Cooling Tower 3DTrasar Manual

F
3D TRASAR® Systems
Operation Manual
2/90
1. Principles of Operation ........................................................................... 4
Contents 1.1. 3D TRASAR & 3D TRASAR Starter........................................................... 4
1.2. Scale Control ............................................................................................. 5
1.3. Corrosion Control....................................................................................... 9
1.4. Microbiology Control ................................................................................ 10
1.5. Additional Monitoring & Control ............................................................... 15
1.6. Communication, Data Logging & Alarms ................................................. 16
2. Components & Specifications .............................................................. 17

2.1. Instrumentation Assemblies..................................................................... 17
2.2. Sensors & Piping ..................................................................................... 18
2.3. Pellet Feeder (Optional)........................................................................... 21
3. Installation.............................................................................................. 22
3.1. Typical Installation Diagrams ................................................................... 22
3.2. General .................................................................................................... 24
3.3. Plumbing.................................................................................................. 24
3.4. Sensors.................................................................................................... 24
3.5. Pellet Feeder ........................................................................................... 24
3.6. Dosing pump calibration .......................................................................... 24
3.7. Electrical .................................................................................................. 25
4. Start-Up................................................................................................... 37
4.1. Before Start-Up ........................................................................................ 37
4.2. Procedure ................................................................................................ 37
5. Operation................................................................................................ 44
5.1. Controller Configuration ........................................................................... 44
5.2. Calibration................................................................................................ 55
5.3. Pellet Feeder ........................................................................................... 56
5.4. Internet Communications ......................................................................... 57
6. Maintenance ........................................................................................... 58
6.1. Preventative Maintenance Schedule........................................................ 58
6.2. Pellet Feeder Maintenance ...................................................................... 58
6.3. Spare Parts.............................................................................................. 60
7. Troubleshooting..................................................................................... 62
7.1. Alarm Listing ............................................................................................ 62
7.2. Additional Troubleshooting ...................................................................... 66
Appendix A. 3D TRASAR for High Fouling Applications .............................. 67

A.1. Additional Components and Specifications.............................................. 67
A.2. Additional Installation Information ............................................................ 70
A.3. Additional Configuration Information ........................................................ 72
A.4. Additional Maintenance Information......................................................... 72
Appendix B. 3D TRASAR for Explosive Atmospheres .................................. 73

B.1. Additional Components and Specifications.............................................. 73
B.2. Additional Installation Information ............................................................ 77
B.3. Additional Configuration Information ........................................................ 78
B.4. Additional Maintenance Information......................................................... 80
B.5. Additional Troubleshooting Information.................................................... 80
Appendix C. 3D TRASAR for Reverse Osmosis ............................................ 81

C.1. Principles of Operation............................................................................. 81
C.2. Components and Specifications .............................................................. 81
C.3. Installation................................................................................................ 83
C.4. Start-Up ................................................................................................... 85
C.5. Operation ................................................................................................. 85
C.6. Maintenance ............................................................................................ 88
C.7. Troubleshooting ....................................................................................... 88
3/90
1. Principles of
Operation
1.1. 3D TRASAR & 3D The 3D TRASAR programme manages, scaling stresses, corrosion stresses &
microbiology stresses in open recirculating cooling water systems:
TRASAR Starter
SCALE
STRESS
MANAGEMENT
MICROBIOLOGY CORROSION
3D TRASAR Starter allows you to enter the 3D TRASAR programme at a starter

level. 3D TRASAR Starter can be upgraded with all 3D TRASAR capabilities.
Control Capability 3DT 3DT Starter

Required for upgrade
Scaling Conductivity Control z z -
pH Control z ~ pH sensor / cable
Nalco Scale Index z { 3DT Fluorometer (white) 1)
Tagged Polymer Control z { 3DT Fluorometer (white) 1)
TRASAR Control z z -
Corrosion
Corrosion Monitoring z { Corrosion sensors 2)
Micro- Nalco Bio Index z { 3DT Fluorometer (white) 1)
biology ORP Control z ~ ORP sensor / cable
Biocide Timers z z -
- All other features and piping z z -
1)
z Included Instead of blue 3DT
{ Optional; upgrade requires a license code Starter Fluorometer
2)
~ Functionality included, but sensor and cable 1 or 2 sensors; cable
optional; upgrade does not require a license included with sensor
code
) This manual describes all capabilities of the 3D TRASAR systems.

If your 3D TRASAR is a Starter version then you need to know which capabilities
from the above table are available to you when reading this manual.
4/90
1.2. Scale Control 3D TRASAR prevents scale formation by detecting polymer consumption on-line.
This is possible by measuring the fluorescence of an inert TRASAR molecule and
that of a tagged polymer (a polymer that includes a fluorescent monomer in its
structure). The fluorescence is expressed as product concentration and combining
these two measurements, polymer consumption is calculated.
Polymer consumption gives a good indication of increased stress in the system.

Based on consumption, the Nalco Scale Index is calculated. Cycles of
concentration can be adjusted to reduce or increase stress by automated changes
of the blowdown conductivity setpoint based on this index (3D Scale control).
Stress can also be reduced or increased by adjusting the scale inhibitor
concentration, by automated changes of the inhibitor dosage setpoint (2-drum
approach only; see §1.2.1). pH effects the scaling stresses as well, and so pH
control is also available with 3D TRASAR.
Nalco Scale Index Relative scaling stress level

<10 Low
10 – 30 Moderate
>30 High
1.2.1. Scale Inhibitor Dosage Products: The inert TRASAR and the tagged polymer can be in 1 product (1-
drum approach) or in 2 products (2-drum approach). Additional products can be
slaved to these products.
Dosage: With the 1-drum approach, the product dosing pump is activated (on/off)
when the tagged polymer concentration, calculated from fluorescence
measurement, is below the setpoint (tagged polymer control). The pump can
also be controlled with the TRASAR concentration setpoint (TRASAR control).
With the 2-drum approach, 1 product will be dosed based on polymer
concentration and the other based on TRASAR.
Background fluorescence: To compensate for external fluorescent influences,

background fluorescence values have to be entered in the controller. Values are
determined in Nalco's analytical lab.
Value Details
TRASAR background
fluorescence
) Do not use TRASAR control or 3D Scale
control if > 15%.
Tagged polymer
background fluorescence
) Do not use tagged polymer control if > 75%.
Do not use 3D Scale control if > 30%.
Tagged polymer ratio Ratio for tagged polymer background fluorescence
correction.
Tagged polymer method Fixed offset correction or online background
correction for tagged polymer control. Only use
online, with tagged polymer ratio’s of 1.41 - 1.71.
5/90
Measurements
TAGGED
POLYMER
DETECTOR EMISSION
FILTER
EMISSION
FILTER
TRASAR
DETECTOR
EXITATION FLOW
LIGHT FILTER CELL
SOURCE FLUORESCENCE
READING * A PRODUCT FACTOR
WATER => PRODUCT CONCENTRATION
Diagrams Tagged Polymer & TRASAR in 1 Product

FLUOROMETER
TANK WITH: 3D TRASAR
CONTROLLER QT OPEN
PRODUCT RECIRCU-
WITH TAG LATING
POLYMER CONTROL COOLING
OR
+ SIGNAL SYSTEM
90-240VAC WATER
TRASAR
Tagged Polymer & TRASAR in 2 Products

FLUOROMETER
CONTROLLER QT OPEN
PRODUCT RECIRCU-
WITH TAG LATING
POLYMER CONTROL COOLING
OR
SIGNALS SYSTEM
90-240VAC WATER
DOSING PUMP
TANK WITH:
CONTROL OR
SIGNAL 230VAC
PRODUCT
+
TRASAR
DOSING PUMP
6/90
Control Tagged Polymer & TRASAR in 1 Product, with Tagged Polymer Control
PRODUCT, BASED ON TRASAR
ACTIVE PRODUCT, BASED ON TAGGED POLYMER

EQUAL OR LOWER/CONSUMED DUE TO SCALE
FORMATION
SETPOINT
+/- CONTROL
RANGE
CONCEN-
TRATION
[PPM]

DOSING
PUMP
ON

Tagged Polymer & TRASAR in 2 Products

SETPOINT
ACTIVE +/- CONTROL
PRODUCT RANGE
CONCEN-
TRATION
BASED ON
TAGGED POLYMER
[PPM]
TAGGED POLYMER
PRODUCT
DOSING
PUMP ON

SETPOINT
PRODUCT +/- CONTROL
CONCEN- RANGE
TRATION
BASED ON
TRASAR
[PPM]

TRASAR
PRODUCT
DOSING
PUMP ON

7/90
1.2.2. Conductivity Measurement,
Water Blow Down
Diagram CONDUCTIVITY
3D TRASAR
CONTROLLER QE OPEN
RECIRCU-
LATING
COOLING
CONTROL OR SYSTEM
SIGNAL 90-240VAC WATER
BLOW DOWN VALVE
DRAIN
Control SETPOINT
+/- CONTROL
RANGE
CONDUCTIVITY
[US/CM]
BLOW DOWN
VALVE
OPEN

1.2.3. Nalco Scale Index, TRASAR

Conductivity or Scale Inhibitor ACTIVE TAGGED SCALE INHIBITOR
Setpoint Adjustment NALCO SCALE INDEX Ç (BASED ON
[CHANGE IN TAG POLYMER RATE] /
[CHANGE IN TRASAR RATE] )
FLUORE-
SCENCE
TAG POLYMER RATE INDEX È
TRASAR RATE
CONDUCTIVITY
SETPOINT
AUTOMATIC ADJUSTMENT
[US/CM]
OR
SCALE
INHIBITOR
SETPOINT AUTOMATIC ADJUSTMENT
[PPM] (2-DRUM APPROACH ONLY)

When starting Nalco Scale Index, 3D TRASAR requires a learning period during
normal / low scaling conditions. You should also perform a ‘relearn’ to clear the
learned data when you change any of the following:
• Conductivity or pH • Product 1 or 2 set point • Change any product or

setpoint product factor
• Product 1 or 2 control (TRASAR or tagged
• Blowdown control method
polymer)
method
• Number of products
8/90
Nalco Scale Conductivity setpoint Tagged scale inhibitor
Index NSI adjustment setpoint adjustment
<0 Increased (e.g. NSI => -20; Decreased (e.g. NSI => -20;
conductivity setpoint adjusted conductivity setpoint
by +2.0%) adjusted by -2.0%)
0 None None
>0 Decreased (e.g. NSI => +20; Increased (e.g. NSI => +20;
conductivity setpoint adjusted conductivity setpoint
by -2.0%) adjusted by +2.0%)
1.2.4. pH Measurement, Acid or

Caustic Dosage
Diagram PH
CONTROLLER QE OPEN
ACID OR RECIRCU-
CAUSTIC LATING
CONTROL COOLING
OR
SIGNAL SYSTEM
90-240VAC WATER
DOSING PUMP
Control SETPOINT
+/- CONTROL
RANGE
PH
ACID
DOSING
PUMP
ON

(ACTION IS REVERSE FOR CAUSTIC DOSING PUMP)
1.3. Corrosion Control

1.3.1. Corrosion inhibitor control Corrosion inhibitor can be Control
Part of tagged polymer product with Tagged polymer product setpoint
TRASAR
Separate product without TRASAR Slaved to tagged polymer product
Separate product with TRASAR TRASAR setpoint
For measurement and control, see §1.2.1, p.5.
1.3.2. Corrosion Monitoring Steel and copper corrosion are monitored with 2 Nalco corrosion sensors.
Measurements are not linked to controls.
9/90
1.4. Microbiology Control
1.4.1. 3D Bio Control, Oxidising Control is based on the use of a fluorescent bio-reporter that is fed to the system
Biocide Dosage water. This bio-reporter is converted by microbial activity to a fluorescent bio-
product. By on-line monitoring of the ratio between these two species, the
microbial activity of the system is determined, and the oxidizing biocide dosed
based on this parameter. Microbial activity is measured as Nalco Bio Index.
Nalco Bio Index Biological Stress Level

-20 – 10 (can be negative) Low
10 – 30 Mild
30 – 80 High
> 80 Very High
Only Actibrom, Stabrex and Sodium Hypochlorite (bleach) can be used with Nalco
Bio Index; other oxidising and non-oxidising biocides cannot be used. Nalco Bio
Index cannot be used in monitoring mode and is not compatible with ORP control
or continuous biocide feed. Nalco Bio Index is however compatible with
supplemental shot dosing of biocides and biodispersants.
Nalco Bio Index should be turned off proir to any desinfection or oxidising biocide
shot dose. To restart Nalco Bio Index, TRH (total residual halogen) must be < 0.1
ppm (free Cl2).
Bio-reporter is dosed to the cooling system in:

Form Equipment Cooling system volume
Solid (pellets) Pellet feeder >45m3
Liquid Dosing pump <45m3
Bio-Reporter & System Volume

Bio- Form & System volume [m3] Blow down
reporter concentration Recom- “Do NOT [m3/h]
mended exceed” Upper limit
3DTBR06 Liquid, 0.6% 0 – 45 110 -
3DTBR8 Pellet, 8% 45 – 110 375 45
3DTBR20 Pellet, 20% 110 – 225 3750 110
3DTBR40 Pellet, 40% 225 – 7500 7500 * 225
3
* Contact your Nalco representative for system volumes > 7500m
Principle
BIO-PRODUCT
2
BIO-REPORTER 1
ENZYMATIC REACTION
MICROBE, ALIVE
PLANKTONIC OR SESSILE
10/90
Measurement
PRODUCT
DETECTOR EMISSION
FILTER
EMISSION
FILTER
REACTANT
DETECTOR
EXITATION FLOW
LIGHT FILTER CELL
SOURCE CONCENTRATION
WATER
Diagrams Bio-reporter in solid form

FLUOROMETER
3D TRASAR
FEEDER WITH: CONTROLLER QT OPEN
RECIRCU-
BIO-REPORTER LATING
PELLETS CONTROL COOLING
SIGNAL SYSTEM
WATER
CONTROL OR
TANK WITH:
SIGNAL 90-240VAC
OXIDISING
BIOCIDE
DOSING PUMP
Bio-reporter in liquid form

FLUOROMETER
3D TRASAR
TANK WITH: CONTROLLER QT OPEN
RECIRCU-
BIO-REPORTER LATING
SOLUTION CONTROL COOLING
OR
SIGNAL SYSTEM
230VAC WATER
DOSING PUMP
CONTROL OR
TANK WITH:
SIGNAL 90-240VAC
OXIDISING
BIOCIDE
DOSING PUMP
11/90
Bio-reporter Pellet Feeder
PELLET
CONTAINER
MOVEMENT
SENSOR X
M
OVERFLOW
MOTOR M
DRAIN
WATER
STRAINER
TO HOLD PELLET
Pellets are stored in a container with a rotor (disk with holes) at the bottom. When
the rotor rotates, 1 pellet falls on top of a ball valve. A sensor detects the falling
pellet. If not detected, the 3D TRASAR controller will generate an alarm.
When the ball rotates, the pellet falls into the water stream. A strainer holds the
pellet in place while it dissolves slowly. When the ball rotates to its original
position, a small amount of (blue) water will spill from the overflow pipe.
Control Bio-Reporter Pellet

