Nalco 3D TRASAR Series User manual

This manual covers the following
models:
• 3D TRASAR 5500 Series
• 3D TRASAR 3500 Series
• 3D TRASAR Technology for
Closed Loop Applications
• 3D TRASAR Technology for
High Fouling Applications
• 3D TRASAR Models for the
Pacific
3D TRASAR®
Technology
Installation and Operation Manual
Version 8.0

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany i
Technical Help
(630) 305-CHEM
TRASAR Technology License
Nalco Company
1601 W. Diehl Road
Naperville, IL 60563
Trademarks
PRISM, Vantage, 3D TRASAR, STA-BR-EX, ACTI-BROM, Nalco and the logo are Registered
Trademarks of Nalco Company.
Towerbrom is a registered trademark of Occidental Chemical Corporation.
Nalco has one or more patents and related know-how, which pertain to either TRASAR or 3D
TRASAR method of use or practice of technology (“Tracer Technology”). Buyer’s purchase of
equipment, software and chemicals from Nalco conveys to Buyer a non-assignable and non-trans-
ferable express license to practice Tracer Technology that correlates with equipment, software and
chemicals that Buyer chooses to purchase from Nalco for its water treatment facilities needs for the
practice of Tracer Technology. Such license, however, terminates upon Buyer’s discontinued use of
Nalco chemical(s) with Tracer Technology, unless, Buyer negotiates a separate express license
agreement with Nalco.

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany TOC-1
TechnicalHelp
(630) 305-CHEM
Table of Contents
Section 1: Introduction
1.1 About the 3D TRASAR®5500................................................................................1-1
1.2 About this Manual .................................................................................................1-1
1.3 3D TRASAR 3500 and 3D TRASAR 5500 Models and Optional Components ..1-1
1.4 3D TRASAR 3500 and 3D TRASAR 5500 Overview ............................................1-3
1.5 How the 3D TRASAR 5500 System Works ..........................................................1-4
1.5.1 Fluorometer ...............................................................................................................1-4
1.5.2 3D TRASAR Scale Control, 3D TRASAR Bio-Control, & NCM Corrosion Technology1-4
1.5.3 Data Storage / Reporting and Communications .........................................................1-5
1.6 Safety .....................................................................................................................1-6
Section 2: Installation and Start-Up
2.1 STEP 1 - Unpack and Identify...............................................................................2-2
2.1.1 Identify Hardware Model ............................................................................................2-2
2.1.2a Pre-Installed Items (all models)..................................................................................2-4
2.1.2b Pre-Installed Items (3D TRASAR 5500 models only) .................................................2-4
2.1.3a Items Requiring Assembly (all models) ......................................................................2-4
2.1.3b Items RequiringAssembly (3D TRASAR 5500 models only)......................................2-4
2.1.4 Pellet Feeder Assembly (Optional).............................................................................2-5
2.1.5 Items Shipped Separately ..........................................................................................2-5
2.1.5a 3D TRASAR Starter Upgrades ..................................................................................2-5
2.1.5b 3D TRASAR Start-up and Maintenance Kits..............................................................2-5
2.2 STEP 2 - Mount the Controller..............................................................................2-6
2.2.1 General Instructions...................................................................................................2-6
2.2.2 3D TRASAR Controller Dimensions ..........................................................................2-7
2.2.3 Wall Mounting Templates......................................................................................... 2-11
2.2.4 Frame Mount Template ............................................................................................2-14
2.3 STEP 3 - Install Bio-reporter Feeder ..................................................................2-15
2.3.1 InstallBio-reporterPellet Feeder .............................................................................. 2-15
2.3.2 InstallLiquid Bio-reporterPump ............................................................................... 2-17
2.4 STEP 4 – Plumb Controller.................................................................................2-18
2.4.1 Sample Point Selection ............................................................................................ 2-18
2.4.2 3D TRASAR 5500 Inlet Water Plumbing.................................................................. 2-19
2.4.3 3D TRASAR 5500 Outlet Water Plumbing ...............................................................2-20
2.4.4 Chemical Feed Pumps ............................................................................................2-21
2.4.5 Typical Installation Drawing ...................................................................................... 2-22
2.5 STEP 5 – Plumb Bio-reporter Feeder ................................................................2-23
2.5.1 PelletFeeder Plumbing ............................................................................................ 2-23
2.5.2 Pellet Feeder Best Practices.................................................................................... 2-24
2.5.3 Liquid Bio-reporter Plumbing ....................................................................................2-24
2.6 STEP 6 – Install Probes ......................................................................................2-25
2.6.1 Fluorometer Installation ............................................................................................2-26
2.6.2 pH Probe Installation ................................................................................................ 2-27

