevent: Pre-Bleed, Feed, Post-Feed, Recovery.

PreBleed: User may choose to blowdown the system prior to an oxidant slug. This option istypically used if the blowdown is locked out during the time of the oxidant slug to compensate for increasing conductivity. The blowdown is controlled by conductivity set point with atime limit for the process.

Slug Feed: Oxidant is fed into the system. A user-set time limit determines the duration ofthis segment. The user may choose between ORP control or timer control of the oxidizingbiocide pump. Under ORP control, the time limit determines the duration of ORP control atan ORP set point, whereas under timer control, this time limit determines the oxidizingpump on time. The user may choose to lockout the blowdown during oxidizing biocide feed.

Post-Feed: User may choose to lockout the blowdown following an oxidizing biocide slug.The post feed blowdown lockout time is determined by a user set time limit or by a user setORP set point with an over-riding time limit.

Recovery: The ORP is monitored until it returns to values close to those measured immediately before the oxidant slug. This is the recovery period. At the end of this time period thebio-reporter feed and normal 3D TRASAR Bio-Control is resumed. If the ORP does notachieve values close to pre-slug values within a specified time limit (typically 24-48 hours)the system will go into failsafe operation of the oxidizing biocide pump.

The 3D TRASAR Configurator program must be used to set these parameters governing theoxidant slug/shock.




6.3 Bio-Reporter SelectionThe bio-reporter product comes in both liquid and pellet form. Before starting up 3D TRASAR Bio-Control, refer to the table below to make sure you are using the appropriate product.

!Important! 3DTBR10 is formulated in concentrated sulfuric acid. Please contact yourNalco Representative for recommendations on fluid handling equipment compatible withconcentrated acid.

6.4 3D TRASAR Bio-Control/3D TRASAR Bio-Shock Start-UpProcedureWe recommend running a system under ORP control with a control range of ±20mV for a weekbefore proceeding to 3D TRASAR Bio-Control. The ORP readings during this period should beevaluated. If the ORP readings swing much wider than the control band of ±20mV then the entireoxidant feed system should be evaluated. Common reasons for poor ORP control include:

• The Oxidizing biocide pump is air locking• The Oxidizing biocide is entering the system in front of the intake for the controller• The Oxidizing biocide is being fed into a dead leg or a potential dead leg (e.g. Makeup water

tank)• The oxidizing biocide pump rate is set too high or too low• The system does not recirculate properly.

Oxidant feed issues should be resolved prior to 3D TRASAR Bio-Control initiation.

STEP 1 - Turn off oxidant feed to allow cooling system residual to fall below 0.1 ppm TRH(Depending on system volume this can take as long as 24 hours). Measure the total halogenresidual with a DR/2800 or DR/890 DPD test (Reagent P/N 460-S0461.87).

STEP 2 - Verify BioReporter and oxidant feed systems are ready for service. DO NOT feed theoxidant and BioReporter in close physical proximity. Make sure both feed points are sufficientlyseparated in distance that thorough mixing of each occurs. Failure to do so will negatively impactthe performance of 3D TRASAR Bio-Control. Do not feed bio-reporter or Oxidizing biocide directlyupstream of the 3D TRASAR controller sample point.

Bio-ReporterProduct

Bio-ReporterType

RecommendedSystem Volume

Gallons

"Do not Exceed"System Volume

Gallons

BlowdownUpper Limit GPM

3DTBR06 Liquid (0.6%) 0-12,000 30,000 N/A

3DTBR8 Solid pellet (8%) 12,000 to 30,000 100,000 200

3DTBR20 Solid pellet (20%) 30,000 to 60,000 1,000,000 500

3DTBR40 Solid pellet (40%) 60,000 to 2,000,000 2,000,000* 1,000

3DTBR10 Liquid (10%) >5,000,000 N/A N/A




6.4 3D TRASAR Bio-Control/3D TRASAR Bio-Shock Start-UpProcedure (con’t)Bio-reporter Pellet Feeder (recommended for system volumes between 12,000 and2,000,000 gallons)

• TURN ‘OFF’ Pellet Feeder and 3D TRASAR Controller (pellet feeder power switch islocated on the bottom of the feeder near cable connectors).

• Connect pellet feeder to controller using pellet feeder cable (see Section 2 for wiringdetails).

• Fill pellet feeder hopper with pellets, insert desiccant (from pellet container) in hopper lid.• Ensure water flow through pellet feeder is between 4 and 5 gpm.• Do not feed bio-reporter directly upstream of skid/fluorometer sample stream inlet.• Do not feed bio-reporter into a low flow/mix or dead leg portion of system.• Do not feed bio-reporter into a makeup water stream if flow is intermittent.• Return pellet feeder discharge directly back to tower basin or tower return header.• Turn ‘ON’ pellet feeder (power indicated by green LED) and 3D TRASAR Controller.• Manually feed one pellet into the system to verify operation. At controller keypad press

Information, Diagnostic Data, Pellet Feeder Data. Press the number ‘0’ to feed onepellet.

Bio-reporter Liquid Feed Pump (use 3DTBR06 for systems <12,000 gallons, 3DTBR10 forsystems >500,000 gallons)

3DTBR06 recommended pumps:.• Grundfos DME (volume < 3,000 gallons): P/N 6008505• Iwaki EZB10 (3,000 to 12,000 gallons): P/N 141-PJ4035.88

3DTBR10 REQUIRES an acid feed pump• LMI pump P/N 121-PJ2039.88

Important! 3DTBR10 is formulated with concentrated sulfuric acid. Use chemical feedequipment compatible for feeding concentrated sulfuric acid into water streams.

• Connect feed pump to control relay 3 (see Section 2 for wiring details).• Plumb pump suction tube to bio-reporter liquid container and ensure pump is primed.• Do not feed bio-reporter directly upstream of skid/fluorometer sample stream inlet.• Do not feed bio-reporter into a low flow/mix or dead-leg portion of system.• Do not feed bio-reporter into a makeup water stream if flow is intermittent.• Return liquid pump discharge directly back to tower basin or tower return header.• Manually turn on pump from the keypad to verify operation (see Section 4.10.8 for manual

relay control).• Set pump feed rate between 0.1 and 0.2 gpd. Make sure pump does not lose prime at thislow rate.

!




6.4 3D TRASAR Bio-Control/3D TRASAR Bio-Shock Start-UpProcedure (con’t)

• If using 3DTBR10, feed into the main recirculating linewith an acid/heat compatibleinjection quill P/N 231-P4611.88 (Hasteloy). Heat is generated at the point of injection ofthe product into the recirculating line. Use injection quill, check valves and pumps capable ofwithstanding the heat and the low pH. High recirculating water flow rates will assist in dissi-pating the heat. Use injection quill with sufficient length to discharge product into the centerof the recirculating line. Do not feed product close to the walls of the recirculating pipewhich may result in increased localized corrosion, and product deposit.• 3DTBR10 will precipitate solids unless installed into pipes with adequate water flow(5 gpm minimum). Do not feed into potential dead legs. Product will precipitate unless thereis adequate flow and dilution at the point of injection.

Oxidant Feed Pump

• Connect oxidant feed pump to control relay 4 (see Section 2 for wiring details).

• Verify oxidant injection point is located sufficiently far enough from the bio-reporter injec-tion point so that oxidizing biocide is thoroughly mixed. Preferred location is downstream ofbio-reporter injection point.

• Do not feed oxidant directly upstream of skid/fluorometer sample stream inlet.

• Do not feed oxidant into a low flow/mix or dead-leg or intermittent (e.g. make up waterheader) portion of system.

• Manually operate pump from the keypad to verify operation (see Section 4.10.8 for manualrelay control).

• For standard 3D TRASAR Bio-Control, set the oxidant feed pump rate, so that, if the pumpoperated continuously it would deliver to the system a 0.3 ppm TRH residual.

• For 3D TRASAR Bio-Shock mode set the oxidant pump rate so that the ORP set point canbe easily achieved in the configured Ox slug feed time.

• For Towerbrom 960 applications using 3D TRASAR Bio-Shock mode: Aspecial setupneeds to be done on the Towerbrom control panel to allow the 3D TRASAR controller totake over biocide feed. The program is compatible with Towerbrom feeder models ATF 500-2, 2370-2 and 2370-10. The following setup steps are required:

• The ATF must be converted to Semiautomatic mode prior to the startup.• Depending on the design of the control panel, the wiring from the 3D TRASARcontroller to Towerbrom shall be connected as the “Remote Start Input” listed in theATF manual. The Ox relay on the 3D TRASAR supplies a 60 second dry contactclosure to begin a feed cycle. ATFs that have a touch screen control panel must beset-up to havethe entire feed cycle exceed 1 minute. Older style feeders will need toadd a special timer relay to convert the 60 second contact closure to a momentarycontact closure. Contact the NGES Help Desk for specific information onimplementing these changes.• The ATF will dump the preprogrammed number of product dumps as entered oncontrol panel when in semi-automatic mode. The ATF will feed one dump of productwhen in manual mode. Each dump is either two pounds or ten pounds dependingon the ATF model.




6.4 3D TRASAR Bio-Control/3D TRASAR Bio-Shock Start-UpProcedure (con’t)

• Any further question regarding the relay wiring and setup, please contact 3D TRASARSupport or NGES Help Desk.

! NOTE: Verify oxidant residual is below 0.1 ppm TRH before proceeding any further! UseDPD Total Colorimetric Test (P/N 460-S0461.87) with the Nalco DR/890 or DR/2800.

STEP 3 - Using the Configurator, set up the controller for 3D TRASAR Bio-Control or 3D TRASARBio-Shock mode.

• In the System Information window, enter the system volume (system volume needs to beas accurate as possible).

• In the Control Settings window, set the oxidizing biocide control method to “3D TRASARBio-Control” or “3D TRASAR Bio-Shock Mode”.

• If using scheduled Ox slugs with 3D TRASAR Bio-Control or 3D TRASAR Bio-Shockmode, set up the slug parameters (prebleed, feed, post feed and recovery) in the Ox slugwindow.

• If using Ox slugs or 3D TRASAR Bio-Shock mode, make sure the ORP probe is clean andcalibrated.

• Select the desired bio-reporter and indicate if the oxidant feed pump is optimally sized,oversized or undersized for the system.

• In the Alarm Settings window, select the appropriate Alarm Pump Duty for the oxidizingbiocide (see Section 4.5.4).

• Upload the modified configuration to the controller.• Check to make sure the Configurator program asked for a ‘Reinitialization or Reboot’ of

the Controller. If not, either power cycle the Controller using the on/off switch or Rebootfrom Configurator program.

STEP 4 - If using a pellet feeder and the system volume exceeds 160,000 gal, deliver the requirednumber of bio-reporter Quick Dose Pouches to the cooling system (see Section 6.7).

6.5 Pellet Feeder OperationThe 3D TRASAR Pellet Feeder automatically feeds pelletized bio-reporter to the cooling system atpredetermined intervals and dosages (# of pellets) as directed by the 3D TRASAR controller.

The feeder consists of a chemical hopper to hold the pelletized product, a motorized ball valve andfeeder neck assembly. This is connected to a piping assembly containing a y-strainer designed totrap the fed pellets in a flowing water stream where they quickly dissolve into the circulating water.

When a pellet is to be fed, a signal from the controller initiates the process. The feeder assembly atthe bottom of the hopper, not unlike that in a “gumball” machine, rotates and traps a pellet, drops itdown into the feeder tube past an LED that ‘counts’the pellet, and into the ball valve assemblywhich then rotates to drop the pellet into the flowing water stream.




6.5 Pellet Feeder Operation (con’t)Several fail-safes and alarms are built in to the Pellet Feeder assembly. Feeder jamming (a veryrare occurrence due to built-in motor reversal) or failure to feed a pellet, both generate alarms onthe main control panel.

It is important to keep the Pellet Feeder at least ¼ full in order to preserve continuous operation.The 3D TRASAR Bio-Control scheme requires bio-reporter residuals. If the pellet feeder is emptyfor any period of time, the system will transition to failsafe operation and 3D TRASAR Bio-Controlwill have to be restarted using the initial start-up instructions.

The feeder holds approximately 8000 pellets, each refill canister holds approximately 1,500 pellets(as a general rule the pellet feeder can hold 5 full containers of pellets).

6.6 Filling the Pellet Feeder

!

!

!

NOTE: It is very important that the feed hopper remain dry. Moisture or water in the hoppercan cause pellet degradation and possible jamming.

WARNING: ALWAYS TURN ‘OFF’ POWER BEFORE OPENING PELLET FEEDER LID!

NOTE: Wear appropriate safety equipment when handling the pellets or filling the feeder.Refer to MSDS supplied with pellets for appropriate handling.

1. Turn off power.

2. Carefully open the hinged top.

3. Slowly pour the pellets from the storage container into the hopper. Add only enoughpellets for two months of operation.

4. Place the desiccant cartridge from the pellet container into the lid basket. Close the lidand screw fastener tightly.

5. Turn on power

WARNING: NEVER PLACE FINGERS IN PELLET DROP HOLES!!!

!




6.7 Bio-reporter Initial System DosingIf a pellet feeder is used for large systems (larger than 160,000 gal) start-up of 3D TRASAR Bio-Control requires the manual application of an initial dosage of bio-reporter chemical. Use QuickDose Pouch (P/N 460-3DTBRC.87).

Refer to the chart below and find your system’s total water volume. Read across to the “# ofPouches Required” column. Add this number of packets to the tower basin by carefully placingthem in the water at a point of good circulation and turbulence. The packets will quickly dis-solve in the water and release the bio-reporter contents.

If the system volume is less than 160,000 gallons or 3DTBR10 is used as the bio-reporter product,no pouches are needed (simply initiate 3D TRASAR Bio-Control as instructed in Section 6.3above). The Liquid Pump or Pellet Feeder will automatically feed the correct amount of bio-reporterto the system.

System Volume (gal)

From ToNo. of

PouchesRequired

160,000 300,000 1310,000 450,000 2460,000 600,000 3610,000 750,000 4760,000 900,000 5910,000 1,050,000 6

1,060,000 1,200,000 71,210,000 1,350,000 81,360,000 1,500,000 91,510,000 1,650,000 101,660,000 1,800,000 111,810,000 1,950,000 121,960,000 2,100,000 13

System Volume(gallons)

3DTBR40(# of pellets)

Weight of Pellets(grams)

200,000 21 28500,000 53 71750,000 79 106

1,000,000 105 1422,000,000 210 284

If pouches are unavailable and your system size exceeds 160,000 gal use the following table tocalculate startup dosages. It is imperative that the startup pellets be placed in a region of good flowso that they dissolve quickly (do not dump into a slow flowing area in the tower basin).




6.8 Pellet Feeder CleaningFor trouble free operation the pellet feeder must:

• Be kept clean and dry• Be kept ¼ full and NEVER allowed to empty

Periodically check the inside of the pellet feeder. If excessively dirty it will require a cleaning. If keptdry, cleaning is rarely required.

To clean the pellet feeder:

1. Manually remove the pellets from the feeder and store them temporarily in a clean DRYlocation.

2. Use a soft cloth to wipe clean any debris from the vessel sides, bottom to top.

3. Do not use a damp rag or introduce any moisture to the vessel.

When clean refill with the old pellets and manually feed a pellet to test for correct operation.

Refer to the bio-reporter MSDS sheet for safe handling procedures and required safetygear.

Contact with any moisture will cause the pellets to impart an intense blue coloring. This iswater-soluble and can be washed away with water.

6.9 Pellet Feeder MaintenanceThe bio-reporter pellet feeder may require periodic maintenance. How often maintenance is requiredis dependent upon pellet feed rates and the pellet feeder working environment. Typically the cleaningand adjustments listed below will need to be performed once a year. Larger systems that feed morepellets may require maintenance more frequently.

Pellet Feeder maintenance SHOULD ONLY BE DONE IF NEEDED.

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!

Clean Exit Tube - Section 6.9.1 Indicated by alarm or visual inspection.

Tighten Valve Seat - Section 6.9.2 Indicated by alarm or excessive weeping ofwater from pellet feeder.

Replace Pellet Shield - Section 6.9.3 Indicated by alarm, pellet feeder jamming, orvisual inspection.

!




Exit Tube

ClearTube

Exit TubePowerSwitch

Figure PF1 Figure PF2

6.9.1 Cleaning Pellet Feeder Exit Tube

During operation an LED/Detector is used to detect a pellet falling to “prove” delivery. This is howthe controller is alerted if the pellet feeder is empty or a malfunction occurred. The exit tube mayrequire cleaning should dust or dirt obstruct the LED light path.

To clean the tube, follow the procedure below:

STEP 1 - Turn pellet feeder power “Off”. See Figure PF2 for location of pellet feeder powerswitch.

STEP 2 - Locate the clear tube assembly that connects the pellet feeder body to theinjection valve. See Figure PF1.

STEP 3 - Directly above the clear tube assembly is the exit tube. Remove the clear tubefrom the coupling immediately above the ball valve. No tools are required, it is asnug but unglued connection.

STEP 4 - Insert the tube brush (provided with the pellet feeder)and clean the exit tube.DO NOT USE WATER. Use the brush ONLY. The LED is 1" to 2" up from thebottom of the tube.

STEP 5 - Replace the clear tube removed in Step 1.

STEP 6 - Turn pellet feeder power “On”.

STEP 7 - Manually feed a pellet at the 3D TRASAR controller from the pellet feeder diagnosticscreen. Press ‘0’ to feed a pellet.

STEP 8 - At the pellet feeder diagnostic screen, verify that ‘Sen’ value is in the range of3 to 7. If not, re-clean the tube and check again until satisfactory.




PipeStrap

Figure PF3

UpperUnion

UpperPlumbingAssembly

6.9.2 Tighten Valve Seat

The pellet feeder ball valve is designed to drop the bio-reporter pellets into a pressurized water line.As the pellets are fed a small amount of water equivalent to the displacement of the pellet will weepfrom the valve through the side drain port. This is normal and no cause for concern. Over time theseats may wear slightly and a larger amount of water may weep from the valve. This is an indicationthat a seat tightening is required.

STEP 1 - Turn off power to the pellet feeder (switch located below hopper seeFigure PF2).

STEP 2 - Remove the upper plumbing assembly to access the top of the ball valve. This isdone by removing the upper union fitting and the pipe strap (see Figure PF3).

Note: Under normal operation, the side drain port should be plumbed to drain, or connected to thebio-reporter Liquid Overflow Container (P/N 060-TR5350.88).

Plumbto drain




Figure PF4

AdjustmentNut

6.9.2 Tighten Valve Seat (con’t)

STEP 3 - Tighten the valve adjustment nut in a clockwise direction. See Figure PF4. Use aspanner wrench or the tips of needle nose pliers if necessary. Adjustment requiresonly a 1/8 to 1/4 rotation. DO NOT OVERTIGHTEN. Over tightening will causepremature wear, erratic operation and a “High Current” alarm.

STEP 4 - The unit can be manually activated to determine if excessive leaking occurs. Small“burps” of water during rotation are normal. If excessive leaking persists, tightenfurther.

STEP 5 - Replace the upper plumbing assembly and restore power.

STEP 6 - Manually feed a pellet at the 3D TRASAR controller from the pellet feeder diagnosticscreen. Press ‘0’ to feed a pellet.

STEP 7 - At the pellet feeder diagnostic screen, verify that ‘Ball’ value is in the range of400 to 600. If not, repeat steps until satisfactory.




Figure PF5New Shield

Figure PF6Distorted Shield

Figure PF7Pellet Feeder Shield Kit

6.9.3 Pellet Shield Replacement

The pellet shield may distort over time and require replacement, particularly for larger systemswhere many pellets are fed. A visual inspection will help identify if the pellet shield requires re-placement. The figures below show a new shield and a pellet shield that requires replacement.

STEP 1 - Obtain a replacement Pellet Feeder Shield Kit (P/N 060-TR5313.88).




!

Figure PF8

Remove these four screws

Exit tube covered by shield

6.9.3 Pellet Shield Replacement (con’t)

STEP 2 - Refer to the MSDS sheet for Safe Handling Procedures and Safety Equipmentrequired before proceeding!

Wearing a minimum of rubber gloves and dust mask, clean out any product from the PelletFeeder hopper. Do not use water! Contact with the product will cause a blue “stain”. Avoidcontact. The stain is not permanent and will wash away.

STEP 3 - Turn off power

STEP 4 - Loosen the four screws and washers holding the tabs of the pelletshield. Note the orientation to the ‘Exit Tube’ (shown in drawings).

STEP 5 - Remove the pellet shield, rotor retainer, and screws/washers as a unit.




Figure PF9

Note orientation of exit hole.When reinstalling shield assem-bly, the shield should be centeredover exit tube and completelycover it.

6.9.3 Pellet Shield Replacement (con’t)

STEP 6 - Remove the screws and washers from the tabs of the removed shield.

STEP 7 - Remove the used pellet shield from the rotor retainer and replace it with a new one.

