Om0108 3d Trasar 5500i and Omanual

3D TRASAR® Technology
Installation and Operation Manual

Version 8.0
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 5500 - Installation & Operation Manual
TRASAR Technology License

Nalco has one or more patents and related know-how, which pertain to either TRASAR or 3D
TRASAR method of use or practice of technology (“Tracer Technology”). Buyer’s purchase of
equipment, 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 and
chemicals that Buyer chooses to purchase from Nalco for its water treatment facilities needs for the
practice of Tracer Technology. Such license, however, terminates upon Buyer’s discontinued use of
Nalco chemical(s) with Tracer Technology, unless, Buyer negotiates a separate express license
agreement with Nalco.
Nalco Company
1601 W. Diehl Road
Naperville, IL 60563
Trademarks
PRISM, Vantage, 3D TRASAR, STA-BR-EX, ACTI-BROM, Nalco and the logo are Registered
Trademarks of Nalco Company.
Towerbrom is a registered trademark of Occidental Chemical Corporation.
Technical Help 521-OM0108.88 i

(630) 305-CHEM Copyright  2009 Nalco Company
Table of Contents
Section 1: Introduction
1.1 About the 3D TRASAR® 5500 ................................................................................ 1-1
1.2 About this Manual ................................................................................................. 1-1
1.3 3D TRASAR 3500 and 3D TRASAR 5500 Models and Optional Components .. 1-1
1.4 3D TRASAR 3500 and 3D TRASAR 5500 Overview ............................................ 1-3
1.5 How the 3D TRASAR 5500 System Works .......................................................... 1-4
1.5.1 Fluorometer ............................................................................................................... 1-4
1.5.2 3D TRASAR Scale Control, 3D TRASAR Bio-Control, & NCM Corrosion Technology 1-4
1.5.3 Data Storage / Reporting and Communications ......................................................... 1-5
1.6 Safety ..................................................................................................................... 1-6
Section 2: Installation and Start-Up

2.1 STEP 1 - Unpack and Identify ............................................................................... 2-2
2.1.1 Identify Hardware Model ............................................................................................ 2-2
2.1.2a Pre-Installed Items (all models) .................................................................................. 2-4
2.1.2b Pre-Installed Items (3D TRASAR 5500 models only) ................................................. 2-4
2.1.3a Items Requiring Assembly (all models) ...................................................................... 2-4
2.1.3b Items Requiring Assembly (3D TRASAR 5500 models only) ...................................... 2-4
2.1.4 Pellet Feeder Assembly (Optional) ............................................................................. 2-5
2.1.5 Items Shipped Separately .......................................................................................... 2-5
2.1.5a 3D TRASAR Starter Upgrades .................................................................................. 2-5
2.1.5b 3D TRASAR Start-up and Maintenance Kits .............................................................. 2-5
2.2 STEP 2 - Mount the Controller .............................................................................. 2-6
2.2.1 General Instructions ................................................................................................... 2-6
2.2.2 3D TRASAR Controller Dimensions .......................................................................... 2-7
2.2.3 Wall Mounting Templates ......................................................................................... 2-11
2.2.4 Frame Mount Template ............................................................................................ 2-14
2.3 STEP 3 - Install Bio-reporter Feeder .................................................................. 2-15
2.3.1 Install Bio-reporter Pellet Feeder .............................................................................. 2-15
2.3.2 Install Liquid Bio-reporter Pump ............................................................................... 2-17
2.4 STEP 4 – Plumb Controller ................................................................................. 2-18
2.4.1 Sample Point Selection ............................................................................................ 2-18
2.4.2 3D TRASAR 5500 Inlet Water Plumbing .................................................................. 2-19
2.4.3 3D TRASAR 5500 Outlet Water Plumbing ............................................................... 2-20
2.4.4 Chemical Feed Pumps ............................................................................................ 2-21
2.4.5 Typical Installation Drawing ...................................................................................... 2-22
2.5 STEP 5 – Plumb Bio-reporter Feeder ................................................................ 2-23
2.5.1 Pellet Feeder Plumbing ............................................................................................ 2-23
2.5.2 Pellet Feeder Best Practices .................................................................................... 2-24
2.5.3 Liquid Bio-reporter Plumbing .................................................................................... 2-24
2.6 STEP 6 – Install Probes ...................................................................................... 2-25
2.6.1 Fluorometer Installation ............................................................................................ 2-26
2.6.2 pH Probe Installation ................................................................................................ 2-27
Technical Help 521-OM0108.88 TOC-1

2.6.3 ORP Probe Installation ............................................................................................. 2-28

2.6.4 Conductivity Probe Installation ................................................................................. 2-29
2.6.5 NCM Corrosion Probe Installation ............................................................................ 2-30
2.7 STEP 7 - Wiring ................................................................................................... 2-32
2.7.1 General Information ................................................................................................. 2-32
2.7.2 Controller Box Layout............................................................................................... 2-33
2.7.3 Controller Wiring Details .......................................................................................... 2-34
2.7.4 Junction Box Layout ................................................................................................ 2-36
2.7.5 Junction Box Details ................................................................................................ 2-37
2.7.6 System Power Connections ..................................................................................... 2-38
2.7.7 Internal Power Connections ...................................................................................... 2-38
2.7.8 Control Relay Connections - Powered (120 VAC fused @ 2.5 amps) ....................... 2-39
2.7.9 Control Relay Connections - Non-Powered (fused @ 2.5 amps) .............................. 2-40
2.7.10 Control Relay Connections - Termination Details ..................................................... 2-41
2.7.11 Pellet Feeder Connections ....................................................................................... 2-43
2.7.12 System Probe Connections ..................................................................................... 2-43
2.7.13 Analog I/O Connections ........................................................................................... 2-45
2.7.14 Factory Wired Digital Inputs ..................................................................................... 2-46
2.7.15 User Wired Digital Inputs ......................................................................................... 2-46
2.7.16 Alarm Output Connections ....................................................................................... 2-47
2.7.17 Phone Line Connections .......................................................................................... 2-47
2.7.18 Ethernet (Direct Connect to 3D TRASAR 5500) ....................................................... 2-48
2.7.19 LAN Connections ..................................................................................................... 2-48
2.7.20 SCADA Connections (Modbus RTU) ....................................................................... 2-48
2.7.21 Nalco Global Gateway .............................................................................................. 2-48
2.8 STEP 8 – Calibration & System Checkout ........................................................ 2-49
2.8.1 Establish Sample Flow & Apply Power...................................................................... 2-49
2.8.2 Calibrate Probes ...................................................................................................... 2-50
2.8.3 Checkout Control Relays ......................................................................................... 2-51
2.9 STEP 9 - Start-up System ................................................................................... 2-52
Section 3: 3D TRASAR Configurator

3.1 PC system requirements ...................................................................................... 3-1
3.2 Installing the software .......................................................................................... 3-1
3.3 Configurator support ............................................................................................ 3-2
3.3.1 Sample Help Screen .................................................................................................. 3-2
3.3.2 Sample Search Screen .............................................................................................. 3-2
Section 4: Controller Settings

4.1 3D TRASAR 3500 and 5500 Control Unit Overview ............................................... 4-1
4.1.1 The Display Panel ...................................................................................................... 4-1
4.1.2 The Keys ................................................................................................................... 4-1
4.1.3 The Graphical Icons ................................................................................................... 4-2
4.2 Menu, Information, Actions and Alarms Flow Diagram....................................... 4-3

4.3 The Menu Key ....................................................................................................... 4-4

4.3.1 Password Screen ....................................................................................................... 4-4
4.4 Control Settings Submenu ................................................................................... 4-4
4.4.1 Background Correction Screen .................................................................................. 4-5
4.4.2 TRASAR (Relay 1) Product Screen ........................................................................... 4-6
4.4.3 Tagged Polymer (Relay 2) Product Screen ................................................................ 4-6
4.4.4 Oxidizing Biocide Screen ........................................................................................... 4-6
4.4.5 Blowdown Screen ....................................................................................................... 4-6
4.4.6 pH Screen .................................................................................................................. 4-6
4.5 Alarm Settings Submenu ...................................................................................... 4-7
4.5.1 System Alarms Screen .............................................................................................. 4-7
4.5.2 Control Alarms Screens ............................................................................................. 4-7
4.5.3 Performance Alarms Screen ...................................................................................... 4-7
4.5.4 Relay Alarms Screens .............................................................................................. 4-8
4.5.5 4-20 mA Alarm Screen ............................................................................................... 4-8
4.6 Preferences Submenu .......................................................................................... 4-9
4.7 Network Submenu .............................................................................................. 4-10
4.8 System Information Submenu ........................................................................... 4-10
4.9 The Information Key ........................................................................................... 4-11
4.9.1 System Performance Screens ................................................................................. 4-11
4.9.2 Operating Data Screens .......................................................................................... 4-12
4.9.3 Product Usage Screens ........................................................................................... 4-12
4.9.4 Water and Energy Screens ...................................................................................... 4-13
4.9.5 Plot Data Screens .................................................................................................... 4-13
4.9.6 Control Methods Screens ........................................................................................ 4-14
4.9.7 Timer Status Screens .............................................................................................. 4-15
4.9.8 External Inputs Screens ........................................................................................... 4-15
4.9.9 Product Factors Screen ........................................................................................... 4-15
4.9.10 Diagnostic Data Screen ........................................................................................... 4-16
4.10 The Actions Key .................................................................................................. 4-17
4.10.1 Password Screen ..................................................................................................... 4-18
4.10.2 Clean and Calibrate Screen ..................................................................................... 4-18
4.10.3 Fluorometer Calibration Screens .............................................................................. 4-19
4.10.4 pH Calibration Screens ............................................................................................ 4-20
4.10.5 ORP Calibration Screens ......................................................................................... 4-21
4.10.6 Conductivity Calibration Screens ............................................................................. 4-22
4.10.7 Probe Calibration / Maintenance List ........................................................................ 4-25
4.10.8 Manual Relay Control Screens ................................................................................ 4-26
4.10.9 Pumping Rates Screens .......................................................................................... 4-27
4.10.10 Slug Feed Biocide Screens ...................................................................................... 4-28
4.10.11 System Startup Screens .......................................................................................... 4-29
4.10.12 Test Email Screen .................................................................................................... 4-29
4.10.13 Service Email Screen ............................................................................................... 4-29
4.11 The Alarms Key ................................................................................................... 4-30
4.11.1 Sensor Alarms ......................................................................................................... 4-30

4.11.2 System Alarms ........................................................................................................ 4-30

4.11.3 Communication Errors ............................................................................................. 4-31
4.11.4 Performance Alarms ................................................................................................ 4-31
4.11.5 Control Alarms ......................................................................................................... 4-31
4.11.6 Relay Timeout Alarms .............................................................................................. 4-32
4.11.7 Analog Alarms .......................................................................................................... 4-32
4.11.8 Failsafe Mode .......................................................................................................... 4-32
4.11.9 Startup Mode ........................................................................................................... 4-32
Section 5: 3D TRASAR Scale Control

5.1 Nalco Scale Index (NSI) Measurement ................................................................ 5-1
5.1.1 3D TRASAR Scale Blowdown Control – Uses NSI to Adjust the Blowdown Setpoint ... 5-1
5.1.2 3D TRASAR Scale Tagged Polymer Control – Uses NSI to Adjust the Tagged Polymer
Setpoint ............................................................................................................................. 5-1
5.2 3D TRASAR Scale Blowdown Control ................................................................ 5-2
5.2.1 3D TRASAR Scale Blowdown Control: 1-Drum Program Overview ............................ 5-2
5.2.2 Start-Up Procedure for 1-Drum 3D TRASAR Scale Blowdown Control ...................... 5-3
5.2.3 3D TRASAR Scale Blowndown Control: 2-Drum Program Overview .......................... 5-5
5.2.4 Start-up Procedure for 2-Drum 3D TRASAR Scale Blowdown Control ....................... 5-6
5.3 3D TRASAR Scale Tagged Polymer Control ...................................................... 5-9
5.3.1 3D TRASAR Scale Tagged Polymer Control: 2-Drum Program Overview ................. 5-9
5.3.2 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 Mode

6.1 Nalco Bio-Index Measurement (NBI) ................................................................... 6-2
6.2 Oxidizing Biocide Application and Slug Feeds .................................................. 6-2
6.2.1 3D TRASAR Bio-Control and Overlaid Ox Slugs ........................................................... 6-3
6.2.2 3D TRASAR Bio-Shock Mode ....................................................................................... 6-4
6.2.3 Ox-slug/shock control settings ...................................................................................... 6-4
6.3 Bio-reporter Selection .......................................................................................... 6-5
6.4 3D TRASAR Bio-Control/3D TRASAR Bio-Shock Start-Up Procedure .............. 6-5
6.5 Pellet Feeder Operation ........................................................................................ 6-8
6.6 Filling the Pellet Feeder ........................................................................................ 6-9
6.7 Bio-reporter Initial System Dosing ..................................................................... 6-10
6.8 Pellet Feeder Cleaning ........................................................................................ 6-11
6.9 Pellet Feeder Maintenance ................................................................................. 6-11
6.9.1 Cleaning Pellet Feeder Exit Tube ............................................................................. 6-12
6.9.2 Tighten Valve Seat ................................................................................................... 6-13
6.9.3 Pellet Shield Replacement ....................................................................................... 6-15
6.10 3D TRASAR Bio-Control & 3D TRASAR Bio-Shock FAQ’s .............................. 6-18
Section 7: Communication and Data Management

7.1 3D TRASAR Optimizer .......................................................................................... 7-1
7.2 3D TRASAR Configurator ..................................................................................... 7-1

7.3 3D TRASAR 5500 Controller ................................................................................ 7-1

7.4 SCADA Systems .................................................................................................... 7-1
7.5 3D TRASAR Web ................................................................................................... 7-2
7.5.1 3D TRASAR Web Set Up .......................................................................................... 7-2
7.5.1a Create/Edit Users ...................................................................................................... 7-3
7.5.1b Assign Controllers (Data Sources) ............................................................................. 7-4
7.5.1c Manage Controller (Data Source) Setup Information .................................................. 7-5
7.5.2 3D TRASAR Web Data ............................................................................................. 7-6
7.5.3 3D TRASAR Reports ................................................................................................. 7-7
7.5.4 3D TRASAR Web Alarms .......................................................................................... 7-8
7.6 Vantage V100 ......................................................................................................... 7-9
7.6.1 Import 3D TRASAR Data into Vantage V100 ............................................................. 7-9
7.6.2 Vantage V100 3D TRASAR EZ Reports .................................................................. 7-11
7.6.3 Vantage V100 3D TRASAR Specification Limits ...................................................... 7-13
7.7 Nalco Global Gateway......................................................................................... 7-15
Section 8: Maintenance
8.1 Maintenance Schedule ......................................................................................... 8-1
8.2 Clean Fluorometer Flow Cell ................................................................................ 8-2
8.3 Check/replace Fluorometer Desiccant ................................................................ 8-2
8.4 Check Sensor Calibration .................................................................................... 8-2
8.5 Probe Replacement Schedule ............................................................................. 8-3
8.6 Cleaning Basket / Wye Strainer ............................................................................ 8-3
8.7 Pellet Feeder Maintenance ................................................................................... 8-3
8.8 Check / Refill Pellet Feeder ................................................................................... 8-3
Section 9: Troubleshooting
9.1 General Troubleshooting ...................................................................................... 9-1
9.2 Alarm Screen Troubleshooting ............................................................................ 9-7

Appendix A: Specifications
Appendix B: Drawings
Appendix C: Replacement Parts/Accessories
Appendix D: Air Purging System
Appendix E: SCADA and LAN
Appendix F: 3D TRASAR Starter Upgrade Procedures
Appendix G: 3D TRASAR Technology for Closed Loop Applications
Appendix H: 3D TRASAR Technology for High Fouling Applications
Appendix I: Halogen Analyzer Control
Appendix J: 3D TRASAR Models for the Pacific
Appendix K: Warranty Policy
Glossary

Section 1: Introduction
1.1 About the TRASAR® 3500 and 5500
The Nalco 3D TRASAR ® 5500 is the most advanced water treatment control system on the market
today. The design is based on years of field research and a broad base of industry experience and
application. The introduction and use of the 3D TRASAR 5500 will dramatically change the standard
for cost-efficient and reliable cooling tower control.
The Nalco 3D TRASAR Starter 3500 makes 3D TRASAR technology more accessible. It is customizable
to meet specific user needs, yet offers the flexibility for future upgrades to utilize all features of 3D
TRASAR.
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 is
a better, safer, more reliable system that runs more efficiently.
1.2 About this Manual

This manual is a simple, step-by-step description of what you need to do to get your new system up
and running in the shortest amount of time.
Keep in mind, as you begin, that your Nalco Technical Representative has already done some of the
preliminary configuration work for you. Don’t hesitate to contact that person if you have a question or
problem, as they are familiar with your situation and can be very helpful in addressing any specific
needs you may have.
! Additional help is available at 630-305-CHEM (2436).
1.3 3D TRASAR Starter 3500 and 3D TRASAR 5500 Models and

Optional Components
3D TRASAR 3D TRASAR
Starter
3D TRASAR Starter Fluorometer X
3D TRASAR 6 channel Fluorometer X
3D TRASAR Starter and Modem X X
3D TRASAR comparison. Web Accessibility X X
Conductivity Measurement and Control X X
pH Measurement and Control X
ORP Measurement and Control X
Biocide Timers X X
3D TRASAR Scale Control X
3D TRASAR Bio-Control X
Nalco Corrosion Measurement X
Technical Help 521-OM0108.88 1-1

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

Optional Components (con’t)
The 3D TRASAR 3500 and 5500 are available in a variety of models. T
alk to your Nalco
representative about which model is right for your application.
3D TRASAR 3D TRASAR Description
Starter Models Models
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 and
pre-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 and
3D TRASAR Starter
060-TR3530.88 060-TR5530.88 Air Purged Wall Mount w/ Juncti on Box
Wall Mount unit
060-TR3532.88 060-TR5532.88 Air Purged Wall Mount w/J-Box and
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 Applications
060-TR5515.88 Wall Mount for Hi gh Fouling Applications
060-TR5516.88 Frame Mount for Hi gh Fouling Applications
060-TR5525.88 Enclosed Wall Mount for Hi gh Fouling
Applications
060-TR5526.88 Enclosed Frame Mount for Hi gh Fouling
Applications
Accessories
060-TR5120.88 Bio-Reporter Pellet Feeder, for systems
greater than 12,000 gal
141-PJ4035.88 Liquid Bio-Reporter Pump, Iwaki, for
systems 3,000 to 12,000 gal
6008505 Liquid Bio-Reporter Pump, Grundfos, for
systems less than 3,000 gal
060-TR5540.88 High Pressure Water Reinjection System 3D TRASAR
060-NGG100.88 Nalco Global Gateway US (Domestic) with Frame Mount unit
1-year contract
060-NGG200.88 Nalco Global Gateway International with 1-
year contract
500-TSRKITSTR.88 TR3500 Start-Up Calibration Kit
500-TSRKIT.88 TR5500 Start-Up Calibration Kit
Enclosed Frame Mount unit

with Junction Box
and Pellet Feeder

1.4 3D TRASAR 3500 and 5500 Overview
Stress Management for Cooling Systems

Communications
Pager
(NCM100) Cell phone
Palm
Performance-Based Control Corrosion Laptop
Save energy and water DCS
Reduce manpower Web
Increase throughput
Improve product quality
Extend equipment life
Enhance safety
Predict cash needs
Knowledge Management
Vantage V100
Microbio Scale/Fouling
(3D Sc
- Control) a le Con
io trol)
(3D B
Blowdown
Biocides Inhibitor I Inhibitor II Acid Pump
Valve
The 3D TRASAR 5500 utilizes state-of-the-art optical fluorescence sensing to monitor and control
chemical 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 system
stresses before costly scaling and fouling can occur.
The 3D TRASAR Starter 3500 utilizes proven TRASAR technology to monitor and control chemical
feed. Features of the 3D TRASAR 5500 are available as upgrades to the 3D TRASAR Starter
3500.

1.5 How the 3D TRASAR System Works
1.5.1 Fluorometer
TRASAR chemistries contain a uniquely fluorescing molecule that allows the fluorometer to detect
exactly how much chemical has been fed in order to determine chemical residual. This information
is 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 Nalco
products 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 . As
a solid-state device, the fluorometer offers trouble free long life.
Water Sample Out
Detector
Excitation
Filter
Emission
Filter
Flow
LED Cell
Light
Source
Water
Water Sample In
1.5.2 3D TRASAR Scale Control, 3D TRASAR Bio-Control, and NCM Corrosion

Technology
3D TRASAR Scale Control, 3D TRASAR Bio-Control and NCM Corrosion Monitoring T
echnology
are 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 occur
without 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 cooling
water 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 an
innovative “tagged” high stress dispersant polymer. As scale forming particles increase in the
cooling system, the active polymer is consumed. By monitoring this consumption rate and the active
polymer level, 3D TRASAR Scale Control can take corrective action well before the conditions
needed 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 in

cooling systems. Afluorescent “bio-reporter” is introduced into the cooling system and reacts
enzymatically with microbes. The reaction changes the bio-reporter’s fluorescent signature. 3D
TRASAR Bio-Control measures the difference between the reacted and unreacted bio-reporter and
adjusts biocide feed to optimize control. 3D TRASAR Bio-Control is the only bio-control system
available that adjusts system operation in response to changes in bio-activity. This unique Nalco
innovation 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. This
patented 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) corrective
action 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 measurements
to a central database that is accessible via the Internet. This allows operational data to be viewed
and 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 Safety
Always 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 exceed
90 psi.
• Maximum water temperature should not exceed 120 deg F.
• Always wear the appropriate Personal Protective Equipment (PPE) when working on a 3D
TRASAR 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 system
components.
NOTE: Both the 3D TRASAR controller and the Bio-reporter Pellet Feeder operate well
! below 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.
Unpack and identify Mount controller Install Bio-Reporter feeder
Details Details Details

Section Section Section
2.1 2.2 2.3
Install Main Control Panel in well-lit, dry Install Bio-Reporter Feeder in well-lit, dry
Unpack all parts and identify them. location convenient to points of use.
location convenient to points of use. Mount
at eye level.
Plumb controller Plumb bio-reporter feeder Install probes
Details Outlet Details Details

½”
Section Union
0.5
Section Section
2.4
GPM
2.5 2.6
ORP Probe
Plumb utilizing ball valves provided. Inlet Connect discharge back to recirculating Install probes and attach connectors.
water from recirculating system must be at system downstream from supply in basin
5 GPM or greater. where possible.
Wiring Calibration & checkout Start-up system
Details Details
Section Section Details
2.7 2.8 Section
2.9
Connect cable between controller box and pellet feeder.

Wire pumps using supplied pigtails (or hardwire). Connect Calibrate probes following instruction on Enter set points.
85 to 250 VAC @ 20 amps power using supplied power screen. You are up and running!
cord (or hardwiring).

2.1 STEP 1 - Unpack and Identify Unpack and identify
IMPORTANT: If you do not have all of the items

needed for your application, call your Nalco
! representative before proceeding.
2.1.1 Identify Hardware Model
Unpack and identify all parts.

Hardware Models
3D TRASAR 3D TRASAR
Description
Starter Model Model
060-TR3500.88 060-TR5500.88 Wall Mount, S mall 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 Fouli ng Applications
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.
2.1.1 Identify Hardware Model (con’t) Unpack and identify
Small Back Panel Large Back Panel

Part # 060-TR3500.88, Part # 060-TR3510.88,
060-TR5500.88 (wall mount) 060-TR5510.88 (wall mount)
!
Drawings shown with all probes
assembled. pH, ORP, and Cor-
rosion probes are av ailable as
upgrades for 3D TRASAR 3500
systems.
Enclosed Part # 060-TR3520.88, Air Purged Part # 060-TR3530.88,

060-TR3522.88, 060-TR5520.88, 060-TR3532.88, 060-TR5530.88,
060-TR5522.88 (wall mount) 060-TR5532.88 (wall mount)
Bio-reporter Feed Options
Recommended for
Model Number Description
system sizes:
060-TR5120.88 Pellet Feeder Assembly 12,000 gallons and larger
141-PJ4035.88 Liquid Bio-reporter pump, Iwaki 3,000 to 12,000 gallons
6008505 Liquid Bio-reporter pump, Grundfos Less than 3,000 gallons

2.1.2a Pre-Installed Items (all models) Unpack and identify
Conductivity Probe Fluorometer Cable

Qty. (1) 3/4” Ball Valve Qty. (1)
Part # 060-TR5432.88 Qty. (2) Part # 060-TR5221.88
2.1.2b Pre-Installed Items

(3D TRASAR 5500 models only)
ORP Probe Cable pH Probe Cable
Qty. (1) Qty. (1)
Part # 060-TR5422.88 Part # 060-TR5412.88
2.1.3a Items Requiring Assembly (all models)
Fluorometer Fluorometer Outlet Fluorometer Inlet Valve Pigtail 16/3 SJOW

Qty. (1) Assembly and Tubing Connector Qty. (5)
Part # 060-TR5220.88 (3D) Qty. (1) Qty. (1) Part # 991-05053481.88
or 060-TR3220.88 (Starter)
Ethernet Crossover Cable (6 ft., orange) Service (Power) Cord 12/3 SJOW Additional Items
Qty. (1) Qty. (1) Replacement Fuses (4), Part # 991-50473718.88
Part # 991-05047661.88 Part # 991-01928722.88 Installation and User Manual, Part # 521-OM0108.88
2.1.3b Items Requiring Assembly

(3D TRASAR 5500 models only)
pH Probe
Qty. (1) Corrosion Probe
Part # 060-TR541 1.88 Probe Restraint Device Qty (2) (Steel and Copper std.)
Qty. (2) Part # 400-NCMP1B.88 (steel)
Part # 400-NCMAC15.88 Part # 400-NCMP2B.88 (copper)
ORP Probe Part # 400-NCM4B.88 - Cu/Ni 90/10 (optional)
Qty. (1) Part # 400-NCMP5B.88 - Cu/Ni 70/30 (optional)
Part # 060-TR5421.88 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)

2.1.4 Pellet Feeder Assembly (Optional)

Unpack and identify
PELLET
FEEDER
25'
Pellet Feeder Cable (25 ft.)
Qty. (1)
Part # 060-TR531 1.88
(shipped with pellet feeder only)
Additional Items
Pellet Feeder Brush Part # 500-P2818.88 Unpack and identify all parts.
Pellet Feeder Assembly

Qty. (1)
Part # 060-TR5120.88
2.1.5 Items Shipped Separately

2.1.5a 3D TRASAR Starter Upgrades
Part # Upgrade Upgrade Includes
060-TR3200.88 Fluorometer Patented 3D TRASAR technology upgrade procedure, 3D TRASAR

Fluorometer, rebate return instructions and upgrade confirmation sticker.
060-TR3205.88 NCM Patented NCM technology upgrade procedure, 2 probe restraints, 2

NCM probe f ittings, and upgrade confirmation sticker (purchase NCM
probes 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.
2.1.5b 3D TRASAR Start-up and Maintenance Kits

3D TRASAR 3500 Start-up Kit
(must be ordered separately)
Part # 500-TSRKITSTR.88
Includes:
3D TRASAR Cal Soln, 1L 460-S0940.75
10% Sulfuric Acid Soln, 1L 460-S0800.75
Fluorometer Probe Brush 500-P2817.88
Plastic beakers, qty 3, 500 mL 500-P0116.88
Plastic syringe, qty 3, 60 cc 500-P2147.88
3D TRASAR 5500 Start-up Kit
(must be ordered separately)
Part # 500-TSRKIT.88
Includes:
3D TRASAR Cal Soln, 1 L 460-S0940.75
pH 7.0 Buffer Soln, 1 L 460-S0407.75 Maintenance Value Package
pH 10.0 Buffer Soln, 1 L 460-S0408.75 (must be ordered separately , order 2 per year)
ORP 200 mv Buffer Soln, 1 L 460-S0932A.75 Part # 060-TRMNKIT.88
ORP 600 mv. Buffer Soln, 1 L 460-S0933A.75 Includes all components of the 3D TRASAR 5500
10% Sulfuric Acid Soln, 1 L 460-S0800.75 Start-up Kit plus:
NCM probe Mild Steel with ferrule 400-NCMP1B.88 pH probe 060-TR5411.88
NCM probe Copper with ferrule 400-NCMP2B.88 ORP probe 060-TR5421.88
Fluorometer Probe Brush 500-P2817.88 NCM probe, Mild Steel, with ferrule 400-NCMP1B.88
Plastic beakers, qty 3, 500 mL 500-P0116.88 NCM probe, Copper, with ferrule 400-NCMP2B.88
Plastic syringe, qty 3, 60 cc 500-P2147.88 (includes 2 of each NCM probe)
Fluorometer desiccant cannister 060-TR5222.88
Fluorometer desiccant indicator 060-TR5223.88

2.2 STEP 2 - Mount the Controller Mount controller
IMPORTANT: The 3D TRASAR controller is

designed to meet NEMA 4X standards for weather
! resistance. It is recommended that the unit be
installed in a sheltered area to minimize the
chance of water or debris entering the enclosure
when the cover is opened for wiring and mainte-
nance.
In order to maintain the NEMA 4X rating:
• Unused cord grips must remain plugged. Install Main Control Panel in well-lit, dry
location convenient to points of use. Mount at
• Enclosure cover must be tightly closed at eye level.
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 it
to a maximum of 100ft.
b. The Pellet Feeder should be plumbed to the bottom 3/4” sensor outlet piping of the
3D 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-reporter
tank and the 3D TRASAR controller.
8. Chemical feed pumps should also be mounted conveniently to the 3D TRASAR controller
and chemical feed tanks.

