Once Through Cooling Water Controller Setup and
Contents
1. ppr m lamin oF rE mlam ir mimin mlemin The items which may appear on the Home screen will change based on the selections made on other screens For example if Control Corrosion has not been selected on the Product Selection screen the Corrosion Rate item will not appear on this screen Similarly if less than four pumps were selected on the Product Selection screen fewer than four pumps will appear on this page The Alarm indication in the upper right will only appear if the timeout alarms for one or more pumps have been configured on the individual pump setup screens and the alarm has actually been activated When the button is being displayed touching it will bring up the Alarm screen where any active pump timeout alarms can be viewed and if desired cleared The Bleach On indication will only appear if an external signal has been wired into the controller to signal when an external bleach pump is operating The green squares for each pump will show either an A when the pump is in auto mode or an M when the pump is in manual mode Nalco Global Equipment Solutions 9 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller Main Menu The choices available on the Main Menu screen like the items appearing on the Home screen will change based on selections made on the Product Selection screen For example if only two treatment p2. After the username has been successfully entered you will be prompted to enter the password for the controller Press the SYMBOL key on the keypad to change the keypad from letters to numbers The password for the Once Through controller is 3000 Press the ENTER key to have the controller accept the password Nalco Global Equipment Solutions 7 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller Once you have successfully logged in the Main Menu screen will appear NOTE After 15 minutes of inactivity you will automatically be logged off the system the screen will blank and the Home screen will become the default screen The next time you select the Main Menu you will have to log in again Data Entry For all of the screens shown below touching one of the boxes outlined in grey containing numerical values will allow you to change the value in the box The first touch of the box will turn the background of the data white indicating that the box has been selected The second touch will open up a numeric keypad where the existing value can be changed After changing the value on the keypad press the ENTER key to accept the change Pressing the EXIT key once cancels the change The user cannot directly change any values not displayed in a box outlined in gray 8 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Home Screen Mey ims fa
3. Home screen display Nalco Global Equipment Solutions 5 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller Panel Buttons The button on the top left of the display screen shown with a green square is the Home screen button Pressing this button will bring up the Home screen The MENU button shown in blue on the lower left of the display will bring up the Main Menu screen Access to all the adjustments that can be made to the controller are reached by pressing one of the selection buttons on the Main Menu screen Screen Timeout All of the display screens blanks out after 15 minutes of inactivity to preserve the life of the screen backlights To make the screen reappear press one of the panel buttons User Login To change of view setting for the controller press the MENU button located on the lower left portion of the panel When first bringing up this menu you will be asked to log into the controller 6 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO SECURE ACCESE CONTROL Hust Authenticate to Access Page Lagan T Press the LOGON button and use the alphabetic keypad that appears to enter your username The default username for the Nalco Once Through Controller is nalco all in lower case Press the ENTER key to have the controller accept the username ENTER USERTNANE naleo f RRL PREH EATER EMIT
4. YOUR SITE 6PJ SISNET 1 0 Tool Kit New Project Chit Open Project Crl o save Project As Load Station Station Type p Verify Humber a All Statio 1 VT MIPM 241 D Tie ft Read Back Ey IPm Remote Terminal u EI mA CPU GA Auto Detect EtherTRAK Stations ict Test 1 0 Datalogging Sixlog amp Load Confowraton to Station My Set the Clock amp Ele Operations Advanced Operations q Read Configuration from Station _ Erase Configuration from Station i List E E in Station Read Data Recut la TS Read and Clear Nata Rernrr 32 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO 13 In the dialog box that appears make sure the Station name is CPU and the configuration name is ot_log Click OK Choose Sixlog Station name JK Cancel Sislog configuration name Help ot log j 14 From the dialog box that appears choose the number of records you wish to download and decide if you want to append the data records to an existing file When you click OK the data records will be downloaded from the controller Read Data Options Total number of records m station 7141 Stating record 0 logged on MonrApt 23 16 17 03 2007 Lancel J Ending record 140 logged on Tho
