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Catalyst Manual - Softrol Support

1. 2 HY HUB Hub card HY HUB for single Catalyst Ooo goood 51000 SLUT 8 8X8 Inputs 1 Standard Outputs SLUT __ ARCFIBER ARCFIBER Communications m 24 VDC 5 A Power Supply m for CataPulse Interface a Flow Mem T MicroPulse Power Supply i mm Memory Card 22020000 5 VDC for Control REESE 15 VDC for Alarm z OUT 16 Air Push N 2 t Machines 17 20 ES i5 L d DK 23 OUT 16 Chemicals 9 16 i8 Machines 9 16 __ OUT 16 Chemicals 1 8 Machines 1 8 Processor 4 AND 4 120VAC gt ON OFF Switch TO GROUND 2 AMP BREAKER eee SWITCH 24 VAC Transformer All Outputs and Inputs X A Relay for Alarm Main F E ain Fuse iu Ze N Te ojo gm ERE s Llc A al e fs seal s A 24VAC 40W P clo mm AN vp yp ga E Panax B _ 5 Fuse for 24
2. 9 SOF TROL CataPulse lt lt Interface Machine gt gt gt QAI SEL AY He jen ex o na o wel 9 u o un z o Eees 55 15 3 154 c 2 5 o MEIN o jum m o E 1049305 i E CLR Xo o CATAPULSE INTERFACE INPUT CONVERTER 23 Catalyst SOFTROL CATALYST The input converter should be wired on the interface side as follows Fig 2 Terminal Wire Color 1 Orange 2 White 5 Blue Black 6 Jump to 2 10 Black 11 Blue 12 Blue White 13 Green 14 Green White 15 Red 16 Red White 17 Black White 18 White Black www Softrol com SOFTROL The wires should be Once the connections are made the power and the Arcnet communications must be connected to the interface The Arcnet runs on stranded Cat 5 twisted pair wire The power line is a two conductor 18 ga Wire To access these connections remove the small box at the base of the inter
3. are ES All of the communications involved with the Catalyst run on an ArcNet network ArcNet is an industrial high speed network designed to be rugged and trouble free The network can be run on RG 62 Coaxial cable Cat 5 twisted pair or fiber optic cables Most all of the Catalyst installations now use Cat 5 Twisted pair cable and is attached to the controller with Phoenix connectors All the chemical requests from the machines and interfaces to the Catalyst are transmitted over this network If the network is not functioning properly the delivery of chemicals can be impeded The network is typically laid out in a bus fashion with an active hub Note If it is a single Catalyst using twisted pair the hub card may be located in the controller in slot 8 If there are multiple Catalysts or the system is older an active hub will be used The illustration above depicts a Mod Hub on the left for older coax networks and an Arc hub on the right Usually twisted pair For more information on the layout of the network please see section 2 10 of Installation and Configuration Troubleshooting the network The active hub Pic
4. catalyst Interface Interface Catalyst Een 5 7 7 9 o ob po eem ES 1 d de Gt mg eS 4 8 9 To Pu Loc 15 Conductor Catalyst chemical Catalyst LZ LLL wire system afalyst 07 chemical injection system RG 62 Coax network layout Cable If it is a single system the hub card will be in the Catalyst control If there are multiple systems then there will be a separately powered hub e The ArcNet cable is run as abus system with the lines from an active hub run in a daisy chain fashion e The maximum number of nodes machines interface computer or Catalyst on one line from the hub is 8 The last node on a line should have a 93 ohm terminator The cable should be installed to avoid coming in close contact with high voltage lines do not attach cable to incoming power to a machine and variable speed drives for motors If you must cross a high voltage line run the communication cable perpendicular to it The arcnet layout varies with each plant but a typical layout is as shown above Note The Catalyst Lite system has a maximum of 8 machines and does not use an active hub All the nodes on the network are
5. 16151413 121110 9 8 7 65 43 8 1 COLORED DOT IDENTIFICATION 90 Catalyst SOFTROL www Softrol com CATALYST Slot 8 HYHUB TP CAT This card is sometimes used in place of a hub It will have three branches from it 1 Catalyst Computer 2 Machine branch 1 3 Machine Branch 2 J C O O C O C lei lei ae LIITILLLLLLLLILLLLILLIILLLLI LIE LILL JUMPJ1 IF USI HYBHUB CARD WITH MTHHUB MOTHERBOARD i N ARCHUB ENCLOSURE DO NOT JUMP J1 IF USING HYBHUB CARD IN CATALYST CONTROL Catalyst SOFTROL www Softrol com SOFTROL CATALYST Catalyst Pneumatics Air Push Solenoid Machine Valve PUSH 22 Manifold 90 PSI 1 5 I gt T FK D o o lt io
6. JUMPER s E TERMINATE TWISTED PAIR 83 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Catalyst Arcnet Card Twisted Pair Hub Card ADD JUMPER IF CARD IS USED IN SEPERATE HUB JUMPER IF CARD IS IN CATALYST CUNTRIU This card is used in the Catalyst control when the system does not have a hub If the card is used in the Catalyst control the jumper MUST be removed 84 Catalyst SOFTROL www Softrol com SOFIROL CATALYST Twisted Pair Network ARCNET TWISTED PAIR POLARITY GUIDE FOR THE CATALYST Min ARCFIBER CATALYST 8 Wi Z L lug PCI20 COMPUTER 85 White d Z lt HYHUB HUB Catalyst White gt lt 4 OPTARC INTERFACE Z hit COMPUTER SOFTROL Catalyst Electronics www Softrol com SOFTROL CATALYST
7. The cylinder has graduations in 20 ml increments convert ml to Oz divide by 29 57 Be sure to measure 7 the chemical only and not foam This will result in more accurate injections AAG Z Z Example 1760 ml 29 57 59 5 Oz Catalyst SOFTROL www Softrol com SOFTROL CATALYST 13 Press ENT to accept the counts The controller will display a suggested amount based on the previous calibration Press CLR and enter in the new amount Enter the amount to the tenths place Example 58 Oz 58 0 14 Press ENT The Catalyst will display Save Calibration As 12 Initial 22 H Factor 3 Update 4 V Factor 0 Discard and Exit 15 Select 1 to store the calibration as the initial calibration This is very important if it is not done the calibration will be lost 16 The controller will then return to the calibration menu 17 Press and hold 1 amp ENT to flush chemicals 1 8 for 5 seconds Then press and hold 3 amp ENT to flush chemicals 9 16 for 5 seconds Finally press and hold CLR amp ENT to flush the system for about 15 seconds H Factor Calibrations This is used for greater accuracy for small dispense amounts 6 Oz If you do wish to do a H Factor calibration skip to step 26 18 Select 1 for calibrate chemicals 19 Select the same chemical as previously calibrated 20 Select 1 for Flow sensor calibration 21 Place the 250
8. Example Desired 64 Oz Received 62 Oz 64 62 2 2 64 03125 03125 X 100 3 125 error 43 Catalyst SOFTROL www Softrol com SOFTROL CATALYST If any calibrations are outside the desired tolerance normally 196 596 see the section Trouble With Calibrations Taking a painstaking approach to the calibration procedure will pay off later with extremely accurate chemical injections By contrast a poorly executed calibration routine will result in inaccurate and possibly costly chemical injections Flush the system when finished by the procedure in step 17 and press ENT amp YES to enable the Catalyst to resume pumping 44 Catalyst SOFTROL CATALYST ML to Oz Conversion Table 660 22 3 690 23 3 o 790 26 7 830 28 1 840 28 4 850 28 7 860 29 1 870 29 4 880 29 8 890 30 1 N oo POT NO PM Ol NIO 0 Po o ooo Co ro m O N N lt cO O S S O O O KR co 950 32 1 2 5 970 32 8 980 33 1 33 5 000 33 8 010 34 2 020 34 5 AR BY CO P CO O CO CO
9. 1A Fuse for 4A Fuse for 5 15 VDC 5 VDC Typical Catalyst Electronics Layout 86 Catalyst J SOFTROL www Softrol com SOFTROL CATALYST PROC Slot PRO K4A REM K4A DISPLAY E3 PR S3K4A TOP VIEW o d ole COM 1 COM REM K4A This card contains the software that controls the Catalyst It also contains the Catalyst setups and the current calibrations of the chemicals CUM 1 CUM 2 2 vo t3 1198 1 N QUO e L R 2D AUX COM AUX COM 2 M 570515 BOOT N Jey N THIS SDCKET IS 49 0 R QO UE L CURRENTLY USED FOR PROGRAM N E By 49 040 3 Bo 90PC L 9823 NI Y PRO K4A This card is the main processor for the system Sess 26 PIN CONNECTOR TEST PLUG FPD CONNECTION IIC gt 2 Ce BOOT R J E E T H B PRO K4A db i 1 4 d que 111111 K
10. a 1 1 ad ke s c s quo fo faye J a 1 1 I I I I I I I lt Om slags isles sigla ogg s g Sas 1 0 Lo 12 a a Lo 4 olg N Air Push Regulat Ir FUS egulator 25 PSI 9 Chemical Valve Manifold 90 PSI Ol info Lye Er 5 5 5 5 i js e e n f D Q ol ol N Low Pressure k e EID m j Pump Manifold 50 PSI Ue 55 ja esf uj N af eye eta FIT 8181915 8 High Pressure N Low Air Pressure Sensor Pump Manifold 70 PSI Open at below 65 PSI The pneumatic layout will vary with the system configuration A l
11. 770 974 0435 CL ASSIU PUMP AND VALVE LHEMS B Y MACHINES SINGLE SYSTEM 120VAC SERVICE 2 AMP BREAKER DC POWER SUPPLY 4 AMP ATO MB8 POWER 1 AMP ATO 5 AMP ATO 24VAC SECONDARY 24VAC ON s7 02 RESERVED FOR THIRD FLOAT LEVEL SWITCH FLUSH TANK HIGH LEVEL ACHIEVED FLUSH TANK LOW LEVEL OPTIONAL RESERVED FOR 3RD FLOAT LEVEL SWITCH 37 05 He AIR PRESSURE IS OK 57 07 E STOP IS OK CONTACT 1 E STOP CONTACT e E STOP SOF TROL SYSTEMS CATALYST CLASSIC SCHEMATIC S3CATALYSTCLASSIC 11 03 04 PAGE 2 24AE CALIBRATION VALVE OUTPUT COPTIONAL gt B8 POWER FLUSH TANK FILL VALVE 1 COLD OUTPUT 108 FLUSH TANK FILL VALVE 8 2 HOT OR MIXED OPTIONAL TEMPERATURE SWITCH FLUSH 1 CHEMS 1 8 DUTPUT FLUSH 2 CHEMS 9 16 DUTPUT FLUSH 3 ALL MACHINES OUTPUT BACK FLUSH VALVE OUTPUT FLUSH PUMP DUTPUT CONTROL ALARM RELAY DUTPUT COIL CRA SELECT CHEMICAL VALVE 1 OUTPUT CHEMICAL PUMP 1 OUTPUT SELECT CHEMICAL VALVE 8 CHEMICAL PUMP 2 T CHEMICAL VALV OUTPUT SELECT CHEMICAL LVE 3 CHEMICAL PUMP 3 OUTPUT SELECT CHEMICAL VALVE 4 CHEMICAL PUMP 4 SOF TROL SYSTEMS CATALYST CLASSIC SCHEMATIC S3CATALYSTCLASSIC 11 03 04 PAGE 3 SELECT CHEMICAL VALVE 5 DUTPUT CHEMICAL PUMP 5 SELECT CHEMICAL VALVE 6 OUTPUT CHEMICAL PUMP 6 SELECT CHEMICAL VALVE 7 OUTPUT CHEMICAL PUMP 7 SELECT CHEMICAL VALVE
12. 1 5 So s FormulaEnd 5 23 4 Ed l L e 61 Catalyst 19 www Softrol com SOFTROL 3 AKAIFLUSH 3 18 2 2 i www 55 22 E 2 _ CATALYST 8 Latch SOFTROL www Softrol com SOFTROL CATALYST Catalyst Formula Formula 41 White Bar Towels 0001 Bar Towels 0002 Chemical Step 1 0003 Add 30 Oz of Alkali 0004 Run Time 0 00 0005 Chemical Step 2 0006 Add 72 Oz of Alkali 0007 Add 48 Oz of Detergent 0008 Run Time 0 00 0009 Chemical Step 3 0010 Add 24 Alkali 0011 Add 24 Oz Detergent 0012 Run Time 0 00 0013 Chemical Step 4 0014 Add 64 Oz Bleach 0015 Run Time 0 00 0016 Chemical Step 5 0017 Add 4 Oz Antichlor 0018 Run Time 0 00 0019 Chemical Step 6 0020 Add 8 Oz Sour 0021 Run Time 0 00 0017 END OF FORMULA Ellis Formula AWC outputs 17 18 1920 21 22 23 Interface inputs 1 2 4 8 16 32 Latch The Ellis formula above is programmed to identify formula 1 and call for the appropriate chemical injections Step 1 Identifies the formula to the interface as formula 1 The interface will start the formula and proceed to the step ender line 4 This includes chemical step 1 so the Alkali will be injected as the washer fills Step 8 tells the interface to go to chemical step 2 The interface will add the break chemicals and stop a
13. 87 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Slot 1 OUT 16 This card has the outputs for chemicals 1 8 and machines 1 8 The outputs go from right to left and are 51 01 to 51 16 This stands for slot 1 outputs 1 16 m THIS COMMON SERVES PINS 9 16 THIS COMMON SERVES PINS 1 8 681514 161110 9 8 6 5 4 e RUM N Z N 2 Slot 2 OUT 16 Optional This card has the outputs for chemicals 9 16 and machines 9 16 Slot 3 OUT 16 Optional This card is used in a dual inject system and has outputs for pumps 1 16 Slot 4 OUT 16 Optional This card is used for the Air Push feature 88 Catalyst SOFTROL Slot 5 FLOW MEM This card contains the memory for the system for formulas and totals and has 4 flow meter inputs The Catalyst uses channel one for its meter The card should be jumped for DC on channel 1for the Catalyst meter PUT JUMPER DN 2 PINS CLOSEST AC FOR AC INPUT PUT JUMPER CLOSEST IN 8
14. f feon P IB Es fse Tie mises vie riot eos Tier o Ring eors I So new F Snap Ring wey e mee cl 12 0 oe 158 ve utr assembly P L wo use rer Bone 16 90005 1881 9991 I DIAPHRAGM PUMP SERVICE GENERAL SERVICE NOTES Inspect and replace old parts with new parts as necessary Look for deep scratches on metallic surfaces and nicks or cuts in O rings 7 16 wrench 1 2 wrench 7 16 socket 1 2 socket torque wrench measuring inch pounds O ring pick FLUID SECTION DISASSEMBLY 1 Remove 34 top manifold 36 swivel assembly Note Manifold options involve single piece manifolds 60 61 or three piece swivel type manifolds with clamps 2 Remove 41 ball cages 22 balls 19 and 20 O rings and 21 seats Note If cages are difficult to remove at this step it may may helpful to proceed through step 5 and remove them once they are accessible from the inside of the fluid cap Remove 35 bottom manifolds 36 swivel assembly Remove 19 O rings 21 seats and 22 balls Remove 15 fluid caps Remove 6 diaphragm nut 8 7 Teflon models only dia phragm s and 5 diaphragm was
