3D TRASAR Boiler Manual Ver 4.2 11-10-10

Pen Flourometer Operation Manual
OM0208
3D TRASAR Boiler Technology

33
Installation and Operation
Manual OM0211
Date 11-10-10
Version 4.2
Nalco Global Equipment Solutions
1601 West Diehl Road
Naperville, IL 60563-1198
3D TRASAR Boiler Technology Installation and Operation Manual

OM0211

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Table of Contents
1.0 Introduction...................................................................................................... 9
3D TRSAR Boiler Technology............................................................................................ 9
3D TRASAR Boiler Models and Optional Component ...................................................... 11
About This Manual........................................................................................................... 12
Potential Applications ...................................................................................................... 12
1.4.1 Feedwater Treatment Programs............................................................................. 12
1.4.2 3D TRASAR Cycles Control ................................................................................... 13
1.4.3 Hardness Excursion Override................................................................................. 13
1.4.4 BT Phosphate / pH Product Line Control ................................................................ 13
1.4.5 Condensate Monitoring .......................................................................................... 13
1.5 Safety.............................................................................................................................. 14
1.5.1 Explanation of Symbols.......................................................................................... 14
1.6 Installation, Assembly, Start-Up and Control Tuning Overview ......................................... 15
1.1
1.2
1.3
1.4
2.0 System Installation ........................................................................................ 17

2.1
Unpack and Identify Parts................................................................................................ 17

2.1.1 Frames and Panels ................................................................................................ 17
2.1.2 Items Requiring Assembly...................................................................................... 18
2.1.3 Additional Items Shipped Loose ............................................................................. 18
2.2 Mount the Panel (or Frame)............................................................................................. 19
2.2.1 General Installation Instructions ............................................................................. 19
2.2.2 Wall Mounting ....................................................................................................... 20
2.2.3 Frame Mount Dimensions ...................................................................................... 21
2.2.4 Installation Overview Diagrams .............................................................................. 22
2.2.4.1 TRASAR Fluorometer and NCSM Feedwater Systems..................................... 22
2.2.4.2 TRASAR Fluorometer Feedwater Systems ...................................................... 23
2.2.4.3 NCSM Feedwater Systems .............................................................................. 24
2.2.4.4 TRASAR Fluorometer Blowdown Systems ....................................................... 25
2.2.4.5 Continuous Blowdown Conductivity Probe And Valves..................................... 26
2.2.4.6 Timed-Sample Blowdown Conductivity Probe And Valves ............................... 27
2.2.4.7 Condensate Monitor......................................................................................... 28
2.3 Plumb the System ........................................................................................................... 29
2.3.1 Plumbing Requirements ......................................................................................... 29
2.3.2 Plumbing Connections ........................................................................................... 30
2.3.3 Plumbing Notes...................................................................................................... 31
2.3.3.1 Sample Point ................................................................................................... 31
2.3.3.2 Sample Lines................................................................................................... 32
2.3.3.3 Discharge Line................................................................................................. 33
2.3.3.4 Cooling Water Lines......................................................................................... 33
2.3.3.5 Blowdown Conductivity Probe Assy, Control Valve & Flow Control Valves........ 34
2.3.3.6 Condensate Conductivity Probe Assy, Sample Take-Off, Control Valve & Flow
Control Valves ................................................................................................. 37
2.3.3.7 Boiler NCM100 Probe Installation..................................................................... 38
3.0 Electrical Wiring and Connections............................................................... 39

3.1
3.2
Run Wires in the Control Box ......................................................................................... 39

Terminate Wires in the Control Box ................................................................................ 40
3.2.1 System Power Connections ................................................................................... 40
3.2.2 Internal Power Connection ..................................................................................... 40
3.2.3 Fuses..................................................................................................................... 40

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3.2.4 Control Relay Connections ..................................................................................... 41
3.2.4.1 Control Relays Powered and Non-Powered Wiring ........................................ 41
3.2.4.2 Relay Connections Inside Controller................................................................. 42
3.2.4.3 Blowdown Valve Relay Box Connections.......................................................... 43
3.2.5 Alarm Relay Connections ....................................................................................... 44
3.2.6 Fluorometer Connections ....................................................................................... 44
3.2.7 Conductivity Probe Connections............................................................................. 45
3.2.7.1 Compensating vs. Non-Compensating Probes................................................ 45
3.2.7.2 Conductivity Probe Wiring............................................................................... 47
3.2.8 High Impedance (pH/ORP) Connections................................................................. 54
3.2.9 Nalco Corrosion Monitor (NCM100) ....................................................................... 55
3.2.10 Analog Inputs ......................................................................................................... 55
3.2.11 Analog Input Module (Optional) .............................................................................. 57
3.2.12 Analog Outputs ...................................................................................................... 59
3.2.13 Interlock ................................................................................................................. 59
3.2.14 Temperature (RTD) Inputs ..................................................................................... 60
3.2.15 Digital Inputs .......................................................................................................... 61
3.2.16 Modem/Phone Line Connections ............................................................................ 62
3.2.17 Ethernet Connections ............................................................................................. 62
3.2.18 LAN Connections ................................................................................................... 63
3.2.19 USB ....................................................................................................................... 63
3.2.20 SCADA (RS232/485/Ethernet)................................................................................ 63
3.2.21 3D TRASAR Boiler Controller Terminal Connection Diagram .................................. 65
3.2.22 3D TRASAR Boiler Controller Default Wiring .......................................................... 66
4.0 Final Assembly and Start-up......................................................................... 67

4.1
4.2
4.3
4.4
Installation Check and Safety Check .............................................................................. 67

Shut all 3D TRASAR Boiler System Valves ................................................................... 67
Install and Connect the TRASAR Fluorometer................................................................ 68
Power Up Control System Without Sample or Cooling Water Flowing............................. 69
4.4.1 TRASAR Fluorometer and NCSM System .............................................................. 69
4.4.2 TRASAR Fluorometer Systems .............................................................................. 69
4.4.3 NCSM Systems...................................................................................................... 69
4.5 Configure System and Upload to 3D TRASAR Controller ................................................. 69
4.5.1 PC System Requirements ...................................................................................... 69
4.5.2 Installing the Software ............................................................................................ 69
4.5.3 Configurator Support .............................................................................................. 70
4.6 Reboot the 3D TRASAR Controller .................................................................................. 70
4.7 Verify the Configuration Using the Controller Keypad/Screens ......................................... 70
4.8 Calibrate the Fluorometer ................................................................................................ 71
4.8.1 Fluorometer Calibration Procedure ......................................................................... 71
4.8.2 Fluorometer Calibration Screen Instructions ........................................................... 71
4.8.2.1 Fluorometer 2-Point Calibration Screens Instructions (Successful Calibration).. 72
4.8.2.2 Fluorometer 2-Point Calibration Screens (Cancel Selected During Calibration). 72
4.8.2.3 Fluorometer 2-Point Calibration Screens (Calibration Fails) .............................. 72
4.9 NCSM Short Circuit Test.................................................................................................. 73
4.9.1 NCSM Short Circuit Test Procedure ....................................................................... 73
4.9.2 NCSM Short Circuit Test Screens Instructions........................................................ 73
4.10 Refurbish and Test the NCSM Reference Electrode......................................................... 74
4.10.1 NCSM Probes ........................................................................................................ 74
4.10.2 ORP/RTD Probes................................................................................................... 74
4.10.3 Reference Electrode............................................................................................... 75
4.10.4 NCSM Probe Cables .............................................................................................. 76
4.10.5 NCSM Probe Checkout .......................................................................................... 76

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4.10.6 Refurbishing the Reference Electrode .................................................................... 76
4.10.7 Reference Electrode Check.................................................................................... 79
4.10.8 Reference Electrode Check Screens ...................................................................... 80
4.10.9 Install the Reference Electrode............................................................................... 80
4.11 Feedwater pH and Conductivity Probe Installation ........................................................... 81
4.12 pH Probe Calibration ....................................................................................................... 81
4.13 Conductivity Probe Calibration......................................................................................... 83
4.13.1 Recommended Conductivity Standards .................................................................. 83
4.13.2 2-Point Calibration.................................................................................................. 84
4.13.3 1-Point Calibration.................................................................................................. 86
4.13.3.1 Continuous Sample On/Off or PID Control .............................................. 86
4.13.3.2 Timed Sample Continuous On/Off Control .............................................. 86
4.13.3.3 Timed Sample Proportional Control......................................................... 87
4.13.4 Extracting a Conductivity Probe from the Blowdown Line of an Operating Boiler ..... 88
4.13.5 Installing a Conductivity Probe into the Blowdown Line of an Operating Boiler ........ 89
4.13.6 Cleaning a Fouled Conductivity Probe.................................................................... 89
4.14 System Leak Test and Final Piping Insulation .................................................................. 89
4.15 Startup ............................................................................................................................ 90
4.15.1 NCSM & Fluorometer Models System Valve Identification ................................... 90
4.15.2 TRASAR Fluorometer and NCSM System Startup.................................................. 90
4.15.3 TRASAR Fluorometer Only System Startup............................................................ 92
4.15.4 NCSM Only System Startup (without Sample Conditioning System) ....................... 93
4.15.5 Condensate Monitor System .................................................................................. 93
4.16 Test Data Download to a USB Data Stick and Laptop Computer ...................................... 95
4.17 Verify Operation of the Control Outputs ........................................................................... 95
4.18 Test High-Temperature Shutdown & Pressure Relief ....................................................... 95
4.19 Check Remote Communications...................................................................................... 96
4.19.1 3D TRASAR Boilers Nalco Global Gateway Setup.................................................. 96
4.19.2 3D TRASAR Boilers Phone Line Verification .......................................................... 98
5.0 Tasks to Perform Before Control Tuning.........................................102

5.1
5.2
5.3
5.4
5.5
Ensure an Interlock Is Connected or Shutdown Process Is Established.......................... 102

Verify Chemical Pump Capability ................................................................................... 102
Check Pump Responses and Measure Lag Times......................................................... 103
Control Selection ........................................................................................................... 104
NCSM Set Point Determination...................................................................................... 105
5.5.1 0-100% Scavenger Pump Test ............................................................................. 105
5.5.1.1 0-100% Pump Test by Manually changing the Output ................................. 105
5.5.1.2 Pump Test Using the NCSM PID Tuning Program ...................................... 106
5.5.2 Comfort Control NCSM Setpoint........................................................................... 106
5.5.3 Ideal Control NCSM Setpoint................................................................................ 107
5.6 TRASAR Setpoint.......................................................................................................... 107
5.7 Intermittent Operation.................................................................................................... 107
5.7.1 General Considerations........................................................................................ 107
5.7.1.1 Interlocks and Alarms .................................................................................... 107
5.7.1.2 Control Options.............................................................................................. 107
5.7.1.3 Control Expectations...................................................................................... 108
5.7.2 Special NCSM Considerations ............................................................................. 108
5.7.2.1 General Considerations ................................................................................. 108
5.7.2.2 Monitoring...................................................................................................... 110
5.7.2.3 Manual Feed.................................................................................................. 110
5.7.2.4 Control ........................................................................................................ 110
5.7.2.4.1 High & Low Temperature Interlock ................................................... 111
5.7.2.4.2 No Flow Switch................................................................................ 112

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5.7.2.4.3
5.7.2.4.4
5.7.2.4.5
Slaved Control ................................................................................. 113

ON/OFF Control............................................................................... 113
PID Control ...................................................................................... 113
6.0 ON/OFF Relay Control ................................................................................. 114

6.1
ON/OFF Control Using the PID 4-20 Outputs ................................................................. 114
7.0 Proportional Control Configuration............................................................ 115

7.1
7.2
Blowdown Control (Cycle Control using 3D TRASAR Fluorometer) ................................ 115

Feedwater Flow-Based Proportional Control .................................................................. 117
8.0 PID Configuration and Tuning .................................................................... 119

8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
9.9
Check PID Configuration................................................................................................ 119

When to Auto Tune........................................................................................................ 119
Before Starting Auto Tune.............................................................................................. 119
Checklist for Auto Tune.................................................................................................. 119
TRASAR PID Auto Tune................................................................................................ 120
NCSM PID Tuning ......................................................................................................... 122
Manual Tuning............................................................................................................... 124
Set PID to ON/OFF Control (or Manual) if PID Auto Tune Cannot Be Completed .......... 125
Monitor PID Control ....................................................................................................... 125
9.0 Blowdown Monitor and Control Setup ....................................................... 126

9.1 Conductivity Monitor & Blowdown Control Setup ............................................................ 126
9.1.1
Conductivity Control Mode Options....................................................................... 126
9.1.2
Temperature Probe Assignment ........................................................................... 126
9.1.3
Conductivity Control Mode.................................................................................... 127
9.1.4
Monitor Only Mode ............................................................................................... 129
9.1.5
PID Control Mode................................................................................................. 129
9.1.6
Continuous (ON/OFF) Control Mode..................................................................... 131
9.1.7
Time Sample (ON/OFF) Control Mode.................................................................. 132
9.7.1.1 Time Sample Continuous Mode................................................................... 133
9.7.1.2 Time Sample Proportional Mode ................................................................. 134
9.1.8
Interval Details ..................................................................................................... 135
9.1.9
Sample Schedule ................................................................................................. 135
9.1.10 Setting Up Timed Sample Proportional Control .................................................. 138
9.1.11 Troubleshooting and Adjusting Tips for Interval Control ........................................ 141
9.1.12 Review Conductivity Control Setup....................................................................... 141
9.1.13 Notes on Control Modes, Alerts and Alarms.......................................................... 142
9.2 Fluorometer-Based Blowdown Control Setup ................................................................. 144
10.0
Condensate Monitor Control Setup ......................................................... 146
11.0
Controller Operation ................................................................................. 149
11.1 Display Panel Functions ................................................................................................ 149

11.2 The Keys ...................................................................................................................... 149
11.2.1 Ethernet and USB Connections and Power Switch ............................................... 149
11.3 The Graphic Icons ......................................................................................................... 150
11.4 Menu, Information, Actions and Alarms Keys Flow Diagram........................................... 150
11.5 Menu Key ...................................................................................................................... 151
11.6 Control Setting Screens ................................................................................................. 151
11.6.1 TRASAR Factors Screen...................................................................................... 151
11.6.2 PID 1-8 Screens................................................................................................... 152

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11.6.3 Relays 1-5 Screens.............................................................................................. 152
11.7 Alarm Setting Screens ................................................................................................... 152
11.7.1 Alarm Settings...................................................................................................... 152
11.7.2 Alarm Screens ..................................................................................................... 154
11.8 Network Screens ........................................................................................................... 154
11.9 Preference Screens....................................................................................................... 155
11.9.1
Units Screens ................................................................................................ 155
11.9.2
Date Screens................................................................................................. 155
11.10 Input Types Screens................................................................................................... 155
11.10.1 pH/ORP Input Screen........................................................................................... 156
11.10.2 Analog Input Screen............................................................................................. 156
11.10.3 TRASAR Fluorometer Screen .............................................................................. 156
11.11 Shortcut Keys............................................................................................................. 156
11.11.1 Calibrate .............................................................................................................. 157
11.11.2 Manual Control..................................................................................................... 157
11.11.3 Test Send ............................................................................................................ 157
11.11.4 Reboot ................................................................................................................. 157
12.0 Communications and Data Management ................................................... 158

12.1 3D TRASAR Boiler Optimizer ........................................................................................ 158
12.2 3D TRASAR Boiler Configurator .................................................................................... 158
12.3 3D TRASAR Boiler Controller ........................................................................................ 158
12.4 SCADA Systems ........................................................................................................... 158
12.5 3D TRASAR Web.......................................................................................................... 159
12.5.1 3D TRASAR Web Setup....................................................................................... 159
12.5.1.1 Create/Edit Users ....................................................................................... 160
12.5.1.2 Assign Controllers (Data Sources ............................................................... 160
12.5.1.3 Manage Controller (Data Source) Setup Information ................................... 161
12.5.2 3D TRASAR Web Data ........................................................................................ 161
12.5.3 3D TRASAR Web Reports ................................................................................... 162
12.5.4 3D TRASAR Web Alarms..................................................................................... 163
12.6 3D TRASAR Wireless Gateway ..................................................................................... 164
13.0 Shutdown and Maintenance ....................................................................... 165

13.1 Shutdown ...................................................................................................................... 165
13.1.1 Combination TRASAR Fluorometer and NCSM System Shutdown ....................... 165
13.1.2 TRASAR Fluorometer Only System Shutdown ..................................................... 165
13.1.3 NCSM Only System Shutdown (without Sample Conditioning System .................. 166
13.2 TRASAR Fluorometer Maintenance............................................................................... 166
13.2.1 Clean TRASAR Fluorometer Flow Cell ................................................................. 166
13.2.2 Calibrate TRASAR Fluorometer............................................................................ 167
13.2.3 Check/Replace TRASAR Fluorometer Desiccant.................................................. 167
13.3 NCSM Maintenance ...................................................................................................... 167
13.4 Sample Conditioning System Maintenance .................................................................... 167
13.5 Conductivity and pH Probe Maintenance ....................................................................... 168
14.0 Troubleshooting........................................................................................... 169

14.1 General System Troubleshooting................................................................................... 169
14.2 TRASAR Fluorometer Troubleshooting.......................................................................... 176
14.3 Alarm Screen Troubleshooting....................................................................................... 177
14.4 NCSM Troubleshooting ................................................................................................. 181
14.4.1 Factors That Affect Corrosion Stress and NCSM Control Ranges ......................... 182
14.4.2 Replacement NCSM Probes................................................................................. 183
14.4.3 Cables ................................................................................................................. 184

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14.4.4 ORP TB11 and NCSM 1024 mV Tests .............................................................. 185
14.4.5 REF Electrode...................................................................................................... 185
14.4.6 ORP Probe Check................................................................................................ 187
14.5 PID Troubleshooting ...................................................................................................... 188
14.5.1 PID Troubleshooting Table ................................................................................... 188
14.5.2 Interpreting & Troubleshooting Auto Tune Failure and Warning Messages............ 189
14.5.2.1 Warning Messages ........................................................................................... 189
14.5.2.2 Failure Messages.............................................................................................. 193
14.6 Blowdown Control Troubleshooting................................................................................ 197
14.7 Feedwater Conductivity Troubleshooting Flow Chart...................................................... 199
14.8 Blowdown Conductivity Troubleshooting Flow Chart ...................................................... 200
15.0 Specifications.............................................................................................. 201

16.0 Replacement Parts and Accessories ........................................................ 207
17.0 Warranty .................................................................................................... 211
18.0 Responsibility for Safe Delivery ................................................................ 211
APPENDICES
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Q.
Scale Control using 3D TRASAR for Boilers...................................................................... 212

NCSM Probe Technology and Advanced Field Tests ........................................................ 224
Pictorial Instructions of NCSM Reference Electrode Refurbishing...................................... 232
Advanced PID Control Settings ......................................................................................... 235
Sample Conditioning System ............................................................................................ 237
Notes On Control Modes, Interlocks, Control Overrides & Alarms...................................... 240
Electrical Grounding Test Procedure for 3D TRASAR Controllers...................................... 245
Panel and Frame System Dimensions............................................................................... 248
3D TRASAR Boiler Systems Features Table..................................................................... 251
Hardness Override Screens .............................................................................................. 254
Coordinated Phosphate Screens....................................................................................... 256
Boiler Blowdown Survey ................................................................................................... 261
Boiler Saturated Steam Tables.......................................................................................... 263
Modbus Communications Settings .................................................................................... 265
Replaceable Battery Removal & Installation ...................................................................... 268
Connecting 2 3D TRASAR Boiler Controllers to 1 NGG (ver. 1.0)...................................... 270
Connecting a 3D TRASAR Cooling Controller and a 3D TRASAR Boiler Controller to
1 NGG (ver. 1.0) ............................................................................................................... 274
R. 3D TRASAR Boiler Automation System Pre-Installation Checklist ..................................... 280

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1.0 Introduction
1.1
3D TRASAR Boiler Technology is a complete boiler performance management system, intended to

maximize safety, reliability, and operating costs associated with boilers and steam generation .
It continuously measures key system parameters and, when upsets occur, takes immediate corrective
action, preventing operational problems and maximizing boiler performance. The 3D TRASAR Boiler
equipment also has the ability to communicate with system users via the 3D TRASAR Web, text
messages or email, keeping the informed of changes or upsets.
Reliable production of steam
Steam availability - no unplanned outages
Minimize scale & corrosion
Safe production of steam
Food safety (FDA, NSF, Kosher)
Environmental / regulatory compliance
Minimize risk to plant personnel
Safety
Reliability
for Boilers
TCO
Cost Performance
Maximize Equipment Life
Overall Lowest Total Cost of Operation
3D TRASAR Boiler System Capabilities
3D TRASAR Controller & Configurator Software
Communication for Remote Monitoring and Alarming
Web Reporting & Data Management
3D TRASAR Fluorometer for Scale Control
Corrosion Stress Monitor (NCSM) for Pre-boiler Corrosion Control
Conductivity-Based Blowdown Control
3D TRASAR Technology-based Blowdown Control
Feedwater pH & Conductivity Monitoring
Condensate Monitoring

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Components
There are 6 primary components to 3D TRASAR Boiler Technology:

Basic Components
Controller
NCSM
Sample
Conditioning
System
(SCS)
Fluorometer
(TRASAR 3)
Feed Water
Monitoring Module
(pH & Conductivity)
Blowdown
Relay Box
Boiler Controller - This is the central component to 3D TRASAR Boiler Technology that defines and
controls system parameters. The Controller is setup and managed by interfacing (locally or remotely)
with Nalcos advanced Boiler Configurator software.
Nalco Corrosion Stress Monitor (NSCM) - This is Nalcos innovative oxidation-reduction potential
technology that directly measures the systems corrosion stresses under actual high temperature and
pressure operating conditions. This measurement is made continuously and on-line so the
appropriate adjustments and responses to changes in corrosion stresses can be made in real time.
The actual measurement is often referred to as AT ORP and is expressed in mV.
3D TRASAR Fluorometer - This is a new solid-state fluorometer that can measure all Nalco
TRASAR 3 products, including all NexGuard internal boiler treatments. The controller uses these
measurements to automatically respond to boiler system changes and maintain optimum treatment
levels of highly effective scale and deposit inhibitors to keep boilers clean and free of scale and
deposits.
10

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The patented 3D TRASAR on-line fluorometer consists of a flow cell and 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 appropriate
frequencies to reliably and precisely measure the chemical properties of the flowing water. This solidstate device provides years of trouble-free operation.
Sampling Conditioning System (SCS) This system is designed to safely cool and reduce the
pressure of the side stream sample prior to entering the Nalco fluorometer. There are two models,
one for low-pressure samples (< 50 psig / 3.4 bar) and one for high-pressure samples (50 -1500 psig
/ 3.4 103 bar). This system is not intended for use on steam samples.
Feed Water Monitoring Module The pH and conductivity of the feed water can be continuously
measured using this module. The sensors are mounted on the piping connecting the SCS and the
fluorometer. There are two models, one for high-purity samples (conductivities from 5-500 S/cm)
and one for low-purity samples (conductivities over 500 S/cm).
Blowdown Relay Box Using the relay box the boiler controller can control up to four motorized
boiler blowdown valves. The relay box provides the 4 SPDT relays needed to operate these types of
valves. This option can be ordered pre-installed on the control system or separately for in-field
upgrades.
Note:
1.2
A conductivity probe assembly must be installed on each boiler where blowdown will be
controlled based on conductivity.
3D TRASAR Boiler Models and Optional Components
The 3D TRASAR Boiler Systems are available in a variety of models. Talk to you Nalco
representative about which model is right for your application. In addition to ordering the 3D TRASAR
Boiler Control System you will need to order one or more of the following accessories:
NCSM Accessories Kit (# 60189090)

3D Boiler TRASAR Startup Kit (# 500-BTSRKIT.88)
Boiler Conductivity Probe Assembly (#060-BDP100.88)
Motorized Blowdown Valve and Flow Control Valve (See SPEC-427)
The complete list of system model numbers, accessories and spare parts are listed in Section 16 and
Appendix I.
11

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1.3
About This Manual.
This manual provides step-by-step instructions to install and startup a 060-BL55XX.88 series system
(3D TRASAR Fluorometer and Corrosion Stress Monitor) in the shortest amount of time. Skip any
sections that are not applicable to the model ordered. The installation of optional sensors and
equipment is also included. Models supplied in some regions require 240 VAC, 50Hz, power instead
of 120 VAC, 60Hz (See Appendix I)
Note:
Models designed for installation in hazardous areas have a slightly different panel layout and
plumbing configuration. Therefore, the installation and startup/shutdown procedures are
different. The controller is the same. See Manual OM0228 for details.
A Nalco Technical Representative will configure the system. Dont hesitate to contact that
person if you have a question or problem.
1.4
Potential Applications
1.4.1
Feedwater Treatment Program Control
The Nalco Corrosion Stress Monitor (NCSM) is highly sensitive and reliable REDOX monitor that can
be used in any aqueous system where corrosion stress is to be monitored or controlled. The NCSM is
primarily used to control the reductive and oxidative state of boiler feed water (controlling the feed of
an oxygen scavenger or metal passivator to the feed water or determining deaerator efficiency). In
addition, corrosion stress can be monitored and controlled in regions of the condensate system.
Illustrations of typical feed water installations are shown below.
Additional 4-20 mA signals can be connected to the Boiler Controller and used to control pumps using
the same control options available for the 3D TRASAR Fluorometer and NCSM, including intermittent
operation. For example, a pH signal could be used for PID control an amine or caustic pump. Setup,
configuration and control tuning of the 3D TRASAR Fluorometer and NCSM serve as examples of the
steps that should be followed to incorporate other signals into control loops.
Deaerator
Deaerator
PREFERRED
N223XX
Feed Point
PREFERRED
N223XX
Feed Point
PID
or
ON/OFF
Feed water
Pump
Scavenger
Feed water
Pump
PID
or
ON/OFF
Scavenge r
N223XX
PID
or
ON/OFF
PREFERRED
Sample Point
PID
N223XX
Sample Point
(minimum 10)
pipe diameters
from product feed
point)
Feed water
Pump
PID
or
ON/OFF
PID
High-pressure sample point installation

Note:
12
Low-pressure sample point installation
Boiler internal treatment chemicals must be fed downstream of any attemperator take
off points.

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1.4.2
3D TRASAR Cycles Control
With the addition of a second fluorometer, the 3D TRASAR Controller can now be used to control the
boiler cycles using TRASAR. It is important to note that one must have good PID control of TRASAR
in the feedwater before starting cycles based control in the blowdown. The boiler cycles cannot be
controlled if the feedwater does not have a consistent TRASAR value. Additionally, the boiler cycles
should be chosen as to not have any potential scaling problems in the boiler. For help in determining
the correct cycles value for your system contact the Nalco TRASAR Help Desk. This type of control
can be configured using either On/Off or Proportional Control. For more information on setting up
these control methods consult the help file in the Configurator.
Note: Currently, this type of control can only be used for TRASAR 3 products.
1.4.3
Hardness Excursion Control Override
The 3D TRASAR Controller can utilize the signal from an on-line hardness analyzer to increase the
feed of scale control product if the hardness concentration in the feedwater exceeds normal operating
levels. Product feed can be increased to accommodate the hardness excursion via two methods:
Fixed pump output level
Multiple of recent pump output history (multiple of Smart Failsafe Output)
1.4.4
BT Phosphate / pH Product Line Control
There are four different phosphate/pH control approaches used in high pressure boiler systems with
the objective to prevent boiler corrosion. These approaches are:
Coordinated Phosphate Control
Congruent Sodium Phosphate Control
Phosphate-Low Hydroxide (Tri-AD) Control
Equilibrium Phosphate Control
The 3D TRASAR Controller enables use of any of these control approaches. On line pH and traced
phosphate (using the XE-2 fluorometer) measurements are needed to implement these controls. It is
imperative to have good control over the boiler water pH.
1.4.5
Condensate Monitoring
There are now models of the 3D TRASAR Boiler System design to monitor condensate. Conductivity
and pH are continuously monitored. If the condensate does not meet the user-specified conditions a
relay is activated. This can be wired to a valve to dump the contaminated condensate and/or trigger
an alarm. Optionally corrosion (Nalco Corrosion Monitor) can also be monitored.
13

OM0211
1.5
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.
Maximum water pressure to the 3D TRASAR Fluorometer should never exceed 90 psi (6.2 bar),
unless equipped with a Nalco Sample Conditioning System.
Maximum water temperature should not exceed 110F (43C), unless equipped with a Nalco
Sample Conditioning System.
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.
The 3D TRASAR Boilers systems 060-BLxxxx.88 Models are designed for use in non-hazardous
areas. Contact NGES Help Desk for other installations. (Use 060-BXxxxx.88 Series Models)
The NCSM probe assembly (probes plus stainless steel cross and fittings) has been designed to
handle water at 2800 psi (193 bar) and 500F (260C). Since measurements are made at the
boiler feedwater pressure and temperature this probe assembly will be very hot and under high
pressure. Extra care should be taken when servicing the system.
The NCSM reference probe is always installed vertically. So, the base of the reference electrode
is at ambient temperature regardless of the water temperature flowing through the cell. The
base portion of the electrode is still at system pressure. Do not assume the sample line has
been closed and depressurized because the base of the reference electrode is not hot.
All piping should be insulated to maintain sample temperature and prevent accidental burns.
A lockable valve should be installed on the sample line to isolate the system for maintenance
and prevent unauthorized energizing of the system. Follow all lock out, tag out requirements for
servicing.
WARNING: Always turn off power before making any electrical connections, which
includes all interconnecting cables, otherwise permanent damage may occur to system
components.
SAFETY WARNING: The 3D TRASAR controller does not create sound above the 85
db noise level. Follow plant hearing protection regulations.
1.5.1
14
Explanation of Symbols
WARNING:
Risk of damage to equipment
CAUTION-DANGER:
High temperature, high pressure or electrical safety risk.
SAFETY WARNING:
Safety equipment is needed or plant safety procedures must be

followed.

OM0211_________________________________________________________________________
1.6
Installation, Assembly, Startup and Tuning Overview

There are 3 major steps to getting the system up and running: Installation, Assembly and Startup,
and PID Tuning. The Installation can be performed by Nalco service technicians, a local
contractor or by plant personnel. Nalco service technicians must perform Assembly and Startup.
PID Tuning will be completed after the system has been monitored long enough to understand
the boiler system dynamics and operation. Nalco service technicians will tune the system.
The complete process includes the following tasks:
Boiler feedwater system, sample point and feed point survey

Boiler blowdown piping and operation survey
1. Installation
Unpack system and identify parts
Mount panel (install frame)
Plumb the feedwater sampling system
- Sample lines
- Pressure test sample lines
- Double-insulate the sample lines
- Drain line
- Sample cooler line
Flush the sample line for 30 minutes
Run wires to control box
- Power
- 4-20 mA control wires
- Nalco Corrosion Stress Monitor (NCSM) wires (remote mount only)
- Interlock (steam flow)
- Phone line (optional)
- Ethernet line (optional)
- Optional analog and/or digital inputs
Install boiler blowdown equipment (optional)
- Plumb conductivity probe assembly
- Plumb blowdown flow control valve and motorized valve
- Run probe wires to 3D TRASAR Controller
- Run motorized valve wires to Relay Box
2. Assembly and Startup
Installation check and site safety check
Shut all 3D TRASAR Boiler System valves
Terminate wires in the control box
Install and connect TRASAR Fluorometer
Power up control system without sample or cooling water flowing
Configure system and upload to 3D TRASAR Controller
- Customer information
- Boiler information
- Probes
- 4-20 mA inputs
- Digital inputs
- Relays
- 4-20 mA outputs
- Communications
Reboot 3D TRASAR Controller
Verify configuration using controller keypad/screens
15

OM0211
Calibrate TRASAR Fluorometer

Nalco Corrosion Stress Monitor (NCSM) short circuit test
Refurbish and test reference electrode (NCSM)
Install reference electrode (NCSM)
System leak test and final piping insulation (NCSM)
Test data download to USB and laptop computer
Check remote communications LAN modem Wireless Gateway
Check Sample Conditioning System high-temperature shutdown
Calibrate boiler conductivity probes (optional)
Install and calibrate feed water pH and conductivity probes (optional)
Verify operation of control relays
Verify pump installation
- Power and 4-20 mA wiring
- Capability
- Check pump and treatment level responses to 4-20 mA changes
Measure system lag time
Ensure interlock connected or shutdown process established
Perform 0-100% oxygen scavenger pump test
Determine control set points (Sales Representative)
Manually open the blowdown control valve/relay and verify the blowdown conductivity set
point can be reached as expected.
3. PID Tuning (second site visit minimum 2 weeks monitoring required)

Check PID setup
Complete PID tuning (each loop)
Monitor PID control
Set PID to ON/OFF control if PID tuning cannot be completed (or leave in manual control).
16

OM0211_________________________________________________________________________
2.0 System Installation

2.1
2.1.1
Unpack and Identify Parts

Frames and Panels
Wall mount:
Configured for wall attachment. Select when floor space is restricted.
Frame mount:
Configured for floor-mounted installation. Select when all space is

restricted.
NCSM Module:
Enables installation of a second NCSM sensor.
Enclosed NCSM:
Provides weather resistant protection. Select for outdoor installations and

wet environments.
HP Sample Conditioning
System
Provides sample conditioning ahead of the fluorometer for samples up to

1500 psi (103 bar) and 500 F (260 C).
LP Sample Conditioning
System
Provides sample conditioning ahead of the fluorometer for samples up to

50 psi (3.4 bar) and 250 F (122 C). Select when sampling from deaerator
storage tank or before the boiler feedwater pump.
Nalco Global Gateway:
Enables wireless communication of important information such as alarms

and performance indicators.
Fluorometer:
Packed separately to prevent damage during shipping
NCSM Reference Probe
Packed separately to prevent damage during shipping
Blowdown Relay Box
Provides SPDT relays needed to operate motorized ball valves
Feed water pH and

conductivity probes
Packed separately to prevent damage during shipping. Install on piping

module between SCS and fluorometer
Blowdown conductivity
probe assemblies
Packed separately to prevent damage during shipping. Install on boiler

blowdown piping. Rated for 250 psi (17.2 bar) and 392F (200C).
17

OM0211
2.1.2
Items Requiring Assembly
Fluorometer
Qty. (1)
Part #
060-BT3220.88
(Scale Control Models)
Fluorometer Outlet
Assembly
Qty. (1)
Ethernet Crossover Cable (8 ft., orange)

Qty. (1)
Part # 991-05047661.88
Fluorometer Inlet Valve

and Tubing Connector
Qty. (1)
Service (Power) Cord 12/3 SJOW

Qty. (1)
Part # 991-01928722.88
ORP/RTD Cable (6ft) Qty (1)

Part # 6026390
ORP/RTD Cable with pre-amp (6ft) Qty (1) remote installations only
(1)
Part # 6031277
2.1.3
Additional Items
Fuses (4), Part #991-50473718
Installation Manual, Part # 521-OM0211.88
Reference Probe (NCSM) Qty. (1)

Part# 991-05058543.88
Fluorometer Cable Qty

Part# 060-TR5221.88
Additional Items Shipped Loose
060-TLM100.88
991-05058543.88
6026028
6018909 *
6018911
6018912
6018913
6018914
6018930
6018931
6031275
6031276
Literature
18
Feedwater
pHSJOW
and
Pigtail 16/3
conductivity
sensors
Qty. (5)
(Optional)
Part
# 991-05053481.88
Tank Level Monitor

NCSM Reference probe
Insulation wrap, 50 ft roll (2 each)
NCSM Accessory Kit - includes the parts listed below
10 cc plastic syringe
Special 14 SS hypodermic needle
Electrode, cell, with BNC, for calibration
High-vacuum grease, 5.3 oz tube
0.1 N KCl Solution, 250 ml bottle
3.8 M KCl, Solution, 250 ml bottle
BNC BA80 Adapter
Cotton Tip Grease Applicators (10/pkg)
Installation DVD, Blowdown DVD, NCSM DVD, Installation Checklist,Spec B-950

OM0211_________________________________________________________________________
500-BTSRKIT.88 *
460-S0980.75
460-S0726.75
500-P2817.88
500-P0116.88
500-P2147.88
500-BTSRKITLA.88 *
460-S0980.75
500-P2817.88
500-P0116.88
500-P2147.88
3D TRASAR Boiler Startup Kit includes the parts listed below

TRASAR 3 Calibration Solution, 1L Bottle
Hydrochloric Acid, 1:1, 1L bottle
Flow cell brush, 16
Beaker, 800 ml, plastic (3 each)
Syringe, 60cc, plastic (2 each)
3D TRASAR Boiler Startup Kit, less acid includes parts listed below
TRASAR 3 Calibration Solution, 1L Bottle
Flow cell brush, 16
* Note: Must be ordered separately
2.2
Mount the Panel

IMPORTANT: The 3D TRASAR controller is designed
to meet NEMA 4X standards for weather resistance. It
is recommended that the unit be installed in a sheltered
area to minimize the chance of water or debris entering
the enclosure when the cover is opened for wiring and
maintenance.
If the NCSM will not be installed in an indoor, protected
area the Enclosed Model must be used.
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
2.2.1
General Installation Instructions
1. Avoid installing the 3D TRASAR controller close (within 10 ft) to any high voltage source(s),
large motors, or any known generator of electrical noise. Boiler feedwater pumps are not a
problem.
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. The enclosed NCSM model must be used.
4. In cold weather climates, provision must be made to prevent any cooling water piping (for
sample cooling coil) from freezing.
5. The mounting location should be accessible to sample water (250-500 ml/min) and an
electrical power source (20 amp circuit at 85-250 VAC).
6. If installing a model that includes a Sample Conditioning System mount the system where
there is access to cooling water, typically 0.5-2.0 gpm (2-7.6 LPM).
7. Chemical feed pumps should also be located conveniently to the 3D TRASAR controller and
chemical feed tanks.
8. Mount the controller as close as possible to the feedwater sample point to minimize lag time.
A maximum distance of 100 ft (30 m) is desirable.
9. NCSM modules (no controller) can be mounted up to 1000 ft (305 m). (3 twisted pair,
shielded 22 AWG cable required)
10. Do not mount on vibrating walls or surfaces. Damage to critical components can occur .
19

OM0211
Note:
Sample points should be chosen based on many considerations:

- Sampled after the product has been applied to the system and has been mixed
- Water sample should be characteristic of that seen by as many boilers as possible
- The sample lag time must be minimized
- Existing customer sample spigots
- Cooling water availability
The preferred sample point is after the Feedwater pumps where the product has been mixed
thoroughly (See Section 1.4 and Appendix XX for additional information).
2.2.2
Wall Mounting
Panels should be mounted on a flat wall so that the controller is at eye level. All SCS panels must be
mounted 1-1/2 below the controller and sensor panel.
Wall Mount Controller & Sensor Panel
Dimensions:
12 D x 33 W x 42 H (31 cm x 84 cm x 107 cm)
Material:
PVC back panel
Mounting Holes:
7/16 diameter
Sample Conditioning System
Dimensions:
8 D x 33 W x 22 H (21 cm x 84 cm x 56 cm)
Material:
PVC back panel
Mounting Holes:
7/16 diameter
20

OM0211_________________________________________________________________________
2.2.3
Frame Mount Dimensions
Frame Mounted System

Dimensions:
Material:
29 D x 33 W x 66 H (74 cm x 84 cm x 168 cm)

PVC back panel on SS frame
21
22
Piping
isolation
valve
1/4" Tubing
connection
Cooling water
supply line
(approx. 0.5-2 gpm)
1/2" FNPT cooling

water connections
Cooling water
to drain
psi
1/4" SS tubing
(100 ft max)
Mustbe 2X insulated!
Pressure
gauge

(29"D x 33"W x 66"H)
SS filter purge line to drain
}
1/4" MNPT connection
(1/4" or 1/2" tubing to
unpressurized drain)
22 AWG
shielded cable
minimum
Power 120 VAC, 60Hz, 10A

(Optional Blowdown Relay Box)
N/O+N/C+Neutral to
Motorized Valves
Relief valve dischargeto drain
NOTE:
060-BLMxx.88, 060-BLLCxx.88 and
060-BLPCxx.88 Models require
240 VAC, 50Hz, 10A power
Install check
valve if there is
a chance of
backflow
Scavenger pump - 4-20mA

NexGuard pump - 4-20mA
Boiler interlock - dry contact
Power 120 VAC, 60Hz, 20A - MUST BE GROUNDED!
2.2.4
Lockable
valve
Feed water header sample: 250-500 cc/min at 1500 psi (103 bar), 500 deg. F (260 deg. C) max.

OM0211
Installation Overview Diagrams
Refer to the drawing in this section for general installation overviews
2.2.4.1 TRASAR Fluorometer and NCSM Feedwater Systems

Piping
isolation valve
1/2" FNPT cooling

water connections
Cooling water
to drain
psi
Cooling water
supply line
(approx. 0.5 - 2 gpm)
1/4" SS tubing
(100 ft max)
Mustbe 2X
insulated!
Pressure
gauge
Lockable
valve

(29"D x 33"W x 66"H)
1/4" Tubing
connection

(Optional Blowdown Relay Box)
N/O+N/C+Neutral to
Motorized Valves

22 AWG
shielded cable
minimum
NOTE:
Install check
valve if there is
a chance of
backflow

NexGuard pump - 4-20mA

OM0211_________________________________________________________________________
2.2.4.2 TRASAR Fluorometer Feedwater Systems
23
24
1/4" SS tubing
(100 ft max)
Mustbe 2X
insulated!
Pressure
gauge
psi
Discharge
(1/4" tubing)
1/4" tubing
connection
Piping
isolation
valve
Wall Mounted System

(8"D x 33"W x 42"H)
}
22 AWG
shielded cable
minimum
RTD
(4-wires)
AT ORP/REF
(2-wires)
NOTE:
Sample with SCS: 250-500 cc/min at 1500
psi (103 bar), 500 deg. F (260 deg. C) max.
NOTE:
If equipped with an SCS the RTD (4-wire)

and solenoid valve (H/N/G) wires must be
run from the SCS junction box to the 3D
TRASAR Controller in separate conduit.
NOTE:
When installing remoteAT ORP modules
signal wires must be run from the junction
box to the 3D TRASAR Controller.
2.2.4.3
Lockable
valve

OM0211
NCSM Feedwater Systems

psi
1/4" Tubing
connection
Piping
isolation
valve
1/2" FNPT
cooling water
connection
NOTE:
Sample line from boiler must be
plumbed following the
"Continuous Blowdown" diagram
(sample takeoff where conductivity
probe is located on diagram)
1/2" FNPT
cooling water
connection
Cooling water
supply line
Cooling water
to drain
1/4" SS tubing
(100 ft max)
Pressure
gauge

(29"D x 33"W x 66"H)

(22 AWG shielded

cable minimum )
Relief valve discharge to drain

(Blowdown Relay Box)
N/O+N/C+Neutral to Motorized Valves
NOTE:
Install check
valve if there is
a chance of
backflow
Modulating Blowdown
Valve (4-20mA)
2.2.4.4
Lockable
valve
Blowdown sample: 250-500 cc/min at 1500 psi (103 bar), 500 deg. F (260 deg. C) max.

OM0211_________________________________________________________________________
TRASAR Fluorometer Blowdown Systems
25

OM0211
2.2.4.5
Continuous Blowdown Conductivity Probe and Valves
Notes:
1. The gate valve upstream from the conductivity probe should be fully open when the boiler is running (to prevent
flashing at the probe).
2. Flow control valves downstream of the conductivity probe must be throttled back to create backpressure to
prevent flashing at the probe and/or control valve).
3. If a fluorometer will be used to control blowdown the sample takeoff point should be located where the
conductivity probe is shown in the diagram.
26

OM0211_________________________________________________________________________
2.2.4.6
Timed-Sample Blowdown Conductivity Probe and Valves
Notes:
1. The gate valve upstream from the conductivity probe should be fully open when the boiler is running (to
prevent flashing at the probe).
2. Flow control valves downstream of the conductivity probe must be throttled back to create backpressure
to prevent flashing at the probe and/or control valve).
27
28
psi
Piping
isolation
valve
Cooling water
to drain
1/2" FNPT cooling

water connections
Cooling water supply line

1/4" Tubing connection
1/4" SS tubing
(100 ft max)
Mustbe 2X insulated!
Pressure
gauge
Lockable
valve

(29"D x 33"W x 66"H)

(Blowdown Relay Box)
N/O+N/C+Neutral to
Motorized Valves
Install check
valve if there is
a chance of
backflow

Condensate sample: 250-500 cc/min at less than 50 psi (3 bar), 250 deg. F (121 deg. C) max.

OM0211
2.2.4.7 Condensate Monitor

OM0211_________________________________________________________________________
2.3
Plumb the System
2.3.1
Plumbing Requirements
The 3D TRASAR Boilers Systems have the following plumbing requirements, depending on the
components included in the specific model ordered.
Feedwater or Fluorometer-Based Systems

Plumbing
Requirement
Sample line
Discharge line
Cooling water line
Plumbing
Requirement
Sample
Models with Sample

Conditioning Systems
NCSM Models without Sample

Conditioning Systems
SS tubing, rate for 1500 psi

(103 bar), 500F (260C) minimum.
SS tubing, rate for 2800 psi (193

bar), 500F (260C) minimum.
Pressure tested
Pressure tested
Flushed prior to system connection
Double insulated up to system
Double insulated up to system
Lockable valve at take off point
Pressure gauge at take off point
tubing or pipe run to

unpressurized drain or flash tank
SS tubing, rate for 2800 psi (193

bar), 500F (260C) minimum.
NA
Pressure tested
NA
Plumbed to system able to accept 500

cc/min sample at 2800 psi (193 bar),
500F (260C) minimum.
tubing or pipe
NA
Blowdown or Condensate Conductivity Probe Assembly

Piping reduced to at assembly cross. Rated for 250 psi (17.3 bar) at
392F (200C) maximum.*
Note: A Sampling Conditioning System will be needed if the sample pressure and temperature
exceeds the conductivity probe limits.
Plumbing
Requirement
Sample line
Condensate Monitor
SS tubing, rate for 50 psi (3 bar), 250F (121C) minimum.
Pressure tested
Insulated up to system
Discharge line
tubing or pipe run to unpressurized drain or flash tank
Cooling water line
tubing or pipe
29

OM0211
2.3.2
Plumbing Connections
The 3D TRASAR Boilers Systems have the following plumbing connections, depending on the
components included in the specific model ordered.
Feedwater System Components
Connection Type
NCSM
Fluorometer
Sample
Conditioning
System
Tube Fitting
FNPT
FNPT
Tube Fitting
MNPT
FNPT
Tube Fitting
Tube Fitting
NA
Tube Fitting
FNPT
FNPT
X
X
X
Sample Inlet
Sample Outlet
Cooling Water
Inlet & Outlet
Condensate System Components

pH &
Conductivity
NCM100
X
X
30
Connection Type
Sample Inlet
Sample Outlet
Cooling Water
Inlet & Outlet
Tube Fitting
FNPT
FNPT
Tube Fitting
FNPT
FNPT

OM0211_________________________________________________________________________
2.3.3
Plumbing Notes
2.3.3.1 Sample Point

The feedwater sampling point must be located where adequate mixing of the NexGuard and
oxygen scavenger has occurred. A sample point downstream of the feedwater pump is
preferred. If a sample tap cannot be installed at this location the sample point should be located
at least 10 pipe diameters from the chemical injection point, preferably after at least one pipe
bend.
The condensate sample point should be located downstream of potential contamination
sources where the condensate line will be full. Condensate receiver tanks offer a convenient
sample location.
It is extremely important to eliminate entrapped air or particulates in the feed water line. This
can be accomplished by sampling from pipe approximately 2 from the internal pipe wall using a
stainless steel sample quill inserted through the side of the pipe (see Replacement Parts
and Accessories).
Be sure to select a sample point where the feedwater pipe will be fully flooded. Avoid vertical
pipe runs for sample points unless the flow is upwards. It is usually acceptable to use the
deaerator drop leg for a sample point. Since it is typically flooded.
Never sample from the bottom of a horizontal pipe run. Particulates be carried into the sample
line and clog filters and/or valves
Install an approved lockable valve on the sample line at the sample point (for lock out, tag out).
A secondary isolation valve is installed at the sensor assembly to facilitate maintenance.
The NCSM sample point for utility boilers should be prior to the deaerator. Probe locations will
vary according to plant type and configuration. Conduct a full plant feedwater audit to identify
NCSM sample locations where the measurement of reduction-oxidation (REDOX) stress will
provide the most benefit. Contact the 3D TRASAR Help Desk.
2
Sample
Point
Sample
Point
5
1
3
Horizontal pipe
1.
2.
3.
4.
5.
1
Vertical pipe
Vertical pipe
Guidance for Selection of Suitable Sample Points:

Select point that provides best opportunity for a reliable sample
Minimize potential for vapor in sample
Avoid locations that could introduce excessive suspended solids
Vertical piping OK if it is the deaerator dropleg since no bubbles present
Use a SS sample quill that extends approx. of the radius (2 maximum) into the pipe.
31

OM0211
2.3.3.2
Sample Lines
Sample water flow of 250-500 ml/min is typically required. If the flow drops below 200 ml/min
the control will cease and the unit will alarm.
Use OD 316 stainless steel tubing for all sample lines. Larger diameter tubing or the use of
piping will greatly increase sample lag time and adversely affect control.
Pitch the sample line downward at least 10 towards the sample outlet.
Minimize the number of valves, fittings and elbows. Bend tubing rather than installing a fitting.
Avoid traps or pockets where fluid or sludge can collect.
Throttle the sample flow at the Sample Conditioning System rotameter or NCSM discharge
(NCSM only models).
The NCSM probe should ideally be located within 40 ft (12.2 m) of the sample take-off point. A
distance of 100 ft (30 m) is tolerable (total piping length). Long distances create temperature
losses, which affect probe performance.
The NCSM measurements are made directly on the un-cooled sample and are not temperature
compensated. All sample lines must be well insulated (2X wrapped) to ensure that the
temperature of the water reaching the probe is as hot as possible and has a constant
temperature. Insulation is also needed to protect personnel from the hot tubing.
The sample flow rate must be kept constant to ensure accurate measurements and obtain good
dosage control. Keeping a constant temperature and flow rate will also help troubleshoot any
questionable NCSM values.
Insulating should be performed after it has been ascertained that there are no leaks. Be sure to
insulate the NCSM probe as described in this manual.
A pressure gauge must be installed on the sample line downstream from the lockable valve.
So, the pressure in the line can be checked prior to any maintenance.
It is recommended that a valve be installed on the end of the sample line. This will allow the
control panel to be completely isolated.
A Nalco Corrosion Monitor (NCM100) probe can be installed on the 3D TRASAR System inlet
plumbing providing the sample temperature is under 250F (121C) and under 1000 psi (69
bar). The probe must be installed in the special 1 x 3/8 tee such that the probe tips are
pointing down into the sample flow. The discharge from the tee must be upward (discharge
form 3/8 side port) to ensure the tee remains flooded.
Strip insulation should be double and triple wrapped to minimize
heat loss from the sample line and NCSM probe. The NCSM cell
(cross) should be insulated last with a small piece of insulation
that can easily be removed when the probes need to be
refurbished or checked. Be sure to leave access to the SS fittings
on the probes (that connect the probes to the cross). Do not
insulate the ORP/RTD and Reference probes. The picture shows
the cross after insulation has been applied.
32

OM0211_________________________________________________________________________
NOTE:
During initial startup, the sample is likely to contain solids (such as oxides of iron, grease,
dirt, etc.) that settle in the sample tubing. It is very important that these solids be flushed
out to avoid plugging of the system. The incoming sample line should be purged for 15 to
20 minutes prior to connecting it to the sample conditioning system
CAUTION-DANGER: The discharge from the line will be flashing steam. It must be
directed to a drain capable of accepting water at the systems operating temperature and
pressure. Maximum for NCSM is 2800 psi (193 bar0, 500F (260C).
2.3.3.3
Discharge Line
Sample discharge should flow unrestricted to a free-falling drain/vessel with no backpressure

that can damage the fluorometer.
Pipe rises greater than 10 feet [3m] should be avoided. If the discharge must be located above
the system install a check valve on the discharge line.
NOTE:
Ensure that if there is no feedwater flow (FW pumps turned off) boiler water does not
siphon back through the 3D TRASAR skid. There should be FW check valves in place to
prevent this from occurring (do not assume that they exist or are working they need to be
checked). This siphoning could cause a high temperature alarm and control suspension
and skid-flow shut down even if the SCS is in operation.
Do not combine the discharge from other controllers.
CAUTION-DANGER: Do not combine the fluorometer or NCSM sample discharge with the
SS filter purge line, pressure relief vent, or NCSM pressure bleed
vent into a single manifold. This will prevent the safety devices from
functioning properly.
The sample water outlet flow can be plumbed into a containment vessel and pumped to an unpressurized condensate receiver to minimize waste.
On NCSM models without sample coolers, the sample discharge line must be insulated to
protect personnel from the hot tubing.
CAUTION-DANGER: The discharge from a NCSM not equipped with a Sample

Conditioning System must be cooled and depressurized unless the
system receiving the discharge can safely accept 500 cc/min at 2800
psi (193 bar), 500F (260C).
2.3.3.4
Cooling Water Lines
Chilled water should be used.

The cooling water inlet is at the bottom of the sample cooler and cooling water outlet is at the
top.
The purpose of the sample conditioning system is to cool the sample below 110F (43C) and
depressurize the sample to below 50 psig. So, it is safe for workers and the instrumentation.
Typical cooling water flow rate will be in the 0.5 to 2 gallons per minute range.
It is recommended that both the cooling water inlet and outlet lines be fitted with a tee and two
valves. This will to allow the cooling water to be drained and cooler shell to be flushed with acid
to remove any scale.
Cooling water to be used should be of good quality, free from suspended solids and
miscellaneous debris. Cooling water must flow continuously and at a constant pressure.
33

OM0211
2.3.3.5
Blowdown Conductivity Probe Assembly, Control Valve and Flow Control

Valve
A conductivity probe, control valve (motorized ball valve) and flow control valve must be installed on
each boiler where blowdown will be controlled using conductivity. All are ordered separately. The
plumbing arrangement is dependent on the blowdown requirements. The diagrams below illustrate
the installation for continuous sampling; recommended for systems blowing down > 5000 lbs/hr
(2273 kg/hr) and intermittent sampling; recommended for systems blowing down < 5000 lbs/hr
(2273 kg/hr).
34

OM0211_________________________________________________________________________
IMPORTANT NOTES:
1. The maximum temperature and pressure the conductivity probe can handle is 392F (200C)
and 250 psig (17.2 bar). If the boiler operates above these conditions a sample conditioning
system must be installed upstream of the conductivity probe to reduce the temperature and
pressure.
CAUTION-DANGER: DO NOT install the conductivity in a boiler above 392F
(200C) and 250 psig (17.2 bar). Probe failure and serious
personal injury will result.
2. Both flow control valves downstream of the conductivity probe must be throttled back
to maintain backpressure in the lines. The valves cannot be in the wide-open position.
Otherwise, flashing in the line will occur if the line discharges to atmospheric pressure.
WARNING:
Flashing will damage the conductivity probe and valve seals.
3. Restrictions in the piping upstream of the conductivity probe can cause a pressure drop and
flashing. This will result in erratic readings and damage the probe and valve seals. All
upstream isolation valves should be full-port and set to fully open.
35

OM0211
4. The motorized ball valve and flow control valve must be installed downstream from the
conductivity probe.
DO NOT install the conductivity probe between the valves. Flashing will occur.
5. The flow control valve must be installed downstream from the motorized ball valve to prevent
flashing. Mount within 12-18 (0.3-0.5 m) of the motorized ball valve to avoid water hammer.
DO NOT exceed 18 (0.5 m) or flashing may still occur inside the ball valve.
6. To ensure the piping remains full at the conductivity probe run a segment of piping
downstream of the probe above the level of the probe cross (see diagram).
7. Likewise, wide spots (small diameter piping bushed up to larger piping) upstream of the
probe will cause flashing. Larger diameter piping from the boiler should transition down to the
cross and probe without reverting to pipe segments of increased diameter. In addition,
larger diameter piping should not be installed immediately downstream the cross.
8. Ensure the flush valve installed on the bottom of the cross and probe closes properly.
Leaking will cause flashing at the probe or improper flooding of the conductivity probe.
9. The conductivity probe must be installed so the flow-through hole in the probe is in line with
the sample flow. The K-factor is stamped on the probe and is aligned with the hole (see
photo).
10. Mount the probe cross in a horizontal pipe run at least 2 ft (0.6 m) downstream of any
elbows or fittings that may cause turbulence.
DO NOT mount the probe on a vertical pipe run.
11. Piping can be reduced to diameter downstream of the conductivity probes on boilers with
blowdown rates under 5000 lbs/hr (2273 kg/hr). So, a motorized ball valve and flow
control valve can be used.
12. Mount the motorized ball valve away from the boiler. So, it does not overheat the electronics.
13. Follow pipe length guidelines shown on the diagrams. Piping that is too lengthy will require
longer flush times for the piping and probe to reach boiler water temperatures (required for
accurate measurements). On smaller boiler systems this may result in excessive boiler
blowdown.
36

OM0211_________________________________________________________________________
2.3.3.6
Condensate Conductivity Probe Assembly/Sample Take-Off, Control Valve

and Flow Control Valve
Condensate lines can be monitored using a conductivity probe assembly installed directly into the
condensate line. Alternately, a sample line can be run to the 3D TRASAR Condensate Monitor where
pH, conductivity and corrosion (via NCM100) are monitored. In either case a flow control valve must
be installed on the sample line to ensure the probe sample lines are full. A 3-way motorized control
valve can be installed on the condensate line to dump contaminated condensate.
Conductivity
Probe or Sample
Take-Off
3-Way Valve
Condensate
Receiver Tank
Throttling
Valve
Condensate
Storage Tank
Condensate
Pump
Condensate
Dump
Notes:
1.
The condensate probe assembly (P/N 060-BCP100.88) is similar to the blowdown probe
assembly except it is designed for measuring lower levels of conductivity (up to 500 S/cm)
and includes an RTD for temperature compensation. Follow the probe plumbing guidelines in
Section 2.3.3.5.
CAUTION-DANGER:
2.
DO NOT install the conductivity probe in a condensate line

above 392F (200C) and 250 psig (17.2 bar). Probe failure
and serious personal injury will result.
Use SS tuning for the sample take-off for the 3D TRASAR Condensate Monitor. Follow the
sample line guidelines outlined in Section 2.3.3.2.
CAUTION-DANGER:
Samples supplied to the 3D TRASAR Condensate Monitor

must have a pressure below 50 psi (3.4 bar). If the
Condensate Monitor is equipped with the optional NCM100
the sample temperature must also be below 250F (121C).
37

OM0211
2.3.3.7
Boiler NCM100 Probe Installation
The high-temperature, high-pressure NCM100 probe must be used for boiler feedwater applications
(Nalco P/N 400-NCCMP6.88). A NPT compression fitting is included with the probe. There are two
ways of installing the boiler probe assembly.
Into a stainless steel housing

Into system piping
Note: The boiler NCM100probe is rated for 1000 psi (69 bar) and 250F (121C) maximum.
Note:
The boiler NCM100is recommended for samples over 5 S/cm and over 200F (93C)
CAUTION-DANGER:
Installation of a bleed valve with the boiler corrosion probe assembly

is highly recommended to allow proper and safe depressurization of
system lines prior to probe removal. If system
lines are not properly depressurized, probe
ejection may occur upon removal.
Installing into a Tee Fitting

The probe assembly 400-NCMP6.88 can be installed in a 1 stainless steel
housing (Nalco P/N 400-NCMAC13.88). Insert the probe assembly into the
housing carefully. The probe should be oriented vertically as shown below. It is
crucial that the electrode tips are flooded and positioned against the direction of
the oncoming flow. An alignment notch can be found on the probe body. The
notch must be in line with the direction of water flow. If using the 1 stainless
steel housing the nut on the housing can be tightened down when 3-9/16 of the
probe body protrudes above the nut. See illustrations
Installing into System Piping
The boiler NCM100 probe assembly (Nalco P/N) 400-NCMP6.88 can
also be installed directly in system piping using the NPT compression
fitting included with the probe. Carefully insert the probe assembly into a
pipe tee as shown below. The probe should be oriented so that the
electrodes are flooded and are perpendicular to the direction of the water
flow. An alignment notch can be found on the probe body. This notch
must be in line with the direction of the water flow. See illustration below.
The length of the probe body protruding above the nut will change with
pipe size.
The boiler NCM100 probe has an adjustable insertion length that is
limited by the overall probe length (8) Pipe reducers needed for
installations on pipes over 1 OD will reduce the distance the probe can
actually be inserted into the pipe.
Note:
38
A flow rate of 5 gpm (19 lpm) is recommended. Lower flow rates

can result in higher (pitting) corrosion rates.