2.2.2 3D TRASAR Controller Dimensions

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

060-TR3501.88, 060-TR5501.88

Wall Mount with Junction Box

060-TR3510.88, 060-TR5510.88 Mount controller
Frame Mount with Junction Box

060-TR3511.88, 060-TR5511.88

Enclosed Wall Mount with Junction Box

060-TR3520.88, 060-TR3522.88, Mount controller
060-TR5520.88, 060-TR5522.88
Enclosed Frame Mount with Junction Box

060-TR3521.88, 060-TR3523.88
060-TR5521.88, 060-TR5523.88

Air Purged Wall Mount with Junction Box

060-TR3530.88, 060-TR3532.88 Mount controller
060-TR5530.88, 060-TR5532.88
Air Purged Frame Mount with Junction Box

060-TR3531.88, 060-TR3533.88
060-TR5531.88, 060-TR5533.88

2.2.3 Wall Mounting Templates

Mount controller
Panels should be mounted on a flat wall so that

the controller display is at eye level.
Use the template below to locate and drill mounting

holes for Model #s 060-TR3500.88 and
060-TR5500.88 (approximate weight 75 lbs).
Note: For ease of installation, use 3D TRASAR

easy mounting bracket Part # 060-TR5245.88.
! For models 060-TR3500.88 and 060-TR5500.88 only.
Dimensions shown are in inches

Use the template below to locate and drill mounting holes

for Model #s 060-TR3510.88 and 060-TR5510.88 Mount controller
(approximate weight 90 lbs).

Use the template below to determine the space require-

ment for Model #’s 060-TR3520.88, 060-TR3522.88, Mount controller
060-TR3530.88, 060-TR3532.88, 060-TR5520.88,
060-TR5522.88, 060-TR5530.88, 060-TR5532.88
(approximate weight 200 lbs.)
Exact hole locations for these units are not available due to variations in manufacturing runs from
the enclosure supplier.

2.2.4 Frame Mount Template

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

2.3 STEP 3 - Install Bio-reporter Feeder Install bio-reporter feeder
The 3D TRASAR bio-control feature requires the use of a

bio-reporter feed system. The bio-reporter product comes in
either 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 TRASAR

bio-control feature.
2.3.1 Install Bio-reporter Pellet Feeder Install Bio-Reporter Feeder in well-lit, dry
location convenient to points of use.
WARNING: Never install the pellet feeder in an explosion rated atmosphere. The
! pellet feeder does not have an explosion proof rating!
WARNING: Always shut-off power before opening the pellet feeder lid and placing your
! hands inside the hopper. NEVER insert your fingers in the pellet drop holes at the
bottom of the hopper!
! WARNING: Never attempt to lift the pellet feeder with a mechanical device, i.e. forklift!
1. Attach the pellet hopper and plumbing assembly to the

stand as shown on the next page.
2. Locate the pellet feeder to the right of the 3D TRASAR
controller (as you face the controller) within 10 ft.
3. It is recommended that the Pellet Feeder be installed in a
sheltered area to minimize the chance of water or debris
entering the hopper when the lid is open.
4. 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 it to a maximum of 100 ft.
5. The Pellet Feeder should be anchored by either (1) the
installed plumbing or (2) by removing the base feet and
bolting to the floor.
Note: The Overflow Container (P/N

060-TR5350.88) shown in the photo
must be ordered separately.

2.3.2 Install Liquid Bio-reporter Pump

Install bio-reporter feeder
Install the liquid bio-reporter feed pump in a loca-
tion convenient to the bio-reporter tank and the 3D
TRASAR controller.
IMPORTANT: Ensure that the suction side

! of the bio-reporter pump is always flooded!
Install Bio-Reporter Feeder in well-lit, dry

location convenient to points of use.
For cooling systems with volumes

less than 3,000 gallons, use
Grundfos pump (P/N 6008505).
For cooling systems with

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

2.4 STEP 4 – Plumb Controller Plumb controller

The 3D TRASAR system has one sample water inlet
plumbing connection and two sample water outlet Outlet
½”
plumbing connections. Refer to the Typical Installation Union
0.5
Drawing in Section 2.4.5 for a general installation GPM
overview.
2.4.1 Sample Point Selection
IMPORTANT: Sample water flow must be a Plumb using ball valves provided. Inlet
! minimum of 5 gpm.
water from recirculating system must be
at 5 GPM or greater.
It is very important to select the appropriate sampling point for your cooling system. Sample points
are system dependent and should be taken from one of the following two locations:
1. Recirculating Pump Discharge - Sample points from the recirculating pump discharge
provide the maximum pressure opportunity for achieving the 5 gpm flow requirement of
the 3D TRASAR system and the Pellet Feeder.
2. Return Header to Cooling Tower - Sample points from the return header give the best
representation 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 lag
times of the chemical feed (lag time is the time it takes the chemical to travel from point of injection
to the controller). In general, the shorter the lag time, the better the control (provided good mixing
has been achieved and recirculation rates are nominal). However, in cooling systems, the effects of
long lag times can be compensated for by decreasing the feed rate of the chemical pump, which
will reduce set-point overshoot.
Consult your Nalco representative for the appropriate sample point location for your system.

2.4.2 3D TRASAR System Inlet Water Plumbing Plumb controller
• Required flow rate through the sample piping is 5 Outlet

gpm total (>0.5 gpm is routed through the Fluorom- ½”
Union
eter and up to 4.5 gpm goes through the sensors). 0.5
GPM
• Plumb the 5 gpm sample water to the inlet ball valve
(¾” female NPT).
• Maximum inlet water pressure should not exceed 90
psig.
• Inlet water temperature should be between 40 and
120 deg F.
Plumb using ball valves provided. Inlet

Inlet Ball Valve
Note: If the required 5 gpm flow cannot be achieved through normal system operating
pressures, 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 the

3D TRASAR system with the operation of the cooling system. In the event that the cooling
! system SHUTS DOWN the booster pump may continue to supply sample water to the 3D
TRASAR system. In this case, all controlling relays will continue to function causing an
overfeed of chemical or excessive blowdown. Refer to Section 2.7.14 for System Interlock
wiring details.

2.4.3 3D TRASAR System Outlet Water Plumbing

Plumb controller
Outlet
½”
Union
0.5
GPM
Plumb using ball valves provided. Inlet

Outlets
• 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 basin
b. Drain
c. 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 basin
c. Lower pressure point in system (minimum differential of 20 psig)
d. Drain (not recommended)
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.

2.4.4 Chemical Feed Pumps

Plumb controller
• Install the chemical feed pumps (inhibitors, dispers-
ants and biocides) as conveniently to the 3D Outlet
½”
TRASAR system and chemical tanks as possible. Union
0.5
• Use pumps that are properly sized for the applica- GPM
tion.
o Oversized pumps can result in product
overfeeds, which can damage the cooling
system.
o Undersized pumps can result in repeated
timeout alarms, which are triggered when a
relay is energized for longer than a user
specified time. Plumb using ball valves provided. Inlet
• Do not inject chemicals immediately upstream of the at 5 GPM or greater.
3D TRASAR sampling point. Chemical injection
points should allow for good mixing prior to reaching
the 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 Equipment
Solutions Group (NGES). Please call (800)323-8483 or (630) 848-3387 for assistance with
selecting the right pump for your application.
Chemical feed pumps available through NGES

2.4.5 Typical Installation Drawing

2.5 STEP 5 – Plumb Bio-reporter Feeder Plumb bio-reportersm feeder

The 3D TRASAR bio-control feature requires the use of a
bio-reporter feed system. The bio-reporter product comes
in either pellet or liquid form.
• If using bio-reporter pellets refer to 2.5.1

To Recirc.
• If using bio-reporter liquid refer to 2.5.3 Water
5 GPM
Note: Not all 3D TRASAR installations use the 3D TRASAR
bio-control feature. Pellet Feeder requires 4 to 5 gpm flow
2.5.1 Pellet Feeder Plumbing
Connect discharge back to recirculating
WARNING: Always shut-off power before opening system downstream from supply in basin
where possible.
the pellet feeder lid and placing your hands inside
! the hopper. NEVER insert your fingers in the
pellet drop holes at the bottom of the hopper!
! WARNING: Maximum inlet water pressure should not exceed 90 psig.
IMPORTANT: The Bio-reporter pellet feeder requires a minimum sample water flow of 4.5
! GPM. The sensor outlet from the 3D TRASAR system or a separate water source can be
used as long as it is returned to the cooling system.
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 theBio-reporter
Liquid Overflow Container (P/N 060-TR5350.88) as shown below. The Overflow
Container must be ordered separately.

2.5.2 Pellet Feeder Best Practices

Plumb bio-reportersm feeder
• The pellet feeder hopper must be maintained with
an adequate supply of pellets at all times.
• Insert the pellet desiccant into the holder
mounted inside the hopper cover.
• Replacement desiccants are included in each
new bottle of pellets and should replace old To Recirc.
Water
desiccants whenever the hopper is refilled. 5 GPM
• The hopper lid must remain tightly closed except
when refilling.
Pellet Feeder requires 4 to 5 gpm flow
• It is recommended that the feeder be installed in
a sheltered area to minimize the chance of water
or debris entering the hopper when the cover is Connect discharge back to recirculating
system downstream from supply in basin
opened for refilling and maintenance. where possible.
• When the Pellet Feeder is not in use (especially
when temperatures are near freezing), it is
strongly recommended to drain the plumbing manifold. Simply close off the inlet and
outlet 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-reporter
pump to a point of good circulation (mixing) sufficiently away from any biocide feed points.
For system volumes be- For system volumes

tween 3,000 and 12,000 less than 3000 gallons,
gallons, use Iwaki pump use Grundfos pump
(P/N 141-PJ4035.88). (P/N 6008505).

2.6 STEP 6 – Install Probes

Installprobes
Install probes
The table below indicates the types of probes included
with the 3D TRASAR Starter and 3D TRASAR systems.
ORP Probe
3D TRASAR 3D TRASAR
Starter
3D TRASAR Starter Included N/A
Fluorometer
3D TRASAR 6 channel Upgrade Included
Fluorometer
Conductivity Included Included
pH Upgrade Included
ORP Upgrade Included Install
Installprobes andand
probes attach
attach
Corrosion NCM100 Upgrade Included connectors.
connectors as shown.
Tighten swage fitting fully.
IMPORTANT: Corrosion Probe #1 must be mild
! steel if mild steel is one of the two metallurgies.
Refer to the chart below for the order of optimal
corrosion probe locations.
s
as
m
el
el
Ste
nu
Ste
Br
er
mi
pp
/N
m
lv
ld
Alu
Ga
Cu
Co
Ad
Mi
Probe #1 Probe #2
Fluorometer
Refer to the drawing on

the left for the installa-
tion location of each
probe.
Conductivity Probe
Corrosion Probe #2
Corrosion Probe #1
pH Probe ORP Probe
WARNING: Always turn off power before making any electrical connections, which in-
! cludes all interconnecting cables, otherwise permanent damage may occur to system
components.
2.6.1 Fluorometer Installation

Install
Installprobes
probes
The fluorometer is shipped unattached to prevent damage.
Install as follows: ORP Probe
STEP 1 - Locate and unpack the fluorometer,

fluorometer inlet valve, tubing connector, and
fluorometer outlet assembly (comprised of a
flow switch housing and three-way ball valve).
STEP 2 - Attach the inlet valve and tubing connector to
the fluorometer inlet using teflon tape Install
probes attach
attach
(Do not over tighten). connectors.
STEP 3 - Thread the fluorometer outlet assembly to Tighten swage fitting fully.
outlet of the fluorometer (do not overtighten).
STEP 4 - Remove the end cap from the sample supply tubing. Connect the supply tubing to
the fluorometer inlet tubing connector.
STEP 5 - Mount the fluorometer (and outlet assembly) to the back panel with the screws
provided. DO NOT FORCE!
IMPORTANT: The length of the sample supply tubing may need to be adjusted to attain
proper alignment of the mounting screws with the back panel. DO NOT BEND sample
! tubing. Excessive force may break fluorometer inlet fitting and internals.A broken inlet
fitting will necessitate the purchase of a new fluorometer which will not be covered under
warranty.
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 with
the flow switch assembly (slotted holes are provided on the three-way valve bracket
for adjustments.)
STEP 7 - Connect the pre-installed fluorometer cable to the fluorometer.

2.6.2 pH Probe Installation

Installprobes
Install probes
Install the pH probe as follows:
STEP 1 - Carefully unpack the pH probe. ORP Probe
STEP 2 - Apply 5 revolutions of Teflon tape to

the pH probe threads.
STEP 3 - Hand tighten the probe in the

threaded tee location indicated in
Section 2.6
STEP 4 - Connect pH probe to pH cable (cable Install

probes attach
attach
is labeled pH.) connectors.

2.6.3 ORP Probe Installation

Installprobes
Install probes
Install the ORP probe as follows:
STEP 1 - Carefully unpack the ORP probe. ORP Probe
STEP 2 - Apply 5 revolutions of Teflon tape to

the ORP probe threads.

Section 2.6.
STEP 4 - Connect the ORP probe to ORP Install

probes attach
attach
cable (cable is labeled ORP). connectors.

2.6.4 Conductivity Probe Installation

Installprobes
Install probes
The Conductivity probe is shipped installed.
Verify probe is hand tight in the tee and the
cable is firmly connected to the controller and ORP Probe
probe.
Install
probes attach
attach
connectors.

2.6.5 NCM Corrosion Probe Installation

Installprobes
Install probes
The 3D TRASAR 5500 system is shipped with 1 mild
steel corrosion probe and 1 copper corrosion probe.
ORP Probe
Corrosion monitoring is an available upgrade for 3D

TRASAR Starter 3500 systems.
IMPORTANT: Brass, CuNi 90/10, CuNi

70/30, aluminum, and galvanized steel
! probes can be ordered separately. Refer
to the Appendix for part numbers.
Install
probes attach
attach
Install the corrosion probes as follows: connectors.
STEP 1 - Carefully unpack both corrosion probes and
locate the two probe restraints.
NCM Probe Restraint

P/N 400-NCMAC15.88
STEP 2 - Attach the probe restraints to each probe. The ring portion of the restraint is installed
between 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)

Installprobes
Install probes
STEP 3 - Insert the mild steel probe in location #1 ORP Probe
as indicated in Section 2.6. Probe tips

must be parallel to the ground. Two
raised dots on the probe end cap can be
used to orient the tips.
Install
probes attach
attach
connectors.
STEP 4 - Insert the copper probe in location #2 as indicated in Section 2.6. Probe tips must be
parallel to the ground. Two raised dots on the probe end cap can be used to orient
the 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 one
input connection on each side of the controller). The 3D TRASAR controller
automatically recognizes the probe metallurgy – no calibration is required.

2.7 STEP 7 - Wiring Wiring
WARNING: Always turn off power before

making any electrical connections, which
! includes all interconnecting cables, other-
wise permanent damage may occur to
system components.
Electrical connections to the 3D TRASAR are either made

directly to the controller box or a junction box depending on
which model you have:
Connect cable between controller box and

Junction Box pellet feeder. Wire pumps using supplied
pigtails (or hardwire). Connect 85 to 250
VAC @ 20 amps power using supplied
power cord (or hardwiring).
3D TRASAR electrical connections are made

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

in the junction box for all other models.
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 12AWG. 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 contacts
for motor starters.
• Alarm outputs are fused at 1 amp.
• Refer to the following diagrams and charts for details on wiring connections.

2.7.2
Controller
Box 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)

Wiring
Notes:
1. Relay voltage jumpers (terminals 4 & 5) -
Remove for non-powered output. Refer 2.7.8
and 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.

2.7.4 Junction Box Layout

2.7.6 System Power Connections

(User Wired in Controller Box or Junction Box) Wiring
For models 060-TR3500.88, 060-TR3501.88, 060-TR5500.88 and 060-TR5501.88, the incoming

power connections are made in the controller box. Power connections are made in the junction box
for all other models.
Connection Controller Box Controller Box Junction Box

Wire Color
Description Board Reference Terminal Terminal
Ground TB9-4 Gnd Not used Not used
Ground TB9-3 Gnd Gnd Green
Neutral TB9-2 N T2 White
Line Power TB9-1 L T1 Black
2.7.7 Internal Power Connections

(Factory Wired in Controller Box)
Connection Controller Box Controller Box
Wire Color
Description Board Reference Terminal
Power Switch Neutral E1 N Black-1
Power Switch Line E2 L Black-2
Switched AC Neutral E3 N Black-3
Switched AC Line E4 L Black-4

2.7.8 Control Relay Connections - Powered

(120 VAC fused @ 2.5 amps) Wiring
(User Wired in Controller Box or Junction Box)
There are 7 pre-defined control relays in the 3D TRASAR controller that can be wired for powered
or non-powered operation. Follow the wiring diagrams below to connect metering pumps and
valves for powered control relay outputs (120 VAC, fused @ 2.5 amps).
In order to power the relay with 120 VAC, a jumper must be placed across
! control relay terminals 4 & 5 in the controller box, or the Line & COM terminals in
the junction box.
Typical Powered Relay Typical Powered Relay

from Controller Box from Junction Box
Fuse
Fuse
Contact
Contact
1 2 3 4 5
1 2 3 4 5
NO N L COM
NO N L COM
WHT
GRN
BLK
Controller
Controller Box
Box
Earth Ground Bus

LINE COM NO N
GRN
WHT
Typical Powered Relay

BLK
Jumper
Output from Controller Box

Controller Box supplies Junction
Line, Neutral, & Earth Gnd
Box
Typical Powered Relay

Output from Junction Box

2.7.9 Control Relay Connections - Non-Powered

(fused @ 2.5 amps) Wiring
There are 7 pre-defined control relays in the 3D TRASAR controller that can be wired for powered
or non-powered operation. Follow the diagrams below to connect motor starters and/or solenoids
for non-powered control relay outputs (fused @ 2.5 amps).
The factory wired jumper must be removed from control relay terminals 4 & 5
! in the controller box, or the Line & COM terminals in the junction box, in order
to remove power from the relay output.
Typical Non-Powered Relay Typical Non-Powered Relay

from Controller Box from Junction Box
Fuse
Fuse
Fuse
Fuse Contact 2.5 amp
Contact
Contact 2.5 amp
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5 NO N L COM
NO N L COM
NO N L COM
Controller
Box
Controller
Box
Controller
Box Ear
th
LINE COM NO
Earth Ground Bus
N Gr
ou
nd
Motor
Bu
Starter s
Controller Box supplies

Line, Neutral, & Earth
Gnd
Junction
Box
External Motor External Motor
Starter Neutral (-) Starter Power (+)
Motor
Starter
External Motor External Motor

Starter Power (+) Starter Neutral (-)

2.7.10 Control Relay Connections -

Termination Details Wiring
The table below lists the different control relays and their
associated terminal connections in the controller box and
junction box.

Junction Box Terminal
TRASAR Feed -
TB1-1 NO1 TRASAR - NO1
Relay 1
TB1-2 N TRASAR - N
TB1-3 Gnd Ground Bar
TB1-4 L TRASAR - L
TB1-5 COM1 TRASAR - COM1
Tag Polymer Feed -
TB2-1 NO2 TAG POLYMER - NO2
Relay 2
TB2-2 N TAG POLYMER - N
TB2-4 L TAG POLYMER - L
TB2-5 COM2 TAG POLYMER - C OM2
Bio-reporter Liquid
TB3-1 NO3 BIO-REPORTER - NO3
Feed - Relay 3
TB3-2 N BIO-REPORTER - N
TB3-4 L BIO-REPORTER - L
TB3-5 COM3 BIO-REPORTER - C OM3
Oxidizing Biocide
TB4-1 NO4 OXIDE BIOCIDE - NO4
Feed - Relay 4
TB4-2 N OXIDE BIOCIDE - N
TB4-4 L OXIDE BIOCIDE - L
TB4-5 COM4 OXIDE BIOCIDE - COM4

2.7.10 Control Relay Connections - Termination

Details (con’t) Wiring

Non-Oxidixing
Biocide Feed - TB5-1 NO5 NONOX BIOCIDE - NO5
Relay 5
TB5-2 N NONOX BIOCIDE - N
TB5-4 L NONOX BIOCIDE - L
TB5-5 COM5 NONOX BIOCIDE - COM5
Blowdown Valve -
TB6-1 NO6 BLOWDOWN - NO6
Relay 6
TB6-2 N BLOWDOWN - N
TB6-4 L BLOWDOWN - L
TB6-5 COM6 BLOWDOWN - C OM6
pH Control Feed -
TB7-1 NO7 pH CONTROL - NO7
Relay 7
TB7-2 N pH CONTROL - NO7
TB7-4 L pH CONTROL - L
TB7-5 COM7 pH CONTROL - C OM7

2.7.11 Pellet Feeder Connections

(User wired in Controller Box or Junction Box) Wiring
The pellet feeder is wired using the supplied pellet feeder

cable (P/N 060-TR5311.88). The cable needs to be hardwired at the controller and connected to
the pellet feeder via the cable connector. The pellet feeder operates on 24 VDC, 0.5 amp, power.
Controller Box
Connection Controller Box Terminal Junction Box
Wire Color
Description Board Reference (Removable Terminal
Connector)
Pellet Feeder TB11 ISO Gnd Gnd Blue with White stripe
TB11 B B Orange with White stripe
TB11 A A White with Orange stri pe
TB11 ISO Gnd Gnd Black
TB11 24V 24V White with Blue stripe
Important: Pay close attention to orientation and placement of terminal block

! for Pellet Feeder. Miswiring, or improperly placing the terminal on the
controller board could damage both pellet feeder and controller, which is not
coveed under warranty.
2.7.12 System Probe Connections

(Factory wired in Controller Box)
Probe wiring for the Fluorometer and Conductivity probe is done at the factory
.
Probe Controller Box Controller Box Terminal

Wire Color
Description Board Reference (Removable Connector)
Fluorometer TB15 A White with Orange stripe
TB15 B Orange with White stripe
TB15 Gnd Blue with White stripe
TB15 6V White with Blue stripe
Conductivity J7-1 Wht White
J7-2 Blk Black
J7-3 Gnd Shield
J7-4 Red Red
J7-5 Blk Black
J7-6 Gnd Shield
J7-7 Grn Green
J7-8 Blk Black
J7-9 Gnd Shield

2.7.12 System Probe Connections (con’t)

(pH, ORP and Corrosion cables are factory wired in the Wiring
Controller Box for 3D TRASAR 5500 models.
Corrosion cables are factory wired, and pH and ORP
cables are user wired in the Controller Box for upgraded
3D TRASAR Starter 3500 Models.)
The pH, ORP, and corrosion probes must be installed and connected using the quick disconnects.
Probe Controller Box Controller Box Terminal

Wire Color
Description Board Reference (Removable Connector)
pH J4 + Black
J4 Gnd Shield
ORP J5 + Black
J5 Gnd Shield
Corrosion 1 J2 Removable Connector Not Used
J2 Removable Connector Not Used
J2 Removable Connector Black
J2 Removable Connector Blue
J2 Removable Connector Green
J2 Removable Connector Brown
J2 Removable Connector Orange
Corrosion 2 J1 Removable Connector Not Used
J1 Removable Connector Black
J1 Removable Connector Blue
J1 Removable Connector Green
J1 Removable Connector Brown
J1 Removable Connector Orange
IMPORTANT: Make sure the pH and ORP probes are connected to the appropriate
! terminals as they look very similar and will display a reading even if connected improperly.