FIXED 20PPB SETPOINT
BIO-REPORTER
[PPB]
FIXED PROPOR-
INTERVALS TIONAL
(20 MIN)
PELLET
FEED

The number of pellets to be fed is calculated with bio-reporter concentration and

system volume.
Bio-Reporter Liquid
FIXED 20PPB SETPOINT
+/- CONTROL RANGE
BIO-REPORTER
[PPB]
BIO-REPORTER
DOSING PUMP
ON

12/90
Oxidising biocide
NALCO
BIO
INDEX

OXIDISING
BIOCIDE
DOSING
PUMP ON

1.4.2. ORP Measurement, Oxidising ORP (Oxidisation Reduction Potential) or redox can provide an indication of the
Biocide Dosage free chlorine concentration in the cooling water. If Nalco Bio Index cannot be used,
oxidising biocide dosage can be controlled with ORP.
The ORP/free chlorine relationship is different for different cooling systems and
varies with pH. The ORP set point has to be determined for each cooling system
and checked regularly using halogen water tests (DPD).
Diagram ORP
CONTROLLER QE OPEN
OXIDISING RECIRCU-
BIOCIDE LATING
CONTROL COOLING
OR
SIGNAL SYSTEM
90-240VAC WATER
DOSING PUMP
Control SETPOINT
+/- CONTROL
RANGE
ORP
[MV]
DOSING
PUMP
ON

1.4.3. Two Biocide Timers One timer for non-oxidising biocide and one timer for oxidising biocide are
available.
Control Timer setting Values

Frequency Every, Every 2nd, Every 3rd or Every 4th
Interval Day, M/W/F, Tu/Th or M/T/W/T/F
Pre-blowdown (blowdown Yes/no, conductivity value (pre-bleed when
before biocide dosage) reading > value) in uS/cm and maximum
duration in #minutes
Lockout blowdown during feed Yes/No
Lockout blowdown after feed Yes/No & #minutes
Start time & duration (12x) hh:mm & #minutes
13/90
Diagram TANK WITH: 3D TRASAR
CONTROLLER OPEN
NON-OXIDISING RECIRCU-
OR OXIDISING LATING
BIOCIDE CONTROL COOLING
OR
SIGNAL SYSTEM
90-240VAC
DOSING PUMP
1.4.4. Biocide Shot Dose An oxidising biocide one-time shot dose can be done by hand or by activating the
oxidising biocide pump via the oxidising biocide pump relay. A non-oxidising
shot dose can be done by hand only.
An oxidising biocide shote dose requires a properly operating ORP. If the non-
oxidising biocide Gluteraldehyde is shot dosed, the oxidising biocide feed will be
suspended for 8 hours.
Settings Description Ox(1) NO(2)

Blow down Optional blow down until the 9 9
Before blow
conductivity limit conductivity limit or time limit has

down
been reached.
Blow down time limit
Feed ORP Biocide feed until only the time limit 9 8

pump relay
Via biocide
limit has been reached or until the either

the time limit or the ORP limit has
Feed time limit
Biocide feed
been reached. Blow down can be

Blow down optionally locked out during biocide
lockout yes/no feed.
None Biocide feed by hand or with another 9 9
hand
By
dosing pump not connected to the

3D TRASAR controller.
Blow down lockout Optional blow down 9 8
both ORP and time
Feed based on
time limit lockout until only the

time limit has been
Blow down lockout
limit
reached or until either

After biocide feed
ORP limit
the time limit or the
ORP limit has been
reached.
Blow down lockout 9 9
on time limit
Feed based
only or fed
by hand
until the time limit,

has been reached (30
minutes or higher for
Ox(1)).
Time limit 3D Bio-control resumes when ORP 9(3) 8
Recovery
value reaches levels 5% above ORP

levels before feed or when a time
limit is reached.
(1)
Ox = Oxidising biocide, (2) NO = Non-oxidising biocide, (3) Only with 3D Bio
control
14/90
1.5. Additional Monitoring
& Control
Flow Detection & Interlock Signal Details Control

No sample flow Sample water does not Activation of dosing pumps,
represent system water blow down valve and pellet
No interlock Cooling system not in feeder is interrupted until
(remote on/off) operation flow/interlock is restored.
Temperature Water temperature is measured by the RTD (resistance temperature detector)

inside the conductivity sensor. This is used to compensate the conductivity and pH
readings.
Turbidity Turbidity is measured by the fluorometer in Nalco Turbidity Units. Consistent with
Nephelometric Turbidity Units up to 40 NTU. Deviates from standard NTU above
40 NTU.
Cell Fouling Cell fouling (in %) of the fluorometer cell is measured by the fluorometer.
Timers All relay outputs for the dosing pumps and blowdown valve can be controlled by
their own timer. The timers are the same as the biocode timers (§Two Biocide
Timers, p.13), but without the pre-blowdown and blowdown lockout timers.
Calculated Values Values Calculations based on

Holding time index, system volume * Entered dosing pump rates and/or
measured residuals
Product usage * Entered dosing pump rates and actual
dosing pump activation periods
Blow down rate, make-up, heat Mass balance equations
rejected, circulation rate
* Can be disabled; pump rates are not entered.
15/90
1.6. Communication, Data
Logging & Alarms
Communication Methods
3D TRASAR CONFIGURATION; DATA DOWNLOAD LOCAL
CONTROLLER DIRECT CABLE (NETWORK CONNECTION) PC
CONFIGURATION; DATA DOWNLOAD REMOTE

MODEM, PHONE LINE PC
ANALOGUE
DATA DOWNLOAD
ALARM E-MAILS
INTERNET CONNECTION
DATA E-MAILS, EVERY 6 HOURS

ALARM E-MAILS NALCO
INTERNET CONNECTION VIA PHONE LINE SERVER
External Interface
3D TRASAR MODBUS INTERFACE (READ ONLY) CONTROL
CONTROLLER ROOM
COMMON ALARM
8X READING 4-20MA
REMOTE ON/OFF (INTERLOCK)
4-20mA outputs: §4-20mA Wiring, p.32
Data Logging Historical data is stored in the 3D TRASAR controller for approx. 2 months.
Timeout Alarm If a dosing pump or the blow down valve remains activated, but the setpoint is not
reached within a specified period, a timeout alarm is generated.
More information: §Relay Timeout Alarms, p.65
Failsafe In the event of an alarm (e.g. pH too high) the ‘failsafe’ functionality can activate
the controlled device (e.g. acid dosing pump) to ensure that an average dosage
(or blow down) occurs. It is either a fixed percentage of a 15-minute cycle or the
average actuation of the previous 7 days (smart failsafe).
Alarm listing: §7.1, p.62
16/90
2. Components &
Specifications
2.1. Instrumentation
Assemblies
Part no. 060-TRM5500.88 Part no. 060-TRM5501.88

Compact assembly, wall mounted Compact assembly, floor mounted
Part no. 060-TRM5511.88 Part no. 060-TRM5521.88

Industrial assembly, floor mounted, Enclosed industrial assembly (shown
with electrical cabinet without door), floor mounted, with
electrical cabinet
Specification Details
Dimensions (HxWxD) 060-TRM5500.88: 0.85 x 0.85 x 0.30m
060-TRM5501.88: 1.75 x 0.85 x 0.70m
060-TRM5511.88: 1.75 x 0.85 x 0.70m
060-TRM5521.88: 1.75 x 0.93 x 0.70m (excl.
water connections)
Installation Indoor
3D TRASAR Part No. Equivalent 3D TRASAR Starter Part No.

060-TRM5500.88 060-TRM3500.88
060-TRM5501.88 060-TRM3501.88
060-TRM5511.88 060-TRM3511.88
060-TRM5521.88 060-TRM3521.88
17/90
2.2. Sensors & Piping
BALL VALVE
FLUOROMETER
DIAPHRAGM VALVE
BALL VALVE
CONDUCTIVITY
SENSOR
CORROSION PH & ORP CORROSION

SENSOR 2 SENSORS SENSOR 1
FLOW METERS
& SWITCH
BALL VALVE Y-STRAINER 2X ADAPTOR UNION

PVC SOLVENT PVC SOLVENT
CONNECTION, 25MM CONNECTION, 25MM
Water flow Depending on water velocity required for corrosion
sensors (see §Corrosion Sensor (2x), p.20).
Water pressure < 5 bar @ 40ºC
Water temperature 5-50ºC
3D TRASAR Controller, Model 5000 CORROSION CORROSION

SENSOR 2 SENSOR 1
CONNECTION CONNECTION
DISPLAY
PC CONNECTION KEYPAD
ON/OFF SWITCH
Power supply 90-240Vac, 50/60Hz, 20A
Dosing pumps & blow 7x Potential free or 90-240Vac, NO (normally
down valve output relays open), max 2A, 2.5A fuse
Alarm output relay 1x Potential free, NO (normally open) & NC
(normally closed), 1A fuse
Digital inputs 1x Interlock, 2x General input
Analogue I/O 4-20mA, non-isolated; 8x output, internally
powered, max. 600Ohm; 2x input
SCADA RS-232 and RS-485 Modbus
PC connection Ethernet port (for supplied Ethernet crossover
cable)
18/90
Modem Analogue, RJ11 connector & terminals
For pre-wired connections (fluorometer, sensors, flow switch, etc.) and the pellet
feeder connection, see §3.7, p.25.
Water & dust protection IP65
Ambient temperature 5-40ºC
Electrical Cabinet WIRING

CONDUITS
MAINS SWITCH
For 3D TRASAR instrumentation assemblies that are supplied with an electrical

cabinet, the remote connections are extended to terminals inside the electrical
cabinet. The pre-wired local connections to sensors, flow switch, etc. are made
inside the 3D TRASAR controller.
Power supply 90-240Vac, 50/60Hz
Mains circuit breaker 20A
Connections 8x relay output: 7x control, 1x alarm
3x digital input: 1x interlock, 2x general
10x analogue 4-20mA: 2x input, 8x output
3x other: 1x pellet feeder, 1x SCADA, 1x modem
Water & dust protection IP65
Ambient temperature 5-40ºC
Fluorometer
1/4” NPT
DESICCANT *
CABLE CALBRATION
CONNECTION INJECTION VALVE
1/4” NPT
+/- 150 L/H
* Desiccant canister and colour-coded humidity indicator to ensure that the optics
is not exposed to condensation.
Measurements 1. Tagged polymer in ppm product
2. TRASAR in ppm product
3. Tagged polymer background fluorescence
4. Bio-reporter in ppb bio-reporter
5. Bio-product in ppb bio-product
6. Cell fouling in % fouling
7. Turbidity in Nalco turbidity units (consistent with
Nephelometric Turbidity Units up to 40 NTU;
deviates from standard NTU above 40 NTU)
Power & communication Via 3D TRASAR controller (6V & Modbus)
19/90
Conductivity & Temperature Sensor INDUCTIVE
CONDUCTIVITY
SENSOR
The inductive conductivity sensor reading is not affected by fouling.

The reading is temperature compensated; the temperature sensor (RTD:
resistance temperature detector) is built into the conductivity sensor. The aperture
should be oriented as indicated on the drawing.
pH/ORP Sensors
QUICK CONNECT
CABLE
PH/ORP SENSOR CONNECTOR
3/4” NPT
The pH reading is temperature compensated via the conductivity sensor RTD.
Corrosion Sensor (2x)
CORROSION
SENSOR
(MILD STEEL OR TUBE FITTING
COPPER) 3/4” NPT
SENSOR
RESTRAINT
The unit is supplied with a mild steel corrosion sensor (sensor 1) and a copper
sensor (sensor 2). In theory, corrosion sensor 1 should be mild steel, to avoid
copper ions plating out on the steel sensor and thereby artificially increasing the
steel corrosion rate. The effect however is negligible under normal conditions. If
mild steel is not used, the probe location is not relevant.
The water velocity (m/s) for the corrosion sensor should match the average or
critical water velocity (for areas with expected highest corrosion) in the cooling
system. Note: The sensor tips should be in the horizontal plane.
Water velocity Flow in 25mm pipe *

[m/s] [L/min] [m3/h]
0.25 5 0.29
0.50 10 0.58
0.75 14 0.86
1.00 19 1.15
1.25 24 1.44
1.50 29 1.73
* Surface area calculated with 21.2mm inside diameter and 4.6mm diameter
corrosion sensor tips.
20/90
Flow meters & flow switch FLUOROMETER
FLOW METER
20-200L/H
CORROSION
FLOAT SENSORS
FLOW METER
FLOW SWITCH 5-50L/MIN
(FLOAT ABOVE SWITCH = FLOW)
2.3. Pellet Feeder BOLT

H = 1162 MM (WITH LID CLOSED)
LID
(Optional) W = 838 MM
D = 457 MM DESICCANT
BASKET
PELLET
CONTAINER
PELLET FEEDER
POWER &
ON/OFF CONTROL
SWITCH CABLE
& LED
PELLET
BALL VALVE EXIT TUBE
CABLE
MOTORISED OVERFLOW
BALL VALVE DRAIN
3
> 0.9 M /H
STRAINER Y-STRAINER
BALL VALVE BALL VALVE

PVC, 25MM PVC, 25MM
SOLVENT WELD * SOLVENT WELD *
* The first version of the pellet feeder has internally threaded ¾” NPT connections.
Please check your feeder.
Power & communication Via 3D TRASAR controller (24V & Modbus). Cable
supplied with feeder, 8m (extend to max. 30m).
Volume Max. 8000 pellets (refilled with 1500 pellet
containers).
Water Pressure < 5 bar @ 40ºC, temperature 5-50ºC
Part number 060-TRM5120.88 Pellet feeder
060-TR5311.88 Pellet feeder cable
500-P2818.88 Pellet feeder cleaning brush
21/90
22/90
Diagrams
Bio-reporter in solid form

3. Installation
3.1. Typical Installation
MAKE-UP
PORTA-FEED TRASAR INHIBITOR
WATER
TANK
PORTA-FEED OXIDISING BIOCIDE

TANK
PORTA-FEED NON-OXIDISING BIOCIDE

TANK
PELLET
FEEDER
FROM FLUOROMETER
TATION
SAMPLE WATER
3D TRASAR
INSTRUMEN-
PROCESS
BLOW DOWN WATER

Bio-reporter in liquid form
MAKE-UP
TANK BIO-REPORTER
WATER
PORTA-FEED TRASAR INHIBITOR

TANK
PORTA-FEED OXIDISING BIOCIDE

TANK
PORTA-FEED NON-OXIDISING BIOCIDE

TANK
FROM FLUOROMETER
TATION
SAMPLE WATER
3D TRASAR
INSTRUMEN-
PROCESS
BLOW DOWN WATER
23/90
3.2. General
Location • Install indoors.
• Do NOT install close to large generators.
• Do NOT install the pellet feeder in a (potentially) moist environment.
Sample Point & Product Injection

Locations
SAMPLE
POINT
SAMPLE
POINT
HORIZONTAL PIPE: SAMPLE VERTICAL PIPE: SAMPLE FROM RISING FLOW

FROM CENTRE TO AVOID DIRT TO AVOID AIR IN SAMPLE
AND AIR
• Make sure injection points have adequate mixing.