OM0211_________________________________________________________________________
3.0
Electrical Connections and Wiring
3.1
Run Wires to the Control Box
Wires for the following items must be connected at their source and run to the control box. DO NOT
terminate the wires inside the 3D TRASAR Controller. These will be completed during startup.
IMPORTANT NOTE: The 3D TRASAR Boiler Control System MUST BE PROPERLY
GROUNDED! Measurements will drift badly or be erratic if the unit is
not grounded. See Appendix for testing procedure.
Controller supply power must be 120 VAC, 60Hz at 20 amps or 240 VAC, 50 Hz at 10 amps
on a dedicated GFCI protected circuit (install lockable disconnect if hardwired). See
Appendix I for power requirements by model number.
A separate power circuit is required for the blowdown relay box; 120 VAC, 60Hz at 10
amps or 240 VAC, 50 Hz, at 5 amps.
4-20 mA control wires (Scavenger pump and NexGuard pump)

NCSM wires (remote mount module only)
Interlock (steam flow)
Phone line (optional)
Ethernet line (optional)
Optional analog or digital signals
Blowdown conductivity probes and motorized ball valves (See Section 3.2.7 for details)
CAUTION-DANGER: Always turn power OFF before making any electrical

connections or connecting or disconnecting wires, cables or
connectors or permanent damage may occur to components.
Follow plant lock out, tag out procedures.
All electrical connections must conform to applicable state and local codes.
A power cord without termination has been provided. A proper plug for 20-amp service must be
provided or the unit may be hard wired (using 12 AWG wire).
If an extension cord is used, it must be a grounded 3-prong type. Using an ungrounded 2-prong
plug will result in inaccurate readings.
Failure to provide 20-amp (dedicated) service could result in intermittent operation, caused by
circuit breaker overload.
Signal wires must be brought into the controller via waterproof cable glands.
Pump connections (ON/OFF control only) can be made via supplied pigtails with receptacles or
hardwired (using 14 AWG wire) directly to the terminals inside the control box as appropriate.
There are 5 control relays individually fused at 2.5 amps (designed to operate at 2 amps
maximum). In cases where more amperage is required, the control relays can be wired as dry
contacts for motor starters.
The alarm relay is fused at 1 amp.

Each control output and alarm output is fused. A fuse holder is located adjacent to each relay. To
replace a fuse, remove the snap-on cover. Replacement fuse is rated 2.5 amps for control
outputs and 1 amp for alarm outputs. Make sure the power is disconnected.
Use 22 AWG shielded cable (minimum) for remote NCSM, analog and digital signal, RTD, and
blowdown conductivity probe wires.
Each conductivity probe installed in the blowdown line will require 4 wires (8 wires if temperature
compensating). Use 2 or 4 shielded twisted pair 22 AWG cable. (See Section 3.2.7.2)
The phone line connection is located inside the controller box. A RJ11 analog phone jack must be
provided.
Do not overtighten power supply terminal strip connections. This may damage the terminal strip.
39

OM0211
3.2
Terminate Wires in the Control Box
Note:
Wires should only be connected in the 3D TRASAR Controller by a qualified Nalco Service
Technician.
Refer to diagrams and charts for details on wiring connections.

Cables for the NCSM probes and Sample Conditioning System will be wired in the controller at the
factory. Connect the remaining wire and cabling as follows:
3.2.1
System Power Connections
Connection
Description
Line Power
Neutral
Ground
Controller Box
Board Reference
TB1-1
TB1-2
TB1-3
Controller Box
Terminal
L
N
Gnd
Wire Color
Black or Brown
White or Blue
Green
IMPORTANT NOTE:
The 3D TRASAR Boiler Control System MUST BE PROPERLY

GROUNDED! Measurements will drift badly or be erratic if the unit is
not grounded. See Appendix for testing procedure.
IMPORTANT NOTE:
Verify the NEUTRAL is properly connected. Measurements will be

erratic and RTD failures will result if the neutral is lost or improperly
connected.
3.2.2
Internal Power Connections
Connection
Description
Power Switch Neutral
Power Switch Line
Switched AC Neutral
Switched AC Line
3.2.3
Controller Box
Terminal
N
L
N
L
Wire Color
White
Black
White
Black
Fuses
Fuse Description
Main Power Fuses (2)
Alarm Fuse (1)
Relay Fuses (5)
40
Controller Box
Board Reference
E1
E2
E3
E4
Rating
1 Amp
1 Amp
2.5 Amp
Supplier Information
5x20 mm, Slo-Blow (Littlefuse 218 1.00)
5x20 mm, Slo-Blow ( Littlefuse 218 1.00)
5x20 mm, Slo-Blow (Littlefuse 218 2.50)

OM0211_________________________________________________________________________
3.2.4
3.2.4.1
Control Relay Connections

Control Relays Powered and Non-Powered Wiring
There are five control relays in the 3D TRASAR Boiler controller that can be wired for powered or
non-powered operation. Follow the wiring diagrams below to connect metering pumps and valves for
powered control relay outputs (120/240 VAC, fused at 2.0 amps).
Note 1:
Connecting the control relays to a capacitive-type load (such as a motor-driven pump) will
damage the relay contacts. Always follow the manufacturers pump and valve wiring
connection guidelines.
Note 2:
The factory wired jumper must be removed from control relay terminals C and L in the
controller box in order to remove power from the relay output.
2.5 A
Fuse
Contact
NO
BLK
GRN
WHT
3D TRASAR Boiler
Controller
Figure 1: Typical Powered Relay from Controller Box (pumps below 2.0 amps)
2.5 A
External
Power (+)
Fuse
Motor Starter
Contact
Contact
External
Neutral (-)
N
NO
GRN
BLK
WHT
WHT
L
Earth
Ground
GRN
BLK
3D TRASAR
Boiler Controller
Motor
Starter
Motor
Starter
External Motor
Starter Neutral (-)
External Motor
Starter Power (+)
Figure 2: Typical Non-Powered Relay from Controller Box (pumps over 2.0 amps)
41

OM0211
3.2.4.2 Relay Connection Inside Controller.

The table below lists the five control relays and their associated terminal connections.
Note:
Terminal strip connections are not the same as those in the 3D TRASAR Cooling
Controller.
Connection
Description
Control Relay 1
Control Relay 2
Control Relay 3
Control Relay 4
Control Relay 5
Note:
42
Controller Box
Board Reference
TB2
TB2
TB2
TB2
TB2
TB3
TB3
TB3
TB3
TB3
TB4
TB4
TB4
TB4
TB4
TB5
TB5
TB5
TB5
TB5
TB6
TB6
TB6
TB6
TB6
Controller Box
Terminal
(GND)
N
NO
C
L
(GND)
N
NO
C
L
(GND)
N
NO
C
L
(GND)
N
NO
C
L
(GND)
N
NO
C
L
Description
Earth Connection
AC Neutral
Normally Open Contact 1
Common Contact 1
AC Hot (Line)
Earth Connection
AC Neutral
Common Contact 2
AC Hot (Line)
Earth Connection
AC Neutral
Common Contact 3
AC Hot (Line)
Earth Connection
AC Neutral
Common Contact 4
AC Hot (Line)
Earth Connection
AC Neutral
Common Contact 5
AC Hot (Line)
Be careful not to overtighten wiring connections. Damage to the relay may result.

OM0211_________________________________________________________________________
3.2.4.3
Blowdown Valve Relay Box Connections
The optional Blowdown Valve Relay Box provides 4 single-pole, double-throw relays that can be used
to power open and power closed motorized ball valves. It will be pre-wired to relays 1-4 in the 3D
TRASAR Boiler controller. All connections to the valve are made in the Blowdown Valve Relay Box.
Note:
Although the blowdown valve is grounded via the piping local regulations may require a
ground wire to be run from the valve to the relay box. There is a grounding strip in the box.
3D TRASAR
Controller
Relay
Connections
Blowdown Relay Box (4 Relays)

Motor Actuator
Connections
5
NO
SPDT Relay
R1
Coil + (5)
115
Relay
Coil
Coil - (1)
NO (3)
To motorized ball valve N/O 1
NC (2)
To motorized ball valve N/C 1
Common (4)
OMRON
G2R-1-S-AC120R
NO
SPDT Relay
R2
Coil + (5)
115
Relay
Coil
Coil - (1)
NO (3)
NC (2)
Common (4)
OMRON
G2R-1-S-AC120R
NO
SPDT Relay
R3
Coil + (5)
115
Relay
Coil
Coil - (1)
NO (3)
NC (2)
Common (4)
OMRON
G2R-1-S-AC120R
NO
SPDT Relay
R4
Coil + (5)
115
Relay
Coil
Coil - (1)
NO (3)
NC (2)
Common (4)
Fuse
10A, SloBlo
OMRON
G2R-1-S-AC120R
120 VAC
Power Supply
Connections
120 VAC Hot
To motorized ball neutral 1

120 VAC Neutral

Earth Ground
Attached to Back Plate
43

OM0211
Note:
Wire 3-way valve right and left connections to the NO and NC terminals (check
valve positions).
3.2.5
Alarm Relay Connections
There is one alarm relay in the 3D TRASAR Boiler controller. It is initiated by the user alarm
(firmware) configuration. It is not wired to a power source and is fused at 1.0 Amps.
C
NO
NC
Figure 3: Alarm Relay Diagram

Connection
Description
Alarm Relay 1
3.2.6
Controller Box
Terminal
C
NO
NC
Description
Common
Normally Open Contact
Normally Closed Contact
Fluorometer Connections
Connection
Description
FW Fluorometer
BD Fluorometer
44
Controller Box
Board Reference
TB7
TB7
TB7
Controller Box
Board Reference
TB20
TB20
TB20
TB20
TB21
TB21
TB21
TB21
Controller Box
Terminal
6V
GND
1B
1A
6V
GND
2B
2A
Description
White with Blue Stripe
Blue with White Stripe
Orange with White Stripe
White with Orange Stripe
White with Blue Stripe
Blue with White Stripe
Orange with White Stripe
White with Orange Stripe

OM0211_________________________________________________________________________
3.2.7
3.2.7.1
Conductivity Probe Connections

Compensating vs. Non-Compensating Conductivity Probes
There are two types of conductivity contacting probe models supported.
Compensating
These probes are used for boiler blowdown monitoring where the sample temperature varies
significantly or for condensate line monitoring. They have a built-in 4-wire RTD to measure the
sample temperature. The controller corrects the conductivity measurement based on its temperature.
A probe with a cell constant of 1.0 (conductivity = 5 - 10,000 S/cm) is used for blowdown
measurements.
A probe with a cell constant of 0.1 (conductivity = 1 500 S/cm) is used for condensate
measurements
Note:
A maximum of 3 RTDs can be connected to the 3D TRASAR Controller (1 is required for the
NCSM (RTD 2) and 1 is required for the Sample Conditioning System (RTD 1)).
Note:
Nalco Best Practices is to use a compensating probe if there is only one boiler to control.
The integral RTD can then be wired to the RTD 3 input.
Non-compensating
These are the standard probes used for blowdown and feed water monitoring where the sample
temperature does not vary significantly. They do not include a built-in 4-wire RTD for temperature
compensation.
A probe with a cell constant of 1.0 (conductivity = 5 - 10,000 S/cm) is used for blowdown and
high-conductivity feedwater measurements.
A probe with a cell constant of 0.1 (conductivity = 1 500 S/cm) is used for high-purity feed
water monitoring.
Note:
The 0.1 cell constant probe should be used on high-purity samples (conductivity < 100
S/cm).
Note:
The conductivity probe for feedwater monitoring (room temperature) has a PVC cover on the
wires. The wiring and probe potting cannot withstand high temperature samples.
Note:
When monitoring boiler feedwater the RTD on the sample conditioning system can be used
for temperature compensation.
45

OM0211
Conductivity Probe Identification
High range probes (K = 1.0) have a flow-through hole that exposes only a small amount
of the electrode. Range: 5-10,000 S/cm.
Low range probes (K= 0.1) have a large oval-shaped flow-through hole. The entire
electrode element is exposed. Range: 0-500 S/cm.
Conductivity probes rated for high temperature (condensate or blowdown) have 8

Teflon coated leads and high-temperature potting. Maximum Limits: 250 psi (17.2 bar)
and 392F (200C).
Blowdown Probe
(Non-compensating)
Nalco P/N 6035384
Blowdown Probe
(Compensating)
Nalco P/N 6034004
Conductivity probes rated for lower temperatures/pressures (cooled feedwater) have 48

PVC coated leads. Maximum Limits: 200 psi (13.8 bar) and 158F (70C)
Feedwater High-Range Probe

(Non-compensating)
Nalco P/N 6035385
Note:
46
Condensate Probe
(Compensating)
Nalco P/N 6034005
Feedwater Low-Range Probe

(Non-compensating)
Nalco P/N 6035386
Some conductivity probes are supplied with 2 Black Wires and 2 Red Wires (and 2 Green
and 2 White Wires on Compensating Probes) to eliminate the need for jumpers.

OM0211_________________________________________________________________________
3.2.7.2
Conductivity Probe Wiring
Conductivity Probe Wires and Jumpers
Correct wiring of the probes is very important.

Use a minimum of 22 AWG, shielded wire (each pair is shielded).
Probes wire lengths cannot exceed 1000 ft (305 m).
PROBES MOUNTED ON THE CONTROLLER PANEL (feedwater)

Probe red and black wires are jumpered inside the 3D TRASAR Controller.
ALL REMOTE MOUNTED PROBES (blowdown or condensate)

The red and black wires must be jumpered at the J-box. Wires must be jumpered on the probe
input side of the terminal strip inside the J-box.
Jumpering the wires at the probe end enables 4 wires for the conductivity and 4 wires for the RTD
(if using a probe with an integral RTD) to be sent back from the probe to the controller. Since the
conductivity probe is normally installed a distance away from the controller, sending the
conductivity/RTD signal through 4 wires will compensate for the length of the cable that is used.
Signal loss will occur if the conductivity or RTD signal is sent through 2 wires (instead of
four wires) over a distance.
Wires from probe (with jumpers)
Input
J-box
Output
Wires connected to controller

IMPORTANT
NOTE: Probes supplied in 2010 are equipped with 2 red and 2 black
wires (and 2 green and 2 white wires for temperature compensating
probes). This eliminates the need to add jumpers in the field. All 4 (or 8)
wires must be connected in the controller.
47

OM0211
Feedwater Conductivity Probe Wiring (non-compensating):
Since the feedwater conductivity probe is very close to the controller (mounted on same panel)
connections are made in the controller (TB13-15).
Connect the probe red wire to the (-) terminal (this wire is physically attached to the body of the
probe). Add a jumper wire from (-) to (S-).
Connect the probe black wire to the (+) terminal (as this wire is physically attached to the center
conductor of the probe). Add a jumper wire from (+) to (S+).
Note:
The Sample Conditioning System RTD can be used for temperature compensation of
feedwater conductivity measurements. This is normally wired to the RTD 1 input (TB-9) and
is assigned in Configurator.
22 AWG
shielded wire
Black wire
Red wire
Conductivity probe
Note:
48
+
S+
S+
S+
S-
22 AWG
shielded wire
Black wires
Conductivity Inputs
(TB13-TB15)
Red wires
+
S+
S+
S+
S-
Conductivity Inputs
(TB13-TB15)
Conductivity probe
Some conductivity probes are supplied with 2 Black Wires and 2 Red Wires to
eliminate the need for jumpers. Connect all 4 wires to the controller.

OM0211_________________________________________________________________________
Blowdown Conductivity Probe (non-compensating):
Since the blowdown conductivity probe is installed at a distance away from the controller, 4 wires are
needed to compensate for the length of the cable that is used. Connections must be m ade in the Jbox and in the controller.
Black wire
Black
Black
Red
Red
Red wire
+
S+
S+
S+
S-
Conductivity Inputs
(TB13-TB15)
J-Box
22 AWG
shielded wire
Conductivity probe (2-wire)
Note:
Some conductivity probes are supplied with 2 Black Wires and 2 Red Wires to eliminate the
need for jumpers. Connect all 4 wires to the controller.
Black wires
Black
Black
Red
Red
Red wires
+
S+
S+
S+
S-
Conductivity Inputs
(TB13-TB15)
J-Box
22 AWG
shielded wire
49

OM0211
On the input side of the J-box terminal strip, connect the probes red wire to the first terminal.
Add a jumper wire across the first and second terminals. On the output side of the terminal strip,
connect a signal wire to each of the 2 terminals (opposite the probes red wire and jumper).
On the input side of the J-box terminal strip, connect the probes black wire to the fourth terminal.
Add a jumper wire across the third and fourth terminals. On the output side of the terminal strip,
connect a signal wire to each of the 2 terminals (opposite the probes black wire and jumper).
Connect the 2 wires from the probes red wire to TB13-15 (-) and (S-) terminals in the controller.
Connect the 2 wires from the probes black wire to TB13-15 (+) and (S+) terminals in the
controller.
Note:
To minimize wiring errors between the J-box and controller, use color coded wires. Two
separate twisted pair cables can be used (2 red wires and 2 black wires). See photo at the
beginning of this section.
Blowdown/Condensate Conductivity Probe (compensating):

Since the blowdown/condensate conductivity probe is installed at a distance away from the controller
4 wires for conductivity and 4 wires for temperature are needed to compensate for the length of the
cable that is used. This probe has an integral 4-wire RTD (2 white & 2 green wires). Connections
must be made in the J-box and in the controller. However, since the RTD already has 4 wires, only
the conductivity wires (red & black) must be jumpered in the J-box. Use separate cables for
conductivity and temperature.
S22 AWG
shielded wire
n
ee
Gr n
ee
Gr te
hi
W e
hit
W
Green wires
White wires
Black
Black
Black wire
Red
Red
Red wire
J-Box
+
S+
S+
S+
S-
S+
+
SS+
+
SS+
+
RTD Inputs
(TB9)
Conductivity Inputs
(TB13-TB15)
50

OM0211_________________________________________________________________________
Note:
Some conductivity probes are supplied with 2 Black Wires and 2 Red Wires to eliminate the
need for jumpers. Connect all 8 wires to the controller via the J-box.
S22 AWG
shielded wire
n
ee
Gr n
ee
Gr te
hi
W e
hit
W
Green wires
White wires
Black
Black
Black wires
Red
Red
Red wires
J-Box
+
S+
S+
S+
S-
S+
+
SS+
+
SS+
+
RTD Inputs
(TB9)
Conductivity Inputs
(TB13-TB15)
On the input side of the J-box terminal strip, connect the probes red wire to the first terminal.
Add a jumper wire across the first and second terminals. On the output side of the terminal strip,
connect a signal wire to each of the 2 terminals (opposite the probes red wire and jumper).
On the input side of the J-box terminal strip, connect the probes black wire to the fourth terminal.
Add a jumper wire across the third and fourth terminals. On the output side of the terminal strip,
connect a signal wire to each of the 2 terminals (opposite the probes black wire and jumper).
On the input side of the J-box terminal strip, connect the probes 2 white wires to the fifth and
sixth terminals. On the output side of the terminal strip, connect a signal wire to each of the 2
terminals (opposite the probes white wires).
On the input side of the J-box terminal strip, connect the probes 2 green wires to the seventh and
eighth terminals. On the output side of the terminal strip, connect a signal wire to each of the 2
terminals (opposite the probes green wires).
Connect the 2 wires from the probes red wire to TB13-15 (-) and (S-) terminals in the controller.
Connect the 2 wires from the probes black wire to TB13-15 (+) and (S+) terminals in the
controller.
Connect the 2 wires from the probes white wires to TB9 (+) and (S+) terminals in the controller.
Connect the 2 wires from the probes green wires to TB9 (-) and (S-) terminals in the controller.
51

OM0211
3D TRASAR Conductivity Inputs (TB13-TB15)
All conductivity probes are
connected in the 3D TRASAR
Controller on terminal strip TB13-15.
Feedwater probes (located on

the same panel as the
controller) are wired directly to
the terminal strip.
Remote probes (blowdown or

condensate) probes are first
wired to a J-box. Wires (noncompensating 4-wires,
compensating 8-wires) are then
run from the J-box to the
controller
Note:
Note:
52
The conductivity probe RTD

wires (white and green) are
connected in the controller
on terminal strip TB9
Feedwater
conductivity probe
with jumpers
Remote
conductivity probe
(jumpers in J-box)
When connecting the conductivity probe wires into the controller, it is important to note which
input the conductivity probe is being wired into. This is critical when conductivity is being
configured in the Configurator, especially, when multiple probes are being used.

OM0211_________________________________________________________________________
Connection
Description
Controller Box
Board Reference
Conductivity Probe 6
Controller Box
Terminal
Description
TB15-6
6+
Pos. Cond. 6 (Red C+)
TB15-6
S6+
Positive Sense 6
TB15-6
S6-
Negative Sense 6
TB15-6
6-
Neg. Cond. 6 (Black C-)
TB15-5
5+
TB15-5
S5+
TB15-5
S5-
Negative Sense 5
TB15-5
5-
TB14-4
4+
TB14-4
S4+
Positive Sense 4
TB14-4
S4-
Negative Sense 4
TB14-4
4-
TB14-3
3+
TB14-3
S3+
TB14-3
S3-
Negative Sense 3
TB14-3
3-
TB13-2
2+
TB13-2
S2+
Positive Sense 2
TB13-2
S2-
Negative Sense 2
TB13-2
2-
TB13-1
1+
TB13-1
S1+
TB13-1
S1-
Negative Sense 1
TB13-1
1-
Positive Sense 5
Positive Sense 3
Positive Sense 1
53

OM0211
3.2.8
High Impedance (pH/ORP) Connections
The 3D TRASAR Boiler controller can read two high impedance signal inputs (either pH or ORP).
Note:
Make sure the probes are connected correctly. They will display a reading even if connected
improperly.
Note:
A ground wire must be run from the high-purity pH probe to the grounding terminal inside the
controller (SCADA ground TB17 can be used).
Connection
Description
pH/ORP 1
pH/ORP 2
54
Controller Box
Board Reference
TB11
TB11
TB12
TB12
Controller Box
Terminal
1+
12+
2-
Description
Positive Input 1
Negative Input (Shield) 1
Positive Input 2
Negative Input (Shield) 2
NCSM
Description
ORP 1 (white)
REF 1 (black)
ORP 2 (white)
REF 2 (black)

OM0211_________________________________________________________________________
3.2.9
Nalco Corrosion Monitor (NCM100)
The controller is capable of reading one NCM100 probe. It will automatically detect the type of probe
(mild steel). The table below lists the internal connections (factory installed). The Nalco NCM100
cable plugs into a receptacle on the side of the control box.
Connection
Description
Corrosion 1
Controller Box
Board Reference
J4
J4
J4
J4
J4
J4
J4
Controller Box
Terminal
Removable
Removable
Removable
Removable
Removable
Removable
Removable
Description
Not Used
Not Used
Black
Blue
Green
Brown
Orange
3.2.10 Analog Inputs

The 3D TRASAR Boiler can read four analog inputs. Each analog input can be (individually)
configured to read 4-20 mA or 0-10 volt signals (via dip switch setting and firmware configuration).
Connection
Description
Analog Input 1
Analog Input 2
Analog Input 3
Analog Input 4
Note:
Controller Box
Board Reference
TB10
TB10
TB10
TB10
TB10
TB10
TB10
TB10
TB10
TB10
TB10
TB10
Controller Box
Terminal
24V
1+
124V
2+
224V
3+
324V
4+
4-
Description
24 VDC Source
AI1+
AI124 VDC Source
AI2+
AI224 VDC Source
AI3+
AI324 VDC Source
AI4+
AI4-
Additional analog input can be wired into the controller using the optional Analog Input
Module (See Section 3.2.11)
Below are analog 4-20 mA and 0-10 V wiring diagrams for powered and non-powered connections.
55

OM0211
-N
AMP
Sensor
+N
-N
AMP
+N
24V
24V
24 VDC
+
-
24 VDC
3DT Boiler
Controller
Sensor
+
+
3DT Boiler
Controller
Self-Powered Input
(No Loop Power Needed)
Loop-Powered Input
(24 VDC Loop Power Needed)
Analog 4-20 mA Input (User) Wiring Diagram
-N
+N
AMP
Sensor
+
24V
24 VDC
+
3DT Boiler
Controller
Analog 0-10V Input (User) Wiring Diagram
Note 1:
N = 1, 2, 3, or 4 (Analog Input Channel)

mA / V
SELECTOR
4-20 mA
1234
0-10 V
Figure 6: mA / V Dip Switch Selector

Note 2:
Note 3:
56
Set each input dip switch (SW1) to 4-20 mA or 0-10 V operation

All analog inputs are factory set to 4-20 mA operation

OM0211_________________________________________________________________________
3.2.11 Analog Input Module (Optional)

The Analog Input Module allows the user to connect up to
8 additional analog inputs to the 3D TRASAR Controller. It
can be mounted on the back of the 3D TRASAR skid or on
a wall nearby. A 24 VDC enables connection of signals
that require power. The module requires 115 VAC, 50 Hz
power (power cord provided).
Installation
1.
The Analog Input Module connects to the 3D TRASAR

controller via the RS-485 .Connect the supplied cable
to the 3D TRASAR controller:
Note:
Red to TB20 A
Black to TB20 B
Green to TB20 Gnd
TB20 is located inside the 3D Boiler Controller. The Analog Input Module cannot be used
if a second Fluorometer is attached (cannot share this wiring connection).
3D TRASAR cable connections
Analog Input Module cable connections
2. Connect 4-20 mA inputs on the ADAM module.

Note:
4-20 mA signal loops are not powered from the Adam module. Use the supplied 24V terminal
strip if required.
3. Plug in the Analog Input Module power cord and the hardware installation is complete.
57

OM0211
ADAM - 4117
Analog Input 6+
Vin 5+ 1
Vin 4-
Analog Input 5-
Analog Input 6-
Vin 5-
Vin 4+
Analog Input 5+
Analog Input 7+
Vin 6+
Vin 3-
Analog Input 4-
Analog Input 7-
Vin 6-
Vin 3+
Analog Input 4+
Analog Input 8+
Vin 7+
Vin 2-
Analog Input 3-
Analog Input 8-
Vin 7-
Vin 2+
Analog Input 3+
TB20* 2A
(Y) DATA+
Vin 1-
Analog Input 2-
TB20* 2B
(G) DATA-
Vin 1+
Analog Input 2+
(R) +Vs
Vin 0-
Analog Input 1-
Vin 0+
Analog Input 1+
TB20* GND
(B) GND
20
10
Earth Gnd
11
Loop Power
Connections
120 VAC
Line
1 Amp Slo Blow
Neutral
Earth Gnd
NEMA 4X Enclosure
Note:
58
24 VDC
+
0.5 A
+24 VDC
Common
The ADAM-4117 module is configured at the factory for 4-20 mA inputs and communication
with the 3D TRASAR Boiler Controller.

OM0211_________________________________________________________________________
3.2.12 Analog Outputs

The 3D TRASAR Boiler controller has eight self-powered 4-20 mA analog outputs, 600 ohms.
Connection
Description
4-20 mA Output 1
4-20 mA Output 2
4-20 mA Output 3
4-20 mA Output 4
4-20 mA Output 5
4-20 mA Output 6
4-20 mA Output 7
4-20 mA Output 8
Controller Box
Board Reference
TB22
TB22
TB22
TB22
TB22
TB22
TB22
TB22
TB22
TB22
TB22
TB22
TB22
TB22
TB22
TB22
Controller Box
Terminal
1+
12+
23+
34+
45+
56+
67+
78+
8-
Description
AO1+
AO1AO2+
AO2AO3+
AO3AO4+
AO4AO5+
AO5AO6+
AO6AO7+
AO7AO8+
AO8-
3.2.13 Interlock
The controller has one system interlock input. It is primarily used for systems that operate
intermittently. A jumper is installed at the factory. Keep it in place unless an external interlock signal
is connected. Removal of this jumper will suspend operation of ALL control relays and 4-20 mA
outputs and will also initiate an interlock alarm.
Connection
Description
Interlock
Note:
Controller Box
Board Reference
TB16
TB16
Controller Box
Terminal
+
-
Description
Interlock +
Interlock -
All digital input or analog inputs can now also be used as interlocks, permitting intermittent
operation based on the operation of more than one boiler feedwater pump. See Appendix F.
59

OM0211
3.2.14 Temperature (RTD) Inputs

The 3D TRASAR Controller has three 1000 ohm, platinum RTD inputs.
Desc.
RTD
Probe 3
RTD
Probe 2
RTD
Probe 1
Controller
Board
Terminal
RTD Wires Labels & (Color)

Description
NCSM
SCS
Conductivity
TB93
3-
Neg. RTD 3
TC- com
(Green)
(Black or White)
TC
(Green)
TB9-3
S3-
Neg. Sense 3
TC(White)
(Black or White)
TC
(Green)
TB9-3
S3+
Pos. Sense 3
TC+
(Red)
(Red)
TC
(White)
TB9-3
3+
Pos. RTD 3
TC+ com
(Black)
(Red)
TC
(White)
TB9-2
2-
Neg. RTD 2
TC- com
(Green)
(Black or White)
TC
(Green)
TB9-2
S2-
Neg. Sense 2
TC(White)
(Black or White)
TC
(Green)
TB9-2
S2+
Pos. Sense 2
TC+
(Red)
(Red)
TC
(White)
TB9-2
2+
Pos. RTD 2
TC+ com
(Black)
(Red)
TC
(White)
TB9-1
1-
Neg. RTD 1
TC- com
(Green)
(Black or White)
TC
(Green)
TB9-1
S1-
Neg. Sense 1
TC(White)
(Black or White)
TC
(Green)
TB9-1
S1+
Pos. Sense 1
TC+
(Red)
(Red)
TC
(White)
TB9-1
1+
Pos. RTD 1
TC+ com
(Black)
(Red)
TC
(White)
Note:
If the RTD has only 2 wires, connect one RTD wire to (+) and jumper (+) to (S+). Connect the
other RTD wire to (-) and jumper (-) to (S-).
Note:
RTD wire colors vary by device. See above table for devices used on standard 3D TRASAR
Systems.
60

OM0211_________________________________________________________________________
3.2.15 Digital Inputs

The 3D TRASAR Controller has four digital inputs. Each digital input will be capable of reading an
open contact to ground (snap-acting), contact closure device (mechanical water meter action) or open
collector NPN transistor/FET (5mA sink, 24 VDC, signal to ground). The counters will be capable of
reading and totalizing low frequency (water meter) pulse type inputs. Each of the four inputs will have
software reset capability.
For water meter inputs, each pulse represents a pre-defined amount of water usage (i.e., 10
gallons/pulse, 100 gallons/pulse, etc.). The gallon-scaling factor is user-defined in the Configurator.
Note:
The minimum on-time and off-time pulse width is 5 milliseconds for a valid pulse. The
maximum number of pulse counts is 50 per second.
Note: All digital input can now also be used as interlocks, permitting intermittent operation
based on the operation of more than one boiler feedwater pump.
Connection
Description
Digital Input 1
Controller Box
Board Reference
TB8
TB8
TB8
TB8
TB8
TB8
TB8
TB8
Digital Input 2
Digital Input 3
Digital Input 4
Controller Box
Terminal
1+
12+
23+
34+
4-
Description
DI1+
DI1DI2+
DI2DI3+
DI3DI4+
DI4-
Below are typical water meter connection diagrams.

3DT Boiler Controller
Digital Inputs
DI +
DI -
Water Meter
(Reed Switch)
NO Contact
Common Contact
Snap-acting Contact Closure Water Meter

3DT Boiler Controller
Digital Inputs
+24 VDC
Water Meter
(Transistor/FET)
Power (+24 VDC)
DI +
Signal
DI -
Ground
Transistor/FET (sinking) Contact Closure Water Meter
Note:
Use the Analog Inputs (TB10) +24 VDC terminals for the +24 VDC power
source.
61

OM0211
3.2.16 Modem/Phone Line Connections

A modem card is installed in the 3D TRASAR Controller. The modem works globally. Through this
modem connection you can upload firmware updates, upload/download configurations, download
data/alarm files, send out alarms and data files, and view live data.
The phone line connection is located inside the controller box and can be connected through the
RJ11 analog phone jack or hardwired to terminals 1 & 2.
Connection
Description
Modem
(Phone Line)
Controller Box
Board Reference
TB1
Controller Box Terminal

(or Phone Jack)
1
TB1
(J1)
RJ11 Analog
Phone Jack
Description
Telco/PSTN
Ring/Tip
Telco/PSTN
Ring/Tip
1
2
(TELCO/PSTN)
Hard Wire Analog
Phone Connection
Figure 8: Modem Phone Line Connection Diagram

Note:
Connect the analog Tip and Ring phone wires from the telephone company to pins 1 and
2. The modem input is not polarity sensitive, so it does not matter which order the wires are
connected.
3.2.17 Ethernet Connections

There are two Ethernet ports inside the 3D TRASAR Controller.
Ethernet port 1 is primarily used for direct connections with a laptop. Ethernet port 1 is available via
an external connector with waterproof cap. The cap must be in place whenever the port is not in use.
Use the supplied Ethernet Crossover Cable for direct PC connections.
Ethernet port 2 is primarily used for wireless gateway or customer LAN connectivity. The connection
is made internally in the controller.
Through either Ethernet port, you can upload firmware updates, upload/download configurations,
download data/alarm files, send out alarms and data files, and view live data.
62

OM0211_________________________________________________________________________
3.2.18 LAN Connections

The 3D TRASAR Controller can be connected to a LAN system, however, it is required that a Router
be used to isolate the controller from the rest of the LAN network. Processing extraneous broadcast
messages will significantly impact the controller operation.
3.2.19 USB
The 3D TRASAR Controller supports an external USB Data Stick. The USB is available via an
external connector with waterproof cap. The cap must be in place whenever the port is not in use.
Using the USB port, you can upload firmware, upload/download configurations, and download
data/alarm files.
3.2.20 SCADA
General Description
SCADA systems can be used to monitor and modify data variables within the 3D Boiler Controller
configuration. The 3D Boiler controller supports (Slave Mode) Serial Modbus RTU (half-duplex) or
Modbus RTU over Ethernet (ModTCP). For Serial Modbus RTU applications, an RS-232 or RS-485
connection is available.
The 3D Boiler Controller Modbus implementation conforms to the Modicon Modbus Protocol
Standard as described in the Modicon Modbus Protocol Reference Guide PI-MBUS-300 Rev. J
Dated June, 1996. Longs and Float Points are also supported (two consecutive 16 -bit registers).
The SCADA Modbus implementation supports Coil, Input, and Holding registers. Register types
include: Boolean (Coil), Integer (16 bit), Longs (32 bits), and Floats (IEEE format, 32 bit, single
precision). Single and block polls are supported (block polls are preferred to minimize Controller
communication traffic). Byte and Word orientation is configurable (defaults are High/Low Byte,
Low/High Word ordering). The Modbus Register Mapping Table is not hard coded. The user
configures the Modbus Mapping Table via the 3D Boiler Configurator. The user assigns (maps) data
variables from the 3D Controller configuration to Modbus addresses. This makes address mapping
extremely flexible. Configuration details are described in the Configurator help files.
Note:
The 3D Boiler Controller does not support Modbus ASCII, Modbus Plus, or Daniels Floating
Point Extension.
Note:
See Appendix N for Modbus communications settings.
Serial Wiring Connections

Controller
SCADA 232
TX
RX
GND
RS-232
(DB9, PC Connection)
RX (Pin 2)
TX (Pin 3)
GND (Pin 5)
Table 1: RS-232 Connection
63

OM0211
Controller
SCADA 485
1B
1A
GND
Controller
SCADA 485
2B
2A
GND
RS-485
DCS/Control System
+
GND
RS-485
DCS/Control System
+
GND
Table 2: RS-485 Connections
Ethernet Connection
There are two Ethernet ports (on separate networks in the 3D Boiler Controller) available for
Mod/TCP communications. Typically, Port 2 would be assigned for Mod/TCP communications. The
Ethernet port will need to be set with the correct IP address and Subnet Mask for SCADA Master
access.
64
N NO C L
Control RLY 1
TB2
Line 1 (L)
Fuse
TB12
TB11
N NO C L
Control RLY 2
TB3
N NO C L
Control RLY 3
TB4
RELAY CONNECTIONS
+2-
+ 1-
pH/ORP pH/ORP
CONDUCTIVITY INPUTS
N NO C L
Control RLY 4
TB5
N NO C L
Control RLY 5
TB6
C NO NC
ALARM
TB7
TX
RX
GND
1B
1A
GND
2B
2A
GND
6V
GND
1B
1A
6V
GND
2B
2A
TB16 TB17 TB18 TB19 TB20 TB21
Note: Factory-installed jumper between C and L to provide 115 VAC power is not shown.
90-240 VAC
50/60 Hz
TB1
Line 2 (N)
Fuse
Key
L : Line AC (Hot)
N : Neutral AC
: Earth Ground
NO : Normally Open
NC : Normally Closed
C : Relay Common
TB15
TB14
TB13
INTER SCADA
232
LOCK
SCADA 485
MODBUS MASTER
MODEM CARD
+
S+
S+
S+
S+
S+
S+
S+
S+
S+
S+
S+
S-
4-20 mA OUTPUTS
DIGITAL INPUTS
81-0027-00012
+
+
+
+
+
+
+
+
+
+
+
+
TB22
TB8
Fuse Ratings
5x20 mm Slow Blow
Main Power (2) = 1.0A SB
Alarm Relay = 1.0A SB
Control Relays = 2.5A SB
S3
S+
+
SS+ 2
+
SS+ 1
+
0-10 V
4-20 mA
+
24V
+
24V
+
24V
+
24V
mA/V
SELECTOR
1234
TB10
3D TRASAR BOILER CONTROLLER

TERMINAL CONNECTIONS
ANALOG INPUTS
RTD INPUTS

TB9
AC Input Power
90-240 VAC, 50/60 Hz
15A @ 120V, 15A Service
7.5A @ 240 VAC

OM0211_________________________________________________________________________
3.2.21 3D TRASAR Boiler Controller Terminal Connections Diagram
65

OM0211
3.2.22 3D TRASAR Boiler Controller Default Wiring

Most of the 3D TRASAR Boiler System is pre-wired at the factory. Be sure to connect these
components to the terminal strip at the points listed below (Configurator assumes the following wiring
connections).
Configurator Default Wiring Connections

BL55xx
or
BL55xx0x
BL54xx
or
BL54xx0x
BL531x
or
BL532x
(w/ SCS)
BL520x
or
BL530x
(w/o SCS)
BL613x0
BL603xB
Flourometer
Fluorometer
Input #1
Fluorometer
Input #1
NA
NA
Fluorometer
Input #1
Fluorometer
Input #2
SCS Temp
RTD
Input #1
RTD
Input #1
RTD
Input #1
NA
RTD
Input #1
RTD
Input #3
SCS Solenoid
Valve
Relay
Output #5
Relay
Output #5
Relay
Output #5
NA
Relay
Output #5
Relay
Output #4
Flow switch
Digital
Input #1
Digital
Input #1
Digital
Input #1
Jumpered
Digital
Input #1
Digital
Input #2
NCSM Probe
AT ORP
Input #1
NA
AT ORP
Input #1
AT ORP
Input #1
NA
NA
NCSM RTD
RTD
Input #2
NA
RTD
Input #2
RTD
Input #2
NA
NA
Interlock
Jumpered
Jumpered
Jumpered
Jumpered
Jumpered
Jumpered
Options
BL55xxBx
BL54xxBx
NA
NA
BL613xB
BL603xB
Relays Box
Relays
Outputs #1-4
Relays
Outputs #1-4
NA
NA
Relays
Outputs #1-4
Relays
Outputs #1-3
Device
Note: Conductivity and pH sensors must be protected during shipping. So, they are not wired to the
controller at the factory. Sensor input connections must be selected during installation.
66

OM0211_________________________________________________________________________
4.0
Final Assembly and Startup
4.1
Installation Check and Safety Check
Before assembling the unit be sure to familiarize yourself with the area that you are working in, the
operation of the boiler and plant safety procedures. The following items should also be checked:
System meets boiler pressure and temperature ratings

System meets area hazard rating requirements (060-BLxxx models are not rated for hazardous
areas)
Ensure all installation tasks have been completed
Check all plumbing lines for leaks
4.2
Shut all 3D TRASAR Boiler System valves
Note: Pressure regulator must be fully turned counterclockwise to close.
3-way outlet
valve
NCSM
Inlet valve
TRASAR
Fluorometer
inlet valve
NCSM
pressure
bleed valve
Pressure
regulator
Cooler sample
inlet valve
Rotometer
needle valve
SS Filter
purge valve
Grab sample
valve
67

OM0211
4.3
Install and Connect the TRASAR Fluorometer
The fluorometer is shipped unattached to prevent damage.

Install as follows:
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 -
Locate and unpack the fluorometer, fluorometer inlet valve, tubing connector, and
fluorometer outlet assembly (comprised of flow switch housing and three-way ball valve).
Attach the inlet valve and tubing connector to the fluorometer inlet using TEFLON tape.
Do not over tighten.
Thread the fluorometer outlet assembly to the outlet of the fluorometer. Do not over
tighten.
Remove the end cap from the sample supply tubing. Connect the supply tubing to the
fluorometer inlet tubing connector.
Mount the fluorometer (and outlet assembly) to the back panel with the screws provided.
DO NOT FORCE!
IMPORTANT: The length of the sample supply tubing may need to be adjusted to attain
proper alignment of the mounting screws with the back panel. DO NOT BEND sample
tubing. Excessive force may break fluorometer inlet fitting and internals. A broken inlet
fitting will necessitate the purchase of a new fluorometer that will not be covered under
warranty.
STEP 6 -
Connect the flow switch shuttle (prewired to the controller) to the flow switch housing.
STEP 7 -
Connect the preinstalled fluorometer cable to the fluorometer.
3-Way Ball
Valve
Fluorometer
Fluorometer
Inlet Valve
Flow Switch
68

OM0211_________________________________________________________________________
4.4
Power Up Control System without Sample or Cooling Water Flowing
CAUTION:
4.4.1
-
4.4.2
-
4.4.3
-
4.4.4
-
4.5
Before the 3D TRASAR controller is powered up the following valves

must be in the fully closed position:
TRASAR Fluorometer and NCSM Systems

Sample inlet needle valve to the NCSM unit
NCSM pressure bleed line valve
Sample inlet needle valve to the sample cooler
Pressure regulator (fully turned counterclockwise)
Sample cooler drain valve (if installed)
SS Filter purge valve
Rotometer needle valve
Fluorometer inlet valve
3-way sample outlet valve
Grab sample valve
TRASAR Fluorometer Systems

Grab sample valve
NCSM Systems
NCSM sample drain valve
Condensate Monitor Systems

Configure System and Upload to 3D TRASAR Controller
Screen details and latest updates are kept in Help section of the Configurator.
The Configurator is used to:
Initially configure the controller
Upload changes to controller settings
Establish direct and modem connections to the controller
Download Data
Update Firmware
4.5.1
PC System Requirements
For direct connection to a 3D TRASAR controller an Ethernet adapter is required
For remote dial up access to a 3D TRASAR controller a modem is required.
4.5.2
Installing the Software

Software and Software Updates for Nalco personnel will be available via SMS.
69

OM0211
4.5.3
Configurator Support
All user functions have been made as self-explanatory as possible. Additional important information
can be accessed for each Configurator screen by pressing the F-1 function key. Help functions will
continue to be improved to address additional user requirements as they are identified.
Many functions and settings have default values. It is important that you review these default settings
to make sure they are appropriate for your specific systems requirements.
You should upload your initial configuration while using a Direct Connect connection method.
Connect your computer directly to the controller using the crossover cable supplied with the
controller. After you verify your wiring is connected correctly, you may upload your configuration
to the controller by selecting Connect and Upload.
All uploaded Configurator settings and subsequent changes will require a Re-Boot of the
controller before they will become effective on the controller. Changes in PID control tuning
functions are the only parameters that will not require a Re-Boot. (Changing the time of day and
manual pump control do not require a reboot).
When you connect to the controller, the Configurator will compare the configuration on your
computer to the configuration loaded onto the controller. You must decide which version you
want to accept and work with by uploading your computer setting to the controller, or downloading
the Controller settings to your configuration.
4.6
Reboot the 3D TRASAR Controller
After the configuration has been uploaded into the 3D TRASAR Controller it must be rebooted for
the configuration to take effect. Reboot the system using the ACTION key on the front panel and
selecting Reboot. (See Controller Operation Section of this manual)
Remember, any setting changes you make in the Configurator will not be made to the controller
unless you upload the new settings to the controller. Any changes you have uploaded to the
controller will not become effective until after you Re-Boot!
Re-Booting the controller may take up to 5 minutes or longer. Connecting to the controller is not
possible during a Re-Boot. Additionally, all control functions are not operational during the
system Re-Boot process. It is important to carefully make changes in the Configurator so that
you can upload them, and Re-Boot as few times as possible to minimize the time waiting around
while the controller is in a Re-Boot.
Your computer and the Configurator will lose the connection to the controller while the controller
Re-Boots
Note:
4.7
WAIT until the controller has finished Re-Booting before you try to Connect via the
Connect function!
Verify The Configuration Using The Controller Keypad/Screens
Scroll through the various screens on the controller to be sure the configuration was uploaded
correctly. Check inputs, outputs, relays, etc.
70

OM0211_________________________________________________________________________
4.8
Calibrate the Fluorometer
4.8.1
Fluorometer Calibration Procedure
STEP 1
Close fluorometer inlet valve and turn 3-way fluorometer discharge valve to sample
position.
IMPORTANT: Bubbles trapped in fluorometer during injection can cause instrument error. With the
syringe in a vertical position, tap the syringe against a solid object to move the
bubbles to the needle end of the syringe. Then, force the bubbles out by pushing a
small amount of solution through the needle end of the syringe.
STEP 2
(Optional as needed) Clean the fluorometer by injecting acid with syringe (P/N 500PC2147.88) into the flow cell. Fill the syringe with 60 ml of dilute acid. 1:1 HCl, P/N 460S0726.75 is recommended for boiler applications. 10% Sulfuric Acid, P/N 460-S0800.75 is
acceptable but may not readily remove iron. Screw the syringe onto the fitting, inject the
dilute acid at a slow, steady rate into the flow cell, and allow it to stand for 2 minutes. Using
the flow cell brush, carefully clean the cell. The cell should be rinsed after use.
CAUTION:
Wear the appropriate personal protective equipment when cleaning the flow cell.
Check reagent MSDS for details.
STEP 3
Following the screen prompts, use a second clean 60 ml syringe and slowly flush the flow
cell with 180 ml of blank solution. Then slowly inject another 180 ml blank solution and
allow it to remain in the flow cell by leaving the syringe attached. Press Continue.
STEP 4
Following the screen prompts, use a third clean 60 ml syringe and slowly inject the flow cell
with 180 ml of calibration solution (P/N 460-S0980.88) and allow it to remain in the flow cell
by leaving the syringe attached. Press Continue.
STEP 5
Successful calibration will be indicated and must be accepted. Controller will

automatically re-boot after accepting calibration. Turn valves back to operating positions. A
failed calibration is most likely caused by insufficient flushing, contaminated/incorrect
standards, air bubbles in the cell, excessive cell fouling, or a bad probe connection.
4.8.2
1)
2)
3)
Note:
4)
5)
Note:
Fluorometer Calibration Screen Instructions

Press Actions key on control panel
Select Calibrate
Enter PASSWORD 12345 (default) if requested
A password must be entered to access all Actions submenus. The password has to be reentered after 10-minutes of inactivity.
Select Fluorometer and follow directions on screen
To calibrate the Fluorometer, follow the menu selections on the display panel. Calibration is
necessary for proper balance in the system. The need to clean and calibrate is usually
indicated by drift in readings or an error between test results and readings.
Large errors are usually indications of failing probes or loose connections. Investigate the
cause before recalibrating (check for alarms). If probes are removed for cleaning, check
calibration before reinstalling probes.
71

OM0211
4.8.2.1
Fluorometer 2-Point Calibration Screens Instructions

(Successful Calibration Sequence)
Actions Calibrate Fluorometer
Fluorometer Calibrate
Inject 180 ml Blanking

Solution into flowcell.
Fluorometer calibration
was successful.
Accept new values?
Cancel
Cancel
Continue
Measuring
blank values.
Please Wait. . . .
values saved.
Cancel
Done
Inject 180 ml SO980
into flowcell. Use
no other standards.
Cancel
Accept
System Reboot
Rebooting in 5,4,3,2,1 seconds
Continue
Measuring
Standard values.
Please Wait. . . .
Cancel
4.8.2.2
Fluorometer 2-Point Calibration Screens

(If cancel is selected during the calibration sequence)
canceled.
Done
System Reboot
4.8.2.3
Fluorometer 2-Point Calibration Screens

(If calibration fails)
failed.
Done
System Reboot
72

OM0211_________________________________________________________________________
4.9
NCSM Short Circuit Test
Prior to connecting the cables to the electrodes, perform a quick test of the cabling and controller.
4.9.1
NCSM Short Circuit Test Procedure
STEP 1
Short out the central core of both male BNC cable fittings (ORP and Ref) to one another
using the female-to-female BNC (provided in the Accessories Kit). The reading on the
controller should read an ORP of zero millivolts.
STEP 2
Connect the cables to the respective electrodes. The male BNC cable marked Ref should
now be reconnected to the female BNC on the base of the refurbished NCSM Reference
Electrode. The cable end marked ORP should be reconnected to the female BNC on the
Platinum Electrode (ORP).
Note: Under reducing boiler feedwater conditions the NCSM numbers should be negative after a
stabilization period. Positive numbers may be an indication that the cabling is reversed and
should be checked. If the cables are connected properly most likely the system transitioned
into an oxidizing condition. Adding oxygen scavengers and reducing the amount of dissolved
oxygen in the system should result in lower NCSM numbers.
4.9.2
1)
2)
4)
NCSM Short Circuit Test Screen Instructions

Select Calibrate
Note: A password must be entered to access all Actions submenus. The password has to be reentered after 10-minutes of inactivity
5)
6)
Select Short Circuit Test and follow directions on screen.

Connect ORP and REF cables using the supplied BNC connector. Select Continue.
7)
Is the voltage 0 5mV? Select Yes or No.

a. If No is selected controller will display:Short Circuit test failed. Check wiring and retry.
Select Cancel or Retry.
b. If Yes is selected controller will display: Short Circuit test passed Select Continue.
73

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4.10
Refurbish and Test the NCSM Reference Electrode

ORP Cell
Sample
Inlet Valve
ORP/RTD
Probe
Pressure
Gauge
Reference
Electrode
Pressure
Bleed Valve
Protective
Shield
Nalco Corrosion Stress Monitor with NCSM
4.10.1
NCSM Probes
The NCSM Probe System consists of an ORP/RTD combination probe, Reference electrode, 3/8
cross. There is an ORP/REF combination cable and RTD probe cable. The 3/8 stainless steel cross
acts as the ORP cell.
4.10.2
ORP/RTD Probe
The ORP/RTD combination probe is shipped connected to a 3/8 stainless steel cross and
wired to the controller. The ORP probe can be temporarily removed during installation and lightly
cleaned with isopropyl alcohol. The ORP probe must be re-inserted to the exact same depth as
originally provided. This ensures the ORP probe is positioned in the cross within design tolerances.
Remove the probe from cross by undoing the nut closest to the 3/8 cross and removing the L
shaped electrode combination. This is a delicate electrode and care should be taken in handling
the probe. Figure 2 shows the disassembled ORP cell.
ORP Cell Internal Configuration
Platinum and RTD Electrodes
Water Out
Disassembled ORP Cell

RTD +
BNC Connector
Platinum (ORP)
Electrode + BNC
Connector
Protective
Shipping Cap
Water In
Exposed Active
Platinum Tip
RTD +
BNC Connector
Platinum (ORP)
Electrode + BNC Connector
Figure 1.
74
Active
Platinum
Electrode
Platinum (ORP) and

RTD Electrodes
3/8 Stainless
Steel ORP Cell
with Reducing
Unions
Active RTD
Location
Reference
Electrode
Ceramic
Junction
3/8 Stainless
Steel ORP Cell
with 1/4
Reducers
Reference
Electrode
Figure 2.
Figure 3.

OM0211_________________________________________________________________________
The platinum electrode is visible as a band (approximately 1/8 in
diameter) formed about the end of a hollow electrode wrapped
with heat shrink Teflon (see Figure 1). The RTD is encased in
the end of the hollow 1/8 stainless steel tube. The ORP probe
cable connection is the female BNC that points downward and
the RTD connection is the female BNC connection that protrudes
parallel to the ground when assembled correctly.
When assembled, the active portions of the RTD and ORP probe
are all located in the center of the 3/8 stainless steel cross (ORP
cell). The actual arrangement of the probes is shown in Figure 3.
The cross has been cut open to reveal the ORP cell internals. The
true ORP at actual system temperature and pressure is the
potential difference measured on the platinum band as measured
against the silver/silver chloride reference electrode.
A replacement ORP/RTD combination probe is also available
(Figure 1). The protective shipping cap (black boot) must be
removed prior to using the probe.
If the tube connectors are removed and replaced with 3/8
fittings care must be taken to ensure that the fittings and any
tubing are not pushed too far into the cross as this will damage the
ORP probe. There could also be interference with the strict
tolerances for the positioning of the ORP probe and reference
electrode probe.
4.10.3
Reference Electrode
Porous Ceramic
Membrane
1/4 Stainless Steel

Tubing
Teflon Tube Insert
Split in Teflon Tube

Insert
Internal Silver
Rod
BNC Connector
Figure 4
Reference Electrode
The Reference Electrode is shipped loose to prevent damage. It must be refurbished prior to
use (see Reference Electrode Refurbishing Section).
The electrode is then inserted into the bottom of the cross. The fitting should be tightened as with
any standard high-pressure fitting (do not over-tighten see below).
Users must be familiar with the
correct tightening and loosening
procedures for stainless steel
fittings.
The SS tubing housing the
Reference electrode is thin-wall
tubing (0.028 wall thickness). The
fitting affixed to this tube (about 15
long) must not be over-tightened.
This will lead to excessive crimping
of the tubing. Review the installation
papers that are inside the supplied
Reference electrode box along with
the QC sheet for the probe. A copy
of this picture is shown in Figure 5.
Figure 5
75

OM0211
4.10.4
NCSM Probe Cables
Two cables are provided to connect the probes to the 3D TRASAR controller.
The 4 wire RTD cable connects to the
RTD input for the 3D TRASAR controller.
It is already wired to RTD #2 terminal strip
connection in the controller and RTD.
The second cable is a special spliced
cable. One male BNC fitting (ORP)
connects to the female BNC fitting on the ORP probe. The other male BNC (Ref) connects to the
female BNC fitting at the base of the Reference Electrode. The cable is pre-wired to the pH/ORP 1
connections in the 3D TRASAR controller. The white wire is the ORP (1+) lead and the black wire is
the REF (1-) lead.
Note:
In cases where the distances from the NCSM probe to the 3D TRASAR controller is over 6ft
a special cable with an integral operational amplifier is used (060-BL52XX.88 models). This
Op-Amp is lithium-battery powered. The battery should last for several years.
Note:
The battery should be replaced every 2 years to ensure uninterrupted quality NCSM
readings. Change battery with the controller switched off and the cable unplugged.
4.10.5
NCSM Probe Checkout
Both probes should be checked and the

Reference electrode refurbished on start-up and
when the NCSM has been inactive and open to
air.
Removing Reference Electrode Internals
Maintenance and probe verification checks should be

preformed routinely, even when the boiler system is
in normal operational.
All of the probes should look as they do in the
photographs contained within this manual. The
probes should be physically inspected prior to use.
During use the probes also need to be checked
periodically to ensure there are no system leaks and
there are no other obvious issues.
Everything needed to perform the probe checks and
refurbish the Reference Electrode is included in the
Accessory Kit (provided with NCSM System).
Slip out
the
Teflon
insert
attached
to the
base
fitting
Undo the
top 1/4 nut
Reference
Electrode Base
with BNC Fitting
Figure 6 (A and B)
4.10.6 Refurbishing the Reference Electrode

The Ag/AgCl Reference Electrode is an external pressure balanced reference electrode (EPBRE). It
is to be installed in the bottom of the ORP cell (3/8 Cross). The silver/silver-chloride rod resides in a
0.1N KCl solution and is in contact with the high temperature environment via a Teflon tube and a
ceramic membrane (frit). The Teflon tube has been designed so that the bottom portion of the
electrode can be removed from the stainless steel tube for refurbishing (Figure 6).
76

OM0211_________________________________________________________________________
Note: The base of the reference electrode is at ambient temperature but the internals are at
system pressure during operation. Be sure the NCSM probe has been isolated,
depressurized and valve locked and tagged out before servicing. Allow time for the
cell to cool down (to avoid creating air bubbles) prior to removing the probe.
1. There are two SS nuts on the base portion of the reference electrode (see Figure 6). The top
most nut is used to affix the internals of the electrode to the SS tubing (see Figure 5 and
6A). This nut is loosened to remove the internal electrode assembly from the SS tubing (see
Figure 6B). The Teflon-electrode-insert can now be slipped out of the SS tubing.
Note: The long SS tube will usually remain affixed to the 3/8 SS cross after it has been installed
the first time.
Note: The top nut is often loosened and tightened. In successive tightening operations the
nut just needs to be snugged-up with wrenches and should not be over tightened. If
over-tightened the internal portion of the reference electrode cannot be extracted.
The second nut (smaller nut) is welded to the lower square bracket. The bracket houses the female
BNC fitting and is used to prevent the silver rod from ejecting under pressure (see Figure 6). This
smaller SS nut (affixed to the square bracket) is used to tighten the bracket to the SS tube fitting.
There are 3 Teflon ferrules which are crimped down between the SS fitting and heat shrink Teflon,
over the silver rod. This fitting should never need to be adjusted. However, if the fitting is
leaking from this location then the fitting can be tightened (snugged-up only).
Note: There will not be much
resistance to tightening this
fitting as Teflon is being
compressed. The fitting
should not be over-tightened
and only snugged up to
eliminate any leak.
2. After removing the Teflon
tube and base portion of the
reference electrode the Teflon
tube can be separated into two
parts. So, old electrolyte can
be removed from the
reference electrode and
replaced with fresh electrolyte.
A Teflon insert holds the two
portions together (see Figure
7A). It is about 3-4 inches
above the stainless steel base
fitting.
3. Grasp both sides of the
Teflon insert and separate the
Teflon tube into two parts. This
might require some slight
twisting of the Teflon tubing.
With a little force the probe will
separate at this junction (see
Figures 7B and 7C).
Reference Electrode Disassembly (continued)
Separate Teflon insert at this location
B
Resulting in two Teflon pieces
C
Internal Teflon sleeve
D
Top portion contains the ceramic membrane
Figure 7
77

OM0211
The longer piece of tubing will

house the porous ceramic junction.
The shorter section of tubing will
contain the tapered Ag/AgCl rod,
base fitting and female BNC
connector.
Two separated Teflon pieces
Note: Do not pull the two pieces

of Teflon apart with too much
force. This will stretch the Teflon
and the ORP/RTD and REF probe
may short out in the cross. The
two Teflon parts must be twisted
apart while applying a small
amount of pulling.
Two separated Teflon pieces

with electrolyte - filling
syringe
Figure 8
4. Using the 10-ml syringe and
supplied long hypodermic needle (see Figure 8),
extract the internal filling solution from both
portions of the Teflon tubing. When extracting the
solution from the shorter piece of Teflon tubing
make sure that the hypodermic needle is not
rammed into the Ag/AgCl rod, damaging the
silver chloride layer on the rod. Once all the 0.1N
KCl solution has been removed from the reference
probe it is ready to be re-commissioned.
The base
portion of the
Reference
Electrode can
be stood
upright for
filling with
fresh electrolyte
Teflon tube
separation
point
5. Clean the Teflon insert (the small section of

Teflon tubing exposed at the point where the
Teflon tube separates - see Figure 9) by wiping
with a towel. All remaining vacuum grease should
be removed. Make sure not to smear the grease
into the hollow Teflon tubing. This will contaminate
the 0.1N KCl Refill Solution.
Tapered
Silver/Silver
Chloride Rod
within the
Teflon Tube
6. Apply a very small amount of fresh vacuum

grease (tube supplied) to the Teflon insert (Figure
10). This will make it easier to slide the two
Figure 9
sections of the Teflon tubing together after filling
and to separate after many months of use. Set aside these two Teflon pieces.
7. Fill the syringe with about 5 ml of fresh 0.1N KCl Refill Solution (supplied) and fill the two
sections of Teflon tubing. Make sure that there are absolutely no bubbles in the Teflon tubes. It
is easiest to place the syringe into the Teflon-tube and retract the syringe while dispensing fresh
electrolyte into the tube. Leave a small meniscus of fresh KCl on the open ends of the Teflon
tubes.
Fill the bottom portion first. After filling the bottom
portion of the Teflon tube prop this section up
vertically (Figure 9). Then fill up the remaining
Teflon tube with KCl Refill Solution.
78
High vacuum grease

applied to the Teflon
insert
Figure 10

OM0211_________________________________________________________________________
8. With a section of filled Teflon tube in each hand recombine the pieces into one continuous
electrode by slipping the one portion of the Teflon electrode over the smaller Teflon insert (which
was previously greased). Make sure not to introduce any bubbles at this stage. This is
accomplished by matching up the meniscus levels creating liquid-to-liquid contact before squeezing
the two electrode sections together. Maintain pressure to force the two parts to stay together. There
will be one or two drops of KCl electrolyte that will emanate from the porous ceramic frit as the two
sections of Teflon are pushed together. This also provides reassurance that the porous ceramic frit
is working as desired (it also cleans the frit).
9. Wipe off any excess vacuum grease that will have accumulated at the Teflon-to-Teflon junction.
The Teflon tubing should now be in its original configuration (Figure 7A) prior to removing the Teflon
tube from the stainless steel tube.
Note: Electrodes should not be allowed to sit open to the atmosphere for long periods of
time (several minutes), as bubbles will form in the electrode causing a loss of
electrochemical continuity in the KCl solution. The electrode must be reinserted back
into service immediately after the electrode is filled with new KCl solution and the
Reference Electrode Check is quickly performed (see below).
4.10.7 Reference Electrode Check

The electrochemical potential of the reference electrode is now ready to be checked against a
standard saturated KCl Ag/AgCl half-cell (provided). The check should be performed when the
reference electrode is used for the first time, after extended use, or when it is refurbished.
The check can also be performed when the reference electrode is extracted from service, to check
for reference electrode degradation.
Note: During normal operation the NCSM cables are connected as follows. In this configuration the
reference electrode is connected to the negative terminal in the controller.
Cable connections for normal measurement operation
Male BNC fitting (Ref)
Male BNC fitting (ORP)
STEP 1
NCSM Reference Electrode

NCSM Platinum Electrode
When the potential of the newly refurbished electrode is to be measured against

another known reference standard, the cables should be connected as follows:
Cable connections for reference electrode check
Standard reference electrode

AT NCSM Reference Electrode.
STEP 2
Immerse both the refurbished Reference Electrode and the standard reference half-cell in
the same bottle of saturated KCl Test Solution (provided).
STEP 3
Record the potential difference between the refurbished electrode and the standard half cell.
The potential difference is a function of temperature. The temperature effect is relatively
small at ambient temperature (2 mV span from 0 to 50C). The Reference Electrode
should read a voltage of +90 mV +/- 10 mV against the standard half-cell. A significant
deviation could be a result of the following.
79

OM0211
4.10.8
1)
2)
3)
The 0.1N KCl Refill Solution is bad.