5. Apr 26 14 17 01 2007 Help Read all record l Append data file Hwe l Read last Records Read records logged in last Hours Store timestamps as GMT requires GMT set in station s clock Nalco Global Equipment Solutions 33 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller 15 Once the records have been downloaded you may save the data as a csv file by selecting File Save data File As and specify the name and location of the file EA ot_log SXLogView File View Device Operations Advanced Help Save Data File Ctrl 5 Save Data File As Te FlowRate Calcium sodiu Magnesium Mn Iron M_Alk Exit 0 01 0 00 20 00 0 00 2 20 1 10 200 00 4 04 23 2007 16 47 01 0 01 30 40 0 00 898 1 00 0 50 150 00 a 04 23 2007 17 17 01 468 23300 00 3040 0 00 8 98 1 00 0 50 150 00 3 04 23 2007 17 47 01 4 68 23300 00 3040 000 898 1 00 0 50 150 00 4 04 23 2007 18 17 01 4 68 23300 00 3040 0 00 8 98 1 00 0 50 150 00 5 04 23 2007 18 47 01 4 68 23300 00 3040 0 00 8 98 1 00 0 50 150 00 6 04 23 2007 19 17 01 4 68 23300 00 3040 0 00 898 1 00 0 50 150 00 7 04 23 2007 19 47 01 4 68 23300 00 3040 000 898 1 00 0 50 150 00 o 8 04 23 2007 20 17 01 4 68 23300 00 3040 0 00 8 98 1 00 0 50 150 00 9 04 23 2007 20 47 01 4 68 23300 00 3040 0 00 8 98 1 00 0 50 150 00 Gf Ee Ss oo ad d T Fid a mr aaa mir mi mi a m mi riri rb miri a mi mi m mmr d mM m rim
6. SE MS 5 Select a location to save the project file you will be reading from the controller It is recommended that you use a descriptive folder name You can also use this folder to save the data files you will download Click Save to accept Save As Save in OT Controller File name Save as type Project Files 6pj Nalco Global Equipment Solutions 29 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller 6 In the Readback Setup dialog box which appears choose IPm Remote Terminal for the Station Type and Use this IP address with an IP address of 169 254 1 100 in the Ethernet Options Click OK to accept and start the file read back Readback Setup Station type Pon Remote Terminal final gt Ethernet options Cancel UsethisIP address 169 254 1 Help C IF address unkown use broadcast IF M Identification method SS lies 7 After the file has been read back you will notice that the name you specified in 13 7J Step 5 now appears in the program title bar In the Tree View click on the until RTU Configuration is visible then click on it to highlight Tree Views WE All Stations na EFA Stations WID IPm Remote Terminal Units EE Al Stations hy IPm Remote Terminal Units CPU id RTU Configuration 1 9 On Board 1 0 Virtual 1 0 Modules 30 Nalco Global Equipment S
7. Scale Outputs The Once Through controller is capable of sending up to two 4 20 mA signals back to the 3D TRASAR controller for data logging purposes This screen allows you to select the values to be sent The possible choices are Pump 1 feed ppm Pump 2 feed ppm Pump 3 feed ppm Pump 4 feed ppm Calcium Saturation Index Langelier Index Pump 1 ppm CalSat Index NOTE It is possible to choose the same value on both buttons Under normal circumstances this should never be done but if you wish to send a particular signal to both the 3D TRASAR unit for logging and to a customer DCS or chart recorder this is one way to do it without the need for a 4 20 mA signal splitter It could also be done through the 3D TRASAR unit by means of the 4 20 mA Outputs screen in the 3D TRASAR configurator program Nalco Global Equipment Solutions 15 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller Scale Pumps Each treatment product specified will have its own pump control setup screen These screens allow the user to select the pump mode set the pumping rate when the pump is in Manual mode and specify the maximum pumping rate When the pump is in MANUAL mode it will feed at the constant rate determined by the Manual Pump Output setting When in AUTO mode the pump will modulate its feed based on the water chemistry and dosage calculations the controller makes The Pump Output at 100 setting tells the cont
8. _Comecton Carca C Use station s IP address t Metwork Passthru Help gt Gij i i Specify an lF address _ a a a ies 254 1 Timeout 2000 ms l g S F Allow loading via Etheret to serial passthru C Use com port ______ Ciel tarestare def silks nr 40 Nalco Global Equipment Solutions PA NALCO Nalco 3D TRASAR Once Through Cooling Water Controller e Inthe Tree View of the program screen click on the until the RTU Configuration item is visible Click once on RTU Configuration to highlight OT RELEASE 6PJ SIXNET 1 0 Tool File Edit View Device Configure Operation Ee ps HNM I Tree Views 5 x 7H All Stations EEA Pm Remote Terminal Units fa CPU RTU Configuration jj On Board 1 0 7 Virtual 1 0 Modu maT RS 485 Stations e Right click on the highlighted item and choose Configure from the drop down menu that appears OT RELEASE 6PJ SIXNET 1 0 Tool Kit File Edit view Device Configure Operations Tools Panels D g S a EEE E E ER asso Tree Views Wy All Stations Pm Remote Terminal Units E mare 4855ta E IsaGRAF d Configure Dataloaging Nalco Global Equipment Solutions 41 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller e The configuration dialog box appears Change the Serial Number on the General tab to match the serial num
9. for the 3D TRASAR configurator software for detailed information on how to use the configurator software and the 3D TRASAR Installation and User Manual for instruction on the installation setup and operation of the 3D TRASAR controller 3D TRASAR Configurator Controller Model When initially configuring the 3D TRASAR controller be sure to select 83D TRASAR Once Through as the controller model on the on the General Information screen General Information Contiolle Type 30 TRASAR 30 TRASAR 30 TRASAR Starter 3D TRASAR Closed Loop Gud 30 TRASAR CL Starter 30 TRASAR Once Through Lod TRASAR RO System SAP SAP Sold To or Customer Number Spttem Preleiences Unite Convention English Metric Date Format Imm dd yyy fal Controller Decimal a Symbol Period Comma X cancel M Next This will insure that data sent to the 3D TRASAR website is handled properly 3D TRASAR Configurator I O Scaling The Once Through controller send two 4 20 mA analog output signals to the 3D TRASAR controller for logging and alarming and receives six 4 20 mA input signals from the 3D TRASAR controller for use in its pump feed rate calculations The 3D TRASAR configurator software is used to specify the setting for these values inside the 3D TRASAR controller 20 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO External Input Settings for Orke Through_Columbia_Protot