• Dose bio-reporter away from the sample inlet and the other injection points.
3.3. Plumbing Dimensions, water connections and water flows:

• Instrumentation assembly, see §Instrumentation Assemblies, p.17 and
§Sensors & Piping, p.18
• Pellet feeder, see §2.3, p.21
3.4. Sensors The fluorometer is shipped unattached to avoid damage. Mount the fluorometer on
the backboard with the supplied 4 bolts and connect the fluorometer cable.
Do NOT install pH and ORP sensors in their holders until water is connected.
Keep sensors moist to make sure they do not dry out.
For the locations of the sensors, see §Sensors & Piping, p.18.
)
Turn off power before making electrical connections for the sensors to avoid
damage to system components.
3.5. Pellet Feeder The Pellet Feeder is supplied in a few pre-assembled sections. The completely
assembled Pellet Feeder is shown in §2.3, p.21.
Connect the Pellet Feeder cable to the controller (for electrical connection, see
§Fluorometer (Pre-Wired) & Pellet Feeder, p.27).
3.6. Dosing pump The 3D TRASAR controller can calculate product usages and the system volume,
if it knows the exact dosing pump feed rates. The calculations can be enabled or
calibration disabled. If enabled, determine the exact feed rates using the level
gauge/calibration cylinder on the Nalco Porta-Feed tanks and a stopwatch. Other
tanks should also equipped with calibration cylinders.
24/90
3.7. Electrical
Electrical connections should be made by trained personel only.
Turn off power before making electrical connections.
For 3D TRASAR instrumentation assemblies that are supplied with an electrical

cabinet, refer to §3.7.7 for the external connections to dosing pumps, blowdown
valve, scada, inputs, outputs, etc. The pre-wired local connections to sensors, flow
switch, etc. are made inside the 3D TRASAR controller. If your 3D TRASAR
instrumentation assembly is supplied without an electrical cabinet, all connections
are made inside the 3D TRASAR controller.
3.7.1. Controller Circuit Boards

FLUOROMETER,
SENSOR BOARD PELLET FEEDER,
DIGITAL INPUTS,
§3.7.5, p.29
SCADA
§3.7.4, p.26
ANALOGUE INPUT/OUTPUT AND

MODEM BOARD
§3.7.6, p.31
RELAY OUTPUTS
§3.7.3, p.25
POWER SUPPLY INPUT

§3.7.2, p.24
3.7.2. Power Supply Input MAINS FUSE

TO CONTROLLER
F 2.5A
N L TO POWER
4 3 2 1
TB9 OUTPUTS
TB9 4 3 2 1
POWER
GREEN/YELLOW
SUPPLY
90-240VAC
50/60HZ
BROWN
20A
BLUE
PE N L
25/90
3.7.3. Relay Outputs
K1 F1 K2 F2 K3 F3 K4 F4
TB1 TRASAR TB2 TAG POLYMER TB3 BIOREPORTER TB4 OXID BIOCIDE
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
NO1 N L COM1 NO1 N L COM2 NO1 N L COM3 NO1 N L COM4
TB5 NONOX BIOCIDE TB6 BLOWDOWN TB7 PH CONTROL TB8 ALARM

1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
K8 F8
NO1 N L COM5 NO1 N L COM6 NO1 N L COM7
1 2 3
F5 F6 F7
K5 K6 K7
COM NO NC
K1-K8: RELAY 1-8 F1-F7: FUSE 1-7, 2.5A F8: FUSE 8, 1A
Common Alarm Wiring
1.0A
TB8 1 2 3
ALARM
SIGNAL
CONTROL ROOM
Dosing Pump and Blow Down Valve POWERED CONTROL CONTACT CONTROL
OR
Wiring
90-240VAC 90-240VAC
2.5A N PE L 2.5A N PE L
TB1-TB7 1 2 3 4 5 1 2 3 4 5
CONTROL CONTROL
GREEN/YELLOW
SIGNAL SIGNAL
90-240VAC
BROWN
BLUE
L N PE
DOSING PUMP OR DOSING PUMP
BLOW DOWN VALVE
L N PE
EXTERNAL POWER SUPPLY
26/90
3.7.4. Fluorometer, Pellet Feeder, TB15
FLUOROMETER
6V
Digital Inputs, SCADA
PROBE
GND
TB13
SCADA 232
GND TB12
SCADA 485
TX GND
B
RX
A
TB11
ISO TB10
PELLET FEEDER
+24VDC 0.5A MAX
GND
4-
B
4+
A
DIGITAL INPUTS
ISO 3-
GND 3+
24V
INTERLOCK
-
+
FLOW
+
Fluorometer (Pre-Wired) & Pellet FLUOROMETER PELLET FEEDER

Feeder A B GND 6V 24V ISO A B ISO
GND GND
TB15 TB11
BLACK OR BLANK
WHITE/ORANGE
WHITE/ORANGE
ORANGE/WHITE
ORANGE/WHITE
BLUE/WHITE
WHITE/BLUE
WHITE/BLUE
BLUE/WHITE
FLUOROMETER PELLET
FEEDER
Flow Switch (Pre-Wired) & Interlock FLOW INTER-

(Remote Start/Stop, Pre-Wired) LOCK
TB10 - + - + 3- 3+ 4- 4+
- +
FLOW CONTROL
PRE-WIRED
SWITCH ROOM
WITH BRIDGE
27/90
SCADA (Modbus) SCADA 485 SCADA 232
A B GND RX TX GND
TB12 TB13
CONTROL CONTROL
ROOM ROOM
Communications Configuration Item Parameters

Protocol Modbus RTU Slave connection (controller = slave)
Communications Half-duplex (2-wire)
Address 0 – 99, default = 10
Mode RS232 or RS485
Baud rate 1200, 2400, 4800, 9600 or 19200
Data bits 8 Bit
Parity None
Stop bits 1
Select the address, mode and baud rate in the controller; see §Preferences Sub
Menu’s, p.54. Note: Reboot the controller (toggle power) after entering the
settings.
Master Polling/Retry Configuration Item Parameters

Polling interval/block reads 5 – 10 sec (10 is recommended, as signals do not
change frequently)
Message timeout/retry 1 sec/retry
The 3D TRASAR controller supports block reads. It is recommended to always

read information in “Coil” 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.
Coil Map Controller Coil Register Address

Relay 1 – TRASAR product dosing pump 1
Relay 2 – Tagged polymer product dosing pump 2
Relay 3 – Bio-reporter dosing pump 3
Relay 4 – Oxidising biocide dosing pump 4
Relay 5 – Non-oxidising biocide dosing pump 5
Relay 6 – Blow down dosing pump 6
Relay 7 – pH control dosing pump 7
Relay 8 – Alarm output 8
Digital In 1 – No Flow 13
Digital In 2 – Interlock 14
Digital In 3 – Spare 15
Digital In 4 – Spare 16
28/90
Float, Integer & Long Register Map Controller Input Float / Integer Float Integer
Register Address Address Divide value by
Product 1 dosage (TRASAR) 40 150 10
Product 2 dosage (Tagged polymer) 42 151
Rz (bio-reporter) 44 152
Rs (bio-product) 46 153
Turbidity 48 154
Background 50 155
Cell Fouling 52 156
Conductivity 54 157 1
PH 56 158 100
ORP 58 159 10
Corrosion 1 (right side of controller) 60 160 100
Corrosion 2 (left side of controller) 62 161
Sample temperature 64 162 10
Nalco Bio Index 66 163
Nalco Scale Index 68 164
Polymer consumption 70 165
HTI 72 166
Blowdown rate 76 167
Makeup rate 78 168
Analog input 1 84 169
Analog input 2 86 170
Controller Input Float / Long Float Long
Register Address Address Divide value by
(1)
System volume average 74 172 10
(1)
Heat rejected 80 174
Recirculation rate 82 176(1)
(1)
Can be read as Long or Word values (2 words per Long). The values of each
Long are stored in two consecutive words with the most significant value
stored in the lower address.
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. In some 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.
Example: Assume floating point register 40 “Product 1 Dosage (TRASAR)”

contains 103.5 ppm. Integer register 150 will contain the value of 1035. All integer
and long registers will need to be scaled by their unique (documented) scaling
factor.
)
The float and integer addresses in the customer’s system (PLC) will be in a
certain range. A common range is 300000, e.g. integer address 150 equals
300150. However, not every PLC uses the same range. Please check with the
PLC manufacturer or check the PLC manual for the actual range.
Note: These are all registers currently supported by the 3D TRASAR controller.
Future releases of the 3D TRASAR firmware may contain additional registers.
29/90
3.7.5. Sensor Board
CORROSION
#2 PROBES #1
J1 1 J2 1
2+ 1 2+ 1
J4 pH J5 ORP
J7 1 2 3 4 5 6 7 8 9 10
WHT
GRE
RED
BLK
BLK
BLK
GRN SHLD RED SHLD BLU SHLD

CONDUCTIVITY
Conductivity Sensor Wiring (Pre- J7 1 2 3 4 5 6 7 8 9

Wired)
GREEN
CLEAR
CLEAR
CLEAR
BLACK
BLACK
BLACK
WHITE
RED
GREEN SHIELD
BLUE SHIELD
RED SHIELD
CONDUCTIVITY
SENSOR
30/90
pH, ORP and Corrosion Sensor PH / ORP CORROSION 1/2
Wiring (Pre-Wired) 2 1 8 7 6 5 4 3 2 1
J4-J5 J1-J2
FOR OLDER
ORANGE
BROWN
3 WIRE CABLES:
GREEN
BLACK
BLACK
BLUE
DO NOT
REF
CONNECT
SHIELD
CONTROLLER
PH / ORP CORROSION
SENSOR SENSOR
31/90
3.7.6. Analogue Input/Output and
Modem Board
2+ 2- 1+ 1-
4-20mA INPUT
TB16
8+ 8-
7+ 7-
4+ 4- 5+ 5- 6+ 6-
RJ11
ANALOGUE PHONE LINE
4-20mA OUPUT
(PHONE JACK &
WIRED CONNECTIONS)
TB17
1
2
3+ 3-
2+ 2-
1+ 1-
4-20mA Wiring 4-20MA INPUT 4-20MA OUTPUT
(POWERED)
TB16 1+ 1- TB17 1+ 1-
+ - PE + - PE
4-20MA OUTPUT
(POWERED)
TRANSMITTER CONTROL ROOM
Inputs are for data logging and monitoring only.
Outputs can be configured to transmit:
• TRASAR product • Nalco Scale Index • ORP

concentration • Nalco Bio Index • Corrosion #1
• Tagged polymer product • Conductivity • Corrosion #2
concentration
• pH • Water temperature
• Fluorometer cell fouling
)
Inputs & outputs are NOT isolated.
Signal isolators are recommended to fully isolate 3D TRASAR controller from

other devices.
32/90
3.7.7. Electrical Cabinet For 3D TRASAR instrumentation assemblies that are supplied with an electrical
cabinet, the remote connections are extended to terminals inside the electrical
cabinet. The pre-wired local connections to sensors, flow switch, etc. are made
inside the 3D TRASAR controller.
CONTROLLER ELECTRICAL CABINET
Cabinet Layout PRE-WIRED TO CONTROLLER PRE-WIRED

TO CONTROLLER
- - - - - - - - - - - - -
GND
GND
GND
24V
+ + + + + + + + + + + + +
A
B
A
B
1
2
AO1
AO2
AO3
AO4
AO5
AO6
AO7
AO8
INT
DI3
DI4
AI1
AI2
GND
GND
GND
24V
A
B
A
B
1
2
+ + + + + + + + + + + + +
- - - - - - - - - - - - -
ANALOG/DIGITAL I/O PHONE PELLET SCADA
FEEDER
PE
PRE-WIRED TO CONTROLLER & MAINS CIRCUIT BREAKER ‘F’ F
MAINS S
COM1
COM2
COM3
COM4
COM5
COM6
COM7
COM
NO1
NO2
NO3
NO4
NO5
NO6
NO7
CIRCUIT
NO
NC
N
N
L
BREAKER MAINS
2 POLE SWITCH
20A
COM1
COM2
COM3
COM4
COM5
COM6
COM7
COM
NO1
NO2
NO3
NO4
NO5
NO6
NO7
NO
NC
N
N
L
N
L
TRASAR TAG BIO RE- OXID NONOX BLOW PH ALARM
POLYMER PORTER BIOCIDE BIOCIDE DOWN CONTROL
PE
Power Supply Input CONTROLLER - TB9 3 2 1

(§3.7.2, p.24)
TO POWER
OUTPUTS
INSIDE CABINET
F 20A
S
N L
CABINET
GREEN/YELLOW
POWER
SUPPLY
90-240VAC
BROWN
50/60HZ
BLUE
20A
PE N L
33/90
Control & Alarm Outputs Connection Electrical cabinet Controller
Block Term. Block Term.
TRASAR product dosing TRASAR NO1 TB1 1
pump COM1 5
Tagged polymer product TAG NO2 TB2 1
dosing pump POLYMER COM2 5
Bio-reporter dosing pump BIO NO3 TB3 1
REPORTER COM3 5
Oxidising biocide dosing OXID NO4 TB4 1
pump BIOCIDE COM4 5
Non-oxidising biocide NONOX NO5 TB5 1
dosing pump BIOCIDE COM5 5
Blow down valve BLOWDOWN NO6 TB6 1
COM6 5
Acid/base dosing pump PH CONTROL NO7 TB7 1
COM7 5
Alarm output ALARM COM TB8 1
NO 2
NC 3
Control outputs
POWERED CONTROL CONTACT CONTROL
OR
2.5A 2.5A
CONTROLLER
5 1 5 1
TB1 – TB7
(§3.7.3, p.25)
L
90-240VAC
FROM 20A N
MCB PE
COM1-7
COM1-7
NO1-7
NO1-7
CABINET
N
TRASAR – PH CONTROL
L
L
GREEN/YELLOW
CONTROL CONTROL
BROWN
SIGNAL SIGNAL
BLUE
90-240VAC
L N PE
DOSING PUMP OR DOSING PUMP
BLOW DOWN VALVE
L N PE
EXTERNAL POWER SUPPLY
34/90
Alarm output
1.0A
CONTROLLER - TB8 1 2 3
(§3.7.3, p.25)
COM
NO
NC
CABINET - ALARM
ALARM
SIGNAL
CONTROL ROOM
Analogue / Digital I/O Analogue inputs & outputs

Analogue I/O, 4-20mA Electrical cabinet Controller
Block Term. Block Term.
Input 1 ANALOG/ AI1+/- TB16 1+/-
Input 2 DIGITAL I/O AI2+/- 2+/-
Output 1 AO1+/- TB17 1+/-
Output 2 AO2+/- 2+/-
Analogue inputs & outputs - examples

4-20MA INPUT 4-20MA OUTPUT
(POWERED)
CONTROLLER
1+ 1- TB17 1+ 1-
TB16
(§3.7.6, p.31)
CABINET
AI1 + - AO1 + -
+ - PE + - PE
4-20MA OUTPUT
(POWERED)
TRANSMITTER CONTROL ROOM
35/90
Digital inputs
INTER-
LOCK
CONTROLLER
TB10 - + 3- 3+ 4- 4+
(§3.7.6, p.31)
CABINET INT - + DI3 - + DI4 - +
- +
PRE-WIRED
WITH BRIDGE
CONTROL ROOM FUTURE USE
Pellet Feeder & SCADA PELLET FEEDER SCADA 485