15. ni croPul se gt Software amp Control for Automation CONTROL STATION 128 Catalyst Inject Waiting for Chemical System to Flush Machine B 003 3 ENT 2 Jo t 4 YES CLR NU www Softrol com SOFTROL While the controller is idle and waits for an injection request the LCD alternates between the two displays below 32 Software Control for Automation ml c gt So mi croPul se CONTROL STATION The Catalyst Injection System Softrol Systems Inc c 1988 2001 ENT YES Catalyst Qi croPulse Software amp Control for Automation CONTROL STATION Waiting for Chemical Injection Request Depress YES key to Select Formula 7 SOFTROL CATALYST The Main Menu www Softrol com SOFTROL Softwi Automatic E ara 8 Control for Automation CONTROL STATION 1 Setup 2 Program 3 Maint
16. www Softrol com Catalyst Tunnel The Catalyst Tunnel System operates in the same method as other Catalyst Systems including features to ensure superior precision and accuracy for delivering chemicals to a continuous batch washer The Catalyst Tunnel System has the capability to simultaneously deliver up to sixteen 16 chemicals to eight 8 individual modules of a continuous batch washer The unique Softrol Catalyst Tunnel System design allows each continuous batch washer module receiving chemicals to be matched with its own chemical manifold with built in flow meter and flush pump This ensures quick chemical injections with precise volumetric accuracy This design allows simultaneous injection of chemicals to separate continuous batch washer modules without initiating production delays Softrol designed Tunnel Interface Hardware and Catalyst Software is provided with each system which offers user defined programming data collection and report generation 11 Catalyst SOFTROL www Softrol com Many installations may require the additional performance of fully redundant chemical injection systems Softrol also offers their Catalyst Classic and Catalyst Dual Inject systems in fully redundant configurations that provide the unique capabilities of delivering chemicals to 2 3 or 4 machines simultaneously They also can provide the unique capability of delivering chemicals to machines while one of the systems is shut down for preventative ma
17. Softrol Systems also recommends that at the very minimum plant personnel be required to wear all protective equipment suggested in the MSDS Extreme care should be taken when working with a pressurized chemical system Ensure that all pressure has been removed from the system and that all power to the machine is turned off before undergoing maintenance Injection Unit Remove the equipment from the shipping packages Check the system carefully to assure that no damage occurred in shipment If any damage from shipment is apparent call Softrol Systems immediately at 770 974 2700 Clear the area in which it is to be placed This should have already been determined in the Site Survey Uncrate and stand the Catalyst Injection System in the position where it is to be located Be careful in transporting the Catalyst it is heavy Utility Connections 15 Catalyst SOFTROL www Softrol com Make all the electrical air and water connections as explained below The Water Connections The Catalyst requires water 3 GPM at a temperature no greater then 110 F or less than 80 F This can be either tempered water or hot and cold with a mixing valve valve is not supplied The supply line should have shut off valves and stubbed to a 1 2 barb Flexible tubing should be used to connect the water supply line to the fill valve for the flush tank on the Catalyst System The unit has a 1 2 barb connection Tubing not supplied Water pressure
18. ex 04 Lxx 93963 i i fosos i i xex esos DIAPHRAGM OPTIONS SERVICE KITS 7 1 8 19 20 33 x XXX Ball or Duckbill O Ring 4 O Ring 2 Ring 4 66605X XXX XX Diaphragm Diaphragm 2 1 5 16 0 d 1 1 8 o d 1 3 16 o d 637140 X1 Y325 122 Y325 119 Y325 120 637140 X2 Y325 122 Y325 119 Y325 120 Y327 119 Y327 120 m Not shown 94749 MATERIAL CODE _ B Nitrile D EPR F Flouraz GA Groundable Acetal GFN Glass Filled Nylon Hytrel Polypropylene SP Santoprene 55 Stainless Steel 1 Teflon 0 Polyurethane 5 ISP xx 637140 X3 666053 66605J XX4 637140 X4 93111 93465 666056 66605H XX4 637140 X4 93111 93465 Y328 119 o 42151 8 Quantity 22 3111 93465 3760 Y328 119 94749 xs 93762 xe xg Y325 120 DB e3740XB O 93762 O Y325 122 Y325 120 ox xe i oxs i xB Y325 122 325 120 93111 93465 T SP 325 122 94749 325 122 325 120 33 rings are not used on models 66605H XXX 66605J XXX and 66605K XXX WETTED COMMON PARTS POLYPROPYLENE GROUNDABLE ACETAL PURE KYNAR 666053 XXX 66605J XXX 666056 XXX 66605H XXX 666057 XXX 66605K XXX b Mtl PartNo Mtl Part
19. 0005 Add 60 Oz of Detergent 0006 Run Time 0 00 0007 Chemical Step 2 0008 Add 48 Oz of Detergent 0009 Run Time 0 00 0010 Chemical Step 3 0011 Add 256 Oz of Bleach 0012 Run Time 0 00 0013 Chemical Step 4 0014 Add 10 Oz of Antichlor 0015 Run Time 0 00 0016 chemical Step 5 0017 Add 12 Oz of Mildewcide 0018 Add 9 Oz of Sour 0019 Run Time 0 00 0020 END OF FORMULA Braun Formula Braun outputs 1 2 3 4 5 6 7 11 Interface inputs 12 4 8 16 32 64 Latch Steps 1 amp 2 Identify the formula as formula 14 The Catalyst interface will recognize the formula and start formula 14 The formula will proceed to the first step ender line 2 No chemicals are called for and thus will not be injected Step 4 signals the interface to go to chemical step 1 The interface will then place the Braun on hold and request the Alkali and Detergent Once the chemical is delivered the interface will proceed to the next step ender line 6 and release the washer Steps 5 25 will continue to call for the appropriate chemical steps and deliver the chemicals Step 26 signals the interface to end the formula This will start the Load Unload timer until the next formula is run 58 Catalyst SOFTROL Program 31 Step Operation Time Level Temp Flush SS N Drain Rinse Drain Wash Wash Drain Rinse Drain Rinse Drain Rinse Drain Wash Extract Shake
20. 131 INVALID FORMULA Use arrows to scroll ENT Accept NO Exit Formula Number 130 INVALID INJECT Use arrows to scroll ENT Accept NO Exit SOFTROL www Softrol com SOFTROL CATALYST Advancing a Formula If a formula on the machine needs to be advanced the best option is to advance the machine to the chemical identification step This will tell the interface to go to the appropriate step in its formula Canceling a Formula When a formula on the interface is canceled no credit will be received for the run or poundage This may be required when the wrong formula is started To cancel the formula manually do the following Press NO This will pause the formula Press CLR This will silence the alarm Enter in a Password This can be level 1 thru 7 111111 or 777777 Press NO ENT at the same time to take the formula to the end Ending a Formula When the formula is ended credit will be received for poundage and the run time This may be required when a formula has been run and there is a problem with extract and the load is manually removed before the shakeout To end the formula manually do the following Press NO This will pause the formula Press CLR This will silence the alarm Enter in a Password This can be level 1 thru 7 111111 or 777777 Press UP Arrow to take the formula to the end Changing a Formula If the incorrect formula has been started on the machine and the oper
21. N H O O1 29 8 o w NI UI u NNN N N 9 o D D F A Go Po Po olo N oy gt N e N DO NI PO O Po PO PO PO 22 ad Po 4 5 134 4 5 136 4 6 138 4 7 C2 N N N B N R 02 1240 41 9 1340453 Catalyst www Softrol com SOFTROL ML 02 53 8 54 8 780 26 4 1230 41 6 1680 56 8 1690 57 2 1790 60 5 60 9 1970 66 6 SOFTROL CATALYST 46 Catalyst www Softrol com SOFTROL SOFTROL www Softrol com SOFTROL CATALYST 5 Configuring PulseNet The Catalyst Chemical System comes standard with the PulseNet Catalyst Plus Module This software can be used to easily program formulas monitor the system and generate production and consumption reports Before the software can be used properly it must be configured to meet the plant specifications The manual for the PulseNet software has specific details on how to setup the software for your plant The key items for setup can be found in the PulseNet manual and start on page 15 They are as follows e Configure Plant Location This needs to be completed for the reports e Configure Ports This should already be done
22. Note 3 A Major Valve Service Assembly is available separately which includes items 111 132 135 141 Order part no 66362 MATERIAL CODE 8 Nitrile D Acetal SY Syn Seal Bz Bronze Polypropylene U Polyurethane Carbon Steel PS Polyester Zinc CK Ceramic SS Stainless Steel FLUID SECTION REASSEMBLY Reassemble In reverse order Lubricate 1 connecting rod and 2 O ring with Key Lube or equiv alent O ring lubricant Install 5 diaphragm washers with i d chamfer toward diaphragm Whenreplacing Teflon diaphragms install the 93465 Santoprene di aphragm behind the Teflon diaphragm e When installing 41 cage ball guides must line up with notches in 21 seat to prevent damage Before installing 35 34 manifolds 19 O ring should be proper ly seated on the o d of 41 ball cage Before tightening 39 nut and 38 carriage bolts on 36 swivels attach the manifold swivel assembly to the fluid caps Rotate 36 swivel to desired position and tighten each of the nuts approximately 8 9 turns then finish tightening 29 nuts Smart Parts keep these items on hand in addition to the Service Kits for fast repair and reduction of down time 66605X X www Softrol com PARTS LIST 66605X X AIR MOTOR SECTION gt tx TORQUE REQUIREMENTS NOTE DO NOT OVERTIGHTEN FASTENERS 134 Torque to 15 20 Ibs 1 7 2 3
23. Outlet top eo a Flange Nut 5 16 18 Plug 1 2 14 N P T Smart Parts keep these items on hand in addition to the service kits for fast repair and reduction of down time lt o oo Page 4 of 8 66605X X www Softrol com PARTS LIST 66605X X FLUID SECTION OUTLET When duckbills face down the inlet is on the top A Used on 66605X XX4 Teflon models only r TORQUE REQUIREMENTS NOTE DO NOT OVERTIGHTEN FASTENERS 6 Diaphragm nut 95 105 in Ibs 10 7 11 9 Nm 29 62 Fluid caps Manifold nuts 50 60 in Ibs 5 6 6 8 Nm alternately and evenly then re torque after initial run in 39 Nuts 20 25 in Ibs 2 3 2 8 Nm then re torque 63 Plugs 25 in Ibs 2 8 Nm maximum COLOR CODE DIAPHRAGM BALL MATERIAL COLOR COLOR _ N A Orange Red Red 9 Blue Blue 9 Cream N A f E Green Green 5 66605X 0XX 04 en Tm White White URETHANE Clear Red VITON Yellow Yellow 5 STRIPE 9 DOT FOR THE Soi lt 19 AIR MOTOR SECTION SEE PAGES 6 amp 7 FOG lt 5 Figure 2 66605X X Page 5 of 8 www Softrol com PARTS LIST 66605X X AIR MOTOR SECTION Indicates parts included in 637141 Air Section Repair Kit AIR SECTION PARTS Lem Description iinet PartNo m
24. leaks are found fix them immediately Check calibration of the chemicals e Tighten all hose clamps e Check the water temperature it should be 80 110 degrees F Weekly e Check the strainers on the chemical lines for blockage e Check air filters drain if necessary e Clean system by wiping down with a damp cloth Use air to blow off the pump section Monthly Check the torque on the pumps Inspect the system for leaks Check Calibrations Tighten hose clamps Torque on pumps 70 in lbs Use a 1 2 Use 7 16 nut driver Torque wrench Torque from bolt head This is on both sides the side of the air inlet m C om Tighten ALL Tighten all 6 bolts bolts and nuts INLET Exhaust wf 1 X E Ss 7 N 67 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Catalyst Alarms Software amp Contra for Automation CONTROL STATION Chemical 12 Call Maintenance Chemical Watchdog CLR The Catalyst can have 7 different alarms while running They are e Power Interrupted During Formula This happens when the power is lost to the processor while running a formula Press the YES button to resume
25. to meet the intent of ANSI 51 13 1971 CAGI PNEU DIAPHRAGM MATERIAL ROP 55 1 using four microphone locations 1 Neoprene 5 EPR 2 Nitrile 8 Polyurethane NOTICE All possible options are shown in the chart however certain com 3 Viton 9 Hytrel binations may not be recommended consult a representative or the fac 4 T FE Teflon Santoprene B Santoprene tory if you have questions concerning availability CONE CHECK FLOW 04 Top Discharge FLUID SECTION SERVICE KIT SELECTION 66605X X EXAMPLE MODEL 666053 321 Fluid Section Service Kit 637140 21 X X X 637140 Ball Diaphragm INGERSOLL RAND COMPANY BOX 151 e ONE ARO CENTER e BRYAN OHIO 800 276 4658 e FAX 800 266 7016 2 Ingersoll Rand 2004 CCN 99449712 www Softrol com OPERATING AND SAFETY PRECAUTIONS READ UNDERSTAND AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE HAZARDOUS MATERIALS HAZARDOUS PRESSURE EXCESSIVE AIR PRESSURE STATIC SPARK EXCESSIVE AIR PRESSURE Can cause person al injury pump damage or property damage Do not exceed the maximum inlet air pressure as stated on the pump model plate Be sure material hoses and other components are able to with stand fluid pressures developed by this pump Check all hoses for damage or wear Be certain dispensing device is clean and in proper working condition STATIC SPARK Can