STEP 8 - Insert screws and washers into the tabs.

STEP 9 - If the area around the rotor is full of powder, clean it out to allow the rotor retainer tofit properly.

STEP 10 - Insert the entire assembly into the feeder. Be sure to properly align the pellet shieldwith the exit tube - the pellet shield should cover the exit tube as shown in theprevious figures. Be sure the washers are in place.

STEP 11 - Secure the assembly with the screws. Do not over-tighten as the plastic can bedamaged.

STEP 12 - Turn on power.




6.10 3D TRASAR Bio-Control and 3D TRASAR Bio-ShockFrequently Asked Questions

1. What is 3D TRASAR Bio-Control?3D TRASAR Bio-Control is a proprietary Nalco technology for measurement and control of micro-biological activity in open recirculating cooling water systems. 3D TRASAR Bio-Control uses afluorescent bio-reporter to probe the entire system, measure both planktonic and sessile microbialactivity and feed oxidizing biocides in response. Oxidizing biocide is added at the correct time andat the correct dosage resulting in effective microbial control.

An all slug method of bio-reporter control is also available (3D TRASAR Bio-Shock mode). Whenthe measured bioactivity reaches a preset value, the system is slugged with oxidizing biocide. Theamount of oxidizing biocide slugged is set by the user and can be based on ORP set point or timercontrol of the oxidizing biocide pump.

To assist in the penetration of the bio-reporter and the oxidizing biocide into biofilm we stronglyrecommend the use of a BioDetergent along with the oxidizing biocide. For effective microbialcontrol it is important to vary the stresses in a system by routinely applying non-oxidizers. Addition-ally, if alga has been a known issue, an algaecide such as NALCO 90005 must be used routinely.

2. How does 3D TRASAR Bio-Control measure bio-activity in a cooling system?3D TRASAR Bio-Control works by the addition of a micro-biological activity sensor into the recircu-lating cooling water. This bio-reporter travels throughout the cooling system, going wherever thewater flows. This molecule has a characteristic fluorescent signature, which is enzymaticallychanged upon interaction with active, respiring microbes (both planktonic and sessile). The fluores-cence of the bio-reporter and the product of its interaction with bacteria is monitored continuouslyby an in-line fluorometer. The rate of change of the fluorescence with time gives a measure of themicrobiological activity in the system.

Because the bio-reporter is added to the recirculating water, it probes the entire system (bulk waterand surfaces, inaccessible heat exchangers, fill and basin) for microbial activity. The measuredfluorescence change reflects the average response for the entire system. Bio-reporter can onlydetect microbial activity in areas the cooling water samples. Obviously, no response is possiblefrom regions of no-flow (dead legs, etc.). Also, planktonic bacteria and biofilm surfaces will gener-ate a faster response as compared to areas deep within the biofilm where the diffusion rate is verysmall. Since this information will be used to apply oxidizing biocide, this is appropriate, as thebiocide can only access areas where it can diffuse as well.

3. What reaction does the Bio-Reporter monitor?The bio-reporter (Rx) interacts with dehydrogenase, a respiratory enzyme present in the mem-brane of most microbiological organisms. The dehydrogenase is produced when the microbes andalgae are active (respiring) and the activity of the enzyme is directly indicative of the activity of theorganism. The bio-reporter is chemically reduced by the enzyme to a product molecule (Rs), whichfluoresces at a different wavelength. Because the reacted and unreacted forms of the bio-reporterfluoresce at distinct wavelengths, they can be individually monitored to determine their concentra-tions. Both the bio-reporter and the bio-product molecules remain in solution (not attached to themicrobes) and as they circulate in the water their concentration can be measured by the 3DTRASAR Fluorometer.




4. What are the unique benefits of 3D Bio-Control?

3D TRASAR Bio-Control will consistently and automatically feed the correct dose of oxidizingbiocide at the correct time. Optimal dosage of oxidizing biocides has the following benefits:

• Cost savings• Copper and mild steel corrosion is often significantly reduced compared to other modes of

control.• Chlorine contribution from halogen based biocides is minimized. Therefore, impact on

stainless steel pitting and stress corrosion cracking is reduced.• Delignification of wood used in construction of the cooling tower is minimized.• Deleterious impact on scale and corrosion inhibitors is minimized.• AOX (adsorbable organic halogen) generation is minimized.• Optically-based detection of 3D TRASAR Bio-Control is much more reliable than ORP

probes, halogen analyzers and other halogen detectors.• Since 3D TRASAR Bio-Control is measuring microbial activity on-line, real-time, it will

detect any condition that results in an increase in microbiological activity instantly andcommunicate with users. Some examples include opening of dead legs, sour leaks,ammonia leaks, make-up water contamination etc.

• It will detect the sloughing of biomasses from heat exchange surfaces and respond withoxidizing biocide before it inoculates the system

• 3D TRASAR Bio-Control will detect situations where the oxidizing biocide tank is empty,the pump is air-locked or biocide has decreased in potency and notify users.

• 3D TRASAR Bio-Control can document the level of bio-activity in the system and theactions taken to control it, in accordance with Cooling Water Best Practices.

5. How effectively does 3D TRASAR Bio-Control manage microbial populations?

3D TRASAR Bio-Control responds to the total microbial activity in the system, the floaters(planktonics) and the slime (sessile or biofilm, microbes attached to surfaces). The sessile popula-tion constitutes >98% of the total microbial population and cause the problems associated withmicrobial proliferation.

Planktonic counts measured by dipslides or DMAshould be between 103- 105 cfu/ml. Since3D TRASAR Bio-Control responds to the total system microbial activity, it does not necessarily feedoxidizing biocide in response to the floating population measured by water samples and dip-slides.

Under 3D TRASAR Bio-Control, coupon swabs give population counts of 108 cfu/sq cm or less.

6. Is 3D TRASAR Bio-Control compatible with other components (Scale andCorrosion inhibitors) of the cooling water treatment program?

3D TRASAR Bio-Control is completely compatible with the scale and corrosion inhibitor compo-nents of the 3D TRASAR program. In fact, 3D TRASAR Bio-Control has a beneficial impact oncorrosion and scale inhibition.




7.Where is 3D TRASAR Bio-Control not a good fit?

3D TRASAR Bio-Control is not a fit where any one of the following conditions apply:

• The system is NOT an open recirculating cooling water system (e.g. once through, closedloop, etc.).

• System HTI < 6 hours.

• The system volume divided by the recirculation rate exceeds 20 minutes.

• The system has highly halogenated make-up water which is added to the tower in incre-ments greater than 5% of the system volume.

• Bleach (as opposed to bromine) is used with frequent or persistent ammonia contamina-tion.

• The customer requires a fixed halogen residual.

• Near sterile control is desired.

• Oxidizing biocides other than bleach, ACTI-BROM, ST-AB-REX, Chlorine gas, BCDMHand TowerBrom 991 is being used (Note: Check with 630-305-CHEM regarding ongoingwork to include new oxidizing biocides that are compatible with 3D TRASAR Bio-Control.)

• System has high background fluorescence (often associated with yellow tower water).Before bio-reporter is added to the system, check diagnostic screen and see if Rz or Rfreading (background) is greater then 8 ppb. To check the diagnostic data press Informa-tion key, select Diagnostic Data, select Fluorometer Data, read Rz and Rf (number is inppb).

• The amount/timing of oxidizing biocide fed to the system is constrained to be below theamount necessary for adequate control. An example: power plants where the time ofoxidizing biocide feed is limited by regulatory constraints. Another example: the amount ofhalogen fed is limited by how much money is allocated towards microbial control.




System Parameters

Turbidity (NTU) <150HTI (hrs) 6-400Volume (gal) No limit1

Blowdown Rate (gpm) No limit1

System Volume/Recirc Rate Ratio (min) <20Biocide Compatibility

Bleach CompatibleStabrex CompatibleActibrom CompatibleTowerbrom 960 Compatible2

Towerbrom 991 CompatibleCI2 Gas Compatible3

Cl02 Not Compatible3

BCDMH with EASIBROM Feeder Compatible3

Stabilized Bleach Not CompatibleIsothiazolinone CompatibleGlutaraldehyde CompatibleDBNPA Compatible90005 Compatible

Ammonia Levelswith Bleach (ppm) <20with Stabrex (ppm) <100with Actibrom (ppm) <300

Other VariablesIron (ppm) N/A4

SO2 NoneSulfides (ppm) NoneCopper (ppm) <300

8. What are the operating limits for 3D TRASAR Bio-Control?

1Systems with volume greater than 2,000,000 gallons and blowdown rate greater than 1,200 gpm need to use3DTBR10.2Compatible only with 3D TRASAR Bio-Shock mode.3Field tests in progress or trial sites needed. Call 630-305-CHEM.40.5 ppm as Fe2+, but cooling towers are oxidizing environments and Fe2+ is not generally found.




9. Does 3D TRASAR Bio-Control work with highly halogenated make-up water?

To test whether this system is suitable for 3D TRASAR Bio-Control, disconnect the external oxidantfeed and monitor the halogen residual in the system. If >0.1ppm total residual halogen is measuredin the system after an extended period of no halogen feed (>6hours) this system may not besuitable for 3D TRASAR Bio-Control.

Does the Make-Up water come in big slugs (system water volume changes by >10% due to Make-Up valve control dead band)? If so, this system may not work with 3D TRASAR Bio-Control. Use of3D TRASAR Bio-Control in these conditions can cause blue coloration in the water.

We have run systems with Make Up water that have Total Residual Halogen of 3 ppm successfullywith 3D TRASAR Bio-Control, where the above two conditions did not apply.

10. Can 3D TRASAR Bio-Control be operated in monitor mode only?

No. Nalco Bio-Index is a measure of how far the Rf/Rz ratio is compared to the set point. Whenratio exceeds set point + deadband, 3D TRASAR Bio-Control feeds oxidant. When ratio fallsbelow the deadband, 3D TRASAR Bio-Control stops the feed of oxidant (since the oxidant firstreacts with microbes and then with Rf and Rz). In other words, the ratio is maintained at pre-setvalue by optimal dosing of “mini slugs” of oxidant.

If oxidant feed is controlled externally, it is likely that oxidant feed is not in “micro slugs”. Thismeans the ratio drops precipitously when excess oxidant is fed. The 3D TRASAR controller thentries to compensate for bio-reporter loss by feeding more bio-reporter which a) lowers the ratio b)can turn the tower blue because of reaction with excess oxidant.

The value of the Nalco Bio-Index itself is meaningless in this case because the ratio is not a func-tion of microbial activity, but of oxidant levels in the tower. Another way of saying it is that for NBInumbers to be meaningful, 3D TRASAR Bio-Control MUST be in control of when the oxidant pumpcomes on (ratio has exceeded pre-set limit) and when it shuts off (oxidant feed is enough to kill themicrobes).

11. Will 3D TRASAR Bio-Control reduce my bleach feed?

3D TRASAR Bio-Control applies oxidizing biocide in response to microbial activity. It cannot betuned to add more or less biocide, it will apply biocide to the level that is necessary to control thebio-activity.

If, prior to 3D TRASAR Bio-Control, the customer was underdosing biocide, 3D TRASAR Bio-Control will increase the dosage. On the other hand, in systems with excessive biocide usage, itmay significantly reduce biocide usage.

Systems that maintained oxidizing biocide at a set halogen residual either by ORP control, or byHach Cl-17 control or even by manually-adjusted continuous biocide feed, have typically reducedtheir oxidizing biocide usage under 3D TRASAR Bio-Control, sometimes dramatically.

Systems that were previously slug-dosed once per day to once per week typically record an in-crease in oxidizing biocide usage under 3D TRASAR Bio-Control.




12. Does 3D TRASAR Bio-Control control Legionella?

No biocide program ensures Legionella-free towers. Legionella influx is unpredictable.

There are no Biocides that are specific for Legionella. 3D TRASAR Bio-Control applies conven-tional oxidizing biocides

Legionella are only a small fraction of microbial population in cooling tower. 3D TRASAR Bio-Control monitors the general planktonic and sessile microbial activity in the tower and appliesbiocide as a response. 3D TRASAR Bio-Control does NOT apply Biocides specifically forLegionella.

Use of 3D TRASAR Bio-Control can’t guarantee a Legionella-free tower. Although there is nostatistical correlation between general microbial control and Legionella detection, it is widely ac-cepted within the industry that controlling microbial proliferation and biofilm formation reduces therisk of Legionella proliferation. Numerous case studies have shown that 3D TRASAR Bio-Controlis effective in controlling biofilm and general microbial populations.

Application of an oxidizing biocide is only one component of an effective Bio-Manage program.Other, equally important aspects of a properly administered Bio-Manage program include: ad-dressing mechanical and operational issues (dead-legs, recirculation problems), routine towercleaning and disinfection, proper oxidizing biocide selection, routine application of an appropriatenon-oxidizing biocide at proper dosage and coordinated with detergent slugs.

For systems where control of Legionella and health related risks is a water treatment program goal,Nalco Environmental Hygiene Services should be contacted for risk assessment and management.

13. Does 3D TRASAR Bio-Control control SRB’s (Sulfate Reducing Bacteria)?

The bio-reporter can respond to anaerobic bacteria such as SRB’s.

Numerous case studies have shown that 3D TRASAR Bio-Control is effective in controlling biofilmand general microbial populations. SRB’s are typically found under deposits and biofilm. Control ofbiofilm can help control SRB proliferation in the system.

SRB’s are only a small fraction of microbial population in cooling tower. 3D TRASAR Bio-Controlmonitors the general planktonic and sessile microbial activity in the tower and applies oxidizingbiocide as a response. 3D TRASAR Bio-Control does NOT apply Biocides specifically for SRB’s.

SRB’s are typically found under deposits, which are inaccessible to the bio-reporter and oxidizingbiocide. It is effective to use a biodetergent and a non-oxidizing biocide to better disperse and treatthe deposits in the system.

If high SRB counts are encountered in the system consider supplementing 3D TRASAR Bio-Controlwith regular Oxidizing biocide slugs. You may also consider using 3D TRASAR Bio-Shock mode fora period in order to bring the system under good microbial control.




14. Does 3D TRASAR Bio-Control control algae growth?

3D TRASAR Bio-Control has not been designed to specifically control algae.

Even though the bio-reporter reacts with and responds to algae, the microbial activity attributable toalgae growth usually represents only a fraction of the total system microbial activity. For thisreason, 3D TRASAR Bio-Control may not apply oxidizing biocide specifically in response to, or at adosage sufficient to control, algae growth.

3D TRASAR Bio-Control does not maintain high residuals of halogen in a tower. If algae is a knownproblem and over-halogenation has been the historical method of algal control, it is crucial that analgaecide be routinely used in conjunction with the oxidizing biocide under bio-reporter control.

If algaecide use is not feasible, another option is to use regular scheduled oxidizing biocide slugsoverlaid on 3D TRASAR Bio-Control.

3D TRASAR Bio-Shock mode, the all slug mode of oxidizing biocide application with bio-reportercontrol may be also used in systems where algae is a problem

Algae grows in semi-wetted areas exposed to light. Chlorine and bromine are not particularlyeffective under these conditions. Using these halogens at high levels in the recirculating waterresults in a vapor pressure of halogen in the tower decks resulting in algae kill. Since 3D TRASARBio-Control only maintains very small TRH levels in the water, algae control by this mechanism isnot active.

We recommend covering exposed tower decks.

15. What key issues I should be aware of before I decide to use 3D TRASAR Bio-Control?

• 3D TRASAR Bio-Control should be used in conjunction with an appropriate oxidizingbiocide, a non-oxidizer and a bio-dispersant. Additionally, if presence of algae has been aproblem in the past and was handled through high TRH levels in the tower, an algaecide such asN-90005 must be used.

• 3D TRASAR Bio-Control will impart a slight blue color to the tower water. The effect will be ampli-fied as the depth of the water in the basin is increased. This is normal.

• 3D TRASAR Bio-Control may or may not reduce the oxidant usage in the system. It dependsupon whether the system was in good control or not before 3D TRASAR Bio-Control.

• 3D TRASAR Bio-Control is not the same as maintaining a fixed halogen residual. The measuredTRH levels depend upon the system microbiological activity and demand. In fact, measured TRHlevels may be zero during a significant portion.




15. What key issues I should be aware of before I decide to use 3D TRASAR Bio-Control? (con’t)

• 3D TRASAR Bio-Control applies oxidizing biocides based on the measured total microbiologicalactivity — planktonic and sessile. The bulk of the microbiological activity in the system is sessileand 3D TRASAR Bio-Control responds to this measured activity with oxidizing biocide. 3DTRASAR Bio-Control will maintain planktonic counts around 104 cfu/ml for the most part. Butinjured and inhibited microbes (inactive) will be nursed back to health on dip slides or petrifilm andwill show up in the planktonic counts. Planktonic population fluctuations between 103-105 cfu/mlshould be expected.

• Note that there will always be systems where microbiological control is not a chemical treatmentissue. There are mechanical, operational and chemical parameters (e.g. dead legs, severelyfouled tower basins, continuous process leaks etc.) that can make bio-control difficult. Goodmicrobiological control may not be possible where these issues are not separately addressed.

16. What if I don’t use a non-oxidizer or bio-dispersant?

Do not expect optimum performance of 3D TRASAR Bio-Control under these circumstances. Toassist in the penetration of the bio-reporter and the oxidizing biocide into biofilm we strongly recom-mend the use of a Bio-detergent along with the oxidizing biocide. The detergent should be fed byslug feed (not continuous). For effective microbial control it is important to vary the stresses in asystem by routinely applying non-oxidizers. Additionally, if algae has been a known issue, analgaecide such as N-90005 must be used routinely. In systems where non-oxidizer use is notpossible we strongly recommend regular scheduled Oxidizing biocide slugs to vary microbialstresses.

17. How does 3D TRASAR Bio-Control apply Oxidizing biocide?

Principle: The bio-reporter (Rz) is converted by dehydrogenase, a membrane-bound respiratoryenzyme, to the Bioproduct (Rf). The concentration of Rz and Rf are determined from the intensity oftheir fluorescence peaks. A decision on whether to feed oxidizing biocide is made every 20min. Theoxidizing biocide is dosed depending on measured demand.

Bio-Reporter Control: Bio-Reporter is fed into the system as a liquid or a pellet based on the mea-sured concentration of the Rz signal. The liquid bio-reporter is fed based on dead band control. Forpellets, the decision is made every 20minutes. The number of pellets that will be fed at a time is afunction of the pellet concentration, entered system volume and historical system response.

Fluorometer signals: Rz and Rf intensities are collected every 5 sec and a ratio value (Rf/Rz) iscalculated for each data point. The data collected is validated to ensure that the fluorescence datais above a lower threshold value and below saturation values for the fluorometer.

Data Processing: A quadratic fit to the collected ratio values is calculated at the end of each 20 mincycle. A goodness of fit criteria (chi-square) is used to evaluate if the data is too noisy or the fit isunsuitable. The oxidizing biocide pump is turned on/off depending on the value of the calculatedratio and the slope of the fit.




17. How does 3D TRASAR Bio-Control apply Oxidizing biocide? (con’t)

Control Band (3D TRASAR Bio-Control):The ratio is maintained within a control band by applyingoxidizing biocide. The decision on whether to apply oxidizing biocide and how long to turn on thepump is a complex function of the biocide being used, how far the ratio is from the control set point,the slope of the ratio trajectory, and the historical response of the system.

Control Band (3D TRASAR Bio-Shock): When the ratio reaches a set point, bio-reporter feed intothe system is suspended. The system slugs oxidant into the tower. The duration of the slug feed isset by the user. During the Ox-slug the oxidizing biocide is maintained under ORP control with apreset setpoint and range. The oxidant slug can also be simple timer based. After the slug is com-pleted the system waits for the ORP readings to dissipate to preslug values. Bio-Reporter is thenagain added to the system and the ratio is monitored.

Control Loop: After 20min, the response of the system is again evaluated by processing the ratioand a decision is made again on whether or not to feed oxidant and for how long.

Non-Oxidizer Feed: 3D TRASAR feeds non-oxidizer based on a timer. Feed of a biodispersant isslaved to the feed of the non-oxidizer.

Ox Slugs: Oxidizing biocide slugs may be applied to the system when it is under normal 3DTRASAR Bio-Control. These slugs may be scheduled or be manually triggered from the controller.During the Ox slug bio-reporter feed is suspended. The duration of the slug feed is set by the user.During the Ox-slug the oxidizing biocide is maintained under ORP control with a preset setpoint andrange. The oxidant slug can also be simple timer based. After the slug is completed the systemwaits for the ORP readings to dissipate to preslug values. Bio-Reporter is then again added to thesystem and normal 3D TRASAR Bio-Control resumes. We recommend using the slug feed featureonce a week in order to vary the system stresses for good microbial control

18. What is 3D TRASAR Bio-Shock Mode?

3D TRASAR Bio-Shock mode is an alternate oxidant feed strategy to normal 3D TRASAR Bio-Control. This is an all shock method of applying oxidizing biocide. The bio-reporter monitors micro-biological activity and when it reaches a preset value oxidizing biocide is slugged into the system.The duration of the slug can be user set from 10 minutes to 35 hours and the ORP setpoint for theslug is also user set. This mode allows the user to actively control the dosage of the oxidizingbiocide. Thus under 3D TRASAR Bio-Shock mode the bio-reporter determines the timing of thebiocide feed but the user determines the amount of biocide to be applied.