24V ISO A B ISO
CONTROLLER GND GND A B GND
TB11 TB12
(§3.7.4, p.26)
GND
GND
GND
CABINET
24V
PELLET FEEDER SCADA

WHITE/ORANGE
ORANGE/WHITE
BLACK/DRAIN
WHITE/BLUE
BLUE/WHITE
PELLET CONTROL
FEEDER ROOM
Note: If the SCADA connection RS-232 is required, move the connector inside the
controller from TB12 to TB13.
36/90
4. Start-Up
4.1. Before Start-Up Required for start-up:
• Controller configuration upload file (3D TRASAR Configurator Software Manual)
• Background fluorescence lab test report (§1.2.1, p.5); results are entered in the
configuration upload file.
• Estimated system parameters (system volume, HTI, make-up conductivity, delta
T) are entered in the configuration upload file.
• Nalco Bio Index, pellet feeder: Determine initial bio-reporter dosage for approx.
20ppb:
Pellet type Concentration Pellets
3DTBR8 8% 2.0 per 10m3
3DTBR20 20% 8.2 per 100m3
3DTBR40 40% 41 per 1000m3
) TRH (Total Residual Halogen) must be < 0.1 ppm to start-up of Nalco Bio
Index
Make sure the following items & utilities are installed / connected / in order:
• Power supply, all electrical wiring & phone line
• Sample water & piping
• Chemical products, dosing pumps, dosing tubing and blow down valve
4.2. Procedure
4.2.1. 3D TRASAR Controller & Topic Task Details Reference
Sensors
Switch on §3D TRASAR
Controller, p.18
§2.3, p.21
Upload 3D TRASAR
configuration Configurator
Check controller If new firmware Software Manual
& Pellet feeder and pellet feeder is available via
firmware versions Configurator
then upload the
new firmware
(this may take
up to an hour)
Dosing pumps Check control Put in manual- §Manual Relay
Blow down valve on mode Control Sub
(temporarily) Menu’s, p.51
Calibrate pumps Enter values §Dosing pump
calibration, p.24
§Pumping Rates
Sub Menu’s, p.51
Calibrate 1-point §5.2, p.55
calibration for
pH, ORP &
conductivity
37/90
Topic Task Details Reference
Check switch Start/stop flow §5.1.1, p.44 for ‘no
control through flow’ & ‘no
fluorometer interlock’ indication
Check remote Toggle on/off §Flow meters &
on/off control (e.g. from flow switch, p.21
& Interlock control room)
Start-up mode Change start-up Extends relay §Relay Alarms,
factor timeout periods p.54
Activate (multiplied with §System Start-Up
start-up factor) Sub Menu’s, p.52
4.2.2. 3D Bio Control Prior to start-up of Nalco Bio Index, make sure to have completed the related
topics from §4.1, p.37 and the start-up procedure from §4.2.1, p.37.

Oxidising biocide Check control Put in manual- §Manual Relay
dosing pump on mode Control Sub
(temporarily) Menu’s, p.51
Adjust For 0.3ppm
continuous
dosage
Pellet Feed Topic Task Details Reference

Pellet feeder Check Feed 1 pellet §Pellet Feeder
functionality Data, p.47
Change control Put in ‘manual-
off’ mode
Fill With pellets §5.3, p.56
Initial bio-reporter Feed pellets Crush & dilute
dosage pellets (20ppb)
Feed manually
(slowly) to
cooling system
basin.
Check Rz: 20ppb §Fluorometer
concentration Data, p.47
3D TRASAR
Configurator
Software Manual
Pellet feeder Change control Put in ‘auto’ §Manual Relay
mode Control Sub
Menu’s, p.51
38/90
4.2.3. 3D Scale Blow Down Control, Prior to start-up of Nalco Scale Index, make sure to have completed the related
1-Drum Approach topics from §4.1, p.37 and the start-up procedure from §4.2.1, p.37.
CONDUCTIVTY
DOSED TRASAR CORROSION INHIBITOR
ACTIVE TAGGED SCALE INHIBITOR
STAGE 1 STAGE 2 STAGE 3 & 4

>5 HTI 7-8 HTI
TRASAR CONTROL MONITOR
TAG MONITOR CONTROL
BLOW CONTROLLED BY CONTROLLED BY CONTROLLED BY

DOWN CONDUCTIVITY SCALE INDEX * SCALE INDEX
* WITHOUT CONDUCTIVITY SETPOINT ADJUSTMENT
Stage 1 – TRASAR control

Tagged polymer Connect dosing To relay 1 §3.7.3, p.26
product pump
Change control To ‘TRASAR 3D TRASAR
control’ Configurator
Blow down Change control To ‘conductivity Software Manual
setpoint’
Change blow To 240 minutes
down valve or higher
timeout limit
Wait >5x HTI
Stage 2 – Tagged polymer control with 3D Scale monitoring

Tagged polymer Connect dosing To relay 2 §3.7.3, p.26
product pump
Change control To ‘Tagged 3D TRASAR
Polymer Configurator
control’ Software Manual
Enter setpoint With 3D
(average from TRASAR
logged tagged Configurator
polymer reading) Software
Or with §Plot Data Sub
controller ‘plot Menu Example,
data’ menu p.46
Blow down Change control To ‘3D Scale 3D TRASAR
Change ‘3D To enabled Software Manual
Scale Control
Settings - Monitor
Only’
39/90
Upload changes
and reinitialise
controller
Click ‘relearn See note *
now’
)
* Learning period must be during normal (low) scaling conditions without
system upsets
Wait until the learning period of 7-8 HTI (user input HTI) or 22 days if HTI>72h,
has ended and the Nalco Scale Index appears
Stage 3 – 3D Scale control

Blow down Change ‘3D To disabled 3D TRASAR
Scale Control Configurator
Settings - Monitor Software Manual
Only’
Change ‘setpoint To 0%
increase limit’
Change ‘setpoint Value [%] is
decrease limit’ system
specific.
Contact your
Nalco
representative.
Stage 4 – Advanced 3D Scale control

Blow down Change ‘setpoint Value [%] is 3D TRASAR
increase limit’ system Configurator
specific. Software Manual
Contact your
Nalco
representative.
40/90
4.2.4. 3D Scale Blow Down Control, Prior to start-up of Nalco Scale Index, make sure to have completed the related
2-Drum Approach topics from §4.1, p.37 and the start-up procedure from §4.2.1, p.37.
CONDUCTIVTY
STAGE 1 STAGE 2 STAGE 3 & 4

>5 HTI 7-8 HTI
TRASAR CONTROL
TAG MONITOR CONTROL

DOWN CONDUCTIVITY SCALE INDEX * SCALE INDEX
* WITHOUT CONDUCTIVITY SETPOINT ADJUSTMENT

TRASAR product Change control To ‘TRASAR 3D TRASAR
Software Manual
Tagged polymer Change control To ‘Slaved’
product Change dosing To match
pump rate TRASAR
dosing pump
rate
Blow down Change control To ‘conductivity 3D TRASAR
setpoint’ Configurator
Software Manual
Wait >5x HTI
Stage 2 – TRASAR & Tagged polymer control with 3D Scale monitoring

Tagged polymer Change control To ‘Tagged 3D TRASAR
product polymer Configurator
control’ Software Manual
Blow down Continue start-up procedure at §Stage 2 – Tagged
polymer control with 3D Scale monitoring, p.39, from topic
Blow down
41/90
4.2.5. 3D Scale Tagged Polymer Prior to start-up of Nalco Scale Index, make sure to have completed the related
Control, 2-Drum Approach topics from §4.1, p.37 and the start-up procedure from §4.2.1, p.37.
CONDUCTIVTY
STAGE 1 STAGE 3 & 4

>5 HTI
TRASAR CONTROL
TAG MONITOR CONTROLLED BY CONTROLLED BY

SCALE INDEX * SCALE INDEX
DOWN CONDUCTIVITY CONDUCTIVITY CONDUCTIVITY
* WITHOUT TAGGED POLYMER PRODUCT SETPOINT ADJUSTMENT

TRASAR product Change control To ‘TRASAR 3D TRASAR
Software Manual
Tagged polymer Change control To ‘Slaved’
product Change dosing To match
pump rate TRASAR
dosing pump
rate
Blow down Change control To ‘conductivity
setpoint’
Wait >5x HTI
Stage 2 – TRASAR & Tagged polymer control with Nalco Scale Index
monitoring
Tagged polymer Change control To ‘3D Scale 3D TRASAR
product control’ Configurator
Change ‘3D To enabled Software Manual
Scale Control
Settings - Monitor
Only’
Upload changes
and reinitialise
controller
Click ‘relearn See note *
now’
)
* Learning period must be during normal (low) scaling conditions without
system upsets
Wait until the learning period of 7-8 HTI (user input HTI) or 22 days if HTI>72h,
has ended and the Nalco Scale Index appears
42/90
Stage 3 – 3D Scale control
Tagged polymer Change ‘3D To disabled 3D TRASAR
product Scale Control Configurator
Settings - Monitor Software Manual
Only’
Change ‘setpoint To 0%
decrease limit’
Change ‘setpoint Value [%] is
increase limit’ system
specific.
Contact your
Nalco
representative.
Stage 4 – Advanced 3D Scale control

Tagged polymer Change ‘setpoint Value [%] is 3D TRASAR
product decrease limit’ system Configurator
specific. Software Manual
Contact your
Nalco
representative.
43/90
5. Operation
5.1. Controller The 3D TRASAR controller can be configured in two ways:
Configuration • Controller keypad: basic parameters, calibration (not: control methods)

• Configurator software: all parameters, data download, locally or remotely
)
3D TRASAR Configurator software should be run on a Nalco pc.
The software requires a link with a Nalco (Lotus Notes type) database. More
information can be found in the 3D TRASAR Configurator Software Manual.
)
The menu structure on the following pages will be different from your
controller menu structure.
Several parts of the menu structure are changed by the 3D TRASAR Configurator
Software (unused controls are hidden, actual product names and dosages are
displayed, etc.).
Controller firmware upgrades may change parts of the menu structure.
5.1.1. Controller Keypad & Screen NEXT / PREVIOUS

Information
SCREEN / LINE /
CHOICE
Actions
Alarms Cancel Accept Back PREVIOUS

SCREEN
7 8 9
4 5 6
1 2 3
HELPDESK
Menu 0 Help TEL.
ALARM NEXT PAGE AVAILABLE
PREVIOUS PAGE AVAILABLE

Operating Data
3DT265-i 98.5 ppm BOTH AVAILABLE
3DT265-a 90.5 ppm
Cond 1200 uS/cm
pH 8.05 OUTPUT RELAY:
F I 12:00 10/07/2004 ON OFF CONTROL
(M/DD/YYYY) AUTOMATIC
MANUAL
FAILSAFE
F NO FLOW
I NO INTERLOCK (REMOTE STOP ENABLED)

MODEM CONNECTION ESTABLISHED
NOT SHOWN:
MULTIPLE CHOICES
44/90
5.1.2. Password Screen Default password is 12345 and is required for most sub menu’s. It has to be re-
entered after 10 minutes of inactivity.
Enter Password
12345
[Clear] [Accept]
5.1.3. Information Menu Screen text:

Information Menu
Information
System Performance
Operating Data
Product Usage
Water & Energy
Plot Data
Control Methods
Timer Status
External Inputs
Product Factors
Diagnostic Data
[Select]
Information Sub Menu’s Performance

Nalco Scale Index 18
Nalco Bio Index 1.8
Corrosion-Stl 2.1 mpy 1 mpy, mil (milli inch) per year equals
Corrosion-Cu 0.1 mpy 0.0254 mm per year.
Consumption 18 %
Scale Index and Bio Index are only displayed when they have been activated
Operating Data
3DT279 98.5 ppm (TRASAR product)
3DT290 90.5 ppm (Tagged polymer product)
Cond 1200 uS/cm
pH 8.05
ORP 250 mV
Temp 25 ºC
Turbidity 15 NTU (§Turbidity, p.15)
HTI 48 hours (Holding Time Index, §Calculated
Values, p.15)
Product Usage
3DT279 3.52 lpd (§Calculated Values, p.15)
3DT290 1.45 lpd
etc.
Water & Energy

3
Blowdown 1000 m /hr (§Calculated Values, p.15)
Makeup 3000 m3/hr
Heat Rej. 150000 kBTU
Recirc rate 500 m3/hr
Sys. Volume 999999 m3
Plot Data
3DT279 Dosage
3DT290 Dosage
Turbidity
Conductivity
etc.
[Select]
45/90
Plot Data Sub Menu Example
HIGHLIGHTED PERIOD &
AVERAGE VALUE
Conductivity 8/16-8/17 MOVE HIGHLIGHTED PERIOD
150 Z
65 O X ZOOM PERIOD
uS O 1 DAY 1 POINT
50 M
7 DAYS 1 DAY
Y Zoom 7d X Zoom 30 DAYS 7 DAYS
X ZOOM: 1, 7, 30 DAYS
Y ZOOM: STANDARD, ZOOM
Control Methods
3DT279 TRASAR
3DT290 Polymer
Bioreporter Pellets
ST40 Bio Index
Blowdown Scale Index
2894 Timer
pH Acid
Timer Status View screens only

Rly1 Feed 999 min
Rly4 Prebleed
Rly5 Lockout
Rly7 Off
Relay 1 Schedule
Every Other MTWTF
00:00 720 min
04:00 120 min
12:30 240 min
16:00 60 min
External Input Screens

4-20 Input 1 99999.99 Scaled value
4-20 Input 2 99999.99 Scaled value
DI1 State On Sample flow contact
DI2 State Off System interlock contact
DI3 State On Contact or watermeter pulse input
DI4 Current 232.0 L Contact or watermeter pulse input
DI4 Prev 24h 5232.5 L
Product Factors
3DT279 40
3DT290 29
Diagnostic Data
Fluorometer Data
Sensor Data
Pellet Feeder Data
[Select]
Diagnostic data screens are for Nalco personnel and for testing the pellet feeder
(manually feed a single pellet).
46/90
Fluorometer Data
Prod 1 11.1 Bkrnd 13.6
Prod 2 0.0 Turbid 95.9
Rz 2.3 Fouling 40%
Rs 2.2 Temp 25ºC
Model 0
Sensor Data
T: 25 ºC pH: 7.10
C: 63 uS ORP: 371
A1: 0 A2: 0
C1: 1.2 mpy Stl 4 1 mpy, mil (milli inch) per year equals
C2: 0.5 mpy Cu 25 0.0254 mm per year.
Pellet Feeder Data

Ver 0 Ball 0
Cnt 0 Feed 0
Sen 0 Live 0
Status Idle
Press 0 to feed pellet
5.1.4. Actions Menu Screen text:

Action Menu
Actions
Clean & Calibrate
Manual Relay Control
Pumping Rates
Slug Non-Ox Biocide
System Startup
Test Email
[Select]
Action Sub Menu’s Calibration Menu

Fluorometer
pH
ORP
Conductivity
[Select]
Calibration instructions: §Calibration, p.55
Fluorometer Calibration Sub Menu’s