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany TOC-2
TechnicalHelp
(630) 305-CHEM
2.6.3 ORPProbe Installation............................................................................................. 2-28
2.6.4 Conductivity Probe Installation .................................................................................2-29
2.6.5 NCM Corrosion Probe Installation............................................................................ 2-30
2.7 STEP 7 - Wiring ...................................................................................................2-32
2.7.1 General Information ................................................................................................. 2-32
2.7.2 Controller Box Layout...............................................................................................2-33
2.7.3 Controller Wiring Details .......................................................................................... 2-34
2.7.4 Junction Box Layout ................................................................................................2-36
2.7.5 Junction Box Details ................................................................................................2-37
2.7.6 System Power Connections..................................................................................... 2-38
2.7.7 Internal Power Connections...................................................................................... 2-38
2.7.8 Control Relay Connections - Powered (120 VAC fused @ 2.5 amps)....................... 2-39
2.7.9 Control Relay Connections - Non-Powered (fused @ 2.5 amps).............................. 2-40
2.7.10 Control Relay Connections - Termination Details ..................................................... 2-41
2.7.11Pellet Feeder Connections .......................................................................................2-43
2.7.12 System Probe Connections .....................................................................................2-43
2.7.13 AnalogI/O Connections ........................................................................................... 2-45
2.7.14 Factory Wired Digital Inputs..................................................................................... 2-46
2.7.15 User Wired Digital Inputs ......................................................................................... 2-46
2.7.16 Alarm Output Connections.......................................................................................2-47
2.7.17 Phone Line Connections .......................................................................................... 2-47
2.7.18 Ethernet (Direct Connect to 3D TRASAR 5500).......................................................2-48
2.7.19 LAN Connections.....................................................................................................2-48
2.7.20 SCADA Connections (Modbus RTU)....................................................................... 2-48
2.7.21 Nalco Global Gateway.............................................................................................. 2-48
2.8 STEP 8 – Calibration & System Checkout ........................................................2-49
2.8.1 EstablishSampleFlow & ApplyPower......................................................................2-49
2.8.2 Calibrate Probes ...................................................................................................... 2-50
2.8.3 Checkout Control Relays ......................................................................................... 2-51
2.9 STEP 9 - Start-up System ...................................................................................2-52
Section 3: 3D TRASAR Configurator
3.1 PC system requirements ......................................................................................3-1
3.2 Installing the software ..........................................................................................3-1
3.3 Configurator support ............................................................................................3-2
3.3.1 Sample Help Screen ..................................................................................................3-2
3.3.2 Sample Search Screen ..............................................................................................3-2
Section 4: Controller Settings
4.1 3D TRASAR 3500 and 5500 Control Unit Overview...............................................4-1
4.1.1 The Display Panel......................................................................................................4-1
4.1.2 The Keys ...................................................................................................................4-1
4.1.3 The Graphical Icons...................................................................................................4-2
4.2 Menu, Information, Actions and Alarms Flow Diagram.......................................4-3

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany TOC-3
TechnicalHelp
(630) 305-CHEM
4.3 The Menu Key .......................................................................................................4-4
4.3.1 Password Screen.......................................................................................................4-4
4.4 Control Settings Submenu...................................................................................4-4
4.4.1 Background Correction Screen..................................................................................4-5
4.4.2 TRASAR (Relay 1) Product Screen...........................................................................4-6
4.4.3 Tagged Polymer (Relay 2) Product Screen................................................................4-6
4.4.4 Oxidizing Biocide Screen ...........................................................................................4-6
4.4.5 BlowdownScreen .......................................................................................................4-6
4.4.6 pH Screen..................................................................................................................4-6
4.5 Alarm Settings Submenu......................................................................................4-7
4.5.1 System Alarms Screen ..............................................................................................4-7
4.5.2 Control Alarms Screens.............................................................................................4-7
4.5.3 Performance Alarms Screen......................................................................................4-7
4.5.4 Relay Alarms Screens ..............................................................................................4-8
4.5.5 4-20 mA Alarm Screen...............................................................................................4-8
4.6 Preferences Submenu..........................................................................................4-9
4.7 Network Submenu ..............................................................................................4-10
4.8 System Information Submenu ...........................................................................4-10
4.9 The Information Key ........................................................................................... 4-11
4.9.1 System Performance Screens................................................................................. 4-11
4.9.2 Operating Data Screens .......................................................................................... 4-12
4.9.3 Product Usage Screens...........................................................................................4-12
4.9.4 Water and Energy Screens...................................................................................... 4-13
4.9.5 Plot Data Screens....................................................................................................4-13
4.9.6 Control Methods Screens ........................................................................................ 4-14
4.9.7 Timer Status Screens .............................................................................................. 4-15
4.9.8 External Inputs Screens........................................................................................... 4-15
4.9.9 Product Factors Screen........................................................................................... 4-15
4.9.10 Diagnostic Data Screen ...........................................................................................4-16
4.10 The Actions Key ..................................................................................................4-17
4.10.1 Password Screen..................................................................................................... 4-18
4.10.2 Cleanand CalibrateScreen ..................................................................................... 4-18
4.10.3 Fluorometer Calibration Screens.............................................................................. 4-19
4.10.4 pH Calibration Screens ............................................................................................ 4-20
4.10.5 ORP Calibration Screens ......................................................................................... 4-21
4.10.6 Conductivity Calibration Screens ............................................................................. 4-22
4.10.7 Probe Calibration/ Maintenance List ........................................................................4-25
4.10.8 Manual Relay Control Screens ................................................................................4-26
4.10.9 Pumping Rates Screens .......................................................................................... 4-27
4.10.10 Slug Feed Biocide Screens...................................................................................... 4-28
4.10.11System Startup Screens.......................................................................................... 4-29
4.10.12 Test Email Screen.................................................................................................... 4-29
4.10.13 Service Email Screen............................................................................................... 4-29
4.11The Alarms Key ...................................................................................................4-30
4.11.1 Sensor Alarms .........................................................................................................4-30