NCSM Reference Electrode is going bad and might need to be refurbished at the
factory. If these reference electrodes are not abused they should last for many years.
Poor refurbishing procedure (e.g. bubbles in the electrode)
Standard half-cell electrode has gone bad. It might no longer be filled with saturated
KCl. If these electrodes are stored wet (in saturated KCl) they can last for years
without diminished performance.
Controller malfunction.
Reference Electrode Check Screens

Select Calibrate
Note: A password must be entered to access all Actions submenus. The password has to be reentered after 10-minutes of inactivity
4)
5)
6)
7)
8)
9)
Select Reference Test and follow directions on screen.

Refurbish the REF electrode as described in the User Manual. Select Continue.
Connect the ORP cable to the REF electrode. Select Continue.
Connect the REF cable to the Reference half-cell supplied in the accessory kit. Select
Continue.
Immerse both electrodes in the saturated KCL (Test) solution supplied in the accessory kit.
Select Continue.
The voltage is displayed. Is the voltage 90 10mV? Select Yes or No.
c. If No is selected controller will display: Reference test failed. Refurbish and retry.
Select Cancel or Retry.
d. If Yes is selected controller will display: Reference test passed Select OK.
4.10.9
Install The Reference Electrode
After performing the NCSM Reference Electrode Check install the electrode. This electrode should
always be the last electrode to be installed, just prior to opening the sample line valves.
The electrode is then inserted into the bottom of the cross. The fitting should be tightened as with
any standard high-pressure fitting (do not over-tighten).
80

OM0211_________________________________________________________________________
4.11
Feed Water pH and Conductivity Probe Installation
If ordered, the feed water pH and conductivity module piping will be installed on the system in at the
factory. There are two slightly different module configurations:
Low-Purity Module
(Conductivity > 100 S/cm)
High-Purity Module
(Conductivity 1 < 100 S/cm)
The feed water pH and conductivity probes are shipped in their

packaging for protection. They must be installed into the plumbing
module before startup. See Section 3.2.7 and 3.2.8 for wiring
connections.
Module Location
4.12
Note:
Remember to remove the protective cap from the pH probe

before screwing the probe into the tee.
pH Probe Calibration
IMPORTANT NOTE:
On new installations a 2-point calibration must always be

performed.
To perform a pH calibration, use the Actions key and select Calibrate.

Highlight the pH probe you wish to calibrate and hit Select.
You will be notified that you have selected a pH calibration sequence. Select CONTINUE
1-Point Calibration utilizes the system water as the calibration point. It is best used to fine-tune your
calibration to compensate for minor drifting. Leave the probe in the process water.
2-Point Calibration utilizes pH standards that cover the range of measurement. It is best utilized when
installing a new probe or if a major error has developed due to excessive fouling. The user may select
between two 2 point calibration options that are available: Calibration using 4 and 7 pH standards, OR
Calibration using 7 and 10 pH standards.
Highlight the desired 1 or 2 point calibration process and hit SELECT
81

OM0211
2-Point Calibration
STEP 1
Isolate the probe from the system. For feedwater installations, close the sample inlet valve to
the sample cooler. Remove the pH probe from the cross or tee fitting.
STEP 2
Clean the probe with deionized water to remove any deposits or contaminants.
STEP 3
Select the temperature source to be used for the calibration temperature compensation by
highlighting Select Temp and pressing Edit.
The options are None, Temp 1, 2, 3 or USER SET. Use the arrows to toggle between
choices. Select ACCEPT after making a selection and you should be directed to the FIXED
TEMP line.
STEP 4
Fixed Temp represents the temperature of the calibration solution being used. This selection
is only used in the USER SET temperature mode. To modify the temperature being used,
select EDIT. Enter a temperature for the pH standard solutions and select Accept.
Note:
If using Temp 1, 2, 3, or NONE, any temperature setting in this section will be

ignored during the calibration process.
STEP 5
Use the arrows to toggle to START CALIBRATION. Hit SELECT to enter the 4/7 or 7/10
calibration sequence
STEP 6
Follow the on-screen prompts and place the probe in a beaker of clean, fresh 4 or 7 pH
standard as directed. Press CONTINUE.
STEP 7
The controller will measure the pH of the calibration solution.
STEP 8
After the prompt, rinse the probe well in clean deionized water.
STEP 9
Place the probe in a beaker of clean, fresh 7 or 10 pH standard. Press CONTINUE.
STEP 10 After successful calibration, select DONE, and install the probe back into the pipe cross or
tee fitting.
STEP 11 Establish flow through the pH probe. For feedwater installations, slowly open the sample
inlet valve to the sample cooler. If no leaks are observed, open the valve turn from the
fully wide-open position.
If probe calibration is unsuccessful, check the standards, wiring connections, or handheld pH
meter for accuracy and recalibrate.
CAUTION-DANGER A lockable valve should be installed on the sample line to isolate
the system for maintenance and prevent unauthorized energizing
of the system. Follow all lock out, tag out requirements for
servicing.
1-Point Calibration
STEP 1 Leave the probe in the cross or tee with water flowing. Probe should have been installed at
least 20 minutes for equilibrium.
STEP 2 Using a handheld instrument of known accuracy and calibration, locally sample the process
water and determine the pH value.
STEP 3 Select Edit to change pH value.
STEP 4 Enter the measured pH value and select Accept.
Note: Selecting Accept will perform the 1-point calibration sequence. To ensure that the calibration
has been performed correctly, return to the Operating Data screen and confirm that the pH
now reads the value just entered.
82

OM0211_________________________________________________________________________
4.13
Conductivity Probe Calibration
IMPORTANT NOTE:
On new installations a 2-point calibration must always be

performed.
To perform the conductivity calibration, select the Actions key on the 3D TRASAR controller and
Select Calibrate.
Highlight the conductivity probe you wish to calibrate and hit Select.
-Point Calibration utilizes the boiler water or feedwater as the calibration point. It is recommended to
perform this step after a 2-point calibration has been performed to fine-tune the calibration. The probe
is left in the blowdown line or 3D TRASAR system while a representative (cooled) sample is measured
from a reliable handheld meter.
2-Point Calibration utilizes conductivity standards that cover the range of measurement. A 2-point
calibration is required for all new installations. When a major error in the conductivity measurement
has developed due to excessive fouling on the probe, a 2-point calibration is also recommended.
4.13.1
Recommended Conductivity Calibration Standards
The table below lists the conductivity calibration solutions that are available through Nalco.
Calibration Standards
0 S/cm (dry in Air)
40 S/cm
200 S/cm
600 S/cm
3000 S/cm
5000 S/cm
10,000 S/cm
Part Number
-460-S0299.75
460-S0743.75
460-S0298.75
460-S0297.75
001-H07642.88
001-H07641.88
The recommendation for conductivity calibration is to choose two standards that encompass
the expected conductivity range of measurement for the system. The tables below list the
combinations of standards that are required for boiler feedwater and blowdown applications.
Feedwater & Condensate:
K = 1.0
Calibration
Calibration
Solution #1
Solution #2
0
40
40
600
0
600
IMPORTANT NOTE:
K = 0.1
Calibration
Calibration
Solution #1
Solution #2
0
40
40
200
Blowdown:
K = 1.0
Calibration
Calibration
Solution #1
Solution #2
600
3000
600
5000
3000
5000
3000
10,000
5000
10,000
If combinations other than those listed are used, (i.e., 40 S/cm and
10,000 S/cm) the calibration will fail. This is due to the fact that the
resulting conductivity counts for the incorrect combination of standards
will fall outside of the 3D TRASAR controllers calibration range.
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4.13.2
2-Point Calibration
Notes:
STEP 1
Place the probe in the center of a beaker (container) during 2-point

calibration, to avoid wall effects.
Do not stir the probe in the calibration solutions as this may cause air
bubbles to form inside the electrode.
Verify there are no bubbles inside the probe during calibration.
If extracting the probe from a boiler blowdown line, ensure that its
temperature has equilibrated before performing the calibration.
For new installations, proceed to Step 2.
For probes that are currently installed and in service, extracting the conductivity probe from
the system is the first step. Isolate the probe from the system to allow safe extraction. For
feedwater installations, close the inlet valve to the sample line. Remove the conductivity
probe from the cross or tee fitting.
CAUTION-DANGER:
Note:
If the probe is being extracted from the blowdown line of an

operating boiler see Section 4.13.4 for safety precautions and
procedures.
To prevent excessive twisting of the wires during probe extraction:

Feedwater Installations:
The conductivity wires can be pre-twisted upon installation into the tee fitting to
compensate for the twisting of the wires upon removal.
Blowdown Installations:
The signal wires can be disconnected from the output side of the terminal strip inside the Jbox. This will allow the probe to be freely loosened from the pipe cross without twisting the
signal wires. Once the probe has been extracted from the pipe cross, reconnect the signal
wires to the output side of the terminal strip. This re-establishes the electrical connection to
the controller.
STEP 2
Clean the probe with deionized water to remove any deposits or contaminants. If the probe
is severely fouled, see section 4.13.6 on cleaning the conductivity probe.
STEP 3
On the 3D TRASAR controller, select 2-point (Standards) calibration.
STEP 4
Select the temperature source to be used for the calibration temperature compensation by
highlighting Select Cal Temp and pressing Edit.
The options are None, RTD or a Fixed. Use the arrows to toggle between choices. The
entry for the Fixed temp value should be the actual temperature of the calibration solutions.
This can be measured with an external thermometer. This entry will influence the
calibration accuracy so it is important that the correct temperature is entered. If a
conductivity probe with an integral RTD is being used, select the RTD input were the
integral RTD is wired to. After selecting the temperature enter Accept.
Note:
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The temperature value that is entered by the user is in degrees Celsius (C).

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STEP 5
Select Choose Standards. Then select Edit to enter the High and Low conductivity
calibration solutions to be used. The default values are 3000 S/cm and 600 S/cm.
Select Accept.
Select Start Calibration.
STEP 6
Place the probe in a beaker of clean, fresh Low conductivity solution (In this example, 600
S/cm buffer solution is used, P/N 460-S0298.75). Ensure that no air bubbles are trapped
inside the electrode. Press Continue.
STEP 7
The controller will take 60 seconds to measure the conductivity of the calibration solution.
STEP 8
After the prompt, rinse the probe well in clean deionized water.
STEP 9
Place the probe in a beaker of clean, fresh High conductivity solution. (In this example a
3000 S/cm buffer solution is used, P/N 460-S0197.75). Ensure that there are no air
bubbles trapped inside the electrode. Press Continue. If probe calibration is
unsuccessful, check the standards, wiring connections, or handheld conductivity meter for
accuracy and then recalibrate. If calibration is successful, proceed to Step 10.
STEP 10
Install the probe back into the pipe cross or tee fitting. Ensure that the electrodes flowthrough hole is in line with the sample flow. The K factor that is stamped on the
probes hex fitting is aligned with the hole. This probe orientation is critical and will affect
the measurement if it is oriented incorrectly. (See Section 2.3.3.4)
Note:
For feedwater installations, it is recommended to pre-twist the wires to compensate for the
twisting that occurs upon installing into the tee fitting. For blowdown installations,
disconnect the signal wires again from the output side of the terminal strip inside the J-box.
Install the probe into the cross fitting. Once installed, reconnect the signal wires back into
the output of the terminal strip. This will re-establish electrical connections to the controller.
STEP 11
Establish flow through the conductivity probe. For feedwater installations, slowly open the
inlet valve to the sample line. If no leaks are observed, open the valve turn from the
wide-open position. For blowdown installations, see section below for safety precautions
and procedures.
of the system. Follow all plant lock out, tag out requirements for
servicing.
STEP 12
Allow the probe to equilibrate to system conditions. Proceed to the 1-Point Calibration
(Section 4.13.3).
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4.13.3
1-Point Calibration
IMPORTANT NOTE:
A 1-point conductivity calibration must be performed after a 2-point

calibration as part of every field startup. This is important because the 2point calibration is performed under static conditions. The 1-point calibration
will compensate for the flowing sample and the dynamics of the system.
Follow the calibration procedure that corresponds to the control mode in
use.
4.13.3.1
Continuous Sample On/Off or PID Control

On the 3D TRASAR controller, highlight 1-point (Process) calibration then hit Select.
STEP 1
Leave the conductivity probe in the cross assembly. For systems using Continuous
(On/Off) control, allow several minutes for the probe to equilibrate to the conditions of the
boiler water that is continuously flowing through the cross assembly.
STEP 2
Using a handheld, temperature-compensating conductivity meter of known accuracy and

calibration, locally sample the boiler water and measure the (non-neutralized) conductivity
value. For boiler blowdown, sample cooling is required.
STEP 3
After the probe has equilibrated to the blowdown sample, compare the Current
conductivity reading on the display screen to the reading obtained from the handheld meter
in Step 2. These values should be relatively close (i.e., this should not be a 50% offset).
Proceed to Step 4.
STEP 4
Select Edit to change the Enter New conductivity value.
STEP 5
Enter the measured conductivity value and select Accept.
Note:
Selecting Accept will perform the 1-point calibration sequence and leave you at the 1-point
calibration menu. The Current reading should now reflect the new conductivity value
entered.
STEP 6
Select Back to return to the Operating Data screen.
4.13.3.2
Timed Sample Continuous On/Off Control

STEP 1
For systems using Timed Sample - Continuous On/Off Control, the blowdown control
valve will need to be manually opened to allow sample to flow past the conductivity
probe.
To do this, set the corresponding Relay Output for the motorized valve to Manual On
(Actions => Manual Control => (corresponding) Relay => Manual On). This will allow water
to flow through the conductivity probe.
Allow the same amount of time for the probe to equilibrate to the boiler water
conditions as it would during the control cycle.
STEP 2
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Therefore, let the sample flow for a time equal to the Flush Time value entered in the
control screen setup.
Immediately, using a handheld, temperature-compensating conductivity meter of known
accuracy and calibration, locally sample the boiler water and measure the (non-neutralized)
conductivity value. For boiler blowdown, sample cooling is required.

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STEP 3
Compare the Current conductivity reading on the display screen to the reading obtained
from the handheld meter in Step 2. These values should be relatively close (i.e., this
should not be a 50% offset). Proceed to Step 4.
STEP 4
STEP 5
Note:
STEP 6
Note:
entered.
calibration menu. The controller will display the last reading obtained during a control cycle
measurement.
STEP 7
Once calibration is completed set the corresponding Relay Output for the motorized valve
back to Auto (Actions => Manual Control => (corresponding) Relay => Auto.)
Note:
It is critical to remember to switch back the Relay Output from Manual to Auto after
the 1-point calibration step.
4.13.3.3
Timed Sample Proportional Control

STEP 1
For systems using Timed Sample Proportional Control, the blowdown control valve will
need to be manually opened to allow sample to flow past the conductivity probe.
To do this, set the corresponding Relay Output for the motorized valve to Manual On
(Actions => Manual Control => (corresponding) Relay => Manual On). This will allow water
to flow through the conductivity probe.
Allow the same amount of time for the probe to equilibrate to the boiler water
conditions as it would during the control cycle.
STEP 2
STEP 3
Therefore, let the sample flow for a time equal to the Flush Time value entered in the
control screen setup.
Immediately, using a handheld, temperature-compensating conductivity meter of known
accuracy and calibration, locally sample the boiler water and measure the (non-neutralized)
conductivity value. For boiler blowdown, sample cooling is required.
The control valve will need to be closed to trap the blowdown sample, in order to prevent
the sample from flashing. A stable Current conductivity reading can then be obtained.
To do this, set the corresponding Relay Output for the motorized valve from Manual On to
Manual Off (Actions => Manual Control => (corresponding) Relay => Manual Off).
Allow 15 seconds to elapse then compare the Current conductivity reading on the display
screen to the reading obtained from the handheld meter in Step 2. Proceed to Step 4.
STEP 4
Compare the Current conductivity reading on the display screen to the reading obtained
from the handheld meter in Step 2. These values should be relatively close (i.e., this
should not be a 50% offset). Proceed to Step 5.
STEP 5
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STEP 6
Note:
STEP 7
Note:

entered.
calibration menu. The controller will display the last reading obtained during a control cycle
measurement.
STEP 8
Once calibration is completed set the corresponding Relay Output for the motorized valve
back to Auto (Actions => Manual Control => (corresponding) Relay => Auto.)
Note:
It is critical to remember to switch back the Relay Output from Manual to Auto after
the 1-point calibration step.
4.13.4
Extracting a Conductivity Probe from the Blowdown Line of an Operating

Boiler:
Note:
The use of thermal gloves is highly recommended when working on boiler blowdown
lines.
1. Close the 1 isolation gate valve on the blowdown line, located upstream the conductivity
probe cross assembly. For safety reasons, allow the conductivity probe to cool down to
safer temperatures before proceeding.
2. Once the blowdown line has cooled down, depressurize the cross by slowly opening the
flushing valve at the bottom of the cross. If this line suddenly becomes hot, this would be
an indication that boiler water is leaking by the 1 isolation gate valve. If this is the case,
DO NOT PROCEED.
3. Once the cross assembly has been safely isolated, cooled and depressurized, open up the
junction box at the top of the conductivity probe. Disconnect the signal wires from the
output side of the terminal strip. This frees up the probe/J-box from the signal wiring.
4. One can now safely and freely extract the probe from the pipe cross without twisting the
signal wires.
5. If the conductivity probe requires cleaning, follow the cleaning procedures below.
6. Before proceeding with the 2-point calibration, the signal wires will need to be wired back
into the terminal strip of the J-box to re-establish a connection with the controller.
7. Once the wiring is done, follow the procedures for the 2-point calibration. Note that the
conductivity probe and the controller may be a distance away from one another. Therefore,
calibration will require one to walk back and forth between the controller and the
conductivity probe when performing the 2-point calibration. If possible, it would be easier to
have two people perform the calibration one person at the probe end and the other
person at the controller.
of the system. Follow all plant lock out, tag out requirements for
servicing.
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4.13.5
Installing a Conductivity Probe into the Blowdown Line of an Operating Boiler:
Note:
These procedures can be followed for a new installation, after performing a 2-point calibration,
or after probe servicing.
Note:
The use of thermal gloves is recommended when working on boiler blowdown lines.
1. At this point, the probe/J-box is intact and only the signal wiring is disconnected from the
output of the terminal strip inside the J-box.
2. Apply Teflon tape to the threads of the conductivity probe.
3. Install the probe into the top port of the conductivity probe cross assembly.
4. Ensure that the electrodes flow-through hole is in line with the sample flow. The K-factor
that is stamped on the hex fitting of the probe is aligned with the hole. This probe
orientation is critical and will affect the measurement if it is oriented incorrectly.
5. Once installed, reconnect the signal wires to the terminal strip inside the J-box. Ensure that
the correct electrical connections are made.
6. Close the flushing valve at the bottom of the cross.
7. Slowly open the 1 isolation gate valve on the blowdown line, located upstream the
conductivity probe cross assembly. If no leaks are observed around the probe, slowly open
the gate valve approximately turn from the wide-open position.
8. At this point, a 1-point calibration will need to be done. Refer to the 1-Point Calibration
(Section 4.13.3).
4.13.6
Cleaning a Fouled Conductivity Probe

1. Wipe the electrode surface with a paper towel to remove excess solids.
2. If significant fouling remains on the electrode, immerse the electrode into a beaker of dilute
sulfuric acid.
CAUTION-WARNING: Use appropriate PPE when handling acid. Check reagent MSDS.
3. Thoroughly rinse the probe with deionized water.
4. Proceed to performing a 2-point calibration, followed by a 1-point calibration.
4.14
System Leak Test and Final Piping Insulation
Before starting up the 3D TRASAR system ensure that the following steps have been completed.
All the probes have been wired into the controller.

All other electrical connections have been made.
There are no leaks in the piping to and from the unit.
NCSM Short circuit test completed
NCSM Reference Electrode has been refurbished and checked.
NCSM Reference Electrode has been properly installed into the SS cross.
All hot sample lines have been insulated.
Calibration has been performed on the fluorometer (and optional pH and conductivity probes)
All the stainless steel fittings are tight.
Confirm cooling water is available at the sample cooler.
3D TRASAR Controller is turned OFF.
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4.15
4.15.1
Startup
NCSM and Fluorometer Models System Valve Identification
Locate all the valves on the specific model installed . The picture below shows the valves on a unit
equipped with a TRASAR Fluorometer and NCSM. Other models may not have all the components.
3-way outlet
valve
NCSM
Inlet valve
TRASAR
Fluorometer
inlet valve
NCSM
pressure
bleed valve
Rotometer
needle valve
Sample cooler
Inlet valve
Grab sample
valve
Pressure
regulator
Note:
The fluorometer-based blowdown systems have the same valve configuration

as the feedwater models.
4.15.2
TRASAR Fluorometer and NCSM System Startup
CAUTION-DANGER:
90
Before the 3D TRASAR controller is powered up the following

valves must be in the fully closed position:

NCSM pressure bleed line valve
Grab sample valve

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1. Open the cooling water isolation valve. NEVER open the sample inlet valve without
ensuring cooling water is flowing through the sample cooler.
CAUTION-DANGER:
When the 3D TRASAR controller is powered up, the solenoid

valve is energized and will open.
2. Turn on the 3D TRASAR controller.

3. Replace the NCSM (Lexan) protector shield back on its mounting posts.
4. Once the protector shield is installed, with caution, slowly open the NCSM inlet needle valve.
This line will be a high pressure and high temperature sample line so take caution. Carefully
check for leaks, including the base of the Reference Electrode.
CAUTION-DANGER: ALWAYS slowly open the sample line as a sudden pressure surge can be
disastrous if there is a leak, resulting in possible serious injury especially
with high-pressure boiler water or steam.
5. If a leak is observed, close the NCSM inlet needle valve. Snug up the fitting that was leaking.
Do not over tighten Swagelok fittings.
6. If water is leaking out of the base of the Reference Electrode, snug up the fitting as shown in
the picture below. This picture is also included with the Reference Electrode.
Since the Reference Electrode tube is thin-walled stainless steel tubing, it is important that the nut is
not over-tightened. This can be accomplished by turning the 9/16 wrench 1/16 th of a turn at a time in
the clockwise direction, while keeping the wrench stationary. If there is water leaking out of the 3/8
nut of the Reference Electrode, which is the fitting that is connected to the 3/8 cross, snug this fitting
up 1/16th of a turn at a time.
7. Repeat step 5. If no leaks are further observed, proceed to step 8.
8. Slowly open the NCSM inlet needle valve all the way to a quarter turn from the fully open
position.
9. Slowly open the needle valve to the inlet of the sample cooler. Check for leaks up to the
pressure regulator of the sample conditioner. Although the sample is cooled after the sample
cooler, take caution since this is still a high-pressure sample. If there are no leaks, open up the
sample cooler inlet needle valve all the way to a quarter turn from the fully open position.
10. Adjust the pressure regulator (clockwise) until the pressure gauge reads 10 to 20 psig.
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11. Open the rotometer needle valve, the fluorometer inlet valve, and finally the FPT sample
outlet valve.
12. Opening up the last three valves will cause the pressure to drop. Adjust both the pressure
regulator and the rotometer needle valve to establish a pressure of 10 to 20 psig and 300
ml/min of flow.
Note:
If flows over 500 ml/min are needed to obtain good PID TRASAR control, separate 3D
TRASAR Boiler TRASAR Fluorometer and NCSM sample lines must be plumbed.
13. Ensure proper sample drainage.
4.15.3
TRASAR Fluorometer Only System Startup
CAUTION-DANGER: Before the 3D TRASAR controller is powered up the following

-

Grab sample valve
CAUTION-DANGER:


3. With caution, slowly open the needle valve to the inlet of the sample cooler. This sample will
be a high pressure and high temperature sample so take caution. Check for leaks up to the
pressure regulator of the sample conditioner.
4. If there is a leak, close the sample cooler inlet valve. Snug up the fitting that was leaking. Do
not over tighten Swagelok fittings.
5. Once the leak has been addressed, repeat step 3.
6. If there are no further leaks, proceed to step 7.
7. Although the sample is cooled after the sample cooler, take caution since this is still a highpressure sample. Slowly open up the sample cooler inlet needle valve all the way to a quarter
turn from the fully open position.
8. Adjust the pressure regulator (clockwise) until the pressure gauge reads 10 to 20 psig.
9. Open the rotometer needle valve, the fluorometer inlet valve, and finally the FPT sample
outlet valve.
10. Opening up the last three valves will cause the pressure to drop. Adjust both the pressure
regulator and the rotometer needle valve to establish a pressure of 10 to 20 psig and 300
ml/min of flow.
11. Finally, ensure proper sample drainage.
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4.15.4
NCSM Only System Startup (without Sample Conditioning System)

-

NCSM sample pressure bleed valve
Sample outlet needle valve
1. Replace the NCSM (Lexan) protector shield back on its mounting posts.
2. Once the protector shield is installed, with caution, slowly open the NCSM inlet needle valve.
This line will be a high pressure and high temperature sample line so take caution. Carefully
check for leaks, including the base of the Reference Electrode.
3. If a leak is observed, close the NCSM inlet needle valve. Snug up the fitting that was leaking.
Do not over tighten Swagelok fittings. If water is leaking out of the base of the Reference
Electrode, snug up the fitting (See Section 4.10)
4. Repeat step 2. If no leaks are further observed, proceed to step 5.
5. Slowly open the NCSM inlet needle valve all the way to a quarter turn from the fully open
position.
6. Slowly open the NCSM outlet needle valve all the way to a quarter turn from the fully open
position.
7. If the NCSM sample is being sent to the plants sample conditioning system, adjust the plants
flow control valve to establish 300 ml/min through the NCSM probe.
8. Turn on the 3D TRASAR Controller
4.15.5 Condensate Monitor System

-
Sample inlet needle valve

CAUTION-DANGER:
Note:

If the Condensate Monitor is configured for intermittent operation the interlock

input must be jumpered to test the system.

3. With caution, slowly open the needle valve on the sample inlet. This sample will be a high
pressure and high temperature sample so take caution. Check for leaks up to the pressure
regulator of the sample conditioner.
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4. If there is a leak, close the sample cooler inlet valve. Snug up the fitting that was leaking. Do
not over tighten Swagelok fittings.
5. Once the leak has been addressed, repeat step 3.
6. If there are no further leaks, proceed to step 7.
7. Although the sample is cooled after the sample cooler, take caution since this is still a highpressure sample.
8. Open up the 3-way valve on the sample discharge
9. Finally, ensure proper sample drainage.
3-way outlet
valve
Sample inlet
valve
Pressure
relief valve
Cooler water
solenoid valve
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4.16
4.17
Test Data Download to a USB Data Stick and Laptop Computer
Using the Configurator download data to the laptop following the on screen instructions.
Verify that the data was transferred correctly
The USB is available via an external connector with waterproof cap. The cap must be in
place whenever the port is not in use. Using the USB port download data/alarm files
following the on screen instructions. Verify that the data was transferred correctly by
loading it on the laptop.
Verify Operation Of The Control Outputs
Using the keypad on the controller manually turn on and off the relays.
Manually set the Analog Outputs to 0% and 100%.
Verify that the relays and pumps actually perform as expected.
CAUTION-DANGER:
4.18
Be careful to return the SCS relay to automatic control mode after

testing its operation.
Test High-Temperature Shutdown & Pressure Relief
The 3D TRASAR Boiler Automation requires the sample stream to be cooled before being sent to the
TRASAR Fluorometer or pH probes. If the temperature exceeds 110F or 43C, then the safety
solenoid automatically closes (normally closed valve) shutting off the hot sample flow before it reaches
the fluorometer. During the initial startup verify the proper/expected behavior of this safety feature.
1. While the system is in operation and with sample flow passing through the lines, the cooled sample
temperature should be shown on the main display screen of the controller.
2. While actively watching the unit (do not walk away or become distracted by phone or personal
conversation) begin the test by slowly reducing the cooling water flow to the sample cooler.
Eventually the flow of cooling water will become reduced enough that sample temperature from the
boiler system should begin to rise. This may take several minutes due to the cold water already in
place in the sample cooler shell. The goal is to cause a rise of the sample temperature ABOVE the
point where flow is automatically shut off (110F/43C).
CAUTION-DANGER:
DO NOT allow the sample to STEAM by completely turning off cooling

water.
If the temperature rises above 140F (60C) without closing the valve, quickly restore cooling flow
and check all wiring connections and configuration of the solenoid safety shut off.
3. With proper and expected activation of the solenoid shut off feature at high temperature, restore the
sample cooling water flow. Since there is no sample flow it may take several minutes for the sample
near the temperature probe to cool down (ice pack will help).
4. The (high temperature) alarm must be manually cleared (it is not self clearing). The system should
then re-establish flow.
5. Once normal flow is re-established VERY SLOWLY, incrementally increase the sample pressure
(using the sample pressure regulator).
6. Observe the sample pressure on the pressure gauge. The relief valve should start to open around
60 psi. (4 bar) This verifies that the relief valve is working properly.
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7. Reduce the pressure to the normal range (20-30 psi, 1-2 bar). The relief should close.
Note:
The relief valve has a metal ball to metal ring seal. It may drip. If so, repeat steps 8 and 9 to
re-seat until the leaking stops.
4.19
Check Remote Communications
If the 3D TRASAR web service is in use, verify that data and alarms can be sent to the 3D TRASAR
website via phone, wireless gateway or LAN.
4.19.1
1.
3D TRASAR Boilers Nalco Global Gateway Setup
Verify the controller settings are correct using the keypad.

From the keypad go to Menu > Network > Ethernet 1
Ethernet 1
Enabled
IP address
169.254.001.002
Gateway
0.000.000.000
Subnet
255.255.000.000
Ethernet 1DHCP
Disabled
From the keypad go to Menu > Network > Ethernet 2
Ethernet 2
Enabled
IP address
192.168.001.002
Gateway
192.168.001.001
Subnet
255.255.255.000
Ethernet 1DHCP
Disabled
2. Verify that the wireless gateway is installed correctly.
Connect Nalco Global Gateway to internal Ethernet port #2
Two Ethernet cables come with the Nalco Global Gateway. Only one is needed and it
does not matter which one is used. Continue to configuration.
Note:
96
The 3D TRASAR Boiler Controller IN NOT WIRED to the Nalco Global Gateway
the same way as 3D TRASAR Cooling Controllers.

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Connect your Nalco laptop to the controller as shown using the Ethernet crossover
cable supplied with the controller.
Launch the 3D TRASAR Boiler Configurator and Click on the Communication Settings
button.
Choose Connection method and Select the Advanced Communication Settings
Choose the appropriate Alarm Notification Settings. All other setting should be left
as default.
Select OK on both windows and upload changes to the controller.
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4.19.2
3D TRASAR Boilers Phone Line Verification
1. Verify the following.
The phone line is a dedicated analog phone line.
If an analog line is not available and the phone line is digital. Ask the customer what prefix is
needed to dial to an outside line from the phone line that will be connected to the 3D TRASAR.
(Example: 9, 1 and the area code or other prefix).
2. Verify the controller network settings from the controller keypad.
The correct Network settings for Ethernet 1 and Ethernet 2 are listed below.
From the controller keypad go to Menu > Network > Ethernet 1
Ethernet 1
Enabled
IP address
169.254.001.002
Gateway
0.000.000.000
Subnet
255.255.000.000
Ethernet 1DHCP
Disabled
From the controller keypad go to Menu > Network > Ethernet 2
Ethernet 2
Enabled
IP address
192.168.001.002
Gateway
192.168.001.001
Subnet
255.255.255.000
Ethernet 1DHCP
Disabled
3. Verify the 3D TRASAR Boiler Configurator Communication settings.
98
Open the 3D TRASAR Boiler Configurator and click on Communication Settings.
Verify that the Connection method is set for Modem.
Choose the Controller Country from the drop down.
Enter the Controller Phone #.
Click on Find Internet Access #.

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Choose your Country from the drop

down menu.
Choose State from the drop down

menu.
Select the local ISP number from the list

provided.
Click OK.
Note:
If no local access number is listed

check the AT&T Global Network
dialer for a local access number.
The local Internet Access # will populate in the Internet Access # field.
Click OK and upload the changes to the 3D TRASAR controller.
4. Using a Slimline analog phone to verify the dial out string
Connect the phone line that will be connected to the 3D TRASAR to the Slimline phone.
Dial the Internet Access # with the dial out string required (Example: 9,1 and area code).
When you have the correct dial out string and internet access number you will hear a fax
machine sound.
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Enter this dial out string into the 3D TRASAR Boiler Configurator.
Click OK and upload the changes to the 3D TRASAR controller.
5. Using your computer dialer.exe to verify the dial out string.
100
Turn up the sound on your computer.
Connect the phone line that will be

connected to the 3D TRASAR to your
computers modem connection.
Go to Start and click Run.
In the open field enter dialer.exe and click OK.
The Phone Dialer will open.
Click Dial.

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Enter the Internet Access # with the dial out string required. (Example: 9,1 and area code) in
the connect field.
Change the Dial as to Phone call.
Click Place Call.
When the correct dial out string and internet access number is correct the computer will make a
fax machine sound.
Enter this dial out string into the 3D TRASAR Boiler Configurator.
Upload the changes to the 3D TRASAR Boiler Controller.
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Tasks to Perform Before Control Tuning
The 3D TRASAR Boiler System must be in monitor mode for several weeks to obtain enough data to
set up PID control of the scale inhibitor and oxygen scavenger (minimum of 30 days suggested).
The boiler system will need to be operating at a steady feedwater flow rate (for at least 1 hour per
control loop) for the PID tuning to be completed. Feedwater flow rate (i.e. steam flow) changes make
PID tuning difficult or impossible to accomplish.
Note:
5.1
All the following tasks should be completed during the monitor phase. DO NOT wait until
the day PID tuning will be attempted.
Ensure An Interlock Is connected or Shutdown Process Is Established
The 3D TRASAR Boiler System will continue to feed chemical as long as sample flow to the system is
over 200 cc/min even if the boiler is not operating. The controller must be either shut down:
Manually - A plant standard operating procedure must be established.

Automatically Digital interlock signal must be sent from the customers DCS to the controller.
Steam Flow If an analog steam flow signal is used the 3D TRASAR Controller must be
configured to interpret and utilize the data to provide a shutdown process.
5.2 Verify Chemical Pump Capability

During the monitoring mode the capabilities of the chemical feed pumps to be used during automatic
mode should be verified. Review the TRASAR readings and observed feedwater flow rates to be sure
the pump is sized to obtain the target dosage under all conditions (normal, low, and highest feedwater
flow rates). This verification should be done for all pumps; internal treatment, scavenger and for any
slaved treatment pumps.
Ensure the proper size pump has been installed for each scavenger and scale inhibitor feed point.
As a general rule, the pump should be selected that will output three times (2-3X) the average
expected feed rate with the pump stroke length set at 50% and the pump stroke rate at 100%.
If the system has extremely wide load swings (seasonal or due to process demands) verify that the
pump will provide the maximum expected feed rate with the pump stroke length set between 20%
and 80% and the pump speed set to 100%.
Note: During PID tuning a Pump Stroke Calculation Tool will recommend the pump stroke length
setting that should be used. However, this tool can only be accessed when connected to the
controller. The suitability of the pump can be checked for various expected feedwater flow rates by
using the following calculation. The result should be between 20% and 100%.
Pump Stroke Length % = Feedwater (gpm) x TRASAR Setpoint (ppm) x (0.0072)
Pump Capacity (gph)
The feedwater rate is not measured it can be estimated from the steam production rate.
Feedwater (gpm) = Steam Production (lbs/hr) x 0.002
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If PID control will be used pumps should be selected that feature manual stroke length adjustment
and remote stroking rate adjustment (via 4-20 mA). Pumps equipped only with stroke speed
adjustment are acceptable provided they have a wide turndown ratio (1000:1).

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If ON/OFF relay-based control will be used be sure the pumps are connected to the TRASAR
Controller relay outputs (directly if under 2 amps, via a motor starter contact if over 2 amps)
5.3
Check Pump Responses and Measure Lag Times
1. Make sure the 4-20mA wires are connected to the pump and 3D TRASAR Controller.
2. Make sure the pumps are set up to respond to a remote 4-20 mA signal.
3. Testing the effect of chemical pump output changes and measuring the lag time for that control
loop can be accomplished at the same time. All controlled pumps should be tested to identify
potential problems. However, the loop can still be tuned without a lag time measurement.
Note:
Record the measured lag time for each chemical feed system. Record the stroke length %
and stroke speed % of the pump used when the pump was in manual control.
Using the controller keypad or Configurator set the pump (analog output) control to manual control.
Adjust the % output to the same setting used on the pump stroke speed control knob. Allow the
measurement (TRASAR ppm or mV) to stabilize.
Increase the % output signal by approximately 50%. Record the time. Observe how long it takes for
the treatment level to just start to change and record the level and time. If the measurement does
not change check the pump wiring, controller configuration and pump manual/remote setting.
Subtract the start time from the stop time and record the lag time (seconds). This value will be used
later in the PID Auto Tune program and for troubleshooting.
Conduct a pump drawdown test to be sure the pump is functioning properly.

Note: In this manual Lag Time is defined as the time it takes to first observe a change to the measure
parameter (TRASAR, conductivity, etc) after a change to the feed pump or blowdown valve is
made. It is not the time for the measurement to stabilize after a change is made.
Parameter
TRASAR
Manual
Remote Step
Control
Change
Parameters
Parameters
Oxygen Scavenger
Manual
Control
Parameters
Remote Step
Change
Parameters
Pump Capacity (gpd)

Stroke Length (%)
Stroke Speed (%)
TRASAR or mV
Start Time (hh:mm:ss)
NA
NA
Stop Time (hh:mm:ss)
NA
NA
Loop Lag Time (sec)
NA
NA
Note:
There is a Pump Stroke Calculation Tool that will recommend the pump stroke length setting
that should be used for the TRASAR pump when in PID control. This is accessed via the
TRASAR Auto Tune section in the Configurator. TRASAR PID loop tuning time will be
minimized if that tool is used and recommended stroke length is applied to the pump while it is
still in manual control (a corresponding pump stroke speed adjustment must be made).
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Lag Time Reduction
Minimizing the lag time is essential for obtaining good PID control. If the lag time is over 5 minutes (300
seconds) the controller will have difficulty maintaining control during rapid boiler load swings. However,
control is possible despite long lag times if the boiler load changes are not abrupt or frequent.
The follow actions can be taken to help reduce lag time.
Change standard size 5-micron canister filter to optional short filter.

Reduce sample line length and/or diameter (1/4 SS tubing recommend maximum diameter).
Increase the same flow rate (500 cc/min maximum for NCSM, approx. 2000 cc/min maximum for
TRASAR only).
Move 3D TRASAR Boiler System.
Change chemical feed and/or sample points.
5.4
Control Selection
The Configurator must be used to set up all control functions and run the PID Auto Tune program.
Minor adjustments or manual tuning can subsequently be made using the keypad.
If the product is being applied to the feedwater line where there is good mixing and short residence
time, then PID control is recommended
If product is being applied to the deaerator where there is greater residence and mixing time prior to
sampling, ON/OFF control (via 4-20 mA or relay) or PID control can be used. Although, PID control
is preferred. If the lag time is over 5 minutes either control mode may not provide optimal results.
Note:
Chemical metering pumps that accept a 4-20 mA control signal are necessary for PID control.
Pumps that accept a 4-20 mA signal can also be used for ON/OFF control (via a relay or using
the 4-20 mA signal).
Deaerator
PREFERRED
N223XX
Feed Point
PID
or
ON/OFF
Feed water
Pump
Scavenger
PREFERRED
Sample Point
N223XX
PID
or
ON/OFF
PID
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5.5
NCSM Set Point Determination
5.5.1
0-100% Scavenger Pump Test
During the monitoring phase the user must run a 0-100% scavenger pump speed test to define the
range of readings and create a system process response curve (see below). This data will help to:
Verify that the system is responding

Understand the possible NCSM control zones
Learn about system response times for control
Help with alarm setting
Perform a deaerator study
5.5.1.1
0-100% Pump Test by Manually Changing the Output.
Decreasing AT ORP
Increasing Reduced Conditions
1. Turn the scavenger pump off. Allow the NCSM mV readings to stabilize (may be positive or slightly
negative number).
2. Turn on the scavenger pump to 100% speed (and 100% stroke length and allow the NCSM mV
reading to stabilize (should be very negative number).
3. SAVE THIS DATA LOG (Initial NSCM 0-100% System Response Data) to a separate file. It will
be needed for future reference.
0% pump speed
100% pump
speed
Average NCSM value

Comfort control setpoint
Set ideal control
setpoint in this range
Increasing Dissolved Oxygen Scavenger

Increasing Dissolved Oxygen
Example of 0-100% scavenger pump speed curve
and set point determination
The NCSM control is direct acting. An increasing NCSM
values (more positive) will cause the controller to increase
the oxygen scavenger dosage (increase pump output %).
AT ORP vs EPBRE
(mV) at 400oF
+ 300
+ 200
+ 100
0
-100
-200
-300
-400
-500
-600
-700
Preferred
Broader
Broadest
DA+Scav
+Cu
Typical NCSM control zones

These are the general control zones for a
systems with a deaerator that feed oxygen
scavenger. The control zones will be lower
if yellow metals are present.
Note:
The minimum data log interval on the controller is 10 minutes. The resolution of the graph can
be increased by using the NCSM PID Auto Tune program to create the graph. The Auto Tune
program can only be used if the pump accepts a 4-20 mA signal.
Note:
The graph can also be created utilizing ON/OFF control using the PID 4-20mA output. PID
control provides a fast local data log for up to 3 days (data every 5 seconds). It can be
downloaded via USB stick or direct connection to the controller.
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Note:
Certain oxygen scavengers (especially sulfite based scavengers) can reduce the pH of the
feedwater to a point that can appear as an ORP stress event. When feeding acidic sulfite
oxygen scavengers start the initial NCSM control at a higher NCSM set point instead of trying
to drive NCSM values to very low set points. This will assure that acidic scavenger products
like bisulfites are not over fed, leading to pH depression of boiler feedwater.
Example: If the average boiler feedwater NCSM value was -400 mV during the monitoring
phase, a good NCSM initial set point would be -350 mV (or -300 mV). Lower NCSM setpoints
(for corrosion control) could be chosen at a later stage once it had been verified that control
could be achieved at the higher set point without overfeed of the acidic sulfite chemistry. Use
caution to ensure that the pH of the boiler system does not fall below what would be deemed
best practice.
5.5.1.2
0-100% Pump Test using the NCSM PID Tuning Program.
Data is logged every 5 seconds when using the NCSM PID Auto Tune program. This will provide a
detailed graph of the system response and corresponding NCSM values to chemical pump changes. It
can also be used to calculate the true system lag time.
3. Record the current scavenger pump stroke length and speed settings.
4. Set the pump stroke length to zero. Wait for at least 3X the system lag time, possibly much longer.
The Scavanger must be purged from the system. Use discretion, as the system should not be left
without scavenger feed for too long. (Some systems have been left without feed for days).
5. Follow the instructions in Section 6.6 using the following Auto Tune Settings:
The Baseline Output % = 0%

The Baseline Duration = approximately 1X the system lag time
The Step Output % = 100%
The Step Duration = approximately 6X the system lag time
3. Start the Auto Tune cycle and observe the NCSM values. Stop the test once the NCSM values
has dropped and is no longer dropping. (There is no need to over feed the chemical treatment).
4. When the Auto Tune cycle is completed capture the graph by using the Print Screen function and
copy/paste into a Word Document. Alternately an editing tool like Snagit can be used.
5. Exit the Auto Tune program. Do not upload the PID values into the controller.
6. Reset the pump stroke length and speed settings to their original settings on the scavenger pump.
(recorded in step 1 above).
5.5.2
Comfort Control NCSM Setpoint
Using the average NCSM value determined in the monitoring phase as a starting setpoint permits
optimization of the control tuning parameters without a dramatic change to the treatment program.
Determine the average value (green data point in example curve) after extracting known discontinuities
like oxidizing spikes of known origin.
Normally, round down to the nearest 25 mV increment from the calculated average NCSM value.
For example, if the average reading was 363 mV, the setpoint should be 375 mV.
If a system is in a highly reduced state (very negative reading), round up to the nearest 25 mV
increment. For example, the setpoint is 525 mV if the average reading was 536 mV.
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5.5.3
Ideal Control NCSM Setpoint
The ideal control setpoint can be determined after developing a full understanding of the system NCSM
response, corrosion knowledge and other issues such as cost, boiler system specifics and preferences.
The NCSM setpoint (actual values shown in above table) will fall into the zones shown for syste m
corrosion protection.
5.6
TRASAR Setpoint
Refer to the product CPP (Confidential Product Profile) to determine the dosage for the system.
5.7
Intermittent Operation
5.7.1
General Considerations
Boiler feedwater operation can be continuous or intermittent. Higher capacity boilers have continuous
feedwater pumps with modulating feedwater regulators which feed water continuously at varying flow
rates to maintain the boiler water level consistently. But in systems with sporadic steam demand, there
are times when minimal (or no) water is being sent to the boiler.
Smaller ( fire tube) boilers often have water level sensors which turn on the feedwater pumps when the
water level is low and turns them off when the water level reaches the high state. In these cases the
water level in the boiler varies continuously. Again, in these cases there are periods when no water is
being sent to the boiler
When the feedwater pump is off or the feedwater flow regulator is forcing a low or no flow situation, the
3D TRASAR sensors are unable to obtain a representative sample of the water in the system. The
chemicals being pumped into the line are sitting in stagnant pools and the sensors cannot detect their
presence. It is necessary to have an intermittent operation control strategy.
5.7.1.1
Interlock & Alarm
To control systems where the feedwater flow is intermittent the 3D TRASAR controller must be
provided with a signal representing the status of the feedwater flow. This input is used to generate a
feedwater flow off alarm
For boilers with modulating feedwater regulators a 4-20mA analog input signal from the
regulating valve is necessary. The user must define a threshold value at which chemical
application should be suspended.
For boilers with water level sensors which turn the feedwater pump on and off, a digital input
signal representing the feedwater pump state is needed
The feedwater flow off alarm is not logged in the event log but it will show up in the alarm display. This
is because the flow situation is a normal part of the system operation.
These signals should be added to the configuration and designated as the signal used for intermittent
feedwater (please use the Boiler Configurator Help system to configure intermittent operation).
5.7.1.2
Control Options
There are two options for TRASAR or NCSM based chemical feed in intermittently operating systems:
On/Off Control: When the feedwater flow off alarm is engaged, On/Off control of internal
treatment or scavenger feed is suspended. When the alarm is cleared, standard On/Off control
resumes. For On/Off control it is important that the user adjusts the stroke of the pump if it is
found that the measured value routinely over/under shoots the set point.
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5.7.1.3
PID Control: When the feedwater flow off alarm is engaged, PID control of internal treatment
or scavenger feed is suspended. When the alarm is cleared, standard PID control resumes.
o The Integral or I term in the PID equation is retained through the alarm so that the control
resumes in the same place as it was when it was suspended. Retaining the I-term through
the alarm allows the control to stitch together the snippets of incoming valid data (data
collected when the feedwater pump is running).
o For intermittent systems it is important to do the PID tuning only after configuring the
feedwater flow off alarm
By using PID control, it is no longer necessary for the user to carefully adjust the pump to reach
the set pointthe control algorithm adjusts automatically.
Control Expectations
For both on/off or PID control in intermittently operating systems, the control will be more variable than
that we typically obtain in continuously flowing systems. A part of this variability will be cosmetic -segments in the logged data will be measurements taken from a stagnant or nearly stagnant stream.
But even the valid data will show less precise control than if the sample stream was continuous. The
tightness of control will depend on:
variability of the steam load or feedwater flow in the system
fraction of the time that the system remains stagnant
lag time between the detected signal and the applied chemistry.
The measure of control for these systems will be how close the average signal is to the set point. This
is particularly true for the TRASAR, where the applied internal treatment is active in the boiler drum.
5.7.2
5.7.2.1
Special NCSM Considerations

General Considerations
IMPORTANT NOTE: Feeding bisulfite to low alkalinity boilers may depress the pH. Lower pH
waters will detected by the NCSM as stress causing the controller to
increase bisulfite feed, further depressing the pH. If the boiler does not
have good pH control, add a pH override to the NCSM control loop and
consider slaving caustic feed to the NCSM or TRASAR pump. (See 3D
TRASAR Boiler Technology Help Desk FAQ# 29)
Additional factors must be considered when monitoring corrosion stress or controlling oxygen
scavenger in intermittently operating systems. Applying feedwater chemistry control in systems that are
operated intermittently requires a more detailed understanding than constantly operating systems under
well-defined and more stable baseline conditions.
Definition Note:
Down-time: Period when active control is not possible, or makes little sense to run.
Up-time: Period when control is possible.
Intermittently operated systems are bound to produce higher variability in response and possibly higher
corrosion rates than comparably full time, flowing, operating and controlled systems. Users must know
what portions of the system are idle during down time and which portions of the plant are operational
during up-time. Diligent thought needs to be given to where the NCSM is located and how that pertains
to system control.
Control is only possible if during up-time the control variable (NCSM value) can be achieved. This
means that there must be enough time to capture a true NCSM value, and then have the time to react
to that value and preferably time to see the NCSM response to the pump action. So during the up-time
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the NCSM value will have to transition from down-time measurement, through a transition phase, and
then into full NCSM measurement/control during the up-time.
Complete NCSM control can only be instituted with success in the phase when the true NCSM value
(with full representative FW flow) is measured.
There will be cases where the up-time will be too short to be able to institute NCSM control in an
intermittently operated system. In these cases the NCSM value can be gained as a monitoring tool only
to verify current operations. The period of time that is defined as too short will be system specific and
cannot be fully defined without knowledge of the system (including lag times for water to flow and reach
the NCSM probe).
Factors that will play a role include: Baseline FW conditions; air in leakage (system tightness);
scavenger pump capabilities; system design; system volume; 3D TRASAR water flow rates; chemical
feed half lives and residence times; chemical type; temperatures; FW flow; REDOX stresses present
and their variability, system lag times/dead times, amongst others.
Control will clearly be non-optimal if the delay time is long relative to the up-time cycle as not enough
time will transpire between obtaining a relevant NCSM value, making of the control decision and seeing
the effect of that control decision in NCSM terms. If the system delay time is longer than the up-time,
then true control will not be possible.
Care needs to be given in any system scoping and setup. In the Figure below the boiler and pump
might have different duty cycles. There are three possible locations for the 3D TRASAR Boiler skid with
NCSM technology. The duty cycle, presence of check valves, recirculation line functionality, etc will all
play into what the skid locations sees: 1) flowing water all the time; 2) flowing water some of the time; 3)
flowing water that might not be representative water (e.g. location num ber 2 if the boiler is not
operating (calling for water) but the FW pump is operating.
Reductant
Feed
FW Storage Tank
1
Boiler
2
Pump
The goal is to get representative water to the 3D TRASAR Boiler skid and capture REDOX stress. Lag
times should be as short as possible with short sample run lengths and appropriate 3D TRASAR skid
sample flow rates. There might not be an optimal 3D TRASAR skid location/tap point and compromises
may be needed. The configuration and setup will vary on the nature of flow to the 3D TRASAR skid
and the nature of system operations.
Controlling intermittently operating systems with the current boiler configuration operations is in and of
itself a compromise. This manual can help define and bracket control. The user ultimately has to
decide whether good control is possible for their specific installation. If good control is not possible is
control that is better than current operations achievable?
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IMPORTANT NOTE:
Ensure that if there is no feedwater flow (FW pumps turned off) boiler water
does not siphon back through the 3D TRASAR skid. There should be FW
check valves in place to prevent this from occurring (do not assume that they
exist or are working they need to be checked). This siphoning could cause a
high temperature alarm and control suspension and skid-flow shut down even
if the SCS is in operation. This alarm can only be cleared manually. Also, if
there is no High Temperature alarm setting on the NCSM temperature control
could still be occurring, even if there is no FW pump flow. This control would
be trying to control the NCSM value in the boiler feedwater by affecting
chemistry flow into a different part of the cycle not being sampled at that time.
IMPORTANT NOTE:
5.7.2.2
Make sure that all installations ensure that the NCSM probe remains wetted
(not allowed to siphon dry) during down-times. This will ensure the NCSM
probe remains functional and it will return quickly to active measurement of the
true and real NCSM values once the system starts operation again.
Monitoring
During the monitoring phase the user will obtain an understanding of how the NCSM will respond to the
plant conditions. How is the system controlled now and how do NCSM conditions vary with time?
Users will need to understand the NCSM response with respect to up-time and down-time and the
transition between the two. This is especially important to understand within the Factors discussed
above. At this stage hard questions need to be asked about whether NCSM control will be feasible or
should be attempted. If feasible, then how will the control and bracketing of the control be setup?
NCSM monitoring to understand, document and improve the system has great value even if direct
NCSM control might not be possible or not optimal. Remember that a control approach might be
better than what is currently practiced in the plant and could be very important for corrosion control. The
monitoring process can often lead to the discovery of novel solutions to complex issues affecting plants
with intermittent operations.
5.7.2.3
Manual Feed
The manual feed of chemistry (oxygen scavengers and reductants) based on fixed pump speeds is
always a possibility with the 3D TRASAR Controller. Manual feed rates override all interlocks, alarms,
etc.
5.7.2.4
Control
There is no prescriptive solution for NCSM based reductant feed in every case. In those systems
where there is adequate time during the up-time to institute NCSM control, the following set-up can be
instituted with the new 3D TRASAR Boiler Configurator, NCSM probe and control schemes.
The following factors should be considered during control:
1.
2.
3.
110
Is there adequate sample flow to the NCSM probe?