10. will appear showing the progress of the configuration upload Loading station configuration for CPU Load scan list 1 One Load special features Load general settings Load ting monitoring Load 10 transfers Load registration data Load IP security Load SNMP configuration x Load port settings 100 v Load project archive Load S aGHar file P Load user file s CER py Loading user He De wilaturasMy Documentss Once TAroughsOT Overall Progress e When the upload is complete the status box will indicate that the upload was successful port Views Loading project archive to the station Project archive loaded Loading ISaGRAF Ny D WSAWIN APL OT_RELEA appli X6 File loaded Loading user file D wlatura My Documents Once Througt File loaded Loading sixlog configuration ot_log Checking available memory Sending configuration to station Waiting for response from station No errors reported from station Writing tag scaling information ot_log loaded Load Datalog configuration complete E Load complete H 4 gt M Status f fal VI MIPM 241 D CPU The Upgrade is now complete and all cables and connectors can be removed Nalco Global Equipment Solutions 45 Pa NALCO 46 Nalco 3D TRASAR Once Through Cooling Water Controller Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA
11. AR Once Through Cooling Water Controller The 4 20 mA Output Settings for Once Through _Columbia_Prototype form in the configurator is used to configure the measurement signals being set from the 3D TRASAR unit to the Once Through controller 4 70 mA Output Settings for Once Through_Columbia_Prototype Output Settings Name 4 mA Value 20 mA Value Conductivity a ie 4 uis cm 10000 us cm ORP o mv tooo mV 4 Sample Temperature 32 Deg F 212 Deg F E Corro sion 1 lo mpy 10 mpy 6 Corro sion 2 lo mpy 10 mpy Not Used A Set the output type by selecting it from the drop down lists next to each output number The type of signal to be sent on each channel is fixed and must be set as follows for the Once Through controller to operate properly Channel 1 pH Channel 2 Conductivity Channel 3 ORP Channel 4 Sample Temperature Channel 5 Corrosion 1 Channel 6 Corrosion 2 Channel 7 Not Used Channel 8 Not Used The 4 and 20 mA scaling factors used on this form must match those entered in the Inputs section and of Once Through controllers I O scaling screen 22 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Electrical Connections Wiring Diagram for 4 20 mA and Discrete I O The Once Through controller has provisions for bringing in signals from external devices as well as sending discrete alarm signals to an external d
12. LCO Nalco Global Equipment Solutions 47 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller WARRANTY POLICY Nalco Global Equipment Solutions warrants its standard equipment and related installation services to the original purchaser to be free of defects in material or workmanship for one year from the date of shipment unless otherwise specified Key Features Include e Simplified claims processing warranty assistance is just a toll free call away Most claims can be handled by making a single phone call e 12 month coverage of all standard part numbered Nalco equipment offerings excepting consumable items and products with shelf lives of less than 12 months e 12 month coverage of Nalco equipment installation e Repair and on site warranty assistance now available in selected areas Limitations Warranty does not cover damage caused by misuse neglect accident including a force majeure event improper installation or improper maintenance or repair Nalco s liability under this warranty is limited to repair or replacement of defective items or refund of or credit for the product price excluding shipping Nalco DISCLAIMS ALL OTHER WARRANTIES INCLUDING WARRANTIES OF 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 credi
13. Li ro Discrete Input R Return ner 2 z Select DC for sourcing defaut RS232 D Aoi R R T 10 30 For sourcing 4143454749 411 1 3 x VDC inputs connect to 10 30 VDC and set the Return Jumper for DC For sinking inputs connect to 10 30 VDC and set the Return Jumper for oi DO Al A0 Port C QVOOODOOODOOOOOOOO O 31 32 33 4 35 36 37 38 39 40 41 42 43 44 45 46 47 41818 le BF caine DCH RS232 amp RS485 Communication Ground Equivalent DC Input Circuits Equivalent DC Output Circuit sourcing only Sourcing Equivalent Analog 4 20 mA Input Circuit AIN 26 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Downloading Sixnet Controller Data The Sixnet controller along with the 3D TRASAR controller is housed in the Once Through controller box The separate internal data log in the Sixnet controller is sent directly to the 3D TRASAR website This log is primarily designed to capture data for diagnostic and troubleshooting purposes though the data can also be used for other purposes if desired NOTE This data file is not the same as the one that is coolected by the 3D TRASAR controller and sent to the 3D TRASAR website This data log records information every 30 minutes and will hold approximately 90 days worth of data Data items logged consist of Date and Timestamp Residence T