Fluorometer Cal
Last calibrated:
12-12-2004
[Start]
È
Fluorometer Cal
Inject 180 ml blanking solution
into flowcell.
[Cancel] [Continue]
È
Fluorometer Cal
Measuring blank values
Please wait…
[Cancel]
È
Fluorometer Cal
Inject 180 ml calibratin solution
into flowcell.
[Cancel] [Continue]
47/90
È
Fluorometer Cal
Measuring values
Please wait…
[Cancel]
È
Calibration Finished
Fluorometer calibration was
successful. Accept new values?
[Cancel] [Accept]
or
Calibration Failed
Calibration failed. Verify
standards and probe connection.
[Cancel] [Retry]
pH Calibration Sub Menu’s

pH Calibration
Last calibrated:
12-12-2004
[Start]
È
pH Calibration
1-Point/Process
2-Point/Standards
[Cancel] [Continue]
È With 1-Point/Process Selected
pH Calibration
Enter known pH.
8.15 pH
[Cancel] [Accept]
Or with 2-Point/Standards Selected
pH Calibrate
Close valves and remove probe.
Immerse probe in pH 7 standard
solution.
[Cancel] [Continue]
È
pH Calibrate
Measuring
Please wait…
[Cancel]
È
pH Calibrate
Immerse probe in pH 10
standard solution.
[Cancel] [Continue]
È
pH Calibrate
Measuring
Please wait…
[Cancel]
È
48/90
pH calibration was successful.
Accept new values?
[Cancel] [Accept]
or
Calibration Failed
Calibration failed. Clean probe
and retry
[Cancel] [Retry]
ORP Calibration Sub Menu’s

ORP Calibration
Last calibrated:
12-12-2004
[Start]
È
ORP Calibration
1-Point/Process
2-Point/Standards
[Cancel] [Continue]
ORP Calibration
Enter known ORP.
250 mV
[Cancel] [Accept]
ORP Calibrate
Immerse probe in 200 mV
standard solution.
[Cancel] [Continue]
È
ORP Calibrate
Measuring
Please wait…
[Cancel]
È
ORP Calibrate
Immerse probe in 600 mV
standard solution.
[Cancel] [Continue]
È
ORP Calibrate
Measuring
Please wait…
[Cancel]
È
ORP calibration was successful.
Accept new values?
[Cancel] [Accept]
or
Calibration Failed
and retry
[Cancel] [Retry]
49/90
Conductivity Calibration Sub Menu’s
Conductivity Cal
Last calibrated:
12-12-2004
[Start]
È
Conductivity Cal
1-Point/Process
3-Point/Standards
[Cancel] [Continue]
Conductivity Cal
Enter known
conductivity value.
2250 uS/cm
[Cancel] [Accept]
Conductivity Cal
Immerse probe in 0 uS/cm
conductivity standard.
[Cancel] [Continue]
È Use demineralised water; conductivity sensor should be suspended and
not swirled
Cond. Calibration
Measuring.
Please wait…
[Cancel]
È
Conductivity Cal
standard solution.
[Cancel] [Continue]
È Conductivity sensor should be suspended and not swirled
Cond. Calibration
Measuring.
Please wait…
[Cancel]
È
Conductivity Cal
standard solution.
[Cancel] [Continue]
È Conductivity sensor should be suspended and not swirled
Cond. Calibration
Measuring.
Please wait…
[Cancel]
È
Conductivity calibration was
successful. Accept new values?
[Cancel] [Accept]
or
Calibration Failed
and retry.
[Cancel] [Retry]
50/90
Manual Relay Control Sub Menu’s Relay Status
3DT279 is Off
3DT290 is Off
3DTBR06 is On
ST40 is On
2894 is Off
Blowdown is On
Acid is Off
[Select]
3DT279 Example Sub Menu

Manual Control
3DT279
Current Mode Man-Off (Automatic, manual on, manual off)
Auto After 0:00 h:m
(0:00 = No Auto Return)
[Edit]
Entering a ‘Auto After’ time with mode ‘Man-On’ will run the pump/valve for
that time and then return to mode ‘Auto’.
Pumping Rates Sub Menu’s Pumping Rates

3DT279 0.25 lpd
3DT290 0.25 lpd
3DTBR06 0.25 lpd
ST40 0.25 lpd
2894 0.25 lpd
Acid 0.25 lpd
[Edit]
Required for calculations: §Calculated Values, p.15
Slug Feed Biocide Sub Menu’s Slug Feed Biocide

Hand Feed Nonox
Hand Feed Oxidizer
Relay Feed Oxidizer
[Select]
All slug feed settings must be set using the 3D TRASAR Configurator software
whilst connected to the controller
Hand Feed Nonox
Which biocide will you manually
slug feed?
Glutaraldehyde
[Cancel] [Accept]
È Use ‘Hand Feed Nonox’ to hand feed a non-oxidising biocide by an
operator to the cooling system.
Hand Feed Nonox
Glut will be paused for 8 hours.
[Cancel] [Continue]
È 8 hour pause only valid for glutaraldehyde, not for other biocides.
Hand Feed Nonox
Prebleed Cond. 9999 uS
Prebleed Time 999 min
Lockout Time 999 min
[Cancel] [Continue]
È
Hand Feed Nonox
Add biocide to system now or
after prebleed (if enabled) ends.
[Cancel] [Confirm]
51/90
Hand Feed Oxidizer
[Cancel] [Continue]
È Use ‘Hand Feed Oxidizer’ to hand feed an oxidising biocide by an
operator to the cooling system.
Hand Feed Oxidizer
Add biocide to system now or
after prebleed (if enabled) ends.
[Cancel] [Confirm]
Relay Feed Oxidizer

[Cancel] [Continue]
È Use ‘Relay Feed Oxidizer’ to energise the oxidising biocide relay and
activate the dosing pump connected to that relay.
Relay Feed Oxidizer
Press Start to begin feed cycle.
[Cancel] [Start]
System Start-Up Sub Menu’s System Startup

Select an action during system
startup (applies to all controlled
relays)
Activate Startup
[Cancel] [Accept]
Start-up factor: Screen Relay Alarms, p.54
Start-up procedure: §4.2, p.37
Send Test Email Send Test Email

Send alarm email to:
alarms@3dtrasar.com
Send data email to:
data@3dtrasar.com
[Cancel] [Send]
5.1.5. Alarms Menu Screen text:

Alarms
Alarms
10-10-2004 16:48
No Flow
Current alarms
5.1.6. Main Menu Screen text:

Main Menu
Menu
Control Settings
Alarm Settings
Preferences
Network
System Information
[Select]
52/90
Control Settings Sub Menu’s Control Settings
Background (Background Fluorescence)
3DT279
3DT290
ST40
2984
Blowdown
pH
[Select]
Background
TRA Bkgd 10%
TAG Bkgd 20%
TAG Ratio 1.65
TAG Method Offline (Offline, Online)
[Edit]
More information: §1.2.1, p.5
Product Settings Example 1

3DT279 Settings
Setpoint 100 ppm
Control Range ± 4 ppm
[Edit]
More information: §Control, p.7
Settings for Timers can only be adjusted via the 3D TRASAR Configurator
software. Timer status and settings can be viewed via the Information Menu
(§Control Methods, p.46).
Alarm Settings Sub Menu’s Alarm Settings

System Alarms
Control Alarms
Performance Alarms
Relay Alarms
[Select]
System Alarms
Cell Fouling High 30%
Temp High 150ºC
Temp Low 5ºC
[Edit]
Control Alarms
3DT279
3DT290
Conductivity
etc.
[Select]
Product Settings Example
Conductivity Alarms
High Level 1500 uS/cm
Low Level 500 uS/cm
[Edit]
Performance Alarms
Corrosion 1 High 5 mpy
Corrosion 2 High 5 mpy
[Select]
53/90
Relay Alarms
3DT279
3DT290
3DTBT06
ORP
Blowdown
pH
Startup Factor 5
[Select]
Start-up mode: §System Start-Up Sub Menu’s, p.52
Start-up procedure: §4.2, p.37
Example Relay Alarm Sub Menu

3DT279 Relay
Relay Timeout 180 min
Fixed Failsafe 35 %
(Smart Failsafe 18 %)
Failsafe Type Fixed (Smart, Fixed, Off)
[Cancel] [Accept]
More information: §Failsafe, p.16
4-20mA Alarms
Input 1 High 70
Input 1 Low 0
Input 2 High 70
Input 2 Low 0
Preferences Sub Menu’s Preferences

Time 23:08 h:m
Date 30/06/2004
Password 12345
Contrast 28
SCADA Addr 10
SCADA Mode RS232 (0-99)
SCADA Baud 19200 (RS232, RS485)
Date format D/M/Y (1200, 2400, 4800, 9600, 19200)
[Edit]
Note: Scada settings changes require a controller reboot (toggle power)
Network Sub Menu’s Network

DHCP Disabled (Disabled/Enabled)
IP Addr 169.254.001.002
Subnet 255.255.000.000
Gateway 169.254.001.004
[Edit]
Before making changes check with your LAN Administrator or ISP provider. Any
changes made must also be made in the 3D TRASAR Configurator software!
System Information Sub Menu’s System Information

3
Sys. Volume 99 m
Makeup Cond 300 uS/cm
Delta T 5ºC
[Edit]
54/90
5.2. Calibration Check measurements. If >5% inaccurate, calibrate.
Wear appropriate personal safety equipment when handling calibration and

cleaning solutions.
See MSDS’s (Material Safety Data Sheets) supplied with solutions.
Measurements Check Fluorometer
3. OPEN
2. CLOSE
4. INJECT 180ML CALIBRATION

60ML
SOLUTION 460-S0940.75
1. CLOSE
5. READ PRODUCT CONCENTRATIONS

ON SCREEN (Information Sub Menu’s, p.44).
The readings should be approx.:

Product 1: [TRASAR product factor] * (1- [TRASAR background fluorescence %]).
Product 2: [Tagged polymer product factor] for online background correction or
[Tagged polymer product factor] * (1- [Tagged polymer background
fluorescence %]) for offline/fixed background correction.
Refer to §Product Factors, p.46 for the product factors and to §Background, p.53
for the background fluorescence values and correction method.
Conductivity, pH & ORP

Measure cooling system water with handheld conductivity, pH and ORP meters. If
meter(s) is not available, put sensor(s) in beaker with conductivity, pH or ORP
solution calibration solution.
Calibration Fluorometer
Procedure: §Fluorometer Calibration Sub Menu’s, p.47
)
Fluorometer calibration notes:
• The fluorometer is supplied pre-calibrated with the controller on the 3D

TRASAR instrumentation assembly.
• If cell fouling is high (indicated on first calibration screen), clean cell with the
fluorometer brush via top opening; first unscrew the two unions above the
fluorometer. If unsuccessful, inject 60ml dilute acid (10% sulphuric acid is
recommended) and leave in cell for 2 minutes.
• Use different syringes for acid, blank and calibration solutions.
• Remove bubbles from blank and calibration solutions, when in syringe, before
injecting (with syringe upright, tap against solid object).
55/90
Conductivity, pH & ORP
Procedures:
§Conductivity Calibration Sub Menu’s, p.50
§pH Calibration Sub Menu’s, p.48
§ORP Calibration Sub Menu’s, p.49
)
Conductivity, pH & ORP calibration notes:
• 3D TRASAR instrumentation assemblies are pre-calibrated with 3-/2-point

calibrations.
• Standard calibration is a 1-point calibration with the sensors installed and the
sample water flowing. 3-point (conductivity) and 2-point calibration (pH, ORP)
with calibration solutions in beakers are for first calibration of a sensor or to
correct major drifting.
• Conductivity sensor should be suspended in the centre of a beaker and not
swirled. Make sure to do a 1-point conductivity calibration in flowing sample
water after a 3-point calibration.
• Calibration solution values are fixed (for 2-point & 3-point calibration): 0, 600 &
3000uS/cm, pH 7 & 10, 200 & 600mV; use demineralised water for 0uS/cm.
• When changing sensor between calibration solutions, rinse with demineralised
water.
5.3. Pellet Feeder Principle of operation: §Bio-reporter Pellet Feeder, p.12

Drawing & specifications: §2.3, p.21
Start-up: §Pellet Feed, p.38
Wear appropriate personal safety equipment when handling pellets.
See MSDS (Material Safety Data Sheet) supplied with pellet storage container.
Do NOT put your fingers in the rotor holes when the pellet feeder is
powered.
The rotor may be activated by the 3D TRASAR controller when you don’t expect it.
)
If pellets not dosed => restart of Nalco Bio Index required.
Keep pellet feeder at least 25% full to ensure continuous operation.
)
Pellets must remain dry.
Keep pellet feeder lid and storage container closed. Moisture can cause pellet
degradation and possible jamming.
Filling the Pellet Feeder 1. Loosen bolt; open lid.

2. Slowly pour pellets into pellet container; do NOT overfill.
3. Place desiccant cartridge in basket (cartridge supplied with pellets).
4. Close lid; fasten bolt.
56/90
5.4. Internet Alarm e-mails and data e-mails can be automatically sent to the Nalco server by
the controller. The data is processed and made available via a restricted section of
Communications ‘3D TRASAR Web’ on the Nalco website www.nalco.com while the alarm e-mails
can be forwarded to several recipients.
3D TRASAR Web Performance Summary Controller Dashboard Reports
High-level view of every 3D TRASAR scale- Graphs and data can be

controller assigned to microbio-corrosion saved manually or sent
you. triangle and operational automatically.
data.
Requirements • Local ISP settings: the settings from a local internet service provider
(username, password, phone number) need to be setup in the controller with
the 3D TRASAR Configurator software.
• 3D TRASAR Web access: Nalco extranet account, user name and password
need tobe setup for you (contact your Nalco representative); one account can
provide access to data from multiple controllers.
57/90
6. Maintenance
6.1. Preventative Topic Task Interval* Reference
Maintenance Schedule Strainers & flow Clean Monthly
meters
Fluorometer & Check calibration & Monthly §5.2, p.55
conductivity calibrate if required
sensor
pH & ORP Check calibration & Monthly §5.2, p.55
sensors calibrate if required
Replace sensors Yearly
and calibrate
Corrosion sensors Replace sensors Every 6 months §Corrosion
Sensor (2x),
p.20
Pellet feeder Check contents & Weekly §5.3, p.56
fill if required
Clean container When needed §6.2, p.58
(check monthly)
Maintain When needed §6.2, p.58
(typically yearly)
* Interval is recommended starting point; actual interval depending on conditions
6.2. Pellet Feeder Topic Task Do when Reference

Maintenance Container Clean Visual inspection §6.2.1, p.58
Exit tube Clean Alarm or visual §6.2.2, p.59
inspection
Motorised ball Tighten Alarm or §6.2.3, p.59
valve seat excessive
leakage
Pellet shield Replace Alarm, pellet §6.2.4, p.59
feeder jamming,
or visual
inspection
See also §5.3, p.56.
Before maintenance, turn off feeder.
After maintenance, test with 1 pellet (§Pellet Feeder Data, p. 47)
6.2.1. Container Cleaning
Wear a dust mask when cleaning.
More safety information: §5.3, p.56.
1. Manually remove pellets; store in clean and DRY location

2. Clean complete inside of container with DRY soft cloth
3. Refill pellets
58/90
6.2.2. Exit Tube Cleaning A LED inside exit tube is used to detect a
falling pellet.
Clean tube with supplied dry tube brush.
LED (NOT SHOWN)
EXIT TUBE
DRY TUBE BRUSH
6.2.3. Valve Seat Tightening 1. Remove motorised valve; valve

location: §2.3, p.16
2. Tighten adjustment nut; do NOT over-
tighten
BALL
O-RING
ADJUSTMENT NUT
6.2.4. Pellet Shield Replacement