2.7.13 Analog I/O Connections

There are (2) 4-20ma inputs and (8) 4-20ma outputs

available in the 3D TRASAR controller. Both are non-isolated.
The analog inputs must be externally powered. They can be used to control conductivity
, pH, and
ORP. Refer toAppendix I for information on the halogen analyzer
.
The analog outputs are internally powered for a max. load of 600 ohms. The analog outputs can be
used to transmit any of the following variables:TRASAR product dosage, Tag Polymer product
dosage, Cell Fouling, Nalco Scale Index, Nalco Bio-Index, Conductivity, pH, ORP, Corrosion
#1, Corrosion #2, and Sample Water Temperature.
Controller Box Terminal

Connection Controller Box Junction Box
(Removable
Connector)
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 Output 2 TB17 2+ AO2 (+)
TB17 2- AO2 (-)
4-20ma Output 3 TB17 3+ AO3 (+)
TB17 3- AO3 (-)
4-20ma Output 4 TB17 4+ AO4 (+)
TB17 4- AO4 (-)
4-20ma Output 5 TB17 5+ AO5 (+)
TB17 5- AO5 (-)
4-20ma Output 6 TB17 6+ AO6 (+)
TB17 6- AO6 (-)
4-20ma Ouput 7 TB17 7+ AO7 (+)
TB17 7- AO7 (-)
4-20ma Output 8 TB17 8+ AO8 (+)
TB17 8- AO8 (-)

2.7.14 Factory Wired Digital Inputs

(Factory Wired in Controller Box or Junction Box) Wiring
There are two factory wired digital inputs. The first is the
fluorometer 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 that
operate 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 ofALL
control relays and initiate an alarm.
Controller Box
Connection Controller Box Terminal
Description Board Reference (Removable
Connector)
Digital Input 1
Fluorometer Flow TB10 Flow (+) N/A
Switch
TB10 Flow (-) N/A
Digital Input 2
TB10 INTERLOCK (+) INT (+)
System Interlock
TB10 INTERLOCK (-) INT (-)
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 an
unpowered contact or totalize the counts from a low frequency pulse water meter. Note: Please call
630-305-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 TRASAR
Configurator. Note: The minimum on-time and off-time pulse width is 5 milliseconds for a valid
pulse. The maximum number of pulse counts is 10 per second.

Connection Controller Box Junction Box
(Removable
Connector)
Digital Input 3 TB10 3 (+) DI3 (+)
TB10 3 (-) DI3 (-)
Digital Input 4 TB10 4 (+) DI4 (+)
TB10 4 (-) DI4 (-)

2.7.16 Alarm Output Connections

There are two different alarm outputs. The first is a

general alarm (fused @ 1.0 amp) that is initiated by any
of 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 are
fully enclosed. This alarm is initiated if water starts accumulating in the enclosure. This alarm
should be sent to a location where it can be responded to as quickly as possible to avoid damaging
the electronics.

Connection Controller Box
(Removable Junction Box Terminal
Description Board Reference
Connector)
General System
TB8-1 COM ALARM - COM
Alarm
TB8-2 NO ALARM - NO
TB8-3 NC ALARM - NC
Float Switch Terminations made
N/A N/A
Alarm at float swi tch
2.7.17 Phone Line Connections

A phone line can be connected to the 3D TRASAR controller . Through this modem connection you
can upload/download configurations, download history, and view live data. The phone line is also
required to transmit email alarms to users.
The phone line connection is located inside the controller box and can be connected through the
RJ11 analog phone jack or hardwired to terminals 1 and 2.
Connection Controller Box Controller Box Terminal Junction Box
Description Board Reference (or Phone Jack) Terminal
Modem
TB-1 1 AP 1
(Phone Line)
TB-2 2 AP 2
RJ11 Analog
Phone Jack
Note: Connect the analog “Tip” and “Ring” phone wires from the
telephone company to pins 1 and 2. The modem input is not polarity
sensitive, so it does not matter which order the wires are connected.
Hard Wire Analog 1

Phone Connection*
2

2.7.18 Ethernet (Direct Connect)

The ethernet port is primarily used for direct connections Wiring
with a laptop. Through the port you can upload/download
configurations, download history, view live data, and
upgrade firmware. The ethernet port is located on the left-hand side of the box in a connector with a
waterproof cap. The cap must be in place whenever the port is not in use. Use the supplied
Ethernet 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. Processing
extraneous broadcast messages will significantly impact controller operation. Refer to AppendixE
for 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 modbus
connection. Refer to Appendix E for more details.
Connection Controller Box Controller Box Terminal Junction Box

Description Board Reference (Removable Connector) Terminal
SCADA TB12-1 A Rx/A
TB12-2 B Tx/B
TB12-3 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 & System

Calibration & checkout
Checkout
Before starting up the 3D TRASAR system, it is important to
verify probe calibration and test the plumbing and electrical
connections.
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 electrical Calibrate probes following
instruction on screen.
connections.
3. Slowly open the inlet and outlet ball valves on the 3D

TRASAR 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 the
flowswitch.
10. Verify that a “No FlowAlarm” does not exist on the 3D TRASAR controller display
. No flow is
indicated 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

IMPORTANT: Make sure you have the appropriate
! Start-up Kit (P/N 500-TSRKIT.88 for 3D TRASAR
5500 systems, or P/N 500-TSRKITSTR.88 for 3D
TRASAR Starter systems) with a sufficient supply of
reagents on hand before proceeding.
• The calibrations required for the 3D TRASAR 5500
system are Fluorometer, pH, ORP, and Conductivity.
• The calibrations required for the 3D TRASAR 3500
system are Fluorometer and Conductivity.
• Corrosion probes never require calibration. Calibrate probes following
instruction on screen.
• Calibrations are performed through the 3D TRASAR
control panel.
• Make sure to close off inlet and outlet ball valves before
proceeding.
Fluorometer Calibration ORP Calibration
1. Press Actions key on control panel. 1. Press Actions key on control panel.
2. Select Clean & Calibrate. 2. Select Clean & Calibrate.
3. Enter PASSWORD 12345 if requested. 3. Enter PASSWORD 12345 if requested.
4. Select Fluorometer and follow directions 4. Select ORP.
on screen. 5. Select 2-Point/standards and follow
5. Refer to Section 4.10.3 for details. directions on screen.
6. Refer to Section 4.10.5 for details.
pH Calibration
1. Press Actions key on control panel. Note: 1-point calibration can be used after the
2. Select Clean & Calibrate. initial 2-point calibration has been performed.
3. Enter PASSWORD 12345 if requested.
4. Select pH. Conductivity Calibration
5. Select 2-Point/standards and follow 1. Press Actions key on control panel.
directions on screen. 2. Select Clean & Calibrate.
6. Refer to Section 4.10.4 for details. 3. Enter PASSWORD 12345 if requested.
4. Select Conductivity.
Note: 1-point calibration can be used after the 5. Select 2-Point/Process and follow
initial 2-point calibration has been performed. directions on screen.
6. Refer to Section 4.10.6 for details.
Note: 1-point calibration can be used after the

initial 2-point calibration has been performed.
2-point calibration should be performed when-

ever a replacement conductivity probe is
installed.

2.8.3 Checkout Control Relays

Before start-up of the 3D TRASAR controller it is important to
check the functional operation of all pumps and valves. Follow
the procedure below for each control device (There is a
maximum of 7 control relays).
Control Relay Test Procedure

1. 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 Calibrate probes following
press Select. instruction on screen.
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 toAuto.
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 valves
left in “Man-On” mode will result in excessive waste of chemical and water which may
! cause damage to the cooling system.

2.9 STEP 9 - Start-up System

Start-up system
The following is an overview of the steps required to start up
your 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) in

Configurator program).
IMPORTANT: Every 3D TRASAR controller is
configured uniquely for each application through Enter Set Points
! Nalco’s “Configurator” software. Your Nalco
You are up and running!
representative will have created your system
configuration 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 defined
period of time. This prevents false alarming and relay time-outs from occurring until the
cooling 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 Configurator

The 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 controller
! keypad, the configurator must be used for initial controller setup and to make
changes 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 this
time).
NOTE: The configurator software operates optimally when Lotus Notes is installed on
your PC. Lotus Notes is used as a means of obtaining the most recent data for use in the
! configurator. The configurator also has the capability of generating email messages (with
the 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 more
limited 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 Software

For Windows 2000 users, insert the CD and double click on theSetup.exe icon. Follow
the on screen steps to complete the installation.
For Nalco Windows XP users, the configurator program should be pre-installed. To open
click Start, Programs, Nalco Software, 3D TRASAR, 3DT Configurator.
If the program is not pre-installed, it can be downloaded from SMS. To download, click
Start, Programs, System Manager. Scroll through programs, locate Nalco 3D TRASAR
Configurator.
A second program, 3Cdaemon, will also be installed. This is a TFTP server program used
only for controller software upgrades.

3.3 Configurator Support

Important configurator information can be located in the help screen by pressing the F1 function
key. 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

Section 4: Controller Settings
Display Panel
4.1 3D TRASAR 3500 and 5500

Control Unit Overview
Up/
Info
The keypad and display on the Down
control panel is shown to the Action
right. Through this panel you can
Back
perform many basic operations Alarms
quickly and conveniently, including Soft
setting control ranges, performing Keys
calibrations, manual relay operation,
and biocide slug feeds.
Number
4.1.1 The Display Panel Keys
Menu Help
The display panel is a 6-line,
backlit LCD graphical display.
The display panel is used to

edit numeric data and show
status information for the various
system parameters, alarms and pumps.
4.1.2 The Keys

The function of the 20 keys on the control Info................... Indicates system performance, operating
panel's key pad are summarized to the right: data, product inventory, water and energy
Actions............. Allows user to clean and calibrate, update
Pressing any of these keys will change the inventory, feed biocide
information shown on the display and let you Alarms.............. Shows active alarms
quickly check the status of the unit or Numbers 0-9.... Provides for the entry of numerical listings
change its configuration. Menu................ Provides complete main menu list
Help.................. Provides contact information help
Up/Down.......... Used for menu navigation
Back................. Returns to previous screen
Soft Keys..........Used to make selections shown on the
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 their
meaning.
The screen on the left has several ICONS that

indicate a particular function. Refer to the
symbols below for more details.
• Relay is “ON” in Auto mode (no icon indicates Auto “OFF”)

• Relay is “OFF” in Manual mode
• Relay is “ON” in Manual mode
• Relay is “OFF” in Failsafe mode
• Relay is “ON” in Failsafe mode
• Move to next/previous screen (use arrow keys)

• 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 Diagram

The 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.
Menu
Control Alarm Information Actions Alarms

Preferences Network System Info
Settings Settings
System System System Clean and Current

Background Time DHCP
Alarms Volume Performance Calibrate Alarms
Relay 1 Control Makeup Operating Manual Relay

Date IP Address
Product Alarms Cond. Data Control
Relay 2 Performance Product Pumping

Date Format Subnet Delta T
Product Alarms Usage Rates
Oxidizing Relay Water & Slug Feed

Password Gateway
Biocide Alarms Energy Biocide
Analog System
Blowdown Contrast Plot Data
Alarms Startup
SCADA Control
pH Test Email
Address Methods
SCADA Service
Mode
Timer Status
Response
Email
SCADA External
Baud Inputs
Product
Factors
Diagnostic
Data

4.3 The Menu Key
Menu
Information Actions Alarms

Plot Data Control Alarm Preferences Network System Manual
Settings Settings Info Relay
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

Menu

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

Menu

4.4.1 Background Correction Screen

Displays the 3D TRASAR background correction data from aTOWER water sample.
TRA Background Shows the TRASAR background fluorescence value. Note: Do not use
TRASAR Control or 3D TRASAR scale control if TRABackground is > 15%.
TAG Background Shows the tagged polymer background fluorescence value.Note: Do not
use TAG Polymer Control if TAG Background is > 75%. Do not use 3D
TRASAR 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 correction
for tagged polymer control. Note: The preferred Online TAG Method can only
be used if TAG Ratio is between 1.41 and 1.71. Fixed TAG Method can be
used for any TAG Ratio value.
IMPORTANT: Periodically check the Tagged Polymer level on the controller against the
level determined by the Nalco DR/2800 or DR/890 Active Polymer T est (Reagent P/N
! 460-S0811.75). The results from the Active Polymer Test must be multiplied by (Product
Factor 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 (as
product).
% 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 beforeActive Polymer Test
results can be used for comparison.

Menu

4.4.2 TRASAR (Relay 1) Product Screen

Displays the dosage set point and control range for the
TRASAR product controlled by Relay 1.
4.4.3 Tagged Polymer (Relay 2) Product Screen

Displays the dosage set point and control range for the
Tagged Polymer product controlled by Relay 2.
4.4.4 Oxidizing Biocide Screen

Displays the ORP set point and control range. This is used only if
the system has been configured to control the oxidizing biocide
based 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.
NOTE: Control ranges will only be displayed if applicable. Control range is not
! displayed if 3D Scale Index schemes are used. In these cases, the ranges are
determined by the control algorithm.

4.5 Alarm Settings Submenu
Menu

Control Alarm Preferences Network System Manual
This submenu displays the following options for alarm settings.
IMPORTANT: Whenever any alarm condition occurs, a specific alarm email is

! sent (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 setting
to 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, and
conductivity. To change, arrow down to the parameter and press
Select.
NOTE: The duty cycle percentages for high and low alarms
! can 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 high
alarm 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 relay
energize continuously for a time exceeding theRelay Timeout setting,
an alarm condition will occur and the relay will operate in aFailsafe
Duty cycle for that parameter.
Startup Factor allows you to extend the relay time-out period during
startup. Chemical residuals may be extremely low at startup and
require an extended period to equilibrate. The Startup Factor (select-
able between 1 and 99) multiplies this initial time out period for all
relays (i.e. if the Relay Timeout is set for 60 minutes and the Startup
Factor is set for 5, the timeout period will be 300 minutes for startup).
Pump timeout alarms will be cleared automatically if the related parameter concentration is within
the defined control range or can be cleared manually at the controller via the keypad.
Relay Timeout - Maximum time for continuous relay operation before an alarm is initiated and the
Failsafe Duty mode begins.
Failsafe Duty - When any alarm condition exists for the parameter associated with a relay
, the relay
reverts 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 is
activated. For example, if the failsafe duty is set at 20%, the relay will be activated for 3
minutes and deactivated for 12 minutes. This pattern repeats as long as the alarm condition
exists. Set these carefully as improperly set failsafe modes can cause under or overfeed
conditions during "alarm" conditions.
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 alarm
! Failsafe Duty can be set to different values for high or low level alarm conditions
ONLY 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 conditions
based on past performance during failsafe operation. TheFailsafe Duty median is used for
all alarm conditions with the “Smart” setting
4.5.5 4-20 mA Alarm Screen

High and low alarm thresholds for 4-20mA input signals.
Press Edit to modify.

Note: Make sure all alarm parameters have been set prior to startup. Improper
! settings will adversely affect performance of controller and cooling system.
4.6 Preferences Submenu
Menu

This submenu is used to display and edit general settings. The arrow keys can be used to navigate
between fields with more than one setting (i.e., the time field has both hours and minutes).
Time…………………………………Displays the clock setting in hours and minutes (24-hour

format).
Date…………………………………Shows the date setting in the format configured through the PC.
Date Format………………………..Selects the date format (M/D/Y, D/M/Y, Y/M/D).
Password…………………………..Displays the current system password. Changing the passwords

is not recommended under normal circumstances. A lost or
forgotten password may result in a service visit or return of your
system to the factory for reset.
Contrast…………………………….Adjust display contrast.
SCADA Address…………………..The Modbus address for the controller. This information needs
to be supplied by the customer only if SCADA is used.
SCADA Mode………………………The SCADA communication mode (RS-232 or RS-485).
SCADA Baud………………………Selects the SCADABaud rate (1200, 2400, 4800, 9600, 19200).

4.7 Network Submenu

Menu

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 ISP
provider. Any changes made must also be made in the configuration program!
DHCP……………………….. Enables/disables the assignment of the controller IP address for
use on a network. In most cases, this should be disabled.
IP Addr..……………………. Displays the current controller IP address.
Subnet……………………… Indicates the controller subnet address
Gateway……………………. Indicates the controller default gateway address.
4.8 System Information Submenu

Menu

This submenu is used to display the start-up system parameters as entered by theuser. This is the
starting point for the water and energy calculations.
System Volume……………………….. Estimate of system volume in gallons.
Makeup Conductivity..…………….….Measured (microsiemens)
Delta T………...................……………. Temperature drop across cooling towers.

4.9 The Information Key
Menu

The information key accesses general performance information. There are no adjustments or
changeable 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 will
only 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 a
unit-less measure of the scaling tendencies of the system water. It is used for trending
and is not to be viewed as a direct indication of scaling as each system will trend
uniquely.
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 read
uniquely 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 the
difference between the quantity fed and the active quantity remaining in the system. (In
the screen display above, 18% consumption means 82% of active polymer remains.)

Menu

4.9.2 Operating Data Screens

These screens display basic cooling water measurements. The values that appear here depend on
the configuration.
3DT265-i…………………. Real time measurement of inert TRASAR level in one drum

programs.
3DT265-a..…………….…. Real time measurement of active Tagged Polymer level in one

drum programs.
Conductivity……………. Real time measurement from system conductivity probe.
pH………......................... Real time measurement from system pH probe.
ORP.................................. Real time measurement from system ORP probe.
Temp................................ Real time measurement from the RTD in the conductivity probe.
Turbidity...........................Relative measurement of NTU’s by the fluorometer.
HTI....................................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 and
pumping rate. Pumping rates should be based on actual pump draw down.

Menu

4.9.4 Water and Energy Screens

These screens display calculated water and energy usage derived from the calculated average
Holding Time Index.
Blowdown - Calculated blowdown rate in gallons per day based on mass balanceequations.
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 can
be plotted:

Menu

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 the
soft key labeled X Zoom.
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 value
for 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 screen
will display data from the next or previous period of time. The previous 90-days of data may be
displayed.
4.9.6 Control Methods Screens

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

Menu

4.9.7 Timer Status Screens

Press View to show the schedule for a given timer. Schedules are View Only and cannot be set
from the keypad/display. Current state of Biocide Timers (Prebleed, Feed, Lockout, Off) and for
Generic Timers (Feed, Off) is displayed for each scheduled timer.
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 configured
to show On/Off status of a non-powered contact (see DI3 in figure below) or as low frequency water
meter 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 of
raw signals from the sensors.
NOTE: The NDM is not yet a commercial option.

!

4.10 The Actions Key
Main Menu

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.

Menu

4.10.1 Password Screen
Enter Password….12345 (Default Password)
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. Calibration
is 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.

Menu

4.10.3 Fluorometer Calibration Screens

Select Fluorometer and follow screen directions to perform calibration:
STEP 1
Close fluorometer inlet valve and turn 3-way fluorometer discharge valve to
sample 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 the
syringe against a solid object to move the bubbles to the needle end of the
syringe. Then, force the bubbles out by pushing a small amount of solution
through the needle end of the syringe.
STEP 2
Clean the fluorometer by injecting acid with a syringe into the flow cell. Fill the
syringe with 60 ml of dilute acid. 10% SulfuricAcid (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 into
the flow cell, and allow it to stand for 2 minutes. Rinse well with water. Using the
flow cell brush (P/N 500-P2817.88), gently push the brush down through the
opening 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 than
five minutes.
STEP 3
Following the screen prompts, use a second clean 60 ml syringe and slowly
flush the flow cell with 180 ml of blank solution. Then slowly inject another 180 ml
blank solution and allow it to remain in the flow cell by leaving the syringe at-
tached. Press Continue.
STEP 4
Following the screen prompts, use a third clean 60 ml syringe and 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. PressContinue.
STEP 5
Successful calibration will be indicated and must be “accepted”. Controller will
automatically re-boot after accepting calibration. Turn valves back to operating
positions.
A failed calibration is most likely caused by insufficient flush-

! ing, contaminated/incorrect standards, introduction of air
bubbles, excessive cell fouling, or a bad probe connection.
Menu

4.10.4 pH Calibration Screens

Select pH from the Calibration menu and follow screen directions to
perform 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 a

major error has developed due to excessive fouling or probe degradation.
For a 1-point calibration

STEP 1 - Leave probe in tee with water flowing. Select1-point calibration.
STEP 2 - Using a handheld instrument of known accuracy and

calibration, sample the process water and determine the pH
value.
STEP 3 - Enter this value.

STEP 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 buffer

solution (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, wiring

connections, or handheld pH meter for accuracy. Soak probe
! in standard extra 5-10 min or clean probe tip and recalibrate.

Menu

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 a

major error has developed due to excessive fouling or probe degradation.

STEP 1 - Leave probe in tee with water flowing. Select1-point calibration.
STEP 2 - Using a handheld instrument of known accuracy and calibration,

sample the process water and determine the ORP value.

STEP 1 - Select a 2-point calibration.
STEP 3 - Remove the ORP probe the tee.
STEP 4 - Swirl the probe in a beaker of clean, fresh ORP 200 mV buffer
solution (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, wiring

connections, or handheld ORP meter for accuracy. Clean the
! ORP probe tip and recalibrate.

Menu

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 major

error has developed due to excessive fouling or probe degradation.
A 1-point calibration utilizes the system water as the calibration point. tI is best
used to fine-tune your calibration to compensate for minor drifting. Leave the
probe in the process water. The 1-point calibration range is +/-10% of the
second point value of the previous 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 the
value of the process water conductivity value.
STEP 1 - Select a 2-point calibration.

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 minutes
STEP 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 and
! recalibrate.

Menu

4.10.6 Conductivity Calibration Screens (con’t)
Tip
√ A 1-point conductivity calibration can be performed when conductivity
has 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 been
installed at least 15 minutes for equilibrium.) Select 1-point
calibration.
STEP 2 - Using a handheld instrument of known accuracy, locally sample the

process water and determine the conductivity value.
Comparison of Conductivity Calibrations
Firmware Version 8.0 Firmware Version's 6.0 and prior
Curve Setting Calibration 2-Point 3-point

1-point calibration offset Yes Yes
No
Standard Solutions Yes
(Need true conductivity value)
TemCoEff Access Yes No
Data Weighted Filter Yes No
Recommended Range 500-99,999 uS/cm 500-15,000 uS/cm
Built-in Instructions Yes Yes

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 process
water 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 wire
! connections, 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 – o Tols – 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 the

! temperature 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 state
at 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 quickly
changing).

Menu

4.10.7 Probe Calibration / Maintenance List
C a lib r a tio n T y p ic a l T y p ic a l
R e p la c e m e n t M a in te n a n c e
P a r a m e te r S ta n d a r d s M a in te n a n c e P ro b e
P ro b e P a rt # In d ic a tio n
R e q u ir e d S c h e d u le * L ife
U s e s ys te m w a te r C le a n a n d
C o n d u c ti v i t y
C o n d u c ti v i t y 0 6 0 - T R 5 4 4 1 .8 8 a n d p e rfo rm a "1 " c a li b ra te In d e fi n i te
d ri f t
p o i n t c a li b ra ti o n m o n t h ly
C le a n a n d
C e ll fo u li n g C a lib ra t i o n S o lu ti o n
F lu o ro m e te r 0 6 0 - T R 5 2 2 0 .8 8 c a li b ra te In d e fi n i te
a la rm (4 6 0 -S 0 9 4 0 .7 5 )
m o n t h ly
p H 7 .0 B uffe r
(4 6 0 -S 0 4 0 7 .8 8 ) C le a n a n d
pH 0 6 0 - T R 5 4 1 1 .8 8 p H d rift c a li b ra te U p to 1 yr.
p H 1 0 .0 B uffe r m o n t h ly
(4 6 0 -S 0 4 0 8 .8 8 )
200 mV
(4 6 0 -S 0 9 3 2 A .7 5 ) C le a n a n d
ORP 0 6 0 - T R 5 4 2 1 .8 8 O R P d rift c a li b ra te U p to 1 yr.
600 mV m o n t h ly
(4 6 0 -S 0 9 3 3 A .7 5 )
4 0 0 - N C M P 1 B .8 8
S te e l
4 0 0 - N C M P 2 B .8 8
C opper
4 0 0 - N C M P 4 B .8 8
C u N i 9 0 /1 0
4 0 0 - N C M P 5 B .8 8
C u N i 7 0 /3 0
S tu d y In s p e c t p ro b e U p to 6
C o rro s i o n N o t re q u i r e d
c o m p le te d m o n t h ly m o n th s
4 0 0 - N C M P 7 B .8 8
B ra s s 4 4 3
6016180
6 0 6 1 A lu m i n u m
6016182
1 1 0 0 A lu m i n u m
4 0 0 - N C M P 1 0 .8 8
G a lva n i z e d S te e l
* For a detailed maintenance schedule, see Section 8.

Menu

4.10.8 Manual Relay Control Screens
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 press
Accept.
STEP 3 - After selecting desired mode, highlight Auto After and press Edit (Auto After is
the amount of time the relay will remain in the selected mode before reverting back
to auto).
STEP 4 - Enter the Auto After value in hours and minutes using the keypad (0-4-2-5 equals 4
hours 25 minutes). Entering 00:00 will put the relay in the selected mode continu-
ously.
STEP 1 STEP 3
STEP 2 STEP 4

Menu

4.10.9 Pumping Rates Screens
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 determine
system volume. The accuracy of this reporting is dependant on the accuracy of the pumping rates
input 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 greatest
accuracy.

Menu

4.10.10 Slug Feed Biocide Screens
There are three options for slug feeding biocides. Each choice will follow the pre-bleed and lockout
conditions 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.

Menu

4.10.11 System Startup Screens

This screen allows the user to “Activate” a special startup mode in which the alarms are temporarily
suppressed, preventing false alarming until the system has reached a balanced equilibrium. The
startup period is equal to the Relay Timeout Limit multiplied by the Startup Factor (Refer
to 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.
4.10.13 Service Email Screens

Sends an email to the 3D TRASAR Web alarm mailbox. Use this function to indicate one of the
routine maintenance functions listed below have been performed. Service emails will be sent to
the users who are specified to receive alarms.
Change ID (identification code) by selectingID 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
Menu

4.11.1 Sensor Alarms

Sensor Alarms are activated when an error is detected in the sensor probes. These alarms are
typically 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 detect
missing or miswired probes. Therefore, the pH and ORP Sensor Errors are not
! always triggered. Inaccurate or fluctuating readings are another indication of a
miswired or faulty probe.
4.11.2 System Alarms

System Alarms are related to cooling system parameters that are not controlled by the 3D TRASAR
system. Interlock and No Flow alarms supercede all other alarms, such that the other alarms in all
categories are disabled during Interlock and No Flow alarms. Likewise, the Interlock alarm
supercedes 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 the
recirculation pumps to enable or disable the 3D TRASAR control relays. If the recirculation pumps
are turned off, the contact is opened, and the Interlock alarm occurs immediately , disabling all
control relays. Control is restored when the recirculation pumps are turned back on and the contact
is closed, which clears the Interlock alarm. If this feature is not needed, the Interlock input must be
shorted with a wire jumper so the contact is always closed.