Is the plant running - adequate FW flow but no plant steam flow/FW flow interlock signal?
Is it just the boiler stopping its call for FW or is FW flow stopping too?
a. Does the boiler stop and flow to the NCSM probe stops too?
b. Does the boiler stop but flow to the skid is maintained as FW is diverted back to the DA
storage tank (or some other storage tank), when the boiler is not calling for water. This
system is easier to control, as control is unchanged, regardless of whether the boiler is
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4.
What is the duration of the stop flow condition (minutes, hours, days, weeks, months?). How is
it related to how long the boiler is off line?
5. Is the temperature in the NCSM cell appropriate for control to be active? The NCSM
temperature data in a control phase can be as important as the NCSM voltage value itself.
6. Does the NCSM value itself achieve a controllable regime during the up-time? How long does
it take the NCSM probe to stabilize? (Temperature and ORP)
7. Does the NCSM probe remain wetted during no flow conditions? Might add complexity if it is
air bound.
8. Is the system opened to atmosphere or becomes highly oxidizing, or does it remain
reduced?
9. How does control look like?
10. How is control deactivated during off times and activated during on times (digital switch or 420 mA input signal)?
Remember that with NCSM control it is possible that water conditions in the first water to enter the
NCSM probe (during the up-time) might have an NCSM value far removed from the set point. As such
the aggressiveness of control needs to be understood. This has implications for PID control and
ON/OFF control and chemical pump sizing and stroke setting.
The full set of NCSM alarms, control settings (like minimum and maximum pump settings) and pump
time out features to further enhance the control of any system.
Goodness of control: A user will need to decide on the NCSM setpoint and control parameters.
Ultimately the user will need to determine how good control is about the set point, what is considered
poor, adequate and good control for the system. Such conclusions can be based on NCSM values and
variability during the monitoring phase and during various control phases where different control
scenarios might be tested.
It is assumed that during intermittent operations that sound boiler best practices are still followed as
they pertain to pH control as well. One option might be to have pH monitoring that disables NCSM
control if boiler FW pH declines too much. This is more of an issue in systems where acidic reductant
chemistries are fed.
For better control all aspects of the MOC must be considered. This includes a detailed understanding
of where the chemistries are fed and why. Determine if there is a better approach for the feed and
control of corrosion with the NCSM. This includes chemical pump and pump capacities and setup.
5.7.2.4.1
High & Low Temperature Interlock
The NCSM temperature needs to achieve an acceptable level during the up-time before the NCSM
value can be accepted for NCSM control. This is not the case with TRASAR control, as in this case the
NCSM temperature is a critical part of the NCSM reading.
The below Figure shows the System Interlocks screen:
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In the Configurator, if the High or Low Temperature Interlock is Enabled the alarm response can be set
as Forced Off, Fixed Output or Smart Failsafe. The default condition is to have the interlock unchecked
and this might not be the preferred state for your system. Remember too that the System Interlock and
Steam Flow/Feedwater Flow Interlock have the same alarm response options. These will have
overriding precedence in system control.
The Low Temperature Limit can be set to a temperature that is consistent with the NCSM temperature
and NCSM control. In the above example a deaerated FW sample line that usually operates with a
240F (115C) feedwater temperature has the Low Temperature Limit set to 180F (82C). This means
that if the FW temperature drops to below 180F (82C) then the NCSM control will be rendered
inoperable and the reductant feed pump will be turned OFF (RTD #2, in this case). Control would only
be re-established once the NCSM temperature came back above 180F in this case.
Re-iterating: An NCSM set point has to be chosen with due diligence applied to the temperature at
which the set point is chosen. As such, if the temperature falls outside of the determined control range,
then NCSM control to the set point has to be suspect and should not be attempted.
The low temperature interlock only becomes active after 300 seconds, so control will still be in effect for
a further 5 minutes after the activation of this interlock. The interlock is cleared after 1 second if the
temperature rises above the low temperature interlock value.
Options: If there is a system flow or process signal used to limit control (digital switch or 4-20 mA
signal) it could serve as the interlock for NCSM control.
5.7.2.4.2
No Flow Switch
In systems with an SCS attached with a flow switch, there is the No Flow Alarm which can also be
enabled (after 300 seconds of activation). This will activate when flow through the 3D TRASAR skid
flow switch drops below about 100 ml/min. The appropriate response (Forced off, Fixed Failsafe,
Smart Failsafe) for the desired signals needs to be set (see example Figure below).
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5.7.2.4.3
Slaved Control
Reductant feed can be slaved to the TRASAR signal but this is not true NCSM controlled feed of
reductant. It is direct feed of chemistry based on feedwater flow rate.
However, proportionately more scavenger than TRASAR feed may be needed. For example A
TRASAR feed range corresponding to a chemical pump speed of 1% to 20% might correspond to a
desired scavenger pump speed of 5% to 75%. The NCSM values must be monitored during a steady
state to see if the above settings provided a semi-constant NCSM value. One way to counter this
current limitation is to size pumps so that stroke settings can be used to feed proportionately more
scavenger than TRACED product. In this case active REDOX stress management is not being
practiced but it is being attempted.
Reductant feed cannot be slaved to a FW flow signal as the FW flow is not a controlled signal output,
even though it can be a recorded input.
Note:
A ratio factor can be applied to the Slaved Control output to better meet dosage requirements.
5.7.2.4.4
ON/OFF Control
ON/OFF control logic and the setup are no different from ON/OFF control in constant operations.
Control should probably be deactivated during down times and activated in up times based off an input
Interlock (this might not always be the case).
ON/OFF controlled feed of reductant might be more appropriate in some systems that operate i n an
ON/OFF fashion, like intermittent boiler feedwater systems. However, PID controlled feed of scavenger
should be the desired control methodology with pumps that are driven by 4-20 mA signals. Remember
that PID pumps can be setup with small P and I parameters that essentially put the pump into ON/OFF
control. The reverse is not true: That is ON/OFF driven pumps cannot be operated as 4-20 mA
accepting PID capable pumps. As such, when in doubt, purchase pumps to handle 4-20 mA signals.
Setting P=0.01 and I=0.01 will turn those PID pumps into ON/OFF pumps.
5.7.2.4.5
PID Control
The basic logic of set point choice and control still need to apply during up-time. That is, can the
setpoint chosen be achieved, does the set point make sense for corrosion control, and are pumps sized
and set up correctly to address baseline control and REDOX stress event control?
A start might be to choose a set point based on the concepts of comfort control. The question needs to
be asked whether this provides adequate corrosion protection and/or system control for your specific
system. Comfort control should give way to more ideal setpoint control for the right reasons. These
might be better corrosion control and/or optimized use of chemistry via chemical feed on demand for
the right reasons (corrosion and REDOX stress control).
o
PID control could be different in intermittently operating systems as the time in the control
phase might dictate that control might need to be more aggressive (Lower P and I settings) in
order to achieve some form of control in a time limited control loop. More aggressive PID
parameters are probably going to be the norm versus PID parameters for constantly operating
systems.
Also users might have to perform more iterations of fine tuning PID parameters for intermittently
operating systems in order to obtain good control.
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6.0 ON/OFF Relay Control

If ON/OFF control is chosen, the user will be asked to set:
1. Setpoint: Target value of the input
2. Acting: Controller Action
Direct Acting: Controller output increases in response to an increase in the signal input. .e.g.
NCSM control is direct acting because an increase of NCSM reading will result in more scavenger
being applied (increased pump output).
Reverse Acting: Controller output increases in response to a decrease in the signal input. .e.g.
TRASAR control is reverse acting because a decrease in TRASAR reading will result in more
product being applied (increased pump output)
3. Range: This is the deadband control range.
For direct acting control, the output is turned on when the input signal exceeds (setpoint +
range) and remains on until the input signal is below the (setpoint range).
For reverse acting control, the output is turned on when the input signal falls below (setpoint
range) and remains on until the input signal reading is above (setpoint + range).
6.1 ON/OFF Control using the PID 4-20 Outputs

The 3D TRASAR Boiler Controller allows the user to quickly switch between PID and ON/OFF control
without rewiring the treatment pumps (pumps must be controlled via the 4-20 mA signal). Use the PID
setting listed below (Advanced PID Setting Screen) to control the treatment pump as if the system was
in ON/OFF control. This type of control may be very effective when feeding scale control treatment to
the deaerator where the lag time is usually very long.
Settings for ON/OFF Control Using 4-20 mA Outputs
Set:
Set:
Set:
Set:
P = 0.01
I = 0.0
D = 0.0
Setpoint = to desired set point
The minimum and maximum pump output percentages must be changed to a span less than a full 0100%. This will reduce the over shoot and under shoot as the pump % output cycles up and down to
simulate ON/OFF control.
Set: Output Min. = (% pump output to reach set point at minimum feedwater flow)
Set: Output Max. = (% pump output to reach set point at maximum feedwater flow)
Set: Max. Change = 100%
The width of the control band will be determined by several factors including:
114
Sample lag time

Pump maximum and minimum output percentages (pump stroke rate %)
Pump stroke length setting of the pump
Rate of feed water flow changes

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7.0 Proportional Control Configuration

7.1
Blowdown Control (Cycle Control Using 3D TRASAR Fluorometer)
The 3D TRASAR Boiler system can be used to control blowdown based on fluorescence where you
have automated control of TRASAR 3 internal treatments. This control strategy uses a setpoint to
trigger blowdown (does not do automatic cycle calculations). Actual cycles will depend on how tightly
the feedwater and blowdown control loops are established. Therefore good PID control of TRASAR 3
program in the feedwater is needed to achieve accurate blowdown control.
For example, if the feedwater treatment PID setpoint is entered as 6 ppm and you want 50 cycles of
concentration, the blowdown setpoint is 300 ppm. Carefully choose the boiler cycles to avoid any
potential scaling problems in the boiler. For help in determining the correct cycles value for your
system contact the Regional Help Desk.
When using proportional control the blowdown valve will ramp up to a maximum value as the
fluorometer reading climbs above the setpoint. Before setting up proportional control, there are a few
things to consider.
Is the sample point for the fluorometer located on a line where the 4-20mA control valve will need to
be open to get a sample? If so, a minimum output will be needed to ensure a f resh sample is
always going to the fluorometer.
Note:
Utilizing the Continuous Blowdown Sampling plumbing configuration is recommended

(See Section 2).
Should there be an upper limit on the output? Some boilers may not be able to handle the
blowdown control valve open 100% because it will shock the boiler.
Determine the setpoint multiply the feedwater TRASAR setpoint by the number of cycles desired.
What should the Alert points be? A good method is to use the number of cycles you want to control
within.
Setup Procedure
1. Selection proportional on the fluorometer configuration screen.
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2. Enter the setpoint and alarm values.
3. Click on the Advanced PID Settings
Enter the maximum and minimum output %.
Use the equation below to calculate the proportional

band.
Proportional =
(Alert Point Setpoint) x 10000

Maximum Output x (Scale High - Scale Low)
Alert Point = Upper Control Limit of 3D TRASAR wanted in

the boiler, usually High Alert value (or slightly
below)
Scale High & Scale Low = Use default values from Advanced
PID Setting screen
EXAMPLE (shown on all screens in this section):
Proportional = (312 300) x 10000
100 x (1000 - 0)
= 120000 = 1.2
100000
4. Enter the calculated Proportional Band and click OK to accept the control parameters.
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7.2
Feedwater Flow-Based Proportional Control
The flow signal (steam or feedwater) can be used to proportionally feed chemicals to the boiler system.
Using proportional control the pump output will ramp up as the flow input signal (4-20 mA) increases.
Before setting up proportional control, there are a few things to consider.
What is the lowest flow value expected when the boiler is actually running (Example flow meter
may display 20,000 lbs/hr steam flow when the boiler is idle).
Is there a minimum pump output value (% speed) that must be achieved as soon as the flow signal
exceeds its minimum valve to achieve the desired ppm dosage of chemical?
Is an upper limit on the pump output needed? The chemical pump must be sized so it delivers
chemical at the needed dosage over the entire flow signal range (at a fixed pump stroke length).
Setup Procedure
1. Selection PID on the Analog Input configuration screen.
2. Enter the unit of measure, 4mA value and 20 mA value for the input flow signal.
3. Enter the 4 mA value as the setpoint and disable all alarms.
Note:
To start feeding chemical at an input value greater than the 4 mA value use a control override
(Example: Steam Flow of 30 Klbs/hr)
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4. Click on the Advanced PID Settings
Enter Direct Acting
Enter: P = 100, I = 0, D = 0
Enter the maximum and minimum output %.
Enter Scale High & Scale Low (same as on the Analog

Input screen).
EXAMPLE (shown on all screens in this section):

Scale Low: 4 mA = 20 (Klbs/hr)
Scale High: 20 mA = 100 (Klbs/hr)
5. Click OK to accept the control parameters.

Note: If the chemical pump stroke is set so that 100%
pump speed will deliver the correct dosage at the
maximum flow input signal, the proportional term will be
100. Otherwise, use the equation below:
Proportional =
10000
Maximum Pump Output
Maximum Pump Out = % Pump Speed to get correct dosage when flow input signal is 20 mA.
EXAMPLE:
% Pump Speed to get correct dosage when flow input signal is 20 mA = 80%.
Proportional = 10000 = 200

50
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8.0 PID Configuration and Tuning

8.1
Check PID Configuration
Using the Configurator follow the on screen commands to make sure the PID parameters are correct.
Determine the setpoint for TRASAR or NCSM before starting the tuning procedure. Ensure that the
correct values have been entered.
Ensure that the TRASAR and scavenger pumps are wired to the analog output channel selected in
the Configurator.
8.2
8.3
When to Auto Tune

Setting up control on a new controller
After changing the feed pump with a different model
After changing the feed pump stroke length %
There is a change in system conditions and manual tuning adjustments dont improve control.
o Sample line modification
o Sample flow rate change
o Product feed line modifications
Before Starting Auto Tune
Start the Configurator
Connect to the controller
If using a laptop, ensure it is connected to A/C power.
PC Setup - Check Power Option settings in the
Control Panel and change the settings so the laptop
will not go into standby or hibernate mode for at least
3-4 hrs (the duration of the tuning process).
IMPORTANT NOTE:
8.4
Before Auto Tune put the pump in manual mode and adjust the % output
so it is dosing at approximately of the desired ppm dosage (baseline
output used in Auto Tune). This will reduce the overall time needed to
perform the tune.
Checklist for Auto Tune
Pumps in analog control mode (4-20mA) and powered.

Pumps are connected to the correct analog outputs as configured in the PID settings.
Stroke length is set on the pump (prior to tuning).
o Stroke length is typically not changed once chosen unless system conditions change
drastically. If the stroke length is changed after tuning, Auto Tune must be run again.
o Stroke rate (0-100% pump speed) is controlled by the PID algorithm and under typical
operating conditions and load variations should vary between 10-90%. If after tuning the PID
the stroke rate is predominantly outside the 10-90% range, change the stroke length and run
Auto Tune again.
Steam load is as steady as possible during tuning.

o A key to successful tuning is the steady operation of the boiler system feedwater flow rates
during the tuning process.
o Large variations in the steam load during the tuning process could result in failure to tune the
PID loop. (See Section 12.5 for PID troubleshooting.)
Note: Those experienced with PID control tuning may want to input initial guesses for P, I
and D, then monitor the system and adjust the parameters to improve performance.
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8.5 TRASAR PID Auto Tune
The TRASAR tuning procedure is comprised of three steps. The three steps are baseline, first step and
second step. During each step the pump output % is held at a fixed value over a chosen duration. The
TRASAR data is collected after the tuning procedure and fitted to a mathematical model in the
Configurator software. A set of PID values will be computed and can be uploaded to the controller to
begin PID control.
For systems configured as intermittent feed systems, the chemical pump will suspend feeding the
internal treatment during the feedwater down-time (off-time). This will not interrupt the tuning process.
Tuning Steps
1. Select Edit Fluorometer in the Configurator
2. Select Tune PID Controller in the input configuration screen.
3. On the PID tuning dialog box , select Auto Tune to start the auto tune process. In the Auto Tune
PID loop screen, enter the Auto Tune Settings before starting Auto Tune. The Configurator Help
Screens provide detailed information on the steps and parameters.
Ensure that the pump to be controlled has the optimum stroke setting. Click on Calculate
Pump Stroke and enter the required data. It will give the suggested stroke %. The actual feed
rate is shown so that the user can verify by doing a drawdown to confirm the stroke setting.
Confirm the Setpoint is correct.
A Baseline Output value should be entered for the baseline step. The user should choose this
value such that the TRASAR readings will be between the setpoint and 50% of the setpoint
during the baseline duration.
EXAMPLE: If the setpoint is 10 ppm then the Baseline Output should be chosen so that the
TRASAR reading will be between 5 ppm and 10 ppm. So, if the TRASAR pump output
is currently set at 50% to maintain 10 ppm. A Baseline Output of 35% would provide a
TRASAR reading of approximately 7ppm.
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The Baseline Duration is set to 15 minutes by default and can be changed by the user. The
baseline duration should be greater than the system lag time to allow the TRASAR reading
to stabilize.. For intermittent systems, the baseline duration should follow the recommendation,
above as well as exceed the average off-time (down-time) by at least 4 times.
EXAMPLE: If the boiler feed water is off for an average of 5 minutes during an on-off cycle,
then the baseline duration should be at least 20 minutes.
The Step Output is automatically calculated from the baseline output such that the TRASAR
reading goes higher than the setpoint at some point in the tuning process. The setting can be
changed if needed.
The Step Duration is equal to or greater than the baseline duration but can be
changed if needed. The first and second step output durations must always equal to
each other.
For intermittent systems, the step duration must follow the above recommendations as well as
exceed the off-time (down-time) by at least 4 times
4. After all the tune settings are entered, click on the Start Auto Tune button to begin the tuning
process. The analog pump output will automatically change as shown in the plot.
Graphing of the tuning data will be displayed (example)

Note:
When the Auto Tune cycle is completed capture the graph by using the Print Screen function
and copy/paste into a Microsoft XL document. Alternately an editing tool like Snagit can be
used. The graph can be used to calculate the true system lag time.
5. After all three stages of tuning are complete the Configurator will analyze the data and calculate a
set of PID values. Any errors or warnings will be listed on the tuning calculations screen. If any
errors appear, the Upload button will be grayed out. Warnings are indicate whether the tune
followed all the recommended conditions. Click on Upload and the values will be uploaded to the
controller and PID control will initiate. NO REBOOT IS NEEDED.
Note:
TRASAR PID Auto Tune always sets D = 0. This means the controller is truly PI control.
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The I value will typically be equal to or greater than the system lag time (in seconds). This
should have been measured before tuning (see Section 5.3)
6. If the Configurator is unable to calculate a satisfactory set of values error messages will indicate the
cause. .
TRASAR reading did not rise when pump speed increased. Check for problems in controlling
the pump. Check for air-locked pump.
Steam load variation was too high during the tuning process. Repeat the tuning when
conditions in the boiler are more stable.
If the variation in the steam load seen during tuning is typical, increase the first step output by
5% and the first step duration by 5 minutes. Then repeat the Auto Tune procedure.
Note:
Warning messages will permit the user to upload these PID values with the
understanding that the values may need some additional manual tuning after monitoring
control performance
Note: PID parameters can also be entered manually via the keypad or 3D TRASAR Configurator.
For TRASAR tuning, ensure that the change in TRASAR values during the tuning process are
greater than when the pump output is held at a constant output.
Note:
See Section 12.5 for additional PID Troubleshooting.
8.6
NCSM PID Tuning
NCSM tuning is comprised of two steps. They are the baseline and first step. During the baseline, the
pump output % is held at a low value for a chosen duration. During the first step, the pump output % is
held at a higher value for a chosen duration. The NCSM data is collected and a set of PID values is
computed. They are uploaded to the controller to begin PID control.
1. Select Edit AT ORP (NCSM) in the Configurator

2. Select Tune PID in the control page and select Auto tune in the PID tuning screen.
3. Scavenger feed pump must be set to the optimum stroke setting such that it can account for all
changes in load expected in the system. This setting can typically be determined by analyzing data
from the monitoring mode.
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4. On the Auto Tune PID Loop screen enter the Auto Tune Settings before starting Auto Tune. The
Configurator Help Screens provide detailed information on the steps and parameters.
Confirm the Setpoint is correct.

The Baseline Output % is chosen such that the ORP values during the baseline duration are
higher (more positive) than the setpoint.
The Baseline Duration is set to 15 minutes by default and can be changed by the user. The
baseline duration should be greater than the system lag time, although this time should be
less than 1 hour.
In intermittent systems, the baseline duration should follow the above recommendations as well
as exceed the off-time (down-time) by 4 times. For example, if the off-time (down-time) is on
average of 5 minutes, the baseline durations should be at least 20 minutes.
The Step Output % is chosen such that the ORP reading will decrease (more negative) by at
least 30 mV to 50 mV during the tuning process.
The Step Duration is chosen such that the pump output is held long enough at the chosen
value to observe the minimum change in ORP values (greater than the system lag time).
For intermittent systems, the step durations should follow the above recommendations as well
as exceed the off-time (down-time) by at least 4 times.
The total tune duration of baseline and step duration is not recommended to exceed 90
minutes.
Note:
The pump speed is set to 0% after Auto Tune. So, the pump speed and setpoint can be
changed after Auto Tune.
5. After all the tune settings are entered, click on the Start Auto Tune button to begin the tuning
process. The analog pump output will automatically change as shown in the plot
Graphing of the tuning data will be displayed (example)

6. After the two stages of tuning are complete, the Configurator will analyze the data and calculate a
set of PID values. They can be uploaded to the controller to begin PID control. For AT ORP control,
clicking on the Upload button only uploads the PID parameters and does not start PID control.
NO REBOOT IS NEEDED.
At the end of NCSM Auto Tune, the scavenger pump will be turned off (manual 0%)
PID control will resume only when you switch the output from manual to auto via the
Configurator or the controller keypad (analog output controls).
A timer is available to delay switching to auto.
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Note:
NCSM PID Auto Tune always sets D = 0. This means the controller is truly running PI control.
Note:
The I value will typically be a little greater than the system lag time (in seconds). This should
have been measured before tuning (see Section 5.3)
7. If the Configurator is unable to calculate a satisfactory set of values it will display error message(s)
to indicate why the calculation failed.
ORP tuning will typically fail if the ORP readings do not decrease (more negative) when the
scavenger feed is increased. Various factors can cause this behavior and looking at the tuning
log data and knowledge of the condition of the boiler during tuning will help troubleshooting.
Check for problems in controlling the pump. Check for air-locked pump.
Steam load variation was too high during the tuning process. Repeat the tuning when
conditions in the boiler are more stable.
If the variation in the steam load seen during tuning is typical, increase the first step output by
5% and the first step duration by 5 minutes. Then repeat the Auto Tune procedure.
If the tuning process does not satisfy certain quality criteria Warning messages will be displayed
but the user will be permitted to upload these PID values.
Note:
Choose the baseline output % such that while the scavenger is being fed the ORP reads close
to the desired setpoint (more positive than the setpoint). During the tuning process, the ORP
values should change greater than if the pump was held at a constant output.
It is recommended that the baseline output be some value higher than zero. The first step
output is automatically calculated for the user but can be changed if the user is concerned
about fogging the system with scavenger.
Even if the setpoint is not reached during the tuning process, the PB and I terms can still be
used as long as there is a 30 to 50 mV drop during the tuning process and there arent any
other error messages.
8. Steps to complete after putting the system in ORP PID control.

a. Monitor the system for the first week after control is implemented to determine whether the
system is controlling at the setpoint. A PID autotune is meant to be a starting point and will
likely require some adjustment to recover good control. What is perceived as good control will
vary from site to site and is largely limited by the operational characteristics of the boiler. The
overall goal is to minimize excursions away from setpoint.
b. If it is determined that a setpoint change is in order, a small change can be made without
running an additional PID autotune. However, a larger change (>100 mV) may require another
autotune.
8.7
Manual Tuning
Use manual PID tuning to make the control more or less aggressive. Make changes and upload
(no reboot is needed).
o Make the control more aggressive (smaller P) if it takes a long time to reach the set point after
a load swing.
o Make the control less aggressive (larger P) if the measured value constantly oscillates about
the set point while the system load is fairly stable.
Making control more aggressive increases the proportional response to error.

The PB, I, and D parameters can also be changed independently.
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Note:

30
i_tra = TRASAR3
70
o_a1 = Analog 1
25
60
Less aggressive
More aggressive
50
40
15
Pump %
TRASAR ppm
20
30
10
20
5
10
0
0
4/1/2008 21:36:00 4/2/2008 0:00:00 4/2/2008 2:24:00 4/2/2008 4:48:00 4/2/2008 7:12:00 4/2/2008 9:36:00 4/2/2008 12:00:00 4/2/2008 14:24:00 4/2/2008 16:48:00
8.8
Set PID to ON/OFF Control (or Manual) If PID Auto Tune Cannot Be Completed
If the PID Auto Tune cannot be completed on the system due to boiler feed fluctuations (also see PID
troubleshooting first) the controller can be put into ON/OFF control (see Section 6.1 for instructions) and
tuned at a later date. Those familiar with PID tuning may manually select parameters.
8.9
Monitor PID Control
After tuning has been completed the system must be monitored (locally or remotely) to be sure it is
being properly controlled. If the boiler system operational parameters change dramatically the system
may require retuning.
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9.0
Blowdown Monitor and Control
9.1
Conductivity Monitor and Blowdown Control Setup
The Configurator is used to set up conductivity monitoring and control. The settings are described in the
Configurator Help Screens. Alarms are described in Appendix F.
9.1.1
Conductivity Control Mode Options
Up to 6 conductivity probes can be configured. For each conductivity measurement a temperature

probe and control mode must be selected.
9.1.2
Temperature Probe Assignment
Since the conductivity of water varies significantly with temperature, a conductivity probe must have a
temperature probe or a temperature value assigned to it for temperature compensation. An RTD or a
User Set temperature must be selected in the Control and Alarms Settings screen.
Note: The controller is limited to only three RTD inputs. In the BL5500 series, two RTD inputs are
already assigned. Therefore, only one RTD input remain for connection of a conductivity probe with an
integral RTD.
If there is only one boiler to control use a conductivity probe with an integral RTD. If there are multiple
boilers to control, use a probe with an integral RTD on the boiler where water temperature varies the
most. This RTD is usually wired to the RTD 3 input (TB 9-3).
If a feedwater conductivity probe is used, RTD 1 (TB 9-1), which is located on the Sample Conditioning
System RTD, is usually selected as the temperature probe.

If a blowdown probe without an RTD is being used, Select User Set for the Temperature Probe. The
sample water temperature at the probe must be manually entered in the Conductivity Control
screen. In the example above, select Edit for Conductivity 2 to get to this screen.
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The temperature of the boiler water can be
determined from the operating pressure of the
boiler. Refer to Appendix B for the Boiler Saturated
Steam Table. The boiler water temperature
remains constant as long as pressure remains
constant.
Note: The sample temperature will drop between
the boiler and conductivity probe. It is best to
measure the actual sample temperature at the
probe for accurate readings.
Note: Entering the correct temperature is very important. The conductivity measurement will
be off by approximately 11% for every 10F (5.5C)
9.1.3
Conductivity Control Mode
In the Boiler Configurator there are 4 control options that can be selected for each conductivity
probe. The typical uses and type of sample stream required for each option are listed in the table
below.
Boiler blowdown is most often controlled using Timed Sample Control (blowdown rate < 5000 lbs/hr)
or Continuous (On/Off) Control (blowdown rate > 5000 lbs/hr). Only these two control modes are
explained in this manual.
There are two Interval Monitor Mode options under Timed Sample Control. Both are for intermittent
sampling.
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Control
Mode
Sample Flow
Requirement
Typical Applications
Feedwater
Monitor
Only
Continuous
or
Intermittent
Condensate stream
Boiler blowdown
Applications where no control action is desired.
PID Control
Continuous
(On/Off)
Control
Continuous
Boiler blowdown on large high-pressure utility boilers.

A variable flow control valve that accepts a 4-20 mA signal must be
used. The control valve can be on the sample line or on a separate
blowdown line. Sample flow must be continuous.
Continuous
Boiler blowdown (blowdown rate > 5000 lbs/hr)

An On/Off motorized ball valve is installed on the main blowdown line.
The conductivity probe is installed on a separate continuous
blowdown line. The boiler blowdown requirements must be great
enough to permit continuous blowdown for conductivity
measurement.
Boiler blowdown (blowdown rate < 5000 lbs/hr)
An On/Off motorized ball valve and conductivity probe are installed on
the same blowdown line. Timed Sample Control is used on boilers
where continuous sampling will cause excessive blowdown.
Interval Monitor Mode
Timed
Sample
Control
128
Intermittent
Continuous
For systems where the
conductivity readings are
stable when the control valve is
open.
The conductivity is measured. If
the conductivity is below the
setpoint the control valve will
close. If the conductivity is above
the setpoint the blowdown valve
remains open while the
conductivity is being continuously
measured. When the conductivity
level drops below the setpoint the
valve will close.
Proportional
This control method is only used
in systems with erratic
conductivity readings due to
turbulent flow or steam flashing.
A trap time is used to stop flashing
before the conductivity is measured.
After the conductivity is measured,
if the conductivity is above the
setpoint the controller calculates
how long to re-open the valve in
order to blowdown the boiler. This
calculated time interval is
proportional to the difference
between the measured value and
the setpoint.

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9.1.4
Monitor Only Mode
It is recommended to select this method initially for new installations. Monitoring the boiler
blowdown conductivity for a short period of time before going into control, allows the user to get a
better feel for what control method to use and what parameters are needed to achieve good boiler
cycle control.
The Conductivity Name, Operating Temperature (if User Set is selected, enter the boiler water
temperature) and Alarm Settings are entered in the Conductivity Control Monitor Only
screen. If a probe with an integral RTD is used, the Operating Temp field will be disabled.
9.1.5
PID Control Method
PID Control is used for large high pressure utility boilers were boiler blowdown is on a continuous basis.
A variable flow control valve is used to accept a 4-20 mA signal from the 3D TRASAR controller. PID
control of the blowdown conductivity is based on PID parameters that are manually entered by the user.
Only manual PID tuning is available for this control method. For conductivity, the
recommendation is to use Proportional control (Integral and Derivative terms are set to 0).
To use Proportional Control with Conductivity, first select PID as the control method for the
Conductivity device. The Conductivity Name, Output, Output Name, Operating Temperature (if
User Set was selected, enter the boiler water temperature), Control Settings and Alarm Settings
must be entered in the Conductivity Control PID screen. The PID parameters are entered in the
Advanced PID Settings screen. If a probe with an integral RTD is used, the Operating Temp field
will be disabled.
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PID Control Notes:
Proportional conductivity blowdown control is Direct

Acting.
Set the Integral and Derivative terms to 0.
If the conductivity probe is installed on the same

blowdown line as the control valve, the Output Min
must be set to a value large enough to ensure a
constant sample flow across the conductivity probe.
The Output Max is used to prevent the control valve

from opening so wide that the boiler blows down too
rapidly, upsetting boiler operation.
The Max Change % is used to slow down the

response of the control valve to simulate the response
of a pneumatic valve (default = 10%). If the Update
Interval is left at the default 5 seconds it will take 50
seconds to fully close the valve from fully open.
The Scale High and Scale Low must be set

above/below any alert or alarm values.
The Proportional value is calculated using the

following equation:
Proportional =
[Acting x (Setpoint Cond.Max.) x 100] x 100

[(Output Max Output Min) x (Scale High Scale Low)]
Example:
Setpoint = 3000 S/cm
CondMax = 6000 S/cm
Output Min = 5%
Output Max = 40%
Acting = -1 (Direct Acting PID equation for Conductivity Blowdown Control)
Scale Low = 1500
Scale High = 5500
Calculation:
P=
[ -1 x ( 3000 - 6000 ) x 100] x 100

[( 40 5 ) x ( 5500 1500 )]
= 214.29
See the Configurator Help Screens (F1) for detailed instructions.
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9.1.6
Continuous (ON/OFF) Control Method
Continuous method enables traditional ON/OFF control. It is often used to control boiler conductivity
levels in systems where a small amount of boiler water is continuously bled off from a secondary
blowdown line. This stream is continuously monitored, providing a real-time conductivity reading. When
the measured conductivity increases above the setpoint, the control valve, which is installed on the
main blowdown line, is opened to increase the blowdown rate and reduce the measured conductivity to
below the setpoint. This method, which is the easiest method to employ, is used f or systems were the
blowdown rate is greater than 5000 lbs/hr.
In Section 4.1 there is a schematic of a system set up in a Continuous (On/Off) control mode. A tee is
installed on the main blowdown line so a small amount of blowdown sample continuously fl ows through
the conductivity probe assembly, past a flow control valve and then to drain. The main blowdown
extends to the motorized ball valve, which will be wired to and controlled by the 3D TRASAR controller.
IMPORTANT NOTE: Both flow control valves must be throttled back to maintain backpressure in the
lines. The valves cannot be in the wide-open position. Otherwise, flashing in the
line will occur if the line discharges to atmospheric pressure.
In the Configurator, the Conductivity Name, Output, Output Name, Operating Temperature (if
User Set was selected, the boiler water temperature is entered), Control Settings and Alarm
Settings must be entered in the Conductivity Control Continuous screen. If a conductivity
probe with an integral RTD is used, the Operating Temp field will be disabled. The +band must also
be entered. The control valve will open when the conductivity level rises to the Set Point +band and
close when the conductivity level falls to the Set Point .
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9.1.7
Timed Sample (ON/OFF) Control Method
Timed Sample control method is used on boilers were continuous sampling will cause excessive
blowdown. This method is used for systems were the blowdown rate is less than 5000 lbs/hr. In
Section 2.3.3.4 there is a schematic of a system that is set up in a Time Sample (On/Off) Control mode.
Timed Sample enables ON/OFF control of boiler blowdown conductivity. The conductivity probe is
mounted on the same line as the control valve. The control valve is periodically opened on a
predetermined (timed) schedule. If the conductivity level is above the setpoint, the valve remains open.
How long the valve remains open depends on the Monitor Mode selected.
There are two Interval Monitor Modes available for Timed Sample Control Continuous and
Proportional. The table below explains the differences between the two modes.
Interval
Monitor
Mode
Typical Applications
Continuous
For systems where the conductivity readings are stable when the control
valve is open.
After the conductivity is measured, the controller compares the measurement to
the setpoint. If the conductivity is below the setpoint, the control valve will close. If
the conductivity is above the setpoint, the control valve remains open while the
conductivity is being continuously measured. When the measured conductivity
drops below the setpoint, the control valve will close.
Proportional
This control method is only used in systems with erratic conductivity

readings due to turbulent flow or steam flashing.
In these systems, a trap time is used to prevent the blowdown sample from
flashing while the conductivity is measured. After the conductivity is measured, the
controller compares the measurement to the setpoint. If the conductivity is above
the setpoint, the controller calculates how long to re-open the control valve in order
to blowdown the boiler. This calculated time interval is proportional to the
difference between the measured value and the setpoint. See Section 9.1.7.2 on
how to set up Timed Sample - Proportional control.
Note:
132
When using Timed Sample Control (either Continuous or Proportional monitor mode) a
Sample Schedule must be defined.

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9.1.7.1
Timed Sample Continuous Mode
In the Configurator, the Conductivity Name, Output, Output Name, Operating Temperature (if
User Set was selected, enter the boiler water temperature), Control Settings, and Alarm
Settings must be entered in the Conductivity Control Timed Sample screen. If a conductivity
probe with an integral RTD is used, the Operating Temp field will be disabled. The +band is also
disabled in this mode.
The Interval Details and Sample Schedule need to be configured (see Sections 8.8 and 8.9 for
more details). The defaults that have been built into these screens are realistic starting values for
most systems. The user can choose to use these default values initially, or change them. Some of
the parameters have Minimum and Maximum limits to prevent the user f rom entering unrealistic
values.
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9.1.7.2
Timed Sample Proportional Mode
In the Configurator, the Conductivity Name, Output, Output Name, Operating Temperature (if User
Set was selected, the boiler water temperature is entered), Control Settings, and Alarm Settings
must be entered in the Conductivity Control Timed Sample screen. If a conductivity probe with an
integral RTD is used, the Operating Temp field will be disabled.
Note:
The Band field is now active and MUST be calculated. See Section 8.10 for details.
As with the Continuous mode, the Interval Details and Sample Schedule need to be configured (see
Sections 8.8 and 8.9 for more details). The defaults that have been built into these screens are realistic
starting values for most systems. The user can choose to use these default values, initially, or change
them. Some of the parameters have Minimum and Maximum limits to prevent the user from entering
unrealistic values.
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9.1.8
Interval Details
The following inputs are required for both Timed Sample Continuous and Timed Sample
Proportional control methods:
Sample Average Time: Enter the number of seconds over which the sample measurement will be
averaged. By averaging the measured conductivity over a period of time,
the effect of measurement spikes is minimized. The averaging should be
the shortest time needed to attain an accurate conductivity reading. In the
case of Timed Sample - Proportional control where the control valve is
closed when the average conductivity is being measured, it is crucial to
note that the trapped blowdown sample will start to cool shortly after the
control valve is closed. Therefore, large Sample Average Times are not
recommended. The default value is 30 seconds.
Maximum On Time %: Enter the maximum % of the remaining sample interval (Decision Interval
Flush Trap Sample Average Time) that the control valve can remain
open. This should be set to accommodate the highest expected
blowdown rate under any condition. The default value is 85%.
Minimum On Time:
9.1.9
Enter the minimum amount of time the control valve should remain open
during each Decision Interval after the Flush, Trap, and Sample Average
Time interval has occurred. This should be set to provide the minimum
desired blowdown under any circumstances. A typical value for this field
is 30 seconds.
Sample Schedule
A Sample Schedule needs to be configured for Timed Sample Continuous and Timed Sample
Proportional control. Up to 4 Sample Schedules can be configured. The Sample Schedule defines
the time interval that will be used for sampling conductivity. Each probe can be uniquely configured to a
different Sample Schedule. They can be enabled or disabled as desired. However, a Sample
Schedule cannot be disabled if it is being used by a control loop
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Output:
A unique relay must be selected for each Sample
Schedule. In the case of blowdown control, the
Sample Schedule Output is usually set to the
same relay chosen on the Conductivity Control Timed Sample screen. The control valve that is
wired to the chosen relay output is used for both
sampling and control.
Sample Rate:
Select the sampling rate based on when high load
periods are expected for the boiler. The Sample
Rate needs to be chosen to match the times when
the boiler is operating at peak output. Some
manufacturing facilities only operate Monday through
Friday and leave the boiler in a low load or standby
state over the weekend.
A Daily High MTWTF sample rate would best fit this plant that operates under peak conditions during
the week and goes on standby mode on the weekends.
If Normal 24/7 is chosen for a facility, the sampling interval will remain the same over any time period.
The options are:
Note:
136
Normal 24/7
Daily High 7 Days
Daily High MTWTF
If Normal 24/7 is selected then High Rate Start, High Rate End and High Decision Int
fields are disabled because they do not apply to a normal load situation

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High Rate Start:
Starting time for a high load sampling period.
High Rate End:
Ending time for a high load sampling period.
High Decision Int:
Length of time for the complete Sample
Schedule (cycle) in minutes for high load
periods.
Normal Decision Int:
Length of time desired between sampling in
minutes for normal load periods. If the boiler
operates in a Normal 24/7 mode, this is the only
decision interval that is entered. If this value is
set too low, sampling of the boiler blowdown will
be too frequent, which may cause the boiler
water conductivity to decrease over time. Under this condition, the sampling is enough to inadvertently
blowdown the boiler. If this value is too large, sampling will be too infrequent, causing the boiler water
conductivity to increase over time. This will result in over cycling. The default value is 60 minutes.
Note:
During the initial setup, it is better to choose a low decision interval. This may waste a small
amount of energy until a final value is determined, but will greatly reduce the chance of over cycling and damage to the system.
Enable Trap Time:

A sample trap is used to stabilize samples when turbulent flow or entrained steam prevents accurate
conductivity measurements. The sample Trap Time is in seconds. An important consideration is that
too long of a trap time will result in a decrease in the sample temperature. The default value is 10
seconds. This field is only enabled when Timed Sample Proportional control is chosen.
Flush Time:
The minimum time needed (seconds) to flush the sample line and ensure the sample will reach
its maximum temperature. A value between 0 and 86,400 seconds can be entered.
If flush time is too short the sample will not be at its maximum temperature and the conductivity value
will continue to rise as the sample is measured. If this time interval is too large, the boiler could blow
down too much as a result of the sampling alone. The default value is 180 seconds.
Note:
Certain rules have been established covering the allowable entries for the time intervals. An
error message will appear if one or more of the entered values are invalid.
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9.1.10
Setting Up Timed Sample Proportional Control
The control values entered in the Configurator should closely mimic how the system is currently
operated. Otherwise, the boiler will likely blowdown too much or not enough. Below is a diagram of the
conductivity measurement-control cycle.
At the beginning of the Decision Interval the valve opens (Decision Point) to flush the blowdown line,
providing a fresh sample to the conductivity probe (Flush Time). Next, the control valve is closed to
trap the sample and establish an accurate conductivity reading (Trap Time). The conductivity is
measured and averaged (Sample Average Time). Finally, a decision is made as to how long the valve
should be re-opened (Calculated Valve On Time). See the table below for more details on the
controller response.
To determine the correct values it is important to understand how the (Blowdown) Valve On Time is
calculated. The Maximum Calculated (Blowdown) Valve On Time acts as a first defense against
blowing down a boiler too much. This value establishes a time limit on how long the control valve can
remain open after the conductivity has been measured. It is calculated as follows:
Max. Calc. Valve On Time = (Decision Interval Flush Trap Average) x Maximum On Time %
Example:
Decision Interval = 60 minutes
Flush Time = 240 seconds = 4 minutes
Trap Time = 30 seconds = 0.5 minutes
Sample Average Time = 30 seconds = 0.5 minute)
Maximum On Time % = 20%
Max. Calc. Valve On Time = (60 4 0.5 0.5) x 0.20 = 11 Minutes
The Calculated Valve On Time is a portion of the Maximum Calculated Valve On Time. The higher the
conductivity measurement is above the Setpoint, the longer the blowdown valve will be open. It is
calculated as follows.
Calc. Valve On Time = (Max. Calc. Valve On Time) x (Conductivity Value Above Setpoint)
+band
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Example:
Sample Average Time = 30 seconds = 0.5 minutes
Conductivity Setpoint = 5000 S/cm
Max. Calc. Blowdown

Valve On Time
Averaged Conductivity = 5050 S/cm

+band = 100 S/cm
Calc. Valve On Time =
(60 4 0.5 0.5) x 0.20
x (5050-5000) = 5.5 minutes

100
Note: The +band value calculation is presented later in this section of the manual.
How is Valve Open Time Determined?
Note:
Measured Conductivity
Controller Output Response (Valve Action)
Avg. Cond. < Setpoint
Minimum On Time
Avg. Cond. > Setpoint

and
(Avg. Cond Setpoint). < Band
Calculated Valve On Time
Avg. Cond. > Setpoint

and
(Avg. Cond Setpoint). > Band
Maximum Calculated Valve On Time
Minimum On Time (seconds) and Maximum On Time (%) are entered by the user on the Timed
Sample Continuous or Timed Sample Proportional screen, under Interval Details section.
Determining Values To Enter Into The Configurator.

The first step to determine the appropriate values for your system is to perform a Blowdown Test.
This test is used to measure the time it takes to blow down the boiler from a conductivity value above
setpoint.
1. Determine the time-based intervals (Decision Int, Flush Time, Trap Time, and Sample Average
Time). The Boiler operators will be an excellent resource. They know their systems very well and
can aide in the determining an acceptable time interval and the required blowdown time.
Note:
The default values can be used initially. Over time, as the user becomes more comfortable
with the control, these values can be changed accordingly.
2. Perform a Blowdown Test. This test is performed to determine the actual time it takes for the boiler
water to drop from a starting conductivity value to some ending conductivity value.
3. Perform calculations to determine Maximum On Time % and +band values.
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Example:
It is determined that the following values are acceptable.
Additional information was provided by the boiler operators.
Boiler is generally blown down the when the conductivity is approx. 100 S/cm above setpoint.
(Conductivity Value Above Setpoint)
The boiler is never blown down more than 30 minutes at a given time. (Max. Calc. Valve On
Time). This prevents shocking the boiler with cold feed water and allows the deaerator to
maintain its level.
The Blowdown Test gave the following result.
At a conductivity value of 3600 S/cm, it took 12 minutes to blow down the boiler until the
conductivity read 3500 S/cm.
Calc. Valve On Time = 12 minutes
Blowdown Test = (3600 3500) S/cm = 8.33 S/cm
12 min
min
1. First, calculate the Maximum On Time %.

Max. Calc. Valve On Time = (Decision Interval Flush Trap Average) x Maximum On Time %
30 = (120 3 0.25 0.75) x Maximum On Time %

Maximum On Time % = 0.259 or 25.9% (Round 25.9% to 26%)
2. Next, calculate the +band parameter.
Band = (Max. Calc. Valve On Time) x (Blowdown Test)
Band = (120 3 0.25 0.75) x 0.26 x (3600-3500)

12
Band = (116 x 0.26 x 8.33) = 251.3 S/cm
Therefore, the values entered into the Configurator would be as follows:
Band = 251 S/cm
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Note:
Monitor the system very closely for the first few weeks and make adjustments to ensure boiler
blowdown control is operating successfully. The values input by the user are not going to be
perfect. Every blowdown cycle is slightly unique and the calculated blowdown time is not going
to be the exact amount of time needed for every cycle. The values must be adjusted after
multiple decision intervals have occurred (unless there is an extreme response occurring). The
results should be trended to determine what adjustments are needed.
Note: Review all the configured devices and control outputs on the Control and Output Summary
screen to be sure no input errors have been made. Print the screen for reference. Save and
Close (for future Uploading) or Upload the settings to the controller.
9.1.11
Troubleshooting and Adjustment Tips for Interval Control
1. The boiler conductivity continues to decrease over multiple decision intervals (too much blowdown).
Solution 1: Decision interval needs to be increased.
Note: Changing the decision interval causes a change in the maximum blowdown time and
the Maximum On Time % will need to be adjusted accordingly.
Solution 2: Slightly close the Flow Control Valve (decrease turns open).
2. Boiler conductivity continues to increase over multiple decision intervals in Timed Sample
Proportional Mode (too little blowdown).
Solution 1: Increase the Maximum On Time %. If the Maximum On Time % is already large
(>85%), shortening the decision interval or making changes to the Band parameter
may need to be considered.
Note:
Changing the decision interval causes a change in the maximum blowdown time and
the Maximum On Time % may need to be adjusted.
Solution 2: Slightly open the Flow Control Valve (increase turns open).
Note: Be careful not to open the valve too much as to cause flashing.
3. Boiler conductivity is only a few percent above setpoint, but the control valve remains open long
enough to reduce the conductivity where it takes multiple decision intervals to reach setpoint again.
Solution: Reduce the Maximum On Time %.
9.1.12
Review Conductivity Control Setup
Review all the configured devices and control outputs on the Control and Output Summary screen to be
sure no input errors have been made. Print the screen for reference. Save and Close (for future
Uploading) or Upload the settings to the controller
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9.1.13 Notes on Control Modes, Alerts and Alarms

Control Modes
Continuous control is otherwise referred to as ON/OFF Control. The term continuous control is
used here specifically in the place of ON/OFF control for Conductivity Devices as it is an Industry
Standard term for use of the ON/OFF control method for Conductivity.
Timed Sample Control must be used in conjunction with a sample schedule. Timed Sampling
minimizes water loss in small systems. The user is prompted during the configuration set-up to
associate this control with a sample schedule to be used as part of a control cycle. Within Timed
Sample Control are 2 separate control options:
Proportional control: Where the control output is turned on for a calculated period of time that is
proportionally based on how far away the process reading is from set-point (the farther from setpoint the longer the control output is on).
Continuous Control: Similar to ON/OFF control in that the control output is turned on until the setpoint value is satisfied. A difference is that the control output will turn OFF when the maximum time
ON for the sample is reached, regardless of whether the set-point value has been satisfied or not.
Alarms and Alerts
Alarms and Alerts are individually selectable options where appropriate on each configuration
screen. If you have previously selected a communication method, you may also individually select
to be notified, (or not) when reaching any Alarm or Alert value by checking the Notify on Alert
(Alarm). User sets the alarm set point.
Alert: An Alert is a notification alarm. It provides an indication that the input signal is at a value
outside the range of normal operation and the system needs attention. User can enable high or low
alerts for each input signal. Alerts can be set for all input signals whether they are used for control
of outputs or not. During an Alert, an output associated with the signal continues in automatic
control.
Failsafe Alarms: Failsafe Alarms are allowed where signals will control an output. When you
reach a Failsafe alarm level, the output exits automatic control and is placed into timer control (see
failsafe responses). Some overriding alarm conditions such as low steam flow and system
Interlock can place multiple outputs into failsafe operation.
142
Failsafe Low Conductivity - For an operating boiler, is not recommended to ever shut off
blowdown flow totally, even if below the desired conductivity set points. A forced output
response for Failsafe Low Conductivity may be the best option. The fixed output should be set
to provide approximately the minimal suggested mass flow from the boiler as recommended by
the boiler manufacturer or by the plant's specific standard operating procedures.
Failsafe High Conductivity - Should never be set to FORCED OFF. If conductivity is high, the
boiler should be blowing down. The Smart Failsafe is likely not optimum either as it will provide
only the average amount of flow from the boiler. During a High Failsafe condition, the
blowdown rate should be higher than normal. Running the Smart Failsafe (average output)
may only tend to allow for further concentration of the species in the boiler. A fixed output at
the maximum recommended blowdown mass flow (per boiler manufacturer specs) would be the
best practice. In a High Failsafe condition, the boiler conductivity must be lowered quickly and
safely by allowing for the highest safe mass flow from the boiler.
Clearing of Alarms: Some alarms self clear when the input signal returns to normal operating
range. Other alarms (e.g. Temperature High Override or Pump Timeout) can only be cleared by the
user.

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Alarm Delay: An input signal must persist in the alarm state for a set time period before the alarm
is called. This value cannot be user set. When an alarm is cleared by the user, the alarm delay is
automatically increased by a factor of 5 to allow the system to be in automatic control for an
extended period so that the system can exit the alarm condition.
Alarm Deadband: Each alarm has an associated dead band. Alarms will persist until the signal
value differs from the alarm setpoint by the alarm deadband.
Control Timeout Alarm: If a relay based valve is activated for longer than a user set period of
time, the alarm is called. This alarm does not self clear. When applied to Timed Sample blowdown
control it is cumulative over more than one decision interval.If the signal used for automatic
control of the output goes to low or high failsafe, the time out alarm will be cleared.
CAUTION-DANGER:
* SCS HIGH-TEMPERATURE ALARM *
All systems should be configured to alarm on high SCS temperature. Frequent high
sample temperatures are an indication of cooling water supply problems that must be
corrected. Repeatedly subjecting the solenoid valve to high temperatures will cause a
valve failure and a safety risk.
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9.2 Fluorometer-Based Blowdown Control Setup

PID Control is used for large high pressure utility boilers were boiler blowdown is on a continuous basis.
A variable flow control valve is used to accept a 4-20 mA signal from the 3D TRASAR controller. PID
control of the blowdown using fluorescence is based on PID parameters that are manually entered by
the user. Only manual PID tuning is available for this control method. The recommendation is to
use Proportional control (Integral and Derivative terms are set to 0).
To use Proportional Control, first select PID as the control method for the fluorometer. The Name,
Output, Output Name, Operating Temperature (if User Set was selected, enter the boiler water
temperature), Control Settings and Alarm Settings must be entered in the Fluorometer Control
PID screen.
The PID parameters are entered in the Advanced PID Settings screen.
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PID Control Notes:
Proportional conductivity blowdown control is Direct

Acting.
Set the Integral and Derivative terms to 0.
If the conductivity probe is installed on the same

blowdown line as the control valve, the Output Min
must be set to a value large enough to ensure a
constant sample flow across the conductivity probe.
The Output Max is used to prevent the control valve

from opening so wide that the boiler blows down too
rapidly, upsetting boiler operation.
The Max Change % is used to slow down the

response of the control valve to simulate the response
of a pneumatic valve (default = 10%). If the Update
Interval is left at the default 5 seconds it will take 50
seconds to fully close the valve from fully open.
The Scale High and Scale Low must be set

above/below any alert or alarm values.
The Proportional value is calculated using the

following equation:
Proportional =
[Acting x (Setpoint TRASAR .Max.) x 100] x 100

[(Output Max Output Min) x (Scale High Scale Low)]
Example:
Setpoint = 300 ppm
TRASAR Max = 324 ppm
Output Min = 5%
Output Max = 40%
Acting = -1 (Direct Acting PID equation for Conductivity Blowdown Control)
Scale Low = 100
Scale High = 1000
Calculation:
P=
[ -1 x ( 300 - 324 ) x 100] x 100

[( 40 5 ) x ( 1000 0 )]
= 6.86
See the Configurator Help Screens (F1) for detailed instructions.
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10.0
Condensate Monitor Control Setup
The 3D TRASAR Boiler Controller can be configured to control condensate return using a relay. The
system can be set up to activate a relay and dump the returning (contaminated) condensate if any of
several user-specified conditions are met. Generally, conductivity is used as the primary control, with
secondary control from pH, and any 4-20 mA inputs.
1.
Using the Configurator add a conductivity probe to the Control and Alarm Settings section. Set
the control method to continuous.
2.
Open the edit screen for the conductivity probe, and set the output to the relay that you want to
control the condensate return. Also, under control settings put in a set point value, and set acting
to direct. This will set up the controller to activate the relay if the conductivity rises above the set
point. The conductivity must be above the set point + deadband for 5-10 seconds for the relay to
switch on.
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3.
Additional variables can also be used to control the same relay. To add a pH control to the relay,
first add the pH probe to the Control and Alarm Settings section in Monitor mode.
4.
Then add the pH input to the Control Overrides section. Name the override, and input the value
that you want to activate the relay. Next, set the type to low or high. (For example setting the
input value to 5, and the type to low will activate the relay if the pH drops below 5). You can set
up a high and a low pH override to trip the relay by setting up 2 individual overrides (one for high
pH and one for low pH).
5.
For each override click on Edit. Then click the box to activate it, set the output to the same name
as the conductivity probe, set the response to fixed failsafe, and the duty to 100%. Control
override values will switch the relay on after the value has surpa ssed the set point for 5 minutes.
An analog input (particle monitor) can also be set up as a control override.
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Note:
148
If monitoring condensate receiver tanks with an intermittent pump an interlock from the pump
must be assigned to the dump valve as an override.

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11.0
Controller Operation
The keypad and display on the control panel is shown

to the right. This panel is used to perform the basic
operations quickly and conveniently, including setting
control ranges, performing calibrations, manual relay
operation, auto control adjustments and manually
feeding chemicals.
11.1
Display Panel Functions
The display panel is a 6-line, backlit LCD graphical

display.
The display panel is used to edit numeric data and
show status information for the various system
parameters, alarms, and pumps.
11.2
The Keys
The functions of the 20 keys on the control

panels keypad are summarized to the right:
Pressing any of these keys will change the
information shown on the display and let you
quickly check the status of the unit or change its
configuration.
Information
Actions
Alarms
Numbers 0-9
Menu
Help
Up/Down
Back
Soft Keys
11.2.1
Indicates viewing of operating

data, digital inputs, control relays,
analog outputs, software version,
and diagnostics
Allows calibration, changing
output status, and for reboots
Shows active alarms
Provide for the entry of
numerical listings
Provides complete main menu list
Provides contact information help
Used for menu navigation
Returns to previous screen
Used to make selections shown
on the display panel
Ethernet and USB Connections and Power Switch
RJ-45 Ethernet
Connection
USB Flash
Drive
Connection
Power Switch
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11.3
The Graphical Icons
The graphical icons that appear in the display are listed below with a brief explanation of their meaning.
11.4
Move to next/previous screen (use arrow keys)

Scroll through list of choices (use arrow keys)
One or more alarms are active (press Alarms to view)
Modem connection is established (incoming or outgoing)
No flow condition exists (delay for alarm)
Interlock contact is opened (immediate alarm)
Menu, Information, Actions and Alarms Keys Flow Diagram
The flow diagram below shows all of the different screens that can be accessed through the controller
display panel. The remainder of this section gives detail on each of these screens. Certain menu
options will only appear if the related input or output device is connected to the controller.
Menu
Control Settings
Alarm Settings
Network
Preferences
Information
Actions
Alarms
Operating Data
Calibrate
Current Alarms
Digital Inputs
Manual Control
Control Relays
Test Send
Analog Outputs
Reboot
Input Types
TRASAR Factors
Fluorometer
Ethernet 1
Units
ORP/pH 1
PID 1
AT ORP 1
Etherner 2
Dates
ORP/pH 2
PID 2
AT ORP 2
Modem
AI 1
PID 3
pH 1
Internet
AI 2
PID 4
pH 2
SCADA
AI 3
PID 5
Temp 1
AI 4
PID 6
Temp 2
AI 5
PID 7
Temp 3
AI 6
PID 8
Analog 1
AI7
Relay 1
Analog 2
AI 8
Relay 2
Analog 3
Relay 3
Analog 4
Relay 4
NCM
Versions
Diagnostics
Relay 5
Navigation is controlled by the keypad next to the display panel. The main Shortcut Keys are listed
below.
Information
Indicates viewing of operating data, digital inputs, control relays, analog outputs,
software version, and diagnostics
Actions
Allows calibration, changing output status, performing a test data send for verifying
communications and for reboots
Alarms
Shows active alarms
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11.5
Menu Key
Menu
Control Settings
Network
Alarm Settings
Preferences
Input Types
The Menu Key provides access to 5 submenus.
Control Settings Set control parameters.

Alarm Settings Set alarm parameters.
Preferences Set time and date.
Network Network settings
Input Types Set analog inputs to either 4-20mA or 1-10 VDC (internal dip switch change
also need)
A password must be entered to access all submenus.
Enter Password .12345 (Default Password)
The password has to be re-entered after 10 minutes of inactivity.
11.6
Control Setting Screens

Menu
Control Settings
11.6.1
Alarm Settins
Network
Preferences
Input Types
TRASAR Factors Screen
Displays and permits changes to the current settings: Fluorometer Gain, TRA Value, Product Factor
and phosphate factor (for coordinated phosphate control).
Highlight the parameter to be changed. Enter Select.
Use the arrows to select the parameter. Enter Edit.
Use the desired value (use arrows to toggle between choices or 0-9 to enter a value.
Enter ACCEPT
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11.6.2
PID 1-8 Screens
Displays and allows changes to the set point and P, I and D values for each the PID loop configured.
Also permits changes to the current settings: Auto/Manual, Manual % and Auto after (time) See
section 6 for setup and tuning details.
Highlight the PID control to be changed. Enter Select.

Enter ACCEPT
11.6.3
Relays 1-5 Screens
Displays and permits changes to the current settings: Auto/Manual, Manual On/Off and Auto after
(time) of the each of the 5 control relays.
Highlight the Relay control to be changed. Enter Select.