TOP VIEW
INSIDE CONTAINER
PELLET ROTOR &

SHIELD SHIELD
REMOVED
ROTOR WITH EXIT

4 HOLES TUBE
1. Clean container: §6.2.1, p.58

2. Loosen the 4 screws; remove rotor retainer with pellet shield
3. Clean rotor area
4. Remove pellet shield from rotor retainer; place new shield
5. Replace rotor retainer with pellet shield. Shield must cover exit tube hole.
6. Fasten 4 screws and washers. Do not over-tighten.
59/90
6.3. Spare Parts
Fluorometer Item code Description
460-S0940.75 3D TRASAR calibration solution, 1L
500-P2147.88 Syringe, 60ml, plastic
500-P2817.88 Fluorometer brush
460-S0800.74 Cleaning solution, Sulphuric Acid 10%, 50ml
060-TR5222.88 Desiccant canister
060-TR5223.88 Desiccant indicator
060-TR5221.88 Fluorometer cable, 1.2m
Conductivity Item code Description

460-S0298.75 Conductivity calibration solution, 600 uS/cm, 1L
460-S0297.75 Conductivity calibration solution, 3000 uS/cm, 1L
060-TR5441.88 Conductivity sensor, inductive, incl. cable & tee
pH / ORP Item code Description

460-S0408.75 pH calibration solution, pH 10.0, 1L
460-S0407.75 pH calibration solution, pH 7.0, 1L
460-S0932.75 ORP calibration solution, 200 mV, 1L
460-S0933.75 ORP calibration solution, 600 mV, 1L
060-TR5411.88 pH sensor, 3/4” mNPT
060-TR5421.88 ORP sensor, 3/4” mNPT
060-TR5412.88 pH / ORP cable
Corrosion Item code Description

400-NCMP1B.88 Corrosion probe, steel
400-NCMP2B.88 Corrosion probe, copper
400-NCMP4B.88 Corrosion probe, CuNi 90/10
400-NCMP5B.88 Corrosion probe, CuNi 70/30
400-NCMP7B.88 Corrosion probe, 443 brass
400-NCMAC15.88 Probe restraint, SS
6003232 Fitting, Nylon, 3/4" BSP connection
Pellet Feed Item code Description

460-3DTBRC.87 Bio-reporter quick dose pouch
500-P2818.88 Pellet feeder cleaning brush
060-TR5311.88 Pellet feeder cable, 7.5m
060-TR5313.88 Pellet feeder shield kit
3D TRASAR Controller Item code Description

991-05047661.88 Ethernet crossover cable
991-50473718.88 Fuse, 2.5 A, 230Vac (output relay fuse)
60/90
Start-Up Item code Description
6010694 3D TRASAR start-up kit *
* Start-up kit includes:

Item code Description Qty
460-S0940.75 3D TRASAR Calibration Solution, 1L 1
460-S0408.75 pH 10 calibration solution, 1L 1
460-S0407.75 pH 7 calibration solution, 1L 1
460-S0932.75 200mV, ORP calibration solution, 1L 1
460-S0297.75 3000uS/cm, Conductivity calibration 1
solution, 1L
460-S0298.75 600uS/cm, Conductivity calibration 1
solution, 1L
500-P0120.88 Plastic Beaker, 500ml 3
500-P2817.88 Flow cell cleaning brush 1
460-S0800.74 10% Sulphuric Acid cleaning solution, 1
50ml
500-P2147.88 Plastic syringe, 60cc 3
61/90
7. Troubleshooting
7.1. Alarm Listing Alarms are shown on controller display (§5.1.5, p.52), in data download file or in
received alarm e-mail.
Alarm activation delay: 10 minutes (most alarms)

'No interlock' alarm delay: immediate
Sensor Alarms Alarm Probable cause Corrective action Reference

Conductivity Loose wiring Check wiring §3.7.5, p.30
Sensor Error
RTD Sensor Error
pH Sensor Error
Faulty sensor / Replace sensor / §3.7.5, p.30
ORP Sensor Error device device §3.7.4, p.27
NCM Sensor Error
Pellet Feeder
Error
Pellet Sensor Pellet sensor LED Clear and clean exit §6.2.2, p.59
Error is blocked tube
)
pH and ORP are high impedance measurements, and it is difficult to detect
loose or wrongly wired sensors. Therefore, the pH and ORP Sensor Errors are
not always triggered. Inaccurate or fluctuating readings are another indication of a
wrongly wired or faulty sensor.
System Alarms Alarm Probable cause Corrective action Reference

Temperature High Alarm thresholds Adjust alarm §Alarm
too close average thresholds Settings Sub
reading Menu’s, p.53
Temperature Low Cooling water Check cause

problem
Temperature RTD Check with
out of calibration thermometer
Cell Fouling High Cell fouled Clean & calibrate §5.2, p.55
Alarm threshold too Adjust threshold §Alarm
low Settings Sub
Menu’s, p.53
No Flow Valve(s) closed Open valve(s)
Flow switch broken, Check flow switch & §3.7.4, p.27
loose wiring wiring
No Interlock Remote stop active Check remote stop
No bridge on Install bridge §3.7.4, p.27
interlock terminals
)
No Interlock and No Flow alarms supercede all other alarms; other alarms in
are disabled during No Interlock and No Flow alarms. Likewise, the No Interlock
alarm supercedes the No Flow alarm.
62/90
Communication Alarms Alarm Probable cause Corrective action Reference
Fluorometer Loose connector or Fasten connector §3.7.4, p.27
Comm Error wiring and check wiring
Check desiccant Replace/repair
Fluorometer
Pellet Feeder Loose connector or Fasten connector §3.7.4, p.27
Comm Error wiring and check wiring
Sensor Board Loose board Reconnect board
Comm Error connection
Performance Alarms Alarm Probable cause Corrective action Reference

System Stress System upset such Conductivity
High (high as a high pH event, setpoint has been
polymer process leak, high decreased
consumption) heat load event, automatically to
etc. induce blowdown.
If coincident with or Enter lower
subsequent to a conductivity
‘Conductivity setpoint and relearn
adjustment MIN’ system stress.
alarm, the controller
is unable to
respond to the high
stress condition.
Bio Index High Oxidising biocide Check tank and
not dosed pump
Biocide Pump Rate too high or Decrease rate or
Rate High pump too big replace pump
Biocide Pump Rate too low or Increase rate or
Rate Low pump too small replace pump
Bioproduct Low Insufficient bio- Check pellet feeder
Bioproduct Low reporter dosed or dosing pump and
Failsafe tank
Excessive oxidising Reduce oxidizing
biocide is degrading biocide pump
bio-reporter Check for other
source of oxidising
biocide
Bioproduct High Biocide feed unable Manually feed
Bioproduct High to meet microbio oxidising biocide
Failsafe demand until alarm clears
Bio-reporter High To much bio- Wait for level to 3D TRASAR

Bio-reporter High reporter dosed drop Configurator
Failsafe Initial start-up Software
dosage to high Manual
If in conjunction Manually feed

with bioproduct oxidising biocide
high, biocide feed until alarm clears
unable to meet
microbio demand
Bio-reporter Low Pellet feeder unable Add bioreporter
Bio-reporter Low to dose 20ppb in manually
reasonable time
63/90
Alarm Probable cause Corrective action Reference
Failsafe Excessive oxidising Reduce oxidizing
biocide is degrading biocide pump
bio-reporter Check for other
source of oxidising
biocide
Bio Data Noise Bubbles in Reduce flow,
High fluorometer remove source of
Bio Data Noise bubbles
High Failsafe Bio-reporter dosage Change dosing
too close to point
fluorometer
Pellet Rotor Rotor jammed Clear jam §6.2.4, p.59
Current High Replace pellet
shield if required
Pellet Supply Low Pellet feeder empty Fill §5.3, p.56
Pellet Feeder Pellet feeder has
Busy completed a pellet
feed before next
pellet is requested:
pellet supply low
Ball Valve Error Ball not rotating, Repair
separated from
motor shaft
Ball Valve Current Jammed or ball Clear jam or adjust §6.2.3, p.59
High valve seats are valve seats
over-tightened
Corrosion #1 or Low flow past Increase to match
#2 High sensor system velocity
High alarm too low Adjust §Alarm
Settings Sub
Menu’s, p.53
Corrosion treatment Consult your Nalco
needs adjustment representative
Control alarms Alarm Probable cause Corrective action Reference

TRASAR High High alarm too low Adjust §Alarm
Tagged Polymer Settings Sub
High Menu’s, p.53
pH High Dosing pump rate Decrease rate,

too high replace pump
ORP High
Process leak Find source
Out of calibration Calibrate §5.2, p.55
TRASAR Low Low alarm too high Adjust §Alarm
Tagged Polymer Settings Sub
Low Menu’s, p.53
pH Low Dosing pump rate Increase rate,

too low replace pump
ORP Low
Check if tank empty
64/90
Conductivity High High alarm too low Adjust §Alarm
Settings Sub
Menu’s, p.53
Insufficient blow Check if line/valve
down blocked
Check if valve is too
small
Conductivity Low Low alarm too high Adjust §Alarm
Settings Sub
Menu’s, p.53
Too much blow Valve stuck open
down
Conductivity The automatic If required, increase §Control
Adjustment Max conductivity conductivity Settings Sub
setpoint adjustment setpoint and relearn Menu’s, p.53
functionality has stress
adjusted the
setpoint, to
compensate for low
scale stress
conditions
(compared to
learned stress), to
it's maximum
setting
Conductivity The automatic If required decrease
Adjustment MIN conductivity conductivity
setpoint adjustment setpoint and relearn
functionality has stress
adjusted the
setpoint, to
compensate for
high scale stress
conditions
(compared to
learned stress), to
it's minimum setting
Relay Timeout Alarms Alarm Probable cause Corrective action Reference

TRASAR Relay Insufficient product Check tank
Timeout dosage Increase pump rate
Tagged Polymer Replace pump
Relay Timeout
Bio-reporter Relay Timeout limit Adjust §5.1.5, p.52
Timeout setting too low
Oxidizing Biocide
Relay Timeout
pH Relay Timeout
65/90
Blowdown Relay Insufficient blow Check if line/valve
Timeout down blocked
Check if valve is too
small
Timeout limit Adjust §5.1.5, p.52
setting too low
)
Timeout alarms can only be cleared via the controller keypad.
Remote users: Reboot the controller to clear timeout alarm
Analogue Input Alarms The high and low limits for the two analogue inputs generate the alarms ‘Analog
#1 High’, ‘Analog #1 Low’, ‘Analog #2 High’, ‘Analog #2 Low’. They do not affect
any controls. The causes and corrective actions depend on the measurements.
7.2. Additional Problem Probable cause Corrective action Reference

Troubleshooting Controller does No power supply or Check power §3.7.2, p. 25
not power up fuse blown supply, replace fuse
Controller does Configured as ‘Not Change to ‘Monitor 3D TRASAR
not show pH, Installed’ only’ or ‘Controlling’ Configurator
ORP, conductivity with 3D TRASAR Software
or temperature Configurator
Software
Controller does 3D Scale/Bio Change with 3D 3D TRASAR
not show Nalco control not TRASAR Configurator
Scale/Bio Index configured Configurator Software
Software
Output relay does No flow / interlock Check §System
not work signal / alarm Alarms, p.62
Fuse Blown Replace fuse §3.7.3, p.26
Configured as Change to ‘Auto’ §Manual
‘Manual-off’ Relay Control
Sub Menu’s,
p.51
Pellet feeder does Controller not Change 3D TRASAR
not feed pellets configured to feed Configurator
pellets Software
Pellet feeder error / Check §7.1, p.62
alarm
Just powered up Wait max. 25
minutes
No flow / interlock Check §System
signal / alarm Alarms, p.62
Configured as Change to ‘Auto’ §Manual
‘Manual-off’ Relay Control
Sub Menu’s,
p.51
Oxidising biocide Resolve alarm §7.1, p.62
failsafe mode
66/90
Appendix A.
3D TRASAR for High
Fouling Applications
Systems with higher levels of solids and debris tend to cause fouling of the 3D
TRASAR’s fluoresence probe, the fluorometer. To minimise the amount of
physical cleaning, the industrial enclosed version of the 3D TRASAR range has
been modified so it can inject cleaning acid into the fluorometer and remove metal
particulates from the sample water with a magnetic disk inside a strainer.
Cleaning acid 460-S0340.11 is pumped with a dosing pump, which is controlled by

one of the timers of the 3D TRASAR controller. The timer simultaneously activates
the dosing pump and closes a solenoid valve just before the acid injection point.
A.1. Additional
Components and
Specifications
DOOR INTERLOCK
ACID INJECTION
VALVE
SOLENOID VALVE
MULTI FUNCTION
VALVE
ACID DOSING PUMP
SUCTION
LANCE
BUND
TUBING
ACID DRUM
(NOT
INCLUDED)
STRAINER WITH
MAGNETIC DISK
Part Number 060-TRM5525.88
Power Supply 230Vac (120Vac only after replacing the solenoid
valve with a 120Vac version)
The pre-installed solenoid valve requires 230Vac. Therefore the complete 3D

TRASAR unit requires 230Vac.
Replacing the 230Vac solenoid valve with a 120Vac version will allow 120Vac for
the complete 3D TRASAR unit. See also §Solenoid Valve, p.68.
67/90
Dosing Pump Components TUBING CONNECTION 6X9MM
1/2” BSP
INJECTION VALVE
DOSING PUMP
Part Number 6003113
Model DME8
Components Dosing pump, injection valve, foot valve (not
installed), tubing
Capacity 7.5ml/h – 7.5L/h
Pressure <10bar
Materials Head: PVDF, seals: FKM, tubing: PE for discharge
line, PVC for suction line
More specifications Pump Manual
Multi Function Valve TUBING CONNECTION 6X9MM

PULL =
MANUAL
PRESSURE
PRESSURE RELIEF
RELIEF OUTLET
Part Number 6003121
Functions Automatic pressure relief (approx. 11bar), manual
pressure relief, constant back pressure (1.5bar),
anti-siphon
Material PVDF, seals: FKM
Installation Directly on discharge side of dosing pump
Solenoid Valve 3/8" BSP
Part Number 230Vac: 6021657
120Vac: TBD (to be determined)
Type 121
Material PVC; seals: FKM
Control NO (normally open), 230/120Vac to close
Pressure 0…4bar
Temperature -10…+90°C
68/90
Door Interlock Specification Details
Part Numbers Door interlock switch: 6021658
Pump control cable: 6003091
Function Door open (contact open) = dosing pump pause
Suction Lance TUBING CONNECTION 6X9MM
1” BSP
Part Number 6003124
Material PVC
Insertion Length Max 540mm
Bund
Part Number 6018694
Material PE
Volume 60L
Dimensions H=550mm, D=420mm
Strainer with Magnetic Disk 1” NPT
Part Numbers Strainer & screen: 991-50537710.88
Magnetic disk: 991-05058141.88
Material Housing: PP, screen: SS
Screen 80 mesh
69/90
A.2. Additional Installation
Information
Pre-Wired Electrical Connections
The pre-installed solenoid valve requires 230Vac. Therefore the complete 3D