3D TRASAR Bio-Shock mode is recommended in certain situations:• System has recirculation problems (with zones which have stagnant or slow-moving water)• Systems is struggling with algae control• Positive Legionella counts require regular slug dose of Oxidizing biocide into the system• System needs to respond to a process leak• Bio-Reporter is being used to control feed of Towerbrom 991




18. What is 3D TRASAR Bio-Shock Mode? (con’t)

During the slug feed period bio-reporter feed is suspended and oxidizing biocide is applied basedon timer control or system ORP measurement. For timer based slugs the oxidant relay is on con-tinuously for the preset time. For ORP based slugs, the oxidant is dosed to the specified ORP leveland then maintained at that ORP level for the preset time. Bio-Reporter feed restarts after thesystem water has returned to pre-slug ORP values.

Since the oxidant slug condition is defined by the user, the actual oxidant applied can be adjusted.If an increased oxidant dosage is desired, the ORP set point and/or the slug duration can be in-creased. Please note that there is NO oxidant feed between slugs. Under classic 3D TRASAR Bio-Control, the oxidant dosage cannot be adjusted.

3D TRASAR Bio-Shock Mode requires a functional ORP probe to be in place and recalibrated.The ORP probe is used to control the oxidant slug and monitor the system in the recovery periodfollowing the slug. Once the ORP signal has dropped to within 5% of the pre-slug levels, thebio-reporter is redosed. If the ORP signal does not fall back to within 5% of the pre slug level within24 hours (default value), the system will trigger a “slug recovery failure” alarm, and the oxidant willbe dosed based on the failsafe settings. When the alarm is cleared (either by acknowledging thealarm on the 3D TRASAR controller screen or through a power cycle), the system will return tonormal operation and resume bio-reporter feed.

The figure below shows the bio-reporter ratio value during 3D TRASAR Bio-Shock mode. When itreaches the setpoint the Oxidant relay is triggered (to 129). The Oxidant relay remains under ORPcontrol for the preset duration. Thereafter when the ORP signals returns to preslug values and therecovery period is complete, bio-reporter is again dosed into the system and the ratio is monitored.




18. What is 3D TRASAR Bio-Shock Mode? (con’t)

The figure below shows the ORP signal and the Nalco Bio-Index during a slug. During the slug theNalco Bio-Index reads -999. After bio-reporter feed has resumed the Nalco Bio-Index shows lowvalues (-200) which slowly increase with monitored microbial activity and reaches zero around thetime for the Oxidant slug trigger.

Nalco Bio-Index Control

<-20This is often seen within 48 hours of startup.If persistent with no other alarms, call 630-305-CHEM.

-20-+10 Good control10-30 System is working against an influx30-80 System is straining>80 Alarm condition

19. What is the Nalco Bio-Index?

Nalco Bio-Index is a measure of microbiological control in the system based on the bio-reporterresponse. As the Nalco Bio-Index increases the relative microbial control decreases. Ageneralreference is:

Nalco Bio-Index under 3D TRASAR Bio-Control

Nalco Bio-Index Control

-999 System is in Ox s lug-200 to -20 BioReporter is monitoring microbial activity

-20 to 0 System is approaching preset slug setpoint0 System will slug shortly

Nalco Bio-Index under 3D Bio-Shock mode




20. How does 3D TRASAR Bio-Control differ from ATP measurements?

ATP is a molecule used by living organisms to store energy. Handheld ATP measurement devicesuse chemical reagents to measure the amount of ATP in a water sample. Such devices measurethe planktonic microbial activity only. The bio-reporter measures the total microbial activity of thesystem (not just the floating microbial populations). 99% of the microbe populations in a system arebiofilm (adhered to surfaces) and their activity cannot be measured from a grab sample used in ATPanalysis.

ATP measurements cannot be done on-line. The bio-reporter monitors the microbiological activitycontinuously, on-line and in real time.

ATP measurements cannot be used to control the biocide pump. The bio-reporter technology isused for continuous measurement and control of microbial activity.

ATP can survive for a long time after the micro-organism itself is dead. Therefore the readingsobtained from ATP analysis can give an incorrect picture of even the planktonic microbial activity ofa system.

21. How does 3D TRASAR Bio-Control differ from using dip slides or plate counts tomeasure bio-activity?

3D TRASAR Bio-Control responds to the total microbial activity in the system, the floaters(planktonics) and the slime (sessile, microbes attached to surfaces). The sessile population consti-tutes >98% of the total microbial population and cause the problems associated with microbialproliferation (under-deposit corrosion, impedance of heat transfer, odor, environments for pathogengrowth, slime). Dip slides and plate counts only measure the floating microbial population and missthe bulk of the microbes.

3D TRASAR Bio-Control responds to microbial activity, not population. On the dip slides all mi-crobes flourish and form colonies. In the system, injured or inhibited microbes are not active anddo not need biocide.

3D TRASAR Bio-Control responds to microbial activity instantaneously. Dip slides and plates need24-48 hrs to develop. During that period 10’s of generations of microbes may flourish and repro-duce in the system.

3D TRASAR Bio-Control measures and responds to microbial activity at the correct time with thecorrect dosage of oxidizing biocide. This results in good control with efficient use of biocide.

22. How does 3D TRASAR Bio-Control compare to ORP control?

3D TRASAR can control the feed of oxidizing biocide by ORP control or by the 3D TRASAR Bio-Control control strategy. These two methods are distinct.

ORP control is based on an electrochemical measurement and maintains the oxidation reductionpotential in the system between preset bounds. The ORP setpoint suitable for a particular systemis water chemistry and probe dependent. It’s a good idea to monitor the halogen residual in thetower at a particular ORP and fine tune the settings. Maintenance and frequent calibration is criticalfor good control.




22. How does 3D TRASAR Bio-Control compare to ORP control? (con’t)

3D TRASAR Bio-Control feeds oxidant based on the fluorescent bio-reporter response. It is ademand based method of oxidizing biocide feed. No set residual is maintained, oxidizing biocidedosage and timing is varied depending on the microbial loading. The bio-reporter must be fed tothe tower for this control method.

ORP is an electrochemical measurement and the readings from a probe can drift significantly inshort periods. It is important to keep the ORP probe clean and well-calibrated. The bio-reporter isan optical measurement, and maintenance and drift are not problematic.

For ORP control the user chooses the control setpoint. For bio-reporter control, the control band ispreset depending on the oxidizing biocide chosen.

ORP control applies oxidizing biocide so that the system maintains a set ORP. In bio-reportercontrol, oxidizing biocide is applied based on microbial demand and therefore biocide usage isefficient.

Since oxidizing biocide is dosed based on demand, corrosion is often reduced significantly underBio-Control. Therefore is typically a reduction in delignification of wood structures, steel stresscorrosion and cracking, AOX formation under this control method.

23. Does 3D TRASAR Bio-Control maintain Free Residual Halogen?

3D TRASAR Bio-Control uses a fluorescent bio-reporter molecule added to the tower water tocontinuously monitor the total microbial activity in a system. When the activity reaches a control setpoint, oxidizing biocide is applied. If the initial dose was not sufficient, more biocide is applied, untilthe system is brought under control.

When sufficient oxidizing biocide has been added to the system and the microbial activity isbrought into control, the excess oxidant interacts with the reacted bio-reporter. The controller stopsoxidizing biocide application.

Because both the microbial activity and the biocide dosing is continuously monitored it is no longernecessary to maintain a measurable excess oxidizing biocide in the system (residual halogen).

Under 3D TRASAR Bio-Control, the halogen residual may be between 0.8 ppm to 0.02 ppm asmeasured by a total halogen DPD test.




24. Why is 3D TRASAR Bio-Control a better solution than over-feeding oxidants?

Overfeed of bleach can lead to other operational problems such as corrosion and degradation ofscale and corrosion inhibitor products. In the accompanying figure, we see how transition frommanual oxidant control to 3D TRASAR Bio-Control helped control copper corrosion rates. Undermanual control, the oxidant feed was erratic, with spikes in corrosion corresponding to spikes inORP.

It is difficult to ensure that the bleach is consistently overfed especially during process leaks orwhen the make-up water becomes contaminated (e.g. with ammonia). 3D TRASAR Bio-Controlensures that the correct amount of bleach is applied at the correct time.

3D TRASAR will alarm if operational conditions such as an air-locked oxidizing biocide pump orempty oxidizing biocide porta-feeds occur. Thus issues can be dealt with in a more timely mannerand the system does not develop severe fouling problems in the interim.

Continuous overfeed of bleach can lead to delignification of wood.

Continuous overfeed of bleach can result in high levels of AOX formation in the tower water leadingto issues with discharge of the blowdown.

Bleach overfeed can result in SS pitting and stress corrosion cracking of equipment.

Finally, even though bleach has a low $/lb cost, over feed can result in unnecessary high costs.

-

100

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Time (each division = 1 day)

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Before 3D Bio-Control After 3D Bio-Control

Figure: ORP and copper corrosion rates are measured by 3D TRASAR. 3D TRASARBio-Control is superior to ORP control because it 1) reduces the variation in oxidantconcentration, 2) reduces the average oxidant concentration and 3) reduces coppercorrosion rates by eliminating high ORP levels.




25. Can you give me an example where 3D TRASAR Bio-Control varied the Oxidantfeed based on system demand?

In this tower oxidizing biocide is STA-BR-EX. Tower is under 3D TRASAR Bio-Control. On 8/23/04the tower is slugged with 6 ppm of N73550 (biodetergent). Entire system (deadlegs, unusedtowers, unused chillers) is opened up to detergent. 100 ppm of N7330 is added to the tower 1 hrlater. As untreated and sloughed up biofilm is exposed, the Nalco Bio-Index increases and theduration and frequency of the oxidizing biocide feed (Ox pump On time) is increased. The NalcoBio-Index has a double-humped profile (second peak on 08/24/04) due to the detergent continuingto slough off deposits while the N7330 concentration is reduced by consumption and blowdown.System is finally brought back to normal levels of STA-BR-EX feed by 08/25/04 at which time it istreated to 50 ppm of N90005 (quaternary amine algaecide). The algaecide is also a surfactant anda slow acting bactericide. There is an initial increase in Nalco Bio-Index followed by a 21 hr periodduring which no STA-BR-EX is fed into the tower. Compare this to normal operation period (08/20/04-08/22/04). The consecutive application of two non-oxidizers led to low microbiological activityand consequently a 21 hr period of no oxidant feed into the system. Planktonic counts taken on08/26/04 show good microbial control.

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8/20/04 8/22/04 8/24/04 8/26/04 8/28/04

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Ox_pump_ on_timeBF_ratio_ index

N73550 & N7330 slug

N90005 slugNo Ox feed for 21 hrs

26. How do I determine how much Bio-Reporter to use?

The bio-reporter is applied by the controller to maintain 20 ppb of active product. There is someconsumption of the bio-reporter molecule during each blowdown cycle. The product usage per unitblowdown can range between 30-120 ppb (active), while a typical usage concentration is 60 ppb(actives) per unit blowdown. The concentration of the bio-reporter used in a tower per unitblowdown is a function of several factors including: HTI, microbial activity, biocide, tower configu-ration, etc. The chart below can be used to obtain an initial estimate of how much of the bio-reporter product to order. The quantity of bio-reporter can also be obtained by looking at the 3DTRASAR Optimizer report.

Bio-Reporter lbs/Million gal ofblowdown

3DTBR06 83.43DTBR8 6.3

3DTBR20 2.53DTBR40 1.33DTBR10 5.0




27. Where should I feed the Bio-Reporter?

The feed point for the bio-reporter should be distant (downstream) from the intake for the 3DTRASAR fluorometer and the feed point of the oxidizing biocide. It should be in well mixed regionof the recirculating system. If a pellet feeder is being used, flow through the feeder should be aminimum of 5 gpm and the output should return to the system (not to drain) and not to a dead-leg.

28. How do I determine which biocides to use?

3D TRASAR Bio-Control is an oxidizing biocide feed control method based on the online, real-timemonitoring of overall microbial activity. Mechanical and operational factors such as dead-leg open-ing, recirculation problems, routine tower cleaning and disinfection must be addressed/imple-mented before any chemical control program can be optimized. Application of an oxidizing biocideis only one component of an effective chemical Bio-Manage program.

For a complete list of available 3D TRASAR products, please contact your Nalco Sales Represen-tative.

29. Is there anything else I must do before starting?

• Clean out the tower basin and power wash the fill.• Determine the feed point for the bio-reporter. It should be distant from the intake for the fluorom-

eter and the feed point of the oxidizing biocide. It should be in a well mixed region of the coolingsystem. If a pellet feeder is being used, flow through the feeder should be a minimum of 5gpm.

• Tower decks should be covered. Algaecides, non-oxidizers and BioDetergent ordered.

30. Should I slug feed my tower with oxidizing Biocide before starting 3D TRASARBio-Control?

No. You should wait till the halogen levels in the tower dissipate to less than 0.1 ppm total residualas measured by the Hach DPD test before starting 3D TRASAR Bio-Control, otherwise your towerwater will turn blue.

31. What will happen if I initiate 3D TRASAR Bio-Control without waiting for TRHlevels to be <0.1 ppm?

If you initiate 3D TRASAR Bio-Control without waiting for the halogen levels to dissipate to <0.1ppm total residual halogen as measured by the Hach DPD test, there is a potential for the towerwater to turn intensely blue. Large quantities of the bio-reporter product may be wasted.

Some towers will always register a total residual >0.1 ppm total halogen, even when the oxidizingbiocide feed into the tower has been discontinued for 24 hours. In these towers, it may be OK tostart 3D TRASAR Bio-Control without waiting for the total halogen residuals to dissipate to<0.1ppm provided at least 24 hours have elapsed since discontinuation of oxidizing biocide feed.Ensure there is no free halogen residual in the tower water and call 630-305-CHEM before startup.




32. How do I know that 3D TRASAR Bio-Control is working?

In the controller display [press on keypad: Information —> System Performance] the Nalco Bio-Index will be shown with a ‘starting value’which can range from zero ‘0’down to as low as -20 or -30.

A minimum of one hour of data has to be acquired before a calculated value is shown. If the sys-tem has just been dosed with bio-reporter, it will take between 4-24 hours (depending on microbialactivity) for the Ratio_Value to reach the control Ratio set point. During this period, oxidizing bio-cide will not be applied to the system. If after 24 hours oxidizing biocide has not been fed into thesystem please call 630-305-CHEM.

When you wish to follow the 3D TRASAR Bio-Control algorithm and verify correct operation theeasiest thing to do is to download the 3D TRASAR Bio-Control data file (through data downloadscreen). The file can be opened in Excel and the Nalco Bio-Index can be reviewed along with the‘ox pump on time’. The ox pump on time is the length of time (in seconds) the 3D TRASAR Bio-Control turned the oxidant pump on each 20 minute decision interval.

You can also verify that the oxidizing biocide relay has been feeding biocide by checking the [Calcs]portion of the ‘General Data’ log in column Z [Ox Bio Relay Duty %] . You will see a number (per-centage) listed if the ox_biocide relay has come on in the previous 24-hour period.

The Nalco Bio-Index value should be between -10 and +10 during normal operation of 3D TRASARBio-Control after the initial 4-24 hour period has elapsed.

33. How do I determine if the Rz concentration in the system has reached 20 ppb?

• Check the 3D TRASAR controller display.Press Information key, select Diagnostic Data, select Fluorometer Data, select Rz(ppb).

• Check the 3D TRASAR configurator.Connect to the controller. Once connection is established, the Controller menu will appear.Select View Current Readings, Data Tab. Under System Performance box locate theBio-reporter value in ppb.

34. Can I trim-feed oxidizing biocide with a separate pump at low level tocontinuously maintain a halogen residual while on 3D TRASAR Bio-Control?

Only if the oxidizing biocide is being applied to the Make-Up water AND the conditions that prevent3D TRASAR Bio-Control use in systems with high halogen levels in Make Up water do not apply.

If oxidant is fed by external (not 3D TRASAR Bio-Control) control into the tower water, it is likelythat there will be overfeed during times of low microbial activity resulting in degradation of the bio-reporter and BioProduct signals. To compensate, more dye will be added to the system and thewater will become colored.




34. Can I trim-feed oxidizing biocide with a separate pump at low level tocontinuously maintain a halogen residual while on 3D TRASAR Bio-Control? (con’t)

Continuous addition of Oxidizing biocide and bio-reporter into the system can result in the Ratiostaying artificially low (below set point) and no true measure of microbial activity (Nalco Bio-Index)will be obtained.

Nalco Bio-Index can only work by applying mini slugs of oxidizing biocide. The extent and timing ofthe slug has to be controlled by the controller.

35. Can you make 3D TRASAR Bio-Control feed more oxidant into the system?

No. The amount of oxidizing biocide added depends upon the measured microbial activity in thesystem. This cannot be externally modulated or adjusted. However, the scheduled slug optioncan be used to periodically supplement 3D TRASAR Bio-Control.

3D TRASAR Bio-Shock mode, an all slug mode of Biocide feed is an alternative method of applyingoxidizing biocide to the system. The bio-reporter monitors the microbial activity and when it reachesa preset value, an Ox slug is triggered. By setting the duration and ORP level of the slug, the usercan modify the amount of biocide entering the system.

36. Can you make 3D TRASAR Bio-Control feed less oxidant into the system?

No. The amount of oxidizing biocide added depends upon the measured microbial activity in thesystem. This cannot be externally modulated or adjusted.

37. How responsive is 3D TRASAR Bio-Control to changes in the bio-population?

3D TRASAR Bio-Control monitors the fluorescence signal from the reacted and unreacted bio-reporter every 5 seconds. It assesses the data-stream every 20 minutes and makes a decisionregarding whether to turn the oxidizing pump on or not.

If there is a process leak into the system that either increases the amount of nutrient available tothe microbial populations or decreases the efficacy of the biocide (sour leak, ammonia etc) 3DTRASAR Bio-Control will respond with increased biocide feed within 20 minutes of the measuredevent. There may be a delay in response in systems with long recirculation times. The Nalco Bio-Index will take longer to show an increase because it is a 6 hour average measurement.

Typically process leaks affecting the microbiological population have been responded to at orbefore the time that other effects have been observed in the system such as pH changes, turbiditychanges, conductivity changes or ORP changes.




38. When using 3D TRASAR Bio-Control, what halogen residuals can be expected?

The amount of halogen residual measured in the system water will depend on microbial activity inthe system. This in turn can depend upon factors such as ambient temperature, process leaks,system design etc.

The highest level of halogen (total residual) observed in a cooling tower under 3D TRASAR Bio-Control is 0.8 ppm. The lowest level observed is 0.0 (below detection limit of Hach DPD test).During periods of moderate demand, total halogen residuals in a cooling tower can be expected tobe 0.1 - 0.4 ppm TRH. ORP levels at which control is maintained depends upon the oxidizingbiocide used (STA-BR-EX: 150-340 mV, Bleach or Actibrom: 270-340mV).

Variation in ORP (mV) and total halogen levels in a cooling tower under 3D TRASARBio-Control.

In this graph, STA-BR-EX was the oxidizing biocide. On-line halogen was monitored witha Hach Cl-17. Using 3D TRASAR Bio-Control, ORP varied between 180 - 320 mV andthe halogen levels varied between 0.0 - 0.4 ppm (total). 3D TRASAR Bio-Control adjustshalogen dosage based on demand. There is thus seasonal and diurnal variations in theconcentration.




39. What should I monitor in my tower to ensure good microbiological control?

It is strongly recommended that the tower be monitored routinely to ensure that the tower is undergood control. We recommend that you benchmark performance prior to 3D TRASAR Bio-Controlfor later comparison with system performance under 3D TRASAR Bio-Control. The following testregimen are recommended:• Monitor planktonic counts with dip slides weekly.• Send water samples for Bio analysis (DMA-Differential Microbial Analysis) at least quarterly.• Monitor sessile populations with surface swabs at least quarterly.

40. My dip slides show >10,000 cfu/ml. Does this mean 3D TRASAR Bio-Control doesnot work in my system?

No. 3D TRASAR Bio-Control may be working well in your system. The bio-reporter monitors thetotal system microbial activity: planktonic (floating) and sessile (biofilm). The biofilm constitutes thevast majority of the microbial population in the system (>98%) and is unevenly distributed over thesystem surfaces. Dip slides and normal DMA only monitor the floating population, which may notrepresent the bulk of the microbial activity.