Enter ACCEPT.
11.7
Alarm Setting Screens

Menu
Control Settings
11.7.1
Alarm Settings
Network
Preferences
Input Types
Alarm Settings
Alarms are usually set up using the Configurator. However, they can also be set using the controller
keypad. The user can configure the system to raise alarms under certain conditions. Setting up
alarms is optional but recommended for functional control. What alarms are available to the user
depends upon the inputs and the control method. Alarms can be set up for the following:
Input Alarms:
High Failsafe Alarm:
An alarm is raised when the input value exceeds a set level for a period of time. It can only be set for
inputs that are in control of an output. If this alarm is raised, the output that was being controlled will
transition to user set failsafe response.
High Alert Alarm:
An alarm is raised when the input value exceeds a set level for a period of time. This is a notification
alarm, and does not need to be associated with an output. If there is an associated output, the output
continues in designated control mode.
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Low Alert Alarm:
An alarm is raised when the input value falls below a set level for a period of time. This is a
notification alarm, and does not need to be associated with an output. If there is an associated output,
the output continues in designated control mode.
Low Failsafe Alarm:
An alarm is raised when the input value falls below a set level for a period of time. It can only be set
for inputs that are in control of an output. If this alarm is raised, the output that was being controlled
will transition to user set failsafe response.
Examples of Input alarms include:
- TRASAR
- Turbidity
- NCSM
- Cell Fouling
- pH
- Analog Inputs
- Temperature
- Digital Inputs
If an output is being controlled an additional alarm is available:

Pump Time Out Alarm: This alarm is activated when the output has been energized at an Average
Duty Cycle exceeding a user-set value for a time exceeding the Pump Timeout limit
Other Available Alarms
Sample Conditioning System:
- This alarm controls the relay connected to the solenoid for the sample conditioning system.
- The (high temperature) alarm must be manually cleared (it is not self clearing). The system may
also have to be rebooted.
- The alarm is set by the temperature input signal and has high failsafe, high alert, low alert and
low failsafe options analogous to other level alarms
System Interlock Alarms:
The interlock digital input provides the ability to use a signal, for example from the feed water pumps,
to enable or disable the 3D TRASAR control outputs.
- If the feed water pumps are turned off, the contact is opened, and the interlock alarm occurs,
disabling all the control relays.
- Control is restored when the feed water pumps are turned back on and the contact is closed.
Alternatively, a switch in the control room can be used to activate or deactivate this alarm.
- The alarm may be enabled or disabled.
- The alarm response is always the sameall outputs are disabled.
- The user may choose to be notified.
Low Temperature Interlock:
The temperature reading from the NCSM probe can be used to determine if there is flow going past
the probe.
- If the temperature drops significantly (approaches room temperature), it indicates of no sample
flow.
- The user can enable the alarm and set the low temperature limit to a value below which it would
be indicative of a no-flow condition.
Steam Flow/Feedwater Flow Interlock:
If the Boiler system can provide a 4-20mA input from a steam or Feedwater flow meter, this signal
can be used to enable or disable the 3D TRASAR Boiler control outputs when the boiler is not
operating or on standby.
- The user can enable the alarm and set the flow limit to a value below which it would be indicative
of the Boiler being on standby.
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Sensor Alarms:
Sensor alarms are activated when an error is detected in the sensor inputs. These alarms are
typically the result of improper or loose wiring or faulty probes. Inaccurate or fluctuating readings are
another indicator of miswired or faulty probes.
Note:
pH and ORP are high impedance measurements and the sensor alarm is not always
triggered.
Control Overrides Screen:

pH can have an effect on ORP readings. If both a pH and ORP probes are installed, control of ORP
can be overridden if pH exceeds certain high/low limits. These limits are set up on the Control
Overrides screen in the Configurator.
No flow
Zone Interlock
pH/ORP
Other overrides can be added
IMPORTANT:
11.7.2
Whenever any alarm condition occurs the general system alarm relay is
activated. A specific alarm email is sent (i.e. pH High 7.9) if the controller is
connected to the Nalco web site.
Alarm Screens
Alarms can be set for two fluorometers, two pH or NCSM sensors, three RTDs, and four analog
inputs. High and Low Alerts and Failsafe Alarms can be set up for all inputs. High and Low Failsafe
Alarms cannot be set up for inputs used for monitoring only.
Use the arrows to desired sensor. Enter Select

Use the arrows to select the parameter. Enter Edit
Enter ACCEPT.
Note:
Make sure all alarm parameters have been set prior to startup. Improper settings will
adversely affect performance of controller and boiler system
Note:
Additional information on setting up Alarms and Alerts is provided in Appendix H.
11.8
Network Screens
Menu
Control Settings
154
Alarm Settings
Network
Preferences
Input Types

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The Network submenu screen accesses the network settings of the two Ethernet ports. Before
making changes to the network settings check with your local Network administrator or ISP provider.
Any changes made must also be made in the configuration program!
IP 1 or 2
Mask 1or 2
Gateway 1 or 2
Displays the current controller IP address.

Indicates the controller subnet address.
Indicates the controller default gateway address.
SCADA
mb_baud
mb_bits ..
mb_par ...
mb_stop .
Note:
11.9
Selects the SCADA Serial Baud Rate (1200, 2400, 9600, 19200, 38400, 57600,
115,200)
Selects the SCADA Serial Data Bits (7 or 8)
Selects the SCADA Serial Parity (0=None,1=Odd, 2=Even)
Selects the SCADA Serial Stop Bits (1 or 2)
Default is 19200 baud, no parity, 8 data bits, 1 stop bit (19200, n, 8, 1)
Preference Screens
Menu
Control Settings
Alarm Settings
Network
Preferences
Input Types
.
11.9.1
Units Screens
This screen is used to change from gpm to lpm, F to C, etc
11.9.2
Date Screens
This submenu is used to display and edit general settings. The arrow keys can be used to navigate
between fields with more than one setting (i.e., the time field has both hours and minutes).
Time: Displays the clock setting in hours and minutes (24 hour format).
Date: Shows the date setting in the format configured through the PC.
Date Format: Selects the date format (M/D/Y, D/M/Y, Y/M/D).
11.10 Input Types Screens

Menu
Control Settings
Alarm Settings
Network
Preferences
Input Types
Sensor input screens can be edited. They must be initially set up using the Configurator.
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Use the arrows to desired sensor. Enter Select

Use the arrows to select the parameter. Enter Edit
Use the desired value. Enter ACCEPT.
11.10.1 pH/ORP Input Screen

There are two inputs for high impedance sensors. They can be set up as a pH or ORP input.
11.10.2 Analog Input Screen

There are four input connections. They can be set up as 0-10 V or 4-20 mA (internal dip switches
must also be changed).
11.10.3 TRASAR Fluorometer Screen

There are two fluorometer input connections. The gain on the fluorometer can be set up as High for
feedwater or Low for blowdown (future)
Information
Actions
Alarms
Operating Data
Calibrate
Current Alarms
Digital Inputs
Manual Control
Control Relays
Test Send
Analog Outputs
Reboot
Versions
Diagnostics
11.11
Shortcut Keys
Pressing the Actions key allows access to the following options.
Information
Actions
Alarms
A password must be entered to access all Actions submenus.
Enter Password.12345 (Default Password)

The password has to be re re-entered after 10 minutes of inactivity.
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11.11.1 Calibrate
Accesses the calibration screens for the fluorometer, pH, NCSM and conductivity. (See fluorometer
and NCSM calibration procedures in Section 4. Conductivity and pH calibration procedures are
included in the appendices)
11.11.2
Manual Control
Relays
Select the desired relay output.
Selects control relay mode (Manual Off Auto).
Manually activate or shut off relay
Set output to return to Auto after a period of time (m:ss)
4-20 mA Outputs
Select the desired 4-20 mA output
Selects control mode (Manual Off Auto).
Manually output a value (0-100%)
Set output to return to Auto after a period of time (m:ss)
11.11.3
Test Send
This communication test can be initiated from the controller display. A test data file using the
configured setting is sent.
11.11.4
`Reboot
Enables a quick system reset.
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12.0
Communications and Data Management
The overall 3D TRASAR program incorporates a number of software programs and hardware
systems to manage all of the information associated with the control of a boiler system. The diagram
below shows the flow and interaction of this data with the various components.
12.1
3D TRASAR Boiler Optimizer
The 3D TRASAR Boiler Optimizer is a software program used to determine the right treatment
program for your boiler system. Information entered in the 3D TRASAR Boiler Optimizer can be
transferred to the 3D TRASAR Boiler Configurator to avoid duplicate data entry. Contact your Nalco
representative for questions about the 3D TRASAR Boiler Optimizer.
12.2
3D TRASAR Boiler Configurator
The 3D TRASAR Boiler Configurator is a software program used to configure the controller, establish
remote communication, download data, update controller firmware, and change control methods.
Contact your Nalco representative for questions about the 3D TRASAR Boiler Configurator.
12.3
3D TRASAR Boiler Controller
The 3D TRASAR Boiler Controller is the hub for data collection used for reports, graphs, and alarms.
12.4
SCADA Systems
SCADA systems can be used to monitor various parameters of the 3D TRASAR Boiler Controller via
4-20 mA signals or RS-232-485 Modbus.
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12.5
3D TRASAR Web
The 3D TRASAR Web is a convenient way to check the status of your 3D TRASAR cooling water and
boiler applications. Use the 3D TRASAR web to:
View overall system performance.

Create user account profiles and assign them to specific controllers.
View alarm detail and enable alarms to be sent via e-mail.
Generate customized reports.
Download data to PC.
Downloaded data is compatible with Vantage V100. Data is sent to the 3D TRASAR Web every hour
from the 3D TRASAR Boiler Controller via direct file transfer.
12.5.1
3D TRASAR Web Set Up
3D TRASAR Web is accessed through Nalcos website (http://extranet.nalco.com/Extranet/start.asp).

You must have a Nalco Extranet Account to enter the side. Contact your Nalco representative for
information on how to obtain an extranet account.
Click 3D TRASAR Web
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12.5.1.1 Create/Edit Users

Create and edit user profiles in the personal information page. Select which e-mail addresses are to
receive reports and/or alarm messages. Assigning a user to a controller (see section 12.5.1.2) will
automatically request Nalco Extranet access for that user.
12.5.1.2
Assign Controllers (Data Sources)
Assign users access to view data on the website, grant or revoke Manager access to assigned users.
You can also assign users to receive alarm emails (see Section 12.5.4)
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12.5.1.3
Manage Controller (Data Source) Setup Information
The data source management screen provides a view of important controller information such as
facility location, serial number and communication settings. Enter a Customer Number (Sold To) and
click Save to approve any Unapproved Controllers.
12.5.2
3D TRASAR Web Data
Use the 3D TRASAR Web to review multiple systems performance or view specific operating
parameters for one controller.
The Performance Summary page
provides a high-level view of the state
of every controller assigned to a user.
You can filter on Customer Name and
Data Source Type
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The Data Dashboard page
displays detailed information for
a specific controller.
Both pages can be modified to display the parameters and information that you want to show.
12.5.3 3D TRASAR Web Reports

The Basic Report page allows users
to preview graphs, reports, and
download data.
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Reports can be printed, emailed to the

customer, exported to an Excel
spreadsheet, or saved to 3D TRASAR
Web for future use.
Saved Reports can also be added to a
Report Schedule to be generated
automatically and emailed on a routine
basis.
12.5.4 3D TRASAR Web Alarms

Alarm information generated by the 3D TRASAR controller will be sent in an email to the 3D TRASAR
web site where it will be forwarded to the specified users email address identified in their user profile
on the Personal Information Page (see section 12.5.1.1).
Details on the last 50 alarms will also be available on the 3D TRASAR Web, along with information on
probable causes and troubleshooting tips.
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12.6
3D TRASAR Wireless Gateway
The Nalco Global Gateway (Wireless) allows connectivity without the cost and trouble of a phone line
installation. The gateway communicates through the public Cellular/PCS network via the Ethernet
port of the controller.
The gateway provides advanced security including NAT, plus a built in firewall to protect the controller
from unauthorized access via the Internet. When properly installed and configured, the functionally of
both the modem and local Ethernet port remain unchanged.
It is important to verify that the gateway is right for your application. Verifying the site for the gateway
is similar to finding a place in an industrial environment to make a cell phone call. Even the best cell
phone on the market is of little use without an adequate, interference free, stable signal. Use the
guidelines below to determine signal availability in your area.
If you have access to a GSM/GPRS cell phone and can make a web/data connection from the
location where the controller will be installed, there is a very high probability that the gateway will
work from that location.
If you have a non-data GSM phone and can make a voice call from the location that the
controller will be installed, there is a good probability that the gateway will work from that location.
If you cannot make a data connection or phone call, you will probably need the indoor/outdoor
high gain antenna option (P/N 060-TR5284.88). The antenna does not come with a cable, which
is sold separately in 25-foot (P/N 060-TR5284C25.88) and 100-foot lengths (P/N 060TR5284C100.88). This usually occurs when the controller is installed in basements, metal
buildings, or next to electrical equipment.
Detailed installation and configuration instructions are included with the unit. Contact your local Nalco
Representative for ordering information.
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13.0 Shutdown and Maintenance

CAUTION-DANGER:
13.1
Before performing maintenance to any portion of

the 3D TRASAR Boiler System shut down the unit
following the procedures.
Shutdown
13.1.1 Combination TRASAR Fluorometer and NCSM System Shutdown

Note:
The NCSM cell should be allowed to cool well below boiling water temperatures while under
pressure. This will prevent the formation of bubbles in the reference electrode.
1. Slowly close the sample inlet valve on the top of the sample cooler. This line will be a high
pressure and high temperature sample line so take caution.
2. Allow the NCSM assembly to cool before performing maintenance. Removing some of the
insulation about the 3/8 stainless steel cross will hasten probe cooling. The NCSM probe should
be less than 180F. Cooler is better.
3. Remove the protective shield on the NCSM panel. When the NCSM temperature reads below
180F (82C) slowly close the NCSM inlet needle valve. There should be a double blocking valve
arrangement upstream of the NCSM needle valve. Close these valves as well.
CAUTION-DANGER:
Although the sample is cooled after the sample cooler the line
is still under high pressure.
4. Slowly close the fluorometer inlet valve and the , 3-way sample outlet valve.
5. Relieve the pressure in the high-pressure section of the sample line by very slowly opening the
pressure bleed valve located below the pressure gauge on the NCSM assembly. Make sure the
pressure gauge shows no gauge pressure in the NCSM cell before disassembling.
Note:
If the pressure in the NCSM is relieved rapidly air bubbles will form in the Reference
Electrode. It will need to be Refurbished before it can be put back on line.
6. Relieve the pressure in the low-pressure section of the sample line by slowly opening the grab
sample valve located below the pressure gauge on the Sample Conditioning System. Make sure
the pressure gauge shows no gauge pressure in the line.
CAUTION-DANGER: The 3D TRASAR Controller must be ON until after pressure
is relieved in the low-pressure section of the sample line. If
not, the solenoid valve will be closed (normally closed valve)
and the high-pressure section of the sample line will remain
under pressure.
7. If maintenance is to be performed on the sample cooler. Shut off water to the cooler.
13.1.2 TRASAR Fluorometer Only System Shutdown

1. Slowly close the sample inlet valve on the top of the sample cooler. This line will be a high
pressure and high temperature sample line so take caution.
CAUTION-DANGER:
Although the sample is cooled after the sample cooler

the line is still under high pressure.
2. Slowly close the TRASAR fluorometer inlet valve and the , 3-way sample outlet valve.
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3. Relieve the pressure in the low-pressure section of the sample line by slowly opening the grab
sample valve located below the pressure gauge on the Sample Conditioning System. Make sure
the pressure gauge shows no gauge pressure in the line.
CAUTION-DANGER: The 3D TRASAR Controller must be ON until after pressure is
relieved in the low-pressure section of the sample line. If not,
the solenoid valve will be closed (normally closed valve) and
the high-pressure section of the sample line will remain under
pressure
4. If maintenance is to be performed on the sample cooler. Shut off water to the cooler.
13.1.3
Note:
NCSM Only System Shutdown (without Sample Conditioning System)

The NCSM cell should be allowed to cool well below boiling water temperatures while under
pressure. This will prevent the formation of bubbles in the reference electrode.
1. Slowly close the needle valve on the discharge line. This line will be a high pressure and high
temperature sample line so take caution.
2. Allow the NCSM assembly to cool before performing maintenance. Removing some of the
insulation about the 3/8 stainless steel cross will hasten probe cooling. The NCSM probe should
be less than 180F. Cooler is better.
3. Remove the protective shield on the NCSM panel. When the NCSM temperature reads below
180F (82C) slowly close the NCSM inlet needle valve. There should be a double blocking valve
arrangement upstream of the NCSM needle valve. Close these valves as well.
4. Relieve the pressure in the high-pressure section of the sample line by very slowly opening the
pressure bleed valve located below the pressure gauge on the NCSM assembly. Make sure the
pressure gauge shows no gauge pressure in the NCSM cell before disassembling.
Note:
If the pressure in the NCSM is relieved rapidly air bubbles will form in the Reference
Electrode. It will need to be Refurbished before it can be put back on line.
13.2
TRASAR Fluorometer Maintenance
The 3D TRASAR Boiler Fluorometer should be cleaned and calibrated every 90 days.
13.2.1
Clean TRASAR Fluorometer Flow Cell
1. Unscrew pipe plug on the tee located on top of the fluorometer.

2. Using the flow cell rush (P/N 500-P2817.88) provided with the Start-up Kit (P/N 500-BTSRKIT.88
or 500-BTSRKITLA.88, gently push the brush down through the opening and scrub the full length
of the flow switch and fluorometer tube.
CAUTION:
Be sure to wear the appropriate PPE (Personal Protective Equipment) when

cleaning the flow cell. Check the reagent MSDS for details.
3. Flush the fluorometer cell with 60cc (twice) of deionized water using the syringe.
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13.2.2
Calibrate TRASAR Fluorometer
After cleaning is complete, calibrate the fluorometer (Refer to Section 4.8).
13.2.3
Check/Replace TRASAR Fluorometer Desiccant
The fluorometer uses a desiccant canister and a color-coded humidity indicator to ensure that the
optics are not exposed to condensation. Monthly, check the color of the desiccant indicator on the
front of the 3D TRASAR fluorometer.
If the indicator is blue, desiccant does not need to be replaced.

If the indicator is pink, unscrew the desiccant cover from the fluorometer and replace both the
indicator (P/N 060-TR5223.88) and the desiccant canister (P/N 060-TR5222.88).
13.3
NCSM Maintenance
The NCSM probe requires little if any maintenance. See Sections 4.10 and Appendices B and C for
additional information.
13.4
Sample Conditioning System Maintenance
The high-pressure SS filter and low-pressure cartridge filter should be cleaned (or replaced)
periodically to ensure adequate flow to the fluorometer. On new installations purge the highpressure SS filter every day and inspect the low-pressure filter cartridge once a week. After
the system has been in operation for a while they can be inspected less frequently.
High-Pressure Filter Purge
1. Close the sample isolation valve on the inlet of the sample cooler.
2. Open the valve on the bottom of the SS filter housing for a maximum of 2 seconds. This short
purge should dislodge any excess debris on the filter screen.
CAUTION-DANGER:
The discharge line from the bottom of the SS filter MUST BE

PLUMBED TO A SUITABLE DRAIN. DO NOT leave the valve
open for more than 2 seconds. This may overcome the sample
coolers ability to adequately cool the sample (trip the high
temperature alarm) and may result in flashing
3. Close the valve on the fitting bottom of the SS filter housing.

4. Open the isolation valve on the inlet of the sample cooler.
High-Pressure Filter Cleaning
2. Loosen the fitting bottom of the SS filter housing. Be careful to support the strainer body to
minimize strain on the connecting tubing/piping.
3. Slide the purge line valve and tubing out from the fitting so the housing can be removed.
4. Unscrew the housing.
5. Unscrew the retaining screw that holds the filter element in place.
Note:
The retaining screw, filter element, and upper and lower gaskets will drop from the filter when
the bolt is removed. Be careful not to lose any parts.
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6. Tap the back of the strainer body to help loosen the strainer element. You may have to lightly tap
on the side of the element to break it loose from its seating area.
7. Remove and inspect the strainer element. Flush the element or replace it if necessary.
8. Re-insert the strainer element assembly and tighten the retaining screw.
9. Clean the housing gasket and mating surfaces.
10. Replace the housing and tighten securely.
11. Slide the purge line valve and tubing into the fitting so the housing. Retighten the tube fitting.
12. Open the sample isolation valve on the inlet of the sample cooler.
Low-Pressure Cartridge Filter
The filter cartridge may need to be replaced if there is a steady loss of flow through the system (as
seen on the rotometer) or if flow through the system is erratic.
2.
3.
4.
5.
Slowly twist the housing (counterclockwise) to relieve pressure in the cartridge.

Remove the housing by pulling downward.
Pull the old filter cartridge out of the housing. Clean the housing.
Install a new cartridge by sliding it over the center post.
6. Re-assemble the housing to the head and tighten securely.

7. Open the sample isolation valve on the inlet of the sample cooler.
Sample Cooler
Cooling coils require minimal maintenance other than periodic cleaning and regular checks for leaks.
If hard water is used for cooling purposes, acid cleaning of the cooling waterside of the coil every 3
months is recommended.
Use a dilute acidic solution consisting of 1 part acid to 3 parts water. Sulfuric acid (460S0800.75, 10% Sulfuric Acid) is preferred to minimize corrosion of stainless steel. DO NOT USE
concentrated hydrochloric acid for cleaning, as high chlorides will pit stainless steel.
Occasional flushing of the sample lines is also recommended when a cooling coil is taken out of
service.
Note: Cleaning the sample cooler is facilitated if a tee with two isolation valves is installed on the
inlet and outlet of the cooling water connections on the sample cooler.
CAUTION-DANGER: If isolation valves are installed on the cooling water
connections of the sample cooler the valves must be
appropriately tagged and operators trained to ensure that
cooling water flow is not stopped while hot boiler water is
flowing through the sample line.
13.5
Conductivity and pH Probe Maintenance
Conductivity and pH probes should be inspected, cleaned and recalibrated once every month. (See
Appendices F & G)
CAUTION:
168
Be sure to close sample isolation valves, carefully depressurize the line and cool
the probes before performing maintenance.

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14.0
Troubleshooting
CAUTION-DANGER: Remember the system you will be troubleshooting is under high
temperature and pressure conditions in addition to the normal
electrical hazards associated with the 3D TRASAR Boiler Control
System.
SAFETY-WARNING: Always keep Safety in the forefront of your mind and in every
Troubleshooting activity you do. When it comes to your Safety,
there is no room for risk taking, complacency, shortcuts and
poor judgment when working around boiler systems
14.1
General System Troubleshooting
Problem
Possible Cause(s)
Solution
Controller does
not power up
when power
switch is turned
on.
Controller is not plugged

in.
Plug in controller and switch it on.
GFI or circuit breaker is

tripped or fuse(s) blown.
Reset breakers or replace fuse(s) as needed.

Check power fuse inside controller box and replace
if blown.
No Sample Flow
Controller not powered.
Connect controller to power AC power source, and

turn power switch to On position.
One or more valves on

the skid are closed.
Open all valves.
Sample filters or pressure

regulator plugged.
Check in-line filter, cartridge filter, pressure

regulator, faulty pressure relief valve, and other
valves
Clean or replace as needed.
High temperature
solenoid closed.
Make sure cooling water is flowing through sample

cooler at the required rate.
Check to see if there is a high temperature alarm.
Clear this alarm, if present.
Verify the sample flow RTD is functioning correctly.
Check the relay fuse for the sample conditioning
control relay.
Verify the solenoid switch is functional.
Flow switch nonfunctional.
Clean flow switch if fouled.

Check flow switch wiring for proper contact.
Replace flow switch.
Confirm the Boiler system is operating.
Feed water pump is not

operating.
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Problem
There is No flow
but the No Flow
Alarm is not
active
Possible Cause(s)
Solution
The 10-minute delay

period has not passed.
The flow signal (as reflected on the display) must be

absent for 10 min before the alarm will activate.
The flow is near the 200

cc/min setting of the flow
switch, resulting in
intermittent flow/no flow
indications.
This will cause the 10-minute delay timer to reset

each time flow is detected, preventing the alarm.
Increase the flow.
Backlight turns off with

keypad inactivity (to
conserve power).
Press any key and verify the display lights.
Faulty display.
Replace controller.
The controller
configuration is corrupt or
missing.
Reload the controller configuration.
The controller operating

firmware is corrupt.
Reload controller firmware.

Replace controller.
All relays (and

possibly) analog
outputs are off
Interlock is active.
Verify the Interlock connection is connected properly

(or jumpered, if not being used).
Verify the mechanism connected to the controller
interlock is working properly.
One or more
relays or analog
outputs are in
Failsafe Mode
There is an alarm
condition overriding
normal operation of the
associated relay or
analog output.
Determine the alarm condition(s), and fix the

operational problem causing the failsafe condition.
Check the active alarms and adjust settings if
needed.
One or more
relays or analog
outputs are not
operating the
chemical pumps
The jumper supplying

power to the relay contact
closure has been
removed. In this case,
the display will still
indicate that the relay is
On.
Check to be sure the relay (Hot) power jumper is

connected properly.
The product level is

above (or below for blow
down control) the set
point and control range.
The relay or analog output does not need to be on.

This is the correct control response.
For Analog Outputs, the

PID response may lag
behind the system error.
The pumps may not
immediately turn On or
Off, due to a long system
delay response.
This may be normal. It is due to the systems long

lag time response.
Retune the PID.
Adjust the PID I Term factor (with caution).
Display backlight
is off
Display blank but

backlight is on
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Problem
One or more
relays or analog
outputs are not
operating the
chemical pumps
(continued)
Possible Cause(s)
Solution
There is a No Flow
Alarm or No Steam
Flow Alarm condition during which the relays
and analog outputs may
not operate (configuration
dependent). In this case,
the display will still
Off and/or the Analog
Outputs are in failsafe
mode.
Check the active alarms and increase flow if

needed.
A calibration is underway,
during which the relays
and analog outputs will
not operate (respond to
the process control
variable). In this case,
the display will indicate
that the relay(s) are Off.
The associated relay(s) are in Manual Off mode.

The associated analog outputs will be in Failsafe
Mode.
The affected relay(s) is in

Manual Off mode. In this
case, the display will
in Manual Off mode.
Using the keypad Menu item Manual Relay Control,

return the relay to Auto mode.
Erratic Probe
Faulty electrical
respons connection(s) or
e(s)
incorrectly wired probes.
Check and correct any electrical wiring connection

problems. Be sure to look at both ends of the
probes.
Verify the probe cable ends are attached to the
correct terminals inside the controller.
Check the probe wire (or cable) itself. If possible,
perform a continuity test on the wiring connections.
Replace defective connectors, wires, or cables.
Probe response/readings
are not in a normal
operating range, or are
erratic.
Recalibrate probe.
Bad or missing Earth

Ground connection.
Check all electrical connections from the plant

electrical connection. Verify the controller has a
good Earth Ground connection.
Sample Flow is erratic.
Increase or decrease the sample flow rate as

needed to achieve a proper (constant) sample flow.
Check system for filter debris, partially closed or
plugged valves, and pressure relief value.
Check in-line filter, cartridge filter, pressure
regulator, faulty pressure relief valve, and other
valves
171

OM0211
Problem
Possible Cause(s)
Solution
Clean or replace as needed.
Erratic Probe
respons
e
(Contin
ued)
Feed Water
sample
line
probe
has
leaks
Chemical pump
not pumping
when controller is
powered up and
turned on
Configurator
cannot
communicate with
controller using a
direct connection
172
Feed Water sample line

is not insulated or poorly
insulated.
Check Feed Water sample line to be sure it is

properly insulated from sample take-off to the 3D
TRASAR Feed Water sample cooler inlet.
Wrong sample location.
Verify the sample point is correct and is located

downstream the proper length after injection of DO
scavenger and/or TRASAR products.
Loose nut, loose fitting,

over-tightened fittings, or
improperly aligned fitting.
Tighten all leaking fittings.
Feed Water sample line

develops pinhole leak.
Valve off the section with leak and replace with new
stainless steel tubing and proper fittings.
Open closed valve(s) upon completion to confirm
leak is fixed.
Chemical pumps not

wired into the controller.
Faulty or bad wire or
terminal connection.
Verify the pump(s) are wired correctly to the

controller.
Verify pumps work in manual mode.
Chemical feed pump(s)

broken/pump fuse blown/
vapor locked etc.
Check to see if pump is working. Fix any vapor lock

problems/blown fuses etc.
If pump is not operational, replace with new one
Controller Relay is faulty

and/or fuse blown
Replace relay and/or blown fuse.

Pump amp draw is too high (over 2 amps). A motor
starter relay box must be added.
Controller is not
configured properly to
activate pumps
Check the configuration to be sure it is set up

properly to have chemical feed pumps active in
either manual, on-off or PID control with proper set
points/pump limiters, alarms etc.
A standard network cable

is being used instead of a
crossover network cable.
Replace the network cable with a crossover network

cable for connections between the Ethernet
Controller (bulkhead) and PC.
The Ethernet crossover

cable is not connected
securely to the controller
(connector on the side of
the controller) and/or the
PC Ethernet port.
Check all connections and replace the external

Ethernet cable if damaged

OM0211_________________________________________________________________________
Problem
Possible Cause(s)
Solution
The internal Ethernet

jumper (straight-through)
cable is not connected
securely to the Ethernet
bulkhead connector or
circuit board connector.
Disconnect and reconnect each end of the Ethernet

cable.
The PC network adapter

(Local Area Connection
adapter) is not configured
properly.
The default network settings for the controller direct

connection are IP Address 169.254.1.2, Subnet
255.255.0.0.
The IP Address being

used by the Configurator
is incorrect.
The default IP address for the controller direct

connection is 169.254.1.2. In the Configurator's
Connection Window, verify this is the IP address
being used in the connection attempt.
The analog phone cable

is not connected securely
to the controller, PC,
and/or wall jacks.
Check all connections and replace the phone line if

damaged.
The phone line is not

functional for dial in.
Try dialing the number using a landline or cell phone

to see if the controller answers. If it does not,
connect an analog phone to the line in place of the
controller and dial the number again using the same
landline or cell phone. The phone should ring if the
call is coming through.
The phone line is in use.
This can happen if the controller is dialing out to

send an email or if another party is connected to the
controller via modem. Try again later
The phone number used

by the PC is incorrect
Check the phone number you are dialing.
With a modem
connection
established, the
Configurator
cannot
communicate with
the controller
The IP Address being

used by the Configurator
is incorrect.
The default IP address for the controller modem

connection is 192.168.2.1. In the Configurator's
Connection Window, verify this is the IP address
being used in the connection attempt.
Connection can
not be established
to controller
remotely via
Wireless Gateway
Wireless signal
interrupted due to Carrier
related problems or
weather etc
Call carrier to see if they are having a problem.

Wait a while and try accessing the controller again
Configurator
cannot
communicate with
controller using a
direct connection
A connection
cannot
be
establis
hed to
the
controll
er via
modem
173

OM0211
Problem
Problem
downloading
and/or uploading
using USB
connection
Alarm emails are

not being
received from
Nalco web site.
Controller data
cannot be viewed
at Nalco web site.
174
Possible Cause(s)
Solution
USB thumb drive out of

space
Clear sufficient memory space on the USB thumb

drive.
Use a USB thumb drive, which has sufficient
memory.
USB thumb drive version

may not be supported
Use a different USB thumb drive brand.
Analog phone line is not

connected.

damaged.
Phone line is not

functional for dialing out.
Connect an analog phone to the line in place of the

controller and attempt a local call.
Controller is not
configured to send alarm
emails.
Check the Alarm Settings to be sure the email

checkboxes are checked.
Email addresses are

misspelled/incorrect.
Recheck email addresses for spelling or other

errors. An example of the email address format is
email@domain.com.
ISP access phone

number is entered in
wrong format.
Check the phone number to ensure that it is entered

exactly as the controller will dial it, including prefixes
(8 or 9, 1+area code). The character p may be
used as a pause.
Controller email address

is invalid.
Although the controller cannot receive emails, it has

an email address that is used in the from field of
the emails it sends out. Often, the ISP will require
that this address be the one issued to the ISP
account as a security measure (i.e.
username@earthlink.net). In all cases, the domain
of this address (earthlink.net in the example above)
must be an actual domain, or the emails will fail.
ISP settings are incorrect.
Check the following settings: username, password,

DNS server, access phone number.
Analog phone line is not

connected.

damaged.
Phone line is not

functional for dialing out.
Connect an analog phone to the line in place of the

controller and attempt a local call.
Enter cell phone number as the ISP access number.
Remove the system interlock jumper. Your cell
phone will ring if the phone line is functional
Controller is not
configured to send data
emails.
Check the Email Settings to be sure the Send Data

Email parameter is set to Yes.
ISP access phone
Check the phone number to ensure that it is entered

OM0211_________________________________________________________________________
Problem
Possible Cause(s)
Solution
number is entered in
wrong format.
exactly as the controller will dial it, including prefixes

(8 or 9, 1+area code). The character ',' (comma)
may be used as a pause.
Controller email address

is invalid.
Although the controller cannot receive emails, it has

an email address that is used in the "from" field of
the emails it sends out. Often, the ISP will require
that this address be the one issued to the ISP
account (i.e. username@earthlink.net). In all cases,
the domain of this address (earthlink.net in the
example above) must be an actual domain, or the
emails will fail.
ISP settings are incorrect.
Check the following settings provided by your Nalco

Rep: username, password, access phone number.
Controller has not been

registered at 3D TRASAR
Web
The controller must be registered at 3D Trasar.com

in order to view the data. The user should be
prompted to do this during initial configuration. In
the Configurator, this is also accessed through the
Edit menu.
Call 630-305-CHEM
Probe reading is
displayed as
dashes
A Sensor Error is active
Check probe connections in controller.
Product levels
(ppm) are
displayed as
dashes.
A Fluorometer
Communication Error is
active.
Tighten the connector on the Fluorometer probe and

check the Fluorometer cable connections in the
controller. Replace cable if damaged.
Value of -999 is
logged in data
log.
The measurement is
invalid.
A sensor error or some other condition is present,

which is causing the measurement to be invalid.
Check the active alarm list on the display.
System rebooting/not fully

powered up after restart
If reboot occurs close to normal logging time, a

value of 999 may be found.
Controller data
cannot be viewed
at Nalco web site.
Check probe is calibrated and working properly, if

not replace probe
175

OM0211
14.2
TRASAR Fluorometer Troubleshooting
Problem
Display does not
show TRASAR
reading when
controller is
powered and on
Wrong sample point

hooked to the 3D
TRASAR unit
176
Possible Cause(s)
Solution
Chemical feed pump not

pumping TRASAR product.
Check that the chemical feed pump is pumping

chemical into FW and if not fix it.
Confirm TRASAR is present in FW sample using a
recalibrated handheld or pen Fluorometer.
Wrong sample take-off point

hooked to 3D TRASAR for
Boilers system.
Confirm take-off point is the FW or blow down line.

FW take-off location should be downstream of the
TRASAR injection point at least 10 pipe diameters.
Fluorometer not wired into the

controller or the wiring is
loose/disconnected and/or poor
electrical contact at terminal
junction
Check cable/wire is attached properly at

Fluorometer.
Check for loose/disconnected wires and fix. Make
sure Controller is shut off and unplugged before
inspecting for loose wires and reconnecting them.
Remove any unnecessary insulation form wire to
insure good electrical contact.
Afterwards plug in controller and turn it on.
Fluorometer cable/wire is faulty
Check Fluorometer cable/wire and if bad replace it
Fluorometer is faulty,
Fluorometer cell fouled
Check calibration, clean cell and recalibrate

Fluorometer as needed.
Follow troubleshooting procedures in Fluorometer
manual/section. If found faulty replace it.
These measurements do not

appear in Operating Data if the
probes are configured as Not
Installed
Configure these probes as Monitor Only or

Controlling.
Sample point is not on the

correct boiler feedwater or
boiler blow down line
Change sample point to correct location
Sample point is on the correct

boiler FW line but not located
down steam of the TRASAR or
DO scavenger injection point.
Move sample take-off point downstream of TRASAR

product and/or DO scavenger feed point the proper
length to achieve complete mixing of the products in
the FW.
Sample point is down stream of

DO scavenger and/or TRASAR
product injection point but is not
far enough away to achieve
proper mixing of the product(s).
Move sample point further downstream to allow

complete mixing to occur.
Sample point is too far down

stream of the product injection
points and/or the sample lines
are to long creating excessive
lag time affecting monitoring
and control performance.
Relocate the sample point and or shorten sample

line length to reduce lag time.

OM0211_________________________________________________________________________
14.3
Alarm Screen Troubleshooting
1.)
Upon initial start-up measured levels may be low causing nuisance alarms. To prevent
nuisance alarms see Start-up alarm suppression Appendix F.
2.)
To reset an alarm it is necessary to eliminate the alarm condition by either

Placing the control mode in Off temporarily
Adjusting the variable within the alarm limits
Or Changing the alarm limits
3.)
Always, check the source of all alarms. Many alarms are triggered by system conditions or valid
measurements.
General Alarms
Alarm Type
Interlock Override
Low Sample Flow

Failsafe
Indication
The Interlock input has
been deactivated
Insufficient water flow

past the flow switch
Cause
Corrective Action
The Interlocking device

is not active
Check. This may be

expected operation
Interlock is not used

and jumper is not in
place
Replace jumper (refer

to wiring diagram for
location and direction)
Interlock wiring is
loose or not making
good connection
Check and correct

wiring connections
Flow rate too low or

blocked
Check and correct.

Flow may be impeded
by fouled filters.
A valve is partially
closed/fouled
Open, clean and/or

replace valve.
Flow switch is fouled
Clean flow switch
Flow switch wiring is

loose or not making
good connection
Correct wiring problem,

replace flow switch as
needed
Low Steam Flow

Override
4-20mA input signal

from Steam flow
sensor indicates low
steam flow
Boiler is not making

sufficient steam
Check system. If alarm

set point is too high,
change the alarm set
point.
Temp 1 High Alert

Temp 1 High
Override
Temperature of sample
water exceeds alarm
set point.
Safety high
temperature solenoid
cut-off
The RTD following the

sample cooler has
detected sample water
temperature exceeding
alarm set point at
some point.
Ensure cooling water is

flowing and properly
cooling the sample
stream. Then, clear the
alarm using the keypad
or Configurator. The
alarm must be cleared
(does not automatically
reset when cooling
water resumes)
177

OM0211
General Alarms
Alarm Type
Indication
Cause
Corrective Action
Temp 1 Low Alert
Temperature of sample
water below alarm set
point.
Cooling water
temperature is low
Alert for possible

freezing
Nubio Comm Error
The internal boards are

not communicating.
There is a loose
interboard connection
Turn power off, and

gently press on all the
white inter-board
connectors inside the
controller to verify
connections
Component failure
Reboot system by
cycling the power. If
unsuccessful contact
Help Desk at 630-305CHEM.
NCSM Alarms
Alarm Type
Indication
Temp 2 High Alert
Sample temperature
exceeds alarm set
point.
Temperature 2 Low
Alert
Temperature 2 Low
Override
Sample water
temperature below
alarm set point
ORP High Alert

ORP High Failsafe
The measurement
exceeds high alarm
threshold
Cause
Corrective Action
Check if system
operation has changed
There is no sample
water flow past the
ORP probe.
Check if Boiler system

is down and there is no
feedwater flow.
Check if sample flow is
restricted (before and
after the probe). Check
for fouled valves and
filters.
The RTD is faulty
Verify probe by
checking the
temperature of a known
sample. Check wiring.
Scavenger feed cannot

keep up with REDOX
stress
Check if scavenger tank

is empty/pump has lost
prime/faulty pump or
valve
Check if pump rate is
too low
Check if there is
operational stress on
the Boiler water
ORP reading
inaccurate
178
Check ORP probe and

detection as described

OM0211_________________________________________________________________________
TRASAR Alarms
Alarm Type
Fluor Comm Error
TRASAR High
Failsafe Alarm
Indication
Controller is unable to
communicate with the
fluorometer.
TRASAR fluorescence
measurement exceeds
high alarm threshold
TRASAR High Alert
TRASAR Low
Failsafe
TRASAR fluorescence
measurement below
low alarm threshold
TRASAR Low Alert
Cause
Corrective Action
Cable connection on
fluorometer is loose
Disconnect and inspect

for bent pins or other
damage and reconnect
Fluorometer wiring is
loose or miswired
Check and correct (see

wiring diagram)
Component failure
Reboot system by
cycling power. If
needed contact Help
Desk at 630-305CHEM.
Chemical feed rate too

high causing overshoot
Reduce chemical feed

rate (pump)
Chemical being fed to

a low flow area, when
circulation resumes,
there is overfeed
Move chemical feed

point to a location with
less lag time
Chemical pump
siphoning causing
overfeed
Eliminate condition
causing siphoning
Fluorometer is out of
calibration, fouled or
faulty.
Check calibration.
Clean and recalibrate.
Replace if faulty.
Product container
empty
Refill / replace product

inventory

low causing overshoot
Check feed line or

increase chemical feed
rate
Fluorometer is out of
faulty
Check calibration, clean

and recalibrate.
Replace if faulty
Low Alarm threshold

set too high
Readjust alarm
threshold/set-point
Cell Fouling
High/TRASAR FS
Cell Fouling High
Alert
Measurement exceeds
Fluorometer flow cell is

fouled
Clean fluorometer flow

cell brush and cleaning
solution. Recalibrate.
Turbidity
High/TRASAR FS
Turbidity High Alert
Measurement exceeds
Particulates in sample
water filter fouled.
Check cartridge filter

and replace if
necessary.
Sample water has air

bubbles
Adjust positions of
fittings to prevent
bubbles in sample line.
179

OM0211
Conductivity, pH, Temperature, NCM100, Analog inputs High/Low Level Alarms
Alarm Type
High Alert
High Failsafe
Low Alert
Low Failsafe
Indication
Measurement exceeds
High Alarm threshold
Measurement below
Low Alarm threshold
Cause
Corrective Action

high/Low
Adjust pump feed rate.

Refill chemical tank.
Process leak or other

contaminant in system
Confirm (with other

data) and eliminate
source
Chemical pump
siphoning causing
overfeed
Eliminate siphoning
Sensor probe is out of

faulty
Clean and recalibrate if

needed. Replace if
faulty

high/Low
Adjust pump feed rate.

Refill chemical tank.
Process leak or other

contaminant in system
Confirm (with other

data) and eliminate
source
Chemical pump
siphoning causing
overfeed
Eliminate siphoning

faulty
Clean and recalibrate if

needed. Replace if
faulty
Wiring or other
connection is loose.
Retighten wires. Make

sure insulation is not
impeding electrical
contact
Probe failure
Replace probe
Sensor alarms
Sensor Error
Error detected with

indicated sensor probe
Control Outputs (Relays or analog outputs)

Relay Timeout
Analog Output
Timeout
180
Duty cycle for relay or

analog output exceeds
alarm limit for the
timeout period.
Tank empty/Pump lost

prime/faulty pump or
valve
Check tank, pump,

valve, feed line. Repair
as needed
Confirm with other data
and correct/eliminate
problem(s)
Relay timeout
limit/duty cycle set too
low
Readjust alarm
threshold/duty cycle
Feed rate too low for

demand
Readjust pump rate

OM0211_________________________________________________________________________
14.4
NCSM Troubleshooting
NCSM Field Troubleshooting

* NCSM Accessory Kit
* NCSM mV Tester
* Multmeter
Initial
Installation
Problem?
Replacement
probes and
acclimation
Probe
reads (-/+)
opposite of
expected ?
Check for
proper
electrical
grounding.
NO
Check
configuration
vs. wiring.
Check
system MOC
factors
* Ensure insulation stripped and

connections tight
* Ensure TB11 used for ORP #1
Correct wiring
Is wiring
correct?
Intentional
configuration
change?
Remote
NCSM
(BL5200)?
YES
NO
Check probe
response to
pump
change.
YES
* Must use pre-amp cable
* Check/replace battery (6V)
* Check J-Boxes for mixup
* Wire must be < 1000 ft
NO
NO
YES
Cables
passed
test?
Test REF,
ORP & RTD
cables.
Ensure proper
NCSM
configuration and
correct wiring
YES
NO
YES
Reading
OK when
pump turned
off?
NO
YES
Check pump:
* No chemical, valve closed
* Air locked
* Off or in manual control
* Wiring damaged
* AC drive setup changed/wrong
* Fuse or motor problem
Check sample line:

* Valve open
* Flow 200-500 cc/min
* Flow steady
* No leaks
* 1/4" line < 100 ft
Passed
REF probe
test?
NO
Passed
REF probe
test?
Defective
REF probe,
replace
Test ORP
probe
continuity
YES
Refurbish
REF probe
& Test
YES
Defective circuitry,
replace controller
Clean ORP
probe & test
with mV
stds
ORP
probe passed
continuity
test?
Passed
test with
mV std?
YES
NO
Ver 2.2 12-22-08
Replace the
defective cable or
wire.
Passed
TB11 and
-1024mV
tests?
NO
NO
Refurbish
REF probe
& Test
Perform TB11
short circuit &
-1024mV
tests
YES
Correct pump
problem
NO
YES
System
MOC explains
readings?
NO
Check for correct

BNC connections.
ALL must be
completely dry.
Swap TB11
ORP wires
YES
YES
Visually inspect
probe for damage or
debris.
Pump
OK?
Existing Unit
1. System MOC
2. Scavenger Pump
3. Probe Cables
4. Probes
NO
Must use
most recent
configurator
version.
New
Probes?
Probes OK
New Install
1. Grounding Problems
2. Wiring & Configuration
3. Sample Line
4. Scavenger Pump
5. Probes
* Alcohol & 1:1 HCl

* Fresh ORP mV Stds
* Beakers (3) & swabs
* DI water squirt bottle
YES
NO
YES
Problem Cause Probability Ranking
Troubleshooting Equipment
Start
Defective
ORP probe,
replace
NO
YES
ORP Probe
OK
181

OM0211
14.4.1
Factors that Affect Corrosion Stress and NCSM Control Ranges
MOC Factors
Factor
Condition #1
Affect on
Corrosion
Stress
Factor
Condition #2
Affect on
Corrosion
Stress
System design
For example no DA
Tend to be in
higher NCSM
operational zones
Have DA
Lower NCSM
achievable
System design
Complicated flow
patterns
Increases
Simple flow path
Decreases
Metallurgy (copper)
No copper
Can operate at
higher NCSM
zones
Copper used
Need to operate at
lower NCSM zones
Dissolved oxygen
ingress levels
(baseline)
High
Increases
Low
Decreases
Dissolved oxygen level

of makeup and
condensate return
Increasing DO
Levels
Increases
Decreasing DO
Levels
Decreases
Other chemical
additions (e.g. pH)
Lower pH(T) metallurgy specific
Increases
Higher pH(T) metallurgy specific
Decreases
Metal passivator levels
Decreasing
Increases
Increases
Decreases
Process contaminant
leaks (system and
contaminant specific)
Oxidant in leakage
Increases
Reductant in
leakage
Decreases
Temperatures of
makeup and
condensate return
Decreasing
Increases
Increasing
Decreases
NCSM Temperature
Lower
Increases NCSM
values
Higher
Decreases NCSM
values
Flow
Often Increasing
flow
Increases
Often Decreasing
Flow
Decreases
Increases
Good mechanical
operations
Decreases
Mechanical effects (e.g.

Deaerator (DA) tray Bad DA Operations
alignment
DA venting
Poor
Increases
Good venting
Decreases
DA steam supply
Bad DA Operations
Increases
Good supply
Decreases
Condensate versus
makeup ratio
Often Low
Increases
Often High
Decreases
Feedwater pump
problems
Air in leakage
Increases
None
Decreases
Changes in feedwater
(FW) flow
Often High
Increases
Often Low
Decreases
182

OM0211_________________________________________________________________________
MOC Factors
Factor
Condition #1
Affect on
Corrosion
Stress
Factor
Condition #2
Affect on
Corrosion
Stress
Changes in feedwater
(FW) steam load
Often High
Increases
Often Low
Decreases
Scavenger residence
times
Low
Increases
High
Decreases
Scavenger
concentrations (system
specific)
Decreasing
Increases
Increases
Decreases
Scavenger used
Weaker
Increases
Stronger
Decreases
Catalyst presence
NO
Increases
YES
Decreases
Scavenger pump
issues
Problems (in
leakage/binding)
Increases
None
Decreases
Real time system

variations (minutes seasonal yearly)
Variable conditions
Increases
Stable Conditions
Decreases
Real time system

variations (minutes seasonal yearly)
Frequent startup
and load changes
Increases
Base loaded,
stable operations
Decreases
High purity demin boiler

FW (all iron based
metallurgy)
Anion ingress
(chlorides and
sulfates)
Increases (must
operate at lower
NCSM)
Higher purity
water
Decreases (can
operate at higher
NCSM)
14.4.2
Replacement NCSM Probes
When NCSM probes are replaced there will probably be differences between the readings from the
probes that have been in the system for months and the readings from the new (freshly installed)
probes.
Any new NCSM probe will take some brake-in time to become acclimated to the boiler feedwater
system. This is usually several days. The virgin probes are at their most sensitive state when first
installed. This explains in part why they do not line up perfectly with the old probes.
In fact the new probes are more accurately reading the oxidizing power of the feedwater than the old
probes. This is especially true if the older probes haven't been refurbished in several months and the
Pt probe has not been cleaned except for a light wiping off with a paper towel. Probes should be
cleaned and refurbished every 6-12 months.
The older probes are bound to also have copper and iron corrosion products silted on the active Pt
portions.
Over time difference between the new probes and old ones should decrease as the new probes
become more conditioned to the system.
183

OM0211
14.4.3
Cables
There are various cables and options:
RTD cable wired directly to controller.

NCSM combination cable wired directly to the controller. The cable is labeled ORP and Ref to
indicate probe connections.
RTD cable wired to a junction box and signal wiring from the junction box to the controller (up to
1000 ft away).
NCSM combination cable wired to a junction box and signal wiring from the junction box to the
Controller (up to 1000 ft away). This NCSM combination cable contains an integral operational
amplifier (black box with a 6V battery).
Are cables wired-up correctly to ensure electrical signal transference? Verify the connections, look for
wiring insulation inside the green 2-pin connector (bad connection), make sure the stripped wire is not
broken off, make sure the connections are tight, make sure the exposed input wires cannot touch
each other above the green 2-pin connector, etc.
ORP/REF Cable Short Circuit Test
Connect the REF and ORP cables using the female-to-female BNC fitting supplied (in accessories
kit). Controller should read 0 mV +/- 2 mV.
If the reading is zero, then the ORP cable should be OK.

If the voltage is not 0 mV in the short circuit test then run the following test: Remove the (+) and
() inputs to the ORP input (green 2-pin connector) and short circuit the connector with a paper
clip (or small piece of wire). Re-insert the green 2-pin connector into the appropriate ORP input
slot. The ORP reading should be zero.
o
o
If this reading is non-zero the 3D TRASAR controller is defective - return to Nalco.

If this reading is zero ( 2 mV) then suspect a problem with the NCSM cable. Recheck the
cable and all connections (including the battery in the integral Op Amp cable) before
requesting an alternative cable.
For long wired installations: >6 ft where the integral operational amplifier is in use, the same continuity
checks are needed. Added issues that are of concern here are checking all connections in the 6-wire
wiring junction box and also making sure that no wires have been crossed from the junction box to
the 3D TRASAR controller.
Failed short circuit test with long wires and female-to-female BNC fitting across the ORP and
REF BNC cables. Replace the 6V battery and repeat the test.
Failed tests with long leads but not the short circuit test right at the controller. Start by replacing
the 6 ft ORP/REF cable with integral Op Amp and repeat the test. Next check/replace the long
signal wire from the 6-wire junction box to the controller.
RTD Cable
What does the controller read with disconnected RTD leads?
It should display --- for a temperature. If user cannot read temperature correctly once RTD leads
are connected?
Make sure that all four RTD wires are connected correctly within the controller.
Make sure that the RTD BNC cable is connected to the correct portion of the integral ORP/RTD
probe. That is the BNC will be in the horizontal alignment with the floor.
o
184
Now does the RTD reading give a temperature reading (sample temperature or ambient
temperature if no water is flowing through the skid)? YES OK. No, continue

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Make sure the Configurator is properly configured with the appropriate 4-wire RTD inputs.
Make sure that the RTD wires are correctly wired into the 3D TRASAR controller RTD inputs.
Recheck this as wiring inputs can often be wired incorrectly as well as come loose. Long cable
installs (> 6 ft): Make sure that if the wiring junction box is used that all wires are correctly
translated and not crossed-over, from the local junction box to the remote controller.
Still problems, then user can plug any other 4-wire RTD (like the RTD #1 used for the SCS
sample conditioning temperature), into the respective RTD input (like RTD #2). If this reads the
SCS temperature correctly (now on RTD #2 output), but the NCSM, RTD cannot be read
correctly, then there must be a failure with the NCSM, RTD (assuming all RTD cables appear OK
and are wired correctly) and the RTD/ORP combination probe will need to be replaced.
14.4.4
ORP TB11 and NCSM 1024 mV Tests
Open Circuit No wires connected, or BNC fittings on cables unattached and loose (very slow
movement of NCSM reading to -1246 to -1250 mV)
Shorted NCSM leads using the female to female BNC fitting supplied in the Accessories Kit leads
(Controller should read 0 mV +/- 2 mV)
Shorted inputs on green-2-wire NCSM input in the controller box itself, on the high input
impedance red board (can use a wire or paper clip) (Controller should read 0 mV +/- 2 mV)
Insert the NCSM calibration tester (Nalco P/N 6033766) into the NCSM inputs, within the
controller box (Controller should read -1024 mV +/- 2 mV when calibrator is turned on green
LED illuminated; Controller should read 0 mV +/- 2 mV when calibrator is turned off green LED
not illuminated). The 1024 mV voltage signal (from the calibrator) is not a high input impedance
signal, so just because the voltage reads 1024 mV on the 3D TRASAR Controller does not
mean that the NCSM will be displayed correctly if the PROBLEM is with the high input
impedance circuitry itself. Would need to return the Controller if it was suspected that the high
input impedance circuitry had failed.
14.4.5
REF Electrode
An operational leak check:
Visually verify there are no leaks from any part of the REF Electrode.
Is the base of the REF probe at ambient temperature during operation? The long SS tube,
housing the REF probe should be at ambient temperature from its base to within about two
inches of the SS cross cell. If YES it means that there is no leakage of sample water down the
SS tube internals. If NO then suspect leakage from the REF base and double-check. Resolve
the leak. Replace the probe if needed.
Verification checks on probe disassembly:
Follow the manual instructions for shut down (keep the NCSM under pressure as it cools below
180F).
Remove the electrode and wipe off any extraneous material from the Teflon tube and probe top
ceramic portion.
Has the probe physical appearance changed from expected?
Does the dark black/grey, silver/silver chloride tapered portion at the base of the electrode look
good? It might be a flaky, browning, and scabbed in appearance (as viewed through the Teflon
tube). While this REF might still work it is coming to the end of its useful life and a replacement is
needed.
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If the electrode looks OK it is always good practice to check its reference potential (as in the
refurbishing procedure) in this removed state.
o If bubbles have developed check the electrode as described in the manual
o Is the potential still about +90 mV during this check (must be at ambient temperature).
If not the electrode might be too hot, so wait a while. This is a check prior to refurbishing the
electrode for re-use.
Refurbish the REF probe
Probe Refurbishing:
When was the REF probe last refurbished? What were the test results? (+90 mV +/- 15 mV?)
If results were -90 mV +/- 15 mV suspect the wrong wiring configuration was used to check the
probe (see next).
During normal operation the NCSM cables are connected as follows. In this configuration the
reference electrode is connected to the negative terminal in the controller.
Cable connections for standard operation
NCSM Reference Electrode
NCSM Platinum ORP Electrode
When the potential of the newly refurbished electrode is to be measured against another known
reference standard, the cables should be connected as follows:
Cable connections for reference electrode check
186
Standard glass reference electrode
NCSM EPBRE Reference Electrode.
Is the porous ceramic junction, leaking electrolyte on refurbishing? Do a few drops of 0.1 N KCl
drip from the tip of the ceramic frit when mating the two portions of the electrode together?
YES OK
NO - Soak electrode tip in DIW - must have electrochemical continuity through the porous
ceramic junction. Replace the REF probe if this junction is plugged.
Refurbish the probe and test.- OK?
NO Refurbish again. If there are still issues replace.
A significant deviation from the desired (+90 mV +/- 15 mV, EPBRE versus glass, saturated KCL/
silver/silver chloride electrode supplied) could be a result of the following.
o The 0.1N KCl solution is bad not really 0.1 N KCl anymore. get new solutions.
o NCSM REF Electrode is going bad and might need to be refurbished at the factory (rechlorodize the silver). If the reference electrode is not abused it should last for over 5 years.
See physical appearance check above.
o Poor refurbishing procedure (e.g. bubbles in the electrode this tends to give open circuit
responses).
o Standard glass half-cell electrode has gone bad. It might no longer be filled with saturated
KCl. If the electrode is stored wet (in saturated KCl) it can last for years. The internal filling
solution can be replaced with the provided saturated KCl, also using the syringe, long SS
filling tube, and refilling hole in the side of the glass electrode, usually covered with a rubber
sleeve.
o Controller malfunction.
o Probes older than 5 years suggest replacing.

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14.4.6
ORP Probe Check
A standard multi-meter can be used to make sure that there is electrical continuity from the platinum
band to the ORP central BNC pin (once the ORP probe has been removed from the 3/8 cross). A dry
electrode should have no electrical continuity from the BNC central pin (of the ORP electrode) to any
other part of the electrode housing which is made of stainless steel.
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14.5
PID Troubleshooting
14.5.1
PID Troubleshooting Table
Problem
TRASAR PID
tuning
fails
NCSM PID tuning

fails
Possible Cause(s)
Solution
TRASAR signal did not

increase sufficiently during the
first step change of tuning.
Increase the step change pump output

value by 5% and/or the step duration by 5
min then repeat the tune.
Large variation in steam loads

caused variation in TRASAR
signal during tuning.
Repeat the tuning under steady steam load

conditions. If the system typically operates
with large steam load variation then repeat
the tune with larger step change pump
output %.
ORP values did not decrease

sufficiently during the step
change of the tuning.
Increase the step output value by 5% and/or

decrease the baseline output (some value
greater than 0%) and repeat the tuning.
Examine historical data and consider if
increasing the stroke length of the pump is
a suitable option. If so, increase the stroke
and repeat the tune.
TRASAR or NCSM
is oscillating under
PID control
No changes seen
in TRASAR or
NCSM during
tuning
Unable to start PID

control
188
Significant change in steam

load and operating conditions in
the boiler.
If steam load shift or operational change is

verified, then increase PB using the
Configurator making it less aggressive.
Drop in sample flow rate

through the skid. This can be
confirmed by looking for a
decreasing trend in sample
temperature flowing through the
NCSM probe
Adjust the sample flow rate. If desired flow

rate cannot be established increase PB
using the Configurator.
Pump may be in manual control

set at the pump
Ensure that the pump is under analog

control and connected to the analog output
(4 to 20 mA) from the controller
Pump might be air locked.