TRASAR unit requires 230Vac.
Replacing the 230Vac solenoid valve with a 120Vac version will allow 120Vac for
the complete 3D TRASAR unit. See also §Solenoid Valve, p.68.
The power supply of the acid dosing pump and solenoid valve are pre-wired to
relay output 5 (non-oxidising biocide) in the electrical cabinet as shown on the
following drawing.
)
If relay output 5 needs to be used for a non-oxidising biocide, then the acid
dosing pump and solenoid valve can be connected to any of the unused
relay outputs (1-7).
2.5A
CONTROLLER
TB5 5 1
(§3.7.3, p.25)
L
90-240VAC
FROM 20A N
MCB PE
COM5
NO5
CABINET
N
NONOX BIOCIDE
L
(§3.7.7, p.33)
GREEN/YELLOW
CONTROL
BROWN
SIGNAL
BLUE
90-240VAC
L N PE L N PE
ACID DOSING PUMP SOLENOID VALVE
230 OR 120VAC
70/90
The door interlock switch is pre-wired to the remote on/off input of the acid dosing
pump. Enclosure door open = dosing pump pause (off).
DOOR INTERLOCK
REMOTE ON/OFF INPUT
ACID DOSING PUMP
Acid Drum, Bund and Other Install the bund, acid drum, suction lance and the remaining tubing as shown in §0
Components A.1. Additional Components and Specifications, p.67.
Nalco cleaning acid 460-S0340.11 is a highly acidic solution. Take the proper
precautions in handling and disposal. See the MSDS for more information.
)
Make sure that air can flow into the acid drum when it’s contents is pumped
out, e.g. by making a hole in the drum cap. This hole can then also be used for
the pressure relieve tubing from the multi function valve on top of the pump. The
hole should be sufficiently larger then the tubing.
)
To avoid extensive manual cleaning of the strainer install an appropriate
filter before the sample water inlet of the 3D TRASAR unit.
71/90
A.3. Additional Make sure that the following settings are set via the Configurator software
package (See also §5.1 Controller Configuration, p.44).
Configuration
Information Topic Setting Details
‘Non-Oxidising ‘Control Method’ ‘Timer Control’
Biocide Control’ ‘Biocide Name’ ‘Other’
'(Relay Output 5)
‘Name’ S0340
‘Pumping Rate’ 7.5L/h or less if pump is
set to a lower flow
‘Edit BioTimers’ ‘Feed Frequency and ‘Feed Every Day’
Interval’
All ‘Pre-Bleed’ and Deselect
‘Lockout’ Options
‘Current NonOx Schedule’ Time: Hour and Minutes *
Cleaning duration: 10
minutes
‘Alarm Settings’ – ‘Cell-fouling % High’ 25
‘System Alarms’ ‘No Flow Relay Action’ ‘Force Relay Off’
‘No Flow Alarm Delay 10
(min)’
‘External Inputs’ ‘AI 1 Name’ Cell Fouling
‘4 mA Value’ 0
‘20 mA Value’ 100
‘Units’ %
‘High Alarm Limit’ 25
‘Low Alarm Limit’ 0
‘4-20 mA Outputs’ ‘#1 Name’ ‘Cell Fouling’
‘4 mA Value’ 0
‘20 mA Value’ 100
)
* Set the cleaning schedule for a time when the operators are not expected
to be performing manual cleaning of fluorometer.
The dosing pump will stop when the door of the enclosure is open but the lost
dosing time will not be recovered.
)
If relay output 5 needs to be used for a non-oxidising biocide and the acid
dosing pump and solenoid valve have been connected to one of the unused
relay outputs (1-7), then enter the above timer settings for that relay.
‘Pre-bleed’ and ‘lockout’ options may not be available for the selected output relay
and therefore do not have to be deselected.
A.4. Additional Topic Task Interval

Maintenance Strainer & Clean Weekly – Determine appropriate maintenance
Information magnetic disk schedule based on degree of fouling.
72/90
Appendix B.
3D TRASAR for Zone
The 3D TRASAR Assembly for Zone 2 Explosive Atmospheres is based on the
2 Explosive standard Industrial Enclosed 3D TRASAR Assembly. In a Zone 2 area, an
explosive atmosphere is unlikely, but if it does occur, it will persist for short periods
Atmospheres only (e.g. <10 hours per year).
To allow the 3D TRASAR Assembly in Zone 2 area’s, a potentially explosive

mixture of gases, vapours and/or mists must be kept outside the enclosure, or else
sparks caused by the electrical components inside the enclosure could ignite this
mixture. To keep it out, pressurised air maintains a slightly higher pressure inside
the enclosure compared to the surrouding pressure. A pressurisation controller
monitors the pressure difference and alarms when it is too low. The controller also
purges the enclosure after closing the door to make sure any remaining potentially
explosive mixture is removed.
As the door is kept closed for most of the time, a water leak would fill the
enclosure and damage the electrical components. To avoid this from happening, a
leakage detection and control system, consisting of a level sensor and a
pneumatic solenoid valve on the water inlet, is part of the assembly.
B.1. Additional PRESSURISA-

TION
Components and CONTROLLER
Specifications CABLE
GLANDS
AIR OUTLET
(4X)
AIR LINE FOR
CONTROLLER
& ELECTRICAL
CABINET
CONTROL
VALVE FOR
PNEUMATIC
DIAPHRAGM
VALVE BRASS
3/4” BSP
INTERNALLY
THREADED
BRASS
3/4” BSP 2X AIR INLET
INTERNALLY FOR 1X
THREADED PNEUMATIC
VALVE 6x4MM
PNEUMATIC LEVEL SOLENOID & 1X FOR AIR
DIAPHRAGM SWITCH VALVE & NEEDLE PURGING
VALVE (LEAKAGE VALVE 8x6MM
SENSOR)
Power Supply 120 or 230Vac, 50/60Hz
Part Numbers 230Vac version: 060-TRM5531.88
120Vac version: 060-TRM5532.88
Dimensions (HxWxD) 1.94 x 1.18 x 0.70m (excl. water connections)
73/90
ATEX Coding II 3G
II: Device Group II, area’s other than mining
3: Category/protection level 3, safe for use in
normal operation
G: Gases, vapours or mists
Ex Marking Ex [pz] II T4 Ta≤40°C
Ex [pz] II: Protection concept, pressurised
enclosure
T4: Temperature Class T4, maximum surface
temperature must not exceed 135°C
Ta: Ambient temperature must not exceed 40°C
Special Conditions
The following special conditions are essential to ensure the safe operation
of the 3D TRASAR Assembly for Zone 2 Explosive Atmospheres
1. See general conditions in user’s manual F840
2. The minimum pressure of the purge medium about 5.5 up to 7 bars must be
provided and assured from the operator at the install location.
3. Do not change the Bypass- Code to “0000”.
4. The entering of the bypass code turns off the automatic pressure monitoring.
This is for use to maintenance of the opened enclosure. Use this bypass only if
it is sure, that no explosive atmosphere is in the environment.
5. The maximum surface temperature must not exceed 135°C (T4)
6. If the temperature at the cable glands exceeds 70°C, use only cables with a
higher specific working temperature than the detected ambient temperature.
7. Ex post installation of cable glands or the like must not change the protection
class of the housing (IP54 according EN 60529). The cable glands must be ex
proofed or made of metal or synthetic material incorporating the features:
protection class IP 65, cord grip and a minimum radius of curvature of 50 mm.
8. The Ex pz- system (or alarm lamp, alarm message system) has to be located
in a place, where a Ex p- failure can be recognized in a short time.
9. Discharging of flammable gases or liquids into the Ex p housing is not allowed.
10. The maximum temperature of the discharged cooling water is 70°C (max 70°C
for ATEX, 5-50°C for piping).
74/90
Pressure Monitoring and Air Purging
System Principle
PRESSURISATION
CONTROLLER
3D TRASAR ELECTRICAL
AIR CONTROL- CABINET
LER
P
P AIR OUTLET (4X)

115/230VAC
OUTSIDE NEEDLE VALVE

PRESSURE
NOZZLE
AIR
AIR PURGE VALVE WITH 5.5-7BAR
INTERNAL BYPASS
Components
OUTSIDE PRESSURISATION
PRESSURE CONTROLLER
AIR
3D TRASAR ELECTRICAL
CONTROL- CABINET
LER
AIR AIR
AIR AIR PURGE

115/230VAC VALVE WITH
INTERNAL
BYPASS
NEEDLE VALVE
AIR AIR
5.5-7BAR
Pressurisation Controller Power supply: 120 or 230Vac 48-62 Hz
Electrical outputs: 3x relay outputs, max 250Vac
6A (AC1), 1.2A (AC15), solenoid valve output as
mains power supply (fused)
Pressure range: 0…22mbar
Housing: IP54, HxWxD 120x122x90mm, painted
aluminium
Ambient temperature: -20...+40°C @ T6
-20...+60°C @ T5
Interface: LCD screen, languages: English,
German, French, Dutch, Spanish
Model: FS840
ATEX Coding: II 3 G
75/90
Ex Marking: EEx nAC [P] IIC T6 and T5,
Ex nAC [pz] IIC T6 and T5
Certfication No.: TÜV 03 ATEX 2095 X
Solenoid Valve Power supply: 120 or 230Vac
Type: NO (normally open)
ATEX Coding: II 2 G
Ex Marking: EEx m II T6, T5 and T4,
EEx em II T6, T5 and T4
Certfication No.: PTB 00 ATEX 2129 X
Needle Valve Connections: 1/4" BSP inner thread
Length: 46mm
Leakage Detection and Control

System Principle
120/230VAC TO 3DT SENSORS
DIAPHRAGM
VALVE
2 4
CONTROL
VALVE
1 3
LEAKAGE AIR SAMPLE

SENSOR 5.5-7BAR WATER
Components
120/230VAC
CONTROL
AIR VALVE
5.5-7BAR
SAMPLE
WATER
DIAPHRAGM LEAKAGE
VALVE SENSOR
Diaphragm Valve Seal material: PTFE/EPDM
Water connections: 25mm PVC solvent weld
Pilot pressure: >5.5bar
Model: 2030
Part No. Seal: TBD
Control Valve Power supply: 120 or 230Vac
Pressure: 2-10bar
Type: 4/2 way valve
Connections: 2x Inlet 6x4mm tubing connection,
76/90
2x Outlet 1/8” BSP internally threaded
Model: 5470
Part No.: TBD
Leakage Sensor Material: SS 1.4571
Contact: NC (normally closed), max 230Vac, 1A,
60VA
Length: 100mm
Liquid density: >0.8
Environment: IP65
Part No.: TBD
Other Components
Enclosure GRP, IP65, safety glass window, reduced surface
resistance < 109Ω, lockable door
Cable glands in the 22x M16 for 4-8mm cables
enclosure 6x M20 for 6-12mm cables
6x M20 for 10-14mm cables
2x M40 for 20-26mm cables
B.2. Additional Installation Electrical connections for the pressurisation controller, air purge valve and the air
control valve are shown below. The air control valve opens/closes the air flow to
Information the pneumatic diaphragm valve. The 3 components are either 120Vac or 230Vac.
L
90-240VAC
FROM 20A N
MCB PE
Xxx MA
CABINET
AIR
CONTROL
PRESSURE CONTROLLER VALVE 3 1
PE PE
2
1 2 3 4 5 6 7 8 9 10
OUTPUT 1
OUTPUT 2
L N N L
3 1
AIR LEAKAGE
PURGE SENSOR
VALVE 2
Do NOT add components inside the enclosure with an air volume of 6L (1%
of the enclosure) or greater as they require air purging.
77/90
B.3. Additional The 3D TRASAR controller does not require specific settings for ATEX Zone 2
environments.
Configuration
Information The pressurisation controller is configured with the following buttons:
Button Operation mode Configuration mode

Enter the menu Enter (as on pc)
- Move cursor to the right

(De)activate bypass * Move to next menu item
Toggle between display of current Move to previous menu
pressure, flow rate, remaining purge time item
and current state of purging system
* Activate the bypass mode (no purging after closing the door) only when it
is absolutely certain that no explosive atmostphere is present inside and
around the enclosure.
To (de)activate the bypass mode press the Up button on the pressurisation

controller. Use the Right , Up and Enter buttons to enter the By-Code
(see below settings). The screen will show ‘Bypass’ when activated. During
bypass mode no alarms will be generated. The red LED on the pressurisation
controller will be on.
78/90
The pressurisation controller is pre-configured with the highlighted settings in
the below table.
Parameter Setting Explanation
Language English Select from German, English, French,
Dutch, Spanish
Structur Purging Purg Y. The enclosure is air purged 5 times before
the message ‘Ex Ok’ appears
Purg N. The enclosure is not air purged. The
message ‘Ex Ok’ is shown
Auto Auto Y. The pressurisation controller automatically
calculates the air purge time from the air
pressure, the nozzle diameter and the
enclosure volume
Auto N. Air purge time is set manually
01 Func. None Relay output 1 not specified
O-Ex ok Relay output 1 is closed when pressure >
minimum
O-Bypas Relay output 1 is closed in bypass mode
O-Purg Relay output 1 is closed during air purge
O-Signal Relay output 1 is closed when pressure <
signal pressure
O-Pmax Relay output 1 is closed when pressure >
maximum
02 Func. None, O-Bypas, O-Purg, O-Signal & O-Pmax as ‘01
Func.’
O-Ex ok Relay output 2 is closed when pressure >
minimum
O1 no/nc. no Relay output 1 is normally open
nc Relay output 1 is normally closed
O2 no/nc. no Relay output 2 is normally open
nc Relay output 2 is normally closed
Param. Pur. Time 00:36:17 Calculated purge time 36 min, 17 sec,
based on volume of the enclosure,
minimum required pressure and nozzle
diameter. Manual entry only with ‘Auto N.’
Pur. Vol. 600dm3 The volume of the enclosure
Pre-Pres. 5.5bar The minimum required pressure
Nozzle 2mm The nozzle diameter
Min.Pres.P 7mbar Minimum pressure during air purge
Min.Pres.R 0.8mbar Minimum pressure during normal
operation
Max. Pres. 18mbar Maximum pressure during normal
operation
Codes M-Code 1234 Code to enter the main menu. 1234 is pre-
programmed. Cannot be deactivated with
0000.
By-Code 2345 Code to activate the bypass mode. Code
can be deactivated with 0000, but this
should not be done. 9999 disables the
bypass functionality. 2345 is pre-
programmed.
End Exit menu
79/90
B.4. Additional The following additional periodic maintenance tasks apply:
Maintenance • The seals in the ATEX enclosure have to be checked for damage, repaired or
and replaced if required. Electrical connections, especially in the pressurisation
Information controller have to be tightened.
• Cable glands and stopping plugs have to be checked for air leaks.
• Any repairs to the pressurisation controller have to be executed by the
supplier.
• The complete 3D TRASAR assembly must be inspected by a skilled person,
according to IEC 60079-2, EN 60079-14, this manual and other supplied
manuals.
B.5. Additional
Troubleshooting
Information
When the red alarm LED on the pressurisation controller blinks, the
pressure inside the enclosure is below the minimum pressure.
In bypass mode the red alarm LED is continuously on.
80/90
Appendix C.
3D TRASAR for
Reverse Osmosis
C.1. Principles of Operation The 3D TRASAR for Reverse Osmosis is based on the 3D TRASAR Starter. It
provides the following measurements:
Measurement Purpose Standard / Optional

TRASAR Anti-Scalant Dosing Standard
ORP Free-Chlorine level monitoring, Standard
Sulphite level monitoring
Turbidity Turbidity Monitoring Standard
pH pH monitoring Optional
Temperature Temperature compensation of Connection for sensor
TRASAR and pH measurements provided
The 3D TRASAR Starter controller provides a 4-20mA TRASAR reading to a PID

controller. The PID controller controls the Anti-Scalent dosing pump with a 4-20mA
control signal.
The dosing pump remote on/off contact input is connected to a relay of the 3D
TRASAR Starter controller. When the RO is not in operation, the relay opens and
the dosing pump stops. For this to occur, a contact signal from the RO has to be
connected to the interlock (remote on/off) contact input of the 3D TRASAR Starter
controller.
When the flow switch does not detect flow a flow alarm is generated (after a
delay). The alarm does not stop the dosing pump.
C.2. Components and