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany TOC-4
TechnicalHelp
(630) 305-CHEM
4.11.2 System Alarms ........................................................................................................4-30
4.11.3 Communication Errors............................................................................................. 4-31
4.11.4 Performance Alarms ................................................................................................4-31
4.11.5 Control Alarms ......................................................................................................... 4-31
4.11.6 Relay Timeout Alarms..............................................................................................4-32
4.11.7 AnalogAlarms.......................................................................................................... 4-32
4.11.8 Failsafe Mode ..........................................................................................................4-32
4.11.9 Startup Mode ...........................................................................................................4-32
Section 5: 3D TRASAR Scale Control
5.1 Nalco Scale Index (NSI) Measurement ................................................................5-1
5.1.1 3DTRASAR Scale BlowdownControl – UsesNSI to Adjustthe Blowdown Setpoint...5-1
5.1.2 3D TRASAR Scale Tagged Polymer Control – Uses NSI toAdjust the Tagged Polymer
Setpoint.............................................................................................................................5-1
5.2 3D TRASAR Scale Blowdown Control ................................................................5-2
5.2.1 3D TRASAR Scale Blowdown Control: 1-Drum Program Overview............................5-2
5.2.2 Start-Up Procedure for 1-Drum 3D TRASAR Scale Blowdown Control ......................5-3
5.2.3 3D TRASAR Scale Blowndown Control: 2-Drum Program Overview ..........................5-5
5.2.4 Start-up Procedure for 2-Drum 3D TRASAR Scale Blowdown Control .......................5-6
5.3 3D TRASAR Scale Tagged Polymer Control ......................................................5-9
5.3.1 3D TRASAR Scale Tagged Polymer Control: 2-Drum Program Overview .................5-9
5.3.2 Start-up Procedure for 2-Drum 3D TRASAR Scale Tagged Polymer Control........... 5-10
5.4 3D TRASAR Scale Control - Frequently Asked Questions ..............................5-13
Section 6: 3D TRASAR Bio-Control and 3D TRASAR Bio-Shock Mode
6.1 Nalco Bio-Index Measurement (NBI) ...................................................................6-2
6.2 Oxidizing Biocide Application and Slug Feeds ..................................................6-2
6.2.1 3D TRASAR Bio-Control and Overlaid Ox Slugs ...........................................................6-3
6.2.2 3D TRASAR Bio-Shock Mode .......................................................................................6-4
6.2.3 Ox-slug/shock control settings ......................................................................................6-4
6.3 Bio-reporter Selection ..........................................................................................6-5
6.4 3D TRASAR Bio-Control/3D TRASAR Bio-Shock Start-Up Procedure..............6-5
6.5 Pellet Feeder Operation ........................................................................................6-8
6.6 Filling the Pellet Feeder ........................................................................................6-9
6.7 Bio-reporter Initial System Dosing.....................................................................6-10
6.8 Pellet Feeder Cleaning........................................................................................6-11
6.9 Pellet Feeder Maintenance .................................................................................6-11
6.9.1 CleaningPellet Feeder ExitTube ............................................................................. 6-12
6.9.2 Tighten Valve Seat ...................................................................................................6-13
6.9.3 Pellet Shield Replacement ....................................................................................... 6-15
6.10 3D TRASAR Bio-Control & 3D TRASAR Bio-Shock FAQ’s ..............................6-18
Section 7: Communication and Data Management
7.1 3D TRASAR Optimizer ..........................................................................................7-1
7.2 3D TRASAR Configurator.....................................................................................7-1

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany TOC-5
TechnicalHelp
(630) 305-CHEM
7.3 3D TRASAR 5500 Controller ................................................................................7-1
7.4 SCADA Systems....................................................................................................7-1
7.5 3D TRASAR Web...................................................................................................7-2
7.5.1 3D TRASAR Web Set Up ..........................................................................................7-2
7.5.1a Create/Edit Users ......................................................................................................7-3
7.5.1b Assign Controllers (Data Sources).............................................................................7-4
7.5.1c Manage Controller (Data Source) Setup Information ..................................................7-5
7.5.2 3D TRASAR Web Data .............................................................................................7-6
7.5.3 3D TRASAR Reports.................................................................................................7-7
7.5.4 3D TRASAR Web Alarms..........................................................................................7-8
7.6 Vantage V100.........................................................................................................7-9
7.6.1 Import 3D TRASAR Data into Vantage V100 .............................................................7-9
7.6.2 Vantage V100 3D TRASAR EZ Reports .................................................................. 7-11
7.6.3 Vantage V100 3D TRASAR Specification Limits ...................................................... 7-13
7.7 Nalco Global Gateway.........................................................................................7-15
Section 8: Maintenance
8.1 Maintenance Schedule .........................................................................................8-1
8.2 Clean Fluorometer Flow Cell................................................................................8-2
8.3 Check/replace Fluorometer Desiccant ................................................................8-2
8.4 Check Sensor Calibration ....................................................................................8-2
8.5 Probe Replacement Schedule .............................................................................8-3
8.6 Cleaning Basket / Wye Strainer............................................................................8-3
8.7 Pellet Feeder Maintenance ...................................................................................8-3
8.8 Check / Refill Pellet Feeder...................................................................................8-3
Section 9: Troubleshooting
9.1 General Troubleshooting......................................................................................9-1
9.2 Alarm Screen Troubleshooting ............................................................................9-7