Planktonic counts measured by dip slides or DMAshould be between 103-105 cfu/ml. Swabs ofcoupons in systems with 3D TRASAR Bio-Control give population counts of 107 cfu/sq cm or less.Excursions outside this range may happen occasionally, especially after a detergent feed or theopening of a dead-leg. If the problem persists, please call 630-305-CHEM.

It is important to implement a full microbial treatment plan for the system including use of abiodetergent (to allow penetration of the bio-reporter and also the oxidizing biocide into the depos-its) and a non-oxidizing biocide. High planktonic counts may be indicative of continuous inoculationof the system from dispersing biofilm.

41. I just started 3D TRASAR Bio-Control. Why am I not feeding oxidant?

If the system has just been dosed with bio-reporter, it will take between 4-24 hours (depending onmicrobial activity) for the ratio to reach the control ratio set point. During this period, oxidizingbiocide will not be applied to the system. If, after 24 hours, oxidizing biocide has not been fed intothe system, please call 630-305-CHEM.

Since the system has just been dosed with the bio-reporter, the Ratio is low and it is below thecontrol band. As the microbes convert some of the bio-reporter the Ratio will come up to the setpoint. The Nalco Bio-Index is calculated from the averaged value of the Ratio and is not a goodindicator of the Bioactivity in the system at system startup.




42. My Nalco Bio-Index has been reading -80 for the past week. Is there a problem?

There are several causes for a persistently low Nalco Bio-Index:• Is your Makeup water highly halogenated? Are there other sources of oxidant feed into the

tower? Persistent very negative Nalco Bio-Index readings indicates that the bio-reporter is beingdegraded by a separate oxidant feed. Plot the ORP(mV) data from the standard log and see howit varies over time. Other sources of oxidant can be detected by the ORP being maintained orgoing up with makeup water ingress.

• Your HTI may be too low for 3D TRASAR Bio-Control.• Is there any other alarm condition on your controller? Other conditions may be causing the low

Nalco Bio-Index.

43. My Nalco Bio-Index is negative. Why is my oxidizing biocide pump on?

Nalco Bio-Index (NBI) value is NOT used to make decisions on oxidant feed and is for displaypurposes only.

NBI represents the average value of the Rf/Rz Ratio with respect to the control band over the past6 hours. Because it is an averaged value, the response time of this function is slow.

44. 3D TRASAR Bio-Control is controlling, but no oxidizing biocide is being fed.Why?

Did you reboot (cycle power) on the controller after changing control modes?

The standard data log saves a snapshot of the state of the relay every 15minutes. The relay mayhave been in between these logs. The calc (once-a-day) log correctly records the Oxidizing biociderelay duty cycle for the past 24 hours. Check this number to determine if biocide has been appliedor not. The 3D Bio data also logs the Ox relay on times accurately.

If the system has just been dosed with bio-reporter, it will take between 4-24 hours (depending onmicrobial activity) for the ratio to reach the control ratio set point. During this period, oxidizingbiocide will not be applied to the system. If, after 24 hours, oxidizing biocide has not been fed intothe system, please call the help-desk.

Do you have highly halogenated makeup water or other sources of oxidant feed into your system?




45. My tower is blue. Why?

As noted before, 3D TRASR Bio-Control will impart a slight blue color to the tower water. The effectwill be amplified as the depth of the water in the basin is increased. This is normal.

The tower can turn bluer than normal if any one of the following conditions is true:

• Bio-Reporter was accidentally overfed.• 3D TRASAR Bio-Control was initiated without waiting for the halogen levels in the tower to dissi-

pate to < 0.1 ppm.• 3D TRASAR Bio-Control was used in monitoring mode.• Oxidant was slug fed to the tower, intentionally or otherwise (e.g. leakage of bleach tank) without

turning 3D TRASAR Bio-Control off.• Make-up water is highly halogenated (see section above for details)• Recirculation of tower water is not optimal. That is, System Volume/Recirculation Rate >30.• Pellet feeder was left on manual on.

46. Bio-reporter concentrations aren’t approaching set-point. Why?

Please check the following:

• Are you out of bio-reporter product?• Is the tower water recirculating properly?• Is there adequate flow through the pellet feeder? Is the output from the pellet feeder being dis-

charged into the system (not to drain and not to a dead leg) in a well-mixed zone?• Is the Pellet feeder ball valve seat leaking?

47. Why is my Pellet Feeder drain line dripping blue water?

This is normal. Typically, you will notice a small amount of blue water dripping after a pellet feed.Water from the pressurized side of the ball valve will eventually reach the level of the drain line.Each time a tablet is dropped into the valve, a water volume equivalent to the pellet volume will bedisplaced and will exit the drain. This water will be blue due to a small amount of dissolved dye.The drain line should be plumbed to a drain. Water in the drain line is only drained by gravityso any hose or piping should never go above the exit of the drain line.

48. Do I have to adjust the Pellet Feeder ball valve for leakage?

Over time, especially in systems where a large number of tablets are being fed (> 50 per day), theseals may need to be adjusted. This is detailed in the manual. If the drain line is leaking when nopellets are being fed, or if large amounts of water are being expelled during a feed, the sealsshould be adjusted.




49. Why does my Pellet Feeder ball valve keep jamming with pellets?

This has happened in systems with no, low, or intermittent flow through the pellet feeder. The outletline from the pellet feeder should have no blockage. If the flow through the flow switch on thecontroller goes below 0.5 gpm, the system will register a no-flow alarm and pellets will stop beingfed. However, if the feeder is plumbed to a separate line that becomes plugged, or if the flow isthrottled to less than 5 gpm but greater than 0.5 gpm, the feeder will continue to feed. This mayresult in undissolved pellets below the ball valve. Please check the flow through the feeder prior tobeginning pellet feeding. Strainers before and in the pellet feeder may clog resulting in no-flow or lowflow conditions. A separate flow switch on the feeder line (with a 3 to 5 gpm cut-off) could be addedin series with the controller flow switch if intermittent flow is a problem.




Section 7: Communication and DataManagementThe overall 3D TRASAR program incorporates a number of software programs, and hardwaresystems to manage all of the information associated with the control of a cooling system. Thediagram below shows the flow and interaction of this data with the various components.

3D TRASAR Information Flow Diagram

7.1 3D TRASAR Optimizer

The 3D TRASAR Optimizer is a software program used to determine the right treatment programfor your cooling system. Information entered in the 3D TRASAR Optimizer can be transferred tothe 3D TRASAR Configurator to avoid duplicate data entry. Contact your Nalco representative forquestions about the 3D TRASAR Optimizer.

7.2 3D TRASAR Configurator

The 3D TRASAR Configurator is a software program used to configure the controller, establishremote communications, download data, update controller software, and change control methods.Contact your Nalco representative for questions about the 3D TRASAR Configurator.

7.3 3D TRASAR 5500 Controller

The 3D TRASAR 5500 Controller is the hub for data collection used for reports, graphs, and alarms.

7.4 SCADA Systems

SCADA systems can be used to monitor various parameters of the 3D TRASAR 5500 via 4-20masignals or RS-232/485 Modbus. Refer to Appendix E for details. Call 630-305-CHEM for assistancewith SCADA applications.




7.5 3D TRASAR WebThe 3D TRASAR Web is a convenient way to check the status of your 3D TRASAR application.Use the 3D TRASAR web to:

• View overall system performance.• Create user account profiles and assign them to specific controllers.• View alarm detail and enable alarms to be sent via e-mail.• Generate customized reports.• Download data to PC.

Downloaded data is compatible with Vantage V100. Data is sent to the 3D TRASAR Web everyhour from the 3D TRASAR controller via e-mail.

7.5.1 3D TRASAR Web Set Up

3D TRASAR Web is accessed through Nalco's website (www.nalco.com). You must have a NalcoExtranet Account to enter the site. Contact your Nalco representative for information on how toobtain an extranet account.

Log into www.nalco.com

Click Tools, then 3D TRASAR Web




7.5.1a Create/Edit Users

Create and edit user profiles in the personal information page. Select which e-mail addresses areto receive reports and or alarm messages.




7.5.1b Assign Controllers (Data Sources)

Assign users access to view data on the website.




7.5.1c Manage Controller (Data Source) Setup Information

The data source management screen provides a view of important controller information such asfacility location, serial number and communication settings.




7.5.2 3D TRASAR Web Data

Use the 3D TRASAR Web to review multiple systems performance or view specific operatingparameters for one controller.

The “PerformanceSummary” pageprovides a high-levelview of the state ofevery controllerassigned to a user.

The “Data Dashboard”displays detailedinformation for aspecific controller.




The “Basic Report” and“Advanced Report” pages allowusers to preview graphs anddownload data. Historical data iscaptured at 15 minute intervals.

7.5.3 3D TRASAR Web Reports

Reports can be emailed to thecustomer, exported to spread-sheet, or saved for future use(schedule reports to generateautomatically and email on aroutine basis.)




7.5.4 3D TRASAR Web Alarms

Alarm information generated by the 3D TRASAR controller will be sent in an email to the3D TRASAR web site where it will be forwarded to the specified user’s email address. Details onthe last 50 alarms will also be available on the 3D TRASAR Web, along with information onprobable causes and troubleshooting tips.




7.6 Vantage V100Vantage V100 is Nalco’s field data management software program. It allows users to trend opera-tional data, create Statistical Process Control graphs, and report corrective actions.

3D TRASAR files can be downloaded into Vantage V100 by either:

• the 3D TRASAR Configurator, or• the 3D TRASAR Web (using the Vantage V100 Download option in reports.)

Vantage V100 is launched from the Start Menu on your computer.

7.6.1 Import 3D TRASAR Data into Vantage V100

Follow the steps below to import 3D TRASAR data files into Vantage V100.

STEP 1- Click Database Operations

STEP 2- Click Import Data




Note: Use Vantage V100 for more permanent data storage. Transfered data will be ap-pended to the Vantage V100 database, and can be archived for long term storage.The 3D TRASAR controller will only store up to 65 days worth of data.

7.6.1 Import 3D TRASAR Data into Vantage V100 (con’t)

STEP 3 - Click Autoload 3D TRASAR Data File

STEP 4 - Follow the directions below to transfer data

• Select File to Load - click Browse to enter the directory location and name of the 3DTRASAR Data file to import.

• V100 Target Database - click Browse to select an existing Vantage V100 database(*.mdb) or to specify a directory location for a new Vantage V100 database file (*.mdb) tobe created. The database name will default to be the customer name and locationassigned in the controller.

• Select System - there may be multiple systems in one database, select the appropriatesystem for the data to be stored.

• Data Source Name - displays the Vantage V100 Data Source Name.• Click Transfer Data

!




7.6.2 Vantage V100 3D TRASAR EZ Reports

Reports can be generated from Vantage V100 by using the 3D TRASAR EZ Report.

STEP 1 – On the Reports form, choose the 3D TRASAR EZ Report then select the parameters andthe date (with optional statistics range) for data that you wish to include in your report.

STEP 2 – Select the graphs you wish to include in your report. Each row in the grid represents onegraph in the report.




7.6.2 Vantage V100 3D TRASAR EZ Reports (con’t)

STEP 3 – Click on Make to create the report in Excel. Save report template in Vantage V100 byclicking on the Batch Menu and saving to a Batch File in the database.




7.6.3 Vantage V100 3D TRASAR Spec Limits

Since 3D TRASAR specification limits are not included in the data download files, you will need tomanually enter the specification limits into Vantage V100 in order for them to show up in graphs andhave certain statistical values calculated. To do this, you will need to enter the specification limitsinto System Setup as shown below.

STEP 1 – Click System Setup

STEP 2 – Select the appropriate 3D TRASAR Data Source and double-click the measurement inthe grid.




7.6.3 Vantage V100 3D TRASAR Spec Limits (con’t)

STEP 3 – Type in the Specification Limits into the appropriate fields in the Edit Measurement form.Repeat with all 3D TRASAR measurements.




7.7 Nalco Global GatewayThe Nalco Global Gateway [P/N’s 060-NGG100.88 (US) and 060-NGG200.88 (International)] allows aquick, affordable way to obtain connectivity without the cost and trouble of a phone line installation.The Nalco Global Gateway communicates through the public Cellular/PCS network via the Ethernetport of the controller.

The Nalco Global Gateway provides advanced security including NAT, plus a built in firewall toprotect the controller from unauthorized access via the Internet. When properly installed and config-ured, the functionality of both the modem and local Ethernet port remain unchanged.

It is important to verify that the Nalco Global Gateway is right for your application before purchasing.Verifying the site for the Nalco Global Gateway is similar to finding a place in an industrial environ-ment to make a cell phone call. Even the best cell phone on the market is of little use without anadequate, interference free, stable signal. Use the guidelines below to determine signal availability inyour area.

• If you have access to a GSM/GPRS cell phone, and can make a web/data connection fromthe location where the controller will be installed, there is a very high probability that theNalco Global Gateway will work from that location.

• If you have a non-data GSM phone and can make a voice call from the location that thecontroller will be installed, there is a good probability that the Nalco Global Gateway will workfrom that location.

• If you cannot make a data connection or phone call, you will probably need the indoor/outdoor high gain antenna option (P/N 060-TR5284.88, cable not included*). This usuallyoccurs when the controller is installed in basements, metal buildings, or next to electricalequipment.

*Order cable separately by the following part numbers:

060-TR5284C100.88 100-foot Cable060-TR5284C25.88 25-foot Cable

Detailed installation and configuration instructions are included with the unit. Contact your localNalco Representative for ordering information.




Section 8: MaintenanceThe 3D TRASAR system was designed for high reliability utilizing state-of-the-art electronics,elaborate fail-safes and reliable components. Maintenance activities are generally required oncomponents which interact with the cooling system water directly (i.e. Probes, strainers and thelike). Performing periodic maintenance according to the schedule listed below will significantlyimprove reliability and minimize downtime.

8.1 Maintenance Schedule

Maintenance Task* 1 2 3 4 5 6 7 8 9 10 11 12

Fluorometer-clean flow cell X X X X X X X X X X X XFluorometer-calibrate X X X X X X X X X X X XFluorometer-check dessicant X X X X X X X X X X X XpH probe-clean/calibrate X X X X X X X X X X X XORP probe-clean/calibrate X X X X X X X X X X X XCorrosion probes-check X X X XConductivity probe-clean/calibrate X XStrainers-check/clean X X X X X X X X X X X XPellet feeder-check/refill Perform weeklyPellet feeder-clean Prior to refi llPellet Feeder Desiccant-check/replace Prior to refi llPellet feeder ball valve-tighten X X X XPellet feeder rotor shield-replace X*Assuming component is installed.

The Maintenance Value Package (P/N 060-TRMNKIT.88)provides a convenient supply of consumable parts and reagents.The MVP kit includes enough supply of the following to last forsix months of routine maintenance: 3D TRASAR CalibrationSolution 1L (2), pH 7.0 and 10.0 Calibration Solutions 1L (1 ofeach), ORP 200 mv and 600 mv Calibration Solutions 1L (1ofeach), Fluorometer Cleaning Solution 1L, Fluorometer ProbeBrush, 500 mL Plastic Beakers (3), 60 cc Plastic Syringes (3),Replacement pH Probe (1), Replacement ORP Probe (1), Re-placement Mild Steel and Copper NCM Probes (2 of each),Fluorometer Desiccant Canister, Fluorometer Desiccant Indica-tor.

P/N 060-TRMNKIT.88Maintenance Value Package




8.2 Clean Fluorometer Flow CellShut off both the inlet and outlet shut-off valves. Unscrew cap located on top of the flow switch,remove flow switch shuttle assembly.

Using the flow cell brush (P/N 500-P2817.88) provided with the Start-up kit (P/N 500-TSRKIT.88 or500-TSRKITSTR.88), gently push the brush down through the opening and scrub the full length ofthe flowswitch and fluorometer tube.

After cleaning is complete, check fluorometer calibration (Refer to Section 4.10.3).

8.3 Check/replace Fluorometer DesiccantThe fluorometer uses a desiccant canister and a color-coded humidity indicator to ensure that theoptics are not exposed to condensation.

Monthly, check the color of the desiccant indicator on the front of the 3D TRASAR fluorometer.

If the indicator is blue, desiccant does not need to be replaced. If the indicator is pink, unscrew thedesiccant cover from fluorometer. Replace both the indicator (P/N 060-TR5223.88) and desiccantcanister (P/N 060-TR5222.88).

8.4 Check Sensor CalibrationRefer to Section 4.10.3 to 4.10.6 for recommended calibration procedures. Calibrate as recom-mended by the maintenance schedule or if an error is detected.

Sensor Reason for Calibration # CalibrationPoints

Fluorometer Monthly, to verify accuracy 2 (blank andS0940)

pH

Monthly, to fine-tune calibration tocompensate for minor drifting. 1

After installation of new probe, orif probe readings become erraticdue to fouling/degradation.

2

ORP



2

Conductivity



2




8.5 Probe Replacement ScheduleTo minimize downtime, it is recommended to keep spare pH, ORP and Corrosion probes on hand.Part numbers can be found in Appendix C.

* Replace Conductivity probe only in the event of failure.

8.6 Cleaning Basket / Wye StrainerVisibly inspect the inlet basket strainers on both the pellet feeder and the 3D TRASAR system.Debris can be cleared by shutting off the inlet and outlet valves and unscrewing the clear bowl. Paycare not to lose the o-ring seal on the bowl assembly. The mesh screen can be removed, rinsed inclean water and then reinstalled.

The wye strainer assembly on the pellet feeder serves as a dissolving chamber for the bio-reporterpellets. If any residue from bio-reporter pellets remains in the strainer wear rubber gloves whenremoving and cleaning this strainer mesh.

Close the inlet and outlet valves and unscrew the plug at the end of the wye. Remove the mesh andrinse with clean water.

8.7 Pellet Feeder MaintenanceFor trouble free operation, the following maintenance instructions can be found in section 6.

• Check/Refill Pellet Feeder. Replace Pellet Feeder Desiccant. Please refer to section 6.5• Clean Pellet Feeder. Please refer to section 6.7• Tighten Pellet Feeder Valve Seat. Please refer to section 6.8.2• Replace Pellet Feeder Rotor Shield. Please refer to section 6.8.3

8.8 Check / Refill Pellet FeederCheck to see that the Pellet Feeder is at least ¼ full of bio-reporter pellets. If less than ¼ full add afull container of Pellets and replace the desiccant pack in the lid with the new one provided. Re-placement desiccants are included with each container of pellets. Refer to Section 6 for detailedpellet feeder maintenance.

Probe Replacement Frequency

pH Every six months or when probereadings become erratic.

ORP Every six months or when probereadings become erratic.

Corrosion Every sixty to ninety days or whenprobe readings become erratic.




Section 9: Troubleshooting

9.1 General Troubleshooting

Problem Possible Cause(s) SolutionController does not

power up whenpower switch is

flipped.

Controller is not plugged in. Plug in controller.

GFI or circuit breaker is tripped, or fuses blown. Reset breaker, or replace fuse.

Display does notshow pH, ORP,Conductivity, or

Temp.

These measurements do not appear inOperating Data if the probes are configured asNot Installed.

Configure these probes as Monitor Onlyor Controlling.

3D TRASAR 3500 controller requires upgradeto measure pH and ORP.

Purchase 3D TRASAR pH upgradeP/N 060-TR3211.88, or ORP upgradeP/N 060-TR3221.88

Display does notshow NalcoBio- Index.

This measurement does not appear in SystemPerformance unless 3D Bio-Control is selectedas the oxidizing biocide control method.

Select 3D Bio-Control as the oxidizingbiocide control method.

3D TRASAR Starter 3500 system requiresfluorometer upgrade to measure Nalco Bio-Index.

Purchase 3D TRASAR fluorometerupgrade P/N 060-TR3200.88

Display does notshow Nalco Scale

Index.

This measurement does not appear in SystemPerformance unless 3D Scale Control isselected as the blowdown control method.

Select 3D Scale Control as theblowdown control method.

3D TRASAR Starter 3500 system requiresfluorometer upgrade to measure Nalco ScaleIndex

Purchase 3D TRASAR fluorometerupgrade P/N 060-TR3200.88

One or more relaysare in failsafe mode.

There is an alarm condition affecting that relay. Check the active alarms and adjustsettings if needed.

One or more relaysare not operating.

The jumper supplying power to the contactclosure has been removed. In this case, thedisplay will still indicate that the relay is on.

Check to be sure the relay powerjumper is connected properly.

The product level is above (or below forblowdown and caustic control) the set point andcontrol range.

The relay does not need to be on.

There is a No Flow Alarm, during which therelays may not operate. In this case, thedisplay will still indicate that the relay is off.

Check the active alarms and increaseflow i f needed.

There is an Interlock Alarm, during which therelays will not operate. In this case, the displaywill indicate that the relay i s off.

Check the active alarms and be surethe Interlock cable is connectedproperly (or jumper, if Interlock is notused).

A calibration is underway, during which therelays will not operate.

Complete or cancel the calibrationprocedure.

