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

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

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

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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

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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

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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

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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

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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

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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

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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

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