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany TOC-6
TechnicalHelp
(630) 305-CHEM
Appendix A: Specifications
Appendix B: Drawings
Appendix C: Replacement Parts/Accessories
Appendix D: Air Purging System
Appendix E: SCADA and LAN
Appendix F: 3D TRASAR Starter Upgrade Procedures
Appendix G: 3D TRASAR Technology for Closed Loop Applications
Appendix H: 3D TRASAR Technology for High Fouling Applications
Appendix I: Halogen Analyzer Control
Appendix J: 3D TRASAR Models for the Pacific
Appendix K: Warranty Policy
Glossary

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 1-1
TechnicalHelp
(630) 305-CHEM
!
Section 1: Introduction
1.1 About the TRASAR®3500 and 5500
The Nalco 3D TRASAR®5500 is the most advanced water treatment control system on the market
today. The design is based on years of field research and a broad base of industry experience and
application. The introduction and use of the 3D TRASAR 5500 will dramatically change the standard
for cost-efficient and reliable cooling tower control.
The Nalco 3D TRASAR Starter 3500 makes 3D TRASAR technology more accessible. It is customizable
to meet specific user needs, yet offers the flexibility for future upgrades to utilize all features of 3D
TRASAR.
Both systems are simple to use and feature powerful control algorithms that ensure tighter control,
more optimal performance, and requires a minimum of human oversight and testing. The end result is
a better, safer, more reliable system that runs more efficiently.
1.2 About this Manual
This manual is a simple, step-by-step description of what you need to do to get your new system up
and running in the shortest amount of time.
Keep in mind, as you begin, that your Nalco Technical Representative has already done some of the
preliminary configuration work for you. Don’t hesitate to contact that person if you have a question or
problem, as they are familiar with your situation and can be very helpful in addressing any specific
needs you may have.
Additional help is available at 630-305-CHEM (2436).
1.3 3D TRASAR Starter 3500 and 3D TRASAR 5500 Models and
Optional Components
3D TRASAR Starter and
3D TRASAR comparison.
3D TRASAR
Starter 3D TRASAR
3D TRASAR Starter Fluorometer X
3D TRASAR 6 channel Fluorometer X
Modem X X
Web Accessibility X X
Conductivity Measurement and Control X X
pH Measurement and Control X
ORP Measurement and Control X
Biocide Timers X X
3D TRASAR Scale Control X
3D TRASAR Bio-Control X
Nalco Corrosion Measurement X

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 1-2
TechnicalHelp
(630) 305-CHEM
1.3 3D TRASAR Starter 3500 and 3D TRASAR 5500 Models and
Optional Components (con’t)
The 3D TRASAR 3500 and 5500 are available in a variety of models. Talk to your Nalco
representative about which model is right for your application.
Enclosed Frame Mount unit
with Junction Box
and Pellet Feeder
3D TRASAR
Frame Mount unit
3D TRASAR Starter
Wall Mount unit
3D TRASAR
Starter Models 3D TRASAR ModelsDescription
060-TR3500.88 060-TR5500.88 Wall Mount small b ackboard
060-TR3501.88 060-TR5501.88 Frame Mount small backboard
060-TR3510.88 060-TR5510.88 Wall Mount w/ Junctio n B ox
060-TR3511.88 060-TR5511.88 Frame Mount w/ Juncti on Box
060-TR3520.88 060-TR5520.88 Enclosed Wall Mount w/ Juncti on Box
060-TR3522.88 060-TR5522.88 Enclosed Wall Mount w/J-B ox and
pre-installed Nalco Global Gateway
060-TR3521.88 060-TR5521.88 Enclosed Frame Mount w/ Juncti on Box
060-TR3523.88 060-TR5523.88 Enclosed Frame Mount w/J-Box and
pre-installed Nalco Global Gateway
060-TR3530.88 060-TR5530.88 Air Purged Wall Mount w/ Juncti on Box
060-TR3532.88 060-TR5532.88 Air Purged Wall Mount w/J-B ox and
pre-installed Nalco Global Gateway
060-TR3531.88 060-TR5531.88 Air Purged Frame Mount w/ Juncti on B ox
060-TR3533.88 060-TR5533.88 Air Purged Frame Mount w/J-B ox and pre-
installed Nalco Global Gateway
3D TRASAR models for High Fouling Applications
060-TR5515.88 Wall Mount for Hi gh Fouling A pplications
060-TR5516.88 Frame Mount for Hi gh Fouling Applications
060-TR5525.88 Enclosed Wall Mount for Hi gh Fouling
Applications
060-TR5526.88 Enclosed Frame Mount for Hi gh Fouling
Applications
Accessories
060-TR5120.88 Bio-Reporter Pellet Feeder, for systems
greater than 12,000 gal
141-PJ4035.88 Liquid Bio-Reporter Pump, Iwaki, for
systems 3,000 to 12,000 gal
6008505 Liquid Bio-Reporter Pump, Grundfos, for
systems less than 3,000 gal
060-TR5540.88 High Pressure Water Reinjection System
060-NGG100.88 Nalco Global Gateway US (Domestic) with
1-year contract
060-NGG200.88 Nalco Global Gateway International with 1-
year contract
500-TSRKITSTR.88TR3500 Start-Up Calibration Kit
500-TSRKIT. 88 TR5500 Start-Up Calibration Kit