The affected relay(s) is in Manual Off mode. Inthis case, the display will indicate that the relayis in Manual Off mode.

Using the keypad Menu i tem ManualRelay Control, return the relay to Automode.




Problem Possible Cause(s) SolutionThe pellet feeder isnot feeding pellets.

The pellet feeder is not properly connected tothe controller (power and/or communication).The green light on the feeder will be off if thepower wires are not properly connected. Analarm will be listed in the activ e alarms on thedisplay if the communication wi res are notproperly connected.

Check all connecti ons and replacecable if damaged. Ensure powerswitch is in "ON" position.

The controller is not correctly configured tooperate the pellet feeder.

Check the configuration to be sure that(a) 3D Bio-Control is selected as theoxidizing biocide control method, and(b) a solid product is selected as thebio-reporter.

A pellet feeder error i s active, during whichpellets will not be fed. The green light on thefeeder will be blinking if it is an error state.

Check the active alarms and resolvethe alarm condition(s) as needed.

The first 3D Bio-Control decision interval hasnot yet been reached.

On power up, the first pellet feedhappens at the end of the fi rst decisioninterval, which may take up to 25minutes.

The bio-reporter level is above the set poi ntand control range.

No pellets are required.

There is a No Flow Alarm, during which pelletswill not be fed. In this case, the display will stillindicate that the relay is off.

Check the active alarms and i ncreaseflow if needed.

There is an Interlock Alarm, during which pelletswill not be fed. In this case, the display willindicate that the relay is off.

Check the active alarms and be surethe Interlock cable is connectedproperly (or jumper, i f Interlock is notused).

A calibration is underway, during which pelletswill not be fed.

Complete or cancel the calibrationprocedure.

The bio-reporter is in Manual Off mode. Using the keypad Menu i tem ManualRelay Control, return the bi o-reporter toAuto mode.

The oxidizing biocide is in a failsafe mode dueto an alarm conditi on.

Check the active alarms and resolvethe alarm condition(s) as needed.




Problem Possible Cause(s) SolutionThe Configurator

cannotcommunicate with

the controller usinga direct connection.

The Ethernet crossover cable is not connectedsecurely to the controller and/or PC Ethernetports.

Check all connecti ons and replace thecable if damaged.

A standard network cable is being used insteadof a crossover network cable.

Replace the network cable wi th acrossover network cable.

The PC network adapter (Local AreaConnection adapter) is not configured properly.

The default network settings for thecontroller direct connection are IPAddress 169.254.1.2 Subnet255.255.0.0, and Gateway 169.254.14.Your PC Ethernet adapter should beconfigured with the values IP Address169.254.1.***, Subnet 255.255.0.0, andGateway 169.254.14, where ***= anynumber between 3 and 255. This canbe changed in Start/Network and DialupConnections/Local AreaConnection/Properties/InternetProtocol/Properties (see manual).

The IP Address being used by the Configuratoris incorrect.

The default IP address for the controllerdirect connection is 169.254.1.2. In theConfigurator's Connection Window,click on Advanced and make sure thisis the IP address being used in theconnection attempt.

The proxy server settings are incorrect. Open Internet Explorer. Go toTools/Internet Options and cli ck on theConnections tab. Cli ck the LANSettings button, and uncheck "UseProxy Server". Be sure to return thissetting when fi nished if required forother applications.




Problem Possible Cause(s) SolutionA connection

cannot beestablished to the

controller viamodem.

The analog phone cable is not connectedsecurely to the controller, PC, and/or wall jacks.

Check all connecti ons and replace thephone line if damaged.

The phone line is not functional for dial in. Try d ialing the number using a landlineor cell phone to see if the controlleranswers. If i t does not, connect ananalog phone to the line in place of thecontroller and dial the number againusing the same landline or cell phone.The phone should ring if the call iscoming through.

The phone line is in use. This can happen if the controller isdialing out to send an email or ifanother party is connected to thecontroller via modem. Try again later.

The phone number used by the PC is incorrect. Check the phone number you aredialing.

With a gatewayconnection

established, theConfigurator

cannotcommunicate with

the controller.

The IP Address being used by the Configuratoris incorrect.

The default IP address for the gatewayconnection is 192.168.1.2. In theConfigurator's Connection Window,click on Advanced and make sure thisis the IP address being used in theconnection attempt.

There is >0.5 gpmflow through theflow switch, but aNo Flow Alarm is

active.

The flow switch is not connected properly. Remove the flow switch wires and shortthe + and - terminals on the controllerusing a wire jumper. The No Flowindicator on the display and the NoFlow Alarm should clear. Reconnectthe flow switch wires.

The flow switch is not functi onal. Stop the flow, remove the flow swi tchand clear any debris lodged inside. Ifthis does not help, replace the flowswitch.

There is <0.5 gpmflow through the

flow switch, but theNo Flow Alarm is

not active.

The flow switch is not connected properly. Check the flow switch connecti ons inthe controller.

The flow switch is not functi onal. Replace the flow switch.The 10-minute delay period has not passed. The flow signal must b e absent for 10

min before the alarm wi ll activate.The flow is near the 0.5 gpm rati ng of the flowswitch, resulting in i ntermittent flow/no flowindications.

This will cause the 10-minute delaytimer to reset each time flow isdetected, preventing the alarm.Increase the flow.




Problem Possible Cause(s) SolutionAlarm emails are

not being received.Analog phone line is not connected. Check all connections and replace the

phone line if damaged.Phone line is not functi onal for dialing out. Enter cell phone number as the ISP

access number. Remove the systeminterlock jumper. Your cell phone wi llring if the phone line is functional.

Controller is not confi gured to send alarmemails.

Check the Alarm Settings to be surethe email checkboxes are checked.

Email address is misspelled/incorrect. Recheck email address for spelling.The alarm email address must [email protected].

ISP access phone number is entered in wrongformat.

Check the phone number to ensure thatit is entered exactly as the controller wi lldial it, including prefixes (8 or 9, 1+areacode). A comma ',' may be used as apause.

ISP settings are incorrect. Check the following settings providedby your Nalco Rep: username,password, access phone number.

Controller datacannot be viewed

at 3D TRASARWeb.

Analog phone line is not connected. Check all connections and replace thephone line if damaged.

Phone line is not functi onal for dialing out. Enter cell phone number as the ISPaccess number. Remove the systeminterlock jumper. Your cell phone wi llring if the phone line is functional.

Controller is not confi gured to send dataemails.

Check the Email Settings to be sure theSend Data Email parameter is set toYes.

ISP access phone number is entered in wrongformat.

Check the phone number to ensure thatit is entered exactly as the controller wi lldial it, including prefixes (8 or 9, 1+areacode). A comma ',' may be used as apause.

ISP settings are incorrect. Check the following settings providedby your Nalco Rep: username,password, access phone number.

Controller has not been registered at 3DTRASAR Web.

Call 630-305-CHEM.

Product levels(ppm) are displayed

as dashes.

A Fluorometer Communication Error is active. Tighten the connector on the fluorometerprobe and check the fluorometer cableconnections in the controller. Replacecable if damaged. Check desiccant formoisture indication.




Problem Possible Cause(s) SolutionConductivity

(uS/cm) isdisplayed as

dashes.

A Conductivity Sensor Error is active. Check the conductivity probeconnections in the controller. Replaceprobe if all connections are seatedtightly and the error persi sts after poweroff/on.

A Temperature Sensor Error is active. Check the conductivity connections inthe controller. S ince the RTD isembedded in the conductivity probe,replace the conductivity probe if allconnections are seated tightly and theerror persists after power off/on.

Value of -999 islogged in datalog.

The measurement is invalid. A sensor error or some other conditi onis present, which is causing themeasurement to be invalid. Check theactive alarm list on the display. ForBio-Index, -999 is logged for the first 2hours after powerup, which is normaland requires no resolution. For ScaleIndex, this will occur after the learningperiod and immediately after powercycle.

Confusing numbersare logged in the

datalog in the relaystatus fields.

The numbers correspond to the relay state. The relay states are :129 Auto on128 Auto off65 Manual on64 Manual off33 Failsafe on32 Failsafe off16 Forced off9 Flow failsafe on8 Flow failsafe off0 Not controlled




AlarmType Indication Probable Cause Corrective Action

TRASAR, Tagged Polymer, ORP, pH (Caustic Control)

HighMeasurementexceeds HighAlarm threshold

1) Sensor probe is out of calibration.2) High Alarm threshold set too low.3) Chemical feed rate too high causing "overshoot".4) Chemical pump siphoning causing overfeed.5) Process leak or other contaminant in system.

1) Check calibration and recalibrate if needed.2) Readjust alarm threshold.3) Reduce chemical feed rate.4) Elminate condition causing siphoning.5) Confirm (with other data) and eliminate source.

LowMeasurementbelow LowAlarm threshold

1) Sensor probe is out of calibration.2) Low Alarm threshold set too high.3) Chemical feed rate too low or interrupted.4) Product container empty.5) Process leak or other contaminant in system.

1) Check calibration and recalibrate if needed.2) Readjust alarm threshold.3) Check feed line or increase chemical feed rate.4) Refill/replace product inventory.5) Confirm (with other data) and eliminate source.

pH (Acid Control)


1) Sensor probe is out of calibration.2) High Alarm threshold set too low.3) Chemical feed rate too low or interrupted.4) Product container empty.5) Process leak or other contaminant in system.

1) Check calibration and recalibrate if needed.2) Readjust alarm threshold.3) Check feed line or increase chemical feed rate.4) Refill/replace product inventory.5) Confirm (with other data) and eliminate source.


1) Sensor probe is out of calibration.2) Low Alarm threshold set too high.3) Chemical feed rate too high causing "overshoot".4) Chemical pump siphoning causing overfeed.5) Process leak or other contaminant in system.

1) Check calibration and recalibrate if needed.2) Readjust alarm threshold.3) Reduce chemical feed rate.4) Eliminate condition causing siphoning.5) Confirm (with other data) and eliminate source.

Conductivity


1) Sensor probe is out of calibration.2) High Alarm threshold set too low.3) Blowdown valve throttled too low or plugged.4) Process leak or other contaminant in sy stem.

1) Check calibration and recalibrate if necessary.2) Readjust alarm threshold.3) Check blowdown valve for proper operation.4) Confirm (with other data) and eliminate source.


1) Sensor probe is out of calibration.2) Low Alarm threshold set too high.3) Blowdown valve throttled too high or stuck open.4) Process leak or other contaminant in sy stem.

1) Check calibration and recalibrate if necessary.2) Readjust alarm threshold.3) Check blowdown valve for proper operation.4) Confirm (with other data) and eliminate source.

Temperature


1) RTD probe is out of calibration2) High Alarm threshold set too low.3) Cooling system problem. Note: PVC piping is ratedfor 140 F max.

1) Verify temperature using a thermometer.2) Readjust alarm threshold.3) Diagnose and resolve cause of excessive bulkwater temperature.


1) RTD probe is out of calibration.2) Low Alarm threshold set too high.3) Cooling system problem. Note: Freezing will burstpiping.

1) Verify temperature using a thermometer.2 ) Readjust alarm threshold.3) Diagnose and resolve cause of low bulk watertemperature.

9.2 Alarm Screen TroubleshootingNotes:1) Upon initial start-up measured levels may be low causing nuisance alarms. To prevent nuisance

alarms refer to the start-up procedures to select system Start-up alarm suppression (Section4.10.11).

2) To reset an alarm it is necessary to eliminate the alarm condition by either.• placing the control mode in “Off” temporarily• adjusting the variable within the alarm limits• or changing the alarm limits.





[XX] Corrosion ([XX] = Probe metallurgy)

HighMesurementexceeds HighAlarm threshold

1) Insufficient flow rate past probe.2) High Alarm threshold set too low.3) Corrosion treatment program needs adjustment.

1) Verify minimum of 5 gpm flow is present.2) Readjust alarm threshold.3) Consult your Nalco Representative.

Cell Fouling

HighMesurementexceeds HighAlarm threshold

1) Fluorometer flow cell is fouled.

2) High Alarm threshold set too low.

1) Clean flow cell with supplied brush and cleani ngsolution. Recalibrate as needed.2) Readjust alarm threshold.

Control Relays (TRASAR, Tagged Polymer, Bio-reporter, Oxidizing Biocide, Blowdown, pH)

RelayTimeout

Relay has beenactivated forlonger than relaytimeout limit

1) Tank empty/pump lost prime/faulty pump or valve.

2) Relay Timeout Limit set too low.3) Feed/bleed rate too low for demand.

1) Check tank/pump/valve/feed line. Repair asneeded.2) Readjust alarm threshold.3) Increase feed/bleed rate.

General Sensors

SensorError detectedwith indicatedsensor probe.

1) Wiring or other connecti on is loose.

2) Sensor probe failure.

1) Retighten wires or other connections. Be sure wireinsulation is not preventing good contact.2) Replace probe. Probe replacement may beincluded in purchased service plan.

SampleFlowLow

Insufficient waterflow throughfluorometer cell

1) Flow rate too low or back pressure too high. Flowswitch requires 0.5 gpm.2) Flow switch fouled.3) Flow switch wiring is loose or not making goodconnection.

1) Investigate and correct.

2) Clean flow switch.3) Replace flow switch

InterlockAbsent

The interlockinput has beendeactivated

1) The interlocking device is not active.2) Interlock is not used and jumper is not in place.3) Interlock wiring is loose or not making goodconnection.

1) Check. This may be expected operation.2) Replace jumper (refer to wiring diagram forlocation and di rections.3) Check and correct wiring connections.

Fluor.Comm.

Controller isunable tocommunicatewith thefluorometer

1) Cable connector on Fluorometer is loose.

2) Wiring from fluorometer is loose or miswired incontroller.3) Component failure.

1) Disconnect and inspect for bent pins or signs ofdamage, then reconnect.2) Check and correct if needed (see wiring diagramfor details).3) Reboot system by momentarily cycling power toinitiate recovery. If unsuccessful contact Help D esk at630-305-CHEM for assistance.

SensorBoardComm.

The sensorboard is notcommunicatingwith thecontroller

1) Sensor board is loose preventing good con nection.

2) Component failure.

1) Gently press on "Red" circuit board insidecontroller to ensure snug fi t.2) Reboot sytem by momentarily cycling power toinitiate recovery. If unsuccessful contact Help D esk at630-305-CHEM for assistance.

3D Bio Control

PelletFeederComm.

Controller is notcommunicatingwith PelletFeeder

1) Pellet Feeder cable loose or connections not madecorrectly.2) Pellet Feeder power switch is not turned on.3) Component failure.

1) Disconnect and inspect both Pellet Feederconnector and wi ring in controller, then reconnect.2) Turn power switch on.3) Reboot system by momentarily cycling power toinitiate recovery. If unsuccessful contact Help D esk at630-305-CHEM for assistance.

PelletFeederBusy

The PelletFeeder has notcompleted apellet feedbefore the nextpellet is calledfor

1) Pellet supply is low. 1) Check and fill Pellet Feeder, or redistributeremaining pellets.

PelletSupplyLow

The PelletFeeder has notfed a pelletwhen called for

1) Pellet Feeder is empty. 1) Check and refill Pellet Feeder.

PelletSensorError

The PelletSensor LED isblocked.

1) The clear pellet feed tube is blocked or dirtypreventing light transmission.

1) Check and clean feed tube using supplied brush.





Ball ValveError

Pellet Feeder ballvalve not rotati ng

1) Ball valve separated from motor shaft. 1) Contact Help Desk at 630-305-CHEM forassistance.

Ball ValveCurrentHigh

Pellet Feeder ballvalve drawing toomuch current

1) The Pellet Feeder ball valve is jammed.

2) The Pellet Feeder valve seats have been overtightened.

1) Disassemble ball valve, clear jam.2) Adjust valve seats (see Pellet FeederMaintenance Section 6.8).

PelletRotorCurrentHigh

Pellet Feederrotor drawing toomuch current

1) The Pellet Feeder rotor is jammed. 1) Remove pellets from hopper and clear jam. Rotorshield may be worn and require replacement (seePellet Feeder Maintenance Section 6.8).

Bio-IndexHigh

Microbio activityis not undercontrol

1) Oxidizing Biocide tank empty or pump lost pri me.2) Increased biocide demand detected, and controlleris responding appropriately.3) Biocide program requirements have changed.

1) Check and refi ll tank or reprime pump.2) No action required. If this persists for 3 days,contact Help Desk at 630-305-CHEM for assistan ce.3) Reassess biocide program with your local NalcoRepresentative.

BiocidePumpRate High

Biocide feed rateis too high tocontrol accurately

1) Biocide pump rep/stroke are set too high , or pumpis too large for system.

1) Adjust feed rate downward or replace with a lowercapacity pump. After downward adjustment, reset 3DBio-Control by changing the Oxi dizing Biocide ControlMethod first to None (reboot controler) then back to3D Bio-Control (reboot controller). Otherwise,persistant Bio Index High Alarms may occur.

BiocidePumpRate Low

Biocide feed rateis too low tocontrol microbioactivity effectively

1) Biocide pump/stroke are set too low, or pump istoo small for system.

1) Adjust feed rate upward or replace with a h ighercapacity pump.

Bio-productHigh

Bioproduct levelexceeds alarmthreshold

1) Biocide feed unable to meet microbio demand. 1) Manually feed Oxi dizing Biocide into system untilalarm clears.

Bio-productHighFailsafe

Bioproduct levelexceeds alarmthreshold for anextended period,and oxidizingbiocide entersfailsafe mode

1) Same causes as Bioproduct High. 1) Same. Alarm must be cleared at the di splay.

Bio-productLow

Bioproduct levelbelow alarmthreshold

1) Bio-reporter feed is insufficient.2) Excessive Oxidizing Biocide degrading bioreporter.Source of Oxidizing Biocide may be makeup, manualfeed, process or other leak, or oversi zed biocidepump.

1) Check bio-reporter pump or pellet feeder, or verifyadequate bio-reporter inventory.

Bio-productLowFailsafe

Bioproduct levelbelow alarmthreshold for anextended period,and oxidizingbiocide entersfailsafe mode

1) Same causes as Bioproduct Low. Same. Alarm must be cleared at the display.

Bio-reporterHigh

Bio-reporter levelexceeds alarmthreshold

1) Too many Quick Dose pouches were added atstart-up.2) Bio-reporter was overfed by manual control ormalfunctioning pump.3) If in conjunction wi th Bioproduct High, biocide feedunable to meet microbi o demand.

1) Wait for level to come down. Additi onal bio-reporter will not be fed.2) Wait for level to come down. Additi onal bio-reporter will not be fed.3) Manually feed Oxi dizing Biocide into system untilalarm clears.

Bio-reporterHighFailsafe

Bio-reporter levelexceeds alarmthreshold for anextended period,and oxidizingbiocide entersfailsafe mode.

1) Same causes as Bioreporter High. 1) Same. Alarm must be cleared at the di splay.





Bio-reporterLow

Bio-reporterlevel belowcontrol threshold

1) Pellet Feeder unable to bring bio-reporter level upto setpoint in a reasonable time.2) Excessive Oxidizing Biocide degrading bio-reporter. Source of Oxidizing Biocide may be makeup,manual feed, process or other leak, or oversizedbiocide pump.

1) Add additional Quick Dose pouch and wai t formixing. If alarm persists, repeat. Check bio-reporterlevel at controller di splay in Information>DiagnosticData>Fluorometer Data (Rz).2) Remove source of excess biocide.

Bio-reporterLowFailsafe

Bio-reporterlevel belowcontrol thresholdfor an extendedperiod, andoxidizingbiocide entersfailsafe mode.

1) Same causes as Bio-reporter Low. 1) Same. Alarm must be cleared at the display.

Bio-DataNoiseHigh

Excessive noisein data

1) Bubbles in flow cell.

2) Bioreporter feed point is too close to TRASAR5000.

1) Reduce flow rate or remove source of entrained air(i.e., air-locked pump).2) Change feed point to a location furtherdownstream of the intake.

Bio-DataNoiseHighFailsafe

Excessive noisein data for anextendedperiod, andoxidizingbiocide hasentered failsafemode.

1) Same causes as Bio Data Noise High. 1) Same. Alarm must be cleared at the display.

SlugRecoveryFailure

After a Slug theORP did notreturn to pre-slugvalues within thetime limit.

1) ORP probe is fouled and needs calibration2) The system takes a long ti me to dissipate theOxidizing biocide fed during the slug.3) Too much Oxidizing biocide was applied during theslug.

1) Clean and calibrate ORP probe.2) In the Slug Feed screen <3D BioControl RecoverySettings> <Show Advanced Recovery Options>Increase the time limit.3)Decrease the oxidizing Biocide applied bychanging the ORP setpoint for the Oxidant slug. If theslug is applied by timer control, decrease the time forthe Oxidant feed. If TB 960 is the Oxidizing biocide,decrease the weight of the Biocide applied per feed.