Menu

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 or
the component, although the presence of multiple Comm Errors suggests a problem with the
controller.
• 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 indicate
that the oxidizing biocide is fed in failsafe mode when those alarms are activated, and the relay must
be reset at the controller display by clearing the popup window. The bio-reporter is never fed in
failsafe mode.
• System Stress High • Bio-reporter Low Failsafe
• Corrosion #1 High • Bio-product High
• Corrosion #2 High • Bio-product High Failsafe
• Nalco Bio-Index High • Bio-product Low
• Biocide Pump Rate High • Bio-product Low Failsafe
• Biocide Pump Rate Low • Bio Data Noise High
• Bio-reporter High • Bio Data Noise High Failsafe
• Bio-reporter High Failsafe • Pellet Rotor Current High
• Bio-reporter Low • 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 • Conductivity Low
• TRASAR Low • pH High
• Tagged Polymer High • pH Low
• Tagged Polymer Low • ORP High
• Conductivity High • ORP Low
Control Alarms in this category are related to Failsafe Duty and can be set to different values for High
and 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.

Menu

4.11.6 Relay Timeout Alarms

Relay Timeout Alarms are safety alarms activated when a relay has been energized for longer than
the entered Pump Timeout Limit. In Startup Mode, the Pump Timeout Limit is extended by the
Startup Factor.
• TRASAR Relay Timeout • Blowdown Relay Timeout
• Tagged Polymer Relay Timeout • pH Relay Timeout
• Bio-reporter Relay Timeout • Pellet Feeder Timeout
• Oxidizing Biocide Relay 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 (rather
than mA values). Digital input alarms are dry contacts that can be set by the user in the
Configurator. These alarms do not affect any of the control relays and are for information only
.
• Analog #1 High • Digital #3 On or Off

• Analog #1 Low • Digital #4 On or Off
• 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 Failsafe
Mode, 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 3D
TRASAR controller also offers the option of "Smart Failsafe", in which the failsafe duty is calculated
from the actual relay operation under normal conditions. W ith this option, the calculated failsafe duty
can vary as relay usage changes. On initial startup or after erasing the datalog, the Smart Failsafe
Duty must be learned by the controller, which it does automatically after the first 7 days. The first 7
days' values are ignored to avoid skewed values as a result of extreme startup conditions. During
the first 7 days, each relay will use an initial fixed failsafe duty
. This fixed failsafe duty is also logged
as the actual relay duty to indicate that the learning is in progress. The Smart Failsafe Duty is
calculated 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 a
period to allow the 3D TRASAR controller to bring the system under control. See section 4.5.4.

Section 5: 3D TRASAR Scale Control

3D TRASAR Scale Control is a revolutionary way to manage scale stress in cooling systems. The
3D TRASAR 5500 coupled with an innovative “tagged” high stress polymer (essentially a barcode
attached to the polymer molecule) monitors the actual performance of the polymer as system scale
stress changes. 3D TRASAR Scale Control then takes corrective action through blowdown or
chemical inhibitor feed adjustments. For 3D TRASAR Starter controllers, 3D TRASAR Scale
Control 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) Measurement

The Nalco Scale Index (NSI) is a calculated variable that compares the current rate of polymer
consumption against the learned average rate of polymer consumption. The NSI number has a
direct 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 and
low stress conditions. There are two different control methods to choose from, either 3D TRASAR
Scale Blowdown Control, or 3D TRASAR Scale Tagged Polymer Control.
Nalco Scale Index (NSI) Performance Level
<10 Low Stress

10 – 30 Moderate Stress
>30 High Stress
5.1.1 3D TRASAR Scale Blowdown Control – Uses NSI to Adjust the Blowdown
Setpoint
• 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 Tagged
Polymer 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 Control

The 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 transition
and for the 3D TRASAR controller to learn the average scaling stress of your cooling system and
develop the appropriate control responses to optimize the treatment program:
3D Scale Blowdown Control

1-Drum Program Start-Up Overview
Conductivity
TRASAR
100
Tagged Polymer
•TRASAR •TRASAR •Monitor TRASAR •Monitor TRASAR

ppm Control Control
•Control Tagged Polymer •Control Tagged Polymer
•Monitor
Tagged •Monitor Nalco Scale Index •Control Nalco Scale Index
Polymer
0
Before Step 1 Step 2 Steps 3 & 4
Time
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 Scale Control.
Step 1 TRASAR Control Mode – The goal of this step is to determine the Tagged Polymer setpoint
to be used in Step 2. The 1-Drum product is controlled by traditional TRASAR while the aTgged
Polymer level is monitored. Blowdown is controlled based on conductivity during this period. It will
take approximately 5 HTI’s to complete Step 1.
Step 2 3D TRASAR Scale Blowdown Monitoring Mode – In this step the 3D TRASAR controller
learns the typical rate of polymer consumption needed to calculate NSI. The 1-Drum product
control is switched to Tagged Polymer Control using the setpoint determined in Step 1. The
TRASAR level will now only be monitored and blowdown will still be controlled by conductivity
. After
the learning period is complete you can move to Step 3.
Step 3 3D TRASAR Scale Blowdown Control Mode – This step switches the blowdown control
from conductivity-based to 3D TRASAR Scale Control. The controller will now respond to high
system scale stresses by reducing the blowdown setpoint.
Step 4 Advanced 3D TRASAR Scale Blowdown Control Mode – This step adds to 3D TRASAR
Scale Blowdown Control the feature of increasing the blowdown setpoint during low scale stress
conditions to maximize system water and chemical efficiencies.

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 TRASAR
controller, 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 value
recommended 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.
1. Click the Blowdown/pH tab, set the Blowdown Control Method to 3D TRASAR Scale
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. 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 accept
the 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.
• After the controller reboots – go to the Configurator Control Settings window, under the
Blowdown/pH tab, click the RELEARN NOW button to perform a Relearn. This will clear the
memory 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 the
user input HTI.
• The system is now under 3D TRASAR Scale Blowdown Monitoring Mode. Note: The blowdown
set 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–999
for NSI until the required “Learning Period” is completed. The “Learning Period” will last between 7
to 8 HTI’s if the system HTI is < 72 hours, and 22 days if the HTI is > 72 hours. The “Learning
Period” 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.
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.
• 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% in
response to high system stress but will NOT be allowed to go above the user-entered set
! point since the “Set Point Increase Limit” is 0%.
STEP 4 - Advanced 3D TRASAR Scale Blowdown Control Mode

1. Click the Blowdown/pH tab, leave the Blowdown Control Method in 3D Scale Control.
change) box.
• The system is now under Advanced 3D TRASAR Scale Blowdown Control mode.
response to high system stress AND will be allowed to go above the user-entered set point
! by 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 is
necessary for product transition and for the 3D TRASAR controller to learn the average scaling stress
of your cooling system and develop the appropriate control responses to optimize the treatment pro-
gram.
3D Scale Blowdown Control

Conductivity
100 TRASAR
Tagged Polymer
ppm •TRASAR •TRASAR •TRASAR Control •TRASAR Control

Control Control
•Control Tagged Polymer •Control Tagged Polymer
•Monitor
Polymer
0
Time
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 Scale
Control.
Step 1 TRASAR Control Mode - The purpose of this step is to gradually replace any old
UNTAGGED polymer product with the new, TAGGED polymer product. The TRASAR Product is
controlled 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 controller
learns the typical rate of polymer consumption needed to calculate NSI. The T
agged Polymer
product 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 same
conductivity setpoint, while in Scale Monitoring mode with no blowdown setpoint adjustments.
Step 3 3D TRASAR Scale Blowdown Control Mode - This step switches the blowdown control
from conductivity-based to 3D TRASAR Scale Control. The controller will now respond to high
system scale stresses by reducing the blowdown setpoint.
Step 4 Advanced 3D TRASAR Scale Blowdown Control Mode - This step adds to 3D TRASAR
Scale Blowdown Control the feature of increasing the blowdown setpoint during low scale stress
conditions to maximize system water and chemical efficiencies.

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

• 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.
2. Click OK.
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 TAG
Polymer product Pumping Rate (R2) according to the following equation. Note: Make sure
to match the calibration of the TRASAR product pump and the TAG polymer product pump
to the feed rates entered.
R2/R1 = (d1/d2) * (SP2/SP1) * 1.25

Where, R2 = TAG polymer product pump feed rate
R1 = TRASAR product pump feed rate
d1 = density of TRASAR product
d2 = density of TAG polymer product
SP2 = setpoint of TAG polymer product
SP1 = 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 the
TRASAR product Pumping Rate (i.e. TRASAR Pumping Rate = 1 gpm; Tagged Polymer Pumping
Rate = 5.53 gpm).
5. Click OK.

5.2.4 Start-up Procedure for 2-Drum 3D TRASAR Scale Blowdown Control (con’t)
• Operate the cooling system under TRASAR Control and slaved Tagged Polymer Control for
approximately 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 shorter
! period 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

1. Click the Blowdown/pH tab, set the Blowdown Control Method to 3D TRASAR Scale
Control.
3. Click the Inhibitor tab, change the Tagged Polymer Product Control Method to Tagged
Polymer Control, enter the Tagged Polymer Set Point as recommended by the 3D
TRASAR Optimizer, and accept the default control range.
4. Leave the TRASAR product Pumping Rate and the TAG Polymer product Pumping Rate
the same as entered in Step 1.
• 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 the
Blowdown/pH tab, click the RELEARN NOW button to perform a Relearn. This will clear the
memory 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 the
user input HTI.
• The system is now in 3D TRASAR Scale Blowdown Monitoring Mode. Note: The blowdown set
point 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
1. Click the Blowdown/pH tab, leave the Blowdown Control Method in 3D TRASAR Scale
Control.
change) box.
• The system is now under 3D TRASAR Scale Blowdown Control.
response to high system stress but will NOT be allowed to go above the user-entered set
! point since the “Set Point Increase Limit” is 0%.
STEP 4 - Advanced 3D TRASAR Scale Blowdown Control

1. Click the Blowdown/pH tab, leave the Blowdown Control Method in 3D TRASAR Scale
Control.
change) box.
• The system is now under Advanced 3D TRASAR Scale Blowdown Control mode.
response to high system stress AND will be allowed to go above the user-entered set point

5.3 3D TRASAR Scale Tagged Polymer Control

3D 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 the
average scaling stress of your cooling system and develop the appropriate control responses to
optimize the treatment program:
3D Scale Tagged Polymer Control
TRASAR
100 Tagged Polymer
Conductivity
ppm •TRASAR •TRASAR •TRASAR Control •TRASAR Control

Control Control
•Control Conductivity •Control Conductivity
•Monitor
Polymer
0
Time
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 Scale Control.
Step 1 TRASAR Control Mode - The purpose of this step is to gradually replace any old
UNTAGGED polymer product with the new, TAGGED polymer product. The TRASAR Product is
controlled 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 Polymer
product 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 same
conductivity 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 Tagged
Polymer control to Scale Index Control. The controller will now respond to high system scale
stresses by increasing the Tagged Polymer setpoint.
Step 4 Advanced 3D TRASAR Scale Tagged Polymer Control Mode - This step adds to 3D
TRASAR Scale Tagged Polymer Control the feature of decreasing the Tagged Polymer setpoint
during low scale stress conditions to maximize chemical efficiency.

5.3.2 Start-up Procedure for 2-Drum 3D TRASAR Scale Tagged Polymer Control
• 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.
2. Click OK.
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 TAG
Polymer product Pumping Rate (R2) according to the following equation. Note: Make sure
to match the calibration of the TRASAR product pump and the TAG polymer product pump
to the feed rates entered.
R2/R1 = (d1/d2) * (SP2/SP1) * 1.25

Where, R2 = TAG polymer product pump feed rate
R1 = TRASAR product pump feed rate
d1 = density of TRASAR product
d2 = density of TAG polymer product
SP2 = setpoint of TAG polymer product
SP1 = 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 the
TRASAR product Pumping Rate (i.e. TRASAR Pumping Rate = 1 gpm; Tagged Polymer Pumping
Rate = 5.53 gpm).
5. Click OK.

(con’t)
• Operate the cooling system under TRASAR Control and slaved Tagged Polymer Control for
approximately 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 shorter
! period 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

1. Click the Inhibitor tab, leave the TRASAR Control Method to TRASAR Control.
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 the
default control range.
4. Leave the TRASAR product Pumping Rate and the TAG Polymer product Pumping Rate
the same as entered in Step 1.
• After the controller reboots – go to the Configurator Control Settings window, under the Inhibitor
tab, click the “RELEARN NOW” button to perform a Relearn. This will clear the memory 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 the
user input HTI.
• The system is now in 3D TRASAR Scale Tagged Polymer Monitoring Mode. Note: The Tagged
Polymer set point will NOT be adjusted based on NSI until Step 3.

(con’t)
STEP 3 - 3D TRASAR Scale Tagged Polymer Control Mode
1. Click the Inhibitor tab, leave the Tagged Polymer Control Method in Scale Index Control.
4. After returning to the Inhibitor page, uncheck the Monitor Only (Setpoint does not
change) box.
• 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% in
! response to high system stress but will NOT be allowed to go below the user-entered set
point since the “Set Point Decrease Limit” is 0%.
STEP 4 - Advanced 3D TRASAR Scale Tagged Polymer Control Mode

1. Click the Inhibitor tab, leave the Tagged Polymer Control Method in Scale Index Control.
4. After returning to the Inhibitor page, uncheck the Monitor Only (Setpoint does not
change) box.
• 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% in
response to high system stress AND will be allowed to go below the user-entered set point

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. The
3D TRASAR 5500 coupled with an innovative "tagged" high stress polymer (essentially a barcode
attached to the polymer molecule) monitors the actual performance of the polymer as system stress
changes. 3D TRASAR Scale Control then takes corrective action through blowdown or chemical
inhibitor feed adjustments.
2. How does 3D TRASAR Scale Control measure the Scaling Stress in a cooling
system?
Relative Rate of Polymer Consumption, K
K = Rate of (Tagged Polymer Decay / TRASAR Decay)

TRASAR or Tagged Polymer Level (ppm)
Inert TRASAR
TRASAR Decay:
Hydraulic Loss
Tagged Polymer
Tagged Polymer Decay:

Hydraulic loss and scaling/dispersion
After the product(s) is(are) fed to the system and the pump(s) is(are) turned off, the concentrations
of 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 and
tagged polymer level equally. When scaling stress increases in a cooling system, the polymer
decay 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 be
increased. 3D TRASAR Scale Control measures the Relative Rate of Polymer Consumption, K, as
an 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 scaling
stress (upsets) compared to the normal operating conditions and the timely corrective actions that
need 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 of
control by monitoring the active polymer level in the system and determining the scaling tendency of
the cooling tower. With 3D TRASAR Scale Control, scaling stress is automatically reduced by
maintaining the desired active polymer level in the system or by automatically blowing down the
system when needed.
• TRASAR provides only product feed set point control. It does not measure any scaling tendency
or system performance of the cooling tower.
• 3D TRASAR Scale Control employs a new improved Fluorometer with better accuracy for better
product 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 normal
non-scaling operating condition is occurring in real time, so that corrective actions can be taken
automatically (blowdown or feed more scale inhibitor when needed) to minimize and/or prevent
scaling of critical heat exchanger surfaces.
4. What differences will I see when I run 3D TRASAR Scale Control compared to what
I 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 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.
6. Is 3D TRASAR Scale Control compatible with other components (Bio and

Corrosion 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?
System Parameters
Turbidity (NTU) <150
Background Fluorescence Correction 1
Fixed offset 30%
Online real-time 30%
HTI (hrs) Minimum of 14 2
Volume (gal) No limit
Blowdown Rate (gpm) No limit
System Volume/Recirc Rate Ratio (min) <20
Biocide Compatibility
Bleach Compatible
STA-BR-EX Compatible
ACTI-BROM Compatible
Towerbrom 960 See Bromine limits
Towerbrom 991 See Bromine limits
CI2 Gas Compatible
Cl02 Not Compatible3
BCDMH with EASIBROM Feeder See Bromine limits
Stabilized Bleach Compatible
Isothiazolinone Compatible
Glutaraldehyde Compatible
90005 Compatible at 160 ppm 4
DBNPA Compatible
Upper limit of halogen concentration-
impact on polymer/TRASAR fluorescence
Chlorine (FRC)5 <1.5
Bromine (TRO)5 <5
Other Variables
Iron (ppm) <10
SO2 None
Sulfides (ppm) None
Copper (ppm) <40
1
Applies to operation with 10 ppm active polymer- operation with less polymer requires
commensurately lower background level limits.
2
Inhibitor chemical stability should be considered as a potential limiting factor in long HTI
(e.g. >~200 hr) operation.
3
Status may change; Look in Optimizer or call 630-305-CHEM.
4
If foaming occurs on application, loss of TRASAR 2 (PTSA) or polymer may be observed.
Follow 90005 use recommendations to avoid foaming.
5
Corresponds to a 10% loss of fluorescence when exposed to halogen for 24 hrs.

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 T
agged Polymer
product. 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 product
selection guide.
9. What is Nalco Scale Index (NSI)?

consumption 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 point
adjustments 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 PRISM
polymer or tagged High Stress Polymer (HSP). The 3D TRASAR 5500 controller measures the
fluorescent 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 near
ultraviolet can be moderately fluorescent. The fluorescence intensity arising from such species is
known 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 the
conductivity setpoint. Must I allow 3D TRASAR to do this, or can I simply establish a
set 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 the
benefits of 3D TRASAR Scale Control, the controller should be allowed to automatically adjust the
setpoint in order to effectively maximize cycles of concentration to minimize operating cost, or
reduce the cycles as necessary to prevent scale, corrosion and fouling.

13. Can 3D TRASAR Scale Control be operated in Monitoring Mode only (monitoring
Nalco Scale Index, but without Setpoint adjustments)?
Yes. 3D TRASAR Scale Control can be operated in the Monitoring Mode to monitor the Nalco
Scale Index (NSI) without setpoint adjustments.
For 3D TRASAR Scale Monitoring Mode, the NSI will be calculated upon the completion of the
Learning Period. The setpoint adjustment limits are set to zero.
14. Can I compare the Relative Rate of Polymer Consumption with other commonly
used indices, such as Calcite Saturation Ratio?
Yes. The scaling stress or the Relative Rate of Polymer Consumption, K, can be compared to other
commonly 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 to
computer 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 very
closely 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 Relative
Rate of Polymer Consumption and takes corrective actions in a timely manner before scale can foul
the system.
180
Relative Rate of Polymer Consumption or Scaling Stress
160
140
120
100
80
60
40
20
0
20 30 40 50 60 70 80 90 100 110 120 130 140
Calcite Saturation Ratio

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 Nalco
Scale Index, the learning period has completed. If "------" appears, the system is still in Learning
Mode.
Note: After a Power Reset, the LCD also shows "-----" for NSI. NSI will be re-displayed at the end
of 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 appear
in the NSI log, the learning period has completed. If -999 appears, the system is still in Learning
Mode.
17. 3D TRASAR Scale Control has been operational for a while. Why is there no NSI
value 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 the
next 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 if
the Learning Period has been completed.
18. The LCD was showing polymer consumption. Why is it now showing "-----" on
LCD?
• After a Power Cycle, the Polymer Consumption (and NSI) will display as "-----". The Polymer
Consumption 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 indication
of 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, and

TP(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 of
Polymer Consumption with respect to time.
20. I was feeding 23265 and now feed 3DT265. What are 3DT265-i and 3DT265-a
readings 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 polymer
consumption during tagged polymer control?
The TRASAR concentration will vary with time depending on the stress level. As the polymer
consumption changes, the product feed compensates to maintain the tagged polymer at the
setpoint (Product-a). Only the polymer consumption number, and the TRASAR level will vary with
system 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 this
correct?
The cooling system is usually operated under some level of scaling stress. Asa result, there will be
some 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 greater
than the "-i reading".
If the "-a reading" is significantly greater than the "-i reading", it is also possible that:
1. Fluorometer requires recalibration, and/or

2. 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 this
correct? (con’t)
To determine the root cause, perform the following S0940 Check - it verifies fluorometer operation
and 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 the
flow 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 the
cell.
4. Go to the controller keypad and select INFORMATION, Diagnostic Data, Fluorometer
Data.
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 used

Prod 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 used

Prod2 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 working
correctly 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/send
water 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 for
system 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 a
wait 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 and

3D TRASAR Bio-Shock Mode
3D TRASAR Bio-Control and 3D TRASAR Bio-Shock are unique and highly effective control
schemes for the addition of oxidizing biocide to the cooling system. Patented bio-reporter chemistry
is 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 in
the 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 what
amount of biocide is to be added into the system to continuously control the microbiological
activity.
• 3D TRASAR Bio-Shock mode: the bio-reporter determines the time at which the
system is to be shocked with oxidizing biocide. The oxidizing biocide is then fed by timer or
ORP control according to user set parameters. When the oxidizing biocide concentration
dissipates, 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 system
response to biocide feed. It is NOT used to control the feed of oxidizing biocide. The table below
shows the correlation between cooling system biological stress level and the Nalco Bio-Index
number. Please note that the NBI can be negative during normal operation.
Nalco Bio-Index Reading System Biological Stress Level

Often seen within 4 8 hours of startup. If
<-20
persistent, call help desk.
-20 to +10 Low
10 to 30 Mild
30 to 80 High
> 80 Very High
Table 6.1a Nalco Bio-Index Reading for 3D TRASAR Bio-Control.
Nalco Bio-Index Reading System Biological Stress Level

-999 or --- Bio-reporter is not in control of Oxidizing Biocide
Bio-reporter is measuring microbiological activity.
-250 to 0 Increasing Nalco Bio-Index indicates increased
microbiological activity
0 System is about to slug Oxi dizing Biocide
Table 6.1b Nalco Bio-Index Reading for 3D TRASAR Bio-Shock mode.
NOTE: 3D TRASAR Bio-Control cannot be run in ‘Monitoring Mode’. For NBI numbers to
be 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 slug
feed of oxidizing biocide the NBI reverts to –999 since the bio-reporter is not in control of
the Oxidant during that period.
6.2 Oxidizing Biocide Application and Slug Feeds

For most normally operating systems, 3D TRASAR Bio-Control applies the necessary biocide to
maintain microbiological control. In some systems, additional dosing of biocide may be desired for
a 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 the
microbial 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
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 TRASAR
Bio-Control cannot be externally adjusted. Oxidant slugs with user set durations and ORP
setpoints 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 oxidizing
biocide is slugged into the system. The duration of the slug can be set from 10 minutes to
35 hours and the ORP setpoint for the slug is also selectable by the user. This mode allows
the 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 ORP
measurement. A functional ORP probe is required to resume bio-reporter feed (with both timer and
ORP 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 that
ORP level for the preset time. Bio-reporter feed restarts after the system water has returned to
pre-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 the
schedule for feed. We do not recommend more than one slug feed per week. If more
frequent slugs are desired, use the 3D TRASAR Bio-Shock mode.
Manual Slug Feeds: There are two methods of manually initiating slug feeds to the
system:
1. Controller Configurator: Initiate slug from the OxBio Slug Feed screen after
connecting to the controller either directly or via a phone line.
2. Controller Keypad: To initiate a manual slug feed from the controller keypad
press <Actions> and then <Slug Feed Biocide>. Choose:
<Hand Feed Ox> If biocide is applied with pumps or means not controlled by
the controller
<Relay Feed Oxidizing Biocide> In the relay feed option, the controller
applies 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-reporter
ratio (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, and
3D 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 the
system is to an oxidant slug. When the bio-reporter dye is first dosed, the Nalco Bio-Index will be
very negative (-100 to -70). As the bio-reporter reacts with microbes, the Nalco Bio-Index number
will slowly (dependent on the overall microbial activity within the system) increase. As the Nalco
Bio-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/shock
event: Pre-Bleed, Feed, Post-Feed, Recovery.
PreBleed: User may choose to blowdown the system prior to an oxidant slug. This option is
typically used if the blowdown is locked out during the time of the oxidant slug to compen
sate for increasing conductivity. The blowdown is controlled by conductivity set point with a
time limit for the process.
Slug Feed: Oxidant is fed into the system. A user-set time limit determines the duration of
this segment. The user may choose between ORP control or timer control of the oxidizing
biocide pump. Under ORP control, the time limit determines the duration of ORP control at
an ORP set point, whereas under timer control, this time limit determines the oxidizing
pump 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 set
ORP set point with an over-riding time limit.
Recovery: The ORP is monitored until it returns to values close to those measured immedi
ately before the oxidant slug. This is the recovery period. At the end of this time period the
bio-reporter feed and normal 3D TRASAR Bio-Control is resumed. If the ORP does not
achieve 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 the
oxidant slug/shock.

6.3 Bio-Reporter Selection

The 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.
Recommended "Do not Exceed"

Bio-Reporter Bio-Reporter Blowdown
System Volume System Volume
Product Type Upper Limit GPM
Gallons Gallons
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
Important! 3DTBR10 is formulated in concentrated sulfuric acid. Please contact your

! Nalco Representative for recommendations on fluid handling equipment compatible with
concentrated acid.
6.4 3D TRASAR Bio-Control/3D TRASAR Bio-Shock Start-Up

Procedure
We recommend running a system under ORP control with a control range of±20mV for a week
before proceeding to 3D TRASAR Bio-Control. The ORP readings during this period should be
evaluated. If the ORP readings swing much wider than the control band of±20mV then the entire
oxidant 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 halogen
residual 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 the
oxidant and BioReporter in close physical proximity. Make sure both feed points are sufficiently
separated in distance that thorough mixing of each occurs. Failure to do so will negatively impact
the performance of 3D TRASAR Bio-Control. Do not feed bio-reporter or Oxidizing biocide directly
upstream of the 3D TRASAR controller sample point.


Procedure (con’t)
Bio-reporter Pellet Feeder (recommended for system volumes between 12,000 and
2,000,000 gallons)
• TURN ‘OFF’ Pellet Feeder and 3D TRASAR Controller (pellet feeder power switch is
located on the bottom of the feeder near cable connectors).
• Connect pellet feeder to controller using pellet feeder cable (see Section 2 for wiring
details).
• 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 one
pellet.
Bio-reporter Liquid Feed Pump (use 3DTBR06 for systems <12,000 gallons, 3DTBR10 for
systems >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 feed
! equipment 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 this
low rate.


Procedure (con’t)
• If using 3DTBR10, feed into the main recirculating linewith an acid/heat compatible
injection quill P/N 231-P4611.88 (Hasteloy). Heat is generated at the point of injection of
the product into the recirculating line. Use injection quill, check valves and pumps capable of
withstanding 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 center
of the recirculating line. Do not feed product close to the walls of the recirculating pipe
which 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 there
is 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 of
bio-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 water
header) portion of system.
• Manually operate pump from the keypad to verify operation (see Section 4.10.8 for manual
relay control).
• For standard 3D TRASAR Bio-Control, set the oxidant feed pump rate, so that, if the pump
operated 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 can
be easily achieved in the configured Ox slug feed time.
• For Towerbrom 960 applications using 3D TRASAR Bio-Shock mode: Aspecial setup
needs to be done on the Towerbrom control panel to allow the 3D TRASAR controller to
take 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 TRASAR
controller to Towerbrom shall be connected as the “Remote Start Input” listed in the
ATF manual. The Ox relay on the 3D TRASAR supplies a 60 second dry contact
closure to begin a feed cycle. ATFs that have a touch screen control panel must be
set-up to have the entire feed cycle exceed 1 minute. Older style feeders will need to
add a special timer relay to convert the 60 second contact closure to a momentary
contact closure. Contact the NGES Help Desk for specific information on
implementing these changes.
• The ATF will dump the preprogrammed number of product dumps as entered on
control panel when in semi-automatic mode. The ATF will feed one dump of product
when in manual mode. Each dump is either two pounds or ten pounds depending
on the ATF model.