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 1-3
TechnicalHelp
(630) 305-CHEM
1.4 3D TRASAR 3500 and 5500 Overview
The 3D TRASAR 5500 utilizes state-of-the-art optical fluorescence sensing to monitor and control
chemical feed. The central component of the system is a rugged 6-channel fluorometer that mea-
sures:
• TRASAR Chemical Residuals
• Polymer Chemical Residuals
• Bio-reporter Chemical Residual
• Biological Activity
• Instrument Fouling
• Background Fluorescence
These measured variables are used in control algorithms that anticipate and respond to system
stresses before costly scaling and fouling can occur.
The 3D TRASAR Starter 3500 utilizes proven TRASAR technology to monitor and control chemical
feed. Features of the 3D TRASAR 5500 are available as upgrades to the 3D TRASAR Starter
3500.
Scale/Fouling
Corrosion
Microbio
Biocides Inhibitor I Inhibitor IIAcid PumpBlowdown
Valve
Communications
Pager
Cell phone
Palm
Laptop
DCS
Web
Knowledge Management
Vantage V100
Performance-Based Control
Save energy and water
Reduce manpower
Increase throughput
Improve product quality
Extend equipment life
Enhance safety
Predict cash needs
(3D Bio-Control)
(3D Scale Control)
(NCM100)
Scale/Fouling
Corrosion
Microbio
Biocides Inhibitor I Inhibitor IIAcid PumpBlowdown
Valve
Communications
Pager
Cell phone
Palm
Laptop
DCS
Web
Knowledge Management
Vantage V100
Performance-Based Control
Save energy and water
Reduce manpower
Increase throughput
Improve product quality
Extend equipment life
Enhance safety
Predict cash needs
(3D Bio-Control)
(3D Scale Control)
(NCM100)
Stress Management for Cooling Systems

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 1-4
TechnicalHelp
(630) 305-CHEM
Detector
Emission
Filter
Flow
Cell
Excitation
Filter
LED
Light
Source
Water
Water Sample In
Water Sample Out
1.5 How the 3D TRASAR System Works
1.5.1 Fluorometer
TRASAR chemistries contain a uniquely fluorescing molecule that allows the fluorometer to detect
exactly how much chemical has been fed in order to determine chemical residual. This information
is used to deliver accurate control of chemical levels in your cooling system.
The patented 3D TRASAR on-line fluorometer consists of a “Flow Cell”, an LED light source, filters,
and detectors. The filters and detectors are tuned to specific light frequencies unique to Nalco
products and resultant process reactions. The LED light source is extremely bright at the appropri-
ate frequencies to reliably and repeatably measure the chemical properties of the flowing water. As
a solid-state device, the fluorometer offers trouble free long life.
1.5.2 3D TRASAR Scale Control, 3D TRASAR Bio-Control, and NCM Corrosion
Technology
3D TRASAR Scale Control, 3D TRASAR Bio-Control and NCM Corrosion Monitoring Technology
are available upgrades for the Starter 3D TRASAR 3500 controller.
Typical cooling water controllers use simple On/Off control schemes and timers to maintain pre-
determined set points in hopes to avoid operational upsets. The problem with this approach is that,
as system stresses change, scale can form, bio-populations can multiply, and corrosion can occur
without ever being detected. Pre-determined set points are only good for one set of stress condi-
tions!!
The 3D TRASAR 5500 Controller takes a revolutionary proactive approach to managing cooling
water systems. Patented state of the art technology is used to prevent scale formation, control bio-
population levels and continuously monitor corrosion rates.