14. May 2007 Version 3 0 Nalco Global Equipment Solutions 1601 West Diehl Road Naperville IL 60563 1198 Nalco 3D TRASAR Once Through Cooling Water Controller Setup and Operating Manual Operation Manual OM0202 Nalco Model Numbers Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Table of Contents Once Through Controller Setup and Operation cccceeceeeeeeeeeaeeeeeeeaeeenes 5 NEOG TOW aE eset tessecaeanesaedonce E E E 5 a EEE UD oe eves E E T E A E E T E TE TNT 5 RY VENT a a ETE A TE E NE A E E N E O T TET 5 FANG E O ae ceases E EEE EE E EE EAE EE Ea 6 Sen T EOU reese sec EEO E S O TEE EA 6 SCF OO aE E EEE EE E E EE 6 DALEN V e E EE 8 POME OTTOON re E E A EEEE 9 EEA E E E EAT E A EE EE EAT S 10 Frode ele ON err i EEE EEEE EEUE EERE 11 water GNC MIS Wy ocrck paei na aed iLe PENS LEER e Eaa inniit 12 DY SGM OU erene ENTE ia TN 13 SCIEN ar E E E AE 14 CE U era E EE E E OE NRE A 15 DC ler WMS eener e EA E A E N EE EOE 16 Pump HIMGOUL ALANIS cirerer i E EEE ERNE E OEE 17 TEMP OS E ee a E E E ORE 18 LE eo TEEPE EE E E E E E O AEA T TAT 19 3D TRASAR Controller Configurator Setup cccccceec cece ee eeeeeae eae eeaeeaeeaeeneees 20 HOCI UO eee E E EE E 20 3D TRASAR Configurator Controller Model ssssssssssnensssnerrenrrrrrrrnssrrerrreene 20 3D TRASAR Configurator I O Scaling cccccccc ccc eee cece eee eeeeeeeeeeeeaeeaeeeeeay 20 E ECIIGal Connec IONS sii cacse c
15. Save in E OT Controller z Save astype CSV Files csv 34 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Downloading the Sixnet Data File After the First Time Once the Sixnet project has been downloaded it will no longer be necessary to repeat all the above steps to download data on subsequent occasions To download data after the project and the data configurations have been read back from the controller and saved perform the following steps 1 Connect the Ethernet crossover cable for the Ethernet port on the PC to the Ethernet port on the top of the Sixnet controller Start up the Sixnet I O Toolkit software From the main menu choose File Open Project and select the project file you saved above the project file will have a 6pj extension In the Tree View click on the until RTU Configuration is visible Click on the RTU Configuration to highlight From the main menu select Operations Datalogging Read Data Records In the dialog box that appears make sure the Station name is CPU and the configuration name is ot_log Click OK From the dialog box that appears choose the number of records you wish to download and decide if you wish to append the data records to an existing file When you click OK the data records will be downloaded from the controller Once the records have been downloaded you may save the data as a cs
16. as the source for these If external signals are being provided 1 and 20 mA scaling factors must be provided so that the signals can be interpreted properly Refer to the section Wiring Diagram for 4 20 mA and Discrete I O page 23 for details on how to wire in external flow and or turbidity signals Nalco Global Equipment Solutions 13 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller Scale Inputs The Scale Inputs screen is used to adjust signal scaling for the input values of the controller so that incoming signals are interpreted correctly The 3D TRASAR controller is sending a series of six values to the Once Through controller pH e Conductivity e Sample Temperature e ORP e NCM 1 Corrosion e NCM 2 Corrosion These signals are sent as 4 20 mA analog currents The Once Through controller must be told what value is represented by 4 mA and by 20 mA so that it can linearly scale the signal to the correct value NOTE The scaling factors entered on this screen must be the same as those entered on the 4 20 mA Outputs screen in the 3D TRASAR configurator program pH Conduct ity Whe MEM 1 24 00 mpy HEM 2 34 AA ripy After making the required entries here press the MENU button to return to the Main Menu or the HOME button to return to the Home screen 14 Nalco Global Equipment Solutions Pa irr Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO
17. ber printed on the base of the CPU model in the controller IPm Remote Terminal Unit Station Configuration General Ports 1 0 Modules Advanced 1 0 Transfers F Define General Properess Station Name Crug Station number t Seral number 30533 e Click on the Files to Load tab of the dialog box 1 Make sure the Archive the station s Tool Kit configuration box is checked 2 Load station resources I O allocations and Load project tag list should not be checked 3 On the ISaGRAF tab make sure Load an ISaGRAF program is checked Load project archive at the bottom of tab should not be checked The Run time version box should show 3 x Se Pm Remote Terminal Unit Station Configuration General Ports 1 0 Modules Advanced 1 0 Transfers Filesto Load User Software Files to Load During Load AM Nowa m Archive the station s Tool Kit configuration Load station resources 1 O allocations Load project tag list SaGRAF Datalogging Other M Load an SaGRAF program Run time version Ix xm File DAISAWIN APL OT_RELEA applix6m Load project archive 42 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO e Click the x6m File box and browse to the location of the appli X6m file that was provided Select it and click Open Select SaGRAF Executable Look
18. can be downloaded as follows 1 Connect the Ethernet crossover cable from the Ethernet port on the PC to the Ethernet port on the top of the Sixnet controller Note that the Ethernet port is on the far right side of the controller Be sure you do not plug the cable into the RS 232 Port B right next to it which also uses an RJ 45 connector 2 Start up the Sixnet I O Toolkit software and from the main menu choose Device Select Untitled SIXNET I0 Tool Kit File Edit View Deu Tree Yiews ae Configure Operations Tools Panels Hel Status St 3 In the dialog box that appears select Use Ethernet Specify an IP address and Single station with an address of 169 254 1 100 then click OK Select Communications Device C Use Null device demo mode zs Use Ethermel Connection Cancel C Network Passthru amp Single station C Use station s IF address f Specify an IP address 169 254 1 100 Timeout 2000 m Help Allow loading via Ethernet to serial passthru f Use com port l Clie le tareshare detaile rnr 28 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO 4 From the main menu select Operation Read Back Untitled STANET O Tool Kit View Device Configure aeseiiees Tools Panels Help a ee o i g rrr Ja E es me A