Procedure (con’t)
• Any further question regarding the relay wiring and setup, please contact 3D TRASAR
Support or NGES Help Desk.
NOTE: Verify oxidant residual is below 0.1 ppm TRH before proceeding any further! Use
! DPD 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 TRASAR
Bio-Shock mode.
• In the System Information window, enter the system volume (system volume needs to be
as accurate as possible).
• In the Control Settings window, set the oxidizing biocide control method to “3D TRASAR
Bio-Control” or “3D TRASAR Bio-Shock Mode”.
• If using scheduled Ox slugs with 3D TRASAR Bio-Control or 3D TRASAR Bio-Shock
mode, set up the slug parameters (prebleed, feed, post feed and recovery) in the Ox slug
window.
• If using Ox slugs or 3D TRASAR Bio-Shock mode, make sure the ORP probe is clean and
calibrated.
• 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 oxidizing
biocide (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 Reboot
from Configurator program.
STEP 4 - If using a pellet feeder and the system volume exceeds 160,000 gal, deliver the required
number of bio-reporter Quick Dose Pouches to the cooling system (see Section 6.7).
6.5 Pellet Feeder Operation

The 3D TRASAR Pellet Feeder automatically feeds pelletized bio-reporter to the cooling system at
predetermined 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 and
feeder neck assembly. This is connected to a piping assembly containing a y-strainer designed to
trap 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 at
the bottom of the hopper, not unlike that in a “gumball” machine, rotates and traps a pellet, drops it
down into the feeder tube past an LED that ‘counts’the pellet, and into the ball valve assembly
which 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 very
rare occurrence due to built-in motor reversal) or failure to feed a pellet, both generate alarms on
the 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 empty
for any period of time, the system will transition to failsafe operation and 3D TRASAR Bio-Control
will 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
! 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.
WARNING: NEVER PLACE FINGERS IN PELLET DROP HOLES!!!

!
1. Turn off power.
2. Carefully open the hinged top.
3. Slowly pour the pellets from the storage container into the hopper
. Add only enough
pellets for two months of operation.
4. Place the desiccant cartridge from the pellet container into the lid basket. Close the lid
and screw fastener tightly.
5. Turn on power
NOTE: It is very important that the feed hopper remain dry. Moisture or water in the hopper
! can cause pellet degradation and possible jamming.

6.7 Bio-reporter Initial System Dosing

If 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. UseQuick
Dose Pouch (P/N 460-3DTBRC.87).
Refer to the chart below and find your system’s total water volume. Read across to the “# of
Pouches Required” column. Add this number of packets to the tower basin by carefully placing
them 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 6.3
above). The Liquid Pump or Pellet Feeder will automatically feed the correct amount of bio-reporter
to the system.
System Volume (gal)
No. of
From To Pouches
Required
160,000 300,000 1
310,000 450,000 2
460,000 600,000 3
610,000 750,000 4
760,000 900,000 5
910,000 1,050,000 6
1,060,000 1,200,000 7
1,210,000 1,350,000 8
1,360,000 1,500,000 9
1,510,000 1,650,000 10
1,660,000 1,800,000 11
1,810,000 1,950,000 12
1,960,000 2,100,000 13
If pouches are unavailable and your system size exceeds 160,000 gal use the following table to
calculate startup dosages. It is imperative that the startup pellets be placed in a region of good flow
so that they dissolve quickly (do not dump into a slow flowing area in the tower basin).
System Volume 3DTBR40 Weight of Pellets

(gallons) (# of pellets) (grams)
200,000 21 28
500,000 53 71
750,000 79 106
1,000,000 105 142
2,000,000 210 284

6.8 Pellet Feeder Cleaning

For 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 kept
dry, cleaning is rarely required.
To clean the pellet feeder:
1. Manually remove the pellets from the feeder and store them temporarily in a clean DRY
location.
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 safety
! gear.
Contact with any moisture will cause the pellets to impart an intense blue coloring. This is
! water-soluble and can be washed away with water.
6.9 Pellet Feeder Maintenance

The bio-reporter pellet feeder may require periodic maintenance. How often maintenance is required
is dependent upon pellet feed rates and the pellet feeder working environment.ypically
T the cleaning
and adjustments listed below will need to be performed once a year . Larger systems that feed more
pellets may require maintenance more frequently.
Pellet Feeder maintenance SHOULD ONLY BE DONE IF NEEDED.

!
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 of

water from pellet feeder.
Replace Pellet Shield - Section 6.9.3 Indicated by alarm, pellet feeder jamming, or
visual inspection.

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 how
the controller is alerted if the pellet feeder is empty or a malfunction occurred. The exit tube may
require 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 power
switch.
STEP 2 - Locate the clear tube assembly that connects the pellet feeder body to the
injection valve. See Figure PF1.
Exit Tube
Clear
Tube
Exit Tube
Power
Switch
Figure PF1 Figure PF2
STEP 3 - Directly above the clear tube assembly is the exit tube. Remove the clear tube
from the coupling immediately above the ball valve. No tools are required, it is a
snug 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 the
bottom 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 diagnostic
screen. Press ‘0’ to feed a pellet.
STEP 8 - At the pellet feeder diagnostic screen, verify that S

‘ en’ value is in the range of
3 to 7. If not, re-clean the tube and check again until satisfactory.

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 weep
from the valve through the side drain port. This is normal and no cause for concern. Over time the
seats may wear slightly and a larger amount of water may weep from the valve. This is an indication
that a seat tightening is required.
STEP 1 - Turn off power to the pellet feeder (switch located below hopper see
Figure PF2).
STEP 2 - Remove the upper plumbing assembly to access the top of the ball valve. This is
done by removing the upper union fitting and the pipe strap (see Figure PF3).
Pipe Upper
Strap Plumbing
Assembly
Plumb
Upper
to drain
Union
Figure PF3
Note: Under normal operation, the side drain port should be plumbed to drain, or connected to the
bio-reporter Liquid Overflow Container (P/N 060-TR5350.88).

6.9.2 Tighten Valve Seat (con’t)

STEP 3 - Tighten the valve adjustment nut in a clockwise direction. See Figure PF4. Use a
spanner wrench or the tips of needle nose pliers if necessary. Adjustment requires
only a 1/8 to 1/4 rotation. DO NOT OVERTIGHTEN. Over tightening will cause
premature wear, erratic operation and a “High Current” alarm.
Adjustment
Nut
Figure PF4
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, tighten
further.
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 diagnostic
screen. Press ‘0’ to feed a pellet.
STEP 7 - At the pellet feeder diagnostic screen, verify that B‘ all’ value is in the range of
400 to 600. If not, repeat steps until satisfactory.

6.9.3 Pellet Shield Replacement

The pellet shield may distort over time and require replacement, particularly for larger systems
where 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.
Figure PF5 Figure PF6

New Shield Distorted Shield
STEP 1 - Obtain a replacement Pellet Feeder Shield Kit(P/N 060-TR5313.88).
Figure PF7
Pellet Feeder Shield Kit

6.9.3 Pellet Shield Replacement (con’t)

STEP 2 - Refer to the MSDS sheet for Safe Handling Procedures and Safety Equipment
required before proceeding!
Wearing a minimum of rubber gloves and dust mask, clean out any product from the Pellet
Feeder hopper. Do not use water! Contact with the product will cause a blue “stain”.Avoid
! contact. 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 pellet
shield. Note the orientation to the ‘Exit Tube’ (shown in drawings).
STEP 5 - Remove the pellet shield, rotor retainer, and screws/washers as a unit.
Exit tube covered by shield
Remove these four screws
Figure PF8

6.9.3 Pellet Shield Replacement (con’t)
Note orientation of exit hole.

When reinstalling shield assem-
bly, the shield should be centered
over exit tube and completely
cover it.
Figure PF9
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 to
fit properly.
STEP 10 - Insert the entire assembly into the feeder. Be sure to properly align the pellet shield
with the exit tube - the pellet shield should cover the exit tube as shown in the
previous figures. Be sure the washers are in place.
STEP 11 - Secure the assembly with the screws. Do not over-tighten as the plastic can be
damaged.
STEP 12 - Turn on power.

6.10 3D TRASAR Bio-Control and 3D TRASAR Bio-Shock

Frequently 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 a
fluorescent bio-reporter to probe the entire system, measure both planktonic and sessile microbial
activity and feed oxidizing biocides in response. Oxidizing biocide is added at the correct time and
at the correct dosage resulting in effective microbial control.
An all slug method of bio-reporter control is also available (3D TRASAR Bio-Shock mode). When
the measured bioactivity reaches a preset value, the system is slugged with oxidizing biocide. The
amount of oxidizing biocide slugged is set by the user and can be based on ORP set point or timer
control of the oxidizing biocide pump.
To assist in the penetration of the bio-reporter and the oxidizing biocide into biofilm we strongly
recommend the use of a BioDetergent along with the oxidizing biocide. For effective microbial
control 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 the
water flows. This molecule has a characteristic fluorescent signature, which is enzymatically
changed 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 continuously
by an in-line fluorometer. The rate of change of the fluorescence with time gives a measure of the
microbiological activity in the system.
Because the bio-reporter is added to the recirculating water, it probes the entire system (bulk water
and surfaces, inaccessible heat exchangers, fill and basin) for microbial activity. The measured
fluorescence change reflects the average response for the entire system. Bio-reporter can only
detect microbial activity in areas the cooling water samples. Obviously, no response is possible
from 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 very
small. Since this information will be used to apply oxidizing biocide, this is appropriate, as the
biocide 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 and
algae are active (respiring) and the activity of the enzyme is directly indicative of the activity of the
organism. The bio-reporter is chemically reduced by the enzyme to a product molecule (Rs), which
fluoresces at a different wavelength. Because the reacted and unreacted forms of the bio-reporter
fluoresce 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 the
microbes) and as they circulate in the water their concentration can be measured by the 3D
TRASAR Fluorometer.

4. What are the unique benefits of 3D Bio-Control?

3D TRASAR Bio-Control will consistently and automatically feed the correct dose of oxidizing
biocide 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 and
communicate 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 with
oxidizing 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 the
actions 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 with
microbial proliferation.
Planktonic counts measured by dipslides or DMAshould be between 103- 105 cfu/ml. Since
3D TRASAR Bio-Control responds to the total system microbial activity, it does not necessarily feed
oxidizing biocide in response to the floating population measured by water samples and dip-slides.
Under 3D TRASAR Bio-Control, coupon swabs give population counts of108 cfu/sq cm or less.
6. Is 3D TRASAR Bio-Control compatible with other components (Scale and

Corrosion 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 on
corrosion 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, closed
loop, 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, BCDMH

and TowerBrom 991 is being used (Note: Check with 630-305-CHEM regarding ongoing
work 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 Rf
reading (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 in
ppb).
• The amount/timing of oxidizing biocide fed to the system is constrained to be below the
amount necessary for adequate control. An example: power plants where the time of
oxidizing biocide feed is limited by regulatory constraints. Another example: the amount of
halogen fed is limited by how much money is allocated towards microbial control.

8. What are the operating limits for 3D TRASAR Bio-Control?
System Parameters
Turbidity (NTU) <150
HTI (hrs) 6-400
Volume (gal) No limit1
Blowdown Rate (gpm) No limit1
System Volume/Recirc Rate Ratio (min) <20
Biocide Compatibility
Bleach Compatible
Stabrex Compatible
Actibrom Compatible
Towerbrom 960 Compatible2
Towerbrom 991 Compatible
CI2 Gas Compatible3
Cl02 Not Compatible3
BCDMH with E ASIBROM Feeder Compatible3
Stabilized Bleach Not Compatible
Isothiazolinone Compatible
Glutaraldehyde Compatible
DBNPA Compatible
90005 Compatible
Ammonia Levels
with B leach (ppm) <20
with Stabrex (ppm) <100
with A ctibrom (ppm) <300
Other Variables
Iron (ppm) N/A 4
SO2 None
Sulfides (ppm) None
Copper (ppm) <300
1
Systems with volume greater than 2,000,000 gallons and blowdown rate greater than 1,200 gpm need to use
3DTBR10.
2
Compatible only with 3D TRASAR Bio-Shock mode.
3
Field tests in progress or trial sites needed. Call 630-305-CHEM.
4
0.5 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 oxidant
feed and monitor the halogen residual in the system. If >0.1ppm total residual halogen is measured
in the system after an extended period of no halogen feed (>6hours) this system may not be
suitable 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 of
3D 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 successfully
with 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. When
ratio exceeds set point + deadband, 3D TRASAR Bio-Control feeds oxidant. When ratio falls
below the deadband, 3D TRASAR Bio-Control stops the feed of oxidant (since the oxidant first
reacts with microbes and then with Rf and Rz). In other words, the ratio is maintained at pre-set
value 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”. This
means the ratio drops precipitously when excess oxidant is fed. The 3D TRASAR controller then
tries 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 NBI
numbers to be meaningful, 3D TRASAR Bio-Control MUST be in control of when the oxidant pump
comes on (ratio has exceeded pre-set limit) and when it shuts off (oxidant feed is enough to kill the
microbes).
11. Will 3D TRASAR Bio-Control reduce my bleach feed?

3D TRASAR Bio-Control applies oxidizing biocide in response to microbial activity. It cannot be
tuned to add more or less biocide, it will apply biocide to the level that is necessary to control the
bio-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, it
may significantly reduce biocide usage.
Systems that maintained oxidizing biocide at a set halogen residual either by ORP control, or by
Hach Cl-17 control or even by manually-adjusted continuous biocide feed, have typically reduced
their 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 applies
biocide as a response. 3D TRASAR Bio-Control does NOT apply Biocides specifically for
Legionella.
Use of 3D TRASAR Bio-Control can’t guarantee a Legionella-free tower. Although there is no

statistical correlation between general microbial control and Legionella detection,it is widely ac-
cepted within the industry that controlling microbial proliferation and biofilm formation reduces the
risk of Legionella proliferation. Numerous case studies have shown that 3D TRASAR Bio-Control
is 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 tower
cleaning and disinfection, proper oxidizing biocide selection, routine application of an appropriate
non-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 biofilm
and general microbial populations. SRB’s are typically found under deposits and biofilm. Control of
biofilm can help control SRB proliferation in the system.
SRB’s 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 applies oxidizing
biocide 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 oxidizing
biocide. It is effective to use a biodetergent and a non-oxidizing biocide to better disperse and treat
the deposits in the system.
If high SRB counts are encountered in the system consider supplementing 3D TRASAR Bio-Control
with regular Oxidizing biocide slugs. You may also consider using 3D TRASAR Bio-Shock mode for
a 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 to
algae growth usually represents only a fraction of the total system microbial activity. For this
reason, 3D TRASAR Bio-Control may not apply oxidizing biocide specifically in response to, or at a
dosage sufficient to control, algae growth.
3D TRASAR Bio-Control does not maintain high residuals of halogen in a tower. If algae is a known
problem and over-halogenation has been the historical method of algal control, it is crucial that an
algaecide 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 slugs
overlaid on 3D TRASAR Bio-Control.
3D TRASAR Bio-Shock mode, the all slug mode of oxidizing biocide application with bio-reporter
control 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 particularly
effective under these conditions. Using these halogens at high levels in the recirculating water
results in a vapor pressure of halogen in the tower decks resulting in algae kill. Since 3D TRASAR
Bio-Control only maintains very small TRH levels in the water, algae control by this mechanism is
not 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 oxidizing
biocide, a non-oxidizer and a bio-dispersant. Additionally, if presence of algae has been a
problem in the past and was handled through high TRH levels in the tower, an algaecide such as
N-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 depends
upon 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 measured
TRH levels depend upon the system microbiological activity and demand. In fact, measured TRH
levels 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 microbiological
activity — planktonic and sessile. The bulk of the microbiological activity in the system is sessile
and 3D TRASAR Bio-Control responds to this measured activity with oxidizing biocide. 3D
TRASAR Bio-Control will maintain planktonic counts around 104 cfu/ml for the most part. But
injured and inhibited microbes (inactive) will be nursed back to health on dip slides or petrifilm and
will show up in the planktonic counts. Planktonic population fluctuations between 10 3
-105 cfu/ml
should be expected.
• Note that there will always be systems where microbiological control is not a chemical treatment
issue. There are mechanical, operational and chemical parameters (e.g. dead legs, severely
fouled tower basins, continuous process leaks etc.) that can make bio-control difficult. Good
microbiological 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. T o
assist 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 by
slug feed (not continuous). For effective microbial control it is important to vary the stresses in a
system by routinely applying non-oxidizers.Additionally, if algae has been a known issue, an
algaecide such as N-90005 must be used routinely. In systems where non-oxidizer use is not
possible we strongly recommend regular scheduled Oxidizing biocide slugs to vary microbial
stresses.
17. How does 3D TRASAR Bio-Control apply Oxidizing biocide?

Principle: The bio-reporter (Rz) is converted by dehydrogenase, a membrane-bound respiratory
enzyme, to the Bioproduct (Rf). The concentration of Rz and Rf are determined from the intensity of
their fluorescence peaks. A decision on whether to feed oxidizing biocide is made every 20min. The
oxidizing 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. For
pellets, the decision is made every 20 minutes. The number of pellets that will be fed at a time is a
function 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) is
calculated for each data point. The data collected is validated to ensure that the fluorescence data
is 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 min
cycle. A goodness of fit criteria (chi-square) is used to evaluate if the data is too noisy or the fit is
unsuitable. The oxidizing biocide pump is turned on/off depending on the value of the calculated
ratio 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 applying
oxidizing biocide. The decision on whether to apply oxidizing biocide and how long to turn on the
pump 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 into
the system is suspended. The system slugs oxidant into the tower. 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 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 then
again added to the system and the ratio is monitored.
Control Loop: After 20min, the response of the system is again evaluated by processing the ratio
and 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 is

slaved to the feed of the non-oxidizer.
Ox Slugs: Oxidizing biocide slugs may be applied to the system when it is under normal 3D
TRASAR 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 and
range. The oxidant slug can also be simple timer based.After the slug is completed the system
waits for the ORP readings to dissipate to preslug values. Bio-Reporter is then again added to the
system and normal 3D TRASAR Bio-Control resumes. We recommend using the slug feed feature
once 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 the
slug is also user set. This mode allows the user to actively control the dosage of the oxidizing
biocide. Thus under 3D TRASAR Bio-Shock mode the bio-reporter determines the timing of the
biocide 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 based
on 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 level
and then maintained at that ORP level for the preset time. Bio-Reporter feed restarts after the
system 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 period
following the slug. Once the ORP signal has dropped to within 5% of the pre-slug levels, the
bio-reporter is redosed. If the ORP signal does not fall back to within 5% of the pre slug level within
24 hours (default value), the system will trigger a “slug recovery failure” alarm, and the oxidant will
be dosed based on the failsafe settings. When the alarm is cleared (either by acknowledging the
alarm on the 3D TRASAR controller screen or through a power cycle), the system will return to
normal operation and resume bio-reporter feed.
The figure below shows the bio-reporter ratio value during 3D TRASAR Bio-Shock mode. When it
reaches the setpoint the Oxidant relay is triggered (to 129). The Oxidant relay remains under ORP
control for the preset duration. Thereafter when the ORP signals returns to preslug values and the
recovery 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 the
Nalco Bio-Index reads -999. After bio-reporter feed has resumed the Nalco Bio-Index shows low
values (-200) which slowly increase with monitored microbial activity and reaches zero around the
time for the Oxidant slug trigger.
19. What is the Nalco Bio-Index?

Nalco Bio-Index is a measure of microbiological control in the system based on the bio-reporter
response. As the Nalco Bio-Index increases the relative microbial control decreases. Ageneral
reference is:
Nalco Bio-Index Control

This is often seen within 48 hours of startup.
<-20 If persistent with no other alarms, call 630-
305-CHEM.
-20-+10 Good control
10-30 System is working against an influx
30-80 System is straining
>80 Alarm condition
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 setpoint
0 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 devices
use chemical reagents to measure the amount ofATP in a water sample. Such devices measure
the planktonic microbial activity only. The bio-reporter measures the total microbial activity of the
system (not just the floating microbial populations). 99% of the microbe populations in a system are
biofilm (adhered to surfaces) and their activity cannot be measured from a grab sample used in A TP
analysis.
ATP measurements cannot be done on-line. The bio-reporter monitors the microbiological activity
continuously, on-line and in real time.
ATP measurements cannot be used to control the biocide pump. The bio-reporter technology is
used for continuous measurement and control of microbial activity.
ATP can survive for a long time after the micro-organism itself is dead. Therefore the readings
obtained from ATP analysis can give an incorrect picture of even the planktonic microbial activity of
a system.
21. How does 3D TRASAR Bio-Control differ from using dip slides or plate counts to
measure 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 microbial
proliferation (under-deposit corrosion, impedance of heat transfer, odor, environments for pathogen
growth, slime). Dip slides and plate counts only measure the floating microbial population and miss
the 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 and
do not need biocide.
3D TRASAR Bio-Control responds to microbial activity instantaneously. Dip slides and plates need
24-48 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 the
correct 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 TRASARBio-
Control control strategy. These two methods are distinct.
ORP control is based on an electrochemical measurement and maintains the oxidation reduction
potential in the system between preset bounds. The ORP setpoint suitable for a particular system
is water chemistry and probe dependent. It’s a good idea to monitor the halogen residual in the
tower at a particular ORP and fine tune the settings. Maintenance and frequent calibration is critical
for 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 a
demand based method of oxidizing biocide feed. No set residual is maintained, oxidizing biocide
dosage and timing is varied depending on the microbial loading. The bio-reporter must be fed to
the tower for this control method.
ORP is an electrochemical measurement and the readings from a probe can drift significantly in
short periods. It is important to keep the ORP probe clean and well-calibrated. The bio-reporter is
an 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 is
preset depending on the oxidizing biocide chosen.
ORP control applies oxidizing biocide so that the system maintains a set ORP. In bio-reporter
control, oxidizing biocide is applied based on microbial demand and therefore biocide usage is
efficient.
Since oxidizing biocide is dosed based on demand, corrosion is often reduced significantly under
Bio-Control. Therefore is typically a reduction in delignification of wood structures, steel stress
corrosion 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 to
continuously monitor the total microbial activity in a system. When the activity reaches a control set
point, oxidizing biocide is applied. If the initial dose was not sufficient, more biocide is applied, until
the system is brought under control.
When sufficient oxidizing biocide has been added to the system and the microbial activity is
brought into control, the excess oxidant interacts with the reacted bio-reporter. The controller stops
oxidizing biocide application.
Because both the microbial activity and the biocide dosing is continuously monitored it is no longer
necessary 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 as
measured 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 of
scale and corrosion inhibitor products. In the accompanying figure, we see how transition from
manual oxidant control to 3D TRASAR Bio-Control helped control copper corrosion rates. Under
manual control, the oxidant feed was erratic, with spikes in corrosion corresponding to spikes in
ORP.
It is difficult to ensure that the bleach is consistently overfed especially during process leaks or
when the make-up water becomes contaminated (e.g. with ammonia). 3D TRASAR Bio-Control
ensures 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 or
empty oxidizing biocide porta-feeds occur. Thus issues can be dealt with in a more timely manner
and 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 ofAOX formation in the tower water leading
to 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.
1,000 3.0
Before 3D Bio-Control After 3D Bio-Control
900
2.5
800
Copper Corrosion Rate (mpy)

700
2.0
600
ORP (mV)
500 1.5
400
1.0
300
200
0.5
100
- -
Time (each division = 1 day)
Figure: ORP and copper corrosion rates are measured by 3D TRASAR. 3D TRASAR
Bio-Control is superior to ORP control because it 1) reduces the variation in oxidant
concentration, 2) reduces the average oxidant concentration and 3) reduces copper
corrosion rates by eliminating high ORP levels.

25. Can you give me an example where 3D TRASAR Bio-Control varied the Oxidant
feed based on system demand?
In this tower oxidizing biocide is STA-BR-EX. Tower is under 3D TRASAR Bio-Control. On 8/23/04
the tower is slugged with 6 ppm of N73550 (biodetergent). Entire system (deadlegs, unused
towers, unused chillers) is opened up to detergent. 100 ppm of N7330 is added to the tower 1 hr
later. As untreated and sloughed up biofilm is exposed, the Nalco Bio-Index increases and the
duration and frequency of the oxidizing biocide feed (Ox pump On time) is increased. The Nalco
Bio-Index has a double-humped profile (second peak on 08/24/04) due to the detergent continuing
to 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 is
treated to 50 ppm of N90005 (quaternary amine algaecide). The algaecide is also a surfactant and
a slow acting bactericide. There is an initial increase in Nalco Bio-Index followed by a 21 hr period
during 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 activity
and consequently a 21 hr period of no oxidant feed into the system. Planktonic counts taken on
08/26/04 show good microbial control.
Ox_pump_ on_time
300 BF_ratio_ index 30
N90005 slug 25
Ox Pump on sec/600s
250
No Ox feed20
3D Bio Index
200 N73550 & for 21 hrs 15
N7330 slug 10
150
5
100 0
-5
50
-10
0 -15
8/20/04 8/22/04 8/24/04 8/26/04 8/28/04
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 some
consumption of the bio-reporter molecule during each blowdown cycle. The product usage per unit
blowdown 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 unit
blowdown 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 3D
TRASAR Optimizer report.
lbs/Million gal of
Bio-Reporter
blowdown
3DTBR06 83.4
3DTBR8 6.3
3DTBR20 2.5
3DTBR40 1.3
3DTBR10 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 3D
TRASAR fluorometer and the feed point of the oxidizing biocide. It should be in well mixed region
of the recirculating system. If a pellet feeder is being used, flow through the feeder should be a
minimum 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-time
monitoring 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 biocide
is 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 cooling
system. 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 TRASAR
Bio-Control?
No. You should wait till the halogen levels in the tower dissipate to less than 0.1 ppm total residual
as measured by the Hach DPD test before starting 3D TRASAR Bio-Control, otherwise your tower
water will turn blue.
31. What will happen if I initiate 3D TRASAR Bio-Control without waiting for TRH
levels to be <0.1 ppm?
If you initiate 3D TRASAR Bio-Control without waiting for the halogen levels to dissipate to <0.1
ppm total residual halogen as measured by the Hach DPD test, there is a potential for the tower
water 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 oxidizing
biocide feed into the tower has been discontinued for 24 hours. In these towers, it may be OK to
start 3D TRASAR Bio-Control without waiting for thetotal 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 call630-305-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 microbial
activity) 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 the
system please call 630-305-CHEM.
When you wish to follow the 3D TRASAR Bio-Control algorithm and verify correct operation the
easiest thing to do is to download the 3D TRASAR Bio-Control data file (through data download
screen). 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 TRASAR
Bio-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 the
Bio-reporter value in ppb.
34. Can I trim-feed oxidizing biocide with a separate pump at low level to
continuously maintain a halogen residual while on 3D TRASAR Bio-Control?
Only if the oxidizing biocide is being applied to the Make-Up waterAND the conditions that prevent
3D 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 likely
that 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 the
water will become colored.