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 1-5
TechnicalHelp
(630) 305-CHEM
3D TRASAR Scale Control prevents scale formation by continuously monitoring the activity of an
innovative “tagged” high stress dispersant polymer. As scale forming particles increase in the
cooling system, the active polymer is consumed. By monitoring this consumption rate and the active
polymer level, 3D TRASAR Scale Control can take corrective action well before the conditions
needed to produce scale can occur.
Use 3D TRASAR Scale Control to:
• Optimize water and chemical use by actively managing the system based on the stresses
placed upon it.
• Improve throughput by maintaining equipment at peak efficiency, even as operational
factors vary.
• Reduce downtime and maintenance costs by preventing mineral scale, and particulate
fouling.
• Increase asset life and maintain asset reliability by preventing degradation during upsets
and process leaks.
3D TRASAR Bio-Control is an entirely new, innovative approach to the control of bio-populations in
cooling systems. Afluorescent “bio-reporter” is introduced into the cooling system and reacts
enzymatically with microbes. The reaction changes the bio-reporter’s fluorescent signature. 3D
TRASAR Bio-Control measures the difference between the reacted and unreacted bio-reporter and
adjusts biocide feed to optimize control. 3D TRASAR Bio-Control is the only bio-control system
available that adjusts system operation in response to changes in bio-activity. This unique Nalco
innovation delivers comprehensive, continuous control of both sessile and planktonic bio-popula-
tions.
Use 3D TRASAR Bio-Control to:
• Compensate for variations in makeup bio-populations.
• Prevent underdeposit corrosion by controlling sessile bio-populations.
• Optimize water and chemical use by actively managing the system based on the actual bio-
activity present.
• Reduce downtime and maintenance costs by preventing the corrosion and fouling associ-
ated with bio-activity.
• Increase asset life and maintain asset reliability by preventing degradation during upsets
and contamination.
NCM Corrosion Monitoring Technology is also incorporated in the 3D TRASAR 5500. This
patented technology automatically recognizes the corrosion rates of up to 2 different metallurgies.
The available metallurgies include mild steel, galvanized steel, copper, brass, CuNi 90/10, CuNi 70/
30, and aluminum. By monitoring corrosion rates continuously (vs. 90-day snapshots) corrective
action can be taken before the problem becomes serious.
1.5.3 Data Storage / Reporting and Communications
The 3D TRASAR 3500 and 5500 controllers are able to automatically e-mail stored measurements
to a central database that is accessible via the Internet. This allows operational data to be viewed
and analyzed remotely, from one or more authorized locations using just a standard web browser.
Reports may also be setup and automatically emailed on determined dates or at specified times.

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 1-6
TechnicalHelp
(630) 305-CHEM
1.6 Safety
Always follow the safety practices listed below:
• Never perform any installation procedures with electrical power engaged.
• Never perform any repairs with electrical power engaged.
• Never open the 3D TRASAR controller box or junction box with electrical power engaged.
• Never open the pellet feeder hopper with electrical power engaged.
• Maximum water pressure to the 3D TRASAR skid and pellet feeder should never exceed
90 psi.
• Maximum water temperature should not exceed 120 deg F.
• Always wear the appropriate Personal Protective Equipment (PPE) when working on a 3D
TRASAR system (i.e. gloves, protective eyewear, protective shoes, wearing a mask, etc).
• Always observe local and facility safety practices beyond those listed in this manual.
WARNING: Always turn off power before making any electrical connections, which in-
cludes all interconnecting cables, otherwise permanent damage may occur to system
components.
!
NOTE: Both the 3D TRASAR controller and the Bio-reporter Pellet Feeder operate well
below an 85 db noise level.
!

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 2-1
TechnicalHelp
(630) 305-CHEM
Section 2: Installation and Start-Up
Introduction
There are 9 steps to installing and starting-up a 3D TRASAR system.
Details
Section
2.7
Details
Section
2.1
Unpack and identify Mount controller
Install Main Control Panel in well-lit, dry
location convenient to points of use. Mount
at eye level.
Install Bio-Reporter feeder
Install Bio-ReporterFeeder in well-lit, dry
location convenient to points of use.
Plumb bio-reporter feeder
Connect discharge back to recirculating
system downstream from supply in basin
where possible.
Calibration & checkout
Calibrate probes following instruction on
screen.
Wiring
Connect cable between controller box and pellet feeder.
Wire pumps using supplied pigtails (or hardwire). Connect
85 to 250 VAC @ 20 amps power using supplied power
cord (or hardwiring).
Start-up system
Enter set points.
You are up and running!
Install probes
Install probes and attach connectors.
Details
Section
2.2
Details
Section
2.3
Details
Section
2.5
Details
Section
2.6
Details
Section
2.8 Details
Section
2.9
Unpack all parts and identify them.
Plumb utilizing ball valves provided. Inlet
water from recirculating system must be at
5 GPM or greater.
Outlet
½”
Union
0.5
GPM
Plumb controller
Details
Section
2.4
ORP Probe