Chances are high if the pump
stroke is low (typically less than
25%)
Increase the stroke temporarily and attempt

to remove the air lock. Once pumping has
been established return the stroke to the
previous value.
There might be an alarm

condition that is restricting PID
control
If possible clear the alarm or wait for the

alarm to clear by itself and then PID control
will initiate automatically

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14.5.2
Interpreting and Troubleshooting Auto Tune Failure and Warning Messages
There are two types of messages appear at the end of an Auto Tune:
Warning
Failure
14.5.2.1
Warning Messages
Warnings are only meant to indicate that the Auto Tune log did not observe the recommended
conditions for a good tune. It indicates that though PID values were calculated, they may be less
than ideal for the system. The user can proceed with the calculated values and upload them after
understanding the warnings presented to them.
a. TRASAR Product Warning Messages
Figure 1. TRASAR Product Tuning steps
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Baseline Warning Messages:
All display on the first line Baseline data does not conform to recommendations. A more specific
message appears on the second line. Several warnings can be triggered at once.
6
80
TRASAR ppm
Pump %
70
Warning message data
60
Pump %
TRASAR ppm
50
40
30
2
20
1
10
2/28/08 16:12
2/28/08 16:19
2/28/08 16:26
2/28/08 16:33
2/28/08 16:40
2/28/08 16:48
2/28/08 16:55
2/28/08 17:02
2/28/08 17:09
Time
Baseline Zero TRASAR error: If the baseline pump output is >0% and the TRASAR is
reading <0.01ppm at the end of the baseline duration, this warning will be displayed. This
warning is meant to trap issues with the TRASAR feed pump.
Baseline not close to setpoint: If the TRASAR reading is less than 0.5 times the setpoint at
the end of the baseline duration, this warning will be issued. This warning is flagged simply
because the tuning works well when the captured TRASAR data is close to the desired
setpoint.
Step Data Warning Messages:

The first line of these messages will display Step data does not conform to recommendations. A
more specific message appears on the second line. Several warnings could be triggered at once.
6
80
TRASAR ppm
Pump %
70
5
60
4
Pump %
TRASAR ppm
50
40
30
2
20
1
10
0
2/28/08 16:12
0
2/28/08 16:19
2/28/08 16:26
2/28/08 16:33
2/28/08 16:40
2/28/08 16:48
2/28/08 16:55
2/28/08 17:02
2/28/08 17:09
Time
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b.
Step data not close to setpoint: This warning is issued if during the entire tuning process (all
three stages inclusive), the lowest TRASAR reading is higher than the setpoint or the highest
TRASAR reading is lower than the setpoint. This warning is meant to indicate that the tuning
did not occur close to the setpoint.
Step change delta not large enough: This warning is issued if the difference between the
highest and lowest recorded TRASAR value (step change delta) during tuning is less than
10% of the setpoint or 1ppm (whichever is larger). Therefore if the TRASAR setpoint is
10ppm or less, a minimum step change delta of 1ppm is desired. If the TRASAR setpoint is
larger than 10ppm, a minimum step change delta of (0.1x setpoint) is desired.
NCSM Warning Messages
Figure 2. NCSM tuning steps
Baseline Warning Messages:

There is only a single baseline warning message. It displays Baseline data doesnt conform to
recommendations -baseline data should be higher than setpoint. This warning indicates that the
NCSM values during the baseline duration were more negative than the setpoint. For NCSM
tuning, the baseline NCSM value should ideally be more positive (higher) than the setpoint.
NCSM tuning works well when the tuning is initiated (baseline duration) higher/more positive than
the setpoint.
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60
-200
-210
50
-220
-230
40
Pump %
-240
30
-250
Pump %
AT ORP
-260
20
-270
-280
10
-290
0
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
-300
45.00
Time (minutes)
Step Data Warning Messages:

The first line will display Step data does not conform to recommendations. The next line will
display more specific messages:
Step data not close to setpoint: This warning is flagged if the highest NCSM value during
tuning is less than the setpoint or the lowest NCSM value is higher than the setpoint. The is
to check that during the tuning process, NCSM started at some value higher than the setpoint
and ended at some value lower than the setpoint.
Step change delta not large enough: This warning is flagged if the difference between the
highest and lowest NCSM values during a tune is less than 10mV. It is desired that the step
change delta be around 30-50mV for a good tune.
60
-200
-210
50
-220
-230
40
Pump %
-240
30
-250
Pump %
AT ORP
-260
20
-270
-280
10
-290
0
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
-300
45.00
Time (minutes)
c. Autotuning PID Loop Model Fit Is Poor!:

This error appears when the Configurator tries to fit the data to the model to calculate PID
parameters. This error typically indicates that there was a lot of noise or fluctuation during the tuning
process. If such fluctuation is unavoidable then the user can go ahead and use the calculated PID
settings. Performing the tune again in similar conditions will bring up the warning again.
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14.5.2.2
Failure Messages
Failures indicate that either the tuning process or the data fitting did not proceed correctly.
a. Tuning-Related Failure:
Failure in the tuning process occurs when the measured values (TRASAR or NCSM) did not move in
the expected direction.
The expected change in TRASAR is that the values should increase when pump speed increases.
The expected change in NCSM is that the values should decrease when pump speed increases. The
opposite change is expected when the pump speed decreases. Failures in the tuning process are
usually associated with pump setup, product feed configuration and/or product sampling
configuration.
The best way to overcome tuning-related failures is to understand the typical variation in
TRASAR/NCSM due to feedwater or other fluctuations in the system. This can be done for TRASAR
by holding the pump output constant and watching the variation in TRASAR at the constant pump
speed. The step output should be chosen such that the TRASAR will change much larger than (say
3X) times the typical variation. For e.g., if the typical TRASAR variation under constant pump speed is
+/- 2 ppm then a step change delta of 6-10 ppm would be ideal.
b.
Data Fitting-Related Failure:
If the graph shows that the TRASAR or NCSM change as expected, then the possibility of improper
data fitting must be checked as explained below.
To resolve data-fitting failures, an advanced user needs to know more about the system and how that
relates to the data fitting method used.
The data model used for fitting the data is a simple First-Order-Plus-Dead-Time (FOPDT) model. This
fits three parameters K, Tau and Theta. An initial set of K, Tau and Theta is used to converge to the
actual parameters that best fit the data. The errors indicate which parameter does not give the
expected value.
K and Tau are difficult to interpret for a system. However, the Theta value can be validated by an
advanced user. The estimated Theta is close to the system dead time measured in minutes. The
system dead time is defined as the required to see the first response to a change in control action. In
the example shown below, a pump was turned off and the TRASAR values started to drop 6 minutes
later. The dead time is about 6 minutes and if a tuning was done on this system, the calculated Theta
will be close to this value.
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There are failure messages that could appear:
"Auto-Tuning PID loop failed (Invalid K)! Usually indicates that TRASAR or NCSM did
not move in the desired direction. Calculated K is positive for TRASAR and negative for
NCSM
"Auto-Tuning PID loop failed (Invalid Tau)! Must be positive
"Auto-Tuning PID loop failed (Invalid Theta)! Must be positive. Will typically be close to
the dead time measured in minutes
Example for troubleshooting a failure caused by data-fitting

In this example, the plot for the tuning data looks normal but the following error appeared.
Click on Advanced Fit to see the data fitting options

The left side of the form displays the initial values used for the curve fitting and various fit para meters.
In this screenshot, K, Theta and Tau are the initial values used in the fit. The calculated values are to
the right and represent the regression or fitted parameters for the system being tuned. The PB, Ti and
Td values are calculated from the fitted values.
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In the above screenshot, the Theta calculated turned out to be negative after the initial data fit
attempt. The dead time cannot be negative and hence the fitting failure.
In this case, trial and error with various initial value parameters were made that still caused the same
error. Every time an initial parameter is changed, clicking on Calculate will attempt the fit again.
195

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A smaller K, Theta or Tau Step Size increases the accuracy of the fitting. A larger value for Max
Iterations also increases the accuracy of the fitting. Since the error was in the calculated Theta,
decreasing the Theta Step Size to 0.0001 increases the accuracy of the Theta calculation. After
changing the value click on Calculate. This time, no errors appear and the calculated PID values
can be uploaded.
In this example, the actual dead time observed from the tuning graph is about 1 minute. This matche s
the calculated Theta of 1.01 minutes when the fit worked without errors.
196

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14.6
Blowdown Control Troubleshooting
Blowdown Conductivity Alarms

Alarm Type
High Alert
High Failsafe
Low Alert
Low Failsafe
Sensor Error
Relay Timeout
Analog Output
Timeout
Indication
Cause
Corrective Action
Blowdown rate too low
Adjust flow control valve.
Blowdown Decision Interval too

long
Shorten Decision Interval
Maximum Valve On Time % is

too small
Increase Maximum Valve On Time %.
Output Max. %.or Max. Change

% too low (PID Control)
Increase Output Max. %.or Max.

Change %

calibration, fouled or faulty
Clean and recalibrate if needed.

Replace if faulty
Incorrect temperature used for

conductivity standard or boiler.
Check/correct boiler temperature input.

Recalibrate probe using correct
temperature of standards.
Blowdown rate too high
Adjust flow control valve.
Blowdown rate too high for

Continuous Sampling (On/Off or
PID Control)
Switch plumbing and control to TimedSample Control
Blowdown Decision Interval too

short
Lengthen Decision Interval
Maximum Valve On Time % is

too great
Decrease Maximum Valve On Time %.
Output Max. %.or Max. Change

% too high (PID Control)
Decrease Output Max. %.or Max.

Change %

calibration, fouled or faulty
Clean and recalibrate if needed.

Replace if faulty
Incorrect temperature used for

conductivity standard or boiler.
Check/correct boiler temperature input.

Recalibrate probe using correct
temperature of standards.
Error detected
with indicated
sensor probe
Wiring or other connection is

loose.
Retighten wires. Make sure insulation is

not impeding electrical contact
Probe failure
Replace probe
Duty cycle for

relay or analog
output exceeds
alarm limit for
the Timeout
period.
Timeout period set too short
Increase Timeout period
Relay timeout limit/duty cycle set

too low
Readjust alarm threshold/duty cycle
Blowdown rate too low for

demand
See High Alert & High Failsafe
Measurement
exceeds High
Alarm threshold
Measurement
below Low
Alarm threshold
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Blowdown Conductivity General Troubleshooting

Problem
Possible Cause(s)
Erratic or
Questionable
Probe Response
Faulty electrical connection(s) or

incorrectly wired probes
Solution
Be sure the jumpers are installed in the J-box
(not inside the controller).
Check to be sure 4 wires are used for each
conductivity signal and each RTD signal.
Verify the probe cables are attached to the
correct terminals in the controller and J-box.
Check the probe wire itself. Is it minimum 22
AWG shielded cable (each pair shielded)?
Perform a continuity test on the wiring
connections.
Replace defective connectors or wires.
198
Probe response/readings are not in a

normal operating range, or are erratic.
Recalibrate probe (2-point and 1-point). Be

sure an acceptable pair of conductivity
standard is used.
Be sure the expected sample conductivity is
between the high and low conductivity
standards.
Make sure no air bubbles are trapped in probe
during calibration.
Make sure line is flushed for Flush Time
before sampling for 1-point calibration.
Bad or missing Earth Ground connection.
Check all electrical connections from the plant

power supply. Verify the controller has a
good Earth Ground.
Plumbing has restrictions or wide spots

ahead of the probe where flashing can
occur.
Pipe elbow closer than 1-ft upstream of
probe.
Correct plumbing (See Installation Diagrams)

Used Timed Sample - Proportional Control
and enable Sample Trap
Probe is installed in a 1 or larger pipe

cross using a reducer. Probe is not fully
immersed.
Replace pipe cross with cross. Reduce

piping at cross inlet.
Hole in probe not aligned with sample flow.
Correct probe alignment
Cross with probe at high spot in piping

where probe is not fully immersed.
Install a downstream jog in the piping above

the height of the probe.
Probe not reaching equilibrium during

sampling
Increase Flush Time.
Flow control valve open too wide, causing

flashing.
Reduce flow control valve opening.
Probe installed on vertical piping section.
Move probe to horizontal piping section.

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14.7
Feedwater Conductivity Troubleshooting
199

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14.8
200
Blowdown Conductivity Troubleshooting

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15.0
Specifications
The 3D TRASAR boiler systems consist of a number of modules. The modules are factoryassembled on either wall mountable back plate or on a free-standing frame. This modular design
provides a broad range of monitoring and control capabilities.
Note:
The systems sample temperature, pressure and flow limits are defined by the lowest limit
of any module included in the system.
NCSM Module:
Maximum Pressure:
Maximum Temperature:
Accuracy:
Sample Flow:
Inlet/Outlet Connection:
Wetted Materials:
Sensor Protection:
Indoor Model:
Enclosed Model:
Mounting Holes:
Cable with signal booster:
2800 psi (193 bar)

500 F (260 C)
1 mV
250-500 ml/min
SS tubing
316 SS, Teflon, Zirconia, Platinum, PEEK
Lexan shield
Vented SS enclosure
7/16 diameter
Ambient Conditions:40F (4C) to 140F (60C)
Note: Allow at least 8-10 inches below the NCSM sensor for servicing the reference electrode.
Fluorometer Module:
TRASAR Chemistry Measured:
Limit of Quantification:
Lower Detection Limit:
Upper Measurement Limit:
Sample Temperature Limit:
TRASAR #3
0.05 ppb as T3 (0.2 ppm if Product Factor is 40)
0.013 ppb as T3 (0.053 ppm if Product Factor is 40)
150 ppb as T3 (600 ppm if Product Factor is 40)
40-120F (4-50C)
Blowdown Relay Module:

Relays:
Power Requirements:
Enclosure:
4 (SPDT) relays, group fused at 10 amps

115 VAC/60Hz or 220 VAC/50 Hz (model specific)
NEMA 4X
Analog Input Module

Electrical Power:
24 VDC Power Source:
Enclosure:
120 VAC, 60 Hz, 5 Amps or 220 VAC 50 Hz, 5 Amps (model specific),
with 6 ft (2m) 3-prong power cord
+24 VDC @ 500 mA (maximum draw) regulated power source
Nema 4X
Feedwater pH & Conductivity Modules

High Purity Feedwater Module:
Low Purity Feedwater Module:
Samples with conductivity < 100 S/cm

Samples with conductivity >100 S/cm
pH Probe (High Purity):

Max. Pressure:
Max. Temperature:
Accuracy:
Electrode Mounting:
Electrode Cable:
Applications:
50 psi (3.4 bar)

167F (75C)
0.05 pH
1 ( install in1 FNPT cross w/1 tube to NPT adapter)
2-wire, 4-ft (1.2 m)
Samples with 1-10,000 S/cm conductivity
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pH Probe (Low Purity):

Max. Pressure:
Max. Temperature:
Accuracy
Electrode Mounting:
Electrode Cable:
Applications:
150 psi (10.3 bar)

230F (110C)
0.05 pH
3/4 ( install in a FNPT cross)
2-wire, 6-ft (2 m)
Samples with 100 10,000 S/cm conductivity
Conductivity Probe (Blowdown & Condensate):

Max. Pressure:
Max. Temperature:
Electrode Mounting:
Electrode Cable:
Electrode Leads:
Temperature Compensation:
Accuracy:
0-9.99 S/cm:
10-10,000 S/cm:
Range:
Blowdown probe:
Condensate probe:
250 psi (17.2 bar)

392F (200C)
MNPT, install in FNPT cross
4-conductor, shielded, 22 AWG min (probe with TC, 8-conductor).
Teflon coated, 8 (0.2 m)
Optional
20%
5%
5-10,000 S/cm
1-500 S/cm
Conductivity Probe (Feedwater):

Max. Pressure:
Max. Temperature:
Electrode Mounting:
Electrode Cable:
Electrode Leads:
Accuracy:
0-9.99 S/cm:
10-10,000 S/cm:
Range:
Low purity feedwater probe:
High purity feedwater probe:
200 psi (13.8 bar)

158F (70C)
MNPT, install in FNPT tee
4-conductor, shielded, 22 AWG min.
PVC coated, 48 (1.2 m)
20%
5%
5-10,000 S/cm
1-500 S/cm
NCM100 Probe:
Max. Pressure:
Min. Temperature:
Max. Temperature:
Max. pH:
Min. Conductivity:
Accuracy:
0.1 10 mpy
10 99,9 mpy
Probe Mounting:
Probe Cable:
202
1000 psi (69 bar)

200F (93C)
250F (121C)
10.8
5 S/cm
15%
50%
compression fitting, install in 1 FNPT tee or process pipe
6 ft (2 m)

OM0211_________________________________________________________________________

High Pressure/High Temperature Feedwater System
Maximum Pressure:
1500 psi (103 bar)
500 F (260 C)
Sample Flow:
250-1000 ml/min
Low Pressure/Low Temperature Feedwater System
Maximum Pressure:
50 psi (3.4 bar)
250 F (122C)
Sample Flow:
250-1000 ml/min
High Pressure/High Temperature Blowdown System
Maximum Pressure:
1500 psi (103 bar)
500 F (260 C)
Sample Flow:
250-1000 ml/min
Cooling-Depressurizing System
Maximum Pressure:
2800 psi (193 bar)
500 F (260 C)
Sample Flow:
250-500 cc/min
Note:
Use only for cooling and depressurizing the sample before discharging it directly to a suitable
drain. DO NOT install upstream of instrumentation.
All Sample Conditioning Systems

Inlet Connection:
SS tubing
Outlet Connection:
MNPT
Wetted Materials:
316 SS, Teflon, Acrylic, PVC, Polyethylene, Nylon, Polypropylene, Viton
Note: Blowdown Sample Conditioning Systems have 2 sample coolers plumbed in series.
203

OM0211
Condensate Monitor System:

Maximum Pressure:
Minimum Temperature:
Sample Flow:
Sample Inlet Connection:
Sample Outlet Connection:
Cooling Water Connections:
Wetted Materials:
Note:
50 psi (3.4 bar)

200F (93C) only if model with optional NCM100 is ordered
250 F (122C)
250-1000 ml/min
SS tubing
FNPT
FNPT
316 SS, Teflon, Viton
Sample must be cooled to below 158F (70C) downstream of the sample cooler (included).
Condensate Monitor Frame mount model with optional NCM shown.
204

OM0211_________________________________________________________________________
3D TRASAR Controller
Electrical Power
100240 VAC, 50/60 Hz, 12 Amps
(4) Analog Inputs
Non-isolated,16 bit resolution (0-20 mA) or (0 to 10 Volt) inputs. Each input type is individually
settable (4-20 mA or 0-10 volts operation) via dipswitch configuration. For voltage inputs, the input
impedance is 100 K ohms. Inputs are protected against +24 VDC (or less) direct connection.
(1) Interlock (dedicated)
Dry contact (open/close) contact input. (All digital inputs can be used as interlocks)
(4) Digital Inputs
Each digital input will be capable of reading (and scaling) an open contact to ground (snap-acting),
contact closure device (mechanical water meter action) or open collector NPN transistor/FET (5mA
sink, 24 VDC, signal to ground). The minimum on-time and off-time pulse width is 5 milliseconds for
a valid pulse. The maximum number of pulse counts is 50 per second.
(2) pH/ORP Inputs
Each input is a two-wire, individually isolated, high impedance input. The inputs are used to measure
two-wire ORP or pH probes (firmware selectable). The pH measurement range is 0-14 (and can be
temperature compensated). The ORP measurement range is +/- 1000 millivolts (and is not
temperature compensated).
(6) Contacting Conductivity Inputs
Group isolated, 4-wire, contacting head type input type. The conductivity measurement range is 0 to
20,000 S/cm. Each of the inputs can be temperature compensated (user selectable). There are two
contacting probe head types supported (cell constant of 0.1 for conductivity < 10 S/cm; cell constant
of 1.0 for conductivity > 10 S/cm).
(3) Temperature (RTD) Inputs
Non-isolated, 4-wire, 1000 ohm, platinum RTD input types. The measurement range is 32 to 800 F
(0 to 427 C).
(1) NCM100 Corrosion Input
Isolated, NCM100 type corrosion probe input type.
Outputs
(5) Control Relays
Mechanical Form A (SPST) relays rated at 250 VAC and fused at 2.5 amps. Can be (jumper wire)
configured for powered or non-powered contact operation.
(1) Alarm Relay
Mechanical Form C (SPDT) relay rated at 250 VAC and fused at 1.0 amps.
(8) Analog Outputs
Non-isolated, self-powered, 4-20 mA analog outputs. Each 4-20 mA output will provide 12-bit
resolution and be capable of driving up to 600 ohms.
(1) 24 VDC Regulated (User) Power Source
+24 VDC @ 500 mA (maximum draw) regulated power source
205

OM0211
Enclosure
Nema 4X
Ambient temperature
40-120F (4-50C)
Relative Humidity
0-95% non-condensing
Display/Keypad
Numeric keypad plus specialty keys, graphical display with plotting functions
Security
Password protected (user assignable)
Communications
(2) Fluorometer Inputs
Modbus RTU, RS-485 slave connections. +6VDC, 500 mA user power supply.
(1) SCADA Input
Modbus RTU, RS-232 or RS-485 master connection.
(2) Ethernet ports for direct PC connection, network or wireless gateway
USB memory stick (approved devices only)
Built-in modem for direct remote connection or access to 3D TRASAR Web via Internet (requires ISP)
Optional Nalco Global Gateway with monthly service package gateway.
Approvals
CE, UL (pending), CUL (pending)
Software
3D TRASAR Configurator for system configuration and data transfer

Optional Vantage 100 SPC Software for comprehensive data management and analysis.
Systems Dimensions
Wall Mount Controller & Sensor Panel:
Dimensions:
12 D x 33 W x 42 H (31 cm x 84 cm x 107 cm)
Material:
PVC back panel
Mounting Holes:
7/16 diameter
Dimensions:
8 D x 33 W x 22 H (21 cm x 84 cm x 56 cm)
Material:
PVC back panel
Mounting Holes:
7/16 diameter
Frame Mounted System:
Dimensions:
Material:
Note:
206
29 D x 33 W x 66 H (74 cm x 84 cm x 168 cm)

PVC back panel on SS frame
The Sample Conditioning System must be field-mounted 1-1/2 (3.8 cm) below the Control
and Sensor Panel for all Wall Mount installations.

OM0211_________________________________________________________________________
16
Replacement Parts and Accessories
Part Number
6035385
6035386
6035384
6034004
060-BT3220.88
060-BT3221.88
991-05058542.88
991-05058543.88
6035381
060-TR5411.88
Part Number
991-05061451.88
991-05061321.88
991-P01141.88
991-C00745.88
991-05059701.88
991-05048871.88
991-19699314.88
060-TR5222.88 *
060-TR5223.88 *
991-05061051.88
991-05061055.88*
991-05061056.88
991-05061057.88
991-05061711.88
991-05061713.88
991-05061712.88
991-05061715.88 *
991-05061714.88
991-05043142.88
991-05060101.88
991-19432523.88 *
991-50554318.88 *
6037161
991-50588212.88
6037162
991-05061373.88
991-05061053.88 *
991-05043242.88
991-01970443.88
991-05059831.88
500-531062.88
991-01868611.88
6009052
Replacement Probes
Description
Conductivity, low purity feedwater, replacement probe only
Conductivity, high purity feedwater, replacement probe only
Conductivity, blowdown, replacement probe only
Conductivity, blowdown, compensating, replacement probe only
Fluorometer only (feed water)
Fluorometer only (blowdown)
NCSM ORP/RTD Replacement probe only
NCSM Reference probe
pH Replacement probe only, high-purity
pH Replacement probe only, low-purity
Spares & Replacement Parts
Description
Bracket, SS (SCS 10" PP filter)
Bracket, SS (SCS flow meter)
Clamp, pipe, 1/4" OD, SS (C-plate only)
Clamp, pipe, 1/4", black-PA (body only)
Clamp, tube, 1/4"OD, alum/SS (complete)
Clamp, tube, 1/4"OD, blue-PP/SS (complete)
Cross, SS, 1/4, FPT, 150# (SCS)
Desiccant canister (fluorometer)
Desiccant indicator (fluorometer)
Filter housing, PP, 10 (SCS)
Filter, 5 micron, PP, 10 (SCS)
Filter housing, PP, 5 (SCS-optional)
Filter, 5 micron, PP, 5 (SCS-optional)
Filter complete, 200 m, SS, 2800 psi, (feedwater)
Filter complete, 200 m, SS, 2800 psi, (blowdown)
Filter, element, 40 micron, SS, 2-1/4 (feedwater)
Filter, element, 200 micron, SS, 2-1/4 (feedwater)
Filter, element, 200 micron, SS, 3-1/4 (blowdown)
Flow meter, 100-1500 cc/min
Flow switch
Fuse, 10 A, 250V SLO-BLO (main fuse)
Fuse, 2.5 A, 250V (output relay fuse)
Gauge, pressure gauge, 0-100 psi (SCS)
Gauge, pressure gauge, 0-2000 psi (NCSM)
Gauge, pressure gauge, 0-3000 psi (NCSM)
Hose, braided, SS, T x 12 LG (NCSM to SCS)
O-Ring, PP filter
Pressure regulator (SCS)
RTD adapter, 1/8 OD tubing x MNPT, (SCS)
RTD (SCS) (Requires adapter 991-01970443.88)
Sample cooler, 1ft 2
Union, PVC, Soc (for SCS)
Valve, ball, PVC, , FNPT, Viton, T-port (fluorometer outlet)
207

OM0211
991-05045141.88
6036191
991-05043791.88
991-05060031.88
991-01841381
991-05043157.88
991-05043151.88
991-05043155.88
991-50431511.88
991-05043156.88
991-50431510.88
991-05061052.88
Part Number
6037008
6034335 *
6026028 *
6033766 *
6018909 **
6018911 *
6018912
6018913
6018914
6018930 *
6018931
6031275
6031276
Part Number
500-BTSRKIT.88 **
460-S0980.75 *
460-S0726.75
500-P2817.88
500-P0116.88
500-P2147.88 *
500-BTSRKITLA.88
208
Spares & Replacement Parts

Valve, ball, SS, (SCS sample tap)
Valve, ball, SS, PEEK (SCS SS filter)
Valve, labcock, PVC, FPT, EPDM, (fluorometer inlet)
Valve, needle valve, SS,
Valve, relief valve, SS
Valve, solenoid, 3000 psi, 120VAC
Wrench, PP filter
NCSM Parts and Accessories
Description
Junction box (for remote NCSM)
Battery, NCSM pre-amp cable
Insulation wrap, ceramic, 2 x 50' (1 roll supplied with NCSM)
NCSM Calibrator
NCSM Accessory Kit, complete includes parts listed below
10 cc plastic syringe
Special 14 SS hypodermic needle
Electrode, cell, with BNC, for calibration (sat. KCl, Ag/AgCl)
High-vacuum grease, 5.3 oz tube
0.1 N KCl Refill solution, 250 ml bottle
3.8 M KCl Test solution, 250 ml bottle
BNC BA80 Adapter
Cotton tip grease applicators (10/pkg)
Fluorometer Parts and Accessories
Description
3D TRASAR Boiler Startup Kit includes the parts listed below
TRASAR 3 Calibration solution, 1L bottle
Hydrochloric Acid, 1:1, 1L bottle
Flow cell brush, 16
3D TRASAR Boiler Startup Kit, less acid

OM0211_________________________________________________________________________
Part Number
6026390
6031277
991-05058545.88
6035382
060-TR5412.88
060-TR0001.88
991-03509170.88
6036776
6033734
6033777
991-05047661.88
060-TR5221.88
060-BT3230.88
991-05053481.88
991-01928722.88
Cables
Description
Cable, 6 ft, NCSM, REF, stripped & tinned
Cable, 6 ft, NCSM, REF, w/pre-amp, stripped & tinned
Cable, 6 ft, NCSM, RTD
Cable, 4 ft, pH, high purity
Cable, 6 ft, pH, low purity
Cable adapter, USB to RS232
Cable, 2-conductor, 20 AWG, shielded, for 4-20mA pumps (per ft)
Cable, 2-pair, 22 AWG, shielded, for conductivity probes. (per ft)
Cable, 3-pair, 22 AWG, shielded, for remote NCSM (per ft)
Cable, 4-pair, 22 AWG, shielded, for conductivity with RTD (per ft)
Ethernet crossover cable, 6 (2m), orange
Fluorometer cable, 4 ft. (1.2m)
Fluorometer cable, 10 ft. (3m)
Pigtail, 16/3 SJOW, 18 w/US plug
Service cord, 12/3 SJOW (no termination) 8ft (2.4m)
Part Number
6042711
6042712
6039829
6039830
060-BT8000.88
060-BT8002.88
060-HCP100.88
060-LCP100.88
060-BCP100.88
041-HPT1000.88
041-LPT1000.88
041-HPT2000.88
041-LPT2000.88
041-CD0100.88
060-TR5270.88
060-TLM100.88
6036362
060-NGG100.88
060-NGG200.88
6043721
6043722
6043723
160VTG100
6043593*
Optional Accessories
Description
Sample Quill, 4Quill, 304SS, FNPT
Sample Quill, 6 Quill, 304SS, FNPT
Sample Quill, 4 Quill, 304SS, Socket Weld
Sample Quill, 6 Quill, 304SS, Socket Weld
Analog Input Module, 8-input, 120VAC/60Hz
Analog Input Module, 8-input, 230VAC/50Hz
Feedwater conductivity & pH module, high-purity (Cond < 500 S/cm)
Feedwater conductivity & pH module, low-purity (Cond > 500 S/cm)
Condensate conductivity probe w/RTD assy., complete, SS/blk iron
Sample conditioning system, 1500 psi, 500F, 120VAC/60Hz
Cooling-Depressurizing System, 3000 psi (post instrument)
LAN router
Tank Level Monitor (probe)
Tubing, OD SS, pre-insulated (100ft roll)
Wireless Gateway with US plan
Wireless Gateway with Europe and Asia-Pacific plan
Valve, 3-way, Motorized, SS,
Valve, 3-way, Motorized, SS,
Valve, 3-way, Motorized, SS, 1-
Vantage V100
Voltage Tester (for 3-prong input power receptacle)
209

OM0211
Part Number
060-BDRB04.88
060-BDRBE4.88
060-BDP100.88
060-BDP100C.88
991-BDPJBOX.88
041-BLR012.88
041-BLR034.88
041-BLR100.88
041-BLR006.88
041-BLR007.88
041-BLR010.88
041-BLR008.88
041-BLR009.88
041-BLR110.88
991-19070215.88
Blowdown Control Accessories

Description
Relay box, 4-relay, 120VAC/60Hz
Relay box, 4-relay, 230VAC/50Hz
Blowdown conductivity probe assembly, complete, SS/black iron
Blowdown conductivity probe w/RTD assy., complete, SS/black iron
J-Box (for Blowdown or Condensate probe)
Blowdown control & flow valve (w/ indicating scale) package,
Blowdown control & flow valve (w/ indicating scale) package,
Blowdown control & flow valve (w/ indicating scale) package,1
Motorized valve, SS, , 120 VAC/60 Hz
Motorized valve, SS, , 120 VAC/60 Hz
Motorized valve, SS,1, 120 VAC/60 Hz
Flow control valve (w/ indicating scale), "
Flow control valve (w/ indicating scale),
Flow control valve (w/ indicating scale), 1
Reducing coupling, 1 FNPT x FNPT, black iron
001-H07641.88 **
001-H07642.88 **
460-S0297.75 **
460-S0298.75 **
460-S0743.75 **
460-S0299.75 **
460-S0408.75 **
460-S0407.75 **
Conductivity and pH Standard Solutions

Conductivty standard solution, 10,000 S/cm, 500 mL
Conductivty standard solution, 5000 S/cm, 500 mL
Conductivty standard solution, 3000 S/cm, 1L
pH standard solution, pH 10 buffer, 1L
pH standard solution, pH 7 buffer, 1L
400-NCMP6.88
400-NCMA11.88
400-NCMA12.88
400-NCMA13.88
400-NCMA14.88
500-P6113.88
500-P6116.88
Boiler NCM100 Probe and Accessories

Boiler NCM100 probe assembly w/ 3/4 compression fitting
Boiler NCM100 probe tee (1 x 3/8)
Boiler NCM100 probe reducer (1 x 3/4)
Boiler NCM100 probe housing kit (tee and reducer)
Boiler NCM100 probe cable (6 ft)
Boiler NCM100 probe O-ring (ea)
Boiler NCM100 probe MS tips (2 ea)
Notes: * Recommended spare part

** Needed for Fluorometer, NCSM or conductivity calibration. Add to initial system order.
210

OM0211_________________________________________________________________________
17
Warranty
Nalco Global Equipment Solutions warrants its standard equipment and related installation services
to the original purchaser to be free of defects in material or workmanship for one year from the date of
shipment, unless otherwise specified.
Key Features Include:
Simplified claims processing-warranty assistance is just a toll free call away. Most claims can
be handled by making a single phone call
12-month coverage of all standard part-numbered Nalco equipment offerings (excepting
consumable items and products with shelf lives of less than 12 months.
12-month coverage of Nalco equipment installation.
Repair and on-site warranty assistance now available in selected areas .
Limitations:
Warranty does not cover damage caused by misuse, neglect, accident (including a force majeure
event), improper installation or improper maintenance or repair. Nalcos liability under this warranty is
limited to repair or replacement of defective items, or, refund of or credit for the product price
excluding shipping.
Nalco DISCLAIMS ALL OTHER WARRANTIES INCLUDING WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. In no event shall Nalco be
liable for any consequential or indirect damages.
Non-Warranty Equipment Returns

If you wish to return a standard, part-numbered Nalco Equipment Solutions product for credit or
repair, please follow the guidelines below:
Credit: Products purchased from Equipment Solutions may be returned for credit within three (3)
months of purchase if they have never been placed in service and they are returned in the original
packaging complete with all accessories, component with all accessories, component parts, and
manuals.
Repairs: Products eligible for billable repair include standard items that were purchased within the
past five (5) years.
18
Responsibility for Safe Delivery
Nalco Company has done everything possible to protect this equipment from damage due to normal
transportation hazards. After the product leaves the manufacturing site, the transportation company
assumes the responsibility for safe handling and delivery of the equipment.
If the crated unit shows evidence of rough handling, you must request that the person making the
delivery writes Received in Damaged Condition on the delivery receipt. If concealed damage is
revealed after the shipment is unpacked, contact that transportation company and request that a
Damaged Goods report be completed.
In either event, the transportation company should be notified immediately of any damage to the
shipment to protect your rights of recover.
211

OM0211
APPENDIX A
1
1.1
Scale Control using 3D TRASAR Boiler Automation
Boiler Scale Control Application Fit for Automated Control

Practical Limits for Scale Control Using 3D TRASAR Boiler Automation
For any steam generating system where the water fed to the boiler(s) contains minerals, the use of a
scale control treatment is needed to minimize the accumulation of unwanted and insulative scale
within the boiler internal heat transfer surfaces. Scale control is applicable anytime the total acid
hardness of the boiler feedwater is greater than 10 ppb as CaCO3. Steam generating systems with
high purity demineralized makeup water and high quality returned condensate below this 10 ppb limit,
are not specifically treated to prevent scale.
In general, the higher operating pressure of a boiler system, the higher purity/quality of boiler
feedwater required to be fed to the boiler. Most professional and industrial standards including
Nalcos Best Practice standards call for boilers operating above 1000 psig or 69 bar to have nondetectable amounts of hardness in the boiler feedwater. This means that most boilers requiring scale
control actually operate at pressures at or below 1000 psig or 69 bar.
Practical Application Limits for Scale Control Applications Using 3D TRASAR for Boiler Automation*
MAXIMUM BOILER PRESSURE = 1000 psig or 69 bar
FEEDWATER TOTAL ACID HARDNESS >= 10 ppb as CaCO3
* Contact the TRC if you have scale control applications beyond these limits
1.2
Scale Problems in Steam Generation
As the bulk water concentrates near a heat transfer surface due to the formation of high-purity steam
vapor, it is possible for the scale species to exceed its solubility limit at the boiler system
temperatures and to form scale. This scale is typically quite insulating compared to the mild steel
construction of the boiler system. If enough scale forms in a high-heat transfer area, it is possible
that the metal temperature can rise so high as to weaken and lead to the failure of the boiler tube
itself. Standard practices, regulatory clearances, and boiler insurance companies can dictate that a
boiler be chemically cleaned if too much scale accumulates. This boiler cleaning is typically costly
and time consuming and is never welcomed by a Nalco customer. Even if scale accumulation is not
great enough for a boiler tube failure or the threat/need of a boiler cleaning, the visual appearance of
a dirty or scaled boiler during the annual boiler inspection provides un-wanted stress in the
relationship between a customer and Nalco. On the other hand, a clean non-scaled boiler
appearance on the inspection can provide great good will and confidence in Nalcos continued
service of the account.
Although far less prevalent today than thirty years ago, the accumulation of boiler scale can even
impact boiler fuel efficiency. For fire-tube boilers running a precipitating program (coagulation),
significant scale can accumulate that actual fuel energy is wasted up the stack (higher stack exhaust
temperature). In water-tube boiler systems or fire-tube boiler systems running all-polymer, chelate,
clean residual phosphate with polymer dispersant, localized scale is not sufficient to alter the overall
heat balance nor lead to noticed lack of boiler efficiency (higher stack temperatures not noted). For
more details on Scale Control please refer to the PAC-2 Boiler Water Technical Manual.
1.3
Required Dosage of Treatment is Determined by Amount of Scaling Species in

the Feedwater
All of Nalcos scale control boiler treatment programs are based on feeding the product at a specified
and recommended concentration based on the amount of scaling species in the boiler feedwater. A
greater amount of scale in the water means greater stress on the boiler system regarding the
potential for scale formation on the boiler internal heat transfer surfaces.
212

OM0211_________________________________________________________________________
Every Nalco boiler scale control program has a recommended dosage based on the feedwater
concentration of these scaling species (calcium/magnesium hardness and in some cases the amount
of silica). You can find this recommended dosage in the Nalco Product Confidential Product Profile
(CPP).
The Nalco field sales/service representative must decide what is an appropriate concentration of
scale content to base the dosage calculation on. Many Nalco reps. use the average concentration
measured (via sample submission to Nalco or by on-site analysis) to base their dosage on. In other
cases where there is significant variation in the scale species. The Nalco rep. may target the average
plus either one or two times the standard deviation of the measured values.
The amount of scaling species in the boiler feedwater may not be constant over time. It is important
that the customer and Nalco representative monitor and look for changes in the amount of scaling
species as part of their routine boiler system monitoring (grab samples). Changes in the mechanical
steam generating system as well as within the operation of the boilers can lead to variation in these
contaminants over weeks, months, seasons, or even years. The optimum dosage for a Nalco scale
control treatment should be revisited and checked periodically based on review of the measured
scaling species concentration data (hardness and silica) collected.
1.4
Test Method for Scale (Hardness) Content in the Feedwater
When measuring the amount of scaling species in the feedwater for determination of target treatment
dosage, it is important to remember what the detection limit is for the method that you are using. Just
because the test reads ZERO, does not mean that there is no hardness in the water. Note the
detection limits of some typically used field methods for hardness
Method for Measuring Hardness
Nalco drop wise bottle titration method AP-044
Nalco DR based standard hardness AP-043
Best burette titration method
Nalco Ultra Low Level method AP-067
Detection Limit
1.000 ppm as CaCO3
0.500 ppm as CaCO3
0.100 ppm as CaCO3
0.013 ppm as CaCO3
If the method used is frequently recording ZERO, then using a method with a lower detection limit is
suggested. For the purposes of determining a target dosage of scale control treatment, a value equal
to the analytical methods detection limit (not ZERO) should be used when determining the average
and standard deviation for the hardness concentration.
1.5
Treatment Programs Applicable Using 3D TRASAR Boiler Automation
This manual is NOT designed to help the reader to chose or recommend a particular scale control
treatment. That topic is well covered in PAC-2 Boiler Water Technical Manual and the Confidential
Product Profiles for PAC2B treatments. However, for 3D TRASAR Boiler automation for scale control
to be possible, the treatment product must include Nalcos TRASAR 3 dye/technology. Under the
standard product naming convention, if the THIRD digit of the product number is a 3, the product
contains Nalco TRASAR 3.
Example: NALCO W X 3 Y Z would contain TRASAR 3 inert boiler tracer
NEXGUARD 2 2 3 1 0 does contain TRASAR 3
Nalco makes available a broad line of treatment products (2B internal) that contain the necessary
TRASAR 3 component. There are products including Nalcos Best Practice all-polymer NEXGUARD
treatment, residual phosphate with polymer dispersant treatment products, and a chelant/polymer
product with the necessary TRASAR technology. Nalco does not offer coagulation treatment
program with TRASAR technology. Thus a coagulation customer/prospect must be upgraded to
another treatment approach if they want the benefits of 3D TRASAR Boiler Automation.
213

OM0211
Each TRASAR product is formulated with a specific amount of fluorescent tracer in it to provide a
given fluorescence reading by the 3D TRASAR fluorometer. In the product CPP, you will find the
correct PRODUCT FACTOR for that product. This value must be entered into the 3D TRASAR for
Boiler controller. If there is background fluorescence in your boiler system (this is rare unless you
have process leaks in the condensate), the boiler TRB (background TRASAR value) should also be
entered. If you dont have a background fluorescence value for the system, a value of 0 should be
entered into the controller. The product CPP also lists which TRASAR calibration solution should be
used when calibrating the 3D TRASAR for Boilers fluorometer. A known clean deionized water
should be used for the blank during calibration (free of fluorescence and particulates)
The 3D TRASAR Boiler Automation system measures the fluorescence of the sample stream,
calculates, displays, and records the concentration of product (in ppm) 24/7. The built-in control
methods listed below (PID or on/off) will adjust the TRASAR containing treatment pump output so as
to hit the desired feedwater target concentration.
TRASAR 1 based products are NOT applicable at this time for scale control with Nalcos 3D TRASAR
Boiler Automation. The fluorometer used in 3D TRASAR Boiler Automation is not designed to
measure the fluorescence of TRASAR 1.
1.6
Separate Scale Control Treatment Feed & All-in-One Products
Nalco 3D TRASAR Automation for boilers is designed to allow for the separate monitoring and control
of the corrosion and scale control treatments fed to the boiler system. The greatest optimization for
performance and value is made possible when these treatments are fed as separate products (2B
internal treatment for scale control, 2G corrosion control for FW and BW, 2F condensate corrosion
control). It is recommended that a PAC 2B internal treatment product be chosen for scale control.
Although not preferred, the scale control automation offered by Nalco 3D TRASAR for Boilers can
also work for all-in-one 2H treatment products. These products by design contain both a FW
corrosion inhibitor (scavenger) and a scale control treatment. Some 2H products also contain an
additional condensate corrosion inhibitor (amine). A 2H product that contains the Nalco TRASAR 3
tracer, may possibly be used to control.
1.7
Scale Control is Not Just for the Boiler
In the boiler system where steam vapor is produced and the localized concentration of dissolved
scaling species is greatest in concentration, lies the greatest areas of concern for boiler scale control.
However, scale can also form in pre-boiler or feedwater system if there is heat exchange prior to the
injection of the feedwater into the boiler. At the higher surface temperatures seen in conductive heat
transfer (non-boiling), it is possible for scale to form. In addition, under certain operating conditions,
areas of heat exchange within the pre-boiler like the economizer can actually allow for localized
boiling. These steaming economizer conditions are also problematic for scale problems/failures if
not properly protected by a scale control treatment.
The Nalco Best Practice approach is to provide the correct amount (recommend dosage) of the scale
control agent in the boiler FEEDWATER. For years boilers were manually controlled by monitoring
treatment dosages in the boiler water. This older treatment practice does not provide the best
protection throughout the entire boiler system. By providing the correct dosage at all times to the
feedwater, the Nalco 3D TRASAR Boiler Automation simultaneously protects both PREBOILER and
BOILER proper from scale.
1.8
Adherence to Operating Norms for Some Scale Control Treatments
If using a residual phosphate/polymer or chelant treatment product with TRASAR 3 for scale control,
there will be additional dosage adjustments found in the Product Confidential Product Profile for the
product due to the historical boiler residual parameter. Based on the boiler pressure and treatment
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pressure, a recommended excess or residual of chemical (chelant or ortho-phosphate) will be
suggested. In order to provide this residual amount, the feedwater target dosage for these types of
programs is adjusted based on the known cycles-of-concentration of the boiler. The adjustment of
residual treatment will not change unless the number of cycles changes. Nalcos Best Practi ce
NEXGUARD treatment programs do NOT require any residual treatment adjustments.
1.9
Deposit Control
Unlike scale that forms in-situ on the boiler internal surface due to contaminant concentrations
exceeding the solubility limit, deposits are formed by the settling or accumulation of particulate matter.
These particulates come from elsewhere (particulate formed at a location not at the surface where it
accumulates). Typical deposits found in a boiler are metal oxides (corrosion products) or other
particulates insoluble matter like calcite (CaCO 3) or hydroxyapatite (Ca10(PO4)6(OH)2. Deposits most
likely form at the wet/dry interface where steam bubbles are created and released from the heat
transfer surface. Deposits like scale, can form an insulating barrier that impedes heat transfer to the
point where tube overheating/failure can occur. In addition, deposits are frequently porous enough to
allow for conditions favorable to corrosion to exist under them (under-deposit-corrosion). Excess
deposit accumulation can be significant enough that the boiler may require a chemical cleaning.
Nalcos scale control treatment products are formulated with the needed amount dispersant polymer
to minimize the accumulation of deposits throughout the boiler system. By actively controlling and
delivering the correct amount of scale control treatment, the Nalco 3D TRASAR boiler automation
system is also providing the correct amount of deposit control treatment.
1.10 Diagnostic TRASAR: Cycles of Concentration

Nalco has over twenty-years of successful application of Nalco TRASAR technology in boiler for
delivering diagnostic value. The TRASAR 3 tracer is inert in the boiler systems (up to 1000 psig / 69
bar) and can be used across the full breadth of Nalcos industries and market segments. Nalco also
has many regulatory approvals allowing for the use of TRASAR 3 in many countries/regions (see
product CPP and MSDS). One of the most important diagnostic values TRASAR brings in a boiler is
the ability to measure cycles-of-concentration quite accurately.
By measuring the amount of TRASAR in both the feedwater and boiler water sample, the cycles-ofconcentration can be readily determined.
CYCLES = BOILER WATER TRASAR / FEED WATER TRASAR
With Nalco 3D TRASAR Boiler Automation, the amount of TRASAR in the FW will be held at
constant-target concentration in the feedwater. This consistency in the FW measurement rather than
the fluctuations seen in most manual-control applications, allows for more accurate cycles
determination.
By using a TRASAR 3 pen (060-TSR3PEN.88), one can quickly measure the BW TRASAR
concentration and determine the cycles-of-concentration. In the vast majority of accounts, this simple
yet powerful technique (online TRASAR control in the FW and grab sample BW TRASAR) is quite
sufficient to set meaningful blowdown valve settings. These settings are good for both those who
manually adjust the blowdown valve and for those systems using conductivity based blowdown
control schemes.
With the ever-rising cost of energy/fuel and water, helping Nalcos customers run consistently as high
as safely possible for cycles is important in providing on-going value to reduce the TCO (total-cost-ofoperation) for the powerhouse. Nalco 3D TRASAR Boiler Automation allows for this to be done
quickly and routinely for the customer.
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TRASAR Fluorometer
TRASAR chemistries contain a uniquely fluorescing molecule. The fluorometer detects and
quantifies this molecule to give a product concentration. A controller algorithm is used in conjunction
with this product concentration to deliver accurate control of chemical levels in your boiler system.
2.1
Boiler Best Practices Installation for Scale Control Applications
The most successful and highest-customer value scale-control automation application will require
careful consideration concerning the proper placement of treatment feed points and sample extraction
locations. The Nalco PAC-2 Boiler Water Technical Manual provides great background on this topic
as it pertains to both automated and manual (grab) control of boiler scale-control treatment. This
section will highlight the points that are of particular concern when automating.
2.2
DISCOVERY System Audit Diagram the Entire FW/BW System
There is no shortcutting or minimizing the importance of a proper DISCOVERY technical audit of the
boiler system prior to starting any boiler automation project (for either scale-control or for corrosion
control). Simple line diagrams listing the number of boilers and basic flow of water through the
system will not be sufficient to ensure success. The successful audit for scale control will includes
these items.
Boilers
Number/Type/Configuration of each boiler
Pressure of each boiler
Operations (base load, hot stand-by, alternating load, lay-up)
Pattern of operation (vary by time/day/season, production rate, other factors)
Economizer included (treatment injection or sample at either inlet or outlet)
Deaerators
Pressure/temperature
Current chemical feed points and sample points (quill or not for each)
Boiler Feedwater Pumps
Number of and designation of each
Operation (normally used, sometimes used, rarely used, spare only)
Boiler feedwater pressure (must be greater than boiler pressure)
Impeller metallurgy (if treatment is inject near or at the boiler feedwater pump)
Water continuously fed to the boiler or are pumps on/off type controlled by high/low level
Feedwater Header
Diagram listing the approximate run lengths, bends/turns etc between deaerator and boiler
Detailed diagram around the suction and discharge side of all BFWPs
Including discharge lines to each boiler
Including any recycle lines (back to the FW suction side or back to the deaerator)
2.3
Feed Location for Scale Control Treatment
Nalco 3D TRASAR for Boilers automation for scale control is limited to feed of treatment into and
sampled from the pre-boiler section of the system. If the customer/prospect feeds their scale control
treatment directly to the boiler or at a point so late in the pre-boiler that no representative sample can
be withdrawn, it must be moved to a new location. If the customer/prospect dictates that they must
feed directly the scale control to the boiler, then they cannot proceed with automating their scale
control treatment.
The specific recommended feed requirements for any product can be found in the Nalco Confidential
Product Profile (CPP) for that product. This important information will contain details on the
compatible materials of construction for the feed system.
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It is preferred that the scale control treatment be fed directly to the feedwater or pre-boiler system
after the deaerator storage and prior to the boiler feedwater pumps in a section of line COMMON TO
ALL PUMPS. This location minimizes the dead or lag-time for control by eliminating the holding time
of the deaerator from influence. By injecting the treatment to the low-pressure side of the feedwater
pumps, the cost/size of the chemical treatment pump can be minimized.
It is very important to inject the chemical treatment off (away-from) the wall of the feedwater line.
Nalco Best Practice is to use an injection quill that ensures quick and complete mixing of the
treatment by its rapid dilution in the fast moving FW stream.
Using the detailed survey, you are seeking a point where a SINGLE chemical injection can be made
that allows for adequate/complete mixing (via quill or by 20+ pipe diameters down stream before
splitting the stream). It is very important to be sure that no matter which feedwater pump(s) or
boiler(s) are in operation, that the scale control treatment is fed in a way that they all see the same
product concentration.
The survey may show this ideal case cannot be found due to multiple-deaerators (or feedwater
heaters), pipe flow networks where inter-connects and takeoffs between boilers and the feedwater
pumps provide no common point where a single chemical feed will deliver the same product
concentration to all boilers. In those cases, multiple 3D TRASAR Boiler Automation systems m aybe
required. These more difficult or complex systems may also require consulting help from TRC or
SBU ITC consultants to come up with most effective scale control feed point(s).
Although not best practice for scale control, it is possible that the scale control treatment could be fed
alternatively to either the deaerator storage section or to the connection pipe between the dome and
storage section of the deaerator. In either case, the chemical should be fed via quill to get the
concentrated product away from the vessel/pipe metal surface before dilution to use concentration.
Please review the product CPP to make sure it is compatible with deaerator feed. One disadvantage
with deaerator feed of the scale control treatment is that it will significantly increase the lag/delay time
between chemical injection and measurement by the Nalco TRASAR fluorometer. This delay will
necessarily make control less responsive than is possible by direct injection into the feedwater line
would offer. However, accounts have successfully controlled their scale control dosage by feeding
the agent to the deaerator. This type of control is far better than what is ever achieved through
manual grab sampling.
2.4
Scale Control (Nalco TRASAR) Sample Point
The selection of a sample point for Nalco TRASAR automation for boiler scale control is made in
combination with the injection point selection detailed just above. The sample extraction point must
be sufficiently downstream of the injection point to ensure total mixing of the treatment prior to
extraction. Extraction, by Best Practice, should utilize a quill or other nipple/tube/pipe inserted into
the general feedwater flow, rather than taking a tap off the side of the FW pipe. Since all sample
collected for scale control fluorescence measurement is of soluble species, there is no need for isokinetic sampling for TRASAR.
The sample point for scale control will need to be continuously flowing and cooled. The sample
cannot be turned off during operation (it should be properly tagged or secured so that inadvertent
interruption of sample flow cannot occur) The fluorometer cannot directly measure boiler feedwater at
temperature, thus the sample must be cooled with either a Nalco sample conditioning unit or by a
similar and suitably designed customer sampling system.
The sample extraction point should as close to the 20 pipe diameters downstream from the injection
point as possible. The closer the injection and extraction points are located, the lower the system lag
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or delay will be. The lower lag time means improved responsive control when in either PID or on/off
control modes.
The physical location of the extraction point though and the distance from the 3D TRASAR Boiler
Automation skid is also of concern. Long sample tubing runs (sample tubing runs should all be in
316 SS) between the extraction point and the skid can introduce sample lag time that is just as bad
from a control standpoint. The overall goal is to minimize lag time between the scale control
treatment injection and the actual measurement of fluorescence.
In the end, the combination of injection point, extraction point, and actual skid location (tubing run
length) needs to be thought through to keep the installation manageable, serviceable (can you reach
valves fittings?), and to keep lag time as short as possible.
2.5
Scale Control Lag Time Discussion
In the 20+ years of the original Nalco TRASAR for boiler monitoring and control installations using the
prior 350 and Xe2 units, the best results for responsive control have been seen when keeping the lag
time to less than 180 seconds (90-120 optimal). However, marked improvement in control versus
manual has been seen with even lag times of up to fifteen to twenty minutes. If rule number one is to
keep the lag as short as possible, rule number two would be keep the lag as constant as possible.
In PID control, a change in the effective lag/delay time will directly impact the tuning behavior and the
ability to maintain a stable response about the set point. For on/off control, the lag time will impact
the overall overshoot/undershoot seen about the set point. Variation and in the case of PID the
potential for development of un-stable response is possible if the lag time varies significantly during
operation.
Factors Influencing Scale Control Lag Time
Deaerator or Vessel Feed
FW Flow Rate impacts holding time of treatment in the vessel
FW Injection Point
FW flow has minimal impact on lag time
FW Pump Recycle to DA
Increased recycle flow to deaerator effectively increases lag time
Changing Sample Flow Rate
Change in sample flow rate directly impacts lag time
If the scale control treatment is fed directly and uniformly to the deaerator, then we can assume the
concentration leaving the deaerator is an exponential function of the mass contained in the deaerator
(rarely if ever changes) and the extraction mass flow rate (FW flow which frequently is changing).
With greater feedwater flow, the lag time influence of the deaerator is much lessened. However, at
low mass flow rates from the deaerator, the holding time and thus effective lag time of the vessel can
increase significantly. This variation in lag time is one reason we prefer to feed the treatment directly
to the FW line.
Virtually all boiler feedwater pumps require some protection to prevent over pressurization or
cavitation when the pump is operating at an output rate greater than the boiler is calling for water to
enter the boiler. The liquid level control system in the boiler will not respond immediately or perfectly
to the steam load demands. The slow acting boiler level control allows for flow and pressure to be
held back against the impeller before pump speed/frequency/stroke can be adjusted to a lower
setting. To protect the pump, boiler systems generally allow for recycle from the discharge side of the
pump to the suction side of the pump. In some boiler systems, this recycle loop is dumped back into
the deaerator.
With a feedwater pump recycle to the deaerator, the holding time and lag time issues just discussed
for a deaerator can be introduced even if the scale control agent is fed to the feedwater line. The
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amount of recycle and thus variation in lag can be a frequency of overall steam load and on what t ype
and which particular pump(s) is operating at a given time. If a boiler feedwater header pump system
is designed to send the recycle flow directly back to the suction side of the pumps, the influence of
recycle on overall lag time will be minimal.
The lag time is of course to a large part connected to the sample mass flow flowing through the Nalco
3D TRASAR Boiler Automation skid. A target of 300 ml/min has worked very well for many
applications. However, some may find slightly higher flow rates will help to lessen the lag time and
improve overall system responsiveness. It is important that what ever flow is used, that it is not
changed by boiler operators or Nalco personnel once a set of tuning parameters have been found
and tested. In fact, every service visit by the Nalco representative should include a check that the
sample flow rate is on target. If it is too high or too low, appropriate adjustment with the needle valve
at the bottom of the Rotometer is needed. (variation of +/- 10% flow should not be of concern). If flow
rate is varying more than 10% in between adjustments, please consult the sample condition Section
12 on troubleshooting of the filter and pressure regulator to improve the ability to hit a constant
sample mass flow rate.
Although sample flow rate is NOT a measured or recorded value with 3D TRASAR Boiler Automation,
if your scale control sample is extracted from the same place you are measuring NCSM, you can
use the NCSM sample temperature to get an excellent approximation of flow rate. In most boiler
applications where the sample line up to the NCSM is insulated and is isolated from outdoor
weather conditions, variation in temperature will directly correlate to a rise or drop in sample flow to
the skid. The NCSM temperature is routinely recorded by the control system for historical or
remote viewing.
2.6. Choice of Control Schemes for Scale Treatment