Ox ShockFailed

The ORP did notincrease theminimum valueduring a slug

1) The Oxidant pump is airlocked or failed to apply thebiocide.2) The recirculati on time in the tower is long and theapplied Biocide is not seen by the ORP probe withinthe time limit.3) The mi nimum ORP rise setting is too large.4) The ORP probe is fouled/miscalibrated.

1) Fix pump or feeder.2) Increase the ORP Rise Limit Time in the <SlugOxidizing Biocide> <Slug Feed Settings.>3) Decrease the min ORP rise <Slug OxidizingBiocide> <Slug Feed Settings>4) Calibrate/clean probe.

OxidantRelayTimeout

Relay has beenactivated forlonger than relaytimeout limit.In 3D Bio-Shockmode theBioReporter iscalling for toofrequentoxidizingbiocide feed

1) Tank empty/Pump lost prime/faulty pump or valve.2) Relay timeout li mit set too low.3) Pump rate is too low for demand.4) The Oxidizing biocide is not being applied.5) The time limi t between feeds is set too long for thesystem.

1) Check tank/pump/valve/feed line. Repair asneeded.2) Readjust alarm threshold.3) Increase pump rate.4) Check the pump/feeder.5) Decrease the minimum time between feeds.

BioReporterRelayTimeout

Relay has beenactivated forlonger than relaytimeout limit

1) Tank empty/Pump lost prime/faulty pump or valve.2) Relay timeout li mit set too low.3) Pump rate is too low for demand.

1) Check tank/pump/valve/feed line. Repair asneeded.2) Readjust alarm threshold.3) Increase pump rate.

3D Scale Control

SystemStressHigh

Rate of PolymerConsumption ishigh

1) System upset such as a hi gh pH event, processleak, high heat load event, etc.2) If coincident with or subsequent to a Conducti vityadjustment MIN alarm, the controller is unable torespond to the high stress condition.

1) Conductivity setpoint has been decreasedautomatically to induce blowdown.2) Enter lower conductivity setpoint and relearnsystem stress.

Cond. Adj.MAX

ConductivitySetpointadjusted to themaximum

1) System stress is low compared to learned stress. 1) If higher cycles are required, enter higherconductivity setpoint and relearn system stress.Otherwise, no acti on is required.

Cond.Adj.MIN

ConductivitySetpointadjusted to theminimum

1) System stress is high compared to learned stress. 1) If lower cycles are required, enter lowerconductivity setpoint and relearn system stress.Otherwise, no acti on is required.



Technical Help(630) 305-CHEM

A-1

Appendix A: Specifications

Feed and Control MethodsChemical Feed - InhibitorChemical feed based on manual, timer or slave option. On/off control based on TRASAR, TaggedPolymer or 3D TRASAR Scale Control.Chemical Feed - Oxidizing BiocideTimer, manual, or slug based feed with pre-bleed and lockout capability. On/off control based onORP or 3D TRASAR Bio-Control.Chemical Feed - Non-oxidizing BiocideTimer or manual based feed with pre-bleed and lockout capability.pHAcid or caustic on/off, based on flat surface, double junction 2-wire pH probe input, range 0-14 pH.ORPOxidizing biocide feed based on flat surface, double junction ORP probe input, range – 1000 to+1000 mv.BlowdownOn/off based on Conductivity (range 500-99,999 uS/cm) or 3D TRASAR Scale Control.Multipurpose timersTimer based feed on any available relay (no pre-bleed or lockout).

Monitoring FunctionsCorrosion MonitoringContinuous on-line measuring (with Auto-Probe Recognition) mild steel and copper (standard)range 0 to 99 mils per year.Additional Monitored Variables• Cell Fouling• Turbidity• Temperature• Background Fluorescence• Relay Status• Pulse counter with water meterAdditional Calculated Variables• Holding Time Index• System Volume• Blowdown Rate• Heat Rejection (Btus)• Makeup Water Rate• Recirculation Rate• Pump Duty• Product Usage




A-2

SpecificationsPlumbing RequirementsControl Panel 3/4" FNPT inlet, (2) outlets (1) 3/4" FNPT & (1) 1/2" FNPT (once inlet and outlet ballvalves are installed.) Total flow required 5 gpm. Outlet piping must be run separately.Pellet Feeder 3/4" FNPT inlet, 3/4" FNPT outlet, 5 gpm required, 20 psig differential across bothunits.Electrical85 to 250 VAC @ 20 amps serviceSample requirementsminimum Conductivity of 10 uS/cm required for Corrosion measurement.Inputs• (2) unassigned 4-20 mAunpowered non-isolated inputs (used for logging and alarm level call out.)• (1) Flow input (contact closure)• (1) Interlock input (contact closure)• (2) Spare digital inputs (contact closure) used to log input states or low frequency water meter

counts• Modbus RS-232 or RS-485 (choose one) RTU SCADAportOutputs• (7) control relay outputs rated 2.5 amps each (larger loads require external motor starters)• (8) 4-20 mApowered non-isolated outputsAlarms• (1) Alarm output relay (rated 1.0 amp max unpowered)• E-mail notification of alarm conditions (via modem to ISP or Customer’s LAN-based mail server.)EnclosureNema 4XAmbient temperature40-120 °F (4-50 °C)Process water temperature40-120 °F (4-50 °C)Relative Humidity0-95% non-condensingMaximum water pressure90 psiDisplay/KeypadNumeric keypad plus specialty keys, graphical display with plotting functionsSecurityPassword protected (user assignable)Data managementAll variables are data logged in spreadsheet format




A-3

Communications• Ethernet port for direct PC connection• Built-in modem for direct remote connection or access to 3D TRASAR web via Internet (requires

ISP)• Optional Nalco Global Gateway with monthly service package.ApprovalsUL, CUL, CESoftware• 3D TRASAR configurator for system configuration and data transfer• Optional Vantage® 100 SPC software for comprehensive data management and analysis.

Weights and Dimensions of 3D TRASAR Models

3D TRASARStarter P/N

3D TRASARP/N Description

EstimatedEquipmentWeight (lbs)

EstimatedShipping

Weight (lbs)

Dimensions(L x W x H)

060-TR3500.88 060-TR5500.88 Wall Mount, small backboard 45 90 33 x 6 1/4 x 33"060-TR3501.88 060-TR5501.88 Frame Mount, small backboard 140 195 33 x 28 x 66"060-TR3510.88 060-TR5510.88 Wall Mount with Junction Box 90 160 33 x 6 1/4 x 57"060-TR3511.88 060-TR5511.88 Frame Mount with Junction Box 155 225 33 x 28 x 66"060-TR3520.88 060-TR5520.88 Enclosed Wall Mount with Junction Box 195 270 36 7/8 x 13 7/8 x 62 5/8"

060-TR3522.88 060-TR5522.88 Enclosed Wall Mount with Junction Boxand pre-installed Nalco Global Gateway 200 275 36 7/8 x 13 7/8 x 62 5/8"

060-TR3521.88 060-TR5521.88 Enclosed Frame Mount with Junction Box 250 445 36 7/8 x 28 x 65 3/4"

060-TR3523.88 060-TR5523.88 Enclosed Frame Mount with Junction Boxand pre-installed Nalco Global Gateway 255 450 36 7/8 x 28 x 65 3/4"

060-TR3530.88 060-TR5530.88 Air Purged Wall Mount with Junction Box 200 280 36 7/8 x 13 7/8 x 62 5/8"

060-TR3532.88 060-TR5532.88 Air Purged Wall Mount with Junction Boxand pre-installed Nalco Global Gateway 205 285 36 7/8 x 13 7/8 x 62 5/8"

060-TR3531.88 060-TR5531.88 Air Purged Frame Mount with Junction Box 260 470 36 7/8 x 28 x 65 3/4"

060-TR3533.88 060-TR5533.88 Air Purged Frame Mount with Junction Boxand pre-installed Nalco Global Gateway 265 475 36 7/8 x 28 x 65 3/4"




B-1

Appendix B: Drawings

Please see the attached pages for drawings of the 3D TRASAR models. Please note that drawingsshow all probes installed. pH, ORP and Corrosion probes are available accessories for the3D TRASAR Starter (3500 series) models.

Drawings of the Pellet Feeder Plumbing Assembly and High Pressure Water Reinjection system arealso included.

Model Number Description Page #

060-TR3500.88060-TR5500.88 Wall Mount, Small Backboard B-2

060-TR3501.88060-TR5501.88 Frame Mount, Small Backboard B-3

060-TR3510.88060-TR5510.88 Wall Mount with Junction Box B-4

060-TR3511.88060-TR5511.88 Frame Mount with Junction Box B-5

060-TR3520.88060-TR3522.88060-TR5520.88060-TR5522.88

Enclosed Wall Mount with Junction Box B-6

060-TR3521.88060-TR3523.88060-TR5521.88060-TR5523.88

Enclosed Frame Mount wi th Junction Box B-7

060-TR3530.88060-TR3532.88060-TR5530.88060-TR5532.88

Air Purged Wall Mount with Junction Box B-8

060-TR3531.88060-TR3533.88060-TR5531.88060-TR5533.88

Air Purged Frame Mount wi th Junction Box B-9

060-TR5120.88 Pellet Feeder B-10060-TR5540.88 High Pressure Water Reinjection System B-11

PRO

PIET

AR

Y A

ND

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NFI

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3

0H

ELP

78

9

45

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mcampbell

Text Box

Model #s 060-TR3500.88, 060-TR5500.88 Wall Mount, Small Backboard B-2

PRO

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65

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1M

ENU

mcampbell

Text Box

Model #s 060-TR3501.88, 060-TR5501.88 Frame Mount, Small Backboard B-3

PRO

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mcampbell

Text Box

Model #s 060-TR3510.88, 060-TR5510.88 Wall Mount with Junction Box B-4

PRO

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U4 1

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mcampbell

Text Box

Model #s 060-TR3511.88, 060-TR5511.88 Frame Mount with Junction Box B-5

SA

MP

LEIN

LET

OU

TLET

SA

MP

LE

OU

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FLU

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mcampbell

Text Box

Model #s 060-TR3520.88, 060-TR5520.88 Enclosed Wall Mount with Junction Box 060-TR3522.88, 060-TR5522.88 Enclosed Wall Mount with Junction Box and pre-installed Nalco Global Gateway B-6

SA

MP

LEIN

LET

OU

TLET

SA

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LE

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TLET

FLU

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ETER

PRO

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U4 1

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98

Back

mcampbell

Text Box

Model #s 060-TR3521.88, 060-TR5521.88 Enclosed Frame Mount with Junction Box 060-TR3523.88, 060-TR5523.88 Enclosed Frame Mount with Junction Box and pre-installed Nalco Global Gateway B-7

SA

MP

LEIN

LET

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TLET

SA

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FLU

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ETER

PRO

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INS

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NT

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Min

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mcampbell

Text Box

Model #s 060-TR3530.88, 060-TR5530.88 Air Purged Wall Mount with Junction Box 060-TR3532.88, 060-TR5532.88 Air Purged Wall Mount with Junction Box and pre-installed Nalco Global Gateway B-8

SA

MP

LEIN

LET

OU

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SA

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LE

OU

TLET

FLU

OR

OM

ETER

PRO

PIET

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U4 1

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Alar

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Info

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Actio

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98

Back

INS

TRU

ME

NT

AIR

Min

iPur

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mcampbell

Text Box

Model #s 060-TR3531.88, 060-TR5531.88 Air Purged Frame Mount with Junction Box 060-TR3533.88, 060-TR5533.88 Air Purged Frame Mount with Junction Box and pre-installed Nalco Global Gateway B-9

Model #060-TR5120.88Pellet Feeder Plumbing AssemblyB-10

Model 060-TR5540.88High Pressure Water Reinjection SystemB-11




C-1

Appendix C: Replacement Parts/AccessoriesParts / Hardware Models

Parts / Bio-Reporter Feed Options

3D TRASARStarter Model

3D TRASARModel Description

060-TR3500.88 060-TR5500.88 Wall Mount, Small Backboard

060-TR3501.88 060-TR5501.88 Frame Mount, Small Backboard

060-TR3510.88 060-TR5510.88 Wall Mount wi th Junction Box

060-TR3511.88 060-TR5511.88 Frame Mount with Junction Box

060-TR3520.88 060-TR5520.88 Enclosed Wall Mount with Junction Box

060-TR3522.88 060-TR5522.88 Enclosed Wall Mount with Junction Box andPre-Installed Wireless Gateway

060-TR3521.88 060-TR5521.88 Enclosed Frame Mount wi th Junction Box

060-TR3523.88 060-TR5523.88 Enclosed Frame Mount wi th Junction Box andPre-Installed Wireless Gateway

060-TR3530.88 060-TR5530.88 Air Purged Wall Mount with Junction Box

060-TR3532.88 060-TR5532.88 Air Purged Wall Mount with Junction Box andPre-Installed Wireless Gateway

060-TR3531.88 060-TR5531.88 Air Purged Frame Mount wi th Junction Box

060-TR3533.88 060-TR5533.88 Air Purged Frame Mount wi th Junction Box andPre-Installed Wireless Gateway

N/A 060-TR5515.88 Wall Mount for Hi gh Fouling Applications

N/A 060-TR5516.88 Frame Mount for High Fouling Applications

N/A 060-TR5525.88 Enclosed Wall Mount for Hi gh Fouling Applications

N/A 060-TR5526.88 Enclosed Frame Mount for High Fouling Applications

Part Number Description

060-TR5120.88 Bio-reporter, Pellet Feeder Assembly, for system sizes > 12,000 gallons141-PJ4035.88 Bio-reporter, Liquid Feed pump, for system sizes 3,000 to 12,000 gallons6008505 Bio-reporter, Liquid Feed pump, for system sizes up to 3,000 gallons




C-2

Replacement Parts / Probes

Parts / High Fouling Applications


460-S0340.75 Fluorometer Cleaning Solution, 5 gallons (order separately)001-H04066.88 Containment basin, 10 gallons, PE121-P01152.88 Automated Fluorometer Cleaning System (peristaltic pump)121-P01187.88 Replacement tubing for Automated Fluorometer Cleaning System

3D TRASAR Starter Upgrades

Parts / Closed Loop Applications


001-H10506.88 Corrosion Coupon Rack, two station with flow indicator060-TR5540.88 High Pressure Water Reinjection System (see diagram pg C-7.)


060-TR3200.88Fluorometer upgrade (includes: Patented 3D TRASAR technology upgradeprocedure, 3D TRASAR Fluorometer, rebate return instructions, upgradeconfirmation sticker.)

060-TR3205.88NCM upgrade (includes: Patented NCM technology upgrade procedure, 2probe restraints, 2 Swagelock fittings, and upgrade confirmation sticker.Purchase NCM probes separately.)

060-TR3211.88 pH upgrade (includes pH probe and cable.)060-TR3221.88 ORP upgrade (includes ORP probe and cable.)


060-TR5411.88 pH Probe, flat surface, ¾" NPT060-TR5421.88 ORP Probe, flat surface, ¾" NPT060-TR5432.88 Conductivity Probe, torroidal, probe only060-TR5441.88 Conductivity Probe, torroidal probe and tee, (fits 2" Union)400-NCMP1B.88 Corrosion Probe w/ ferrule, Mi ld Steel400-NCMP2B.88 Corrosion Probe w/ ferrule, Copper400-NCMP4B.88 Corrosion Probe w/ ferrule, CuNi 90/10400-NCMP5B.88 Corrosion Probe w/ ferrule, CuNi 70/30400-NCMP7B.88 Corrosion Probe w/ ferrule, 443 Admiralty Brass6016180 Corrosion Probe w/ ferrule, 6061 Aluminum6016182 Corrosion Probe w/ ferrule, 1100 Alumi num400-NCMP10.88 Corrosion Probe Package, Galvanized Steel




C-3

Replacement Parts / Cables

Communication and Data Management Accessories


060-TR5221.88 Fluorometer Cable, 4 ft.060-TR5311.88 Pellet Feeder Cable, 25 ft.060-TR5314.88 Pellet Feeder Cable, 100ft.060-TR5412.88 pH Cable060-TR5422.88 ORP Cable991-01928722.88 Service Cord, 12/3 SJOW (no termination)991-05053481.88 Pigtail, 16/3 SJOW, 18" w/ US plug991-05047661.88 Ethernet Crossover cable, 6' orange


060-NGG100.88 Nalco Global Gateway US (Domestic) with 1-year contract060-NGG200.88 Nalco Global Gateway International with 1-year contract

060-TR5280R.88 US Wireless Gateway Renewal 1- year contract (for Cingular service)Includes SIM - P art Number Expires October 1st, 2009

060-TR5285R.88 International Wireless Gateway Renewal 1- year contract (Rogers network)Includes SIM - P art Number Expires October 1st, 2009

060-NGG100R.88 Domestic Wireless 1-year contract renewal (SIM not included)Available October 1st, 2009

060-NGG200R.88 International Wireless 1-year contract renewal (SIM not included)Available October 1st, 2009

060-TR5284.88 External Antenna for Nalco Global Gateway (Cable sold separately)060-TR5284C100.88 100-foot cable for 060-TR5284.88060-TR5284C25.88 25-foot cable for 060-TR5284.88060-TR5270.88 LAN Router160VTGV100 Vantage V100




C-4

Replacement Parts / Spares and Accessories


060-TR5540.88 High Pressure Water Reinjection System060-TR5217.88 Redboard060-TR5245.88 Easy Mounting Bracket for models 060-TR3500.88 and 060-TR5500.88 only060-TR5240.88 3D TRASAR Frame991-50554318.88 Fuse, 2.5 A, 250V, (output re lay fuse)060-TR5222.88 Desiccant C anister (Fluorometer)060-TR5223.88 Desiccant Ind icator (Fluorometer)500-P2818.88 Pellet Feeder Cleaning Brush060-TR5313.88 Pellet Feeder Shield Kit (Dam Repair Kit)060-TR5350.88 Pellet Feeder Overflow Device060-TR5332.88 Pellet Feeder Upper P lumbing Assembly060-TR5334.88 Pellet Feeder Lower P lumbing Assembly400-NCMAC5.88 Corrosion Probe Swagelock Fitting, Nylon, ¾"400-NCMAC15.88 Corrosion Probe Restraint D evice6000668 Replacement F lowswitch060-TR5224.88 Fluorometer, up per adapter fitting060-TR5225.88 Fluorometer, lo wer adapter fitting991-05055272.88 Controller ScrewsTK-135 Configurator Software CD




C-5

Replacement Parts / Reagents and Calibration Supplies

* This part is available as an optional accessory, but is not included with either the Start-upKit or the Maintenance Value Package.


500-TSRKITSTR.88 3D TRASAR 3500 Series Calibration Start-up Kit3500 Series Calibration Start-up Kit includes 3D TRASAR Calibration Solution 1L (2),Fluorometer Cleaning Solution 1L, Fluorometer Probe Brush, 500 mL Plastic Beakers (3), 60 ccPlastic Syringes (3)500-TSRKIT.88 3D TRASAR 5000 Series Calibration Start-up Kit5500 Series Calibration Start-up Kit includes 3D TRASAR Calibration Solution 1L (2), pH7.0 and 10.0 Calibration Solutions 1L (1 of each), ORP 200 mv and 600 mv CalibrationSolutions 1L (1 of each), Fluorometer Cleaning Solution 1L, Replacement Mild Steel andCopper NCM Probes (1 of each), Fluorometer Probe Brush, 500 mL Plastic Beakers (3), 60 ccPlastic Syringes (3)060-TRMNKIT.88 3D TRASAR 5000 Series Maintenance Value PackageMaintenance Value Package includes 3D TRASAR Calibration Solution 1L (2), pH 7.0 and10.0 Calibration Solutions 1L (1 of each), ORP 200 mv and 600 mv Calibration Solutions 1L(1of each), Fluorometer Cleaning Solution 1L, Fluorometer Probe Brush, 500 mL PlasticBeakers (3), 60 cc Plastic Syringes (3), Replacement pH Probe (1), Replacement ORP Probe(1), Replacement Mild Steel and Copper NCM Probes (2 of each), Fluorometer DessicantCanister, Fluorometer Dessicant Indicator460-S0940.75 3D TRASAR Calibration Solution, 1L460-S0408.75 pH Calibration Solution, pH 10.0, 1L460-S0407.75 pH Calibration Solution, pH 7.0, 1L460-S0932A.75 ORP Calibration Solution, 200 mv, 1L460-S0933A.75 ORP Calibration Solution, 600 mv, 1L460-S0800.75 Fluorometer Cleaning Solution, 1L (Sulfuric Acid 10%)460-S0726.75* Fluorometer Cleaning Solution, 1L (HCl 1:1)500-P2817.88 Flow Cell Brush500-P0116.88 Beaker, 500 mL, plastic500-P2147.88 Syringe, 60 cc, w/ female luer lock, plastic460-3DTBRC.87* Bio-reporter Quick Dose Pouch (pretreats approx. 150,000 gallons)460-S0298.75* Conductivity Calibration Solution, 600 uS, 1L460-S0297.75* Conductivity Calibration Solution, 3000 uS, 1L




C-6

Hardware Piping Layout




C-7

Pellet Feeder Piping Layout - Lower Assembly

P/N 060-TR5334.88

Pellet Feeder Piping Layout - Upper Assembly

P/N 060-TR5332.88




C-8

High Pressure Water Reinjection System

P/N 060-TR5540.88




D-1

Appendix D: Air Purging System

A copy of the manual shown below is included with models 060-TR3530.88, 060-TR3531.88,060-TR3532.88, 060-TR3533.88, 060-TR5530.88, 060-TR5531.88, 060-TR5532.88 and060-TR5533.88. Use this manual for start-up of the Air Purge System. Call 630-305-CHEM for moreassistance.