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 2-2
TechnicalHelp
(630) 305-CHEM
2.1 STEP 1 - Unpack and Identify
Wall Mount: Configured for wall attachment, select when floor space is restricted.
Frame Mount: Configured for floor-mounted installation, select when wall space is
restricted.
Junction Box: Provides convenient access to wiring connections.
Enclosure: Provides weather resistant protection. Select for outdoor installations
and dusty environments.
Air Purge: Depending on site requirements, may satisfy certain industrial explosion
protection ratings. Select for use in hazardous duty applications.
Wireless Gateway: Enables wireless communication of important information such as
alarms and performance indicators.
High Fouling Models: Includes automated fluorometer cleaning system to reduce fouling
from solids, oils and debris found in process water.
IMPORTANT: If you do not have all of the items
needed for your application, call your Nalco
representative before proceeding.
!
2.1.1 Identify Hardware Model
Hardware Models
Unpack and identify all parts.
Unpack and identify
3D TRASAR
Starter Model 3D TRASAR Model Description
060-TR3500.88 060-TR5500.88 Wall Mount, S mall Backboard
060-TR3501.88 060-TR5501.88 Frame Mount, Small Backboard
060-TR3510.88 060-TR5510.88 Wall Mount wi th Juncti on Box
060-TR3511.88 060-TR5511.88 Frame Mount wi th Juncti on Box
060-TR3520.88 060-TR5520.88 Enclosed Wall Mount wi th Junction Box
060-TR3522.88 060-TR5522.88 Enclosed Wall Mount wi th Junction Box and Pre-Installed Nalco Global Gateway
060-TR3521.88 060-TR5521.88 Enclosed Frame Mount wi th Junction Box
060-TR3523.88 060-TR5523.88 Enclosed Frame Mount wi th Junction Box and Pre-Installed Nalco Global Gateway
060-TR3530.88 060-TR5530.88 Air Purged Wall Mount wi th Junction Box
060-TR3532.88 060-TR5532.88 Air Purged Wall Mount wi th Junction Box and Pre-Installed Nalco Global Gateway
060-TR3531.88 060-TR5531.88 Air Purged Frame Mount wi th Junction Box
060-TR3533.88 060-TR5533.88 Air Purged Frame Mount wi th Junction Box and Pre-Installed Nalco Global Gateway
N/A 060-TR5515.88 Wall Mount for High Fouling Applications
N/A 060-TR5516.88 Frame Mount for High Fouling Applications
N/A 060-TR5525.88 Enclosed Wall Mount for High Fouli ng Applications
N/A 060-TR5526.88 Enclosed Frame Mount fo r High Fouli ng Applications

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 2-3
TechnicalHelp
(630) 305-CHEM
2.1.1 Identify Hardware Model (con’t)
Small Back Panel
Part # 060-TR3500.88,
060-TR5500.88 (wall mount)
Large Back Panel
Part # 060-TR3510.88,
060-TR5510.88 (wall mount)
Enclosed Part # 060-TR3520.88,
060-TR3522.88, 060-TR5520.88,
060-TR5522.88 (wall mount)
Air Purged Part # 060-TR3530.88,
060-TR3532.88, 060-TR5530.88,
060-TR5532.88 (wall mount)
Unpack and identify all parts.
Unpack and identify
Drawings shown with all probes
assembled. pH, ORP, and Cor-
rosion probes are av ailable as
upgrades for 3D TRASAR 3500
systems.
Model Number Description Recommended for
system sizes:
060-TR5120.88 Pellet Feeder Assembly 12,000 gallons and larger
141-PJ4035.88 Liquid Bio-reporter pump, Iwaki 3,000 to 12,000 gallons
6008505 Liquid Bio-reporter pump, Grundfos Less than 3,000 gallons
!
Bio-reporter Feed Options

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 2-4
TechnicalHelp
(630) 305-CHEM
Unpack and identify all parts.
Unpack and identify
Conductivity Probe
Qty. (1)
Part # 060-TR5432.88
3/4” Ball Valve
Qty. (2)
Fluorometer Cable
Qty. (1)
Part # 060-TR5221.88
pH Probe Cable
Qty. (1)
Part # 060-TR5412.88
ORP Probe Cable
Qty. (1)
Part # 060-TR5422.88
2.1.2a Pre-Installed Items (all models)
2.1.2b Pre-Installed Items
(3D TRASAR 5500 models only)
2.1.3a Items Requiring Assembly (all models)
Pigtail 16/3 SJOW
Qty. (5)
Part # 991-05053481.88
Service (Power) Cord 12/3 SJOW
Qty. (1)
Part # 991-01928722.88
Ethernet Crossover Cable (6 ft., orange)
Qty. (1)
Part # 991-05047661.88
Additional Items
Replacement Fuses (4), Part # 991-50473718.88
Installation and User Manual, Part # 521-OM0108.88
Fluorometer
Qty. (1)
Part # 060-TR5220.88 (3D)
or 060-TR3220.88 (Starter)
Fluorometer Inlet Valve
and Tubing Connector
Qty. (1)
Fluorometer Outlet
Assembly
Qty. (1)
2.1.3b Items Requiring Assembly
(3D TRASAR 5500 models only)
pH Probe
Qty. (1)
Part # 060-TR541 1.88
ORP Probe
Qty. (1)
Part # 060-TR5421.88
Corrosion Probe
Qty (2) (Steel and Copper std.)
Part # 400-NCMP1B.88 (steel)
Part # 400-NCMP2B.88 (copper)
Part # 400-NCM4B.88 - Cu/Ni 90/10 (optional)
Part # 400-NCMP5B.88 - Cu/Ni 70/30 (optional)
Part # 400-NCMP7B.88 - 443 Brass (optional)
Part # 6016180 - 6061 Aluminum (optional)
Part # 6016182 - 1 100 Aluminum (optional)
Part # 400-NCMP10.88 Galvanized steel (optional)
Probe Restraint Device
Qty. (2)
Part # 400-NCMAC15.88