26. 11 16 01 New layout Revised 05 06 02 Updating Introduction Revised 11 22 04 Updating Calibration Revised 06 29 05 Updating Introduction and Maintenance Revised 07 19 05 Updating Calibration and Maintenance Revised 01 26 06 Updating Maintenance Revised 10 16 07 New layout and added pump information No portion of this manual may be duplicated in any manner without expressed written consent of Softrol Systems Inc 4867 North Main Street Acworth GA 30101 770 974 2700 www softrol com
27. 5 99 sec This setup tells the Catalyst how long to flush the chemical to the machine The further away from the Catalyst the machine is the longer the flush time e Chemical Watchdog 0 00 99 00 This a timer that will alarm if the Catalyst does not answer the chemical request in the specified time e Prompt Weight YES or NO This will allow an operator to enter the weight at the beginning of the formula for reporting or ratiometric chemical addition purposes Signal Mute Time 0 00 5 00 This is the amount of time that the alarm will be silenced by pressing the CLR button Latch Delay The latch time for the interface will also need to be set To set this time first exit to the waiting for formula screen Then enter 273685 This will take you to the main menu Then enter 1 for the setup mode Then enter 935483 This will take you to the EEPROM setups Enter through the setups until you reach Latch Delay This time is noted on the schematic notes for the specific machines This time should never be less than 1 second For machines that can turn on all of their chemical signals at once this time should be 1 second If the machine cannot give multiple signals at once for example a Braun or Milnor EP the latch time will be longer About 30 seconds for a Braun and 20 seconds for a Milnor EP Refer to the Catalyst manual for more programming information as well as the interface schematic Node ID The LAN ID on the CataPulse is
28. Mtl PartNo Part No PartNo Mtl 3084 55 93004 SS 9304 SS 93084 55 93084 55 9304 SS 325 111 Y32511 B v325 111 B Y32511 B 2 111 B v325 111 B 4645 94645 94645 GFN 94645 GFN 94645 GFN P 93103 3 D 931033 D 931034 PK 931034 PK 9310541 GA 93105 11 GA 931059 PK 901059 PK 155 9209 SS 58 Yi2 S SS Sis Pj 3 8 I s S D N eie N N 79 52 a o Item Description size Ring 3 32 x 5 8 Washer 2 o d ty i el lt Fluid Cap includes 26 amp 124 Bolt 5 16 18 x 1 1 2 Nut 5 16 18 Manifold Foot bottom 3099 55 EZ 155 4 3037 55 Y22105 5 P 930973 5 95973 E Es Ea 155 155 Bolt 10 24 x 1 1 2 lt Ball Cage Diaphragm Nut 5 16 18 Sleeve models 66605X 0XX e 92956 1 SS 92956 93886 32 m 57 Ground Kit Assembly Manifold Inlet bottom wo e ce e 93897 2 802 1 801 1 Manifold Outlet top Manifold
29. Setup The LCD screen displays 1 Machine Setup 2 Maintenance Setup 3 Clear Ram Vocabs 4 Passwords 0 Exit Press the 4 key 4 Passwords The LCD screen displays Level 1 Password 111111 Use arrows to scroll ENTER Accept NO Exit Use the arrows to scroll to the password level desired Enter the six digit password for this level Press the ENT key to accept Use the arrow keys to scroll to another password level if desired 34 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Press the NO key to exit Disabling the System The system can be placed in the disabled mode This will allow for maintenance and calibration without the machines calling for chemical From the main screen Press the NO amp ENT keys at the simultaneously to DISABLE the system Hold down the ENT key and then press the YES key to ENABLE the system Downloading Chemical Names Once the system has been installed and the network connections have been established the chemical names and check formulas can be downloaded from the PulseNet computer See section 5 for more details on configuring PulseNet The names and formulas will be downloaded when a Group Formula Update for the Catalyst Group is preformed Once this is accomplished it will be easier to calibrate and prime the system Priming the System To check the Chemical Output Valves Priming the System At the Injection Controller screen Waiting for Chemical Injectio
30. The communication cable uses the Blue pair The Blue wire should connect to the terminal on the right side and the Blue White wire should connect to the left side of the terminal If there is another machine on the daisy chain then the 2 conductor power wire should be connected parallel to the V and OV and run to the next machine Also a Cat 5 cable should run in parallel to incoming communications cable to the next interface If this is the last machine in the daisy chain then only two lines will enter the interface one for power and one for communications The arcnet card in the Catapulse should have the terminating jumper Configuration Machine Interface 25 From the Waiting for Chemical Injection Request display enter a valid level 7 password please refer to Passwords 1 Setups 2 Program 3 Maint 4 Calibrate 5 Totals 6 Clock Selection O exit Select 1 Setups 1 Watchdogs Setups 2 Chemical Setups Select 1 Watchdogs Setups 1 Machine Setup 2 Maintenance Setup 3 Clear Ram Vocabs Catalyst The Catalyst b y Softrol Systems Inc c 1998 2004 www Softrol com SOFTROL CATALYST 4 Passwords 0 Select 1 Machine Setup The setups are e AutoChem Flush
31. cause explosion resulting in severe injury or death Ground pump and pumping system Sparks can ignite flammable material and vapors The pumping system and object being sprayed must be grounded when it is pumping flushing recirculating or spray ing flammable materials such as paints solvents lacquers etc or used in a location where surrounding atmosphere is conducive to spontaneous combustion Ground the dispens ing valve or device containers hoses and any object to which material is being pumped 666056 XXX and 66605H XXX Groundable Acetal pumps Use the pump grounding screw provided Connect a 12 ga mini mum wire kit is included to a good earth ground source Secure pump connections and all contact points to avoid vibration and generation of contact or static spark Consult local building codes and electrical codes for specific grounding requirements After grounding periodically verify continuity of electrical path to ground Test with an ohmmeter from each component e g hoses pump clamps container spray gun etc to ground to insure continuity Ohmmeter should show 0 1 ohms or less Submerse the outlet hose end dispensing valve or device in the material being dispensedif possible Avoid free streaming of material being dispensed Use hoses incorporating a static wire Use proper ventilation Keep inflammables away from heat open flames and sparks Keep containers closed when not in use Pump exhaust may
32. contain contaminants Can cause severe injury Pipe exhaust away from work area and per sonnel In the event of a diaphragm rupture material can be forced out of the air exhaust muffler Pipe the exhaust to a safe remote location when pumping haz ardous or inflammable materials Use a grounded 3 8 minimum i d hose between the pump and the muffler HAZARDOUS PRESSURE Can result in serious injury or property damage Do not service or clean pump hoses or dispensing valve while the system is pressurized Disconnect air supply line and relieve pressure from the sys tem by opening dispensing valve or device and or carefully and slowly loosening and removing outlet hose or piping from pump NOTICE Install the pump in the vertical position The NOTICE HAZARDOUS MATERIALS Can cause serious in jury or property damage Do notattemptto return a pump to the factory or service center that contains hazardous material Safe handling practices must comply with local and national laws and safety code requirements Obtain Material Safety Data Sheets on all materials from the supplier for proper handling instructions Verify the chemical compatibility of the pump wetted parts and the substance being pumped flushed or re circulated Chemical compatibility may change with tempera ture and concentration of the chemical s within the substances being pumped flushed or circulated For specific fluid compatibility consult the chemica
33. if the computer was received from Softrol If not this will need to be completed per the manual e Configure Groups This will need to be completed There should be a group for each different size type of machine Note All machines in the same group will have the exact same formulas There should also be a group created for the Catalyst The cortroller type for this group will be the Catalyst Plus Podium e Configure Supply Inventory Data This will need to be entered to have chemical totals reports The units are the units that the bulk chemical is delivered in This will most likely be in Gal Then the cost would be entered in cost per gallon This will give the Plant Chemical totals report in Gallons not ounces If the units of measurement on the Catalyst are Oz e Configure Plant Utility Data This is generally not used in a Catalyst only plant Please refer to the PulseNet Manual if this option is desired e Configure Classification This can be done for the plant production report Each formula can be assigned to a classification for convenience in reporting Now we get into the group setups These should be done for the first group and then can be copied into each of the other groups Edit Vocab Files The only Vocab that needs to be created is under chemical units and is unit 001 This will be set to whatever units that you will be calibrating in most likely Oz Edit Chemical Assignments This setup is very important for p
34. in one daisy chain Once the network is functional communications can be tested from the PC Formulas should be downloaded to the Catalyst and the machines interfaces This will load the proper chemical names into the Catalyst for priming and calibration 28 Catalyst SOFTROL www Softrol com SOFTROL CATALYST ARCNET TWISTED PAIR POLARITY GUIDE FOR THE CATALYST White lt lt gt 24 Ta 2 2 HYHUB OPTARC CATALYST HUB INTERFACE Whit Ze i p u Bi e lt PCI20 hte RJ45 COMPUTER COMPUTER 29 Catalyst SOFTROL www Softrol com SOFTROL CATALYST 30 Catalyst SOFTROL www Softrol com SOFTROL CATALYST 3 System Operation Injection Controller While an injection formula is running the LCD will show the name and number of the formula the current step and line number the selected machine the total time elapsed T and the step time as shown below y SOFTROL mi croPul se Software Control for Automation C N ii R n STATION 128 Chemical Injection Alkali 064 018 Machine B 002 T 0 12 Step 0 00 After the injection is completed the system will be flushed with water 31 Catalyst SOFTROL CATALYST The LCD will display
35. interface receives an input that indicates a formula that is not currently programmed To clear the formula press CLR NO ENT To select the correct formula use the arrow keys Check the machine programming and chemical outputs to verify proper operation T3 Catalyst Machine Disabled Press YES to Continue Call Maintenance Chem watchdog Chemical 1 Chemical 2 Invalid Formula Selection NO Exit SOFTROL www Softrol com SOFTROL CATALYST Manual Formula Advancement Cancel Advancing a Formula If a formula on the machine needs to be advanced the best option is to advance the machine to the chemical identification step This will tell the interface to go to the appropriate step in its formula Canceling a Formula When a formula on the interface is canceled no credit will be received for the run or poundage This may be required when the wrong formula is started To cancel the formula manually do the following Press NO This will pause the formula Press CLR This will silence the alarm Enter in a Password This can be level 1 thru 7 111111 or 777777 Press NO ENT at the same time to take the formula to the end Ending a Formula When the formula is ended credit will be received for poundage and the run time This may be required when a formula has been run and there is a problem with extract and the load is manually removed before the shake
36. ml graduated cylinder under the calibration port 22 Press and hold YES to dispense 200 220 ml it will contain mostly water n U The small graduated cylinder is marked 2 ml graduations Accurately read the amount and divide by 29 57 to convert to Oz Example 226 ml 29 57 7 6 Oz 23 Press ENT to accept the counts 24 Enter in the amount dispensed It should be slightly more than the suggested amount If the amounts differ by more than 1 oz then it might be necessary to recalibrate 41 Catalyst SOFTROL www Softrol com SOFTROL CATALYST 25 Select 2 H Factor 26 Flush the system by the same procedure in step 17 27 Press O to exit to the main menu 28 Enable the system by holding down the ENT key and pressing YES Time Based Calibration Due to certain circumstances it may be beneficial to calibrate the chemicals based on time rather than flow meter input To calibrate the chemicals without the flow meter do the following e Follow the normal calibration procedure At step 9 select 2 for Time Based Calibration Press YES to dispense the chemical as described in step 11 The controller will display the time on the screen in tenths of a second e Once the product has been dispensed press enter to accept the counts and then enter in the received amount The controller will automatically save the calibration as the Initial calibration e The Catalyst will now