19. evice such as a DCS or alarm annunciator The wiring diagrams below illustrate how external analog and discrete signals can be wired Certain terminals on the controller are dedicated to specific tanks The input and output signals to and from the 3D TRASAR controller are pre wired as follows Al 1 pH Terminal 9 Al 2 Conductivity Terminal 39 Al 3 ORP Terminal 10 Al 4 Sample Temperature Terminal 40 Al 5 Corrosion 1 Terminal 11 Al 6 Corrosion 2 Terminal 41 lf external flow and or turbidity signals are available they should be wired as follows Al 7 Turbidity Terminal 12 Al 8 Flow Terminal 42 The analog outputs being sent to the 3D TRASAR unit are wired as follows AO 1 User Selected Terminal 13 AO 2 User Selected Terminal 43 Terminals have been provided which allow up to four feed pumps to be controlled by the Once Through system The terminal connections are dedicated to specific pumps depending on the system configuration Control signals should be wired to the pump terminals as follows AO 1 First Product Feed Pump AO 2 Second Product Feed Pump AO 3 Third Product Feed Pump AO 4 Fourth Control Pump NOTE The Once Through controller does not provide the pump power only the speed control signal lf an external Bleach Pump signal is available it should be connected as foolows DO 1 Pump 1 Timeout Alarm Terminal 1 Nalco Global Equipment Solutions 23 PA NALCO Nalco 3D TRASAR Once Through Coo
20. g on the number of treatment product selected Each press of one of these buttons will cause the product name displayed on the button face to change Keep pressing the button until the desired product name appears If the end of the list is reached the list will start back at the beginning NOTE While it is possible to choose the same product on more than one button this will result in incorrect product dosage calculations Each button should have a unique product selection Cont rel Scale Control Corrosion Humber of Treatment Products 4 Frodyct 1 Prodyct 2 THR 404 Product 3 Product 4 S0T 102 Nalco Global Equipment Solutions 11 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller After making the desired selections here press the MENU button to return to the Main Menu or press the HOME button to return to the Home screen Water Chemistry The values entered on the Water Chemistry screen are used to calculate a Calcium Saturation Index a Langelier Index a corrosion rate as well as the feed rates for all of the treatment products selected on the Product Selection screen If a value is entered for Iron and or Manganese an additional algorithm will run that will calculate the polymer required for performing FE MN stabilization Car CatOF5 Sod lum for Hes M Alkalinity BSR prem far Catiga Chloride I ppr Cor i Sy LF at 2345 Baal tear 50 Phosp
21. hate 2345 Oa ior Fi Condenser Temp Corrosion Rate Note that different water chemistry values are entered using different units e Calcium e Sodium e Magnesium e tron e Manganese e N Alkalinity e Chloride e Sulfate e Phosphate e Corrosion Rate 12 as CaCO as Na as CaCO as Fe as Mn as CaCO as Cl as SO as PO as mpy Nalco Global Equipment Solutions Pa irr Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Any time values for the parameters here change based on tests run on water samples this page should be updated The more accurate the values are that are entered here the better the Once Through controller will perform in feeding products to control scale corrosion silt and Fe Mn stabilization System Setup In order for the controller to correctly calculate the required pump feed rates and control the treatment pump speed properly the system Residence Time and system Flow Rate values must be entered on this screen If applicable the CLIO Factor should be entered to allow the system to account for the effect it has on required treatment dosages Residence Tim CLIO Factor Flow Rate Turbidity Flow Rate and Turbidity values may either be entered manually or scaled from a 4 20 mA signal provided to the controller from an external source Pressing the Source buttons for these two items will toggle between Man manual and DCS
22. ime Flow Rate Calcium Sodium Magnesium Manganese lron M Alkalinity Sulfate Chloride Phosphate Turbidity CLIO Factor Langelier Index Calcite Saturation Level Corrosion Rate Pump 1 Product Feed Rate Pump 2 Product Feed Rate Pump 3 Product Feed Rate Pump 4 Product Feed Rate ml min ml min ml min ml min Ee wer NN SN The data log file can be downloaded by using special software and a crossover Ethernet cable The following software application will be required to download the data file from the Once Through controller e Sixnet lO Toolkit verson 3 1 with SP1 or later This software may be obtained via SMS by obtaining and filling out a Global Software Request form from the Nalco Global Software Applications website Note that the software is classified as restricted which means that presenting a business justification and obtaining a Manager s approval is necessary to acquire the software Nalco Global Equipment Solutions 27 KION NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller Use Need to download data from Sixnet controller in the 3D TRASAR Once Through controller as the business need for the request Downloading the Sixnet Data File for the First Time NOTE The following describes the steps necessary to download the data file for the first time After the first time a number of the steps described will no longer be necessary Once the software has been installed the data