E-1

Appendix E: SCADA and LAN

SCADA - GeneralThe 3D TRASAR Controller provides a Modbus RTU Slave connection. Users can select either anRS-232 or RS-485 hardware link (choose one). Asingle 3-pin SCADA connector is provided in theController (plug-in to selected communications port).

Master and Slave (3D TRASAR Controller) Communications

Configuration Item Parameters

Protocol Modbus RTUCommunications Half-duplex (2-wire)

Baud Rate (selectable) 1200, 2400, 4800, 9600,or 19200

Data Bits 8 BitParity NoneStop Bits 1

3D TRASAR Display Configuration Guide

3D TRASAR Display Configuration Guide1) Press the Menu soft key.2) Select Preferences option.3) Enter password from the Password Screen (12345 is the default).4) From the Preferences screen, arrow down to the 2nd screen.5) SCADAAddr (0 – 99 is currently supported, 10 is the default). Make selection.6) SCADA Mode (RS232 or RS485). Make selection.7) SCADA Baud (1200, 2400, 4800, 9600, 19200). Make selection.8) Press the Information soft key.9) Select Operating Data.10) Cycle 3D TRASAR Controller power.

Configuration Item Parameters

Polling Interval/Block Reads5-10 seconds (10 seconds isrecommended, as signals do notchange frequently)

Message Timeout/Retry Half-duplex (2-wire)The 3D TRASAR Controller supports block reads. It is recommended to always read information inCoil, Word, Long, and Float blocks (to minimize Controller communication traffic). Floating pointnumbers are formatted using the Modicon Protocol convention (two consecutive 16-bit registers.Note: Daniel’s Floating Point Extension is not supported.

Modbus Master Polling/Retry Parameters




E-2

Register Definitions (Coils, Floats, Words, and Longs)Coil Map

Float Register Map

Controller Coil Registers Address Min Max Units Notes

Control Relay 1 - TRASAR 000001 0 1 On/OffControl Relay 2 - TAG POLYMER 000002 0 1 On/OffControl Relay 3 - BIO-REPORTER 000003 0 1 On/OffControl Relay 4 - OXID BIOCIDE 000004 0 1 On/OffControl Relay 5 - NONOX BIOCIDE 000005 0 1 On/OffControl Relay 6 - BLOWDOWN 000006 0 1 On/OffControl Relay 7 - pH CONTROL 000007 0 1 On/OffAlarm Relay 000008 0 1 On/OffDigital In 1 - No Flow 000013 0 1 On/OffDigital In 2 - Interlock 000014 0 1 On/OffDigital In 3 - Spare 000015 0 1 On/OffDigital In 4 - Spare 000016 0 1 On/Off

Controller Input Float Registers Address Min Max Units Notes

Product 1 Dosage (TRASAR) 300040 0.0 300.0 ppmProduct 2 Dosage (TAG Polymer) 300042 0.0 300.0 ppmRz 300044 0.0 300.0 ppbRs 300046 0.0 300.0 ppbTurbidity 300048 0.0 200.0 ntuBackground 300050 0.0 300.0 ppmCell Fouling 300052 0.0 100.0 pctConductivity 300054 0.0 10,000.0 uS/cmpH 300056 0.0 14.00 -ORP 300058 -1,000.0 1,000.0 mVCorrosion 1 (Right side of controller) 300060 0.0 Note 1 mpyCorrosion 2 (Left side of controller) 300062 0.0 Note 1 mpySample Temperature 300064 32.0 150.0 deg FNalco Bio-Index 300066 -999 999.0 -Nalco Scale Index 300068 -999 999.0 -Polymer Consumption 300070 0.0 100.0 pctHTI 300072 0.0 999.0 hoursSystem Volume Average 300074 0.0 9,999,999.0 galBlowdown Rate 300076 0.0 999.0 gpmMakeup Rate 300078 0.0 999.0 gpmHeat Rejected 300080 0.0 999,999.0 kBTU/dayRecirculation Rate 300082 0.0 999.0 gpmAnalog Input 1 300084 -99,999 99,999.0 -Analog Input 2 300086 -99,999 99,999.0 -




E-3

Integer Register Map (Scaled Input Integer Values)

Long Register Map (Scaled Input Long Values)

Note 1: Corrosion 1 and Corrosion 2 values are user specific; Mild Steel Range (0.0 – 99.9 MPY);Copper, Brass, 90/10 Cu/Ni & 70/30 Cu/Ni Range (0.00 – 9.99 MPY).

Note 2: The “System Volume Average”, “Heat Rejected”, and “Recirculation Rate” registers can beread as Long or Word values (2 words per Long). The values of each Long are stored in two con-secutive words with the most significant value stored in the lower address.

Note 3: In some data acquisition systems, the two 16-bit registers comprising the Floating Pointmay need to be switched. This is usually a configuration setting within the polling set-up routine.

Note 4: The scaled floating point registers (Integers and Longs) were added as a convenience forcontrol systems that do not support reading Floating Point Input registers. The Integer and LongInput registers contain the same information as the Floating Point Input registers. Tables 3, 4, 5 & 6document all registers currently supported by the 3D TRASAR Controller.

Controller Input Integer Registers Address Min Max Units Notes

Product 1 Dosage (TRASAR) 300150 0 300 ppm Divide value by 10Product 2 Dosage (TAG Polymer) 300151 0 300 ppm Divide value by 10Rz 300152 0 300 ppb Divide value by 10Rs 300153 0 300 ppb Divide value by 10Turbidity 300154 0 200 ntu Divide value by 10Background 300155 0 300 ppm Divide value by 10Cell Fouling 300156 0 100 pct Divide value by 10Conductivity 300157 0 10,000 uS/cm Divide value by 1pH 300158 0.00 14 - Divide value by 100ORP 300159 -1,000 1,000 mV Divide value by 10Corrosion 1 (Right side of controller) 300160 0 Note 1 mpy Divide value by 100Corrosion 2 (Left side of controller) 300161 0 Note 1 mpy Divide value by 100Sample Temperature 300162 32 150 deg F Divide value by 10Nalco Bio-Index 300163 -999 999 - Divide value by 10Nalco Scale Index 300164 -999 999 - Divide value by 10Polymer Consumption 300165 0 100 pct Divide value by 10HTI 300166 0 999 hours Divide value by 10Blowdown Rate 300167 0 999 gpm Divide value by 10Makeup Rate 300168 0 999 gpm Divide value by 10Analog Input 1 300169 -99,999 99,999 - Divide value by 10Analog Input 2 300170 -99,999 99,999 - Divide value by 10

Controller Input IntegerRegisters Address Min Max Units Notes

System Volume A verage 300172 0 9,999,999 gal Divide value by 10Heat Rejected 300174 0 999 kBTU/day Divide value by 10Recirculation Rate 300176 0 999 gpm Divide value by 10




E-4

ControllerSCADA 485

RS-232(DB9, PC

Connection)GND GND

B -A +

RS-232 Connection

RS-485 Connection

ControllerSCADA 232

RS-232(DB9, PC

Connection)GND GND (Pin 5)TX RX (Pin 2)RX TX (Pin 3)

Note 5: An example of an Integer representation follows. Assume floating point register 300040“Product 1 Dosage (Trasar)” contains 103.5 ppm. Integer register 300150 will contain the value of1035 (1035/10 = 103.5 pm). All integer and long registers will need to be scaled by their unique(documented) scaling factor.

Note 6: If the controller is configured to display SI units, the corresponding engineering units willappear on the screen and be translated to it’s corresponding Modbus register. As example, “SampleTemperature” will be converted from Deg F to Deg C. The corresponding Modbus registers (InputFloat and Input Integer) will hold the value in Deg C units.

Serial Wiring Connections

Display Location of VariablesControl Relay1 - TrasarActions àManualRelay Control à “Product Name” State

Control Relay2 – Tag PolymerActions àManualRelay Control à “Product Name” State

Control Relay3 - BioreporterActions àManualRelay Control à “Product Name” State

Control Relay 4 – Oxid BiocideActions àManualRelay Control à “Product Name” State




E-5

Control Relay 5 – NonOx BiocideActions àManualRelay Control à “Product Name” State

Control Relay 6 - BlowdownActions àManualRelay Control à “Product Name” State

Control Relay 7 – pHActions àManualRelay Control à “Product Name” State

AlarmRelayInformation àOperating Data à (Alarm Bell in upper left corner of display)

Digital In 1 – No FlowInformation àExternal Inputs àDI1 State

Digital In 2 – InterlockInformation àExternal Inputs àDI2 State

Digital In 3 – SpareInformation àExternal Inputs àDI3 State

Digital In 4 – SpareInformation àExternal Inputs àDI4 State

Product 1 Dosage (Trasar)Information àOperating Data àTRASAR (product name)OR, Information àDiagnostic Data àFluorometer Data àProd1

Product 2 Dosage (Tag Polymer)Information àOperating Data àTAG (product name)OR, Information àDiagnostic Data àFluorometer Data àProd2

Rz (Bioreporter)Information àDiagnostic Data àFluorometer Data àRz

Rs (Bioproduct)Information àDiagnostic Data àFluorometer Data àRs

TurbidityInformation àOperating Data àTurbidityOR, Information àDiagnostic Data àFluorometer Data àTurbid




E-6

BackgroundInformation àDiagnostic Data àFluorometer Data àBkrnd

Cell FoulingInformation àDiagnostic Data àFluorometer Data àFouling

ConductivityInformation àOperating Data àCondOR, Information àDiagnostic Data à Sensor Data àC

pHInformation àOperating Data àpHOR, Information àDiagnostic Data àSensor Data àpH

ORPInformation àOperating Data àORPOR, Information àDiagnostic Data à Sensor Data àORP

Corrosion 1 (Right Side of Controller)Information àSystemPerformance àCorrosion-”Metallurgy”OR, Information àDiagnostic Data àSensor Data àC1

Corrosion 2 (Left side of Controller)Information àSystemPerformance àCorrosion-”Metallurgy”OR, Information àDiagnostic Data àSensor Data àC2

Sample TemperatureInformation àOperating Data àTempOR, Information àDiagnostic Data à Sensor Data àORP

Nalco Bio-IndexInformation àSystemPerformance àN Bio Index**Controller must be configured for 3D Bio Control to be visible

Nalco Scale IndexInformation à System Performance àN Scale Index**Controller must be configured for 3D Bio Control to be visible

Polymer ConsumptionInformation àSystem Performance àConsumption

HTIInformation àOperating Data àHTI




E-7

Blowdown RateInformation àWater & Energy àBlowdown**Controller must be configured for Blowdown Control to be visible

Makeup RateInformation àWater & Energy àMakeup

Analog Input 1Information àExternal Inputs à4-20 Input 1

Analog Input 2Information àExternal Inputs à4-20 Input 2

SystemVolume AverageInformation àWater & Energy àSys. Vol.

Heat RejectedInformation àWater & Energy àHeat Rej.

Recirculation RateInformation àWater & Energy àRecirc Rate

Note: Some variables may not appear on the display if the controller is not configured to use them.These variable(s) should be ignored when processing the Modbus block register response.

LAN - Direct connect via crossover LAN cableThe Controller provides the following Ethernet/email settings. The factory defaults can be modifiedas needed (on site). Power must be cycled before any changes “take effect” in the Controller.

Settings accessed from the 3D TRASAR Controller display• DHCP: Disable (Nalco recommends leaving this setting disabled)• IP Address: 169.254.1.2 (factory default)• Subnet Mask: 255.255.0.0 (factory default)• Gateway Address: 169.254.1.4 (factory default)

Settings accessed using the 3D TRASAR Configurator• Controller Name: [email protected] (In some cases this address will need tobe modified. For example, [email protected]. Contact Nalco Technical Support for help)• DNS Server: (Supplied by customer IS Department)• Mail Server Name/IP: (Supplied by customer IS Department)• Alarm Email Address: [email protected] (Alarm Server address located at NalcoCompany)• Data Email Address: [email protected] (Data Server address located at Nalco Company.This email address is not changeable without contacting Nalco Technical Support)




E-8

LAN - Connect to customer LANThis section will assist you in connecting a 3D TRASAR controller to a customer’s Local AreaNetwork (LAN). This is the preferred communication method if you have an available LAN connec-tion close to the controller and if the customer permits the controller to connect to their network.

This diagram shows the recommended network configuration. Note that the use of a router (P/N060-TR5270.88) is required on LAN’s with more than 25 computers on the same segment as the3D TRASAR controller. If this is ignored the controller’s Ethernet stack may overflow and communi-cation to the controller may not be possible.

The 3D TRASAR Controller sends data and alarms to Nalco via email. All that is required is that thecustomer’s SMTP server grants access to the 3D TRASAR Controller and allows it to send out-bound email to the Nalco mail server (3dtrasar.com).




F-1

Appendix F: 3D TRASAR StarterUpgrade Procedures

There are four different upgrades available for the 3D TRASAR Starter system:

• 3D TRASAR Fluorometer upgrade, P/N 060-TR3200.88

• Nalco NCM Corrosion Measurement upgrade, P/N 060-TR3205.88

• 3D TRASAR pH upgrade, P/N 060-TR3211.88

• 3D TRASAR ORP upgrade, P/N 060-TR3221.88

Please refer to the following pages for more details.




F-2

3D TRASAR Starter Fluorometer Upgrade ProcedureThis procedure details the steps required to complete the 3D TRASAR Starter Fluorometerupgrade. All steps must be completed in order to begin using the features of the 3D TRASARFluorometer.

1. Order UpgradeOrder the 3D TRASAR Starter Fluorometer Upgrade, P/N 060-TR3200.88. Order through Nalcocustomer service, or through the Order Wizard.

2. Unpack and Identify ComponentsThe 3D TRASAR Starter Fluorometer upgrade includes the following:

• 3D TRASAR Fluorometer• Patented 3D TRASAR technology upgrade procedure• Upgrade confirmation sticker• Rebate return instructions

Verify that you have all four components before proceeding.

3. Register New Hardware (http://web.3DTRASAR.com/upgrade)Register new hardware at the 3D TRASAR upgrade website (http://web.3DTRASAR.com/upgrade)In order to complete the registration, you will need the following information: controller serial number,and sales order and SAP Sold to numbers that appear on upgrade order.

Important! Registration must be completed 48 hours before proceeding to next step.!




F-3

4. Replicate Computer with Nalco LAN.48 hours after completion of web registration (step 3) your upgrade will become available on theNalco LAN. You must replicate your computer in order to automatically receive the upgrade.

5. Configure New HardwareConnect computer to controller, and the upgrade will appear in the Manage Controller button onthe Configurator home page. Click Manage Controller to view upgrade details. Click upgradenow to begin upgrade process. Follow screen prompts to complete upgrade.

6. Install New FluorometerReplace old 3D TRASAR Starter fluorometer with new3D TRASAR Fluorometer. For details on how to install theFluorometer, please see section 2.6.1. Place upgradeconfirmation sticker on visible portion of back panel.

7. Configure Features of New HardwareUsing 3D TRASAR configurator program or keypad of3D TRASAR controller, update control settings, setpointsand alarms. For information on:

• Updating controller settings, please see section 4.0. • 3D TRASAR Scale Control, please see section 5.0 • 3D TRASAR Bio-Control, please see section 6.0

8. Return old 3D TRASAR Starter FluorometerComplete rebate return paperwork (included with upgrade order.) Securely pack rebate returnpaperwork and old 3D TRASAR Starter Fluorometer in packaging materials shipped with the new3D TRASAR Fluorometer upgrade.

Important! Rebate will not be processed unless BOTH the rebate return paperwork andFluorometer are returned to Nalco!!




F-4

3D TRASAR Starter NCM Corrosion MeasurementUpgrade ProcedureThis procedure details the steps required to complete the 3D TRASAR Starter NCM CorrosionMeasurement upgrade. All steps must be completed in order to begin using the features of theNCM.

1. Order Upgrade and NCM probes.Order the 3D TRASAR Starter NCM Corrosion Measurement Upgrade, P/N 060-TR3205.88 alongwith required probes (sold separately.) Order through Nalco customer service, or through the OrderWizard.

2. Unpack and Identify ComponentsThe 3D TRASAR NCM technology upgrade includes the following:

• Patented NCM technology upgrade procedure• 2 NCM probe restraints• 2 NCM probe fittings• Upgrade confirmation sticker

Verify that you have all four components before proceeding.

Note! Corrosion probes must be ordered separately.

3. Register New Hardware (http://web.3dtrasar.com/upgrade)Register new hardware at the 3D TRASAR upgrade website (http://web.3dtrasar.com/upgrade). Inorder to complete the registration, you will need the following information: controller serial number,and sales order and SAP Sold to numbers that appear on upgrade order.

!

! Important! Registration must be completed 48 hours before proceeding to next step.




F-5

4. Replicate Computer with Nalco LAN.48 hours after completion of web registration (step 3,) your upgrade will become available on theNalco LAN. You must replicate your computer in order to automatically receive the upgrade.

5. Configure New HardwareConnect computer to controller, and the upgrade will appear in the Manage Controller button onthe Configurator home page. Click Manage Controller to view upgrade details. Click upgradenow to begin upgrade process. Follow screen prompts to complete upgrade.

6. Install Corrosion ProbesFor details on how to install the corrosion probes, please see section 2.6.5 NCM Corrosion ProbeInstallation. Place upgrade confirmation sticker on visible portion of back panel.




F-6

3D TRASAR Starter pH Upgrade Procedure

1. Order UpgradeOrder the 3D TRASAR Starter pH Upgrade, P/N 060-TR3211.88 (includes pH probe, cable andinstallation instructions.) Order through Nalco customer service, or through the Order Wizard.

2. Install New HardwareInstall the pH probe as follows:

STEP 1 - Carefully unpack the pH probe.

STEP 2 - Apply 5 revolutions of Teflon tapeto the pH probe threads.

STEP 3 - Hand tighten the probe in thethreaded tee location indicated indrawing at right.

STEP 4 - Connect pH probe to pH cable(cable is labeled pH.)

STEP 5 - With power off, wire pH cable toproper terminals in controller box(see drawing below.)

STEP 6 - Reconfigure the controller for pH.




F-7

3D TRASAR Starter ORP Upgrade Procedure

2. Install New HardwareInstall the ORP probe as follows:

STEP 1 - Carefully unpack the ORP probe.

STEP 2 - Apply 5 revolutions of Teflon tapeto the ORP probe threads.

STEP 3 - Hand tighten the probe in thethreaded tee location indicated indrawing at right.

STEP 4 - Connect ORP probe to ORPcable (cable is labeled ORP.)

STEP 5 - With power off, wire ORP cableto proper terminals in controllerbox (see drawing below.)

STEP 6 - Reconfigure the controller forORP.

1. Order UpgradeOrder the 3D TRASAR Starter ORP Upgrade, P/N 060-TR3221.88 (includes ORP probe, cable andinstallation instructions.) Order through Nalco customer service, or through the Order Wizard.



G-1Technical Help(630) 305-CHEM

Appendix G: 3D TRASAR Technologyfor Closed Loop Applications3D TRASAR technology delivers superior chemical performance, feed, control and monitoring to closedloops. Nalco’s patented phosphino succinic oligomer (PSO) chemistry provides and effective alterna-tive to traditional nitrite- and molybdate-based treatments. Continuous corrosion rate measurement isavailable using Nalco’s NCM technology. For systems requiring routine feed and control of treatmentchemicals, 3D TRASAR technology is the most advanced system of its type available, providing mea-surement of key system parameters, detection of upset conditions, automatic response and a com-prehensive communications package which allows the user to monitor system performance, continu-ously, on the internet or through system alarms.

3D TRASAR Equipment for Closed Loop ApplicationsClosed loop applications can utilize the standard 3D TRASAR Starter 3500 and 3D TRASAR 5500systems. The following components are required for closed loop applications and must be orderedseparately.

1. Corrosion Coupon Rack

Select a Corrosion Coupon rack (P/N 001-H10506.88) to monitor trends of corrosion rate over time.P/N 001-H10506.88 is a two-station, corrosion coupon rack with rotometer which ships pre-as-sembled and mounted on a backpanel for convenience. Wetted parts are PSF and PVC. Rackdimensions are: 22” W x 25” T, plumbing connections are 3/4” FNPT. Order corrosion couponsseparately from list below. All coupons are bar style and measure 3” x 1/2”.