34. Can I trim-feed oxidizing biocide with a separate pump at low level to
continuously 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 Ratio
staying 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 of
the 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 the
system. This cannot be externally modulated or adjusted. However, the scheduled slug option
can 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 applying
oxidizing biocide to the system. The bio-reporter monitors the microbial activity and when it reaches
a preset value, an Ox slug is triggered. By setting the duration and ORP level of the slug, the user
can 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 the
system. 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 decision
regarding 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 to
the microbial populations or decreases the efficacy of the biocide (sour leak, ammonia etc) 3D
TRASAR Bio-Control will respond with increased biocide feed within 20 minutes of the measured
event. 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 or
before the time that other effects have been observed in the system such as pH changes, turbidity
changes, 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 in
the 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 to
be 0.1 - 0.4 ppm TRH. ORP levels at which control is maintained depends upon the oxidizing
biocide 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 TRASAR
Bio-Control.
In this graph, STA-BR-EX was the oxidizing biocide. On-line halogen was monitored with
a Hach Cl-17. Using 3D TRASAR Bio-Control, ORP varied between 180 - 320 mV and
the halogen levels varied between 0.0 - 0.4 ppm (total). 3D TRASAR Bio-Control adjusts
halogen dosage based on demand. There is thus seasonal and diurnal variations in the
concentration.

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 under
good control. We recommend that you benchmark performance prior to 3D TRASAR Bio-Control
for later comparison with system performance under 3D TRASAR Bio-Control. The following test
regimen 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 does
not work in my system?
No. 3D TRASAR Bio-Control may be working well in your system. The bio-reporter monitors the
total system microbial activity: planktonic (floating) and sessile (biofilm). The biofilm constitutes the
vast majority of the microbial population in the system (>98%) and is unevenly distributed over the
system surfaces. Dip slides and normal DMA only monitor the floating population, which may not
represent the bulk of the microbial activity.
Planktonic counts measured by dip slides or DMAshould be between 103-105 cfu/ml. Swabs of
coupons 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 the
opening 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 a
biodetergent (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 inoculation
of 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 on
microbial activity) for the ratio to reach the control ratio set point. During this period, oxidizing
biocide will not be applied to the system. If, after 24 hours, oxidizing biocide has not been fed into
the 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 the
control band. As the microbes convert some of the bio-reporter the Ratio will come up to the set
point. The Nalco Bio-Index is calculated from the averaged value of the Ratio and is not a good
indicator 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 being
degraded by a separate oxidant feed. Plot the ORP(mV) data from the standard log and see how
it varies over time. Other sources of oxidant can be detected by the ORP being maintained or
going 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 display
purposes only.
NBI represents the average value of the Rf/Rz Ratio with respect to the control band over the past
6 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 may
have been in between these logs. The calc (once-a-day) log correctly records the Oxidizing biocide
relay duty cycle for the past 24 hours. Check this number to determine if biocide has been applied
or 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 on
microbial activity) for the ratio to reach the control ratio set point. During this period, oxidizing
biocide will not be applied to the system. If, after 24 hours, oxidizing biocide has not been fed into
the 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 effect
will 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 be
displaced 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 gravity
so 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), the
seals may need to be adjusted. This is detailed in the manual. If the drain line is leaking when no
pellets are being fed, or if large amounts of water are being expelled during a feed, the seals
should 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 outlet
line from the pellet feeder should have no blockage. If the flow through the flow switch on the
controller goes below 0.5 gpm, the system will register a no-flow alarm and pellets will stop being
fed. However, if the feeder is plumbed to a separate line that becomes plugged, or if the flow is
throttled to less than 5 gpm but greater than 0.5 gpm, the feeder will continue to feed. This may
result in undissolved pellets below the ball valve. Please check the flow through the feeder prior to
beginning pellet feeding. Strainers before and in the pellet feeder may clog resulting in no-flow or low
flow conditions. A separate flow switch on the feeder line (with a 3 to 5 gpm cut-off) could be added
in series with the controller flow switch if intermittent flow is a problem.

Section 7: Communication and Data

Management
The overall 3D TRASAR program incorporates a number of software programs, and hardware
systems to manage all of the information associated with the control of a cooling system. The
diagram 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 program
for your cooling system. Information entered in the 3D TRASAR Optimizer can be transferred to
the 3D TRASAR Configurator to avoid duplicate data entry. Contact your Nalco representative for
questions about the 3D TRASAR Optimizer.
7.2 3D TRASAR Configurator

The 3D TRASAR Configurator is a software program used to configure the controller, establish
remote 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 4-20ma
signals or RS-232/485 Modbus. Refer toAppendix E for details. Call 630-305-CHEM for assistance
with SCADA applications.

7.5 3D TRASAR Web

The 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 every
hour 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 Nalco
Extranet Account to enter the site. Contact your Nalco representative for information on how to
obtain 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 are
to 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 as
facility 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 operating
parameters for one controller.
The “Performance
Summary” page
provides a high-level
view of the state of
every controller
assigned to a user.
The “Data Dashboard”

displays detailed
information for a
specific controller.

7.5.3 3D TRASAR Web Reports
The “Basic Report” and

“Advanced Report” pages allow
users to preview graphs and
download data. Historical data is
captured at 15 minute intervals.
Reports can be emailed to the

customer, exported to spread-
sheet, or saved for future use
(schedule reports to generate
automatically and email on a
routine basis.)

7.5.4 3D TRASAR Web Alarms

Alarm information generated by the 3D TRASAR controller will be sent in an email to the
3D TRASAR web site where it will be forwarded to the specified user’s email address. Details on
the last 50 alarms will also be available on the 3D TRASAR Web, along with information on
probable causes and troubleshooting tips.

7.6 Vantage V100

Vantage 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

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 3D
TRASAR 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) to
be created. The database name will default to be the customer name and location
assigned in the controller.
• Select System - there may be multiple systems in one database, select the appropriate
system for the data to be stored.
• Data Source Name - displays the Vantage V100 Data Source Name.
• Click Transfer Data
Note: Use Vantage V100 for more permanent data storage. T ransfered 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.

7.6.2 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 and
the 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 one
graph 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 by
clicking 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 to
manually enter the specification limits into Vantage V100 in order for them to show up in graphs and
have certain statistical values calculated. To do this, you will need to enter the specification limits
into System Setup as shown below.
STEP 1 – Click System Setup
STEP 2 – Select the appropriate 3D TRASAR Data Source and double-click the measurement in
the grid.

7.6.3 Vantage V100 3D TRASAR Spec Limits (con’t)

STEP 3 – Type in the Specification Limits into the appropriate fields in theEdit Measurement form.
Repeat with all 3D TRASAR measurements.

7.7 Nalco Global Gateway

The Nalco Global Gateway P [ /N’s 060-NGG100.88 (US) and 060-NGG200.88 (International)] allows a
quick, 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 Ethernet
port of the controller.
The Nalco Global Gateway provides advanced security including NA T, plus a built in firewall to
protect the controller from unauthorized access via the Internet. W
hen 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 an
adequate, interference free, stable signal. Use the guidelines below to determine signal availability in
your area.
• If you have access to a GSM/GPRS cell phone, and can make a web/data connection from
the location where the controller will be installed, there is a very high probability that the
Nalco 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 the
controller will be installed, there is a good probability that the Nalco Global Gateway will work
from that location.
• If you cannot make a data connection or phone call, you will probably need theindoor/
outdoor high gain antenna option (P/N 060-TR5284.88, cable not included*). This usually
occurs when the controller is installed in basements, metal buildings, or next to electrical
equipment.
*Order cable separately by the following part numbers:
060-TR5284C100.88 100-foot Cable

060-TR5284C25.88 25-foot Cable
Detailed installation and configuration instructions are included with the unit. Contact your local
Nalco Representative for ordering information.

Section 8: Maintenance
The 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 on
components which interact with the cooling system water directly (i.e. Probes, strainers and the
like). Performing periodic maintenance according to the schedule listed below will significantly
improve 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 X
Fluorometer-calibrate X X X X X X X X X X X X
Fluorometer-check dessicant X X X X X X X X X X X X
pH probe-clean/calibrate X X X X X X X X X X X X
ORP probe-clean/calibrate X X X X X X X X X X X X
Corrosion probes-check X X X X
Conductivity probe-clean/calibrate X X
Strainers-check/clean X X X X X X X X X X X X
Pellet feeder-check/refill Perform weekly
Pellet feeder-clean Prior to refi ll
Pellet Feeder Desiccant-check/replace Prior to refi ll
Pellet feeder ball valve-tighten X X X X
Pellet 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 for
six months of routine maintenance: 3D TRASAR Calibration
Solution 1L (2), pH 7.0 and 10.0 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 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), P/N 060-TRMNKIT.88
Fluorometer Desiccant Canister, Fluorometer Desiccant Indica- Maintenance Value Package
tor.

8.2 Clean Fluorometer Flow Cell

Shut 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 or
500-TSRKITSTR.88), gently push the brush down through the opening and scrub the full length of
the flowswitch and fluorometer tube.
After cleaning is complete, check fluorometer calibration (Refer to Section 4.10.3).
8.3 Check/replace Fluorometer Desiccant

The fluorometer uses a desiccant canister and a color-coded humidity indicator to ensure that the
optics 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 the
desiccant cover from fluorometer. Replace both the indicator (P/N 060-TR5223.88) and desiccant
canister (P/N 060-TR5222.88).
8.4 Check Sensor Calibration

Refer 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.
# Calibration
Sensor Reason for Calibration
Points
2 (blank and
Fluorometer Monthly, to verify accuracy
S0940)
Monthly, to fine-tune calibration to
1
compensate for mi nor drifting.
pH After installation of new probe, or
if probe readings become erratic 2
due to fouling/degradation.
1
ORP After installation of new probe, or
1
Conductivity After installation of new probe, or
8.5 Probe Replacement Schedule

To minimize downtime, it is recommended to keep spare pH, ORP and Corrosion probes on hand.
Part numbers can be found in Appendix C.
Probe Replacement Frequency

Every six months or when probe
pH
readings become erratic.
Every six months or when probe
ORP
readings become erratic.
Every sixty to ninety days or when
Corrosion
probe readings become erratic.
* Replace Conductivity probe only in the event of failure.
8.6 Cleaning Basket / Wye Strainer

Visibly 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.Pay
care not to lose the o-ring seal on the bowl assembly. The mesh screen can be removed, rinsed in
clean water and then reinstalled.
The wye strainer assembly on the pellet feeder serves as a dissolving chamber for the bio-reporter
pellets. If any residue from bio-reporter pellets remains in the strainer wear rubber gloves when
removing and cleaning this strainer mesh.
Close the inlet and outlet valves and unscrew the plug at the end of the wye. Remove the mesh and
rinse with clean water.
8.7 Pellet Feeder Maintenance

For 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 Feeder

Check to see that the Pellet Feeder is at least ¼ full of bio-reporter pellets. If less than ¼ full add a
full 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 detailed
pellet feeder maintenance.

Section 9: Troubleshooting
9.1 General Troubleshooting

Problem Possible Cause(s) Solution
Controller does not Controller is not plugged in. Plug in controller.
power up when
power switch is GFI or circuit breaker is tripped, or fuses blown. Reset breaker, or replace fuse.
flipped.
Display does not These measurements do not appear in Configure these probes as Monitor Only
show pH, ORP, Operating Data if the probes are configured as or Controlling.
Conductivity, or Not Installed.
Temp. 3D TRASAR 3500 controller requires upgrade Purchase 3D TRASAR pH upgrade
to measure pH and ORP. P/N 060-TR3211.88, or ORP upgrade
P/N 060-TR3221.88
Display does not This measurement does not appear in System Select 3D Bio-Control as the oxidizing
show Nalco Performance unless 3D Bio-Control is selected biocide control method.
Bio- Index. as the oxidizing biocide control method.
3D TRASAR Starter 3500 system requires Purchase 3D TRASAR fluorometer
fluorometer upgrade to measure Nalco Bio- upgrade P/N 060-TR3200.88
Index.
Display does not This measurement does not appear in System Select 3D Scale Control as the
show Nalco Scale Performance unless 3D Scale Control is blowdown control method.
Index. selected as the blowdown control method.
3D TRASAR Starter 3500 system requires
Purchase 3D TRASAR fluorometer
fluorometer upgrade to measure Nalco Scale
upgrade P/N 060-TR3200.88
Index
One or more relays There is an alarm condition affecting that relay. Check the active alarms and adjust
are in failsafe mode. settings if needed.
One or more relays The jumper supplying power to the contact Check to be sure the relay power
are not operating. closure has been removed. In this case, the jumper is connected properly.
display will still indicate that the relay is on.
The product level is above (or below for The relay d oes not need to be on.
blowdown and caustic control) the set point and
control range.
There is a No Flow Alarm, during which the Check the active alarms and increase
relays may not operate. In thi s case, the flow if needed.
display will still indicate that the relay is off.
There is an Interlock Alarm, during which the Check the active alarms and be sure
relays will not operate. In thi s case, the display the Interlock cable is connected
will indicate that the relay i s off. properly (or jumper, if Interlock is not
used).
A calibration is underway, during which the Complete or cancel the calibration
relays will not operate. procedure.
The affected relay(s) is in Manual Off mode. In Using the keypad Menu i tem Manual
this case, the display will indicate that the relay Relay Control, return the relay to Auto
is in Manual Off mode. mode.


The pellet feeder is The pellet feeder is not properly connected to Check all connecti ons and replace
not feeding pellets. the controller (power and/or communication). cable if damaged. Ensure power
The green light on the feeder will be off if the switch is i n "ON" position.
power wires are not properly connected. An
alarm will be listed in the activ e alarms on the
display if the communication wi res are not
properly connected.
The controller is not correctly configured to Check the configuration to be sure that
operate the pellet feeder. (a) 3D Bio-Control is selected as the
oxidizing biocide control method, and
(b) a solid product is selected as the
bio-reporter.
A pellet feeder error i s active, during whi ch Check the active alarms and resolve
pellets will not b e fed. The green light on the the alarm condition(s) as needed.
feeder will be blinking if it is an error state.
The first 3D Bio-Control decision interval has On power up, the first pellet feed
not yet been reached. happens at the end of the fi rst decision
interval, which may take up to 25
minutes.
The bio-reporter level is above the set poi nt No pellets are required.
and control range.
There is a No Flow Alarm, during which pellets Check the active alarms and i ncrease
will not be fed. In this case, the display will still flow if needed.
indicate that the relay is off.
There is an Interlock Alarm, during which pellets Check the active alarms and be su re
will not be fed. In this case, the display will the Interlock cable is connected
indicate that the relay is off. properly (or jumper, if Interlock is not
used).
A calibration is underway, duri ng which pellets Complete or cancel the calibration
will not be fed. procedure.
The bio-reporter is in Manual Off mode. Using the keypad Menu i tem Manual
Relay Control, return the bi o-reporter to
Auto mode.
The oxidizing biocide is in a failsafe mode due Check the active alarms and resolve
to an alarm conditi on. the alarm condition(s) as needed.


The Configurator The Ethernet crossover cable is not connected Check all connecti ons and replace the
cannot securely to the controller and/or PC Ethernet cable if damaged.
communicate with ports.
the controller using A standard network cable is being used i nstead Replace the network cable wi th a
a direct connection. of a crossover network cable. crossover network cable.
The PC network adapter (Local Area The default ne twork settings for the
Connection adapter) is not configured properly. controller direct connecti on are IP
Address 169.254.1.2 Subnet
255.255.0.0, and Gateway 169.254.14.
Your PC Ethernet adapter should be
configured with the values IP Address
169.254.1.***, Subnet 255.255.0.0, and
Gateway 169.254.14, where ***= any
number between 3 and 255. This can
be changed in Start/Network and Di alup
Connections/Local Area
Connection/Properties/Internet
Protocol/Properties (see manual).
The IP Address being used by the Configurator The default IP address for the controller
is incorrect. direct connection is 169.254.1.2. In the
Configurator's Connection Wi ndow,
click on Advanced and make sure thi s
is the IP address being used in the
connection attempt.
The proxy s erver settings are incorrect. Open Internet Explorer. Go to
Tools/Internet Options and cli ck on the
Connections tab. Cli ck the LAN
Settings button, and uncheck "Use
Proxy Server". Be sure to return this
setting when fi nished if required for
other applications.


A connection The analog phone cable is not connected Check all connecti ons and replace the
cannot be securely to the controller, PC, and/or wall jacks. phone line if damaged.
established to the The phone line is not functional for dial in. Try d ialing the number using a landline
controller via or cell phone to see if the controller
modem. answers. If it does not, connect an
analog phone to the line in place of the
controller and di al the numb er again
using the same landline or cell phone.
The phone should ring if th e call is
coming through.
The phone line is in use. This can happen if the controller is
dialing out to send an email or if
another party is connected to the
controller via modem. Try again later.
The phone number used by the PC is incorrect. Check the phone numb er you are
dialing.
With a gateway The IP Address being used by the Configurator The default IP address for the gateway
connection is incorrect. connection is 192.168.1.2. In the
established, the Configurator's Connection Window,
Configurator click on Advanced and make sure thi s
cannot is the IP address being used in the
communicate with connection attempt.
the controller.
There is >0.5 gpm The flow switch is not connected properl y. Remove the flow switch wires and short
flow through the the + and - terminals on the controller
flow switch, but a using a wire jumper. The No Flow
No Flow Alarm is indicator on the display and the No
active. Flow Alarm should clear. Reconnect
the flo w switch wires.
The flow switch is not functi onal. Stop the flow, remove the flow swi tch
and clear any debris lodged inside. If
this does not help, replace the flow
switch.
The flow switch is not connected properl y. Check the flow switch connecti ons in
the controller.
There is <0.5 gpm The flow switch is not functi onal. Replace the flow switch.
flow through the The 10-minute delay period has not passed. The flow signal must b e absent fo r 10
flow switch, but the min before the alarm wi ll activate.
No Flow Alarm is The flow is near the 0.5 gpm rati ng of the flow This will cause the 10-minute delay
not active. switch, resulting in i ntermittent flow/no flow timer to reset each time flow is
indications. detected, preventing the alarm.
Increase the flow.


Alarm emails are Analog phone line is not connected. Check all connections and replace the
not being received. phone line if damaged.
Phone line is not functi onal for dialing out. Enter cell phone number as the ISP
access number. Remove the system
interlock jumper. Your cell phone wi ll
ring if the phone line is functional.
Controller is not confi gured to send alarm Check the Alarm Settings to be sure
emails. the email checkboxes are checked.
Email address is misspelled/incorrect. Recheck email address for spelling.
The alarm email address must be
alarms@3dtrasar.com.
ISP access phone number is entered in wrong Check the phone number to ensure that
format. it is entered exactly as the controller wi ll
dial it, including prefixes (8 or 9, 1+area
code). A comma ',' may be used as a
pause.
ISP settings are incorrect. Check the following settings provided
by your Nalco Rep: username,
password, access phone number.
Controller data Analog phone line is not connected. Check all connections and replace the
cannot be viewed phone line if damaged.
at 3D TRASAR Phone line is not functi onal for dialing out. Enter cell phone number as the ISP
Web. access number. Remove the system
interlock jumper. Your cell phone wi ll
ring if the phone line is functional.
Controller is not confi gured to send data Check the Email Settings to be sure the
emails. Send Data Email parameter is set to
Yes.
ISP access phone number is entered in wrong Check the phone number to ensure that
format. it is entered exactly as the controller wi ll
dial it, including prefixes (8 or 9, 1+area
code). A comma ',' may be used as a
pause.
ISP settings are incorrect. Check the following settings provided
by your Nalco Rep: username,
password, access phone number.
Controller has not been registered at 3D Call 630-305-CHEM.
TRASAR Web.
Product levels A Fluorometer Communication Error is active. Tighten the connector on the fluorometer
(ppm) are displayed probe and check the fluorometer cable
as dashes. connections in the controller. Re place
cable if damaged. Check desiccant for
moisture indication.


Conductivity A C onductivity Sensor Error is active. Check the conductivity probe
(uS/cm) is connections in the controller. Re place
displayed as probe if all connections are seated
dashes. tightly and the error persi sts after power
off/on.
A Temperature Sensor Error is active. Check the conductivity connections in
the controller. S ince the RTD is
embedded in the conductivity probe,
replace the conductivity probe if all
connections are seated tightly and the
error persists after power off/on.
Value of -999 is The measurement is i nvalid. A sensor error or some other conditi on
logged in datalog. is present, whi ch is causing the
measurement to be invalid. Check the
active alarm li st on the display. F or
Bio-Index, -999 is logged for the first 2
hours after powerup, which is normal
and requires no resolution. F or Scale
Index, this will occur after the learning
period and immediately after power
cycle.
Confusing numbers The numbers correspond to the relay state. The relay states are :
are logged in the 129 Auto on
datalog in the relay 128 Auto off
status fields. 65 Manual on
64 Manual off
33 Failsafe on
32 Failsafe off
16 Forced off
9 Flow failsafe on
8 Flow failsafe off
0 Not controlled

9.2 Alarm Screen Troubleshooting

Notes:
1) Upon initial start-up measured levels may be low causing nuisance alarms. T o prevent nuisance
alarms refer to the start-up procedures to select system Start-up alarm suppression (Section
4.10.11).
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.
Alarm
Indication Probable Cause Corrective Action
Type
TRASAR, Tagged Polymer, ORP, pH (Caustic Control)
1) Sensor probe is out of calibration. 1) Check calibration and recalibrate if needed.
Measurement 2) High Alarm threshold set too low. 2) Readjust alarm threshold.
High exceeds High 3) Chemical feed rate too high causing "overshoot". 3) Reduce chemical feed rate.
Alarm threshold 4) Chemical pump siphoning causing overfeed. 4) Elminate condition causing siphoning.
5) Process leak or other contaminant in system. 5) Confirm (with other data) and eliminate source.
Measurement 2) Low Alarm threshold set too high. 2) Readjust alarm threshold.
Low below Low 3) Chemical feed rate too low or interrupted. 3) Check feed line or increase chemical feed rate.
Alarm threshold 4) Product container empty. 4) Refill/replace product inventory.
pH (Acid Control)
Measurement 2) High Alarm threshold set too low. 2) Readjust alarm threshold.
High exceeds High 3) Chemical feed rate too low or interrupted. 3) Check feed line or increase chemical feed rate.
Alarm threshold 4) Product container empty. 4) Refill/replace product inventory.
Measurement 2) Low Alarm threshold set too high. 2) Readjust alarm threshold.
Low below Low 3) Chemical feed rate too high causing "overshoot". 3) Reduce chemical feed rate.
Alarm threshold 4) Chemical pump siphoning causing overfeed. 4) Eliminate condition causing siphoning.
Conductivity
1) Sensor probe is out of calibration. 1) Check calibration and recalibrate if necessary.
Measurement
2) High Alarm threshold set too low. 2) Readjust alarm threshold.
High exceeds High
3) Blowdown valve throttled too low or plugged. 3) Check blowdown valve for proper operation.
Alarm threshold
4) Process leak or other contaminant in sy stem. 4) Confirm (with other data) and eliminate source.
1) Sensor probe is out of calibration. 1) Check calibration and recalibrate if necessary.
Measurement
2) Low Alarm threshold set too high. 2) Readjust alarm threshold.
Low below Low
3) Blowdown valve throttled too high or stuck open. 3) Check blowdown valve for proper operation.
Alarm threshold
4) Process leak or other contaminant in sy stem. 4) Confirm (with other data) and eliminate source.
Temperature
1) RTD probe is out of calibration 1) Verify temperature using a thermometer .
Measurement
2) High Alarm threshold set too low. 2) Readjust alarm threshold.
High exceeds High
3) Cooling system problem. Note: PVC piping is rated 3) Diagnose and resolve cause of excessive bulk
Alarm threshold
for 140 F max. water temperature.
1) RTD probe is out of calibration. 1) Verify temperature using a thermometer .
Measurement
2) Low Alarm threshold set too high. 2 ) Readjust alarm threshold.
Low below Low
3) Cooling system problem. Note: Freezing will burst 3) Diagnose and resolve cause of low bulk water
Alarm threshold
piping. temperature.

Alarm
Type
[XX] Corrosion ([XX] = Probe metallurgy)
Mesurement 1) Insufficient flow rate past probe. 1) Verify minimum of 5 gpm flow is present.
High exceeds High 2) High Alarm threshold set too low. 2) Readjust alarm threshold.
Alarm threshold 3) Corrosion treatment program needs adjustment. 3) Consult your Nalco Representative.
Cell Fouling
Mesurement 1) Fluorometer flow cell is fouled. 1) Clean flow cell with supplied brush and cleani ng
High exceeds High solution. Recalibrate as needed.
Alarm threshold 2) High Alarm threshold set too low. 2) Readjust alarm threshold.
Control Relays (TRASAR, Tagged Polymer, Bio-reporter, Oxidizing Biocide, Blowdown, pH)
Relay has been 1) Tank empty/pump lost prime/faulty pump or valve. 1) Check tank/pump/valve/feed line. Repair as
Relay activated for needed.
Timeout longer than relay 2) Relay Timeout Limit set too low. 2) Readjust alarm threshold.
timeout limit 3) Feed/bleed rate too low for demand. 3) Increase feed/bleed rate.
General Sensors
1) Wiring or other connecti on is loose. 1) Retighten wires or other connections. Be sure wire
Error detected
insulation is not preventing good contact.
Sensor with i ndicated
2) Sensor probe failure. 2) Replace probe. Probe replacement may be
sensor probe.
included in purchased service plan.
1) Flow rate too low or back pressure too high. Flow 1) Investigate and correct.
Sample Insufficient water switch requires 0.5 gpm.
Flow flow through 2) Flow switch fouled. 2) Clean flow switch.
Low fluorometer cell 3) Flow switch wiring is loose or not making good 3) Replace flow switch
connection.
1) The interlocking device is not active. 1) Check. This may be expected operation.
The interlock
Interlock 2) Interlock is not used and jumper is not in place. 2) Replace jumper (refer to wiring diagram for
input has been
Absent 3) Interlock wiring is loose or not making good location and di rections.
deactivated
connection. 3) Check and correct wiring connections.
1) Cable connector on Fluorometer is loose. 1) Disconnect and inspect for bent pins or signs of
Controller is damage, then reconnect.
unable to 2) Wiring from fluorometer is loose or miswired in 2) Check and correct if needed (see wiring diagram
Fluor.
communicate controller. for details).
Comm.
with the 3) Component failure. 3) Reboot system by momentarily cycling power to
fluorometer initiate recovery. If unsuccessful contact Help D esk at
630-305-CHEM for assistance.
The sensor 1) Sensor board is loose preventing good con nection. 1) Gently press on "Red" circuit board inside
Sensor board is not controller to ensure snug fi t.
Board communicating 2) Component failure. 2) Reboot sytem by momentarily cycling power to
Comm. with the initiate recovery. If unsuccessful contact Help D esk at
controller 630-305-CHEM for assistance.
3D Bio Control
1) Pellet Feeder cable loose or con nections not made 1) Disconnect and inspect both Pellet Feeder
Controller is not correctly. connector and wi ring in controller, then reconnect.
Pellet
communicating 2) Pellet Feeder power switch is not turned on. 2) Turn power switch on.
Feeder
with P ellet 3) Component failure. 3) Reboot system by momentarily cycling power to
Comm.
Feeder initiate recovery. If unsuccessful contact Help D esk at
630-305-CHEM for assistance.
The P ellet 1) Pellet supply is low. 1) Check and fill Pellet Feeder, or redistribute
Feeder has not remaining pellets.
Pellet completed a
Feeder pellet feed
Busy before the next
pellet is called
for
The P ellet 1) Pellet Feeder is empty. 1) Check and refill Pellet Feeder.
Pellet
Feeder has not
Supply
fed a pellet
Low
when called for
Pellet The P ellet 1) The clear pellet feed tube is blocked or dirty 1) Check and clean feed tube usi ng supplied brush.
Sensor Sensor LED is preventing light transmission.
Error blocked.