37. proof of flush The MicroPulse will alert operators if there are any problems with any part of the injection process These safeguards prevent chemical waste and costly errors due to improper processing of valuable goods 13 Catalyst SOFTROL 14 Catalyst www Softrol com SOFTROL www Softrol com 2 Catalyst Installation amp Configuration Several weeks prior to the installation an on site survey should be conducted to determine the best location in the plant for the Catalyst system Consideration should be given to the location of the chemicals in relation to the washroom and the length of the run from the chemical storage area to the washers The shorter the length of the Catalyst to the machines the faster the injection times will be This is very important with the Catalyst Tunnel system A plant layout with the proposed location for the Catalyst along with the list of chemical and typical injection amounts should be sent to Softrol when the system is ordered Also include a list of machines and their controller types with the chemical output voltage This will help ensure that the configuration and layout of the system is optimal Before beginning the installation Softrol Systems recommends that plant personnel be familiar with the types of chemicals they will be working with and the potential hazards that are associated with the chemicals this information must be supplied in the form of a Material Safety Data Sheet or MSDS
38. set via a set of dip switches This located in the bottom of the interface and is accessed via the small box on the bottom interface The dip switches give the interface a binary code for the LAN ID This LAN ID should be set the same as the machine number This is very important since the interface communicates this ID and the Catalyst will dispense chemical out the valve associated with this machine ID The ID goes from right to left When the switch is in the up position it is on See figure on the next page for the proper configuration 26 Catalyst SOFTROL CATALYST Dipswitch settings for Ids 1 20 1 2 3 4 5 6 7 8 9 10 27 Bottom of CataPulse with connection box removed Catalyst www Softrol com SOFTROL SOFTROL www Softrol com SOFTROL CATALYST Installation ArcNet Network
39. the system is enabled If the system is enabled and this condition exists the system will display the message and continue to fill the tank for 1 minute before sounding the alarm The injection cannot start until this has been corrected To silence the alarm disable the Catalyst by pressing No amp Ent and correct the problem The input for flush tank low is 97 04 and turns on when the tank level is low Current Calibrations Do not Match Slot 5 The Catalyst will check the calibration value in the REM K 4 and compare it to the value held in the memory card in slot 5 if they do not match an alarm will occur and the system will display this message This problem will occur when either the memory Flowmem Slot 5 or processor memory card REM K4 Proc Slot is replaced If the Flowmem is replaced the calibrations will need to be copied to Slot 5 If the REM K4 is replaced the calibrations will need to be copied from Slot 5 To copy the calibrations do the following Enter in the level 7 password Select 2 for Program Select 5 for Copy Select 3 for Copy Calibrations Select 1 to copy the Calibrations to Slot 5 Or Select 2 to copy the Calibrations from Slot 5 The controller will prompt you to enter a password Enter the level 7 password The controller will return to the main menu Exit the menu and the controller should return to the waiting for formula state The chemicals can also be re calibrated to el
40. the cover Tighten the bolts ina staggered manner The bolts should only be finger tight 10 12 in lbs e Attach the cable Release the Emergency Stop Button e Restart the system and check flowmeter to make sure it is functioning properly 72 Catalyst SOFTROL Interface Troubleshooting www Softrol com SOFTROL CATALYST Catalyst s Call Maintenance Chem watchdog Chemical 1 Chemical 2 POWER 7 9 The Catalyst interface can have 4 different alarms while running N They are Power Interrupted During Formula This happens when the power is lost to the processor while running a formula Press the YES button to resume the formula Power Interruption During Formula Execution Press YES to Continue e Machine Disabled This happens when the machine on input is lost during the formula The machine on light ENTER key at the top right of the keypad must be on to run the formula This is input D1 e Chemical Watchdog This alarm occurs when the interface has requested chemical and the Catalyst has not responded Enter in a level 4 password or higher and then press YES to resume If the Catalyst does not answer the chemical request then there might be a problem with the Catalyst or the network If this happens often check the chemical watchdog setup in the interface Invalid Formula This will be displayed when the
41. the flow meter please do the following 1 oos 8 9 At the Waiting for Chemical Injection screen on the Injection Controller disable the system by pressing No amp ENT This will prevent the system from receiving chemical requests from machines Open the valve at the end of the calibration line and place the graduated cylinder underneath it Press CLR ENT to flush the system Make sure the system is thoroughly flushed Empty and dry the cylinder Enter the Level 7 password to access the Main Menu Press 4 4 Calib Press 1 12Calibrate Chems Use the 1 and 4 arrows to scroll through the available chemical numbers until the chemical to be calibrated is displayed on line 1 of the LCD display Press the ENT key to select that chemical Select 1 for flow sensor calibrations 10 Press and hold the YES key to dispense chemical This will stop when the YES key is released For chemicals with large injections Alkali Detergent Bleach etc fill the cylinder to 1800 ml For chemicals with small injections lt 60z ex Sour A C etc fill the cylinder to about 800 ml 11 The Catalyst screen will display the counts from the flowmeter These should be about 18 30 counts per oz 12 Close the valve at the end of the calibration line Place the graduated 40 cylinder on a level surface and accurately read the amount of chemical in the graduated cylinder
42. 01 PH 70974 2700 FAX 70914 0435 LATAPULSE CHEMICAL INTERFACE BEX SDFTRDL SYSTEMS CATAPULSE CHEMICAL INTERFACE SICATAPULSE 07 28 03 PAGE 1 REF B C D E F G F 120VAC LOCATED IN CATALYST ELECTRONIC CABINET CATIFC BOARD ID 1 CATIFC BOARD ID 2 INPUT 1 NP 1 MACHINE DN BLUE BLACK INPUT 2 INPUT 3 pe SPARE OUTPUT 1 CONTROL ALARM DUT 8 OUTPUT 2 2 ENABLE MACHINE FORMULA DRANGE OUTPUT 3 ENABLE MACHINE FORMULA RELAY DNE CONTACT DF THIS RELAY MUST USED TO STOP FORMULA EXECUTION WHEN ENERGIZED SEE MACHINE SPECIFIC INFORMATION FOR CORRECT USE SDFTRDL SYSTEMS CATAPULSE CHEMICAL INTERFACE SICATAPULSE 07 28 03 PAGE 2 REF B C D E F G F XUSE THIS PAGE IF MACHINE VOLTAGE 12 24 VAC DC MACHINE CHEMICAL VOLTAGE 12 24 VAC DC USE APPROPRIATE VOLTAGE FORMULA INPUT BINARY 2 BLUE WHITE FORMULA INPUT BINARY 4 GREEN FORMULA INPUT BINARY 8 GREEN WHIT 105 805 FORMULA INPUT BINARY 16 RED 8 FORMULA INPUT BINARY 32 RED WHITE 16 I 106 I I I I I 107 80 FORMULA INPUT BINARY 64 BLACK WHIT 17 I I I I I I I 108 j I DATA LATCH FORMULA END WHITE BLACK 18 I I I I I I I E3 CATRLY ITHESE CONTACTS INSIDE 1 THESE INPUTS IN INTERFACE IRELAY BOARD i IWASHER CONTROL FPD WIRES 5 LONG SOFTROL SYSTEMS CATAPULSE CHEMICAL INTERFACE SICATAPULSE 07 28 03 PAGE 3 R
43. 4 Calib 5 Totals 6 Clock Selection O Exit 1 ves ITO To access the Main Menu you must enter a password The Injection Controller is shipped from the manufacturing facility with 8 pre programmed passwords Each password consists of 6 digits that correspond to each password level For example Level 12 111111 Level 2 222222 Level 3 2 333333 Level 4 444444 only 33 Level 5 555555 Level 6 666666 Level 7 2 777777 Level 8 888888 freezes the timer Catalyst SOFTROL www Softrol com SOFTROL CATALYST These passwords should be changed see below and customized for each level There can only be one password assigned to each level for a total of eight passwords To determine which password level is needed for access to each function see the following table Action Password Level Manual Chemical Injection No Password Cancel Signal Levels 4 7 Cancel Steps Levels 1 7 Access Totals Levels 2 7 Calibrate Levels 3 7 Set Clock Levels 3 7 Cancel Maintenance Watchdogs Levels 4 7 Setups Levels 6 7 Program Formulas Levels 6 7 Freeze Timers Level 8 To Edit Change Passwords at the Controller Input the Level 6 or 7 password to access the Main Menu Press the 1 key 1 Setup Press the 1 key 1 Watch Dogs
44. 6 Programming from PulseNet The Catalyst Chemical System comes standard with the Pulsenet Catalyst Plus Module This software can be used to easily program formulas monitor the system and generate production and consumption reports One of the best features of PulseNet is the ease with which formulas can be programmed We will show you how to program a few simple formulas in order to get you started quickly and painlessly There are many details involved in programming a formula These are covered fully in the PulseNet User s Manual included with this installation We will only use the basic programming tools on this tutorial Wet Process Formula Editor OF x File Edit re Utilities Help pepe I B 194 0001 LIGHT REACT VS P 0002 Fill Hot When Level lt 10 0 Until Next Step 0003 Fill Cold When Level lt 20 0 Until Next Step 0004 Steam When Temperature lt 160 F Until Next Step 0005 Cooldown When Temp gt 138 F Until Next Step 0006 Extract High Until Next Step 0007 Extract Low Until Next Step 0008 Run Time 5 00 001 0005 00 0009 Desize 0010 Normal Rotation 0011 Fill Hot When Level lt 15 0 Until Next Step 0012 Steam When Temperature lt 140 F Until Next Step 0013 Wait to Satisfy 0014 Run Time 1 00 002 0006 00 0015 HOT SUDS 0016 Dwell Timer 999 Seconds 0017 Fill Hot When Level lt 10 0 Until Next Step 0018 Wai
45. 8 OUTPUT CHEMICAL PUMP 8 SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SOF TROL SYSTEMS CATALYST CLASSIC SCHEMATIC S3CATALYSTCLASSIC 11 03 04 PAGE 4 OUTPUT SELECT CHEMICAL VALVE CHEMICAL PUMP 9 OUTPUT SELECT CHEMICAL VALVE CHEMICAL PUMP 10 OUTPUT SELECT CHEMICAL VALVE CHEMICAL PUMP 11 OUTPUT SELECT CHEMICAL VALVE CHEMICAL PUMP 12 OUTPUT SELECT CHEMICAL VALVE CHEMICAL PUMP 13 OUTPUT SELECT CHEMICAL VALVE CHEMICAL PUMP 14 OUTPUT SELECT CHEMICAL VALVE CHEMICAL PUMP 15 OUTPUT SELECT CHEMICAL VALVE CHEMICAL PUMP 16 SOF TROL SYSTEMS CATALYST CLASSIC SCHEMATIC S3CATALYSTCLASSIC 11 03 04 PAGE 5 SELECT MACHINE DUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT 52 14 SELECT MACHINE OUTPUT SELECT MACHINE OUTPUT AIR PUSH OPTIONAL OUTPUT 15 VDC FROM POWER SUPPLY CONTROL ALARM SELECT APPROPRIATE VOLTAGE AND PUT WIRE ON ALARM RELAY CONTACT COMMON WIRE TO CORRECT COMMON EXTERNAL AUDIBLE ALARM E3 FLOWMEM SLOT 5 RED BLK 15VDC RED WHT SIGNAL GREEN GRDUND SYSTEMS CATALYST CLASSIC SCHEMATIC S3CATALYSTCLASSIC 11 03 04 PAGE 6 SOFIROL Software amp Control for Automation 486 N MAIN ST ACWORTH GA 301
46. CH TIME 5 SEC the supply outputs OUTPUT 24 VDC CATAPULSE LAVATEC FUNCTION DESCRIPTION TERMINAL TERMINAL BINARY 1 INPUT 101 BLUE BINARY 2 INPUT 102 BLUE WHITE BINARY 4 INPUT 103 GREEN BINARY 8 INPUT 104 GREEN WHITE BINARY 16 INPUT 105 RED BINARY 32 INPUT 106 RED WHITE BINARY 66 INPUT 107 DO NOT USE BLACK WHITE LATCH INPUT 108 148 WHITE BLACK COMMON COM O0VDC BLACK HOLD HOLD COM 24 ORANGE HOLD HOLD NC 42 ORANGE BLACK MACHINE ON POWER 24 BLUE BLACK MACHINE ON COMMON 0VDC RED BLACK Ellis Washer w ACS Control NOTES All connections to be made in Ellis control Outputs are dry contacts LATCH TIME 5 SEC Connect 24 VDC 24 to terminal 38 This will make outputs 24 VDC Common OUTPUT 24 VDC BONDE 25 CATAPULSE ELLIS FUNCTION DESCRIPTION TERMINAL TERMINAL BINARY 1 INPUT 101 BINARY 2 INPUT 102 BLUE WHITE BINARY 4 INPUT 103 GREEN BINARY 8 INPUT 104 GREEN WHITE BINARY 16 INPUT 105 RED BINARY 32 INPUT 106 RED WHITE BINARY 66 INPUT 107 BLACK WHITE LATCH INPUT 108 WHITE BLACK COMMON COM BLACK HOLD HOLD COM ORANGE HOLD HOLD NC ORANGE BLACK MACHINE ON POWER BLUE BLACK MACHINE ON COMMON RED BLACK SDFTRDL SYSTEMS CATAPULSE CHEMICAL INTERFACE SICATAPULSE 07 28 03 PAGE 7 REF B C D E F G F BRAUN OP WASHER NOTES FOR GREATER THAN 15 FORMULAS MUST HAVE OUTPUT TINE DT BEC PAD Fon SIGNALS 6 7 11 17 SET DIP SWITCH S2 4 ON TO ENABLE OUTPUT 24 VAC CATAPULSE BRAUN W