In Sections 6 and 7 of this manual, there is a detailed discussion on the use of PID and ON/OFF
control of treatment pumps. This section deals with issues on that topic specific to scale control.
2.6.1
On/Off Boiler Feedwater Pumps
If during the DISCOVERY audit, it was determined that the boiler feedwater pumps only provide water
to boiler on an on/off basis (not continuous) then this section applies. If the boiler feedwater pumps
are continuously providing water to the boiler, please skip this section.
In on/off feedwater pump control, the boiler pump turns on when the low level sensor goes dry in the
boiler and turns off when the high level sensor becomes wetted in the boiler. For this type of boiler
system an interlock will need to be provided from the customers level and/or boiler feedwater pump
control system so that the 3D TRASAR Boiler Automation system knows when to turn on the
treatment pump. The scale control treatment should only be turned on during the times when the
boiler feedwater pump is turned on.
2.6.2
Manual Control for Scale Treatment
The foundation for any automated control is the ability to correctly control the treatment pumps in a
manual (constant setting) mode. Since for most treatment pumps, the stroke length is fixed by an
adjustment on the pump itself, the controlled parameter available to the 3D TRASAR Boiler
Automation system is pump speed or frequency (strokes per time). In PID control or pseudo On/Off
control the pump frequency will be controlled by a 4-20 ma output from the 3D TRASAR controller. In
relay based on/off control, the pump frequency is also set directly at the pump. Proving that the
pumps can be put successfully into MANUAL mode by adjustment on the controller keypad and via
the Configurator software can prove all wiring and connections are ready for automated control.
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During manual control with a 4-20 mA connection, the pump should be able to be commanded across
the full available range of input (i.e. from 0% frequency to 100% on). With on/off relay type wiring, the
pump should be commanded to be ON or OFF by the manual settings.
Manual control allows for the user to quickly determine the effective overall system lag time between
injection of the scale control treatment and the response noted at the Nalco fluorometer. Under
constant FW flow conditions, by holding a constant pump output (or on/off relay condition) the user
can determine the lag-time between a step-change in dosage (changing pump output frequency or
switching the opposite off/on pump condition).
2.6.3
PID Control for Scale Treatment
If the sample lag time between chemical injection of the scale treatment and fluorometer response is
under 240 seconds, your system is a candidate PID control. If sample lag-time is found to be
between 240 and 360 seconds PI may or may not be a good fit. If your lag time is over 360 seconds,
on/off control (via 4-20 ma or with on/off relay) may be a better choice for your system.
PID control when properly tuned can provide the best protection for both the pre-boiler and boiler
system against scale formation. Nalco has found over the years that using the PI (proportional and
integral) elements of control are sufficient. The derivative portion is most generally set to 0 or turned
off in Boiler TRASAR control tuning. See Section 6.7 for details on tuning PID control loops.
The PID tuning initially found are determined for your boiler system although valid when run, may not
cover the boiler system under a full breadth of Mechanical and Operational conditions. Large
variations in system hydraulics (large change in boiler FW or Steam Rates) can lead to instability
developing in a previously valid tune. (instability is when the TRASAR does not hold or converge on
the set point but rather continues to oscillate or wander) The boiler CONFIGURATOR software
provides built-in tools for the user to improve the tuning parameters to make them more stable. See
Section 5.1 of the manual. In addition, the response of the TRASAR dosage may become so slow or
sluggish that it is slow to recover to the set point, in-fact never overshooting the set point. In the case
of a too-sluggish response, increase the aggressive nature of the tune may be required.
Some boiler systems may require periodic tuning adjustments. For other systems, the tune initially
set for the scale control will work under all conditions. In general, the more dynamic changes in flow
characteristics in the feedwater, the more likely adjustment in tuning parameters will be required.
2.6.4
ON/OFF Control Using Relay Based Pump Control
Just as in section 5.4.4 above, on/off control based on energizing the pump via the relays in the 3D
TRASAR Boiler Automation skid is viable for many systems where PID control is not practical. This
type of control does not require 4-20 mA input treatment pumps. However a pump wired in this relay
on/off method cannot be used to test or evaluate PID control in the system. See Section 5.1 covering
this type of control system.
2.7
Extra Value Information with PID Treatment Scale Control Automation
For the boiler system where PID control is successfully applied to control scale control dosage in the
FW to a target concentration, the PUMP OUTPUT% channel becomes a very valuable tool. Since to
hit a constant feedwater TRASAR concentration, the 3D TRASAR Boiler Automation controller must
vary scale treatment pump output based on the changes in feedwater mass flow. For a system
where the customer does not provide a Steam Flow input to the controller, this scale control pump
output while in good PID control becomes an approximate flow meter. The feedwater mass flow rate
will in rough approximation follow/track the pump output.
This is only an approximation, because the actual treatment pump output is also influenced by the
amount of FW being re-circulated back to the deaerator (if applicable). If the recirculation rate varies,
then error in the flow estimation via TRASAR treatment pump would grow.
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For a customer that provides steam flow input to the 3D TRASAR Boiler Automation to the controller,
the scale control treatment pump output under PI control provides a method to see the impact of
recycle. If deaerator pump recycle varies by specific feedwater pumps online or by the duty load on
those pumps, it will become quite obvious by directly comparing the STEAM MASS flow directly to the
treatment pump output. Portions of the data where there is deviation in the look/shape between the
two can frequently be explained by the recycle behavior of the feedwater back to the deaerator. This
information provides diagnostic value to the customer as to operating changes/behavior. However, if
proper tuning is in place, the recycle loop will have no impact on the scale control performance
because the 3D TRASAR Boiler Automation actively compensates to keep the scale treatment
concentration on target.
2.8
Fail-Safe for Scale Control
Every control system requires a series of safety or escape modes by which the system will go to by
choice or default if the operation does not behave as expected or wanted. The 3D TRASAR Boiler
Automation system has a very versatile and rich fail-safe control system built into it. See Appendix F
details how to set and use these controls. This section details items for the user regarding these fail safe modes and scale control treatment in particular.
2.9
Minimum Pump Output TRASAR Scale Control Pump Output
If using PID or on/off control via PID (4-20 ma), the user can select a MIMIMUM pump output during
normal operation. See Section 5.1 on details on how to set/adjust this feature. This setting should
be very carefully set as it could lead to significant overdosing of the scale control treatment during low
feedwater flow (low steam flow). On the one hand, it makes sense that the customer would always
want scale control inhibitor fed to their system and thus a minimum dosage would be appropriate.
However, systems with recycle of FW to the deaerator or systems that have periodic carryover of
boiler water from the blowdown flash tank into the deaerator coupled with low FW flow, can result in a
significantly higher than desired dosage actually in the FW/pre-boiler.
2.10
Maximum Pump Output TRASAR Scale Control Pump
If using PID or on/off control via PID (4-20 ma), the user can select a MAXIMUM pump output during
normal operation. See Section 6 on details on how to set/adjust this feature. This feature is of
particular benefit if the treatment pump in service has an output capacity that far exceeds the
reasonable treatment feed rate expectation at maximum feedwater and steam flow.
For example, if the pump volumetric output at the set stroke setting is for example 1.0 gal/day but it is
clear from the maximum feedwater flow that no more than 0.5 gal/day is ever going to be needed to
hit the target FW concentration, setting a maximum pump out of approximately 55% would make
perfect sense. Such a limit would cover the highest steam load conditions of the system, while
ensuring that if a control problem developed, the system would not grossly overfeed or pump dry the
container of scale control treatment.
This maximum output is done on a case-by-case basis. If the pump stroke is changed on the pump
or if a new pump is installed with different output characteristics, a new maximum output setting
should be entered into the controller.
2.11
Automatic Shut Off Scale Control Treatment Pump
If all flow is down to the boiler system (no feedwater flow), the scale control treatment pumps should
be turned off so as not to grossly overfeed the scale control treatment to either the pre-boiler,
feedwater line, boiler feed pumps, or deaerator storage section. Scale control treatments when
overfed can lead to increased corrosion of the boiler system during the shutdown. The advantage of
using an automatic shut down method, is that the entire control system can be brought back on-line
once the boiler is back up.
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a) System Interlock Some customers maybe able to provide an interlock (low/high voltage
signal) that will be energized if the boiler system is online and that is not energized if the
boiler system is down/off. The 3D TRASAR Boiler Automation system can take this interlock
voltage signal as an input and use it to control the scale treatment pump. If the interlock is
energized, then the scale control treatment can be used in manual, on/off, or PID modes.
However, if the interlock is low (not energized), then the treatment pump would be set to
OFF. See (Future Section) on how to connect, set-up, and adjust this feature.
b) Low Steam Flow (or feedwater flow) One benefit of connecting an input to the 3D TRASAR
Boiler Automation from the plants feedwater or steam flow meter, is that this signal can be
used to sense that the boiler system is down. If the steam flow drops below a certain
threshold value or hits ZERO, the alarm system can automatically shut down the scale
control treatment pump (even if a minimum percent output is in place). The Low Steam Flow
alarm will automatically clear once flow is reestablished, returning the scale control treatment
back to its prior state (manual, on/off, or PID). See (Configurator Help Screens) on how to
connect, set-up, and adjust this feature.
c) If either method of automatic shutdown of scale control is employed, it also must be decided
whether to shut down all flow to the skid as well. If there is no NCSM, then closing the
solenoid and shutting off sample flow to the skid during the shutdown is preferred when the
boiler system is off. If NCSM is used, the control aspects of NCSM should dictate whether
flow is shut-off or not. See (Configurator Help Screens) on how to connect, set-up, and
adjust this feature.
2.12
Power Off 3D TRASAR Boiler Automation Skid
If there is a known outage (set/scheduled length of time) for the boiler system, simply turning off the
power switch on the 3D TRASAR Controller system is a viable means to shut-off or safe the control
scheme. In addition, power should be turned off to all treatment pumps as well (some brand/types of
pumps may not go to 0% output with loss of control signal (4 ma) from the 3D TRASAR controller.
One disadvantage of course is that the SOP must clearly state that both 3D TRASAR controller and
pumps be turned back on just prior to starting up the boiler. If the controller and pumps are not
energized, the boiler will not receive the needed scale control treatment.
If there is an automatic shut off system enabled (Configurator Help Screens) and if the length of time
of the boiler shutdown is short (a few days) or of an unknown timeframe (hours to days), it is better to
leave the 3D TRASAR controller and pumps powered up. This allows the system to get back in
control and to target concentrations as quickly as possible.
2.13
Scale Control Automation When Using a PAC2H (multi-functional) Treatment
The Nalco Best Practice is to feed the scale control, pre-boiler corrosion control (scavenger), and
condensate corrosion inhibitor (2B, 2G, 2F) separately. This is also Best Practice when automating.
However, Nalco has several all-in-one or multifunctional treatment programs that include TRASAR 3
that can be used in an automated control scheme.
2.14
When Using a Multifunctional Use a Supplemental Scavenger Ahead of the
Multifunctional
Virtually all multi-functional products utilize a sulfite based oxygen scavenger/reducing agent to
minimize FW or pre-boiler corrosion. If fed separately and ahead of the 2H multifunctional product,
this supplemental scavenger could be controlled by an NCSM technique. That would allow the 2H
product to be dosed and control based on the measured TRASAR signal. Consult the Nalco
Confidential Product Profile for each product (2H and supplemental scavenger) to determine the
correct dosage.
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The PAC2H Pre-Section in LOTUS NOTES provides an important overview of how scavenger
performance is improved significantly in multifunctional applications if a supplemental scavenger is
fed in advance of the multifunctional 2H product.
2.15
No Supplemental Scavenger What Dominates Scale or Corrosion Control
If the separate feed of treatment (2B, 2G, 2F) nor the supplemental scavenger can be sold to the
customer, then the Nalco sales/service representative must determine what stress factor, either scale
or FW corrosion, is the critical parameter in the account for the 2H multifunctional product. If a
NexGuard 2H product is used, the Product Selection tool (excel) found in LOTUS NOTES will show
the rep. what is controlling the recommended dosage, either scavenger/dissolved oxygen loading or
hardness loading.
If the variation in hardness and the fact that the product fed at the account is limited in terms of
hardness control, then TRASAR should be the dominant control factor. If sulfite dosage to control
dissolved oxygen is the dosage-determining factor for the 2H product, then NCSM should be used
to control the 2H product.
No matter whether TRASAR (scale control) or NCSM (FW corrosion control) is chosen as the control
element, the setting of meaningful maximum and minimum pump output limits can be set to ensure
both scale and corrosion are cared for.
A full installation of 3D TRASAR Boiler Automation with both TRASAR fluorescence and NCSM
capabilities would allow the Nalco representative to run studies to see which factor (scavenger or
scale control) actually demands more product concentration. This study is NOT required though as a
theoretical determination of the rate limiting factor from the CPP dosage calculations should be
sufficient for most small to moderate size boiler system installations.
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APPENDIX B
1
NCSM Probe Technology and Advanced Field Tests
Introduction
Corrosion occurs in all boiler feedwater systems. Traditionally to reduce the corrosion rate to
acceptable values the pH and dissolved oxygen levels of the boiler feedwater are controlled.
Chemical treatment programs often include the addition of passivating oxygen scavengers after
mechanical deaeration of the boiler feedwater.
Corrosion in boiler water systems is occurring at elevated temperatures and pressures. Therefore,
the best operational and control data is based on measurements at actual operational conditions.
Gathering corrosion stress information at the boiler feedwater temperature and pressure is very
difficult and seldom done.
Nalcos innovative NCSM technology provides the industry, for the first time, a direct performance
measurement for managing pre-boiler corrosion. Controlling the reductive and oxidative state of the
feedwater environment itself (controlling the REDOX stress) can accomplish this goal. This state-ofthe-art, patented technology measures corrosion stresses in the pre-boiler at actual system
temperatures and pressures unlike other measurements that must be performed at room
temperature. This high temperature and pressure measurement is faster, permitting a much quicker
response to corrosion stresses. In addition, the Nalco NCSM measurement is much more accurate
and sensitive enabling the sensor to detect corrosion events that cannot even be detected with
traditional room-temperature ORP, dissolved oxygen, metallurgy-specific corrosion rate, or scavenger
residual measurements.
This early detection of pre-boiler corrosion stresses enables proactive adjustments to the treatment
program instead of changes after corrosion has already occurred. The real-time, continuous
optimization of the oxygen scavenger/ metal-passivator program is possible with the Nalco NCSM
program. This program can prevent problems that lead to lost steam production, downtime, reduced
asset life and higher operating costs.
2 Probe Life
These types of probes have worked flawlessly for over a year and can be stable for years in
controlled environments. The lifetime of the probe depends on many factors. These include fouling,
contamination, system operation (downtime), probe abuse, etc. Probes will generally last longer in
higher purity demineralized water accounts, than in dirtier boiler feedwater typically found in lower
pressure boiler systems. Probes should be checked when the response of the electrodes becomes
noisy or sluggish, or if responses are observed that do not seem to be related to system/plant
variations (see below verification checks). Probes should always be checked before placing
probes back into service after downtimes (see probe check sections).
Probe servicing takes less than hour and the reference electrode potential can be easily checked
against another known half-cell (see later). A standard KCl//AgCl/Ag electrode is provided in the
Accessories Kit. Assuming that all refurbishing procedures can be performed and are performed on a
regular basis: The external pressure balanced reference electrode (EPBRE), used in the NCSM cell
will only really fail (assuming no mechanical abuse) when the AgCl coating on the silver portion of the
electrode deteriorates. This often leaves that area of the silver rod (base of the electrode within the
Teflon tubing)) looking non-uniform and can take on a scabbed/scaled brown appearance as
compared to its virgin grey appearance (as viewed through the heat shrink Teflon tubing). Electrodes
of this design have lasted for 5-10 years without replacement of the silver/silver chloride portion of the
electrode.
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The reference electrode should be laid up wet when the system is inactive. It is also suggested that
during some of the inactive periods that probes be checked, refurbished and cleaned. As with any
piece of analytical equipment the NCSM system should be placed on a routine inspection
schedule. Typically it is more convenient to inspect the system during downtimes, but the probe
arrangement can easily be checked at full system load since it can be valved-out from the system at
any time. The maintenance interval is highly dependent on the environment and should be
determined for each application.
An initial plan might include probe checking every 3-6 months. The time period between inspections
and probe checking can be increased as confidence is gained in using these NCSM probes for any
specific application. Typically if users see no real probe deterioration in their specific system they will
let the probes run for longer and longer periods without inspection. This should however not breed
complacency that probes are always functioning. As mentioned in the Probe verification section (see
later) there are on-line tests that can be performed to further enhance the confidence in probe
responses. Some high purity, high duty accounts (systems that do not experience much downtime)
will have probes that can run for well over a year. This is one of the advantages of this techn ology
over some of the more conventional water monitoring technologies.
Electrode and System Verification Checks during Operations:
During operation there are several checks that can be performed while the probes are in the system.
Below is a list of just some of the probe and system checks.
1.
Thoroughly check all the seals. Check to ensure the appearance of all the probes and
connections is as desired.
2.
Disconnect the probe leads and short the leads together using the supplied female-to-female
BNC connector. The 3D TRASAR Controller should read close to 0 mV during this test. This
test is important to perform from time to time, especially if the cable being used contains the
integral amplifier. (Part # 6031277). This cable contains a battery that should be replaced
every year.
3.
Purposefully upset the system: The probe response should be known as users become familiar
with the NCSM numbers and how the system affects these numbers. This includes how turning
scavenger feed off and on (at high pump rates) might affect the NCSM numbers. With time
similar tests can be performed to make sure the probes are performing as expected. For
example a Utility customer periodically turns scavenger feed off and then on to make sure the
probes are responding as expected, and that the magnitude of their response is as expected.
This has also helped the customer gain confidence with the NCSM technology. Does the ORP
respond as expected? If not are there plant reasons for the difference like plant conditions
have changed. Purposefully turning off the reductant for short periods of time should make the
system more oxidizing and NCSM numbers should eventually increase to reflect this. Another
approach might be to increase scavenger feed to see if conditions become more reducing and
NCSM numbers should decrease.
4.
Perform a 0% and high scavenger feed test. Running a 0% scavenger feed test followed by a
high scavenger feed test can provide useful information.
To gain knowledge of the system performance what is the expected NCSM
space/spectrum in the system - trying to control NCSM outside this space is impossible.
To gain knowledge about NCSM probe performance and response.
To provide a baseline for later comparison during different time periods (different seasons,
different stress conditions (high and low steam loads for example)).
To check probe responses with time.
To check system response with time.
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Verification checks on probe disassembly:
Several checks can be performed on the probes after removal from the system. Follow all safety
precautions for the removal of any probe that might have been at high temperature and pressure.
3.
4.
5.
It is preferable to have pressure in the NCSM cell while the cell temperature cools well
below boiling water temperatures. This ensures that there is no bubble formation in the
reference electrode on disassembly. This can be accomplished by shutting off any valve down
stream of the NCSM probe. This will also mean that there is no flow through the ORP cell.
Removing some of the insulation about the 3/8 stainless steel cross will hasten the probe
cooling process. Typically, temperatures of less than 180F should be striven for, and the
cooler the better.
Close the NCSM sample inlet valve.
Relieve the pressure in the cell by opening the pressure bleed valve. Make sure the pressure
gauge shows no gauge pressure in the NCSM cell before opening the cell. Refer to the probe
installation instructions (Section 4.10) to figure out which Swagelok fitting to loosen in order to
slip out the Teflon internals of the Reference Electrode with the base fittings intact.
Note:
4.1
The Reference Electrode should be checked first and relatively quickly as bubbles can form
in the Teflon portion of the probe on disassembly. If desired the platinum portion of the
ORP probe combination can be checked later. Materials for checking the Reference
Electrode should have been prepared and be close at hand, before opening up the
NCSM cell.
Reference Electrode Check Notes:
The external pressure balanced Reference Electrode (EPBRE) check that can be performed is
the same as the procedure for checking the reference electrode prior to installation.
Note:
If the user was not able to check the potential of the reference electrode without bubbles
forming in the electrode shaft, creating an open circuit, then follow this procedure: Tap all
of the bubbles to the top portion of the electrode, containing the porous ceramic frit. Then
refurbish/ refresh the solution in the top portion of the electrode only (refill with fresh 0.1 N
KCl supplied.). The solution about the silver portion of the electrode will then still be the
same as the solution used during operations. Rechecking the electrode in this fashion will
suffice as the post operational check.
Note:
This check should be done every time the Reference Electrode is removed or
reinserted into the NCSM cell. This will give the user great confidence in the operation of
the Reference Electrode over time.
Note:
If there is any doubt that this electrode is not performing as desired it should be returned
and replaced (see probe longevity section of this manual).
Note:
When removing the Reference Electrode the Teflon insert containing the base of the
electrode is extracted from the long stainless steel tube. The Teflon shaft can be wiped
with an absorbent tissue paper on extraction from the stainless steel tube. Any extraneous
material on top of the porous zirconia fritt can be washed and scrubbed off. Some
extraneous corrosion material might have collected in the base of the electrode between
the Teflon insert and the stainless steel fitting. This material will flush out onto the WipeAll
as the probe is removed from the stainless steel tube. Its often interesting to see just how
much corrosion product falls out of this creviced area as it is an indication of corrosion
transport in the system and this zone of the electrode acts like a corrosion particle trap.
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4.2.
ORP Probe Verification Tests:
The ORP probe is really a combination platinum and RTD (resistance temperature detector) probe.
On removal from a system the probe should always be inspected and given some or other cleaning
process as needed (see list immediately below). Thereafter the user has several options if they wish
to check this probe.
Probe Cleaning: There are several things that can be done to clean the NCSM probe. These can
include, in order of severity:
Flush with deionized water and air dry.

Wiping with a soft absorbent tissue paper followed by a water wash. The wiping should not be
forceful and it should be longitudinal in fashion instead of circumferential. Absolutely no
scouring of the probe system should be performed with abrasives and abrasive paper of
any type.
Wash the platinum portion in isopropyl alcohol (use acetone if there is no isopropyl alcohol),
followed by a light wipe with a WipeAll. Do not soak the electrode. Contact with these
chemicals should be brief. This should remove greases and some extraneous particulate
material. Rewash with deionized water after this process.
The tip of the electrode can be dipped in acid (concentrated nitric acid) for a few seconds,
removed and thoroughly washed with deionized water. This will remove corrosion products that
become more aggressively attached to the platinum surface.
Other cleaning processes can include cathodic cleaning where hydrogen bubbles are formed
on the platinum surface to lift off extraneous material at the platinum interface. This is done
with external electrochemical stimulus. Untrained individuals should not perform this type of
cleaning on these probes.
Probe replacement: If there are still doubts about the performance of any of the probes or
other components, after all the checks and possible cleanings have been performed, then the
probes should be replaced.
After probe cleaning there are several verification checks that can be performed:
The RTD can be checked as the resistance between the central pin and side shield of the RTD
BNC should be 1000 Ohms, as there is a Pt 1000 resistor at the base of the 1/8 stainless steel
(one end closed) tube.
A standard voltmeter can be used to make sure that there is electrical continuity from the
platinum band to the ORP central BNC pin. A dry electrode should have no electrical continuity
from the BNC central pin (of the ORP electrode) to any other part of the electrode housing
which is made of stainless steel.
Obtain a +200 mV ORP standard and check the potential of the ORP platinum probe as
compared to the saturated KCL//AgCl/Ag electrode provided. +200 mV ORP standards can be
purchased. These are typically a solution of potassium ferrocyanide trihydrate, potassium
ferricyanide and potassium chloride in water. These solutions however typically have a shelf
life that can be as short as 9 months if refrigerated.
Remove the platinum/RTD probe (referred to as the ORP probe) from the 3/8 cross. Carefully slip
the probe from the 3/8 fitting being careful not to damage the probe in the disconnection from the
3/8 stainless steel cell and cross.
It is suggested that the removed electrode be given a light wipe to remove any easily removable
extraneous material/debris/corrosion product. Be careful not to damage the platinum portion of the
electrode in any way.
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Additional cleaning might involve the chemical steps discussed above.
Prepare a beaker into which the saturated KCL//AgCl/Ag electrode is placed (slip down the rubber
boot covering the air hole in this electrode), and the +200 mV is placed. If the saturated
KCL//AgCl/Ag electrode has not been used in a while, use the syringe and needle provided to remove
all of the filling solution and refill with fresh saturated KCL (provided in the refurbishing kit).
The saturated KCL//AgCl/Ag electrode will be connected to the BNC cable as the Ref lead.
Connect the ORP probe to the ORP cable and dip the active platinum portion of the probe in the
standard. Make sure not to submerge the entire probe (just make sure the entire platinum band is
submerged). This will prevent the standard from being drawn into the fitting itself.
In this configuration the ORP probe should read +200 mV versus the known standard, glass,
saturated KCL//AgCl/Ag electrode. If the leads are switched the reading will be 200 mV. That is the
ORP electrode is used as the Reference (Ref) lead and the glass reference electrode is used as the
ORP connection. This is because all that is being measured is the potential difference between the
two probes.
In the standard configuration the ORP reading should be +200 mV at 25C(77F). Since conditions
are very rarely standardized in this fashion and the platinum electrode has been conditioned to actual
testing conditions it is expected that the ORP reading could be in the +200 mV (+/- 40 mV) regime,
although readings of +200 mV (+/- 15 mV) are more likely. New ORP probes should read closer to
the +200 mV reading.
Note 1:
It might take some time for the removed and cleaned ORP probe to become conditioned
to the +200 mV standard so the reading might trend towards the desired reading with time.
Be patient when taking this reading.
Note 2:
Ideally the platinum band portion of the electrode should be in close proximity to the base
of the glass reference electrode that houses the porous junction of the saturated
KCL//AgCl/Ag electrode, during the above test.
Note 3:
Users will need to define for themselves whether they feel confident that the ORP electrode
is functioning as prescribed in this test. If there is any doubt, it is suggested that the ORP
electrode be replaced with a new electrode and the original ORP electrode can be sent
back to be refurbished or discarded.
Note 4:
When re-inserting the NCSM probe back into the system (3/8 cross) it will take some time
for the system and ORP readings to reach stabilized background conditions again. The
time to reach the expected baseline will depend on the system. Typically systems that
have been operating in the more oxidizing regime will come back to baseline NCSM
readings quickly. Systems that were highly reduced might take a lot longer to revert to
baseline reduced conditions as the probe and cell internals have now been exposed to air,
during the above process.
228
The NCSM probe can also be checked in a +200 mV ORP standard using the 0.1N
KCL/Ag//AgCl EPBRE as the reference electrode. So the above test can also be performed with
the 0.1N KCL//AgCl/Ag EPBRE that is used in the high temperature NCSM cell. (In this case the
0.1N KCL//AgCl/Ag EPBRE electrode should be checked against the known standard, glass,
saturated KCL//AgCl/Ag electrode, as describe in the initial installation instructions on the NCSM
cell.)

OM0211_________________________________________________________________________
For this test the Ref lead is connected to the 0.1N KCL//AgCl/Ag EPBRE as the potential difference
of the ORP probe is measured against this 0.1N KCL//AgCl/Ag EPBRE in the +200 mV standard.
This test can be used to check the platinum and 0.1N KCL//AgCl/Ag EPBRE combination. Typically
readings in the +200 mV standard will be +110 mV (+/- 40 mV) range see NOTE below. Once
again users will need to define for themselves whether they feel confident that the ORP electrode and
0.1N KCL//AgCl/Ag EPBRE are functioning as prescribed in this test. If there is any doubt, it is
suggested that the ORP and/or 0.1N KCL//AgCl/Ag EPBRE electrode be replaced with new
electrodes and the original ORP and/or 0.1N KCL//AgCl/Ag EPBRE electrode can be sent back to be
refurbished, discarded and/or replaced.
NOTE: Since the 0.1N KCL//AgCl/Ag EPBRE measured +90 mV (typically) versus the saturated
KCL//AgCl/Ag electrode (in saturated KCl), then in this test the ORP electrode will measure +110 mV
(+200 90) versus the 0.1N KCL//AgCl/Ag EPBRE, in the +200 mV ORP standard. Another example
is given here: If the 0.1N KCL//AgCl/Ag EPBRE had measured +97 mV versus the saturated
KCL//AgCl/Ag electrode, then in this test the ORP electrode will measure +103 mV (+200 97)
versus the 0.1N KCL//AgCl/Ag EPBRE, in the +200 mV standard ORP solution.
4.3
Other Standard ORP Solutions
There are various ORP standards that can be obtained from vendors, for ORP probe verification.
However, the best way to obtain a fresh standard is to make them up from their basic constituents as
all ORP standards have fixed shelf lives.
There is an ASTM standard (D 1498-93) that contains a recipe for making up additional ORP
standards. Two standards could be made-up for ORP number verification. They are the FerrousFerric Reference Solution and the Quinhydrone solution in pH 7 (or 4) buffer. The advantage of
making up the ferrous-ferric reference solution is that it does have a shelf life of about a year. The
quinhydrone solution shelf life is days (at best). Below is the recipe for making up the standard
solutions (extracted from ASTM Standard D 1498-93).
1.
Redox Standard Solution; Ferrous-Ferric Reference Solution Dissolve 39.21g of ferrous
ammonium sulfate ((Fe(NH4)2(SO4)2.6H2O), 48.22g of ferric ammonium sulfate ((FeNH 4(SO4)2.12H2O)
and 56.2 ml of sulfuric acid (H2SO4 , specific gravity = 1.84) in water and dilute to 1 L. It is necessary
to prepare the solution using reagent grade chemicals that have an assa y confirming them to be
within 1% of the nominal composition. The solution should be stored in a closed glass or plastic
container. The ferrous-ferric reference solution is a reasonably stable solution with a measurable
oxidation reduction potential. The Table below presents the potential of the platinum electrode for
the two reference electrodes at 25C in the standard ferrous-ferric solution.
Table I:
Potential of the NCSM platinum electrode for the two reference electrodes at 25C in the
ferrous-ferric reference solution.
Reference Electrode
ORP (mV)
Saturated KCL//AgCl/Ag Reference Electrode

0.1N KCL//AgCl/Ag EPBRE
+476
+388
2. Redox Reference Quinhydrone Solutions Mix 1 L of pH 4 buffer solution with 10g of

quinhydrone. Mix 1 L of pH 7 buffer solution with 10g of quinhydrone. Be sure that excess
quinhydrone is used in each solution so that solid crystals are always present. These reference
solutions are stable for only 8 hours. Table II below lists the nominal mV redox readings for the
quinhydrone reference solutions at temperaures of 20C, 25C, and 30C. As can be seen, the ORP
response is a function of temperature.
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Table II
ORP (mV)
Buffer solution, nominal pH
Temperature (C)
Reference Electrode
Saturated KCl/Ag//AgCl Reference
Electrode
0.1N KCl/Ag//AgCl EPBRE
20
4
25
30
20
7
25
30
+268
+263
+258
+92
+86
+79
+180
+175
+170
+4
-2
-9
So there are many ways to verify the performance of the NCSM electrodes. The electrode readings
should be verified without having to alter the bias of measurement electronics which should be factory
calibrated and maintain calibration.
4.4
Verification of the NCSM Sensing Hardware:
Verification of the electronics themsleves (not the electrodes) and the wiring can be made with
voltage sources. These voltage sources are calibrated and designed to be used as pH or ORP
voltage signal generators. There are several excellent manufactures of quality high input impedance
devices designed for electronic calibration. The user can search the Internet for a reputable source.
4.5
Measuring the Corrosion Potential of Stainless Steel:
The current NCSM and RTD combination can also be used to measure the corrosion potential of
stainless steel. This is the grounded corrosion potential of stainless steel assuming that the plant
piping is grounded (which should be the case).
The 3D TRASAR box can be used to do this without having to do anything with the NCSM probe. All
the right connections can be made within the 3D TRASAR box itself. It just needs to be wired-up.
Essentially a connection needs to be made from the stainless steel cell (this includes any item
electrically shorted to the cell, such as the L-shaped bracket on the ORP probe itself) to the ORP
input. The ORP probe input needs to be disconnected to make this measurement.
Use a separate wire to connect from the +ve NCSM input (Pt input, on the two wire NCSM input
white lead) to the stainless steel cell. It is most convenient if this wire end has an alligator clip to clip
onto the L-shaped bracket of the ORP probe itself. Remove the platinum (white) lead while doing this
test. Temperature readings will be taken as normal during this test.
Now the NCSM displayed value will in fact be the corrosion potential of stainless steel. At the end of
this test, return all wiring to its previous configuration so that NCSM is read as desired.
As with NCSM numbers the corrosion potentials of stainless steel will become more positive in an
oxidizing environment and more negative in a reducing environment. The absolute values of the
corrosion potentials will usually be different from the NCSM numbers and have specific corrosion
implications for stainless steel alloys (this will not be discussed further here). In this configuration the
corrosion potential of stainless steel proves to be a useful additional diagnostic tool. If the corrosion
potential number is different from the NCSM number then both probes are functioning as individual
probes, which is expected to be the case. If for some reason the numbers for the NCSM and the
corrosion potential of stainless steel are identical, then it is suspected that there might be a problem
with the NCSM probe and further checks of the probe (described above) should be performed.
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Electrode Storage
Reference Electrodes should always be stored wet. The electrode should be filled with the
appropriate electrolyte (0.1N KCl in the case of the EPBRE Reference Electrode and saturated
KCl in the case of the saturated standard reference electrode). The electrodes should be
placed in a solution of the appropriate filling solution to make sure the ceramic membrane does
not dry out.
ORP/RTD probes should always be stored in the dry condition. After use, wipe off excess
moisture; clean the electrode and store in a dry place. The platinum electrode might be stored
in the 3/8 SS cross to protect the electrode from damage.
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APPENDIX C
Pictorial Instructions of NCSM Reference Electrode

Refurbishing
Close water inlet outlet (2) and let

cool. Close inlet (1).
Pressure relief (warning: only if valves

1 and 2 are closed: hot water or steam
might escape)
Disconnect reference BNC
Disconnect ORP BNC
Connect ORP BNC to reference

electrode
Place saturated KCl solution

somewhere near the electrodes
Open reference electrode tube with

upper nuts only
A
Connect saturated KCl electrode (A)
to reference BNC
Remove reference electrode (R)
232
Remove saturated KCl electrode from

solution
Put both in saturated KCl solution.

Place tips at same level. Should read
approx. 87mV +/- 10 mV
Remove reference electrode (R) BNC

OM0211_________________________________________________________________________
Carefully open reference electrode in middle with twisting motion. Grip near opening.
Dispose of KCl
Open 0.1N KCl solution
Remove old grease from joint
Fill the syringe. Dispose. Fill again.
Carefully remove KCl from both sections of reference electrode with syringe needle.
Do not touch Ag/AgCl with needle
Put new grease on cotton swab
Fill both sides of reference electrode.

Remove needle slowly while filling.
Ensure that 0.1 N KCl is used
Put new grease on joint. Make sure

not to plug the Teflon tube with
grease.
Make sure a drop of KCl is present on

the tip of the joint
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Make sure there are no air bubbles
Wipe off excess grease
Put both in saturated KCl solution.

Place tips at same level. Should read
approx. 87mV +/- 10 mV. If not:
Check for bubbles and repeat filling
procedure.
Check wiring
Join the two parts of the electrode
Thoroughly inspect reference

electrode for air bubbles, otherwise
repeat filling procedure
Connect ORP and reference BNCs

with connector. Should read
0mV on controller.
1.
If not check the connections
to the controller.
2.
If this does not work suspect
lead or controller issue.
Grip close to the joint. Use a twisting

motion
A few drops of KCl must exit the frit
Connect reference electrode (R)

to ORP BNC
Remove saturated KCl electrode from

solution
Replace reference electrode ( R)
Tighten Swagelok fittings: careful, do

not over tighten: hand tight + snug-up
(<1/16th turn)
Connect ORP and temp BNCs
234
Connect reference BNC
Close pressure relief valve
Open water outlet (2) and inlet (1)

slowly. Clean syringe and needle with
demin (not shown)

OM0211_________________________________________________________________________
APPENDIX D
Advanced PID Control Settings
The standard ISA Non-Interacting form of the position PID algorithm has the following form:
u (t ) =
100
1
de (t )
e(t ) + e (t ) dt + Td
PB
Ti
dt
The following PID equation has been implemented in the 3D TRASAR Boiler controller firmware.
u (t ) =
100
1
de (t )
e(t ) + e (t ) dt + T d
+ Bias + IntegralWi ndUp _ FB
PB
Ti
dt
Where, u is the control variable and e is the control error (e = set point process variable). The
control variable is the sum of four terms: the P-term (which is proportional to the error), the I-term
(which is proportional to the integral of the error), the D-term (which is proportional to the derivative of
the error), and Bias (constant offset term). The IntegralWindUp_FB term uses the time constant Tt
to provide Integral Wind-up protection.
These features will be included for each PID algorithm: equation update rate (period), auto/manual,
reverse/direct acting, bumpless transfer (from manual to automatic operation and failsafe to
automatic), integral windup protection, max change/period, min/max scale, min/max clipping, manual
bias term, and (backward difference) derivative filter.
PID Control Parameters
Acting: Controller Action (Reverse/Direct)
Direct Action: Controller output increases in response to an increase in the signal input. .e.g. ORP
control is direct controller action because increasing values of ORP will result in increasing amount of
scavenger being applied (increased pump output)
Reverse Action: Controller output increases in response to a decrease in the signal input. .e.g.
TRASAR control is Reverse controller action because a decrease in TRASAR reading will result in
increasing amount of product being applied (increased pump output)
Bias: Bias Value
The bias term is used to add a constant offset to the PID algorithm. It is only used in a P only control
system. Most systems will used the integral term in place of the constant Bias term (Range: 0.0 to
100.0%; Default = 0.0%).
Max Change: Maximum Change Value (Per Cycle)
Value specifies the maximum amount the PID output is allowed to change in a single control cycle.
This value is used to limit the output slew rate.
Note: Never set to zero (0), or the output will not change.
(Range: 1.0 to 100.0%; Default = 10.0%).
Output Max: Maximum PID Output
Value specifies the maximum allowable PID output. This setting would be used to limit (clip) the
maximum output value.
(Range: 0.0 to 100.0%; Default = 100.0%).
Output Min: Minimum PID Output
Value specifies the minimum allowable PID output. This setting would be used to limit (clip) the
minimum output value.
(Range: 0.0 to 100.0%; Default = 0.0%).
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PB: Proportional Band Constant
The proportional band (PB) affects all three PID terms (Control Error, Integral, and Derivative). This
tuning constant is located in the denominator (100/PB of the PID equation. Notice the smaller the
value of PB, the greater the impact (response) it has on all three PID terms. Also, note only (100/PB)
affects the Control Error term.
(Range: 10-6 to 106; Default = 100.0).
Process Variable SH:
PID Process Variable Scale High
The Process Variable Scale High value is the maximum value of the Process Variable input. This
value is used to normalize the PID output (0 100%).
(Setting value is dependent on the Process Variable)
Process Variable SL:
PID Process Variable Scale Low
The Process Variable Scale Low value is the minimum value of the Process Variable input.
This value is used to normalize the PID output (0 100%).
(Setting value is dependent upon the Process Variable)
Td: Derivative Time Constant (Seconds)
The derivative time constant (Td) affects only the Derivative Term. This tuning constant is located in
the numerator (Td) of the PID equation. Notice the larger the value of Td, the greater the impact it
has on the rate of change of the control variable. Also, note both (100/PB) and (Td) affect the
Derivative Time Constant term.
Note: Setting Td = 0, disables the derivative term.
(Range: 0.0 to 106; Default = 0.0).
Ti: Integral Time Constant (Seconds)
The integral time constant (Ti) affects only the Integral Term. This tuning constant is located in the
denominator (1/Ti) of the PID equation. Notice the smaller the value of Ti, the greater the impact it
has on the history of the control variable. Also, note both (100/PB) and (1/Ti) affect the Integral Time
Constant term.
Note: Setting Ti = 0, disables the integral term.
(Range: 0.0 to 106; Default = 150.0).
Tt: Tracking Time Constant (Seconds)
The tracking time constant (Tt) is used to prevent integral wind-up. The tracking constant is an
external feedback element used to limit the integral term so that it does not integrate to infinity (i.e.,
saturate the algorithm). This variable is normally preset and not exposed to the end user. Tt
should not be modified without the help of the Nalco Help Desk.
-6
6
(Range: 10 to 10 ; Default = 106).
Update Interval: PID Update Rate (Seconds)
Value specifies how often the PID equation runs. The default is 5 seconds.
(Range: 5 to 60 seconds; Default = 5 seconds)

PID PV: Process Variable
The process variable used by the PID equation.
PID SP: PID Set Point
The set-point used by the PID equation.
(Setting value is dependent upon the process variable)
236

OM0211_________________________________________________________________________
APPENDIX E
The Sample Conditioning System (SCS) is a pre-assembled system for providing water
samples from a boiler system to the TRASAR fluorometer and other on-line analytical
instrument. It provides sample cooling, pressure reduction, particulate filtration and sample
flow rate adjustments that are necessary for effective and safe instrument operation.
This system is not intended for use on steam samples.
Hot sample water passes through a sample cooler, inline strainer, solenoid valve and a
downstream pressure-regulating valve. Temperature and pressure gauges provide indication
of these parameters. Cooled, pressure-reduced sample is then passed through a cartridge
filter, an RTD and flow sensor and adjustable rotometer (flowmeter). The outlet sample flow is
controlled by adjusting the rotometer. The grab sample valve can be plumbed to a drain and
left partially open. This can be used increase sample flow when the lag time is lengthy.
An adjustable pressure relief valve opens to atmosphere if the factory setting of 65 psi [4.5
bar] is exceeded. An RTD, connected to the 3D TRASAR Controller, activates the inlet
solenoid valve to shut off sample flow if the factory temperature setting of 110F [43C] is
exceeded. The flow sensor provides a dry contact closure if sample flow is over 200 cc/min.
There are two model sample conditioning systems. One is designed to handle samples up to
1500 psi (103 bar) and 500 F (260 C). The other is designed for the low-pressure sections
of the boiler and can handle samples up to 50 psi (3.4 bar) and 250 F (122C).
General Specifications
Power:
Electrical Enclosure:
Cooling Water Flow:
High Temperature Shut-Off:
Inlet Strainer Element:
Cartridge Filter Element:
Sample Cooler Limits:
Coil:
Shell:
Low Flow Switch:
Pressure Relief:
Inlet Connection:
Outlet Connection:
Wetted Materials:
120 VAC, 60 Hz or 220 VAC, 50 Hz, A, pre-wired to controller

NEMA 4X
0.5-3 gpm [1.9-11.4 lpm] recommended; 200 psi [13.8 bar] maximum
Factory set at 110F [43C],
316 SS, 40 micron
PP, Nylon, 5 micron
5000 psi @ 800F [427C]
250 psi @ 125F [52C]
200 cc/min [0.053 gpm], fixed
65 psi [4.5 bar], 3/8 tube connection
SS tubing
MNPT
316 SS, Teflon, Acrylic, PVC, PE, Nylon, PP, Viton
Sample Specifications:
High Pressure/High Temperature Feedwater System
Maximum Pressure:
1500 psi (103 bar)
500 F (260 C)
Sample Flow:
250-1000 ml/min
Low Pressure/Low Temperature Feedwater System
Maximum Pressure:
50 psi (3.4 bar)
250 F (122C)
Sample Flow:
250-1000 ml/min
High Pressure/High Temperature Blowdown System
Maximum Pressure:
1500 psi (103 bar)
500 F (260 C)
Sample Flow:
250-1000 ml/min
237

OM0211
Sample Cooler
The Sample Cooling Coils have the capacity to remove approximately 250 BTU of heat per
minute per GPM of cooling water flow from a hot sample. This is based on a cooling water
delta T of 30F. So, if 3 GPM of cooling water flow is available with delta T of 30F,
approximately 750 BTU per minute of heat can be removed.
Operating performance of sample coolers is expressed in terms of "approach temperature".
The approach temperature, when added to the cooling water temperature, results in the
sample outlet temperature. The table below provides approach temperatures for
combinations of sample temperatures and sample flow rates. The figures assume a cooling
water flow rate of 3 gpm, which is recommended. Higher cooling water flows do not result in
significantly improved performance. Lower flows will result in reduced performance. The
resulting sample outlet temperature is calculated by adding the approach temperature to the
known cooling water temperature as follows:
To = Tc + Ta
Where - To = sample outlet temperature in F
Tc = cooling water temperature in F
Ta = approach temperature in F (from table below)
SAMPLE TEMPERATURE
Sample Flow
cc/min
200F
300F
400F
500F
600F
250
0.5F
0.8F
1F
1.3 F
1.5 F
500
1.5F
2F
2.5F
3.F
4.5F
750
3F
5F
7.5F
10F
18.5F
1000
6F
11F
20F
24F
28F
1500
13F
24F
35F
51F
66F
2000
20F
40F
63F
95F
120F
APPROACH TEMPERATURES
BASED ON 3 GPM COOLING WATER FLOW
For Example
Sample temperature:
200F
Sample Flow:
1000 cc/min
Cooling water temperature (Tc): 80F
Cooling water flow:
3 gpm
The Approach Temperature (Ta) from the table is 6F. Therefore, the outlet temperature (To)
is calculated as: To = 80F + 6F = 86F
Note:
238
Sample cooler performance in the table is stated for total sample flow through the cooler. If
some sample is intentionally by-passed, the sample flow through the cooler will be greater
than the flow rate shown on the rotometer. The by-pass and outlet stream temperatures are
affected by the total sample flow, not just the flow indicated on the rotometer.

OM0211_________________________________________________________________________
CAUTION:
Care should be taken around the sample cooler and sample lines. The tubing and
fittings may be hot and present a burn hazard.
Maximum Sampling Rates for 1 Sq. Ft. Models*

Sample Type
Temperature
Maximum Sampling Rate
Boiler Water
400 F (204C)
950 mL/min
Boiler Water
500 F (260C)
850 mL/min
Boiler Water
600 F (316C)
600 mL/min
* Cooling water @ 3 GPM (114 LPM), T=30F (17C). Final sample temperature of 100 F (38C).
239

OM0211
APPENDIX F
Notes on Control Modes, Interlocks, Control Overrides and

Alarms
Control Modes
Continuous control is otherwise referred to as ON/OFF Control. The term continuous control
is used here specifically in the place of ON/OFF control for Conductivity Devices as it is an
Industry Standard term for use of the ON/OFF control method for Conductivity.
Timed Sample Control must be used in conjunction with a sample schedule. Timed Sampling
minimizes water loss in small systems. The user is prompted during the configuration set-up to
associate this control with a sample schedule to be used as part of a control cycle. Within
Timed Sample Control are 2 separate control options:
o
Proportional control: Where the control output is turned on for a calculated period of time that
is proportionally based on how far away the process reading is from set-point (the farther
from set-point the longer the control output is on).
Continuous Control: Similar to ON/OFF control in that the control output is turned on until the
set-point value is satisfied. A difference is that the control output will turn OFF when the
maximum time ON for the sample is reached, regardless of whether the set-point value has
been satisfied or not.
Interlocks
The Intermittent Feed screen allows the User to select which outputs are affected by an Intermittent
Feed signal. In order to use this function, the Signal Used for Intermittent Feed water? box must be
checked when an analog or digital input device is configured.
Note:
Only 1 input can be configured as the Intermittent Feed Water signal.
When the signal falls below the threshold selected, the Intermittent Feed function will take action
based on the settings specified on the intermittent feed screen:
240

OM0211_________________________________________________________________________
Output Override: If this box is checked, the output override function will be enabled for the OUTPUT
DEVICE identified.
Output Device: This column lists all of the Outputs that are configured via the Control and Alarm
Summary screen.
Response: The response that will be taken when an Intermittent feed condition is reached.
Notify: Select this to enable the controller to call out to the 3D TRASAR Web if an intermittent feed
water event occurs. This box should only be checked if the loss of feed water is an abnormal event.
Note:
In the example shown the following will occur:
1. The DO Pump, Elimin-Ox Pump, 22310 Pump, and Caustic Pump will all be Forced Off when a
loss of flow is detected by the flow device.
2. The operation of the PID 3 BD Valve and AT ORP chart Recorder outputs will not be affected .
OK: Saves settings and closes the application. If you choose this option by accident, you may use the
File menu function at the top of the MDI screen to re-open the configuration.
Cancel: Closes the current screen.
Note:
Choosing Cancel will not change any previously saved selections and settings .
241

OM0211
Control Overrides
A Control Override is used to override automatic control of a pump or valve output due to a separate
input signal that what is being used for control. Two examples of how a control override could be
used are as follows.
If an acidic oxygen scavenger is being fed to the system, the scavenger pump can be Forced
Off if the pH drops below a user set value.
A digital input signal that identifies whether a boiler is operational could be used to shut off a
blowdown relay when the boiler is off or idle while other boilers and blowdown in the plant are
operating. For information on setting up a control override consult the help file in the
Configurator.
Hardness Override
The hardness override permits the use of a hardness signal from a sensor to alert of a hardness
upset in the makeup water. When this upset occurs, additional internal treatment can be fed to the
boiler to prevent scaling.
The Hardness Override screen is accessed on the Configurator tool bar under the Edit tab.
Hardness Override using a Hach APA6000 Hardness Analyzer

The benefit of using the Hach analyzer is that it has internal checks to confirm that the instrument is
giving an accurate reading of the hardness. Due to this alarming capability, there are three devices
that need to be configured for this override as follows:
o
o
o
Fluorometer in PID control

Analog Input of the hardness reading
Digital Input for the hardness analyzer alarm to alert for a false hardness reading due to Hach
Sensor warnings or Hach sensor alarms.
Both the analog and digital input will need to be configured on both the Hach APA 6000 and the 3D
controller. Consult the Hach manual for further instructions on how to configure the outputs. Assign
one of the Hach alarm relays for sensor warning and alarms.
242

OM0211_________________________________________________________________________
Other Hardness Sensors: Configure a generic control override.
Note:
Other hardness analyzers generally do not have alarming capability and therefore there is the
possibility to get a false hardness reading and excess chemical would be fed as a result. For
more information on setting up these overrides see Appendix J.
Alarms and Alerts
Alarms and Alerts are individually selectable options where appropriate on each configuration
screen. If you have previously selected a communication method, you may also individually
select to be notified, (or not) when reaching any Alarm or Alert value by checking the Notify on
Alert (Alarm). User sets the alarm set point.
Alert: An Alert is a notification alarm. An Alert provides an indication that the input signal is at
a value outside the range of normal operation and the system needs attention. User can enable
high or low alerts for each input signal. Alerts can be set for all input signals whether they are
used for control of outputs or not. During an Alert, an output associated with the signal
continues in automatic control.
Failsafe Alarms: Failsafe Alarms are allowed where signals will control an output. When you
reach a Failsafe alarm level, the output exits automatic control and is placed into timer control
(see failsafe responses). Some overriding alarm conditions such as low steam flow and system
Interlock can place multiple outputs into failsafe operation.
Clearing of Alarms: Some alarms self clear when the input signal returns to normal operating
range. Other alarms (Temperature High Override or Pump Timeout) can only be cleared by the
user.
Alarm Delay: An input signal must persist in the alarm state for a set time period before the
alarm is called. This value cannot be user set. When an alarm is cleared by the user, the alarm
delay is automatically increased by a factor of 5 to allow the system to be in automatic control for
an extended period so that the system can exit the alarm condition.
Alarm Deadband: Each alarm has an associated dead band. Alarms will persist until the signal
value differs from the alarm setpoint by the alarm deadband.
Control Timeout Alarm: If a relay based pump is activated for longer than a user set period of
time, the alarm is called. This alarm does not self clear. The duty cycle of the output is
continuously averaged and this alarm takes effect when this pump duty cycle over the user set
period becomes close to 100%. When applied to Timed Sample blowdown control it is cumulative
over more than one decision interval.
Relay
If the signal used for automatic control of the output goes to low or high failsafe, the pump time
out alarm will be cleared.
Relay Pump Timeout
1.2
1
0.8
0.6
0.4
0.2
0
Pump Timeout
360min
200
400
600
800
1000
Time (minutes)
243

OM0211
Pump Timeout for Analog Outputs: The timeout alarm for a pump/valve controlled via a 4-20
mA signal has both an On Time and Duty Limit component. The pump/valve must be on for
the user selected On time for (on average) the user selected % output level for the alarm to be
triggered. The controller calculates a continuous average of the pump duty cycle.
Analog Out%
Analog
120
100
80
60
40
20
0
Pump Timeout
360min 90%
200
400
600
800
1000
Time (minutes)
For analog outputs, configure the Pump Maximum, to be able to rapidly respond to system
upsets. The Pump timeout should be set so that it alarms if the pump is operating at a high value
(lower than the output maximum) for an unreasonable duration of time.
An example of where Pump timeout is useful, you are feeding sulfite using the NCSM control and
the setpoint is too low. So the controller pumps so much sulfite that the water becomes acidic.
The NCSM value does not drop because of the increase in corrosivity. The pump timeout can
alarm in such a situation.
SCS High-Temperature Alarm: All systems should be configured to alarm on high SCS
temperature. Frequent high sample temperatures are an indication of cooling water supply
problems that must be corrected. Repeatedly subjecting the solenoid valve to high temperatures
will cause a valve failure and safety risk.
Failsafe Alarms Output Responses
Smart Failsafe Duty (default): User sets the initial value of the duty cycle. This value is
continuously averaged in with the daily output duty cycle. The smart failsafe duty cycle will reflect
the average of the past 12 days of operation.
Fixed Failsafe Duty: User sets the failsafe duty cycle.
Relays: In Fixed Failsafe mode, the relay is turned on every 15 min period for a period of
time set by the duty cycle.
Analog Outputs: In Fixed Failsafe analog output operates at a constant repetition rate set by
the Failsafe duty cycle
Force Off: Output is off during failsafe control
244

OM0211_________________________________________________________________________
APPENDIX G
Electrical Ground Testing Procedure for the 3D TRASAR

Controller
PURPOSE
To make electrical measurements of the voltages supplied to 3D TRASAR Controllers to

determine if there is proper electrical grounding.
BACKGROUND
During a customer visit to troubleshoot a difficult conductivity probe reading problem, an electrical
source grounding' problem was discovered. Replacement of controllers, red boards, and multiple
probes did nothing to eliminate the badly drifting and erratic readings. And while this installation
had a 'junction box' installed, it was not the source of the grounding problem.
Rather it was the plant 'electrical source' to the controller that was the problem. Specifically - the
electrical supply was not properly grounded. When the electrical source to the 3D TRASAR
controller was changed to a properly grounded source - the problem disappeared, and has since
not returned.
The procedure below is to be implemented around the globe as a standard part of new
installations, and in existing installations where conductivity probe readings problems are
routinely experienced despite equipment replacements.
The idea here is to verify that the power connections are correct and go to the right place. This
test will not guarantee a good Earth Ground. How a good earth ground is established in each
situation is up to the local electrician.
In another case NCSM values were shown to be low and unresponsive to known changes in
system redox stress. Trouble shooting also showed this to be due to a nonexistent ground
connection to the 3DT Boiler skid. It is particularly important to make sure that good grounding is
always present when readings (NCSM, conductivity, pH etc) are taken in low conductivity water
environments typically found in boiler water systems.
TESTING PROCEDURE
1. For Safety of personnel and equipment - have a qualified electrician only take the measurements
below.
2. Disrupt power to the 3D TRASAR controller, e.g. with a MCB (mains circuit breaker) or the mains
switch on the electrical panel, etc. Use lock-out procedures as required.
3. Leave the 3D TRASAR controller electrical wires inside the controller connected to the electrical
source (hot, neutral, ground). This will measure exactly what the controller is seeing when taking
the measurements below.
4. Take measurements inside the controller at the main power terminal block (Pt. 1-L,
Pt. 2-N, and Pt. 3-GND).
Note:
If a J-Box (junction box) is installed take the measurements both inside the controller, and
inside the J-Box at the main power terminal points.
245

OM0211
If a problem is found below then proceed to take the same measurements at the customer
electrical panel or source to the controller or J-Box.
It may be unsafe to try to press (hold) the voltmeter probes on the ends of the powered terminal
screws. It is safer to clamp on the voltmeter probes (with the power off), then turn on the power,
and then make each voltage reading (Step #6 below).
5. Energize the 'electrical source' as required to make the measurements below.

6. Using a Volt Meter:
For the US only, a good check is to measure the voltage from "Hot to Neutral" and "Hot to
Ground". If they are very close to the same value (+115 VAC), then at least you know the Earth
Ground Wire is connected and not open. Determining if the "Earth Ground" is actually connected
to the site's Earth Ground is very difficult to determine. However, in most cases what we are
finding is that the Earth Ground wire is open - on the customer side.
Measure the voltage from "Line (L) to Neutral (N)"

Measure the voltage from "Line (L) to Earth Ground (PE)"
Both measurements should be close to each other, e.g. +115 + 10% VAC
Outside the US, this test is dependent on the power distribution system which needs to be
determined on a case by case (country by country) basis. Some countries use 230 VAC with both
sides floating above earth ground (like the US). Some countries use 230 VAC and tie one side of
the power to Earth Ground. It varies. RE: Diagram below!!
o
For testing 230 VAC with one side connected to Earth Ground
L (Line) = Hot Side
N (Line) = Neutral Side
G = Earth Ground
For testing 230 VAC with neither side connected to Earth Ground (US 230 VAC)
L (Line) = Hot Side/Phase A
N* (Line) = Hot Side/Phase B
G = Earth Ground
246
Line to Neutral VAC reading should be around 230 VAC + 10%

Line to Ground VAC reading should be around 230 VAC + 10%
Neutral to Ground VAC reading should be close to 2 or 3 VAC
Line to Neutral VAC reading should be around 230 VAC + 10%

Line to Ground VAC reading should be around 115 to 130 VAC + 10%
Neutral to Ground VAC reading should be around 115 to 130 VAC + 10%

OM0211_________________________________________________________________________
7. To safely reconnect the electrical source to the 3D TRASAR Controller and reenergize the
system:
Follow the instructions in Step #2 above.