Alarm
Type
1) Ball valve separated from motor shaft. 1) Contact Help Desk at 630-305-CHEM for
Ball Valve Pellet Feeder ball assistance.
Error valve not rotati ng
1) The Pellet Feeder ball valv e is jammed.

Ball Valve Pellet Feeder ball 1) Disassemble ball valve, clear jam.
Current valve drawi ng too 2) Adjust valve seats (see Pellet Feeder
2) The Pellet Feeder valve seats h ave been over
High much current Maintenance Section 6.8).
tightened.
Pellet 1) The Pellet Feeder rotor is jammed. 1) Remove pellets from hopper and clear jam. Rotor
Pellet Feeder
Rotor shield may be worn and require replacement (see
rotor drawing too
Current Pellet Feeder Maintenance Section 6.8).
much current
High
1) Oxi dizing Biocide tank empty or pump lost pri me. 1) Check and refill tank or reprime pump.
Microbio activity 2) Increased biocide demand detected, and controller 2) No action required. If this persists for 3 days,
Bio-Index
is not under is responding appropriately. contact Help Desk at 630-305-CHEM for assistan ce.
High
control 3) Biocide program requirements have changed. 3) Reassess biocide program with your local Nalco
Representative.
1) Biocide pump rep/stroke are set too high , or pump 1) Adjust feed rate downward or replace with a lower
is too large for system. capacity pump. After downward adjustment, reset 3D
Biocide Biocide feed rate
Bio-Control by changing the Oxi dizing Biocide Control
Pump is too high to
Method first to None (reboot controler) then back to
Rate High control accurately
3D Bio-Control (reboot controller). Otherwise,
persistant Bio Index Hi gh Alarms may occur.
Biocide feed rate 1) Biocide pump/stroke are set too low, or pump is 1) Adjust feed rate upward or replace with a h igher
Biocide
is too low to too small for system. capacity pump.
Pump
control microbio
Rate Low
activity effectively
Bio- Bioproduct level 1) Biocide feed unable to meet microbio deman d. 1) Manually feed Oxi dizing Biocide into system until
product exceeds alarm alarm clears.
High threshold
Bioproduct level 1) Same causes as Bioproduct High. 1) Same. Alarm must be cleared at the di splay.
exceeds alarm
Bio-
threshold for an
product
extended period,
High
and oxidizing
Failsafe
biocide enters
failsafe mode
1) Bio-reporter feed is insufficient. 1) Check bio-reporter pump or pellet feeder, or verify
Bio- Bioproduct level 2) Excessive Oxidizing Biocide degrading bioreporter. adequate bio-reporter inventory.
product below alarm Source of Oxidizing Biocide may be makeup, manual
Low threshold feed, process or other leak, or oversi zed biocide
pump.
Bioproduct level 1) Same causes as Bioproduct Low. Same. Alarm must be cleared at th e display.
below alarm
Bio-
threshold for an
product
extended period,
Low
and oxidizing
Failsafe
biocide enters
failsafe mode
1) Too many Qui ck Dose pouches were added at 1) Wait for level to come down. Additi onal bio-
start-up. reporter will not be fed.
Bio- Bio-reporter level
2) Bio-reporter was overfed by manual control or 2) Wait for level to come down. Additi onal bio-
reporter exceeds alarm
malfunctioning pump. reporter will not be fed.
High threshold
3) If i n conjunction wi th Bioproduct High, biocide feed 3) Manually feed Oxi dizing Biocide into system until
unable to meet microbi o demand. alarm clears.
Bio-reporter level 1) Same causes as Bioreporter High. 1) Same. Alarm must be cleared at the di splay.
exceeds alarm
Bio-
threshold for an
reporter
extended period,
High
and oxidizing
Failsafe
biocide enters
failsafe mode.

Alarm
Type
1) Pellet Feeder unable to bring bio-reporter level up 1) Add additional Quick Dose pouch and wai t for
to setpoint in a reasonable time. mixing. If alarm persists, repeat. Check bio-reporter
Bio- Bio-reporter
2) Excessive Oxidizing Biocide degrading bio- level at controller di splay in Information>Diagnostic
reporter level below
reporter. Source of Oxidizing Biocide may be makeup, Data>Fluorometer Data (Rz).
Low control threshold
manual feed, process or other leak, or oversized 2) Remove source of excess biocide.
biocide pump.
Bio-reporter 1) Same causes as Bio-reporter Low. 1) Same. Alarm must be cleared at the display.
level below
Bio- control threshold
reporter for an extended
Low period, and
Failsafe oxidizing
biocide enters
failsafe mode.
1) Bubbles in flow cell. 1) Reduce flow rate or remove source of entrained air
Bio-Data
Excessive noise (i.e., air-locked pump).
Noise
in data 2) Bioreporter feed point is too close to TRASAR 2) Change feed point to a location further
High
5000. downstream of the intake.
Excessive noise 1) Same causes as Bio Data Noise High. 1) Same. Alarm must be cleared at the display.
in data for an
Bio-Data extended
Noise period, and
High oxidizing
Failsafe biocide has
entered failsafe
mode.
1) ORP probe is fouled and needs calibration 1) Clean and calibrate ORP probe.
2) The system takes a long ti me to dissipate the 2) In the Slug Feed screen <3D BioControl Recovery
After a Slug the Oxidizing biocide fed during the slug. Settings> <Show Advanced Recovery Options>
Slug ORP did not 3) Too much Oxidizing biocide was applied during the Increase the ti me limit.
Recovery return to pre-slug slug. 3)Decrease the oxidizing Biocide applied by
Failure values within the changing the ORP setpoint for the Oxidant slug. If the
time limit. slug is applied by timer control, decrease the time for
the Oxi dant feed. If TB 960 is the Oxidizing biocide,
decrease the weight of the Biocide applied per feed.
1) The Oxidant pump is airlocked or failed to apply the 1) Fix pump or feeder.
biocide. 2) Increase the ORP Rise Limit Time in the <Slug
The ORP did not
2) The recirculati on time in the tower is long and the Oxidizing Biocide> <Slug Feed Settings.>
Ox Shock increase the
applied Biocide is not seen by the ORP probe within 3) Decrease the min ORP rise <Slug Oxidizing
Failed minimum value
the time limit. Biocide> <Slug Feed Settings>
during a slug
3) The mi nimum ORP rise setting is too large. 4) Calibrate/clean probe.
4) The ORP probe is fouled/miscalibrated.
Relay has been 1) Tank empty/Pump lost prime/faulty pump or valve. 1) Check tank/pump/valve/feed line. Repair as
activated for 2) Relay timeout li mit set too low. needed.
longer than relay 3) Pump rate is too low for demand. 2) Readjust alarm threshold.
timeout limit. 4) The Oxidizing biocide is n ot being applied. 3) Increase pump rate.
Oxidant In 3D Bio-Shock 5) The time limi t between feeds is set too long for the 4) Check the pump/feeder.
Relay mode the system. 5) Decrease the minimum time between feeds.
Timeout BioReporter is
calling for too
frequent
oxidizing
biocide feed
Bio Relay has been 1) Tank empty/Pump lost prime/faulty pump or valve. 1) Check tank/pump/valve/feed line. Repair as
Reporter activated for 2) Relay timeout li mit set too low. needed.
Relay longer than relay 3) Pump rate is too low for demand. 2) Readjust alarm threshold.
Timeout timeout limit 3) Increase pump rate.
3D Scale Control
1) System upset such as a hi gh pH event, process 1) Conductivity setpoint has been decreased
System Rate of Polymer leak, high heat load event, etc. automatically to induce blowdown.
Stress Consumption is 2) If coincident with or subsequent to a Conducti vity 2) Enter lower conductivity setpoint and relearn
High high adjustment MIN alarm, the controller is unable to system stress.
respond to the high stress condition.
Conductivity 1) System stress is low compared to learned stress. 1) If higher cycles are required, enter higher
Cond. Adj. Setpoint conductivity setpoint and relearn system stress.
MAX adjusted to the Otherwise, no acti on is required.
maximum
Conductivity 1) System stress is high compared to learned stress. 1) If lo wer cycles are required, enter lower
Cond.
Setpoint conductivity setpoint and relearn system stress.
Adj.
adjusted to the Otherwise, no acti on is required.
MIN
minimum

Appendix A: Specifications
Feed and Control Methods

Chemical Feed - Inhibitor
Chemical feed based on manual, timer or slave option. On/off control based on TRASAR, Tagged
Polymer or 3D TRASAR Scale Control.
Chemical Feed - Oxidizing Biocide
Timer, manual, or slug based feed with pre-bleed and lockout capability. On/off control based on
ORP or 3D TRASAR Bio-Control.
Chemical Feed - Non-oxidizing Biocide
Timer or manual based feed with pre-bleed and lockout capability.
pH
Acid or caustic on/off, based on flat surface, double junction 2-wire pH probe input, range 0-14 pH.
ORP
Oxidizing biocide feed based on flat surface, double junction ORP probe input, range – 1000 to
+1000 mv.
Blowdown
On/off based on Conductivity (range 500-99,999uS/cm) or 3D TRASAR Scale Control.
Multipurpose timers
Timer based feed on any available relay (no pre-bleed or lockout).
Monitoring Functions
Corrosion Monitoring
Continuous 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 meter
Additional Calculated Variables
• Holding Time Index
• System Volume
• Blowdown Rate
• Heat Rejection (Btus)
• Makeup Water Rate
• Recirculation Rate
• Pump Duty
• Product Usage
Technical Help 521-OM0108.88 A-1

Specifications
Plumbing Requirements
Control Panel 3/4" FNPT inlet, (2) outlets (1) 3/4" FNPT & (1) 1/2" FNPT (once inlet and outlet ball
valves 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 both
units.
Electrical
85 to 250 VAC @ 20 amps service
Sample requirements
minimum 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 SCADAport
Outputs
• (7) control relay outputs rated 2.5 amps each (larger loads require external motor starters)
• (8) 4-20 mA powered non-isolated outputs
Alarms
• (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.)
Enclosure
Nema 4X
Ambient temperature
40-120 °F (4-50 °C)
Process water temperature
40-120 °F (4-50 °C)
Relative Humidity
0-95% non-condensing
Maximum water pressure
90 psi
Display/Keypad
Numeric keypad plus specialty keys, graphical display with plotting functions
Security
Password protected (user assignable)
Data management
All variables are data logged in spreadsheet format

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.
Approvals
UL, CUL, CE
Software
• 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

Estimated Estimated
3D TRASAR 3D TRASAR Dimensions
Description Equipment Shipping
Starter P/N P/N (L x W x H)
Weight (lbs) Weight (lbs)
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-TR5522.88 200 275 36 7/8 x 13 7/8 x 62 5/8"
and pre-installed Nalco Global Gateway
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-TR5523.88 255 450 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-TR5532.88 205 285 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-TR5533.88 265 475 36 7/8 x 28 x 65 3/4"

Appendix B: Drawings
Please see the attached pages for drawings of the 3D TRASAR models. Please note that drawings
show all probes installed. pH, ORP and Corrosion probes are available accessories for the
3D TRASAR Starter (3500 series) models.
Drawings of the Pellet Feeder PlumbingAssembly and High Pressure Water Reinjection system are
also included.
Model Number Description Page #

060-TR3500.88
Wall Mount, Small Backboard B-2
060-TR5500.88
060-TR3501.88
Frame Mount, Small Backboard B-3
060-TR5501.88
060-TR3510.88
Wall Mount with Junction Box B-4
060-TR5510.88
060-TR3511.88
Frame Mount with Junction Box B-5
060-TR5511.88
060-TR3520.88
060-TR3522.88
Enclosed Wall Mount with Junction Box B-6
060-TR5520.88
060-TR5522.88
060-TR3521.88
060-TR3523.88
Enclosed Frame Mount wi th Junction Box B-7
060-TR5521.88
060-TR5523.88
060-TR3530.88
060-TR3532.88
Air Purged Wall Mount with Junction Box B-8
060-TR5530.88
060-TR5532.88
060-TR3531.88
060-TR3533.88
Air Purged Frame Mount with Junction Box B-9
060-TR5531.88
060-TR5533.88
060-TR5120.88 Pellet Feeder B-10
060-TR5540.88 High Pressure Water Reinjection System B-11
Technical Help 521-OM0108.88 B-1

Information
Actions
Alarms Back
7 8 9
4 5 6
1 2 3
MENU HELP
0
PROPIETARY AND CONFIDENTIAL
Model #s 060-TR3500.88, 060-TR5500.88

Wall Mount, Small Backboard
B-2
Information
Actions
Alarms Back
7 8 9
4 5 6
1 2 3
MENU HELP
0
Model #s 060-TR3501.88, 060-TR5501.88

Frame Mount, Small Backboard
B-3
Information
Actions
Alarms Back
7 8 9
4 5 6
1 2 3
MENU HELP
0
Model #s 060-TR3510.88, 060-TR5510.88

Wall Mount with Junction Box
B-4
Information
Actions
Alarms Back
7 8 9
4 5 6
1 2 3
MENU HELP
0
Model #s 060-TR3511.88, 060-TR5511.88

Frame Mount with Junction Box
B-5
Information
Actions
Alarms Back
7 8 9
4 5 6
1 2 3
MENU HELP
0
FLUOROMETER
OUTLET
SAMPLE
OUTLET
SAMPLE
INLET
Model #s 060-TR3520.88, 060-TR5520.88

060-TR3522.88, 060-TR5522.88
Enclosed Wall Mount with Junction Box and
B-6
Information
Actions
Alarms Back
7 8 9
4 5 6
1 2 3
MENU HELP
0
FLUOROMETER
OUTLET
SAMPLE
OUTLET
SAMPLE
INLET
Model #s 060-TR3521.88, 060-TR5521.88

060-TR3523.88, 060-TR5523.88
Enclosed Frame Mount with Junction Box and
B-7
Information
Actions
Alarms Back
7 8 9
4 5 6
1 2 3
MENU HELP
0
FLUOROMETER
OUTLET
MiniPurge
INSTRUMENT
AIR
SAMPLE
OUTLET
SAMPLE
INLET
Model #s 060-TR3530.88, 060-TR5530.88

060-TR3532.88, 060-TR5532.88
Air Purged Wall Mount with Junction Box and
B-8
Information
Actions
Alarms Back
7 8 9
4 5 6
1 2 3
MENU HELP
0
FLUOROMETER
OUTLET
MiniPurge
INSTRUMENT
AIR
SAMPLE
OUTLET
SAMPLE
INLET
Model #s 060-TR3531.88, 060-TR5531.88

060-TR3533.88, 060-TR5533.88
Air Purged Frame Mount with Junction Box and
B-9
Model #060-TR5120.88
Pellet Feeder Plumbing Assembly
B-10
Model 060-TR5540.88
High Pressure Water Reinjection System
B-11
Appendix C: Replacement Parts/

Accessories
Parts / Hardware Models
3D TRASAR 3D TRASAR
Description
Starter Model Model
060-TR3500.88 060-TR5500.88 Wall Mount, S mall 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 Juncti on Box
Enclosed Wall Mount with Juncti on Box and
060-TR3522.88 060-TR5522.88
Pre-Installed Wireless Gateway
060-TR3521.88 060-TR5521.88 Enclosed Frame Mount wi th Junction Box
Enclosed Frame Mount wi th Junction Box and
060-TR3523.88 060-TR5523.88
060-TR3530.88 060-TR5530.88 Air Purged Wall Mount with Juncti on Box
Air Purged Wall Mount with Juncti on Box and
060-TR3532.88 060-TR5532.88
060-TR3531.88 060-TR5531.88 Air Purged Frame Mount wi th Junction Box
Air Purged Frame Mount wi th Junction Box and
060-TR3533.88 060-TR5533.88
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
Parts / Bio-Reporter Feed Options
Part Number Description
060-TR5120.88 Bio-reporter, Pellet Feeder Assembly, for system sizes > 12,000 gallons
141-PJ4035.88 Bio-reporter, Liquid Feed pump, for system sizes 3,000 to 12,000 gallons
6008505 Bio-reporter, Liquid Feed pump, for system sizes up to 3,000 gallons
Technical Help 521-OM0108.88 C-1

3D TRASAR Starter Upgrades

Fluorometer upgrade (includes: Patented 3D TRASAR technology upgrade
060-TR3200.88 procedure, 3D TRASAR Fluorometer, rebate return i nstructions, upgrade
confirmation sticker.)
NCM upgrade (includes: Patented NCM technology upgrade procedure, 2
060-TR3205.88 probe 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 (i ncludes ORP probe and cable.)
Parts / Closed Loop Applications

001-H10506.88 Corrosion Coupon Rack, two station with flow indicator
060-TR5540.88 High Pressure Water Reinjection System (see diagram pg C-7.)
Parts / High Fouling Applications
460-S0340.75 Fluorometer Cleaning Solution, 5 gallons (order separately)

001-H04066.88 Containment basin, 10 gallons, PE
121-P01152.88 Automated Fluorometer Cleaning System (peristaltic pump)
121-P01187.88 Replacement tubing for Automated Fluorometer Cleaning System
Replacement Parts / Probes
060-TR5411.88 pH Probe, flat surface, ¾" NPT

060-TR5421.88 ORP Probe, flat surface, ¾" NPT
060-TR5432.88 Conductivity Probe, torroidal, probe only
060-TR5441.88 Conductivity Probe, torroidal probe and tee, (fits 2" Union)
400-NCMP1B.88 Corrosion Probe w/ ferrule, Mi ld Steel
400-NCMP2B.88 Corrosion Probe w/ ferrule, C opper
400-NCMP4B.88 Corrosion Probe w/ ferrule, C uNi 90/10
400-NCMP5B.88 Corrosion Probe w/ ferrule, C uNi 70/30
400-NCMP7B.88 Corrosion Probe w/ ferrule, 443 Admiralty Brass
6016180 Corrosion Probe w/ ferrule, 6061 Aluminum
6016182 Corrosion Probe w/ ferrule, 1100 Alumi num
400-NCMP10.88 Corrosion Probe Package, Galvanized Steel

Replacement Parts / Cables

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 Cable
060-TR5422.88 ORP Cable
991-01928722.88 Service Cord, 12/3 SJOW (no termination)
991-05053481.88 Pigtail, 16/3 SJOW, 18" w/ US plug
991-05047661.88 Ethernet Crossover cable, 6' orange
Communication and Data Management Accessories
060-NGG100.88 Nalco Global Gateway US (Domestic) with 1-year contract

060-NGG200.88 Nalco Global Gateway International with 1-year contract
US Wireless Gateway Renewal 1- year contract (for Cingular service)
060-TR5280R.88
Includes SIM - P art Number Expires October 1st, 2009
International Wireless Gateway Renewal 1- year contract (Rogers network)
060-TR5285R.88
Includes SIM - P art Number Expires October 1st, 2009
Domestic Wireless 1-year contract renewal (SIM not included)
060-NGG100R.88
Available October 1st, 2009
International Wireless 1-year contract renewal (SIM not i ncluded)
060-NGG200R.88
Available October 1st, 2009
060-TR5284.88 External Antenna for Nalco Global Gateway (Cable sold separately)
060-TR5284C100.88 100-foot cable for 060-TR5284.88
060-TR5284C25.88 25-foot cable for 060-TR5284.88
060-TR5270.88 LAN Router
160VTGV100 Vantage V100

Replacement Parts / Spares and Accessories
Part N umber Description
060-TR5540.88 High P ressure Water Reinjection System

060-TR5217.88 Redboard
060-TR5245.88 Easy Mounting B racket for models 060-TR3500.88 and 060-TR5500.88 only
060-TR5240.88 3D TRA SAR Frame
991-50554318.88 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 F eeder Cleaning Brush
060-TR5313.88 Pellet F eeder Shield Kit (D am Repair Kit)
060-TR5350.88 Pellet F eeder Overflow Device
060-TR5332.88 Pellet F eeder Upper P lumbing Assembly
060-TR5334.88 Pellet F eeder Lower P lumbing Assembly
400-NC MAC 5.88 Corrosion Probe Swagelock Fitting, N ylon, ¾ "
400-NC MAC 15.88 Corrosion Probe Restraint D evice
6000668 Replacement F lowswitch
060-TR5224.88 Fluorometer, up per adapter fitting
060-TR5225.88 Fluorometer, lo wer adapter fitting
991-05055272.88 Controller S crews
TK -135 Configurator Software C D

Replacement Parts / Reagents and Calibration Supplies

500-TSRKITSTR.88 3D TRASAR 3500 Series Calibration Start-up Kit
3500 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 cc
Plastic Syringes (3)
500-TSRKIT.88 3D TRASAR 5000 Series Calibration Start-up Kit
5500 Series Calibration Start-up Kit includes 3D TRASAR Calibration Solution 1L (2), pH
7.0 and 10.0 Calibration Solutions 1L (1 of each), ORP 200 mv and 600 mv Calibration
Solutions 1L (1 of each), Fluorometer Cleaning Solution 1L, Replacement Mild Steel and
Copper NCM Probes (1 of each), Fluorometer Probe Brush, 500 mL Plastic Beakers (3), 60 cc
Plastic Syringes (3)
060-TRMNKIT.88 3D TRASAR 5000 Series Maintenance Value Package
Maintenance Value Package includes 3D TRASAR Calibration Solution 1L (2), pH 7.0 and
10.0 Calibration Solutions 1L (1 of each), ORP 200 mv and 600 mv Calibration Solutions 1L
(1of each), Fluorometer C leaning Solution 1L, Fluorometer Probe Brush, 500 mL Plastic
Beakers (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 D essicant
Canister, Fluorometer Dessicant Indicator
460-S0940.75 3D TRASAR Calibration Solution, 1L
460-S0408.75 pH Calibration Solution, pH 10.0, 1L
460-S0407.75 pH Calibration Solution, pH 7.0, 1L
460-S0932A.75 ORP Calibration Solution, 200 mv, 1L
460-S0933A.75 ORP Calibration Solution, 600 mv, 1L
460-S0800.75 Fluorometer Cleaning Solution, 1L (Sulfuric Acid 10%)
460-S0726.75* Fluorometer Cleaning Solution, 1L (HCl 1:1)
500-P2817.88 Flow Cell Brush
500-P0116.88 Beaker, 500 mL, plastic
500-P2147.88 Syringe, 60 cc, w/ female lu er lock, plastic
460-3DTBRC.87* Bio-reporter Quick Dose Pouch (pretreats approx. 150,000 gallons)
460-S0298.75* Conductivity C alibration Solution, 600 uS, 1L
460-S0297.75* Conductivity C alibration Solution, 3000 uS, 1L
* This part is available as an optional accessory, but is not included with either the Start-up
Kit or the Maintenance Value Package.