23. imson 2 0 software e Select File Open from the main menu der Untitled File G306 Crimson 2 0 a8 Edit View Link Help New Ciri Open Save Save AS 36 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NALCO e Browse to the location of the provided OT_Release cd2 file and select it Open File Look in E Crimson J 2 test cd2 otcd2 OT Release cd2 OT Release co Crimson 2 0 Database cd2 e After the file has been loaded into the Crimson application select Link Options from the main menu OT Release G306 Crimson 2 0 e Edit View igs Help Update send Extract oy Support Upload Mount Flash Bismount Flash Format Flash Send Time Optons Nalco Global Equipment Solutions 37 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller e Select USB from the Communication Port options Make sure Send to Emulator is not checked Click OK Link Options F alo Lint Ronhgure e Select Link from the main menu and make sure Support Upload is checked OT_ Release G306 Crimson 2 0 View Pas k fa Send shit F9 Extract w Support Upload Mount Flash Dismount Flash Format Flash Once the upgrade file has been sent the Crimson application can be closed and the USB cable can be disconnected 38 Nalco Global Equipment Solu
24. in OT_RELEA fie c E Oven Files of type SaGRAF Executable x6m e Click the Datalogging tab and make sure that the ot_log file has a check mark next to it Click OK iPm Remote Terminal Unit Station Configuration General Ports 1 0 Modules Advanced 1 0 Transfers Filesto Load User So Files to Load During ont All Nive Load station resources I O a Load project tag list ISaGRAF Datalogging Other Stdog files to load Nalco Global Equipment Solutions 43 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller e From the main menu choose Operations Load Load All Now Predefined Files 1 0 Tool Kit 2 Beeseiiegem Tools Panels Help tn mzz ve TB eA Load dh Load Now Basic Parameters Only amp verify Load Onion n d Read Back Load Advanced Select Files s Ep Auto Detect EtherTRAK Stations L fide ce i Omane Ga Test 1 o e Awarning box will appear Click Yes to continue Warning Warning This operation will load all the files and applications that have been defined in the Files to Load tab of the configuration for the selected station Existing ISaGRAF programs datalog and files in the station will be erased by this configuration load process Continue 44 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO e A dialog box
25. ing Water Controller and those specific setting on the 3D TRASAR controller that must be set to insure the Once Through controller functions properly For complete instructions on the setup and use of the 3D TRASAR controller including installation piping instrument calibration and software configuration refer to the 3D TRASAR controller manual and the help file provided with the 3D TRASAR configurator software The touch screen display on the Once Through controller is the primary means for setting up and operating the Once Through system Initial Setup When setting up the Once Through controller for the first time setup should proceed through the following sequence of screens Product Selection Water Chemistry System Inputs Scale Inputs Scale Outputs Pump Controls 1 to 4 depending on the number of treatment products specified in step 1 Temperature Offset Set Clock 3D TRASAR Controller Setup via configurator software PT a 2 Following this sequence will minimize the chance of failing to provide all necessary information for the proper operation of the Once Through controller Main Panel Below is a picture of the complete front panel of the Nalco Once Through Controller display with the Home screen being displayed The Home screen will appear in a few moments after the controller has been powered up Below the panel display is a close up view of the actual
26. ling Water Controller Four discrete outputs can be used to signal timeout alarms for up to four treatment pumps lf you wish to sue these signals they should be wired as follows 24 DO 1 DO 2 DO 3 DO 4 Pump 1 Timeout Alarm Pump 2 Timeout Alarm Pump 3 Timeout Alarm Pump 4 Timeout Alarm Terminal 7 Terminal 37 Terminal 8 Terminal 38 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NALCO RS485 l 10 30 VDC PotA User Supplied R5232 Ethernet IO Tl Chassis RJ45 RJ45 Port B 10 100 19 20 21 22 23 DOODO Ea pI Discrete Input Retum Jumper OO amp Select DC for sourcing default or DC for sinking m Di r D0 Al AO Port D QVVOWVDOVDOVDODOVOVDOEOVUDOE 1 23 45 6 7 8 9 10 11 12 13 14 15 16 17 18 Self powered Al ean _ 10 30 1 shown Bwat HM a VDC Loop powered All Return shown rr DI e a DO Al AO Port C 0000000000000000 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 AAEN ole R 232 amp RS485 Communication Ground Equivalent Analog Equivalent Analog 4 20 mA Input Circuit 4 20 mA Output Circuit AIN Nalco Global Equipment Solutions 25 NALCO Nalco 3D TRASAR Once Through Cooling Water Controller l RS485 10 30 VDC Port A User Supplied RS232 Ethernet IS T Chassis RJ45 RJ45 Port B 10 100 3 20 21 22 23 AAAA
27. ll be visible lf the alarm is on and the pump output falls below the Alarm On Percent the alarm will automatically clear by itself To clear the alarm manually press the appropriate Clear Alarm button on the Pump Timeout Alarms screen see below Pump Timeout Alarms The screen below shows which if any pump time out alarms have been tripped If no pumps are in alarm this screen will appear blank lf any pumps are in alarm a red box will appear with the name of the pump in alarm showing PEL 402A THR 404 Purp Timeout Alarm Furmp Timeout Harm Funp Timeout Alarm Pressing the Clear Alarm button will reset the alarm for that pump set the alarm tier back to zero and turn off the discrete signal being sent to the discrete output terminal on the controller Refer to the Wiring Diagram for 4 20mA and Discrete I O Section on page 23 for details Nalco Global Equipment Solutions 17 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller Temp Offset The Once Through controller receives one sample temperature from the 3D TRASAR controller In some cases the sample temperature will not be the same as the actual water temperature at the location where scale formation is being measured nor at the condenser where the corrosion rate is being measured sample Tenperature Condenser Temp Offset Scale Calc Temperature Condenser Tenperature F OF The Sample Temperatu