47. D MANUALLY SHOULD NOT HAVE THE FORMULA IDENTIFICATION STEP Press and hold the 1 button to view the chemicals 1 8 that are in the step The 1 column is the desired amount the 27 column is the received amount Button 2 shows chemicals 9 16 Advancing a Formula If a formula on the machine needs to be advanced the best option is to advance the machine to the chemical identification step This will tell the interface to go to the appropriate step in its formula Ending a Formula To end a formula the machine can be advanced to the end formula signal Latch by itself or it can be ended manually To end the formula manually do the following Press NO This will pause the formula Press CLR This will silence the alarm Enter in a Password This can be level 1 thru 7 111111 or 777777 37 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Press NO ENT at the same time to take the formula to the end This will cancel the formula and it will not accrue weight or runs in the totals report It will show up as a canceled load If the formula is advanced to the end use UP arrow the load will be considered complete 38 Catalyst SOFTROL www Softrol com SOFTROL CATALYST 4 Calibration Calibration of chemicals with the Injection Controller is done on a per chemical basis This allows you to have extremely accurate injections of chemicals with a wide range of varying specific gravity and viscosity The flow propertie
48. DO 22 92 be t2 22 12 02 61 9E SE EE ZE IE BE 62 86 AV 1321 lt lt lt Softrol J vc 23VAv2 2JV O0CT gt gt gt auruoey gt gt gt lt lt lt 9uTuoey lt lt AV 13 9UA vC soegaequI gt gt gt five W187 LHA IHA 18 1HA A C38 ad 1HM ZNJD Nad 8 n a LHM gt x 18 n8 ATTACH PREWIRED CATAPULSE CABLE 808 21 1 208 908 508 708 085 2085 1068 8 98 Ci vu 98 18 inant 1 1 1 4 LNdNI LNdNI 1ndNII 2 09 NO 3NIHOVW ON NO 3NIHOVW IND AV138 NAO KG41nD AVT38 OTOH i EE SICATAPULSE 07 28 03 KDL PAGE 5 SOF TROL SYSTEMS CATAPULSE CHEMICAL INTERFACE THE FOLLOWING CONNECTIONS ARE BASED ON PREVIOUS INSTALLATIONS VERIFY THE CONNECTIONS WITH THE ACTUAL MACHINE SCHEMATIC FIRST THESE TERMINAL CONNECTIONS SHOULD BE USED A GUIDELINE ONLY SDFTRDL SYSTEMS CATAPULSE CHEMICAL INTERFACE SICATAPULSE 07 28 03 PAGE 6 REF B C D E F G Fo NOTES USE TERMINALS 32 amp 33 ON INTERFACE BOARD TO BREAK THE ALARM CIRCUIT WIRE NUMBER 190 Verify on machine schematic USE CHEM FAULT FOR HOLD PROGRAM CHEMICAL 7 SUPPLY G FOR 30 SECONDS TO HOLD RUN WIRE FROM 24 TO TERMINAL 140 FOR DRY Lavatec Washer CONTACTS ON THE SUPPLY OUTPUTS This uses the Lavatec 24 VDC for LAT
49. E Howto End 0 Stopped 1 Reversing 2 Drain Speed Break 4 Tumbling Q Option STEP OPERATIONTYPEMMQ FFF H C 3 B L S CC NNW SSS RPMD R SIE CHEMICAL 01 15 2 030 180 1 00 0 3 3 01 01 0 0050 0 Formula ID Chem Step 1 _ 02 O2Flush 2 012 000 1 00 0 3 00 00010001 jo 777 OXBresk 2 100160 10 0 0 2 30202 o 050 O ChemStep2 04 O2Flusn 2 012 000 1 00 0 3 00 0001000 31 05 Suds 2 060 175 1 0 0 0 2 3 01 01101050 ChemStep3_ L 7 06 O2Flsh 2 012 1702 3 0 0 3 0 00 000 000 07 o2 Fush 2 012 165 2 3 0 0 3 0 00 000100 fof 08 O2Flsn 2 012 160 2 30 0 3 0 00 00101000 09 o2 Flush 2 012 156 2 30 0 3 0 00 000 000 jo 0 10 OGBleach 2 100 1150 11000 2 50303 210020 O ChemStep4 11 07 2 020 135 2 3 0 0 3 0 00 00101000 fof 3 12 oBAnticlor 2 020 120 2 30 0 3 0 01 01101050 ChemStep5 arrsa 13 07 2 010 105 2 3 0 0 3 0 00 00101000 10 777 14 10Sour 2 042 09023 00 2 o o2o2 o oso ChemStepe _ 1 J ijjjy jesosojoso 3 2 7 15 1 5 2 002 090 2 3 0 0 2 0 05 05 0 00 foj _ FomuaEND 16 ivextract 6 joo TIT Tit LI I i eit 63 Catalyst SOFTR
50. EF B C D E F G F XUSE THIS PAGE IF MACHINE VOLTAGE 120VAC MACHINE CHEMICAL VDLTAGE 120 VAC FORMULA INPUT BINARY 2 BLUE WHITE 12 FORMULA INPUT BINARY 4 GREEN FORMULA INPUT BINARY 8 GREEN WHIT 803 FDRMULA INPUT BINARY 16 RED 15 105 16 I I I I I I I I I i FORMULA INPUT BINARY 32 RED WHITE I I I I 7 E FORMULA INPUT BINARY 64 BLACK WHITE 17A AA 20 108 I DATA LATCH FORMULA END wHITE BLACk 18 19 I I V V V I I E3 CATRLY ITHESE CONTACTS INSIDE I E THESE INPUTS IN INTERFACE RELAY BDARD IWASHER CONTROL SOFTROL SYSTEMS CATAPULSE CHEMICAL INTERFACE SICATAPULSE 07 28 03 PAGE 4 REF lt m gt lt C lt Le CY Lu Z z lt O gt C 2 gt lt lt O IVA0eT 29917107 20185 NDILO3NDO 15 1 an LAdLAO 1 1 41 1nadinn LAdLNO LAdLno LAdLno 1 1 8 L3 98 Gi yi Et eg 18 NOWWOS LAdLNO WOIIWSHS WOIIWAHS WO2IW3H2 WOIIWSHS WOIIWSHS WOIIWSHS WOIIWSHS WOIIWSHS W2IWN3H2 1109 NO NO 1991 0 1 IN G IDH 19v1ND3 I ON G IDH 1991 09 T WOO ANIHIVW ANIHIVW ANIHIVW 3NIHOVN 3NIH3VN 3NIH3VN 3NIH3VN 3NIH3VN 3NIH3VN 3NIH3VN 3NIH3VN 3NIH3VN 3NIH3VN 3NIH3VN 3NIH3VN 3NIH3VN 24 5 72 3 DA 3NIHOVN 3I ACIS 32V4e31NI NO 123NN
51. H OTHER Insert 111 spool into 135 valve block Install 137 O ring on 136 plug insert plug into 135 valve block Install 140 valve insert and 141 valve plate into 135 valve block Note After 9 92 parts 140 141 are white ceramic the dished side of the 140 valve insert should be against the shiny face of 141 valve plate for best performance Replace 132 gasket and install valve block assembly on 101 body 66605X X Page 7 of 8 www Softrol com TROUBLE SHOOTING Product discharged from air exhaust Check for diaphragm rupture Check tightness of 6 diaphragm nut Air Bubbles in Product Discharge Check connections of suction plumbing Check band clamps on intake manifold e Check O rings between intake manifold and fluid caps Check tightness of diaphragm nut Pump blows air out main exhaust when stalled on either stroke Check U cups on 111 spool in major valve Check 141 valve plate and 140 insert for wear e Check 103 sleeve and 2 O ring on diaphragm connecting rod Check 119 O rings on 118 piston for wear Low output volume Check air supply Check for plugged outlet hose For the pump to prime itself it must be mounted in the vertical posi tion so that the balls will check by gravity e Check for pump cavitation suction pipe should be 1 2 min or larg er if high viscosity fluids are bei
52. IRE FUNCTION DESCRIPTION TERMINAL TERMINAL COLOR BINARY 1 INPUT 101 BLUE BINARY 2 INPUT 102 BLUE WHITE BINARY 4 INPUT 103 GREEN BINARY 8 INPUT 104 GREEN WHITE BINARY 16 INPUT 105 RED BINARY 32 INPUT 106 RED WHITE BINARY 64 INPUT 107 BLACK WHITE LATCH INPUT 108 WHITE BLACK COMMON COM BLACK HOLD HOLD COM ORANGE HOLD HOLD NC ORANGE BLACK MACHINE ON POWER BLUE BLACK MACHINE ON COMMON RED BLACK BRAUN BLUELINE WASHER NOTES THE HOLD INPUT IS NOW CALLED LSI SIGNAL LATCH TIME 30 SEC CHEMICAL OUTPUT TIME IS PROGRAMMED IN TENTHS OF A SECOND SUPPLY A 50 I PPLY A FOR 5 SECOND OUTPUT 24 VDC ex SU 50 IS SU OR 5 SECONDS CATAPULSE BRAUN WIRE FUNCTION DESCRIPTION TERMINAL TERMINAL COLOR BINARY 1 INPUT 101 BLUE BINARY 2 INPUT 102 BLUE WHITE BINARY 4 INPUT 103 GREEN BINARY8 INPUT 104 GREEN WHITE BINARY 16 INPUT 105 RED BINARY 32 INPUT 106 RED WHITE BINARY 64 INPUT 107 BLACK WHITE LATCH INPUT 108 WHITE BLACK COMMON BLACK HOLD HOLD COM ORANGE HOLD HOLD NC ORANGE BLACK MACHINE ON POWER BLUE BLACK MACHINE ON COMMON RED BLACK SDFTRDL SYSTEMS CATAPULSE CHEMICAL INTERFACE SICATAPULSE 07 28 03 PAGE 8 www Softrol com SOFIROL Software amp Control for Automation Please visit us on the World Wide Web at www Softrol com Softrol Catalyst Manual Entire contents 1995 2005 Softrol Systems Inc 1st Edition 10 31 96 Revised 07 10 01 Updated for new K4 processor Revised
53. Nm wait 10 minutes then re torque to 15 20 in Ibs 1 7 2 3 Nm 131 MAJOR VALVE see note 3 page 6 AIR MOTOR SECTION SERVICE Service is divided into two parts 1 Pilot Valve 2 Major Valve Air Motor Section Service is continued from Fluid Section repair PILOT VALVE DISASSEMBLY Remove 122 and 104 snap rings Remove 143 plates Remove 103 sleeve and 102 O rings Remove 118 piston 142 washers 119 O rings and 120 spacers from 101 center body PILOT VALVE REASSEMBLY Assemble 119 O rings 120 spacers and 142 washers on 118 pilot rod Insertthe stack into the 101 body Sleeve 103 may be usedto as sist pressing stack into body Install 103 sleeve and 102 O rings into 101 body Install 143 plates and 122 and 104 snap rings 101 118 Figure 3 eo m OPTION 129 see note 2 page 6 201 OPTION see note 2 page 6 103 102 S 7 130 129 dii Dee 104 PILOT VALVE 142 119 0 4 120 119 120 119 449 122 MAJOR VALVE DISASSEMBLY Remove 129 exhaust cover and 130 gasket Pull 135 valve block assembly from 101 body Remove 134 bolts 133 washers and 132 gasket from 135 valve block Remove 141 valve plate and 140 valve insert Remove 136 plug and 111 spool MAJOR VALVE REASSEMBLY Install new 139 and 138 U cups on 111 spool LIPS MUST FACE EAC
54. OL www Softrol com SOFTROL CATALYST Milnor Mark I V Formula 01 BAR TOWELS prion ela lr EL CN IS MILD ION PE F C ME ad EE M El Flsh 0 1 1 Step 1 5 Dll SLM ses 03 03 2 10018 1 291010 0 2 2 b EE pre Els 0 2 2 E REI Ed ini 02 Flush 10 06 2 100 1511 2151010 h 0 3 3 07 Rinse 2 020 E 2 3 3 64 Catalyst SOFTROL www Softrol com SOFTROL 042 0 0 Pa Se Step 6 2 5 eee eo a Hold LA SI HL t Note The washer must have the option for Chemsave and be enabled for more than 8 chemicals If not the washer should be programmed as shown in the previous Milnor example and held by the water levels Milnor Formula Milnor outputs 1 Interface inputs 1 23 4 5 67 8 2 4 8 16 32 64 Latch The Milnor formula above is programmed to identify formula 1 and call for the appropriate chemical injections Step 1 Identifies the formula to the interface as formula 1 The interface will start the formula and proceed to the step ender line 4 This includes chemical step 1 so the Alkali will be injected as the washer fills Step 3 tells the interface to go to chemical step 2 The interface will add the break chemicals and stop at line 8 Step 10 tells the interface to go to chemical step 4 The interface will add the Bleach and stop at line 15 Not
55. PINS DC AND ON DC FOR DC INPUTS 40 04 1 PL68 983 AMJIIV8 WOTHI 128k O Slot 6 ARCFIBER B This card is used for the communications to the PC and the machines The card can be used either for BNC coax cable or for twisted pair CAT 5 N ION eX A N 81L96 21j sc PIN aa 69 Catalyst www Softrol com SOFTROL CATALYST SOFTROL www Softrol com SOFTROL CATALYST Slot 7 8X8 This card has 8 inputs and 8 outputs The inputs are on the left side and are from left to right 57 03 Flush tank full Tank will try to fill when off 57 04 Flush tank empty Turns on when tank is low 57 06 Air Pressure is OK Turns on when gt 65 PSI 57 08 Emergency stop is OK Turns off when E stop is pressed The outputs are 57 09 Calibration Valve S7 10 Fill Flush Tank 57 11 Flush Chems 1 8 57 12 Flush Chems 9 16 57 13 Flush Machine valves 57 14 Back Flush 7 15 Flush Pump 57 16 Signal p THIS COMMON SERVES PINS 9 16 r THIS COMMON SERVES PINS 1 8
56. Programming Formulas and Operations The washer formulas can be very complex and are beyond the scope of this For more information on developing these formulas consult the washer manual as well as the PulseNet manual 51 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Programming the Interface Using the PulseNet software in the same way as the washer formulas can program the interface However since the interface does not have all of the capabilities of the washer controller it has a limited instruction set These are the instructions that may be used Add Chemical by Percent Add Chemical by Unit Chemical Step Run Time Signal Wait to Satisfy The formula on an interface consists of chemical steps and chemical amounts Each step must end with a Run Time 0 00 This tells the interface to wait there until the washer calls for the next step The formula always begins with the Formula Name and ends with the End of Formula When the washer identifies the formula to the interface the interface starts the formula The interface will execute all the instructions in the first step This can include chemical injections If no injection is desired at the identification of the formula the formula name should be immediately followed by a run time of 0 00 For example a flush at the beginning of a formula Formula 18 Bar Mops 0001 Bar Mops 0002 Run Time 0 00 0003 Chemical Step 1 0004 Add 30 Oz of Alka
57. a do the following 1 At the Waiting for Chemical Injection screen on the Injection Controller disable the system by pressing No amp ENT This will prevent the system from receiving chemical requests from machines 2 Open the calibration port and place the graduated cylinder underneath it 3 Press YES and then enter in the formula number Press ENT to begin 4 The controller will ask you to select the destination Press ENT to select the Calibration port This is very important so the unit will not flush after dispensing the chemical 5 The controller will then ask you to key in adl N the desired amount a a 6 Then press YES to begin the dispensing pesired amount SENE of the chemical 128 meien 7 The controller will display the desired Alkali Oop amount as well as the received amount T 042 Sp 000 Delivered Amount The received amount should be counting up to the desired amount 8 Once the injection is complete measure the amount of chemical that has been dispensed 9 To determine the amount of error subtract the measured amount received from the amount desired Divide this DOM number by the amount desired and then A multiply by 100 This will give you the percentage error