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 2-5
TechnicalHelp
(630) 305-CHEM
Pellet Feeder Assembly
Qty. (1)
Part # 060-TR5120.88
PELLET
FEEDER
Pellet Feeder Cable (25 ft.)
Qty. (1)
Part # 060-TR531 1.88
(shipped with pellet feeder only)
25'
2.1.4 Pellet Feeder Assembly (Optional)
Additional Items
Pellet Feeder Brush Part # 500-P2818.88
2.1.5 Items Shipped Separately
3D TRASAR 5500 Start-up Kit
(must be ordered separately)
Part # 500-TSRKIT.88
Includes:
3D TRASAR Cal Soln, 1 L 460-S0940.75
pH 7.0 Buffer Soln, 1 L 460-S0407.75
pH 10.0 Buffer Soln, 1 L 460-S0408.75
ORP 200 mv Buffer Soln, 1 L 460-S0932A.75
ORP 600 mv. Buffer Soln, 1 L 460-S0933A.75
10% Sulfuric Acid Soln, 1 L 460-S0800.75
NCM probe Mild Steel with ferrule 400-NCMP1B.88
NCM probe Copper with ferrule 400-NCMP2B.88
Fluorometer Probe Brush 500-P2817.88
Plastic beakers, qty 3, 500 mL 500-P0116.88
Plastic syringe, qty 3, 60 cc 500-P2147.88
Unpack and identify all parts.
Unpack and identify
Part # Upgrade Upgrade Includes
060-TR3200.88 Fluorometer Patented 3D TRASAR technology upgrade procedure, 3D TRASAR
Fluorometer, rebate return instructions and upgrade confirmation sticker.
060-TR3205.88 NCM Patented NCM technology upgrade procedure, 2 probe restraints, 2
NCM probe f ittings, and upgrade confirmation sticker (purchase NCM
probes separately, refer to page 2-4 for available metallurgies.)
060-TR3211.88 pH pH probe and cable.
060-TR3221.88 ORP ORP probe and cable.
2.1.5a 3D TRASAR Starter Upgrades
Maintenance Value Package
(must be ordered separately , order 2 per year)
Part # 060-TRMNKIT.88
Includes all components of the 3D TRASAR 5500
Start-up Kit plus:
pH probe 060-TR5411.88
ORP probe 060-TR5421.88
NCM probe, Mild Steel, with ferrule 400-NCMP1B.88
NCM probe, Copper, with ferrule 400-NCMP2B.88
(includes 2 of each NCM probe)
Fluorometer desiccant cannister 060-TR5222.88
Fluorometer desiccant indicator 060-TR5223.88
3D TRASAR 3500 Start-up Kit
(must be ordered separately)
Part # 500-TSRKITSTR.88
Includes:
3D TRASAR Cal Soln, 1L 460-S0940.75
10% Sulfuric Acid Soln, 1L 460-S0800.75
Fluorometer Probe Brush 500-P2817.88
Plastic beakers, qty 3, 500 mL 500-P0116.88
Plastic syringe, qty 3, 60 cc 500-P2147.88
2.1.5b 3D TRASAR Start-up and Maintenance Kits

3D TRASAR5500 - Installation & Operation Manual
521-OM0108.88
Copyright 2009NalcoCompany 2-6
TechnicalHelp
(630) 305-CHEM
2.2 STEP 2 - Mount the Controller
IMPORTANT: The 3D TRASAR controller is
designed to meet NEMA4X standards for weather
resistance. It is recommended that the unit be
installed in a sheltered area to minimize the
chance of water or debris entering the enclosure
when the cover is opened for wiring and mainte-
nance.
In order to maintain the NEMA 4X rating:
• Unused cord grips must remain plugged.
• Enclosure cover must be tightly closed at
all times.
• Ethernet port cover must also be in place
when this port is not in use.
!
2.2.1 General Instructions
1. Avoid installing the 3D TRASAR controller close to any high voltage source(s), large motors,
or any known generator of electrical and strong magnetic noises.
2. The mounting location should be well lit and dry.
3. If mounting outside, provisions must be made to protect the controller from direct sunlight
and driving rain.
4. In cold weather climates, provisions must be made to prevent piping from freezing.
5. The mounting location should be accessible to sample water (5 gpm minimum) and an
electrical power source (20 amp circuit at 85-250 VAC).
6. If using the bio-reporter Pellet Feeder, install it on the right hand side of the 3D TRASAR
controller (as you face the controller) within 10 ft.
a. The Pellet Feeder is electrically connected to the 3D TRASAR controller with a 25 ft.
pre-configured cable. If necessary, this cable can be spliced in the field to lengthen it
to a maximum of 100ft.
b. The Pellet Feeder should be plumbed to the bottom 3/4” sensor outlet piping of the
3D TRASAR controller off the right side of the panel (Refer to Section 2.4.3).
7. If using liquid bio-reporter, mount the feed pump in a location convenient to the bio-reporter
tank and the 3D TRASAR controller.
8. Chemical feed pumps should also be mounted conveniently to the 3D TRASAR controller
and chemical feed tanks.
Mount controller
Install Main Control Panel in well-lit, dry
location convenient to points of use. Mount at
eye level.