28. olutions PA NALCO Nalco 3D TRASAR Once Through Cooling Water Controller 8 From the main menu select Operations Datalogging Sixlog List Configurations in Station Your site 6pj SIXNET I O Tool Kit File Edit View Device Configure Qeeejyee Tools Panels Help ma yak ry L E HARE EE FS E i Tree Views Load d _ E at Verify FE All Stations SmE CPU Gy Auto Detect EtherTRAK Stations o WE FRU Configuratie _ he IE Pm Remote Terminal Li al Read Back Mg On Board 1 0 IG Virtual 1 0 Mody ste fa Test 1 0 Datalogging Sixlog GA Set re ee W Reade amp Hile Operations ye Ersse c k ml List Configurations in Station Advanced Operations 9 Adialog box will appear listing the data files in the controller Normally only one ot_log will appear Click on it to select it it will appear highlighted and then click on Read Back File List Sitlog files found inthe statics Read ck Nalco Global Equipment Solutions 31 PA NALCO Nalco 3D TRASAR Once Through Cooling Water Controller 10 A dialog box will appear notifying you that the data file has been successfully read and back Click OK at acknowledge it and clear the box Fille List 11 From the main menu select File Save to save the Sixlog data file configuration to the project file
29. oue lt eaintavieesswsegsewenieinn tee assmncindseantiveccgasesseaece nee waeeaaeiess 23 Wiring Diagram for 4 20 mA and Discrete I O cccceeceee cece eee eneeeeeeaeeeaeeas 23 Downloading Sixnet Controller Data cc ccc ccc cee eee ec eee eee eeeeeee eee ecaeeaeeaeeaeenas 27 Downloading the Sixnet Data File for the First Time cccceeceseeeeeeeeeee ees 28 Downloading the Sixnet Data File After the First Time ccccceeeeeeeeees 35 Upgrading the Once Through Software cccccccce eee eec eee e eases eeeeeaeeeaeeaeeaeeaness 36 Hardware ReQuired cccccccccecee cece eeeneeeeee eee eeeneeeeeeeeeaeeeeaeeteaeeegeeeegneegaees 36 Application Software R qQuired cccccc ccc eee eee eee eee e eases teat eaeeaeeeaeeaeeane eas 36 Pooc TRIO SiasdacnecaxanceculansaeyiveninneeediuanVaceedacanrantiusoncareaieaeiesiiasedGenseauese tants 36 Upgrading the Crimson Display Configuration File cccceceeeeeeeeeeeeeeeaeeaes 36 Upgrading the Sixnet Controller Configuration Files cccccce cece sees eeeeenees 39 Nalco Global Equipment Solutions 3 Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Once Through Controller Setup and Operations Introduction The Once Through Cooling Water Controller includes both a 3D TRASAR controller and a separate Once Through Cooling Water Controller This manual covers only the setup and operation of the Once Through Cool
30. re Offset allows you to independently adjust the two temperatures used in the control equations from the single temperature signal that the controller receives The Offset values entered will be added or subtracted from the Sample Temperature to arrive at the actual temperature values used in the scale and corrosion calculations NOTE An offset is not required An offset value set at zero means the actual sample temperature will be used in the corresponding calculation 18 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Set Clock The Set Controller Clock screen is used to adjust the time on the Once Through controller Note that this time is only used for the internal data log kept by the controller It does not affect the data log kept on the 3D TRASAR controller that is sent to the 3D TRASAR website nor does it affect the time stamp on the alarm emails that the 3D TRASAR controller sends Mon Day Year Se Controller Clock Do Not Use Daylight Savings Time UMT OFFset Nalco Global Equipment Solutions 19 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller 3D TRASAR Controller Configurator Setup Introduction Follow the normal configuration procedure for a new 3D TRASAR controller with the exception of those items detailed below which are specific to the 3D TRASAR controller used in a Once Through system See the help file
31. roducts are chosen the two pump buttons on the right side of the screen will not appear The pump labels will change based on the treatment product selected All of the non pump selection buttons will always be visible Product Se leet ton Water Chemistry THR 464 PCL 461 3DT 102 Pump Funmp Pump The Home button returns to the Home screen described above the other selections are described below 10 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Product Selection The Product Selection screen is where the choices for the type of control the controller will perform is determined as well as the treatment products that will be used Pressing the Control Scale and or Control Corrosion buttons will toggle YES and NO selections that determine whether or not the scale control and corrosion control feed algorithms run If you wish to control for one of both of these factors make sure you set the toggle buttons to YES Choose the number of treatment products you wish the Once Through controller to control by pressing the pressing the Number of Treatment Products button Each press of the button will increment the number of products up to a maximum of 4 at which time an additional press of the button will return the value to one The four product selection buttons that appear on the bottom portion of the screen will appear and disappear dependin