58. ate diaphragm pump functions 1 AIR SECTION 2 FLUID SECTION The Fluid Section is divided further to match typical active MATERIAL OPTIONS DUCKBILL CHECK VALVES OPTIONAL Pump models with the suffix OCX or ODX come equipped with duckbill type checks Standard duckbill pumps are shipped with the materialinlet inthe top and the material outlet on the bottom manifold To change the direction of flow disassemble the pump as instructed inthe FLUID SEC TION and reassemble as described below A pump that was factory built with balls and seats can be retro fitted with duckbill type check valves by purchasing the necessary parts and installing them as shown Reassembly The duckbills may be installed in either direction to produce flow from top to bottom ofthe pump or from bottom to top of the pump In either case all of the 42 duckbills must point in the same direction Flow from Top to Bottom see page 5 1 With 15 fluid caps installed stand the pump upside down 2 Place 21 insert into 42 duckbill and slide 41 sleeve over 42 duckbill 3 Slide the complete check assembly into the fluid cap bore with the 21 insert end first Duckbills 42 point up 4 Position 19 O ring over 41 sleeve 5 Attach 35 manifold feet 26 swivel assembly to the fluid caps 6 Turn pump over to right side up position 7 Assemble duckbill check as in step 1 8 Slide the complete check assembly into the fluid cap bore
59. ator desires a new formula the best option is to Cancel the formula on the interface This will not give the credit for the incorrect formula in PulseNet and will show up as a canceled load Note f this is not done and the machine is restarted on the new formula the interface will switch to the new formula and the old formula will be credited with a run The machine must be restarted from the very beginning of the formula to identify the new formula to the interface TT Catalyst SOFTROL www Softrol com SOFTROL CATALYST Hardware replacement The CataPulse is designed for limited in field service The two main components of the interface are the mother board and the arcnet card The following directions should be used for replacement of the mother board SOF TROL CotoPulse Replacement Procedure 1 OO 78 Remove the small junction box at the bottom of t
60. ayout is mounted inside the pneumatic box Air push is a option and may not be included or available 92 Catalyst SOFTROL www Softrol com OPERATOR S MANUAL 66605X X INCLUDING OPERATION INSTALLATION amp MAINTENANCE RELEASED 4 15 87 1 2 DIAPHRAGM PUMP 1 1 RATIO NON METALLIC LLI READ THIS MANUAL CAREFULLY BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT It is the responsibility of the employer to place this information in the hands of the operator Keep for future reference SERVICE KITS Refer to Model Chart to match the pump material options 637140 XX for fluid section repair see page 4 637141 for air section repair see page 6 PUMP DATA Models See Model Description Chart for XXX Pump Type Non Metallic Air Operated Double Diaphragm Material See Model Description Chart Weight Polypropylene 7 2 3 3 kgs Groundable Acetal 8 8 4 0 kgs P MD F Kynar 9 5 4 3 kgs Maximum Air Inlet Pressure 100 p s i g 6 9 bar Maximum Material Inlet Pressure 10 p s i g 0 69 bar Maximum Outlet Pressure 100 p s i g 6 9 bar 4 Air Consumption 1 gallon approx 66605K XXX 666057 XXX Maximum Flow Rate Ball 13 g p m 49 2 l p m Figure 1 Duckbill 10 g p m 37 9 l p m F s m Maximum Particle S
61. brication required other than the O ring lubricant which is applied during assembly or repair If lubricated air is present make sure that it is compatible with the Nitrile O rings in the air motor section of the pump OPERATING INSTRUCTIONS Always flush the pump with a solvent compatible with the material being pumped if the material being pumped is subject to setting up when not in use for a period of time Disconnectthe air supply from the pump if itis to be inactive for a few hours e The outlet material volume is governed not only by the air supply but also by the material supply available at the inlet The material supply tubing should not be too small or restrictive Be sure not to use hose which might collapse When the diaphragm pump is used in a forced feed flooded inlet situation it is recommended that a Check Valve be installed at the air inlet Secure the diaphragm pump legs to a suitable surface to insure against damage by vibration www Softrol com MAINTENANCE Certain ARO Smart Parts are indicated which should be available for fast repair and reduction of down time Provide a clean work surface to protect sensitive internal moving parts from contamination from dirt and foreign matter during service disassembly and reassembly Keep good records of service activity and include pump in preven tive maintenance program Service kits are available to service two separ
62. calibrated chemical injections throughout the process formulation This highly automated system incorporates a full featured yet simple to operate Softrol Catalyst Plus software to provide user defined programming and process reporting All functions of this unit are automated including automated operation of calibration valves and a back flush valve for easy maintenance of the system Additionally the Catalyst Classic incorporates a larger integrated 7 5 gallon flush tank providing isolated and tempered water for flushing the injectors This system has Redundancy capabilities Please see below for additional descriptive information 9 Catalyst SOFTROL www Softrol com Catalyst Dual Inject The Catalyst Dual Inject System has similar features of the Catalyst Classic but offers dual injection capability during the delivery of chemicals to washers For high production facilities this unit can deliver chemicals to two 2 machines simultaneously while ensuring minimum formula hold times thus increasing productivity The Catalyst Dual Inject System does not require any additional chemical pumps to provide multiple machine injections In addition the system incorporates a large integrated 15 gallon flush tank with an additional flush pump 2 to ensure proper flushing during simultaneous chemical injections This Dual Inject System also has redundancy capabilities Please see below for additional descriptive information 10 Catalyst SOFTROL
63. card Remove the EPROM chip and insert into new board Install the OPT ARC card on the new board Reconnect all the cables to the new card Power up the interface Enter in valid setups Including the LAN ID Send a group formula update for the interface POWER CABLE s 5 Ns n P as 2 n _ EEPROM FPD CABLE CHIP EPROM CHIP RAM CHIP gt i 8 Ed 19 E N k CABLE TRS jo ES nu 5 T5 Catalyst SOFTROL www Softrol com SOFTROL CataPulse Interface Troubleshooting The CataPulse interface can have 6 different alarms while running They are 1 76 CATALYST Power Interrupted During Formula This happens when the power is lost to the processor while running a formula Press the YES button to resume the formula Power Interruption During Formula Execution Press YES to Continue Machine Disabled This happens when the machine on input is lost during the formula The machine on light ENTER key at the top right of the keypad must be on to run the formula This is input D1 Machine Disabled Press YES to Continue Chemical Watchdog This alarm occurs when the interface has requested chemical and the Catalyst has not responded Ente
64. ck on the first selection Input the inches of water of hot fill In this case input 10 0 Press Enter The main editing display will show the newly inserted instruction 50 Catalyst SOFTROL www Softrol com SOFTROL CATALYST The next instruction to be inserted is a Run instruction Move the cursor to the END FORMULA line and press the Insert key The window with the instruction icons will be displayed Click on the Clock Icon the first icon on the top left Input the Run Time For this example input 5 00 The newly inserted instruction will be displayed on the editing screen The formula has been programmed The display should look like below 0001 Hot Wash 0002 Fill Hot When Level 10 0 Until Next Step 0003 Run Time 5 00 0004 END FORMULA The formula must be saved or it will be lost when the computer is turned off To save the formula click on File and then click on Save To exit the editor click on the Door Icon on the top of the window For additional information refer to the PulseNet User s Manual Programming Operations using PulseNet Operations are small but complete sections of instructions that perform a specific task They are reusable and are used to construct the more complex formulas Operations are programmed in the same manner as formulas From the main screen in the formula editor click on the File and select Open Operation Refer to the PulseNet User s Manual for more information on
65. d for the hold This will reduce the number of outputs available for the interface Ideally all 8 outputs from the washer can be turned on at the same time If the washer cannot do this then the maximum time between output signals should be no more than 20 seconds The following pages show examples of formulas for different machines These are general guidelines for programming and should be used only as such 56 Catalyst SOFTROL CATALYST Braun Formula Program 14 Bar Mops Step Operati 1 2 RC 23 24 25 26 27 57 Rinse Rinse Drain Break Drain Rinse Drain Wash Drain Rinse Drain Rinse Drain Rinse Drain Wash Drain Rinse Drain Rinse Drain Wash Extract Shakeou t Extract Shakeou t End Time Level 0 0 2 17 12 9 2 17 2 9 2 17 2 17 2 17 10 9 2 17 2 17 5 9 2 1 0 6 0 0 Temp Flush SS 0 0 140 0 170 0 160 0 170 0 170 0 160 0 160 0 145 0 145 0 130 0 100 0 0 0 0 0 Catalyst B B m UJ UJ SPL VO SPL VO A 2 11 L A 5 3 11 www Softrol com SOFTROL L B 5 Option 2 4 8 Lat ch Formula 14 ST T Chem Step 1 ST T Chem Step 2 Chem Step 3 Chem Step 4 Chem Step 5 Low Spd Formula End SOFTROL www Softrol com SOFTROL CATALYST Catalyst Formula Formula 14 Bar Mops 0001 Bar Mops 0002 Run Time 0 00 0003 Chemical Step 1 0004 Add 280 Oz of Alkali
66. dispense that particular chemical without reference from the flow meter e There is no need to change the programming on the machines or interfaces the Catalyst will still dispense the chemical in the desired units e On time based delivery the controller will open the chemical valve and turn on the pump for a specified time If there is no flow or lack of product the Catalyst will not alarm Calibration Errors e Ocannot be entered in for a Calibration e f No counts or low counts lt 1 per second are detected the Catalyst will alarm with a Minimum Frequency Error If this occurs press No to exit and check the flow rate as well as the response from the meter Checking the Calibration WARNING DO NOT USE THE CALIBRATION ROUTINE TO CHECK CALIBRATION ACCURACY OR THE CALIBRATION WILL BE ALTERED INSTEAD PROGRAM A CALIBRATION TEST FORMULA 42 Catalyst SOFTROL www Softrol com SOFTROL CATALYST After the chemical is calibrated it is preferable to run a calibration check formula These are the formulas that are stored on the Catalyst itself These formulas should correspond to the chemical number For example formula 1 checks chemical 1 If chemical 1 is Alkali formula 1 should be called Check Alkali and when run it will dispense the requested amount of Alkali Check Formula example 001 Check Alkali 002 Set Chemical Flush 0 003 Add 0 oz of Alkali 004 Run Time 0 00 005 END FORMULA To run the check formul
67. e PN 193122 Hazards or unsafe practices which could result in severe personal injury death or substantial property damage Hazards or unsafe practices which could result in minor personal injury product or property damage Important installation operation or maintenance information Page 2 of 8 66605X X GENERAL DESCRIPTION The ARO diaphragm pump offers high volume delivery even at low air pressure and a broad range of material compatibility options available Refer to the model and option chart ARO pumps feature stall resistant design modular air motor fluid sections Air operated double diaphragm pumps utilize a pressure differential in the air chambers to alternately create suction and positive fluid pressure in the fluid chambers Ball checks insure a positive flow of fluid Pump cycling will begin as air pressure is applied and it will continue to pump and keep up with the demand It will build and maintain line pres sure and will stop cycling once maximum line pressure is reached dis pensing device closed and will resume pumping as needed Models 666056 X and 66605H X The Acetal material used in these pumps contains Stainless Steel fibers It s conductivity allows it to be connected to a suitable ground A ground screw and ground wire kit is provided for this AIR AND LUBE REQUIREMENTS Afilter capable of filtering out particles larger than 50 microns should be used on the air supply There is no lu