Specifications
Instrumentation Assemblies
Part no. 060-ROM3500.88 Part no. 060-ROM3501.88

Compact assembly, wall mounted Compact assembly, floor mounted
Dimensions (HxWxD) 060-ROM3500.88: 0.85 x 0.85 x 0.30m
060-ROM3501.88: 1.75 x 0.85 x 0.70m
Installation Indoor
81/90
Start-up Kit Item code Description
6027251 3D TRASAR for RO start-up kit *
* Start-up kit includes:

Item code Description Qty
460-S0940.75 3D TRASAR calibration solution, 1L 1
500-P0120.88 Plastic Beaker, 500ml 3
500-P2817.88 Flow cell cleaning brush 1
460-S0800.74 10% Sulphuric Acid cleaning solution, 1
50ml
500-P2147.88 Plastic syringe, 60cc 3
Components BALL VALVE

3D TRASAR PVC SOLVENT
STARTER 3DT STARTER CONNECTION
CONTROLLER FLUOROMETER 25MM
BALL VALVE
FLOW METER &

SWITCH
DIAPHRAGM
VALVE
CONTROL BOX OPENING FOR ORP OPENING ADAPTER

WITH PID TEMPERATURE SENSOR FOR PH UNION
CONTROLLER SENSOR SENSOR PVC SOLVENT
CONNECTION
25MM
Water flow >120L/h
Water pressure < 5 bar @ 40ºC
Water temperature 5-50ºC
See §2.2. Sensors & Piping for the specifications of the ORP sensor, optional pH
sensor, flow meter & switch, controller and fluorometer. The specifications of the
fluorometer are for the ‘normal’ fluorometer; the Starter fluorometer from the 3D
TRASAR for RO, does TRASAR, cell fouling and turbidity measurements.
82/90
PID Controller
Make Yokogawa
Type UT320 (single coloured display) or UT321 (two
coloured display)
C.3. Installation
General See §3.2. General.
Plumbing For dimensions, water connections and water flow see §Instrumentation
Assemblies, p.81 and §Components, p.82.
Sensors See §3.4. Sensors and §Components, p.82 for the location of the sensors.
Dosing Pump
)
A Nalco labelled DME dosing pump, e.g. a DME2, should be used to dose the
Anti-scalent. Make sure the DME pump is equipped with a multi-function
valve (or a separate pressure relief valve and back pressure valve) and a
control cable.
Alternatively a dosing pump with a 4-20mA input and a potential free remote on/off
input can be used.
Typical installation FROM MULTI MEDIA

FILTER OR OTHER PRE- RO SYSTEM
TREATMENT
CARTRIDGE
FILTER
120L/H
MULTI-
FUNC-
DOSING DRAIN
TION
PUMP
VALVE
NALCO PORTA-FEED TANK

WITH PERMACARE
ANTI-SCALANT
Electrical See §3.7. Electrical. Disregard the Conductivity sensor. The pH sensor is optional
but not pre-wired. Additional electrical connections and wiring, specific to the 3D
TRASAR for RO, are shown below.
83/90
Signals to Dosing Pump
(Pre-wired between 3D TRASAR Starter Controller and PID Box)
BLOWDOWN RELAY
90-240VAC
4-20MA OUTPUT 2.5A N PE L

(POWERED)
TB17 1+ 1- TB6 1 2 3 4 5
PID CONTROLLER
4-20MA 4-20MA OUTPUT CONTROL

INPUT (POWERED) SIGNAL
12+ 13- 16+ 17-
PID BOX 12+ 13- 16+ 17- 18 19
BROWN
BLACK
GRAY
BLUE
DOSING PUMP
MODEL DME
L N PE
POWER SUPPLY
Data Logging of 4-20mA PID Control Signal (Pre-wired)

4-20MA INPUT
TB16 1+ 1-
PID CONTROLLER
4-20MA OUTPUT
(POWERED)
14+ 15-
PID BOX 14+ 15-
Flow Switch (Pre-wired) and Interlock

FLOW INTER- NOTE: IF NOT
LOCK CONNECTED,
TB10 - + - + 3- 3+ 4- 4+ DOSING PUMP
CONTINUES WHEN
RO IS OFF
- +
FLOW RO
SWITCH
PRE-WIRED
WITH BRIDGE
84/90
C.4. Start-Up
Before Start-Up See §4.1. Before Start-Up. Disregard the Nalco Bio Index.
Procedure See §4.2.1. 3D TRASAR Controller & Sensors. Disregard the topics conductivity
sensor and Start-up mode. The pH sensor is optional.
1. When the PermaCare Anti-Scalent is already dosed before the installation of
the 3D TRASAR for RO, start by monitoring the Anti-Scalent concentration
with the 3D TRASAR for RO for 1-2 weeks so see the current control pattern.
2. Connect the dosing pump (§Dosing Pump, p.83) to the 3D TRASAR for RO
controller (§Signals to Dosing Pump, p.84)
3. Set a setpoint in the PID controller (§PID Controller Configuration, p.86),
configure the 3D TRASAR controller (§Controller Configuration, p.85) and the
dosing pump (§DME Dosing Pump Configuration, p.88)
4. Perform an autotune on the PID controller (§Operational Parameters, p.87)
5. Check the control pattern and, if available, compare to the previous pattern.
C.5. Operation
Controller Configuration See §5.1. Controller Configuration. The required settings are as follows:
Required Parameters
Parameter Setting
Conductivity Not installed
ORP Monitor only
pH / Temperature Not installed or Monitor only (option)
Inhibitor Feed based on TRASAR
No. of Inhibitor Products 1
Product Name Other, e.g. PC191T, TRASAR Product Factor 25,
Polymer Product Factor 0, Density 1.36 gr/cm3
TRASAR High/Low Alarm Depending on setpoint and range
ORP High/Low Alarm Depending on setpoint and range
Anti-Scalent (e.g. PC191T) 0min
Pump Timout Limit
Anti-Scalent (e.g. PC191T) Fixed Failsafe Duty
Pump Alarm Response
Initial Smart Duty 0%
4-20mA output 1 #1 = TRASAR Product, 4mA=0ppm, 20mA=50ppm
4-20mA input 1 4mA=0, 20mA=100, Units=%, High Alarm=100,
Low Alarm=0
Blowdown Relay Manual on, 0hrs, 0mins. Requires a live connection
between pc and controller, directly or via modem.
Can also be set on controller
Not used parameters, but required by Configurator

Parameter Setting
Holding Time Index 1hr
System Volume 1m3
Tower Delta T 1°C
Make-up Conductivity 1µS/cm
Cost of Water 0
TAG Background 0 / m3
TAG Ratio 1.3
TAG Background Online real-time correction
Correction Method
Inhibitor Setpoint 1ppm as Product
Control Range 0.1ppm
Pumping rate 1L/hr
85/90
PID Controller Configuration The PID controller comes pre-configured, except for the setpoint. This section
shows the pre-configured settings and how to change settings.
PID Controller
PROCESS VALUE (PRESENT VALUE)

PV PARAMETER TYPE
SETPOINT
SP
PARAMETER
SP2 3 4 MAN
AUTOMATIC / MANUAL INDICATION
AL 1 2 3
ALARM INDICATION
AUTOMATIC / MANUAL
A/M ENTER/SET
SET KEYS
)
SP2, 3 and 4 are not used, only setpoint 1 (SP) is used.
Leave unit in automatic mode. Change with [A/M] if required.
Button Description
Back to operating display (3 sec)
Next parameter
Accept setting
Change setting in menu’s
Change setpoint when operating display is shown
PID Controller Menu Structure
Operating
Display
3 Sec
OP.PA STUP
FUNC I/O
Operating Functional Input/Output

Parameters Parameters Parameters
PID 1 GR
Operating PID
Parameters Parameters
86/90
Input/Output Parameters
Parameter Setting Description
IN 41 Input type (code 41=1-5V signal)
Unit - Selects units for the PV screens. Not Shown when
input is a voltage signal
RH 5 Maximum value of PV input range
RL 1 Minimum value of PV input range
SdP 1 Number of decimal places displayed in PV screen
SH 50 Maximum value of PV input scale
SL 0 Minimum value of PV input scale
BSL Off Selection of PV input burnout action
OT 2 Output type. Type 2 directs the output to the pump
RET 1 Retransmission output type. Type 1 directs the
signal to the PV screen
RTH 50 Maximum value of retransmission output scale
RTL 0 Minimum value of retransmission output scale
DIS 1 Controls on/off and auto/manual functions. The
default value for the 3DT for RO should be 1
Functional Parameters
SPH 50 Setpoint range high (default=SH)
SPL 0 Setpoint range low (default=SL)
A11 1 Alarm 1 type
A12 2 Alarm 2 type
A13 1 Alarm 3 type
Hy1 0.1 Hysteresis of alarm 1
dy1 0 Alarm 1 delay timer
Ct 30 Control output cycle time (on/off control)
Po 0 Preset output
Cmd 0 PID control mode
Zon off Zone PID selection
Ar Auto Anti-reset windup
Tmu 0 Ramp-rate time unit
Test 0 (This parameter cannot be set)
Operational Parameters
LL on LL communication interface selection
A1 50 Alarm 1 trigger point
At off Autotune. Function sets the P, I & D factors of
the PID controller. Change to 1 during start-up, to
start the autotune. The MAN light will blink until
autotune finishes automatically. During autotune the
dosing pump will go to max and min capacity.
SC off Super function (off, 1, 2, 3)
87/90
SP.no 1 Target setpoint value (1,2,3)
PID Accesses PID menu
Press [▲]. You will see “1 Gr”; press [ENT]
1.P = proportional value; press [ENT]
1.I = integral value; press [ENT]
1.D = derivative value
For tighter control, change P to 5 * P
FL 15 Input filter (0-120 seconds)
Bs 0 Input bias
Upr off Setpoint up ramp rate
Dnr off Setpoint down ramp rate
OH 100 Output range high (0-100%)
OL 10 Output range low (0-100%)
Dr 0 Direct/Reverse action (0=reverse)
Orb 0.3 On/Off control detection band
OrH 100 On/Off control high limit (0-100%)
OrL 0 On/Off control low limit (0-100%)
Or 0 On/Off rate
1.SP Setpoint 1
DME Dosing Pump Configuration The DME dosing pump manual shows how to navigate the menu structure.
Required DME dosing pump settings

Parameter Setting
Maximum Capacity 2 * feed dosage (2 * PID setpoint 1)
Control Analogue, 4-20mA
Input NC (normally closed)
Calibration See §5.2. Calibration to calibrate the Fluorometer, the ORP sensor and the
optional pH sensor.
Internet Communications See §5.4. Internet Communications
C.6. Maintenance
Preventative Maintenance See §6.1. Preventative Maintenance Schedule. Disregard the conductivity sensor,
corrosion sensors and the pellet feeder. The pH sensor is optional.
Spare Parts See §6.3. Spare Parts. Disregard the conductivity sensor, corrosion sensors and
the pellet feeder. The pH sensor is optional.
C.7. Troubleshooting See §7. Troubleshooting.
88/90
89/90
Nalco Operations North America: 1601 West Diehl Road • Naperville, Illinois 60563-1198 • USA
Europe: ir.G.Tjalmaweg 1 • 2342BV Oegstgeest • Netherlands
Pacific Pte, Ltd: 2 International Business Park • #02-20 The Strategy Tower 2 • Singapore 609930
Latin America: Av. das Nações Unidas 17.891 • 6° Andar 04795-100 • Sao Paulo • SP • Brazil
www.nalco.com
TRASAR, NALCO and the logo are Registered Trademarks of Nalco Company
©2004-2007 Nalco Company All Rights Reserved OM3DTEU01-E V2.2 6-07
90/90

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F

2. Components & Specifications .............................................................. 17

Appendix A. 3D TRASAR for High Fouling Applications .............................. 67

Appendix B. 3D TRASAR for Explosive Atmospheres .................................. 73

Appendix C. 3D TRASAR for Reverse Osmosis ............................................ 81

3D TRASAR Starter allows you to enter the 3D TRASAR programme at a starter

Control Capability 3DT 3DT Starter

) This manual describes all capabilities of the 3D TRASAR systems.

Polymer consumption gives a good indication of increased stress in the system.

Nalco Scale Index Relative scaling stress level

Background fluorescence: To compensate for external fluorescent influences,

Diagrams Tagged Polymer & TRASAR in 1 Product

Tagged Polymer & TRASAR in 2 Products

ACTIVE PRODUCT, BASED ON TAGGED POLYMER

Tagged Polymer & TRASAR in 2 Products

BLOW DOWN VALVE

1.2.3. Nalco Scale Index, TRASAR

• Conductivity or pH • Product 1 or 2 set point • Change any product or

1.2.4. pH Measurement, Acid or

(ACTION IS REVERSE FOR CAUSTIC DOSING PUMP)

1.3. Corrosion Control

For measurement and control, see §1.2.1, p.5.

Nalco Bio Index Biological Stress Level

Bio-reporter is dosed to the cooling system in:

Bio-Reporter & System Volume

Diagrams Bio-reporter in solid form

Bio-reporter in liquid form

Control Bio-Reporter Pellet

The number of pellets to be fed is calculated with bio-reporter concentration and

Control Timer setting Values

Settings Description Ox(1) NO(2)

conductivity limit conductivity limit or time limit has

Feed ORP Biocide feed until only the time limit 9 8

limit has been reached or until the either

been reached. Blow down can be

dosing pump not connected to the

time limit lockout until only the

reached or until either

until the time limit,

value reaches levels 5% above ORP

Flow Detection & Interlock Signal Details Control

Temperature Water temperature is measured by the RTD (resistance temperature detector)

Calculated Values Values Calculations based on

* Can be disabled; pump rates are not entered.

CONFIGURATION; DATA DOWNLOAD REMOTE

DATA E-MAILS, EVERY 6 HOURS

REMOTE ON/OFF (INTERLOCK)

4-20mA outputs: §4-20mA Wiring, p.32

More information: §Relay Timeout Alarms, p.65

Alarm listing: §7.1, p.62

Part no. 060-TRM5500.88 Part no. 060-TRM5501.88

Part no. 060-TRM5511.88 Part no. 060-TRM5521.88

3D TRASAR Part No. Equivalent 3D TRASAR Starter Part No.

CORROSION PH & ORP CORROSION

BALL VALVE Y-STRAINER 2X ADAPTOR UNION

3D TRASAR Controller, Model 5000 CORROSION CORROSION

Electrical Cabinet WIRING

For 3D TRASAR instrumentation assemblies that are supplied with an electrical

The inductive conductivity sensor reading is not affected by fouling.

The pH reading is temperature compensated via the conductivity sensor RTD.

Corrosion Sensor (2x)

Water velocity Flow in 25mm pipe *

(FLOAT ABOVE SWITCH = FLOW)

2.3. Pellet Feeder BOLT

STAGE 1 STAGE 2 STAGE 3 & 4

STAGE 1 STAGE 2 STAGE 3 & 4