Make sure the 'power switch' on the side of the controller, and handle on
Junction Box if one is installed, is switched to the 'OFF' position.
Disconnect all leads to the voltmeter if clamped to any electrical terminal
point.
Reconnect all power leads as required.
Re-energize the main power source to the controller, following all lock-out
procedures.
Re-energize the J-Box and turn the controller power switch to the 'ON'
position.
Additional Information:
Here's a drawing for the most common 400V/230V power networks in Europe. The
neutral is connected to the ground, so the voltage between the live and the neutral or
ground should be both 230VAC. The voltage between the live and ground could be a few volts lower,
depending on where the neutral and the ground are connected.
There are some areas with older networks that give you 2 live wires. The voltage between the live
wires is 230V. The voltage between one live wire and the ground is 130V.
Schematic above is showing is the case where 230 VAC is tied to Earth Ground on one
side. The US 230 VAC is the case where neither side is connected to Earth Ground.
247

OM0211
APPENDIX H
PANEL AND FRAME SYSTEM DIMENSIONS
The following diagrams are representative of the systems in each model series. They have been
selected to illustrate the broad variety of possible configurations. The actual equipment included in
each system is dependent on the specific model number.
060-BL55XXXX.88 Series
Part Number 060-BL5521BH.88
248

OM0211_________________________________________________________________________
Part Number 060-BL5321.88
249

OM0211
Part Number 060-BL6131B.88
250

OM0211_________________________________________________________________________
APPENDIX I
3D TRASAR Boiler System Features Tables

3D TRASAR Boiler System Numbering Convention
Region
Model
Series
USA
Canada
Europe
110 VAC/60 Hz
110 VAC/60 Hz
220 VAC/50 Hz
Latin America
110 VAC/60 Hz
Asia-Pacific
220 VAC/50 Hz
220 VAC/50 Hz
BL50xxx
060-BL50xxx.88 060-BLC50xxx.88 060-BLM50xxx.88 060-BLL50xxx.88 060-BLLC50xxx.88
060-BLPC50xxx.88
BL52xxx
060-BL52xx.88
060-BL52xx.88
060-BLM52xx.88
060-BL52xx.88
060-BL52xx.88
060-BL52xx.88
BL53xxx
060-BL53xx.88
060-BLC53xx.88
060-BLM53xx.88
060-BLL53xx.88
060-BLLC53xx.88
060-BLPC53xx.88
BL54xxx
060-BL54xx.88
060-BLC54xx.88
060-BLM54xx.88
060-BLL54xx.88
060-BLLC54xx.88
060-BLPC54xx.88
BL55xxx
060-BL55xx.88
060-BLC55xx.88
060-BLM55xx.88
060-BLL55xx.88
060-BLLC55xx.88
060-BLPC55xx.88
BL6xxxx
060-BL6xxx.88
060-BLC6xxx.88
060-BLM6xxx.88
060-BLL6xxx.88
060-BLLC6xxx.88
060-BLPC6xxx.88
Note: BL52xxx models do not require a power supply.
3D TRASAR Technology for Pre-Boiler Control

Scale Control and Corrosion Stress Control
Corrosion Stress
Monitor
Controller
Fluorometer
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Lexan
Shield
SS
Enclosure
High
Pressure
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Low
Pressure
None
Mounting
Wall
Frame
Y
Y
Y
Y
Y
Y
High Purity Low Purity
115 VAC/60Hz
060-BL5520.88
060-BL55200L.88
060-BL55200H.88
060-BL5520B0.88
060-BL5520BL.88
060-BL5520BH.88
060-BL5521.88
060-BL55210L.88
060-BL55210H.88
060-BL5521B0.88
060-BL5521BL.88
060-BL5521BH.88
060-BL5522.88
060-BL55220L.88
060-BL55220H.88
060-BL5522B0.88
060-BL5522BL.88
060-BL5522BH.88
060-BL5523.88
060-BL55230L.88
060-BL55230H.88
060-BL5523B0.88
060-BL5523BL.88
060-BL5523BH.88
060-BL5510.88
060-BL55100L.88
060-BL55100H.88
060-BL5510B0.88
060-BL5510BL.88
060-BL5510BH.88
060-BL5511.88
060-BL55110L.88
060-BL55110H.88
060-BL5511B0.88
060-BL5511BL.88
060-BL5511BH.88
060-BL5512.88
060-BL55120L.88
060-BL55120H.88
060-BL5512B0.88
060-BL5512BL.88
060-BL5512BH.88
060-BL5513.88
060-BL55130L.88
060-BL55130H.88
060-BL5513B0.88
060-BL5513BL.88
060-BL5513BH.88
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Nalco Part Number
None
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Feedwater pH & Conductivity

Blowdown
Relay Box
251

OM0211

Scale Control
Corrosion Stress
Monitor
Controller
Mounting
Fluorometer
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Lexan
Shield
SS
Enclosure
High
Pressure
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Low
Pressure
None
Wall
Frame
Y
Y
Y
Y
Y
Y
High Purity Low Purity
115 VAC/60Hz
060-BL5420.88
060-BL54200L.88
060-BL54200H.88
060-BL5420B0.88
060-BL5420BL.88
060-BL5420BH.88
060-BL5421.88
060-BL54210L.88
060-BL54210H.88
060-BL5421B0.88
060-BL5421BL.88
060-BL5421BH.88
060-BL5410.88
060-BL54100L.88
060-BL54100H.88
060-BL5410B0.88
060-BL5410BL.88
060-BL5410BH.88
060-BL5411.88
060-BL54110L.88
060-BL54110H.88
060-BL5411B0.88
060-BL5411BL.88
060-BL5411BH.88
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Nalco Part Number
None
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y

Blowdown
Relay Box
Y
Y
Y

Corrosion Stress Control
Corrosion Stress
Monitor
Controller
Lexan
Shield
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Mounting
Fluorometer
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
SS
Enclosure
High
Pressure
Y
Y
Y
Y
Y
Y
Y
Y
Low
Pressure
Cool &
Depressurize
None
Wall
Frame
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Blowdown
Relay
Box
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA

High Purity
Low
Purity
None
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Nalco Part Number

115 VAC/60Hz
060-BL5320.88
060-BL5321.88
060-BL5322.88
060-BL5323.88
060-BL5310.88
060-BL5311.88
060-BL5312.88
060-BL5313.88
060-BL5300.88
060-BL5301.88
060-BL5302.88
060-BL5303.88
060-BL5340.88
060-BL5341.88
060-BL5342.88
060-BL5343.88
Corrosion Stress Sensor Module

Corrosion Stress
Monitor
Controller
Lexan
Shield
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
252
Mounting
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
SS
Enclosure
High
Pressure
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Low
Pressure
Cool &
Depressurize
Y
Y
Wall
Frame
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
None
Y
Y
Y
Y
Y
Y

Blowdown
Relay Box
Fluorometer
Y
Y
Y
Y
Y
Y
Y
Y
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
High Purity
Low
Purity
None
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
US Nalco Part
Number
115 VAC/60Hz
060-BL5220.88
060-BL5221.88
060-BL5222.88
060-BL5223.88
060-BL5210.88
060-BL5211.88
060-BL5212.88
060-BL5213.88
060-BL5200.88
060-BL5201.88
060-BL5202.88
060-BL5203.88
060-BL5240.88
060-BL5241.88
060-BL5242.88
060-BL5243.88

OM0211_________________________________________________________________________
3D TRASAR Technology for Boiler Control
Boiler Control
Corrosion Stress
Monitor
Controller
Fluorometer
Y
Y
Y
Y
Y
Y
Y
Y

Low
Pressure
Mounting
Lexan
Shield
SS
Enclosure
High
Pressure
NA
NA
NA
NA
NA
NA
NA
NA
Y
Y
Y
Y
Mounting
None
Wall
Frame

Blowdown
Relay Box
Y
Y
Y
Y
Y
High Purity
Low Purity
NA
NA
NA
NA
NA
NA
NA
NA
None
NA
NA
NA
NA
US Nalco Part
Number
115 VAC/60Hz
060-BL61300.88
060-BL61310.88
060-BL6130B.88
060-BL6131B.88
Boiler Control Fluorometer M odule

Corrosion Stress
Monitor
Controller
Fluorometer
NA
NA
NA
NA
Y
Y
Y
Y
Lexan
Shield
SS
Enclosure
High
Pressure
NA
NA
NA
NA
NA
NA
NA
NA
Y
Y
Y
Y
Low
Pressure
None
Wall
Frame

Blowdown
Relay Box
Y
Y
Y
Y
Y
Y
High Purity
Low Purity
NA
NA
NA
NA
NA
NA
NA
NA
None
NA
NA
NA
NA
US Nalco Part
Number
115 VAC/60Hz
060-BL60300.88
060-BL60310.88
060-BL6030B.88
060-BL6031B.88
3D TRASAR Technology for Boiler Condensate Control

Condensate Monitor
Controlle r
Fluorometer
Y
Y
Y
Y
NA
NA
NA
NA
Nalco Corrosion
Monitor
Condensate Sample
Conditioning System
Y
Y
Y
Y
Y
Y
Mounting
Wall
Frame
Y
Y
Y
Y
Blowdown
Relay Box
Y
Y
Y
Y

High Purity
Low Purity
None
Y
Y
Y
Y
NA
NA
NA
NA
NA
NA
NA
NA
US Nalco Part
Number
115 VAC/60Hz
060-BL50100.88
060-BL50101.88
060-BL50200.88
060-BL50201.88
253

OM0211
APPENDIX J
Hardness Override Screens
This screen allows the User to override an output device based on input signal reading water
hardness. It is accessed in the Configurator tool bar under the Edit tab.
Note:
Monitoring a systems hardness actually requires two input signals. The first input signal is
the hardness value, the second signal is used to tell the controller whether the first signal is in
an alarm state or not.
Note:
In the case of a hardness override, a factor can be entered by the User which will be applied
to the override response, in the case of a historical failsafe.
Enable Override: The User may use this box to enable/disable the alarm.
Note:
If the User continues to disable the override, all of the fields must be cleared and disabled.
Hardness Input: This field contains a list of all of the installed analog inputs (IBox and Modbus
analog inputs also included).
Caution:
The value selected cannot be the same as the value in the TRASAR Signal box.
Hardness Alarm Input: This field contains a list of all of the installed digital inputs (Modbus digital
inputs also included).
TRASAR Input: This field contains a list of all of the installed fluorometer and analog inputs
(including Modbus analog inputs) using a control method other than monitor only.
Alarm Action: This field contains two options (see above):

1. Fixed Failsafe Duty - If the user selects fixed failsafe duty, the Alarm Factor textbox is set to one
and disabled.
2. Smart Failsafe Duty - If the user selects smart failsafe duty, the Alarm Factor text box is
enabled.
254

OM0211_________________________________________________________________________
Failsafe Duty%: This field is used to determine the output % for a pump if the failsafe alarm limit is
reached.
Alarm Factor: This factor is an integer value between one and 10.
Note:
This field is only enabled if the Alarm Action value is Smart Failsafe Duty.
Ok: When this button is selected, in non-connected mode the screen values will be saved into the
configuration structure and kept in memory before closing the screen. When the controller is in
connected mode the button will be labeled upload and selecting it will upload the new settings to the
controller.
Note:
No pending changes made on this screen will be saved.
255

OM0211
APPENDIX K
Coordinated Phosphate Screens
This screen can be used to configure the pH and TRASAR Signal for Coordinated Phosphate control.
Users may choose 1 pH and 1 fluorometer device for phosphate control.
Note:
Users will not be able to configure or edit a device designated for phosphate control
unless there is 1 pH and 1 fluorometer device with that control method.
How to access this screen:

1. On the Control and Alarm Settings screen the User must have both a Fluorometer channel and
pH channel available to use Phosphate Control.
2. Select both a Fluorometer and pH channel under the Control Method pick lists, and assign them
to Phosphate Control. Select either Configure (first time) or Edit to configure the Phosphate
control settings. Selecting Edit for Either the Fluorometer or pH meter will take you to the
Phosphate control screen.
3. If you are using Analog Input devices for either or both the TRASAR (XE-2 for example) and pH
inputs, you can assign the Phosphate Control method to the channel. See below.
256

OM0211_________________________________________________________________________
Functions and Features
Inputs
pH or TRASAR Signal: This field contains all of the pH/TRASAR devices with a Phosphate Control
method.
Analog Input Scaling: Upon pressing this button a screen will open that will allow the User to select
whether the Analog Input uses current or voltage units, as well as enter the values of the scale.
Operating Temp: If the User chooses an RTD device on the Control and Alarm Settings screen this
field will be populated with the name of the RTD device (disabled). If the User chooses User set on
the Control and Alarm Settings screen for this device, then the field will be enabled. The conductivity
device is compensated with a constant temperature value entered by the User, or with an RTD
device.
TRA Background: This background value (0 to 20%) must be entered by the User.
Note:
This is a required field.
PO4 Feed Point: Here the User may choose Boiler or Feed water as the feed point. If the user
chooses feed water then the following fields will be disabled:
a.
Diag. TRASAR Product
b.
Diag. TRASAR Output
c.
Diag. TRASAR Output Name
d.
Diag. TRASAR Product Name
Phos. Phosphate Factor: This factor is the ratio of the combined Phosphate Pump Output to the
diagnostic TRASAR Pump Output.
Note: This field is only for the Boiler PO4 Feed Point Selection.
Example: A value of 1.0 means that if the TRASAR pump has an output of 20%, then the combined
output of both the low and high pH products will also be 20% (more examples: 10% low
& 10% high, 5% low & 15% high, 19% low and 1 % high, etc).
Caution:
Zero is NOT a valid input.
Caution:
This important setting is specific for every field situation. Factors such as pump size
and pump stroke settings will influence the output ratio desired between the diagnostic
treatment pump and that of the phosphate pumps. Increasing the Phos. Pump Factor
(ratio) will give a higher phosphate content in the boiler for any given TRASAR
concentration in the FW (assuming properly operating pumps at consistent pump stroke
settings).
257

OM0211
Products and Outputs
Low or High pH Product: This field contains a list of products. When the user selects a product from
the list, the name of the product will be displayed in the Low/High pH Product Name field.
Note:
If the User other, the Product Name box will become editable allowing the User to enter the
product name.
Note:
Selecting a product from the dropdown will populate a default value into the Low/High pH
Output Name field.
Low/High pH Product Name: The name of the pH product.

Low/High pH Output: A list of the available, unallocated, analog outputs.
Caution: Once an output is chosen it will be considered allocated and cannot be used again.
Low/High pH Output Name: The User-friendly name of the output.
Low/High pH TRASAR Factor: The User-defined pH TRASAR factor.
Note:
If a specific TRASAR product was selected from the Product field, the corresponding product
factor (from the database) will be displayed here.
Diag. TRASAR Product: A list of the TRASAR products.

Note:
The diagnostic TRASAR fields will only be enabled if the PO4 Feed Point is set to Boiler.
Diag. TRASAR Product Name: The name of the Diag. TRASAR product.
Diag. TRASAR Output: A list of the available, unallocated, analog outputs.
Diag. TRASAR Output Name: The User-friendly name of the output.
Diag. TRASAR Factor: The User-defined Diag. TRASAR factor.
TRASAR/pH
Control and Alarm Settings
High Failsafe Alarm: The High Failsafe Alarm group box is described here. The Low Alarm Failsafe
Group box functions similarly for Low alarm levels.
Caution:
IF ENABLED, reaching an Alarm level WILL force the controller into the backup
control mode set up in the Alarm Response Settings.
High Failsafe Limit: This field is used to enter the high failsafe alarm limit. The value entered by the
User must be greater than the high alert limit value entered on this screen and must also be greater
than zero. This is a required field.
Enabled: This check box will determine whether or not the parameter is enabled.
Notify On Alarm: This field is used to determine whether or not a notification is sent to the User when
this failsafe value is reached. This field is enabled or checked by default. The User must set up a
communication method in the configurator in order for notifications to be sent.
Low/High pH alarm Resp.: This dropdown list option determines what alarm response will be
executed if the failsafe limit is reached. The options are:
a. Smart Failsafe Duty: When the alarm level is reached, the controller is set to feed/control on a
duty cycle representing the average feed/control rate recorded by the controller over the last
several days.
258

OM0211_________________________________________________________________________
b. Fixed Failsafe Duty: When the alarm level is reached, the controller is set to feed/control based
on a duty cycle set by the User. This will be entered by the User representing a percent time on.
c.
Forced Off: When the alarm level is reached, control functions will be turned off.
Initial high failsafe duty: The output % for a control if the failsafe alarm limit is reached. This value can
only be entered if the alarm response option is Smart Failsafe or Fixed Failsafe. The value entered
here must be a whole number between 0 and 100. If the alarm response option is Forced Off, this
field is set to zero.
High Alert
High/Low Failsafe Alarm: The High Failsafe Alarm group box is described here. The Low Alarm
Failsafe Group box functions similarly for Low alarm levels.
Caution:
IF ENABLED, reaching an Alarm level WILL force the controller into the backup
control mode set up in the Alarm Response Settings.
Control Settings
Set Point: The set point value for the PID process, must be less than 14 and greater than 0.
Reading: This field will display the current reading for the input device. This is a read-only field. This
field is not active unless the User is connected to an operating controller.
Pump Timeout Alarm
Low/High pH Pump Timeout (mins.): The pump timeout limit.
Note:
This value is used in conjunction with the Timeout Duty Limit setting on the Advanced PID
screen.
Example: The Pump Timeout setting is 60 minutes. The Timeout Duty Limit setting on the
Advanced PID screen for this control is set at is 90%. Based on these settings, the pump
timeout alarm will be activated if the control output to the pump has been at 90% or
greater output for 60 minutes.
Alarm Response: This dropdown list option determines what alarm response will be executed if the
failsafe limit is reached. The options are:
a. Smart Failsafe Duty: When the alarm level is reached, the controller is set to feed/control on a
duty cycle representing the average feed/control rate recorded by the controller over the last
several days.
b. Fixed Failsafe Duty: When the alarm level is reached, the controller is set to feed/control based
on a duty cycle set by the User. This will be entered by the User representing a percent time on.
c.
Forced Off: When the alarm level is reached, control functions will be turned off.
Initial failsafe duty: The output % for a control if the failsafe alarm limit is reached. This value can only
be entered if the alarm response option is Smart Failsafe or Fixed Failsafe. The value entered
here must be a whole number between 0 and 100. If the alarm response option is Forced Off, this
field is set to zero.
Low/High pH Timeout Duty Limit: This function is used in conjunction with the Pump Timeout Alarm
on the main control screen, and must be a number that is at or above the Output Min, and at or
below the Output Max settings. The Low/High pH Timeout Duty Limit sets the minimum % of control
output excessive enough to cause concern.
Note:
This setting, in conjunction with the Low/High pH Pump Timeout setting in minutes
determines if the pump timeout alarm is activated.
259

OM0211
Example: The Timeout Duty Limit setting is 90%. The pump timeout alarm setting on the main
screen is set at 60 minutes. Based on these settings, the pump timeout alarm will be
activated if the control output to the pump has been at 90% or greater output for 60
minutes.
Advanced Fluorometer: If pressed, this button will take the User to screen used to set alerts for
Turbidity and Cell Fouling.
Tune TRASAR PID: This button is used to display the TRASAR PID Auto Tune dialog box which will
allow the User to enter the data required to auto tune a TRASAR PID controller.
Tune pH PID: This button is used to display the pH PID Auto Tune dialog box which will allow the
User to enter the data required to auto tune a PID controller.
Adv. TRASAR PID: If pressed a popup screen will appear in which the User can set specific
TRASAR PID values as well as the Timeout Duty Limit that is associated with the pump timeout
alarm.
Adv. PID Settings: Select this to open a screen where the User can set PID specific values. When
the button is pressed a dialog box with all of the PID settings will be displayed. If the User selects
OK on dialog form, the values will be saved to the current configuration in memory. When the User
returns to the PID control screen he/she will have the option to upload any new advanced PID
settings.
Ok: Select this to save settings to the current configuration in memory.
Note:
260
No pending changes made on this screen will be saved.

OM0211_________________________________________________________________________
APPENDIX L
Boiler Blowdown System Survey
Boiler Operation Survey

Boiler water temperature (F/C) ___________ (use Steam Table in Appendix B if
unknown)
Boiler pressure (psig/bar) _____________
Boiler conductivity target (S/cm) _____________
Feedwater conductivity (S/cm) ___________
Current boiler conductivity control range (+/- S/cm) __________
Blowdown piping ahead of probe
Length of pipe run (ft./m) _____________
Diameter of piping (ft/m) _____________
Minimum steam rate (lbs/hour ) ____________

Maximum steam rate (lbs/hour ) ____________
Time it takes conductivity probe reading to stabilize (thermal equilibrium) while
continuously blowing down (minutes) ___________ (this is the flush time)
---------- Information needed for Timed Based Proportional Control ---------Longest time blowdown valve can be left open without shocking the boiler with cold
water (minutes) _________ (this is the Max. Calc. Valve On Time)
Time it takes boiler conductivity to drop from upper control range to setpoint or setpoint
to lower control range (minutes) ___________ (this is the Calc. Valve On Time needed
to calculate the band parameter)
Note: The boiler blowdown valve can be manually operated, and the conductivity
manually measured, to determine this parameter.
Determine if CONTINUOUS or TIMED BASED Sampling is needed

1. Calculate Cycles = Boiler target Conductivity Feedwater Conductivity ________
2. Calculate Blowdown Rate = Minimum Steam Rate Cycles
If the Blowdown Rate > 5000 lbs/hour (2268 kg/hr) use Continuous (On/Off)
Control
If the Blowdown Rate < 5000 lbs/hour (2268 kg/hr) use Timed Sample Control
If conductivity readings are stable when the control valve is open use Timed
Sample Control Continuous Interval Monitor Mode
If conductivity readings are inconsistent due to turbulent flow or steam

flashing use Timed Sample Control Proportional Interval Monitor Mode
261

OM0211
Boiler Blowdown Plumbing Survey

OK
Fix
The maximum temperature and pressure the conductivity probe can handle is 392F
(200C) and 250 psig (17.2 bar). If the boiler operates at higher levels a sample
conditioning system must be installed upstream of the conductivity probe to reduce the
temperature and pressure.
The motorized ball valve and flow control valve are installed downstream from the
conductivity probe. Conductivity probe NOT installed between the valves.
The flow control valve installed downstream from the motorized ball valve.
Flow control valve installed within 12-18 (0.3-0.5 m) downstream of the motorized ball
valve.
Segment of piping downstream of the probe plumbed above the level of the probe cross
to keep probe flooded.
All isolation valves upstream of the conductivity probe are full-port and set to fully open.
Larger diameter piping from the boiler transitions to the cross and probe without pipe
segments of increased diameter (no wide spots in the blowdown line upstream and
immediately downstream from the conductivity probe cross)..
Flush valve installed on the bottom of the cross and probe closes properly.
Conductivity probe installed such that flow is through the hole in the probe. The K-factor
is stamped on a probe face with a hole.
Probe cross in a horizontal pipe run at least 2 ft (0.6 m) downstream of any elbows are
fittings that may cause turbulence. Probe NOT mounted on a vertical pipe run.
Piping can be reduced to diameter downstream of the conductivity probes on boilers
with lower blowdown rate requirements if blowdown rate is less than 5000 lbs/hr (2268
kg/hr).
Motorized ball valve mounted away from the boiler. So, it does not overheat the
electronics.
Piping runs upstream of conductivity probe kept short. So, flush times do not result in
excessive boiler blowdown.
262

OM0211_________________________________________________________________________
APPENDIX M
Boiler Saturated Steam Tables
Saturated Steam Tables

Steam Pressure
Saturated Temperature
PSIG
Bar
Deg. C
Deg. F
10
0.69
116
240
15
1.03
121
250
20
1.38
126
259
25
1.72
131
267
30
2.07
134
274
35
2.41
138
281
40
2.76
142
287
50
3.45
148
298
60
4.14
153
308
70
4.83
158
316
75
5.17
160
320
80
5.52
162
324
90
6.21
166
331
100
6.90
170
338
110
7.59
173
344
125
8.62
178
353
130
8.97
180
356
140
9.66
183
361
150
10.34
186
366
160
11.03
188
371
170
11.72
191
375
175
12.07
192
377
180
12.41
193
380
190
13.10
196
384
200
13.79
198
388
225
15.52
203
397
250
17.24
208
406
275
18.97
212
414
300
20.69
216
421
325
350
22.41
24.14
221
224
429
436
263

OM0211
APPENDIX N
Modbus Communication Settings
Description
The 3D Boiler SCADA application supports a very flexible Modbus addressing scheme. This
configuration tool provides the User with the ability to translate 3D Boiler registers (data items) to
Modbus registers with assignable addresses.
Modbus Communication Settings

Modbus Node: The Node address is needed to uniquely identify the 3D Boiler controller slave device
on the Modbus (serial) network. A Node address is needed for serial (RS-232 or RS-485) Modbus
RTU half-duplex connections, but not for Modbus over Ethernet connectivity.
Connection Type: This field is used to capture the Modbus connection type. The serial adapter
converter options are:
1. Mod-TCP
2. RS-485 Note: The IP Addr. and the Modbus Node text boxes are disabled for this setting
because they do not apply to this communication method.
3. RS-232
264

OM0211_________________________________________________________________________
Baud Rate: This is the number of distinct events made to the transmission medium per second in a
digitally modulated signal or a line code. The list options are:
1. 1200
2. 2400
3. 9600
4. 19200
5. 38400
6. 57600
7. 115200
Parity: A method of error checking. The options are:
1. Odd
2. Even
3. None
Data Bits: The number of data bites in the byte. The options are:
1. 7
2. 8
Note: RTU mode requires 8. ASCII mode is usually 7 but may be 8.
Stop bits: The number of stop bits for each byte sent. The options are:
1. 1
2. 2
Note: The Modbus Node, Baud Rate, Data Bits, Parity, and Stop Bit input boxes are not active for
ModTCP operation.
Modbus/SCADA Mapping
Swap words within float and long data types: The Modbus message word order is configurable.
The default (unchecked) order is Low Word/High Word ordering (Modicon default).
Reverse byte order within words: The Modbus message byte order is configurable. The default
(unchecked) order is High Byte/Low Byte ordering (Modicon default)
Enabled: When the Enabled field is selected, the associated tag is enabled for Modbus register
access.
Signal Description: This is the User selection of 3D Boiler controller data tags.
Signal ID: This is the default identification name given to the signal.
Format: If the signal is enabled the options here would be:
1. Word
2. Float
3. Long
Register Type: The memory address register type for the connection. The options are:
1. Holding Register (read only - integer/word variable)
2. Input Register (read only integer/word Boolean)
3. Coil Register (read/write - Boolean/bit variable)
Note: This field is only enabled if the signal is enabled, otherwise the default option will be Input
Register.
Register Number: User assigned address number. This number must be between 0000 and FFFF (0
65535 decimal).
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Scale Factor: A Floating Point number with a default value of 1.0.
Notes:
If reading from the 3D Boiler controller to the Master, the number pointed to by the associated
Signal ID is multiplied by the Scale Factor.
If writing to the 3D Boiler controller from the Master, the number pointed to by the associated Signal
ID is divided by the Scale Factor.
Remove: This button removes the device associated with the selected row.
Add Mapping: The Add New button will add a new row to the grid. Only 1 blank row will be allowed
in the grid at a time.
Ok: Select this to save settings to the current configuration in memory.
Cancel: Closes the current screen. NOTE: No pending changes made on this screen will be saved.
Misc Notes
Modbus Reference to Zero Addressing
All data addresses in Modbus messages are referenced to zero. For example, the Coil known as Coil
1 in a PLC is addresses add as Coil 0000 in the data address field of a Modbus message. So, all
addresses are offset by one.
Casting
The Signal ID value can be cast to a different Modbus data type. Care must be taken when casting
3D Controller data types to different Modbus data types. Usually, a scaling factor must be included.
Note: In most instances, Scaling and Casting data types should not be needed unless the end user
does not support Longs and/or Floating Point numbers.
Register Types
Coils: Boolean
Words: 16 bits
Longs: 32 bits, sent as 2 consecutive 16-bit words
Floats: 32 bits, IEEE Single Precision Format, sent as 2 consecutive 16-bit words
Function Call Supported

Coils
Function Code 1: Read 1 or more coils
Function Code 5: Write a single coil
Function Code 15: Write multiple coils
Input Registers
Function Code 4: Read 1 or more input registers
Holding Registers
Function Code 3: Read 1 or more holding registers
Function Code 6: Write a single holding register
Function Code 16: Write multiple holding registers
Register Types: Integers, Longs, Floats
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Diagnostics
Function Code 8
Diagnostics Code 00
Note: Return Query Data command loop-backs whatever data was sent it.
ModTCP
The 3D Boiler controller has 10 Megabit networks. There are two Ethernet ports (on separate
networks in the 3D Boiler Controller) available for Mod/TCP communications. The Ethernet port will
need to be set with the correct IP address and Subnet Mask for SCADA Master access. For ModTCP
Slave mode, the controller Node address is not needed.
General Addressing Comments

There are many different Modbus addressing schemes. Many systems use a numbering scheme to
understand how to process the data (5000 = Longs, 7000 = Floats, etc.). The 3D Boiler will respond
to the entered register number (be sure and remember the Offset by One rule specified by the
Modbus specification).
In many cases, it will be necessary to experiment with the configuration address mapping. The intent
of the configuration tool is to let the end user select the Modbus addresses (no hard coded table).
Assistance
To assist in troubleshooting, a captured communications session (via 3 rd party tools) should be
provided for analysis.
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APPENDIX O
Replaceable Battery Removal and Installation
WARNING: DO NOT attempt to service the unit at any time unless it has been powered OFF.
Please follow Nalcos and Site specific safety procedures before servicing this
electronic device. Requires 2 Lithium Batteries Rayovac BR2335
Battery Removal Steps:

Step 1:
Before starting any work
ensure gloves are worn and
electrostatic protection is used.
Step 2:
Locate power switch on side of
unit and turn to O (OFF) as
shown.
Step 3:
Remove power source for unit
by dis-connecting wiring or
simply unplug-ging, depending
on how the unit is installed.
Step 4:
Open the cover and locate
the two battery assemblies in
the upper left corner of the
enclosure.
Step 5:
Unplug the cable located
directly above the batteries
and set them aside.
Step 6:
To remove the upper battery,
grasp the top edge as shown
and gently remove.
Step 7:
To remove the lower battery,
place a hooked object (90
degree pick) under-neath the
exposed edge.
Step 8.
Gently pull up the edge
of the battery.
Step 9.
Use a pick to grab the back
edge of the battery and
completely remove it.
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Step 10:
To install the upper battery, hold the battery with
+ or positive side visible.
Step 12:
To install the lower battery, hold
the battery with the + or
positive side visible.
Step 11.
Gently slide it under the retaining clip until it is
fully inserted into the holder.
Step 13:
Gently slide the battery under
the retaining clip.
Step 14:
The battery must be fully
inserted into the holder.
Step 15:
Reinsert the cable battery
assemblies.
Check and confirm all steps have been correctly done.
Turn the controller back ON.
This completes the battery replacement procedure.
*Above procedure applies to 3D TRASAR Boiler Water Controllers with Serial #10561 and greater.
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APPENDIX P Connecting 2 3DTRASAR Boiler Controllers to 1 NGG ver 1.0

Install the NGG
The NGG must be powered and have 3 to 4 yellow signal bars and a cellular link light.
Each 3DT boiler water controller will require 1 CAT5E LAN cables for each controller.
Connect each CAT5E cable to Ethernet port #2 on both controllers
See photo below for controller connections.
The CAT5E cable for the 2nd controller will need to be connected to the NGG port switch.
Use the controller keypad to set the Network settings.

Controller #1
Verify the IP settings on the controller.
Press the Menu key on the control panel.
Enter password.
Select Network 2 by using the up & down arrows on the keypad to verify the settings below.
DHCP is Disabled
IP Address 192.168.001.003
Subnet 255.255.255.000
Gateway 192.168.001.001
If you need to make a change press the edit key & make changes as stated above.
Reboot the controller & verify settings again.
Controller # 2
Enter password.
DHCP is Disabled
IP Address 192.168.001.004
Subnet 255.255.255.000
Gateway 192.168.001.001
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How to direct connect to a 3DT boiler water controller
This will work for controller #1 and controller #2.
No change has been done to the network Ethernet #1 setting
Connect a crossover cable to the connection port on the left side of the 3D TRASAR controller.
Using the 3D TRASAR Boiler Configurator and select the following:
Import Configuration directly from a controller.
Use Direct Ethernet Cable from the drop down window

The default IP Address for Ethernet # 1 will appear in the IP address window.
This should only need to be changed if Ethernet #1 IP address has been changed in the controller
network settings screen.
Click on connect
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Connecting remotely to a 3D TRASAR Boiler Controller that has a port number
Using the 3D TRASAR Boiler Configurator select:
Import configuration directly from controller
OK
Select Wireless AT&T from the drop down

To connect to the first controller
Enter 1 and the NGG phone number and leave the Port # 80
Click on connect
To connect to the 2nd controller

Enter 1 and the NGG number
Enter the Port number in the Port number field
The last number in the IP address is how to determine the port forward address.
Contollers IP address = 192.168.001.003 = :3080 = NGG number 15001234567:3080
Click connect
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Change the 3DTB controller phone number to show the port number
While connected to the controller
Select Communication Settings
Enter the connect Port # for the controller

Click OK
For assistance call 630-305-CHEM (2436) Press #1 for the NGES Help Desk
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APPENDIX Q
Connecting a 3D TRASAR Cooling Controller and a 3D

TRASAR Boiler Controller to 1 NGG ver 1.0
The 3DT cooling water controller requires 2 CAT5E cables

The 3DT boiler water controller requires 1 CAT5E cables
Only 2 CAT5E cables are supplied with the NGG these should be used for the 3DTC controller
Extra materials required for the installation. To be used for the 3DT boiler water controller.
1 CAT5E LAN cables that will reach from the NGG to the 3D TRASAR units.
2 cord grips: One for the NGG and one for the 3D TRASAR unit.
Install the NGG
The NGG must be powered and have 3 to 4 yellow signal bars and a cellular link light.
The cooling water controller CAT5E cable connections
The 3D TRASAR Cooling Controller will require 2 CAT5E LAN cables (supplied with the NGG).
The boiler water controller CAT5E cable connections

The 3D TRASAR Boiler Controller will require 1 CAT5E LAN cable.
Connect the CAT5E cable to Ethernet port # 2 inside the controller.
The CAT5E cable for this controller will also need to be connected to the NGG port switch.
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Use the controller keypad to set the network settings on both controllers
The 3D TRASAR Cooling Controller network settings
Controller #1
Enter password.
Select Network by using the up & down arrows on the keypad to verify the settings below.
o DHCP is Disabled
o IP Address 192.168.001.002
o Subnet 255.255.255.000
o Gateway 192.168.001.001
The 3D TRASAR Boiler Controller network settings
Controller # 2
Enter password.
DHCP is Disabled
IP Address 192.168.001.004
Subnet 255.255.255.000
Gateway 192.168.001.001
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How to direct connect to the controllers
Controller #1 (3D TRASAR Cooling Controller)
Verify the controller IP address.
Enter password.
Select Network settings by using the up & down arrows on the keypad to verify the IP address.
Contoller number 1 = IP Address 192.168.001.002
Connect a crossover cable to your PC and the connection port on the left side of the 3D TRASAR
Cooling Controller.
Using the 3D TRASAR Cooling Configurator and select the following:
Import settings from existing controller
Use direct/Ethernet Connection
Click on Advanced and enter the correct IP address and password (default password is 12345).
Click OK
Click on Connect
Controller #2 (3D TRASAR Boiler Controller)

No change has been done to Ethernet #1 network setting so direct connect as normal.
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Connecting remotely to controller that has a port number
Controller #1 (3D TRASAR Cooling Controller)
Using 3D TRASAR Cooling Configurator select:
Connection method select: Use Wireless Gateway
Enter 1 and NGG number 15001234567
Note if a port forwarding address is used it will need to be entered after the NGG number
To connect to the 2nd controller (3D TRASAR Boiler Controller)

Using the 3D TRASAR Boiler Configurator select:
Import configuration directly from controller
Click OK
Enter 1 and the NGG phone number

Enter the Port number in the Port number field leave the 80
The last number in the IP address is how to determine the port forward address.
Click connect
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Change the 3D TRASAR Cooling Controller phone number to show the port number
While logged on to the controller
Select Email Settings
Enter 1 and the NGG phone number and the correct port number.
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Change the 3D TRASAR Boiler Controller phone number to show the port number
While connected to the controller
Select Communication Settings
Enter the connect Port # for the controller

Click OK
For assistance call 630-305-CHEM (2436) Press #1 for the NGES Help Desk
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APPENDIX R
3D TRASAR Boiler Automation System

Pre-Installation Checklist
Customer Name: __________________ Location:________________________

Nalco Rep.:_______________________3DT Boiler Model #:________________
Installation can be performed by Nalco service technicians, a local contractor or by plant personnel,
however, final assembly and startup can only be performed by Certified Nalco service technicians.
Certified Nalco service technicians will return to tune the systems control loops after operating
conditions have been monitored long enough to characterize system dynamics. To insure you are
aware of system installation requirements, a Certified Nalco service technician will schedule a preinstallation site walk-through visit using this checklist, identifying and addressing any questions or
issues that might arise. It is our expectation that a copy of this checklist, with all applicable sections
completed, will be provided to the customer and whoever will be doing the installation work.
3D TRASAR Boiler Control System Location

The 3D TRASAR Boiler control system should be located where it wont interfere with plant or mill
floor traffic patterns. Based on the model ordered, you must insure that adequate floor or wall space
is available in the selected location to properly install and securely anchored the system. Wall-mount
systems should be anchored at a height that places the 3D TRASAR Boiler controller display at eye
level. Always keep safety considerations foremost in mind. Remember, these units will be connected
to a sample line containing hot, pressurized boiler feedwater. Additional considerations include:
The control system must be oriented so that it can be easily accessed. Ideally, it should also
be located as close as possible to the feedwater sample take-off point. If high (500 cc/min)
sample flow rates can be sustained, the system can be installed farther away, however,
maximum sample line run length should never exceed 100 ft (30 m).
Space requirements:
Wall Mount Controller & Sensor Panel Dimensions:

12 D x 33 W x 42 H (31 cm x 84 cm x 107 cm)
Sample Conditioning System (SCS) Dimensions:

8 D x 33 W x 22 H (21 cm x 84 cm x 56 cm)
Frame Mounted System Dimensions:

29 D x 33 W x 66 H (74 cm x 84 cm x 168 cm)
NOTE:
Separate SCS panels, e.g., those supplied with wall mount units, will need to be
mounted 1-1/2 below the controller panel so be sure to factor this into your size
calculations.
Is the system installed far enough away (over 10 ft or 3m) from any high voltage source(s), e.g.,
large motors or any known generator of electrical noise? (Boiler feedwater pump motors may
be excluded from this restriction.)
The mounting location should be well lit and dry. When the system is to be installed outdoors,
provisions will need to be made to protect the controller from direct sunlight and driving rain.
An enclosed NCSM, rather than the standard Lexan plastic shielded version, must also be
ordered for use in these type installations.
In cold weather climates, provisions must be made to protect the cooling water and sample
lines from freezing temperatures.
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The identified 3D TRASAR Boiler automation system installation location should be near an
electrical panelboard capable of supplying the system with up to 30 amps of grounded AC
power at 85-250 VAC.
If installing a model that includes a Sample Conditioning System, insure you have access to a
reliable, continuously operating cooling water source.
If you will be remotely-locating an NCSM (one without its own 3D TRASAR controller module),
check to insure it will not be located more than 1000 ft (305 m) from the main controller.
NOTE:
Do not mount control systems or devices on walls or surfaces where they will be
subjected to vibration. Damage to critical components can occur that might cause
spurious alarms or premature hardware failure.
Suitable Feedwater Sample Point Selection

A single feedwater sample point is needed to supply a suitable sample to the 3D TRASAR Boiler
automation system. This sample point should conform to all of the following criteria:
1. The preferred sample point location is on the discharge side of the feedwater pump/s where
a representative sample of the feedwater supply to all boilers being controlled can be collected.
This location must be downstream of the NexGuard and oxygen scavenger injection points. If
you are unable to locate the sample tap at this location, continue to step 2, otherwise proceed
to step 3 below.
2. Is the sampling point located downstream of and at a point where adequate mixing of the
NexGuard and oxygen scavenger has occurred? In general, the sample point should be at
least 10 pipe diameters downstream of the chemical injection point, preferably after at least one
pipe bend.
3. A stainless steel sample quill that is long enough to collect a sample from a point
approximately 2 from the inside wall of the pipe. The pipe must be installed through the side of
the feedwater supply line. Be sure and select a quill insertion point that is fully flooded, i.e., at a
point where no trapped air could interfere with collection of the sample. To minimize the
potential for quill fouling, never sample from the bottom of a horizontal piping run. Also, since
the deaerator drop leg supplying the feedwater pump/s is typically fully flooded, it is usually
acceptable to locate the sample point in this run, otherwise, we recommend that you avoid
locating taps in vertical pipe runs unless you are sure flow is upward, guaranteeing that the
pipe is fully flooded where the sample is being collected. Further, insure an approved lockable
valve is installed where the sample line connects to the quill (for lock out, tag out purposes).
4. If this is a utility boiler, contact the 3D TRASAR Help Desk (sample points must be
thoroughly reviewed).
5. The selected sample point should be as close to the 3D TRASAR Boiler automation system
location as possible. For best NCSM measurement results, the sample temperature must be
as close as possible to the temperature of the water at the point it enters the feedwater sample
quill, therefore, short sample line length is important. Short lines minimize both temperature
loss and lag time - an important consideration when tuning system control loops.
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Sample Line Specifications

A continuous sample line must be run from the shutoff valve at the feedwater sample quill to the
NCSM inlet connection point on the 3D TRASAR Boiler automation system. Specific items to check
include:
If you plan to use existing sample piping runs, insure they are no larger than O.D. in size.
Larger diameter tubing or piping of any size greater than 1/8 IPS steel will greatly increase
sample lag time and adversely affect the performance of your new control system. Copper
and other similar (non-ferrous) materials should never be used in construction of the
sample line or for in-line components.
If you will be installing a new sample line, we recommend that the sample line be constructed of
O.D., Type 316 stainless steel tubing, with a nominal wall thickness of 0.035.
A secondary isolation valve should be installed at the end of the sample line, i.e., where it
connects to the 3D TRASAR control system. It is also recommended that a bleed valve be
installed at this location, connected in the line between this secondary valve and the block
valve on the #D TRASAR Boiler automation system. This will enable service personnel to
safety bleed pressure from the line as well as facilitating periodic flushing of the line.
Insure that a pressure gauge is installed on the sample line between the lockable valve on the
quill and the secondary isolation valve at the control system so the pressure in the line can be
checked prior to maintenance.
The sample line must be kept as short as possible. Ideally, the maximum run length should
never exceed 40 feet (12 m), however, if sample flow rates of up to 500 cc/min can be
sustained, e.g., when the system is installed on larger boilers, the maximum sample line length
can be extended to 100 feet (30 m).
NOTE:
During system operation, the sample flow rate and temperature must be kept
constant to ensure accurate measurements and promote optimal dosage control.
This will also help when troubleshooting problems that might arise during system
operation.
You need to insure that the temperature of the feedwater sample reaching the NCSM probe is
as hot as possible and representative of the temperature at the point the sample enters the
sample collection quill. The NCSM measurements are made directly on the uncooled sample
and are not temperature compensated, therefore, the sample line will need to be insulated from
the take-off point all the way to the point where it connects to the sample conditioning system
on the 3D TRASAR Boiler control system. Rolled insulation material is provided with the
system and will be used to double wrap the sample line. For longer sample lines, additional
rolls of insulation might be required - insure sufficient quantities have been ordered to complete
the double wrap requirement.
Note: The insulation wrap also serves a second purpose it protects personnel from burns
that could be caused if someone accidently touched the hot sample line.
The sample line will need to be purged for 15 to 20 minutes immediately prior to connecting it
to the 3D TRASAR Boiler System. This is done to blow potential contaminants/foulants from
the line which is particularly important during the initial system startup, the time when the
incoming sample is most likely to contain solids, e.g., dirt, oxides of iron, grease, installation
debris, etc.,that could plug the filters and small orifices on your new control system. Insure
everyone understands the need for flushing and that this will be repeated immediately prior to
startup.
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Sample Outlet Line

The feedwater sample exits on the right side of the 3D TRASAR Boiler automation skid and should be
piped to an open drain. If you plan to reuse this water, you can also route it to a suitable containment
vessel and pump it back to the system, e.g., to an unpressurized condensate receiver. The following
guidelines will help you install this line properly:
To prevent siphoning and/or backflow, eliminate the potential for backpressure on the
Fluorometer internals, as well as provide a place where a grab sample can be captured during
system maintenance, insure that an air gap exists between the end of the sample discharge
line and the open drain or containment vessel connection.
Outlet line pipe rises greater than 10 feet [3m] should be avoided. If the discharge must be
located above the system, a check valve must be installed in the discharge line to prevent
backflow.
IMPORTANT: You must insure that boiler water does not siphon back through the 3D
TRASAR Boiler automation control system when there is no feedwater flow,
e.g., when the FW pump/s is/are turned off. Siphoning could cause a high
temperature alarm, suspend control action/s and shut down flow through the
system, even if the Sample Conditioning System (SCS) is operating properly.
Check to insure that the sample discharge flow will be unrestricted between the connection
point to the control system and the open drain or containment vessel connection.
Do not combine the discharge lines from multiple controllers into a common header upstream of
the open drain or containment vessel.
On NCSM models without sample coolers, the sample discharge line must also be insulated to
protect personnel from the hot tubing.
CAUTION! DANGER! The discharge from a NCSM not equipped with a Sample Conditioning
System must be cooled and depressurized unless the system
receiving the discharge can safely accept up to 500 cc/min of 2800
psi (193 bar) maximum, 500F (260C) boiler water.
Sample Cooling Water Requirements

Cooling water (chilled water) must be provided if your new 3D TRASAR Boiler automation control
system is equipped with a sample conditioning system. The sample conditioning system is designed
to cool the incoming boiler feedwater sample to a temperature of less than 110F (43C) and to
reduce its pressure to 50 psig or less. This is done to protect the control system and safeguard
workers.
Check that adequate quantities of chilled water will be available at or near the location selected
for the controller. Typical flow rates of from 0.5 to 2 gallons per minute (2-7.6 lpm) will be
required, depending on the cooling water temperature and sample flow rates. Nalcos Sample
Cooler Cooling Water Flow Requirement Estimator , version 1.0, can be used to help you more
accurately determine how much cooling water flow will be needed.
To prevent fouling, the cooling water supplied to the system must be free of suspended solids
and miscellaneous debris. It must also flow continuously and at constant pressure.
The supply side of this chilled water loop will need to be piped to the sample cooler water inlet
connection that is located at the bottom of the sample cooler situated on the left side of the
control system.
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The cooling water discharge should be piped from the connection point at the top of the sample
cooler to a nearby open drain or returned to the chilled water circuit for reuse, as appropriate.
We recommend that the cooling water inlet and outlet lines, where connected to the sample
cooler, be fitted with a tee and two valves. This will allow the cooling water to be drained and
facilitate periodic maintenance of the cooler. Stainless steel valves should be used in case
future descaling requirements necessitate acid flushing of the cooler assembly.
Chemical Feed Points & Chemical Pumps

General: If selecting a new feed pump location, select a site that will facilitate interconnection
with the 3D TRASAR Boiler control system, i.e., one that supports the necessary control and
power wiring connections, yet is close enough to the chemical storage tanks to promote reliable
pump operation.
Internal Treatment (i.e. NexGuard) For optimal control, this chemical should be fed into the
drop leg of the Deaerator. A stainless steel injection quill long enough to inject the chemical
near the centerline of the pipe should be installed at this feedpoint. If the injection point will be
located in the Deaerator, insure its location wont cause excessive (over 15 minutes) lag times
as this could make automated control impossible.
Insure the injection quill is located at least 10 pipe diameters ahead of a bend or elbow. Do not
feed concentrated unmixed product immediately ahead of a bend to avoid FAC or erosionrelated corrosion.
A correctly sized variable speed pump will be needed to feed the TRASAR internal treatment
and/or pH (amine or caustic) adjustment chemical/s. This pump will need to be able to accept a
4-20 mA, 24 VDC control signal output by the 3D TRASAR Boiler automation system to vary
the speed of the pump motor.
If you plan to use an existing deaerator feedpoint, insure it is sited someplace other than in the
dome or where high levels of dissolved oxygen are present.
Oxygen scavenger (i.e. Nalco 1720, 1700, or ELIMINOX) Best practices require use of a
separate injection quill for this product, i.e., do not, if at all possible, inject it using the same quill
as the internal treatment chemical.
A correctly sized variable speed pump for Corrosion Stress (NCSM) control will be needed to
feed the oxygen scavenger. This pump will also need to be able to accept a 4-20 mA, 24 VDC
control signal output by the 3D TRASAR Boiler automation system to vary the speed of the
pump motor.
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Electrical Power
One 120 VAC, 30 A, 60 Hz or, alternatively, one 120 VAC, 20 A, 60 Hz and one 120 VAC, 15 A, 60
Hz grounded and overcurrent protected branch circuit/s are required to power the 3D TRASAR Boiler
control system (some models, destined for use outside the US, require 240 VAC, 15 amp power
sources). Four separate AC power connections may be needed, depending on which system options
have been ordered. If possible, a 120 VAC 4x4 outlet box, containing two grounded 120 VAC, 15 A
and two grounded 120 VAC, 20 A receptacles, should be installed near the skid to power the system
and its associated peripheral devices. If required by Code, component electrical connections might
need to be run in EMT, rigid or Sealtite conduit and hard wired to each respective control system
component.
IMPORTANT NOTE:
The 3D TRASAR Boiler automation system MUST BE PROPERLY

GROUNDED! Erratic instrument readings could result if the unit is poorly or
ineffectively grounded.
NOTE: Separate 120 VAC power wiring should be run to each of the following control system
components. Route the conductors into each box but be sure the installer is aware that we
DO NOT want them terminated at this time. Have him label each set of conductors and
leave each circuit de-energized, following applicable lock out, tag out guidelines. The Nalco
Certified service technician who performs system assembly and startup tasks will be
responsible for correctly connecting these conductors.
Power Connection Specifications:
3D TRASAR Controller: 120 VAC, 20 amp, 60 Hz (240 VAC, 10 amp, 50-60 Hz)
Blowdown Relay Box: 120 VAC, 10 amp, 60 Hz (240 VAC, 5 amp, 50-60 Hz)
Analog Input Module: 120 VAC, < 1 amp, 60 Hz (240 VAC, amp, 50-60 Hz) comes
equipped with a 6-ft long, 3-prong (15A) power cord
Nalco Global Gateway: 120 VAC, <1 amp, 60 Hz (240 VAC, amp, 50-60 Hz),- comes
equipped with a 8-ft long, 3-prong (15A) power cord
When hard-wired connections are used in lieu of plug-in connections, suitable lockable
disconnects must be installed in each power circuit in close proximity to each device, per local
and national Codes.
If an extension cord is used, it must be a grounded 3-prong (15 or 20 A, as applicable) 120
VAC rated cord with conductors suitably sized based on cord length.
We recommend that the 3D TRASAR Boiler controller be connected to its own dedicated 120
VAC, 20 amp (240 VAC, 10 A) circuit since overcurrent conditions generated by other devices
powered by the same circuit could cause control outages or intermittent operation.
The 3D TRASAR Boiler controller contains four solid state ON-OFF relays that can be used to
control external devices. Check to insure that external devices to be connected to these do not
draw more than 120 VAC, 2 A (the maximum ampacity rating of the relay). If higher ampacities
are required, provisions for suitably sized external control relays will need to be included as part
of the electrical installation scope of work for the system.
The controllers internal alarm relay is fused at 1 amp. Check the requirements for any external
alarm interconnection/s to insure it/they do not exceed the 1 amp current limit; install a suitably
sized external control relay, if necessary.
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Sensor, Signal & Control Wires

Wires for the following items must be connected at their source and run into the 3D TRASAR Boiler
control box. (Not all devices listed below may be included in each installation.)
NOTE: Once again, insure the installer DOES NOT land the wires inside the 3D TRASAR
Boiler controller enclosure. He only needs to route them into the enclosure, providing
sufficient (10-12) slack and leaving them de-energized. Final connections will be made by
a Nalco Certified service technician during the assembly/startup process.
All controller enclosure wiring penetrations must be made using NEMA 4X rated hubs, cord
grips and/or conduit connectors in order to maintain the NEMA 4X rating of the enclosure.
Pump connections (Internal Treatment, Oxygen Scavenger, Amine, Caustic, etc.)
ON/OFF Control Check the maximum ampacity requirements of each pump motor that
will be controlled and, using 14 AWG copper conductors and external motor
starter/controllers, as applicable, route the wires to be switched into the controller, leaving
sufficient slack to facilitate later termination.
PID Control The controller has four isolated 24 VDC analog outputs that supply 4-20
mA control signals for pump speed control purposes. Each control loop should be
constructed using 22-24 AWG shielded signal cable. Route each into the enclosure,
leaving sufficient slack and keeping them de-energized. Final connections will be made
by the Nalco certified service technician during the assembly/startup process.
NOTE: Only the analog control signal is supplied by the controller. Pump power and
associated disconnect means must be provided separately and are not
addressed in this section.
22 AWG (minimum) shielded twisted-pair signal cabling must be used for remote NCSM,
analog and digital inputs, RTD and blowdown conductivity sensor probe wiring that will be
connected to the controller. The number of conductors required for each signal loop is
provided below:
Conductivity Probe: 4 wires per probe (8 wires per probe on temperature compensated
models)
NCSM: 6 wires per remote module (e.g., model 060-BL52xxx.88)
Steam Flow (4-20 mA): 2 wires
Boiler Interlock (dry contact): 2 wires
Analog & Digital Signals: 2 wires
Does your system include a Blowdown Relay Box? If so, you will need to install conduit
between the Relay Box and the blow down valve/s and, using three 14 AWG power conductors
(red, black and white conductor jacket coloring is recommended) and one ground conductor,
connect the 120 VAC power circuits to the applicable blowdown valve actuator terminals.
Again, all that is required on the controller end will be the routing of each set of valve
conductors into the enclosure, providing sufficient slack and leaving them de-energized. As
before, final connections will be made by the Certified Nalco service technician as part of the
assembly/startup process.
NOTE: DO NOT run 120 VAC wires and low-voltage DC signal wires inside the same conduit.
286

OM0211_________________________________________________________________________
Communication Wiring
A Nalco Global Gateway (NGG) is supplied with each controller. It communicates with the Internet
using a cellular phone system interface, therefore, in addition to a solid cellular signal, it only
requires a 120 VAC, <1 A, 60 Hz power connection to function. An analog phone line or Ethernet line
can also be connected to the 3D TRASAR Boiler controller if cellular service is unavailable or weak
cellular signal conditions cause connection reliability problems.
Using your cell phone, check to insure that you have a solid (3 bars or more of signal strength)
signal at the proposed location of the global gateway. If the cellular signal does not penetrate
into the area where the unit will be installed but a strong enough signal is available in an
adjacent area of the facility, e.g., the unit is being installed in a basement where the signal is
too weak for reliable communications but one floor up the signal strength is adequate, consider
installing a remote antenna for the gateway (see catalog for part numbers).
If required, has the analog phone line been run to the controller box? The line should be run
into the 3D TRASAR controller enclosure and terminated with an RJ11 plug. Nalcos Certified
service technician will connect this and program the applicable dial-out phone numbers into the
unit during assembly/start up.
Similarly, if required, has a CAT-5e or CAT-6 Ethernet cable been run to the controller box?
This cable should be run through a suitably sized NEMA 4X cord grip, into the 3D TRASAR
controller enclosure and terminated with an RJ45 plug. Nalcos Certified service technician will
connect this and set the applicable network IP address/es during assembly/start up.
Blowdown Plumbing
A conductivity probe, control valve (motorized ball valve) and flow control valve must be installed on
each boiler to implement conductivity-based blowdown control. These parts must all be ordered
separately. The actual configuration of the blowdown piping run/s is dependent on system
requirements. The diagrams in Manual OM0211 illustrate the installation for continuous sampling;
recommended for systems blowing down > 5000 lbs/hr (2273 kg/hr) and intermittent sampling;
recommended for systems blowing down < 5000 lbs/hr (2273 kg/hr).
NOTE:
Existing piping runs must be surveyed to determine if any alterations must be made.
Complete the checklist items detailed below in order to identify alterations that might be
required:
Boiler Blowdown Piping Survey

OK
Fix
The maximum temperature and pressure rating for the conductivity probe that will be
installed in the blowdown line is 392F (200C) and 250 psig (17.2 bar), respectively. If
the boiler operates at higher levels, a sample conditioning system must be installed
upstream of the conductivity probe to reduce the temperature and pressure appropriately.
All isolation valves installed upstream of the conductivity probe are full-port and fully
open.
Piping runs upstream of the conductivity probe should be kept short. This will keep flush
times short and enable us to better control the amount of water loss that occurs during
each measurement cycle.
The motorized ball valve and flow control valve/orifice must be installed downstream of
the conductivity probe, i.e., the conductivity probe must NOT be installed between
these two valves.
287

OM0211
OK
Fix
The blow down flow control valve must be installed downstream of the motorized ball
valve.
041-BLR006.88
Motorized valve, SS, , 120 VAC/60Hz
041-BLR007.88
Motorized valve, SS, , 120 VAC/60Hz
041-BLR010.88
Motorized valve, SS, 1, 120 VAC/60Hz
The flow control valve must be installed downstream and within 12-18 (0.3-0.5 m) of the
motorized ball valve.
041-BLR008.88
Flow control valve (w/ indicating scale), "
041-BLR009.88
Flow control valve (w/ indicating scale), 3/4"
041-BLR110.88
Flow control valve (w/ indicating scale),1"
Check to insure that there are no wide spots in the blowdown lines installed immediately
upstream and downstream of the NPS conductivity probe mounting cross.
The conductivity probe mounting cross should be installed in a horizontal pipe run at least
2 ft (0.6 m) downstream of any elbows or fittings that may cause turbulence at the probe
location.
Check to insure that the probe is not mounted on a vertical pipe run.
Check to insure that a flush valve is installed on the bottom of the cross/probe assembly
and that it closes properly.
If the Nalco conductivity probe is already installed, check the face of the hex nut that is
part of the threaded collar and find the K-factor stamped on its face. This stamp is in
alignment with the hole so should be located on either the upstream or downstream side
of the probe when mounted in the cross.
The tip of the conductivity probe must remain flooded or it will not operate properly.
Check to insure multiple pipe reducing bushings havent been installed in the probe
mounting cross, or any other condition might exist that would raise the probe up and out
of the sample stream.
The blowdown piping installed downstream of the probe should include a riser that traps
liquid in the probe cross and insures it is always flooded.
The blowdown piping installed downstream of the conductivity probe mounting cross can
be reduced to diameter pipe on boilers with low blowdown rate requirements, e.g., if
the required blowdown rate is less than 5000 lbs/hr (2268 kg/hr).
The actuator head on the motorized ball valve must be located where it wont overheat,
i.e., it shouldnt be located so close to the boiler that it picks up heat from the boiler and
gets too hot, damaging the electrical circuits inside the actuator head.
NALCO Certified Technician:_________________________Date: _________
NALCO Customer:__________________________________Date: _________
288

OM0211_________________________________________________________________________
289

OM0211
NALCO COMPANY OPERATIONS

North America: Headquarters - 1601 West Diehl Road Naperville, Illinois 60563-1198 USA
Energy Services Division 7705 Highway 90-A Sugarland, Texas 77478 USA
Europe: Ir.GF.Tjalmaweg 1 232 BV Oegstgeest The Netherlands
Asia Pacific: 2 International Business Park #02-20 the Strategy Tower 2 Singapore 609930
Latin America: Av das Naes Unidas 17.891 6 Andar 04795-100 So Paulo SP Brazil
www.nalco.com
NALCO and the logo, TRASAR, 3D TRASAR, Nalco Corrosion Stress Monitor and VANTAGE are
Trademarks of Nalco Company
2009 Nalco Company
290
All rights Reserved 11-10-10
MANUAL OM0211

3D TRASAR Boiler Manual Ver 4.2 11-10-10

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Pen Flourometer Operation Manual

3D TRASAR Boiler Technology

Nalco Global Equipment Solutions

3D TRASAR Boiler Technology Installation and Operation Manual

Nalco Global Equipment Solutions

3D TRASAR Boiler Technology Installation and Operation Manual

2.0 System Installation ........................................................................................ 17

Unpack and Identify Parts................................................................................................ 17

3.0 Electrical Wiring and Connections............................................................... 39

Run Wires in the Control Box ......................................................................................... 39

Nalco Global Equipment Solutions

3D TRASAR Boiler Technology Installation and Operation Manual

4.0 Final Assembly and Start-up......................................................................... 67

Installation Check and Safety Check .............................................................................. 67

Nalco Global Equipment Solutions

3D TRASAR Boiler Technology Installation and Operation Manual

5.0 Tasks to Perform Before Control Tuning.........................................102

Ensure an Interlock Is Connected or Shutdown Process Is Established.......................... 102

Nalco Global Equipment Solutions

3D TRASAR Boiler Technology Installation and Operation Manual

Slaved Control ................................................................................. 113

6.0 ON/OFF Relay Control ................................................................................. 114

ON/OFF Control Using the PID 4-20 Outputs ................................................................. 114

7.0 Proportional Control Configuration............................................................ 115

Blowdown Control (Cycle Control using 3D TRASAR Fluorometer) ................................ 115

8.0 PID Configuration and Tuning .................................................................... 119

Check PID Configuration................................................................................................ 119

9.0 Blowdown Monitor and Control Setup ....................................................... 126

Condensate Monitor Control Setup ......................................................... 146

Controller Operation ................................................................................. 149

11.1 Display Panel Functions ................................................................................................ 149

Nalco Global Equipment Solutions

3D TRASAR Boiler Technology Installation and Operation Manual

12.0 Communications and Data Management ................................................... 158

13.0 Shutdown and Maintenance ....................................................................... 165

14.0 Troubleshooting........................................................................................... 169

Nalco Global Equipment Solutions

3D TRASAR Boiler Technology Installation and Operation Manual

15.0 Specifications.............................................................................................. 201

Scale Control using 3D TRASAR for Boilers...................................................................... 212

Nalco Global Equipment Solutions

3D TRASAR Boiler Technology Installation and Operation Manual

3D TRASAR Boiler Technology

3D TRASAR Boiler Technology is a complete boiler performance management system, intended to

Reliable production of steam

Steam availability - no unplanned outages

Minimize scale & corrosion

Safe production of steam

Food safety (FDA, NSF, Kosher)

Environmental / regulatory compliance

Minimize risk to plant personnel

Maximize Equipment Life

Overall Lowest Total Cost of Operation

3D TRASAR Boiler System Capabilities

3D TRASAR Controller & Configurator Software

Communication for Remote Monitoring and Alarming

Web Reporting & Data Management

3D TRASAR Fluorometer for Scale Control

Corrosion Stress Monitor (NCSM) for Pre-boiler Corrosion Control

Conductivity-Based Blowdown Control

3D TRASAR Technology-based Blowdown Control

Feedwater pH & Conductivity Monitoring

Nalco Global Equipment Solutions

3D TRASAR Boiler Technology Installation and Operation Manual