68. e The W for when to add chemicals is a 2 which will wait until the washer has filled and reached temp before the bleach is added Step 16 signals the interface to end the formula The Load Unload timer will start and run until the next formula is run 65 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Catalyst Formula Formula 41 White Bar Towels 0001 Bar Towels 0002 Chemical Step 1 0003 Add 30 Oz of Alkali 0004 Run Time 0 00 0005 Chemical Step 2 0006 Add 72 Oz of Alkali 0007 Add 48 Oz of Detergent 0008 Run Time 0 00 0009 Chemical Step 3 0010 Add 24 Cz Alkali 0011 Add 24 Oz Detergent 0012 Run Time 0 00 0013 Chemical Step 4 0014 Add 64 Oz Bleach 0015 Run Time 0 00 0016 Chemical Step 5 0017 Add 4 Oz Antichlor 0018 Run Time 0 00 0019 Chemical Step 6 0020 Add 8 Oz Sour 0021 Run Time 0 00 0017 END OF FORMULA 66 Catalyst SOFTROL www Softrol com SOFTROL CATALYST 8 System Maintenance and Troubleshooting Maintenance The Catalyst Chemical system will require periodic maintenance Doing a few simple procedures can dramatically increase the life of the chemical system The following is a suggested maintenance plan Due to site specific conditions the intervals may need to be changed 15 Week Re torque all chemical pumps e Carefully inspect all connections for signs of chemical or water leaks If any
69. e is opening enough to let chemical flow Turn the adjustment counter clockwise to increase flow 14 If the valves are not turning on troubleshoot the output cards in the controller 71 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Flowmeter Disassembly Cover w embedded sensor FLUSH 1 fo Flowmeter Gears FLUSH 2 CHEM 6 CHEM 7 BACKFLUSH If the flowmeter becomes clogged with debris and cannot be cleared by back flushing it will be necessary to disassemble and clean the flowmeter To disassemble the meter do the following e Press and hold 5 amp ENT for 20 seconds to flush the system with water e Place several rags or towels under the meter The manifold will be full of water e Press the Emergency Stop Button Remove the cable that attaches to the cover of the flowmeter Remove the 8 bolts that hold the cover in place Carefully remove the cover from the manifold Use a screwdriver to pry it loose if necessary e Remove the gears from the meter Remove any debris that may be blocking them e Replace the gears Make sure the magnets on the gears face the cover of the flowmeter The gears should turn freely when in place e Replace the O ring with a new one Replace
70. e lines should be connected together with check valves to form a single line to the washer These connectors are not included but can be ordered from Softrol See drawing below Check Valve Assembly for Catalyst DI Systems and Redundant Systems Check Valve Assembly for multiple DI systems or more than 2 redundant Catalyst systems 19 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Drain Connection There are 2 drain connections for the Catalyst with 1 2 NPT connections The back flush outlet MUST be plumbed to an applicable drain Since this outlet can be pressurized the drain line does not have to be a gravity drain The overflow is for the f
71. e to end the formula The Load Unload timer will start and run until the next formula is run 60 Catalyst SOFTROL Ellis AWC 1000 Formula 1 BAR TOWELS C OPERATION MIN SEC TEMP LEV CHEMICAL KEV S 5 FLUSH 2 8 5 5 2 e mer e 38 5 17 9 BREAK 2 0 710 6 23 d LOL 1 FLUSH 11520 75 2 1 2 J 3 00004 2 14 iet 10 17 18 15 15005 6 15 6 23 M 17 FLUSH 1 30 10 2 2 LH E11 1 3 Pio FLUSH 1 s0 T5 i2 2 2 pan 1 20 Sela 2 a m T 2 3 me 0 N 27 Bean soje O A a O s mm rat F o 2 2 mea 0 5 17 59 amomo 2 tol a Di 5 _ fanse 1 pes p quer ot 9 6 1 na je L senses ew 5 9 6 T gt COE a p a HghEdax 6 5 4 Seu 1 9
72. face The power is 24 VDC The black wire is the OV and connects to the terminal that is connected to the black wire that enters the CataPulse The white wire is 24VDC and should be connected to the terminal that connects to the red wire INTO CATAPULSE RED r BLACK 2 Conductor END OF Daisy Chain 24 BLACK WHITE FROM PREVIOUS MACHINE TO lt NEXT MACHINE MIDDLE OF INTO CATAPULSE RED r BLACK V OV onductor Power Line BLACK WHITE FROM PREVIOUS MACHINE Daisy Chain Catalyst SOFTROL CATALYST Arcnet Connections Arcnet Card must have Terminator INTO CATAPULSE WHITE V OV FROM TO PREVIOUS NEXT J Communication Line MACHINE L BLUE WHITE BLUE END OF Daisy Chain or STAR NETWORK MACHINE WHITE BLUE BLUE E ci www Softrol com SOFTROL Remove Terminator from Arcnet Card SOLID WHITE N INTO CATAPULSE FROM PREVIOUS J Communication Line MACHINE BLUE WHITE BLUE MIDDLE OF Daisy Chain
73. gs Setups 2 Chemical Setups Select 1 Watchdogs Setups TAME ES 1 Machine Setup 2 Maintenance Setup J 3 Clear Ram Vocabs NL E 4 Passwords O exit Select 1 Machine Setup The current setting is shown on the display The Programmable Functions section describes all of the questions in detail Note Use the YES or NO keys and the numbers on the keypad to change the answer to the setup questions Some questions require the operator to enter a value e Press the ENT key to accept the answer e Press only the ENT key to accept the default or keep the previously programmed value e You cannot go backwards through the questions If you need to change the answer to a previous question press the ENT key to accept the current values to the remaining questions then restart the procedure 21 Catalyst SOFTROL www Softrol com SOFTROL CATALYST e Press the CLR key to clear the numeric value of the current question After all setups are complete pressing the CLR key will accept the changes The Catalyst does not store any of the changes in memory until the last setup question is answered and the CLR key is pressed If the power is lost during the setup procedure the changes will not take effect AutoChem Flush This setup answered in seconds i
74. he interface Unplug the power connection and the communications connection Be careful the power will have 24 VDC Remove the 6 screws that hold the cover in place Remove the cover and disconnect the 4 wires that connect it to the mother board Rotate the horn 180 deg The wire connectors should be at the top Remove the plug that connects to the inputs Remove the connector from the outputs Remove the plug for the mother board power Remove the screw that holds the arcnet card in place Remove the arcnet card Remove the EEPROM chip Note the orientation of the chip in the socket The notch on the chip should line up with the notch on the socket f you do not change this chip the latch time will need to be set This is found in the installation and configuration section Remove the mother board from the plastic holder You may need to pry back the sides to release the board Catalyst SOFTROL www Softrol com SOFTROL CATALYST 10 Replace the mother board with a new one Be sure to set the LAN ID to the correct number by using the dip switches in the lower right hand coner of the card You can use the old mother board as a reference or refer to the installation and configuration section Replace the new EEPROM with the old one If you do not change this chip the latch time will need to be set This is found in the installation and configuration section 11 Put the arcnet card back in the holder and insert the screw
75. her from 1 diaphragm connect ing rod 7 Remove 1 connecting rod from air motor 8 Carefully remove remaining 6 diaphragm nut 8 7 Teflon mod els diaphragm and 5 diaphragm washer from 1 connecting rod Do not mar surface of connecting rod Remove 2 O ring from connecting rod 10 Remove 37 clamps from top and bottom manifold swivel assem blies 11 Remove 33 O rings from 36 swivels 9 c Page 6 of 8 Description jizeinincnes Qty PartNo 133 Washer ozio 4 93096 iss 134 Boh a Y64197 SS 135 Valve Block 0 93090 136 pu 9 5 Y32525 18 Packing U Cup 1 8 x 1 o d i 94395 Uy Packing U Cup 1 8 x 1 427 o d i 93116 B io Valve Insert 93276 i 141 Valve Plate 0 93275 ws fnes 143 Plate 01949 ISS 201 Mufflerisee note fono C c qd Keylube Ring Lubricant 937061 637175 Note 1 Part No 93339 1 One Piece Gasket replaces the following parts not shown in models manufactured prior to October 1988 Y325 10 4 Y325 12 93093 93094 Y325 8 Note 2 The 129 Exhaust Cover and 201 Muffler were standard until 9 92 They are available separately for service or piped exhaust applications
76. icals 9 16 thru Calibration port 5 ENT Flush machine flush valves thru Backflush port No ENT Disable the Catalyst YES ENT Enable the Catalyst 36 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Interface Operation Typically the interface is set up to automatically read the formula from the machine when it starts and end the formula when the machine ends its cycle When this is the SOFIROL CataPulse The Catalyst by Softrol Systems Inc c 1998 2004 0856 no operator intervention is required Operator intervention is required when the formula on the interface is started manually This can be useful when the machine lacks multiple chemical outputs or the machine has a chart controller and a normal interface is used To start a formula manually press YES and the enter in the appropriate formula number Additionally it may be useful to have the operator enter in the weight of the load at the start of each cycle This can be used for weight tracking as well as ratiometric chemical additions To use this option turn the setup for Prompt Weight YES It is useful to have the formula started manually if the weight is being tracked This will help speed up the process since the formula identification step will be eliminated ANY FORMULA THAT IS STARTE
77. iminate this error If the memory card has been replaced you will also need to send a Group Formula Update from PulseNet This should be done for the Catalyst group If this error occurs and no cards have been replaced in the controller then it is likely that the calibrations on the processor RAM have been corrupted Follow the same procedure and copy the calibrations from Slot 5 69 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Check Chemical Tanks This error occurs when the input S7 07 turns on This can be used for low level in day tanks Once this input is on the system will not dispense until it is corrected To clear this error disable the system by pressing No amp Ent and fill the tank TO Catalyst J SOFTROL www Softrol com SOFTROL CATALYST How to clear a chemical watchdog on the Catalyst The Catalyst will alarm with a chemical watchdog when the injection takes too long or when the controller does not register any pulses from the flow meter If the controller encounters these faults it will alarm and display the watchdog with the chemical number Do the following 1 Press CLR to silence the alarm 2 Check the supply tank or drum to make sure there is sufficient chemical supply 3 If there is chemical enter the level 7 password The default is 777777 If the unit is out of chemical replace the drum or fill the tank To prime the system enter in the level 7 password and then press and h
78. intenance For Washrooms Requiring Redundant Chemical Injections Catalyst Classic Redundant KS 9er The Catalyst Classic Redundant System can utilize two or more Catalyst Classic Systems to achieve complete redundancy for chemical injection The system utilizes all of the features of the standard Catalyst Classic for effectively automating the delivery of up to sixteen 16 chemicals to a maximum of sixteen 16 washers The Catalyst Classic Redundant System consists of two complete Catalyst Classic Systems which includes complete replication of valves pumps flow meters calibration components and software capable of delivering chemicals to two or more machines simultaneously one machine injection from each system or have the capability to deliver chemicals to machines while one of the units is shut down for preventative maintenance 12 Catalyst SOFTROL www Softrol com Catalyst Dual Inject Redundant The Catalyst Dual Inject Redundant System utilizes two Catalyst Dual Inject Systems to achieve complete redundancy for chemical injection Utilizing all of the features of the Catalyst Dual Redundant for effectively automating the delivery of up to sixteen 16 chemicals to a maximum of sixteen 16 washers The Catalyst Dual Inject Redundant System consists of two complete Catalyst Dual Inject Systems which includes complete replication of valves pumps flow meters calibration components and software capable of delivering chemicals
79. ity and the elevation that it must overcome Viscous chemicals should be kept as close to the unit as possible Also avoid running the suction tubes over an elevation of 6 ft The inlet lines to the pumps must have adequate strainers 12 Mesh minimum On These may be incorporated with drum wands available from Softrol or can be piped inline It is recommended that if the strainers are piped inline a shutoff valve be located on either side as to allow for y easier cleaning G T 3 4 Y Strainer 12 Mesh 3 4 Drum Wand 17 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Chemical Pumps The chemical pumps should be tightened to the proper torque range before use The proper torque is 70 in Ibs Use 7 16 nut driver Torque from bolt head This is on the side of the air inlet Tighten all 6 bolts Use a 1 2 wrench Torque both sides Tighten ALL bolts and nuts 18 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Machine Connections The Catalyst has 3 4 hose barb 1 2 for the Catalyst Tunnel connections for the machine delivery lines A minimum of 5 of tubing should be used even if the machine lines are hard piped For a redundant Catalyst setup or a Catalyst there should be multiple lines to each washer or th