Part number Description500-P5035A.88 Coupon, MS 1010500-P054A.88 Coupon, MS 1010 Passivated500-P5048A.88 Coupon, MS 1010 Scaling500-P5038A.88 Coupon, Copper500-P5034A.88 Coupon, Copper Nickel (70/30)500-P5049A.88 Coupon, Copper Nickel (90/10)500-P5040A.88 Coupon, Admiralty Brass500-P5036A.88 Coupon, SS 316L500-P5037A.88 Coupon, SS 304500-P5057A.88 Coupon, Galvanized Hot Dip

2. UltraSand Plus high efficiency filter

Nalco recommends UltraSand Plus high efficiency filtration systemsfor closed loop applications. The unique design and ultra-fine sandfilter media work to remove particulate matter down to 0.5 microns.To request a proposal please contact NGES technical support at1-800-323-8483, or use the 3D TRASAR Order Wizard.

Corrosion Coupon Rack

UltraSand Plus



G-2Technical Help(630) 305-CHEM

The High Pressure Water Reinjection System(P/N 060-TR5540.88) was designed to enable a 3D TRASARcontroller to be used in high-pressure applications such as HighRises and Closed Loops. The Reinjection System regulatesthe pressure coming into the controller and reinjects the waterback into the same system from which it came. The High Pres-sure Reinjection System is outfitted with a pressure regulatorthat is designed for the inlet water to be a maximum pressure of300-psi, which will be reduced to an operating pressure of ap-proximately 75-psi. The pump draws a suction f rom the3D TRASAR, repressurizing the water and reinjects it back intothe process. The system requires a minimum flowrate of 8gpm.

3. High Pressure Water Reinjection System

High Pressure W ater Reinjection Systemshown with 3D TRASAR system.

High Pressure Water Reinjection System Specifications

Plumbing Requirements• High Pressure Inlet: 1" FNPT • High Pressure Outlet: 1" FNPT• Low Pressure Inlet: 1" Hose Barb • Low Pressure Outlet: 1" Hose Barb• Supply Water: Maximum 300-psi, Minimum 8gpm

Electrical• 220V, Single Phase, 25A

Alarms• Alarm output relay rated for 120V, 1A

Current Protection• Preset under-current protection to prevent cavitation• Preset over-current protection against over pressurization

Pressure Protection• Relief Valve set for 85-psi

Ambient Temperature• 40-120 oF (4-50 oC)

Relative Humidity• 0-95% non-condensing

Maximum water pressure• 300psi

Dimensions• 32"H x 48"W x 12"D

Control Box• Nema 4x enclosure

Indicator Lights• White – Power Light• Red – Alarm Light• Green – Pump Running Light

Refer to operation manual shipped with high pressure water reinjection system for more details.



H-1Technical Help(630) 305-CHEM

Appendix H: 3D TRASAR Technologyfor High Fouling ApplicationsThe 3D TRASAR models for High Fouling Applications are pre-configured to work with an automatedfluorometer cleaning system. This benefits systems running process waters with higher levels ofsolids and debris which tend to cause fluorometer cell fouling. The automated cleaning system re-duces the amount of physical cleaning required for the fluorometer, extending the length of operationbetween maintenance cycles.

3D TRASAR models 060-TR5515.88, 060-TR5516.88, 060-TR5525.88, and 060-TR5526.88include the following enhancements not found on the standard 3D TRASAR models:

• Automated fluorometer cleaning system delivers cleaning solution to the 3D TRASARfluorometer.

• Modified basket strainer includes finer mesh filter (80 mesh) and magnetic disc to removemetal particulates from the process water.

• Solenoid valve, t-fitting, and pre-wired cables simplify connection to automatedFluorometer cleaning system.

• Combination rotameter/flowswitch used in place of separate rotameters and flowswitch.

This appendix supercedes information found in the main portion of the 3D TRASAR manual. Read allsections prior to beginning any installation.

1. Identify Hardware ModelWall Mount

ModelFrame Mount

Model Description

060-TR5515.88 060-TR5516.88 3D TRASAR for High Fouling Applications

060-TR5525.88 060-TR5526.88 Enclosed 3D TRASAR for High Fouling Applications




Analog output 1 is pre-wired (jumpered) to Analog input 1 for the purpose of monitoring andlogging flow cell fouling data (every 15 minutes.)

2. Fluorometer InstallationThe fluorometer is shipped unattached to prevent damage. Follow installation instructions from sec-tion 2.6.1 in the manual with the following exception: a t-fitting is installed on the outlet side of theFluorometer, instead of a flowswitch.

3. WiringA junction box is not available with any of the 3D TRASAR models for High Fouling Applications.

Controller Box LayoutRelay 5 is pre-wired with a power cable for connection to the peristaltic pump andsolenoid valve(used with the fluorometer cleaning system.)




4. Configuration (to monitor cell fouling)

The following steps must be completed as part of the configuration for all high fouling applicationsin order to monitor cell fouling. Select task button from 3D TRASAR Configurator main window, thenfollow list of steps.

4.1 Select External Inputs.For 4-20 mA input 1:1. AI 1 Name enter Cell Fouling

2. 4 mA Value enter 03. 20 mA Value enter 1004. Units enter %5. High Alarm Limit enter 256. Low Alarm Limit enter 0

4.3 Select Alarm Settings. For system alarms:1. Cell-fouling % High enter 25

4.2 Select 4-20 mA Outputs. For output #1:1. #1 Name select Cell Fouling2. 4 mA Value enter 0

3. 20 mA Value enter 100




5. Automated Fluorometer Cleaning SystemSome process waters will leave deposits within the fluorometer which can leadto cell fouling and inaccurate readings. The fluorometer can be cleaned usingthe automated fluorometer cleaning system, which is composed of threeseparate parts:

• 121-P01152.88, Solution pump• 001-H04066.88, Containment basin for cleaning solution• 460-S0340.11, Cleaning solution, Nitric/Phosphoric acid, 5 gallons

(order cleaning solution separately.)

To attach the fluorometer cleaning system, connect the pump outlet to thet-fitting located between the solenoid valve and Fluorometer. Pump ships witha 3/8" check valve which threads directly to the t-fitting. Connect the pump andsolenoid valve power cords to the pigtails pre-wired to relay 5.

IMPORTANT: Prior to physical cleaning of the fluorometer, close ball valve beneathfluorometer and set relay #5 to manual off (through keypad press Actions>ManualRelay Control>Relay #5 (S0340) >Current State>Edit>Manual Off>Accept.)Press Auto After then Edit to select amount of time the relay will remain in selectedmode prior to reverting back to auto. Open ball valve when finished with cleaning.

!

6. Configuration (for Automated Fluorometer Cleaning System.)The following steps must be completed in order to use the automated fluorometer cleaning system.

6.1 Select Control Settings, then Biocides For Non-Oxidizing Biocide Control:

1. Control Method select Timer Control 2. Biocide Name select other. 3. Name enter S0340 4. Pumping Rate enter pump flowrate.

!IMPORTANT: Nalco cleaning solution P/N 460-S0340.11 is a highly acidic solution.Take proper precaution in handling and disposal. The automated fluorometer cleaningsystem is designed to work with cooling water system sizes 25,000 gallons or larger.For smaller systems or to request a MSDS, please contact Nalco at 1-630-305-CHEM.

Plumb outlet of fluorometer to drain or lower pressure point in system (minimum differential 20 psig.)




6. Configuration (for Automated Fluorometer Cleaning System con’t)

Important: Set cleaning schedulefor time when operators are notexpected to be performing manualcleaning of fluorometer.

!

6.2 Select Edit BioTimers For Non-Oxidizing Biocide Control:

1. Feed Frequency and Interval select Feed Every Day.

2. Deselect all Pre-Bleed and Lockoutoptions.

3. Current NonOx Schedule select hour andduration. Set cleaning duration to 10minutes.

4. Click Add. 5. Monitor cell fouling, adjust cleaning

schedule as required.

6.3 Select Alarm SettingsFor system alarms1. No Flow Relay Action select

Force Relay Off2. No Flow Alarm Delay (min)

enter 10

Note: The time set for No FlowAlarm Delay should match thelength of the cleaning cycle.

7. Maintenance

In addition to the maintenance schedule recommended for standard 3D TRASAR units, perform thefollowing activities:

• After start up, check basket strainer, magnet and rotometers weekly. Determine appropriatemaintenance schedule based on degree of fouling.

• Check pump tubing of automated fluorometer cleaning system for wear monthly,replace if necessary.




8. Replacement parts

9. Shipping Weights and Dimensions

Part Number DescriptionEstimatedEquipmentWeight (lbs)

EstimatedShipping

Weight (lbs)Dimensions (LxWxH)

060-TR5515.88 Wall Mount for HighFouling Applications 75 150 33 x 6 1/4 x 57"

060-TR5516.88 Frame Mount for HighFouling Applications 150 225 33 x 28 x 66"

060-TR5525.88 Enclosed Wall Mount forHigh Fouling Applications 180 260 36 7/8 x 13 7/8 x 62 5/8"

060-TR5526.88 Enclosed Frame Mount forHigh Fouling Applications 245 325 36 7/8 x 28 x 65 3/4"


991-05058141.88 Magnetic Disc for basket strainer

991-50537710.88 Basket Strainer, with 80 mesh filter

991-28737119.88 Solenoid Valve, 1/4" Stainless Steel with PTFE seals, NO

991-05058102.88 Rotameter, 0.22-2.2 GPM, for Fluorometer leg

991-05058103.88 Rotameter, 0.44-4.4 GPM, for primary sensor leg

991-05058111.88 Max limit switch for Rotameter

991-01869544.88 T-fitting connection for attachment of cleaning system, 3/8" FPT

991-01869541.88 T-fitting for Fluorometer outlet

121-P01152.88 Automated fluorometer cleaning system (peristaltic pump)

121-P01187.88 Replacement tubing for peristaltic pump

460-S0340.11 Cleaning solution, Nitric/Phosphoric Acid, 5 gallons

001-H04066.88 Containment basin, PE, for 5 gallon pail, 7.5" H x 21.5" dia

991-18469811.88 Tube fitting, 3/8" OD x ½" MNPT (included with S0340)

6010754 Reducing bushing, ¾" MNPT x ½" FNPT (included with S0340)




10. 3D TRASAR Models for High Fouling Applications (Pacific)The following 3D TRASAR models for High Fouling Applications are available to comply with localpower requirements in the Pacific.

Wall MountModels

Frame MountModels

Description

060-TRP5515.88 060-TRP5516.88 3D TRASAR for High Fouling Applications, large backpanel,Pacific, 240/60, 220/50

060-TRP5525.88 060-TRP5526.88 3D TRASAR for High Fouling Applications, enclosed largebackpanel, Pacific, 240/60, 220/50

To meet local voltage requirements, 3D TRASAR models for High Fouling Applications (Pacific)utilize a different pump and solenoid valve. Specifications are shown below.

• 991-05059581.88 Solution pump, Grundfos, DME2, Maximum capacity 0.5 gal/hr, PVDFpump head, PTFE gaskets and ball valve, 110-240VAC, 50-60Hz.

• 991-05059502.88 Solenoid valve, Stainless Steel body with PTFE seals, 1/4” FNPT,240VAC/60Hz, 220VAC/50Hz.

Different wire colors are also used in the control box. Specifications are shown below.



Controller BoxTerminal Wire Color

Ground TB9-4 Gnd Not used

Ground TB9-3 Gnd Green withYellow Stripe

Neutral TB9-2 N BlueLine Power TB9-1 L Brown




I-1

Appendix I: Halogen AnalyzerControl Through an Analog InputThe latest OBC firmware update and respective Configurator updates now provide for the use of anonline halogen analyzer, which helps maintain the residual concentration at a set point. The halogenanalyzer monitors the total or free halogen residual. The output of the halogen analyzer can be usedto control the oxidant feed pump in place of ORP-control oxidant feed. This is accomplished auto-matically through the Configurator.

Analog Input Selection Screen

Wire the analog output ofthe halogen analyzer toeither of the two AnalogInputs of the OBC. Usingthe Configurator, set-up theanalog inputs to use thehalogen analyzer. Thehalogen analyzer can beused to monitor or controltotal or free residual halo-gen (TRH/FRH) levels inthe system. When thehalogen analyzer is used tocontrol the residual halogenlevel in the system, theoxidant feed pump iscontrolled by the OBCbased on set-point controlusing the signal from thehalogen analyzer.




I-2

Select the appropriate option above (Monitor or Control) for the Analog Input that the halogen ana-lyzer is connected to. If you are using the halogen analyzer to control oxidant feed, select the Bio-cides tab in Control Settings and enter the set point and control range. The default range of theanalog output from the halogen analyzer is 0 ppm at 4mA and 5 ppm at 20mA. If this is suitable forthe application, enter these values into the corresponding fields in configurator. If you alter the outputsettings of the halogen analyzer make the adjustments in these fields so the input is scaled cor-rectly.

!IMPORTANT: Disabling of halogen analyzer control of oxidant feed mustbe done through the Analog Input Selection Screen and not through theBiocide Control Settings Screen.

Biocide Control Settings Screen

After the halogen analyzer is chosen, the FRH or TRH concentration will replace ORP on the sys-tem operation screen on the OBC.




K-1

Appendix K: Warranty PolicyNalco Global Equipment Solutions warrants its standard equipment and related installation servicesto the original purchaser to be free of defects in material or workmanship for one year from the dateof shipment, unless otherwise specified.

Key Features Include:• Simplified claims processing-warranty assistance is just a toll free call away. Most claims

can be handled by making a single phone call.• 12-month coverage of all standard part numbered Nalco equipment offerings (excepting

consumable items and products with shelf lives of less than 12 months.• 36-month coverage of all standard part numbered 3D TRASAR and 3D TRASAR Starter

models shipped after January 1, 2006 (excepting consumable items and products with shelflives of less than 12 months. 3D TRASAR consumable components include pH, ORP andCorrosion probes, calibration and cleaning solutions and fuses.)

• 12-month coverage of Nalco equipment installation.• Repair and on-site warranty assistance now available in selected areas.

LimitationsWarranty does not cover damage caused by misuse, neglect, accident (including a force majeureevent), improper installation or improper maintenance or repair. Nalco’s liability under this warrantyis limited to repair or replacement of defective items, or, refund of or credit for the product priceexcluding shipping.

Nalco DISCLAIMS ALL OTHER WARRANTIES INCLUDING WARRANTIES OF MERCHANT-ABILITY AND FITNESS FOR A PARTICULAR PURPOSE. In no event shall Nalco be liable for anyconsequential or indirect damages.

Non-Warranty Equipment ReturnsIf you wish to return a standard, part-numbered Nalco Equipment Solutions product for credit orrepair, please follow the guidelines below:

• Credit: Products purchased from Equipment Solutions may be returned for credit withinthree (3) months of purchase if they have never been placed in service and they are re-turned in the original packaging complete with all accessories, component with all accesso-ries, component parts, and manuals.

• Repairs: Products eligible for billable repair include standard items that were purchasedwithin the past five (5) years.

Equipment Damaged During ShipmentIf Equipment is damaged during shipment, please contact the carrier immediately to file a claim.Your Nalco sales representative, with assistance from the Nalco traffic department, can also assistwith filing this claim. Damaged shipments are not considered a warranty return.




Glossary-1

Glossary

3D TRASAR Bio-Control

3D TRASAR Bio-Control is a proprietary Nalco technology for measurement and control of micro-biological activity in open recirculating cooling water systems. 3D TRASAR Bio-Control uses afluorescent bio-reporter to probe the entire system, measuring both planktonic and sessile microbialactivity and feeding oxidizing biocides in response.

3D TRASAR Scale Control

3D Scale Control is a revolutionary way to manage scale stress in cooling systems. The 3DTRASAR controller, coupled with an innovative “tagged” high stress polymer (essentially a barcodeattached to the polymer molecule) monitors the actual performance of the polymer as system stresschanges. 3D TRASAR Scale Control then takes corrective action through blowdown or chemicalinhibitor feed adjustments.

3D TRASAR System

The Nalco 3D TRASAR system is the most advanced water treatment control system on the markettoday. It represents a total system approach, encompassing service, innovative chemistry, ad-vanced software and sophisticated equipment, that allows you to manage stresses in cooling towersystems on a continuous, ongoing basis.

3D TRASAR Configurator

A PC-based tool which interfaces with the 3D TRASAR controller. The 3D TRASAR Configuratorallows Nalco sales representatives to configure the controller, establish remote communications,download data, update controller software, and change control methods.

3D TRASAR Optimizer

A PC-based tool which allows Nalco sales representatives to design basic cooling water programs,evaluate program alternatives, and analyze the impact of controller or makeup water variables onsystem performance.

Order Wizard

A PC-based tool which assists Nalco representatives with ordering 3D TRASAR chemicals, equip-ment and service.




Glossary-2

Bio-reporter

Bio-reporter is a fluorescent molecule, which is enzymatically changed upon interaction with active,respiring microbes (both planktonic and sessile). The fluorescence of the bio-reporter and theproduct of its interaction with bacteria is monitored continuously by an in-line fluorometer. The rateof change of the fluorescence with time gives a measure of the microbiological activity in the sys-tem.

Conductivity measurement

The ability of a sample to conduct heat or electricity. Electrical conductivity is usually expressed inmicrosiemens (uS.)

Corrosion monitoring

A measurement of the rate at which corrosion is occurring in a system. Corrosion is the deteriora-tion of metal caused by a reaction with its surrounding environment. Corrosion is measured in unitsof mils per year (mpy.)

Failsafe duty, fixed

In the event of alarm conditions, the relay is activated for a period of time equal to a percentage ofa 15-minute period.

Failsafe duty, average or Smart

In the event of alarm conditions, the relay is activated for a period of time equal to the averageoperating conditions of that relay for the last 7 days.

Nalco Bio-Index

Nalco Bio-Index is a measure of microbiological control in the system based on the bio-reporterresponse. As the Nalco Bio-Index increases the relative microbial control decreases.

Nalco Scale Index

The Nalco Scale Index (NSI) is a calculated variable that compares the current rate of polymerconsumption against the learned average rate of polymer consumption. NSI has a direct correla-tion to the cooling system stress level. 3D TRASAR Scale Control uses NSI to make setpointadjustments in response to both high and low stress conditions.

ORP measurement

Oxidation Reduction Potential. A measure of the oxidation-reduction potential of a sample. ORP ismeasured in millivolts (mV.)




Glossary-3

pH measurement

A measure of the acidity or alkalinity of a sample, numerically equal to 7 for neutral solutions,increasing with increasing alkalinity and decreasing with increasing acidity. The pH scale commonlyin use ranges from 0 to 14 pH units.

Start up factor

Extends the relay timeout function during start up. The start up factor is multiplied by the relaytimeout period (ie. if the “relay timeout” is set to 60 minutes, and the start up factor is set to 5, thetotal timeout period will be 300 minutes.)

Relay timeout

Maximum allowable time a relay is allowed to be energized before an alarm is triggered, and thefailsafe duty mode begins (user set.)

Tagged Polymer

A new component of TRASAR cooling water programs (ie. Nalco’s Prism polymer or High StressPolymer (HSP.)) The concentration of the “tag” equals the concentration of available, un-reacteddispersant polymer. The 3D TRASAR algorithm compares the inert TRASAR signal to that of thetagged signal, and then makes appropriate control decisions, either to increase or decrease thetreatment concentration or increase or decrease the conductivity set-point.

Turbidity measurement

A measure of how cloudy or dirty the water is, obtained by quantifying the degree to which lighttraveling through a water column is scattered by the suspended particles. (The greater the scatter-ing, the higher the turbidity.)

Vantage V100

Vantage V100 is Nalco’s field data management software program. 3D TRASAR data files can beimported into Vantage V100 for the purpose of trending and reporting operational data.

Nalco Company Operations

North America: Headquarters – 1601 West Diehl Road, Naperville, IL 60563-1198 ٠ USA Energy Services – 7705 Highway 90-A, Sugarland, Texas 77478 ٠ USA Europe: Ir.GF.Tjalmaweg 1 ٠ 232 BV Oegstgeest ٠ The Netherlands Asia Pacific: 2 International Business Park ٠ #02-20 The Strategy Tower 2 ٠ Singapore 609930 Latin America: Av das Nações Unidas 17.891 ٠ 6° Andar 04795-100 ٠ São Paulo ٠ SP ٠ Brazil

www.nalco.com

Nalco, the logo, PRISM, Vantage, 3D TRASAR, STA٠BR٠EX, ACTI-BROM, are Registered Trade- marks of Nalco Company.

Towerbrom is a Registered Trademark of Occidental Chemical Corporation.

3D TRASAR Technology Installation and Operation Manual · This manual covers the following models: • 3D TRASAR 5500 Series • 3D TRASAR 3500 Series • 3D TRASAR Technology for

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