32. roller the feed rate of the pump when it is running at 100 output This is normally determined by performing a draw down test on the pump The controller assumes that the pump will be off when the output signal is at 0 and will start pumping as soon as the value goes above 0 A linear scaling is done between 0 ml min feed at 0 output and the Pump Output at 100 feed rate at 100 output If the pump is not set up this way the dosage control will not be able to feed the correct amount of treatment product NOTE If the pump stroke rate is changed a new draw down test should be performed on the pump so the feed rate calculations stay accurate Pump Mode MANUAL Nanual Pump Output Pump Output at 1664 BEES nl nin Funp Output Feed Rate Mimin Alarm On Time Alarm On Percent The Alarm On Time and Alarm On Percent settings are used to setup a timeout alarm for each pump If the Alarm On Time value is set to zero 0 the timeout alarm for the pump will be disabled 16 Nalco Global Equipment Solutions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO No timeout alarm will ever occur if the pump is in Manual mode When both values are present and the pump has been pumping at more than the Alarm On Percent setting for more minutes than the Alarm On Time setting the alarm will be tripped lf the alarm is on for any of the pumps the alarm indicator on the Home screen wi
33. t 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 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 the transportation company and request a Damaged Good report be completed In either event the transportation company should be notified immediately of any damage to the shipment to protect your rights of recovery 48 Nalco Global Equipment Solutions
34. tions Nalco 3D TRASAR Once Through Cooling Water Controller NA LCO Upgrading the Sixnet Controller Configuration Files e Connect the Ethernet crossover cable from the Ethernet port on the PC to the Ethernet port on the top of the Sixnet controller Note that the Ethernet port is on the far right side of the controller Be sure you do not plug the cable into the RS 232 Port B right next to it which also uses an RJ 45 connector e Start the Sixnet IO Toolkit software Untitled SIXNET 1 0 Tool Kit mem Edit View Device Configure Operations 5 New Project Ctrl y t Open Project aa ce E G Save Project Ctrl 5 Ee Save Project As Import Export H Look in KE OT Release Software Lo UNTITLED 6P R OT PROTO GP L JOT RELEASE 6F OT RELEASE GPJ Project Files 6pi Nalco Global Equipment Solutions 39 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller e Setup the communications link by selecting Device Select from the main menu OT RELEASE GPJ SIXNET 1 0 Tool Kit File Edit View iui Conf ure Operations e Inthe dialog box that appears select Use Ethernet Specify an IP address and Single station with an address of 169 254 1 100 Click OK Select Communications Device C Use Null device demo mode zs A
35. v file by selecting File Save data File As and specifying the name and location of the file Nalco Global Equipment Solutions 35 NA LCO Nalco 3D TRASAR Once Through Cooling Water Controller Upgrading the Once Through Software Hardware Required Depending on which software is to be upgraded on the Once Through controller the following cables may be required e Standard USB A to B extension cable Similar to Belkin Pro Series Hi Speed USB 2 0 Cable 6 ft Belkin Part F3U133 06 or Dynex 6 5 USB 2 0 A B USB Cable Dynex Model TE USB 2AB 2 0 SBG e Standard or crossover Cat5 6 Ethernet cable port is auto sensing Application Software Required The following software applications will be required to upgrade the application software on the Once Through controller Both can be acquired via SMS using a Nalco Global Software request form e Sixnet lO Toolkit version 3 1 with SP1 or later e Red Lion Crimson 2 0 Build 2 0 0 324 or later Project Files One or more of the following configuration files may be required to complete the upgrade of the Once Through controller OT_Release cd2 Red Lion display configuration file OT_Release 6p Sixnet controller configuration file appli X6M lsaGraf executable file for Sixnet controller Upgrading the Crimson Display Configuration File e Connect the USB cable from a USB port on the PC to the USB port on the underside of the Red Lion display e Start the Cr
36. ype 4 70mA Input 1 i 4 70mA Input 2 AI 1 Name Scale Pump AI 2 Name Corr Pump 4 m Value 4mA Value is 20 mA Value 10 20 mA Value Units lunits units units High Alarm Limit os High Alarm Limit Ba Low Alarm Limit B Low Alarm Limit 10 Digital Inputs r Digital Input 1 Flow Switch i Digital Input 2 System Interlock r Digital Input 3 Digital Input 4 Use as Water Meter Use as Water Meter 1 DI 3 Name o DI 4 Name x seg p OK The External Input Settings form in the configurator software is used to configure the measurement signals being set from the Once Through controller to the 3D TRASAR unit The 4 20 mA Input 1 signal is always set to the Scale Pump feed rate while the 4 20 mA Input 2 signal is always set to the corrosion Corr Pump feed rate The 4 mA Value and 20 mA Value scaling factors used on the form must match those entered in the Outputs section of the Once Through controllers IO Scaling screen The units should be set to pct The High Alarm Limit and the Low Alarm Limit are the pump rate values above or below which the 3D TRASAR controller will generate an alarm Enter a blank value in these boxes if you do not wish to generate alarms based on pump outputs The Once Through controller does not use the Digital Inputs Nalco Global Equipment Solutions 21 NA LCO Nalco 3D TRAS
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