Hardware Piping Layout

Pellet Feeder Piping Layout - Lower Assembly

P/N 060-TR5334.88
Pellet Feeder Piping Layout - Upper Assembly

P/N 060-TR5332.88

High Pressure Water Reinjection System

P/N 060-TR5540.88

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 and
060-TR5533.88. Use this manual for start-up of theAir Purge System. Call 630-305-CHEM for more
assistance.
Technical Help 521-OM0108.88 D-1

Appendix E: SCADA and LAN
SCADA - General
The 3D TRASAR Controller provides a Modbus RTU Slave connection. Users can select either an
RS-232 or RS-485 hardware link (choose one). Asingle 3-pin SCADA connector is provided in the
Controller (plug-in to selected communications port).
Master and Slave (3D TRASAR Controller) Communications

3D TRASAR Display Configuration Guide
Configuration Item Parameters

Protocol Modbus RTU
Communications Half-duplex (2-wire)
1200, 2400, 4800, 9600,
Baud Rate (selectable)
or 19200
Data Bits 8 Bit
Parity None
Stop Bits 1
3D TRASAR Display Configuration Guide
1) 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) SCADA Addr (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.
Modbus Master Polling/Retry Parameters
Configuration Item Parameters

5-10 seconds (10 seconds is
Polling Interval/Block Reads recommended, as signals do not
change frequently)
Message Timeout/Retry Half-duplex (2-wire)
The 3D TRASAR Controller supports block reads. It is recommended to always read information in
Coil, Word, Long, and Float blocks (to minimize Controller communication traffic). Floating point
numbers are formatted using the Modicon Protocol convention (two consecutive 16-bit registers.
Note: Daniel’s Floating Point Extension is not supported.
Technical Help 521-OM0108.88 E-1
Register Definitions (Coils, Floats, Words, and Longs)

Coil Map
Controller Coil Registers Address Min Max Units Notes

Control Relay 1 - TRASAR 000001 0 1 On/Off
Control Relay 2 - TAG POLYMER 000002 0 1 On/Off
Control Relay 3 - BIO-REPORTER 000003 0 1 On/Off
Control Relay 4 - OXID BIOCIDE 000004 0 1 On/Off
Control Relay 5 - NONOX BIOCIDE 000005 0 1 On/Off
Control Relay 6 - BLOWDOWN 000006 0 1 On/Off
Control Relay 7 - pH CONTROL 000007 0 1 On/Off
Alarm Relay 000008 0 1 On/Off
Digital In 1 - No Flow 000013 0 1 On/Off
Digital In 2 - Interlock 000014 0 1 On/Off
Digital In 3 - Spare 000015 0 1 On/Off
Digital In 4 - Spare 000016 0 1 On/Off
Float Register Map
Controller Input Float Registers Address Min Max Units Notes

Product 1 Dosage (TRASAR) 300040 0.0 300.0 ppm
Product 2 Dosage (TAG Polymer) 300042 0.0 300.0 ppm
Rz 300044 0.0 300.0 ppb
Rs 300046 0.0 300.0 ppb
Turbidity 300048 0.0 200.0 ntu
Background 300050 0.0 300.0 ppm
Cell Fouling 300052 0.0 100.0 pct
Conductivity 300054 0.0 10,000.0 uS/cm
pH 300056 0.0 14.00 -
ORP 300058 -1,000.0 1,000.0 mV
Corrosion 1 (Right side of controller) 300060 0.0 Note 1 mpy
Corrosion 2 (Left side of controller) 300062 0.0 Note 1 mpy
Sample Temperature 300064 32.0 150.0 deg F
Nalco Bio-Index 300066 -999 999.0 -
Nalco Scale Index 300068 -999 999.0 -
Polymer Consumption 300070 0.0 100.0 pct
HTI 300072 0.0 999.0 hours
System Volume Average 300074 0.0 9,999,999.0 gal
Blowdown Rate 300076 0.0 999.0 gpm
Makeup Rate 300078 0.0 999.0 gpm
Heat Rejected 300080 0.0 999,999.0 kBTU/day
Recirculation Rate 300082 0.0 999.0 gpm
Analog Input 1 300084 -99,999 99,999.0 -
Analog Input 2 300086 -99,999 99,999.0 -
Integer Register Map (Scaled Input Integer Values)

Controller Input Integer Registers Address Min Max Units Notes
Product 1 Dosage (TRASAR) 300150 0 300 ppm Divide value by 10
Product 2 Dosage (TAG Polymer) 300151 0 300 ppm Divide value by 10
Rz 300152 0 300 ppb Divide value by 10
Rs 300153 0 300 ppb Divide value by 10
Turbidity 300154 0 200 ntu Divide value by 10
Background 300155 0 300 ppm Divide value by 10
Cell Fouling 300156 0 100 pct Divide value by 10
Conductivity 300157 0 10,000 uS/cm Divide value by 1
pH 300158 0.00 14 - Divide value by 100
ORP 300159 -1,000 1,000 mV Divide value by 10
Corrosion 1 (Right side of controller) 300160 0 Note 1 mpy Divide value by 100
Corrosion 2 (Left side of controller) 300161 0 Note 1 mpy Divide value by 100
Sample Temperature 300162 32 150 deg F Divide value by 10
Nalco Bio-Index 300163 -999 999 - Divide value by 10
Nalco Scale Index 300164 -999 999 - Divide value by 10
Polymer Consumption 300165 0 100 pct Divide value by 10
HTI 300166 0 999 hours Divide value by 10
Blowdown Rate 300167 0 999 gpm Divide value by 10
Makeup Rate 300168 0 999 gpm Divide value by 10
Analog Input 1 300169 -99,999 99,999 - Divide value by 10
Analog Input 2 300170 -99,999 99,999 - Divide value by 10
Long Register Map (Scaled Input Long Values)

Controller Input Integer
Address Min Max Units Notes
Registers
System Volume A verage 300172 0 9,999,999 gal Divide value by 10
Heat Rejected 300174 0 999 kBTU/day Divide value by 10
Recirculation Rate 300176 0 999 gpm Divide value by 10
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 be
read 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 Point
may 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 for
control systems that do not support reading Floating Point Input registers. The Integer and Long
Input registers contain the same information as the Floating Point Input registers. ables
T 3, 4, 5 & 6
document all registers currently supported by the 3D TRASAR Controller .

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 of
1035 (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 will
appear on the screen and be translated to it’s corresponding Modbus register . As example, “Sample
Temperature” will be converted from Deg F to Deg C. The corresponding Modbus registers (Input
Float and Input Integer) will hold the value in Deg C units.
Serial Wiring Connections

RS-232 Connection
RS-232
Controller
(DB9, PC
SCADA 232
Connection)
GND GND (Pin 5)
TX RX (Pin 2)
RX TX (Pin 3)
RS-485 Connection
RS-232
Controller
(DB9, PC
SCADA 485
Connection)
GND GND
B -
A +
Display Location of Variables

Control Relay 1 - Trasar
Actions à Manual Relay Control à “Product Name” State
Control Relay 2 – Tag Polymer

Control Relay3 - Bioreporter

Control Relay 4 – Oxid Biocide


Control Relay 5 – NonOx Biocide

Control Relay 6 - Blowdown

Control Relay 7 – pH
Alarm Relay
Information à Operating Data à (Alarm Bell in upper left corner of display)
Digital In 1 – No Flow
Information à External Inputs à DI1 State
Digital In 2 – Interlock
Digital In 3 – Spare
Digital In 4 – Spare
Product 1 Dosage (Trasar)

Information à Operating Data à TRASAR (product name)
OR, Information à Diagnostic Data à Fluorometer Data à Prod1
Product 2 Dosage (Tag Polymer)

Information à Operating Data à TAG (product name)
OR, Information à Diagnostic Data à Fluorometer Data à Prod2
Rz (Bioreporter)
Information à Diagnostic Data à Fluorometer Data à Rz
Rs (Bioproduct)
Information à Diagnostic Data à Fluorometer Data à Rs
Turbidity
Information à Operating Data àTurbidity
OR, Information à Diagnostic Data à Fluorometer Data à Turbid

Background
Information à Diagnostic Data à Fluorometer Data à Bkrnd
Cell Fouling
Information à Diagnostic Data à Fluorometer Data à Fouling
Conductivity
Information à Operating Data à Cond
OR, Information à Diagnostic Data à Sensor Data à C
pH
Information à Operating Data à pH
OR, Information à Diagnostic Data à Sensor Data à pH
ORP
Information à Operating Data à ORP
OR, Information à Diagnostic Data à Sensor Data à ORP
Corrosion 1 (Right Side of Controller)

Information à System Performance àCorrosion-”Metallurgy”
OR, Information à Diagnostic Data à Sensor Data à C1
Corrosion 2 (Left side of Controller)

Information à System Performance àCorrosion-”Metallurgy”
OR, Information à Diagnostic Data à Sensor Data à C2
Sample Temperature
Information à Operating Data à Temp
OR, Information à Diagnostic Data à Sensor Data à ORP
Nalco Bio-Index
Information à System Performance à N Bio Index*
*Controller must be configured for 3D Bio Control to be visible
Nalco Scale Index

Information à System Performance à N Scale Index*
*Controller must be configured for 3D Bio Control to be visible
Polymer Consumption
Information à System Performance à Consumption
HTI
Information à Operating Data à HTI

Blowdown Rate
Information à Water & Energy à Blowdown*
*Controller must be configured for Blowdown Control to be visible
Makeup Rate
Information à Water & Energy à Makeup
Analog Input 1
Information à External Inputs à 4-20 Input 1
Analog Input 2
Information à External Inputs à 4-20 Input 2
System Volume Average

Information à Water & Energy à Sys. Vol.
Heat Rejected
Information à Water & Energy à Heat Rej.
Recirculation Rate
Information à Water & Energy à Recirc 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 cable

The Controller provides the following Ethernet/email settings. The factory defaults can be modified
as 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: CustomerName@3dtrasar.com (In some cases this address will need to
be modified. For example,trasar5000@att.net. 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: alarms@3dtrasar.com (Alarm Server address located at Nalco
Company)
• Data Email Address: data@3dtrasar.com (Data Server address located at Nalco Company.
This email address is not changeable without contacting Nalco Technical Support)

LAN - Connect to customer LAN

This section will assist you in connecting a 3D TRASAR controller to a customer’s LocalArea
Network (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/N
060-TR5270.88) is required on LAN’s with more than 25 computers on the same segment as the
3D 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 the
customer’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).

Appendix F: 3D TRASAR Starter

Upgrade 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.
Technical Help 521-OM0108.88 F-1

3D TRASAR Starter Fluorometer Upgrade Procedure

This procedure details the steps required to complete the 3D TRASAR Starter Fluorometer
upgrade. All steps must be completed in order to begin using the features of the 3D TRASAR
Fluorometer.
1. Order Upgrade
Order the 3D TRASAR Starter Fluorometer Upgrade, P/N 060-TR3200.88. Order through Nalco
customer service, or through the Order Wizard.
2. Unpack and Identify Components

The 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.

4. Replicate Computer with Nalco LAN.

48 hours after completion of web registration (step 3) your upgrade will become available on the
Nalco LAN. You must replicate your computer in order to automatically receive the upgrade.
5. Configure New Hardware

Connect computer to controller, and the upgrade will appear in the Manage Controller button on
the Configurator home page. Click Manage Controller to view upgrade details. Click upgrade
now to begin upgrade process. Follow screen prompts to complete upgrade.
6. Install New Fluorometer

Replace old 3D TRASAR Starter fluorometer with new
3D TRASAR Fluorometer. For details on how to install the
Fluorometer, please see section 2.6.1. Place upgrade
confirmation sticker on visible portion of back panel.
7. Configure Features of New Hardware

Using 3D TRASAR configurator program or keypad of
3D TRASAR controller, update control settings, setpoints
and 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 Fluorometer

Complete rebate return paperwork (included with upgrade order.) Securely pack rebate return
paperwork and old 3D TRASAR Starter Fluorometer in packaging materials shipped with the new
3D TRASAR Fluorometer upgrade.
Important! Rebate will not be processed unless BOTH the rebate return paperwork and
! Fluorometer are returned to Nalco!

3D TRASAR Starter NCM Corrosion Measurement

Upgrade Procedure
This procedure details the steps required to complete the 3D TRASAR Starter NCM Corrosion
Measurement upgrade. All steps must be completed in order to begin using the features of the
NCM.
1. Order Upgrade and NCM probes.

Order the 3D TRASAR Starter NCM Corrosion Measurement Upgrade,P/N 060-TR3205.88 along
with required probes (sold separately.) Order through Nalco customer service, or through the Order
Wizard.
2. Unpack and Identify Components

The 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). 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.
!

4. Replicate Computer with Nalco LAN.

48 hours after completion of web registration (step 3,) your upgrade will become available on the
Nalco LAN. You must replicate your computer in order to automatically receive the upgrade.
5. Configure New Hardware

Connect computer to controller, and the upgrade will appear in the Manage Controller button on
the Configurator home page. Click Manage Controller to view upgrade details. Click upgrade
now to begin upgrade process. Follow screen prompts to complete upgrade.
6. Install Corrosion Probes

For details on how to install the corrosion probes, please see section 2.6.5 NCM Corrosion Probe
Installation. Place upgrade confirmation sticker on visible portion of back panel.

3D TRASAR Starter pH Upgrade Procedure

1. Order Upgrade
Order the 3D TRASAR Starter pH Upgrade, P/N 060-TR3211.88 (includes pH probe, cable and
installation instructions.) Order through Nalco customer service, or through the Order Wizard.
2. Install New Hardware

Install the pH probe as follows:
STEP 1 - Carefully unpack the pH probe.
STEP 2 - Apply 5 revolutions of Teflon tape

to the pH probe threads.

drawing at right.
STEP 4 - Connect pH probe to pH cable

(cable is labeled pH.)
STEP 5 - With power off, wire pH cable to

proper terminals in controller box
(see drawing below.)
STEP 6 - Reconfigure the controller for pH.

3D TRASAR Starter ORP Upgrade Procedure

1. Order Upgrade
Order the 3D TRASAR Starter ORP Upgrade, P/N 060-TR3221.88 (includes ORP probe, cable and
installation instructions.) Order through Nalco customer service, or through the Order Wizard.
2. Install New Hardware

Install the ORP probe as follows:
STEP 1 - Carefully unpack the ORP probe.
STEP 2 - Apply 5 revolutions of Teflon tape

to the ORP probe threads.

drawing at right.
STEP 4 - Connect ORP probe to ORP

cable (cable is labeled ORP.)
STEP 5 - With power off, wire ORP cable

to proper terminals in controller
box (see drawing below.)
STEP 6 - Reconfigure the controller for

ORP.

Appendix G: 3D TRASAR Technology

for Closed Loop Applications
3D TRASAR technology delivers superior chemical performance, feed, control and monitoring to closed
loops. Nalco’s patented phosphino succinic oligomer (PSO) chemistry provides and effective alterna-
tive to traditional nitrite- and molybdate-based treatments. Continuous corrosion rate measurement is
available using Nalco’s NCM technology. For systems requiring routine feed and control of treatment
chemicals, 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 Applications

Closed loop applications can utilize the standard 3D TRASAR Starter 3500 and 3D TRASAR 5500
systems. The following components are required for closed loop applications and must be ordered
separately.
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. Rack
dimensions are: 22” W x 25” T, plumbing connections are 3/4” FNPT. Order corrosion coupons
separately from list below. All coupons are bar style and measure 3” x 1/2”.
Part number Description

500-P5035A.88 Coupon, MS 1010
500-P054A.88 Coupon, MS 1010 Passivated
500-P5048A.88 Coupon, MS 1010 Scaling
500-P5038A.88 Coupon, Copper
500-P5034A.88 Coupon, Copper Nickel (70/30)
500-P5049A.88 Coupon, Copper Nickel (90/10)
500-P5040A.88 Coupon, Admiralty Brass
500-P5036A.88 Coupon, SS 316L
500-P5037A.88 Coupon, SS 304 Corrosion Coupon Rack
500-P5057A.88 Coupon, Galvanized Hot Dip
2. UltraSand Plus high efficiency filter

Nalco recommends UltraSand Plus high efficiency filtration systems
for closed loop applications. The unique design and ultra-fine sand
filter media work to remove particulate matter down to 0.5 microns.
To request a proposal please contact NGES technical support at
1-800-323-8483, or use the 3D TRASAR Order Wizard.
UltraSand Plus
Technical Help 521-OM0108.88 G-1
3. High Pressure Water Reinjection System

The High Pressure Water Reinjection System
(P/N 060-TR5540.88) was designed to enable a 3D TRASAR
controller to be used in high-pressure applications such as High
Rises and Closed Loops. The Reinjection System regulates
the pressure coming into the controller and reinjects the water
back into the same system from which it came. The High Pres-
sure Reinjection System is outfitted with a pressure regulator
that is designed for the inlet water to be a maximum pressure of
300-psi, which will be reduced to an operating pressure of ap-
proximately 75-psi. The pump draws a suction f rom the
3D TRASAR, repressurizing the water and reinjects it back into
the process. The system requires a minimum flowrate of 8gpm.
High Pressure W ater Reinjection System
shown 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.
Technical Help 521-OM0108.88 G-2

Appendix H: 3D TRASAR Technology

for High Fouling Applications
The 3D TRASAR models for High FoulingApplications are pre-configured to work with an automated
fluorometer cleaning system. This benefits systems running process waters with higher levels of
solids 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 operation
between maintenance cycles.
3D TRASAR models 060-TR5515.88, 060-TR5516.88, 060-TR5525.88, and 060-TR5526.88

include the following enhancements not found on the standard 3D TRASAR models:
• Automated fluorometer cleaning system delivers cleaning solution to the 3D TRASAR
fluorometer.
• Modified basket strainer includes finer mesh filter (80 mesh) and magnetic disc to remove
metal particulates from the process water.
• Solenoid valve, t-fitting, and pre-wired cables simplify connection to automated
Fluorometer 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 all
sections prior to beginning any installation.
1. Identify Hardware Model
Wall Mount Frame Mount
Description
Model Model
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
Technical Help 521-OM0108.88 H-1

2. Fluorometer Installation
The 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 the
Fluorometer, instead of a flowswitch.
3. Wiring
A junction box is not available with any of the 3D TRASAR models for High FoulingApplications.
Controller Box Layout

Relay 5 is pre-wired with a power cable for connection to the peristaltic pump andsolenoid valve
(used with the fluorometer cleaning system.)
Analog output 1 is pre-wired (jumpered) toAnalog input 1 for the purpose of monitoring and
logging flow cell fouling data (every 15 minutes.)

4. Configuration (to monitor cell fouling)
The following steps must be completed as part of the configuration forall high fouling applications
in order to monitor cell fouling. Select task button from 3D TRASAR Configurator main window , then
follow 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 0
4. Units enter %
5. High Alarm Limit enter 25
6. Low Alarm Limit enter 0
4.2 Select 4-20 mA Outputs.

For output #1:
1. #1 Name select Cell Fouling
4.3 Select Alarm Settings.

For system alarms:
1. Cell-fouling % High enter 25

5. Automated Fluorometer Cleaning System

Some process waters will leave deposits within the fluorometer which can lead
to cell fouling and inaccurate readings. The fluorometer can be cleaned using
the automated fluorometer cleaning system, which is composed of three
separate 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 the
t-fitting located between the solenoid valve and Fluorometer . Pump ships with
a 3/8" check valve which threads directly to the t-fitting. Connect the pump and
solenoid valve power cords to the pigtails pre-wired to relay 5.
Plumb outlet of fluorometer to drain or lower pressure point in system (minimum differential 20 psig.)
IMPORTANT: Prior to physical cleaning of the fluorometer , close ball valve beneath
fluorometer and set relay #5 to manual off (through keypad pressActions>Manual
! Relay 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 selected
mode prior to reverting back to auto. Open ball valve when finished with cleaning.
IMPORTANT: Nalco cleaning solution P/N 460-S0340.11 is a highly acidic solution.

Take proper precaution in handling and disposal. The automated fluorometer cleaning
system 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.
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.

6. Configuration (for Automated Fluorometer Cleaning System con’t)

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 Lockout
options.
3. Current NonOx Schedule select hour and
duration. Set cleaning duration to 10
minutes.
4. Click Add.
5. Monitor cell fouling, adjust cleaning
schedule as required.
Important: Set cleaning schedule
for time when operators are not
! expected to be performing manual
cleaning of fluorometer.
6.3 Select Alarm Settings

For system alarms
1. No Flow Relay Action select
Force Relay Off
2. No Flow Alarm Delay (min)
enter 10
Note: The time set for No Flow

Alarm Delay should match the
length of the cleaning cycle.
7. Maintenance
In addition to the maintenance schedule recommended for standard 3D TRASAR units, perform the
following activities:
• After start up, check basket strainer, magnet and rotometers weekly. Determine appropriate
maintenance schedule based on degree of fouling.
• Check pump tubing of automated fluorometer cleaning system for wear monthly,
replace if necessary.

8. Replacement parts
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)
9. Shipping Weights and Dimensions
Estimated Estimated
Part Number Description Equipment Shipping Dimensions (LxWxH)
Weight (lbs) Weight (lbs)
Wall Mount for High

060-TR5515.88 75 150 33 x 6 1/4 x 57"
Fouling Applications
Frame Mount for High

060-TR5516.88 150 225 33 x 28 x 66"
Fouling Applications
Enclosed Wall Mount for

060-TR5525.88 180 260 36 7/8 x 13 7/8 x 62 5/8"
Enclosed Frame Mount for

060-TR5526.88 245 325 36 7/8 x 28 x 65 3/4"

10. 3D TRASAR Models for High Fouling Applications (Pacific)

The following 3D TRASAR models for High FoulingApplications are available to comply with local
power requirements in the Pacific.
Wall Mount Frame Mount Description
Models Models
060-TRP5515.88 060-TRP5516.88 3D TRASAR for Hi gh Fouling Applications, large backpanel,
Pacific, 240/60, 220/50
060-TRP5525.88 060-TRP5526.88 3D TRASAR for Hi gh Fouling Applications, enclosed large
backpanel, Pacific, 240/60, 220/50
To meet local voltage requirements, 3D TRASAR models for High FoulingApplications (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, PVDF
pump 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
.
Wire Color
Ground TB9-4 Gnd Not used
Green with
Ground TB9-3 Gnd
Yellow Stripe
Neutral TB9-2 N Blue
Line Power TB9-1 L Brown

Appendix I: Halogen Analyzer

Control Through an Analog Input
The latest OBC firmware update and respective Configurator updates now provide for the use of an
online halogen analyzer, which helps maintain the residual concentration at a set point. The halogen
analyzer monitors the total or free halogen residual. The output of the halogen analyzer can be used
to 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 of

the halogen analyzer to
either of the twoAnalog
Inputs of the OBC. Using
the Configurator, set-up the
analog inputs to use the
halogen analyzer. The
halogen analyzer can be
used to monitor or control
total or free residual halo-
gen (TRH/FRH) levels in
the system. When the
halogen analyzer is used to
control the residual halogen
level in the system, the
oxidant feed pump is
controlled by the OBC
based on set-point control
using the signal from the
halogen analyzer.
Technical Help 521-OM0108.88 I-1

Select the appropriate option above (Monitor or Control) for theAnalog 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 the
analog output from the halogen analyzer is 0 ppm at 4mA and 5 ppm at 20mA. If this is suitable for
the application, enter these values into the corresponding fields in configurator
. If you alter the output
settings of the halogen analyzer make the adjustments in these fields so the input is scaled cor-
rectly.
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.
IMPORTANT: Disabling of halogen analyzer control of oxidant feed must

! be done through theAnalog Input Selection Screen and not through the
Biocide Control Settings Screen.
Technical Help 521-OM0108.88 I-2

Appendix K: Warranty Policy

Nalco Global Equipment Solutions warrants its standard equipment and related installation services
to the original purchaser to be free of defects in material or workmanship for one year from the date
of 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 shelf
lives of less than 12 months. 3D TRASAR consumable components include pH, ORP and
Corrosion 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.
Limitations
Warranty does not cover damage caused by misuse, neglect, accident (including a force majeure
event), improper installation or improper maintenance or repair. Nalco’s liability under this warranty
is limited to repair or replacement of defective items, or, refund of or credit for the product price
excluding 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 any
consequential or indirect damages.
Non-Warranty Equipment Returns

If you wish to return a standard, part-numbered Nalco Equipment Solutions product for credit or
repair, please follow the guidelines below:
• Credit: Products purchased from Equipment Solutions may be returned for credit within
three (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 purchased
within the past five (5) years.
Equipment Damaged During Shipment

If 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 assist
with filing this claim. Damaged shipments are not considered a warranty return.
Technical Help 521-OM0108.88 K-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 a
fluorescent bio-reporter to probe the entire system, measuring both planktonic and sessile microbial
activity 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 3D
TRASAR controller, coupled with an innovative “tagged” high stress polymer (essentially a barcode
attached to the polymer molecule) monitors the actual performance of the polymer as system stress
changes. 3D TRASAR Scale Control then takes corrective action through blowdown or chemical
inhibitor feed adjustments.
3D TRASAR System
The Nalco 3D TRASAR system is the most advanced water treatment control system on the market
today. It represents a total system approach, encompassing service, innovative chemistry, ad-
vanced software and sophisticated equipment, that allows you to manage stresses in cooling tower
systems on a continuous, ongoing basis.
3D TRASAR Configurator
A PC-based tool which interfaces with the 3D TRASAR controller. The 3D TRASAR Configurator
allows 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 on
system performance.
Order Wizard
A PC-based tool which assists Nalco representatives with ordering 3D TRASAR chemicals, equip-
ment and service.
Technical Help 521-OM0108.88 Glossary-1

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 the
product of its interaction with bacteria is monitored continuously by an in-line fluorometer. The rate
of 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 in
microsiemens (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 units
of 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 of
a 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 average
operating 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-reporter
response. As the Nalco Bio-Index increases the relative microbial control decreases.
Nalco Scale Index

consumption 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 setpoint
adjustments 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 is
measured in millivolts (mV.)

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 commonly
in 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 relay
timeout period (ie. if the “relay timeout” is set to 60 minutes, and the start up factor is set to 5, the
total timeout period will be 300 minutes.)
Relay timeout
Maximum allowable time a relay is allowed to be energized before an alarm is triggered, and the
failsafe duty mode begins (user set.)
Tagged Polymer
A new component of TRASAR cooling water programs (ie. Nalco’s Prism polymer or High Stress
Polymer (HSP.)) The concentration of the “tag” equals the concentration of available, un-reacted
dispersant polymer. The 3D TRASAR algorithm compares the inert TRASAR signal to that of the
tagged signal, and then makes appropriate control decisions, either to increase or decrease the
treatment 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 light
traveling 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 be
imported 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.

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3D TRASAR® Technology

Installation and Operation Manual

This manual covers the following

• 3D TRASAR 5500 Series

• 3D TRASAR 3500 Series

• 3D TRASAR Technology for

• 3D TRASAR Technology for

• 3D TRASAR Models for the

TRASAR Technology License

Towerbrom is a registered trademark of Occidental Chemical Corporation.

Technical Help 521-OM0108.88 i

Section 2: Installation and Start-Up

Technical Help 521-OM0108.88 TOC-1

2.6.3 ORP Probe Installation ............................................................................................. 2-28

Section 3: 3D TRASAR Configurator

Section 4: Controller Settings

Technical Help 521-OM0108.88 TOC-2

4.3 The Menu Key ....................................................................................................... 4-4

Technical Help 521-OM0108.88 TOC-3

4.11.2 System Alarms ........................................................................................................ 4-30

Section 5: 3D TRASAR Scale Control

Section 6: 3D TRASAR Bio-Control and 3D TRASAR Bio-Shock Mode

Section 7: Communication and Data Management

Technical Help 521-OM0108.88 TOC-4

7.3 3D TRASAR 5500 Controller ................................................................................ 7-1

Technical Help 521-OM0108.88 TOC-5

Technical Help 521-OM0108.88 TOC-6

1.2 About this Manual

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

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

Technical Help 521-OM0108.88 1-1

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

Enclosed Frame Mount unit

Technical Help 521-OM0108.88 1-2

1.4 3D TRASAR 3500 and 5500 Overview

Stress Management for Cooling Systems

• TRASAR Chemical Residuals

Technical Help 521-OM0108.88 1-3

1.5 How the 3D TRASAR System Works

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

Technical Help 521-OM0108.88 1-4

Use 3D TRASAR Scale Control to:

3D TRASAR Bio-Control is an entirely new, innovative approach to the control of bio-populations in

Use 3D TRASAR Bio-Control to:

1.5.3 Data Storage / Reporting and Communications

Technical Help 521-OM0108.88 1-5

• Never perform any installation procedures with electrical power engaged.

• Never perform any repairs with electrical power engaged.

• Maximum water temperature should not exceed 120 deg F.

Technical Help 521-OM0108.88 1-6

Section 2: Installation and Start-Up

Unpack and identify Mount controller Install Bio-Reporter feeder

Details Details Details

Plumb controller Plumb bio-reporter feeder Install probes

Details Outlet Details Details

Wiring Calibration & checkout Start-up system

Connect cable between controller box and pellet feeder.

Technical Help 521-OM0108.88 2-1

2.1 STEP 1 - Unpack and Identify Unpack and identify

IMPORTANT: If you do not have all of the items

2.1.1 Identify Hardware Model

Unpack and identify all parts.

2.1.1 Identify Hardware Model (con’t) Unpack and identify

Unpack and identify all parts.