80. ize Ball 3 32 dia 2 4 mm _ MODEL DESCRIPTION CHART Duckbill Fibers Maximum Temperature Limits 66605 X X X X 04 EPR kasaq 60 10 280 F 51 to 138 FLUID CAPS amp MANIFOLD MATERIAL Groundable Acetal 10 to 180 F 12 to 82 C 3 Piece Manifold Single Piece Manifold Hytrel 20 to 150 29 to 66 3 Polypropylene J Polypropylene Neoprene 0 to 200 F 18 to 93 C 6 Groundable Acetal Groundable Acetal 10 to 180 F 12 to 82 C 7 Pure Kynar K Pure Kynar Polypropylene 35 to 150 F 2 to 66 C SEAT MATERIAL Polyurethane Seer ea 10 to 150 F 12 to 66 C pio 4 P V D F Kynar P V D F Kynar ETERRA 10 to 200 F 12 to 93 C D Stainless Steel 6 Acetal Santoprene 40 to 225 F 40 to 107 C 3 Polypropylene Teflon 40 to 225 F 4 to 107 C Vion 40 to 350 F 40 to 177 C PALI MATERIAL models Neoprene 8 Polyurethane Groundable 666056 X and 66605H X models only 2 Nitrile A Stainless Steel Dimensional Data see page 8 3 Viton C Neoprene Noise Level 70 p s i 60 c p m 71 1 db A 4 Teflon D Nitrile 5 EPR E Santoprene The pump sound pressure levels published here have been updated to an Equivalent Continuous Sound Level Leq
81. l manufacturer Maximum temperatures are based on mechani cal stress only Certain chemicals will significantly reduce maximum safe operating temperature Consult the chemical manufacturer for chemical compatibility and temperature lim its Refer to Pump Data on page 1 of this manual Be certain all operators of this equipment have been trained for safe working practices understand it s limita tions and wear safety goggles equipment when required Do not use the pump for the structural support of the piping system Be certain the system components are properly supported to prevent stress on the pump parts Suction and discharge connections should be flexible connec tions such as hose not rigid piped and should be compatible with the substance being pumped Prevent unnecessary damage to the pump Do not allow pump to operate when out of material forlong periods of time Disconnect air line from pump when system sits idle for long periods of time Use only genuine ARO replacement parts to as sure compatible pressure rating and longest service life pump may not prime properly if the balls do not check by gravi ty upon start up NOTICE Re torque all fasteners before operation Creep of housing and gasket materials may cause fasteners to loos en Re torque all fasteners to insure against fluid or air leakage NOTICE Replacement warning labels are available upon request Static Spark PN193616 1 Diaphragm Ruptur
82. li 0005 Add 15 Oz of Detergent 0006 Run Time 0 00 If there is chemical desired upon identifying the formula then the first step should include these amounts For example a break at the beginning of a formula Formula 8 Color Pants 0001 Color Pants 0002 Chemical Step 1 0003 Add 30 Oz of Alkali 0004 Add 15 Oz of Detergent 0005 Run Time 0 00 52 Catalyst SOFTROL www Softrol com SOFTROL CATALYST All of the Chemical steps should end with a Run Time 0 00 This includes the last step before the end of formula For example 0012 Chemical Step 4 0013 Add 12 Oz of Softener 0014 Add 10 Oz of Sour 0015 Run Time 0 00 0016 END OF FORMULA The chemicals in a step are injected in order of their chemical number For instance if Detergent is set up as chemical 1 and Alkali as Chemical 2 The Detergent will always be injected before the Alkali when they are in the same step Example 0001 Color Pants 0002 Chemical Step 1 0003 Add 30 Oz of Alkali 0004 Add 15 Oz of Detergent 0005 Run Time 0 00 Some examples of formulas and their functional descriptions are on the following page Programming the Injection Controller Only calibration test formulas should be programmed for the injection controller These formulas will be used to test the accuracy of chemical calibrations Chemical units should be set to 0 When the formula is ran the controller will prompt fo
83. lush tank and cannot be run any higher than the top of the tank It is not necessary to hook up the overflow line however if the level switch fails in the tank water will be forced out this outlet Machine Connections System 1 Machine Connections System 2 A A A 0 m ma Back Flush Port j Overflow Port Fi d BACK VIEW 20 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Configuration Injection Controller The Catalyst machine setups tailor the operation to suit individual preferences and applications These parameters are global meaning they effect all formulas Some of these parameters AutoChem Flush for example can also be set on the machine and override the global parameters and only effect the current injection Use the following sequence to set up the user programmable features From the Waiting for Chemical Injection Request display enter a valid level 7 password please refer to Passwords 1 Setup 2 Program 3 Maint 4 Calib 5 Totals 6 Clock soror e Selection O exit sa CONTROL STATION 1 Setup 2 Progran 3 Maint 4 Calik S Totals 6 Clock Select 1 Setups Slection O0 Exit 1 Watchdo
84. n Request Enter the Level 7 password factory default 777777 Press the 3 key for Maintenance at the Main Menu Press the 1 key for Manual Outputs Press the 3 key for Machine selects Press the Down arrow key to get to calibration port Press Yes to turn the output on Press 0 to exit Press the 1 key for Chemicals Use the arrows to scroll to the chemical to be checked Press and hold the YES key to turn on the chemical s delivery valve and pump Releasing the YES key turns off the valve and pump Use the Stroke Limiting adjustment nut to adjust the flow through the valve Low flow 5 to 1 gpm High flow 1 3 gpm Press the CLR ENT keys to flush the system between each chemical injection Repeat this procedure for each chemical Press the 0 key to exit 35 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Calibration valve FLUSH 2 9 10 MACH 11 MACH 19 MACH 13 MACH 14 em eps S he MACH 2 MACH 3 MACH 4 MACH 5 FLUSH 1 CHEM 1 CHEM 8 CHEM 3 CHEM 4 CHEM 9 SUN Bron HEN 5 m EN 9 zs Stroke Limiting un Adiustment Key Strokes for the Catalyst CLR ENT Flush all valves down the Calibration port 1 ENT Flush Chemicals 1 8 thru Calibration port 3 ENT Flush Chem
85. ne is reached Items that can cause network trouble Duplicate IDs Each node must have a unique ID from 1 to 255 The ID is usually set in the machine setup menu The exception is the ArcFiber card and the CataPulse interface which is used with the K4 Processor This card has a set of 8 dip switches that determine the ID Terminating Jumper Only the last machine on the line should be terminated This terminator can be either a jumper on the card or a BNC terminator connected to the other side of a tee It should not have both The computer must have a tee and terminator if it is at the end of the line it does not have terminating capability If twisted pair is used then the terminating jumpers must be used at the end of the line Un terminated Line This will cause the network to reset This can be a card at the end of the line that does not have a terminator or when the cable is damaged or cut e CX TP Jumper The ArcNet cards can be configured for either Coax or twisted pair communications For the Coax networks the jumpers should be on the CX side For Refer to the parts manual for exact jumper positions Faulty ArcNet Card Due to excessive noise on the line ArcNet cards can be damaged and cause the network to fail If this is the case try to locate the source of electrical noise and correct it Some sources of electronic noise are Cables run too close to power wires If you must cross a power line the cable sho
86. ng pumped Suction hose must be non collapsible type capable of pulling a high vacuum Check all joints on intake manifolds and suction connections These must be airtight Check for sticking or improperly seating check valves f pump cycles at a high rate or runs erratically check 119 piston O rings for wear DIMENSIONAL DATA Dimensions shown are for reference only they are shown in inches and millimeters mm 6 7 167 164 mm re 6 152 mm 5 3 16 132 mm 8 5 32 207 mm 1 1 2 14 ign H 6 mm 11 11 32 288 mm Material Outlet 1 2 14 Air Inlet 1 4 18 Material Inlet 1 2 14 N P T k 2 1 32 51 nm NOTE LOOSENING THESE 4 13 16 122 mm 5 1 2 140 mm FASTENERS WILL ALLOW INLET OUTLET TO ROTATE 5 16 Slot 8 mm 6 5 32 156 mm 8 15 32 215 mm Single Piece Manifold Figure 4 7 ARO IB Ingersoll Rand PN 97999 99 Page 8 of 8 66605X X Software amp Control for Automation 406 N MAIN ACWORTH GA 30101 70974 2700
87. oftrol Catalyst Family Softrol Systems Inc offers six types of Catalyst Chemical Dosing Systems to automatically deliver chemicals to wet processing equipment All of the Catalyst Systems utilize specialized Windows based software to allow user defined programming and process reporting Softrol Catalyst Systems are built in non corrosive enclosures with easy access to valves pumps and electronic parts The Catalyst System uses flow meter based injection technology providing volumetric injection and water flush verification In combination with Softrol engineered electronics flow meter and alarms watchdogs the system measures and verifies each injection With this combined technology chemicals are injected quickly and accurately no excess chemicals enter the machine s Features of Softrol Catalyst Systems include o Connection with any type washer control Properly maintained chemical injections 128 programmable injection formulas User friendly operation 16 user defined chemical names Corrosion resistant materials Control of flow rates from 0 2gpm to 10 0gpm Data recording and reports Programmable alarms 32 preventative maintenance prompts Accurate chemical injections over a wide range of viscosities Simple calibration procedures Modular design for simplified troubleshooting repair and expansion Catalyst System Machine Interface O OOO O O OOO OOO T Catalyst SOFTROL www Softrol com Types of Systems Cataly
88. old YES Once the pump has been primed release the YES key 4 The formula will reset press YES to restart the injection 5 Watch the display It will show the desired amount and the delivered amount The delivered amount should be counting up If not the unit will alarm again 6 If the system alarms and chemical is pumping the flowmeter is likely obstructed and will need to be cleared If chemical did not pump go to step 12 7 Press amp hold CLR amp ENT for approximately 15 seconds to flush the system 8 Press amp hold The Manifold amp CLR for approximately 15 seconds to flush the individual manifold Observe the flowmeter if gears rotate then the are not jammed and the formula should be rstarted If the gears are jammed Then the flowmeter will need to be disassembled See the net section 9 Enter in the level 7 password and press YES to restart the injection 10 If the system is still not metering the chemical flush the system and disassemble the flowmeter Make sure there are no obstructions and the gears turn freely Make sure when replacing the gears the numbers face the back of the meter 11 Enter in the level 7 password and restart the injection by pressing YES Make sure the system is pumping chemical 12 Check the air pilot valve for the chemical valve and pump They should both turn on LED on air valve should come on 13 The chemical valve has a stroke limiting adjustment make sure the valv
89. out End 59 White Bath Towel 0 0 9 17 17 17 17 0 0 160 160 155 155 145 130 115 100 0 0 0 Catalyst UJ UJ UJ 11 www Softrol com SOFTROL CATALYST B Optio n 5 1424448 5 4164 Latch 5 ST T zFormula 31 0 0 ST T 0 Chem Step 2 0 5 Chem Step 3 0 0 Chem Step 4 Formula End SOFTROL www Softrol com SOFIROL CATALYST Catalyst Formula Formula 31 White Bath Towel 0001 White Bath Towel 0002 Chemical Step 1 0003 Add 30 Oz of Alkali 0004 Add 15 Oz of Detergent 0005 Run Time 0 00 0006 Chemical Step 2 0007 Add 48 Oz of Bleach 0008 Run Time 0 00 0009 Chemical Step 3 0010 Add 6 Oz of Antichlor 0011 Run Time 0 00 0012 Chemical Step 4 0013 Add 12 Oz of Softener 0014 Add 10 Oz of Sour 0015 Run Time 0 00 0016 END OF FORMULA Braun Formula Braun outputs 1 2 3 4 5 6 7 11 Interface inputs 1 2 4 8 16 32 64 Latch The Braun formula above is programmed to identify formula 31 and call for the appropriate chemical injections Steps 1 3 Identify the formula to the interface as formula 31 The interface will start the formula and proceed to the step ender line 5 This includes chemical step 1 so the Alkali and Detergent will be injected as the washer fills Step 8 tells the interface to go to chemical step 2 The interface will add the bleach and stop at line 8 Step 18 signals the interfac
90. out To end the formula manually do the following Press NO This will pause the formula Press CLR This will silence the alarm Enter in a Password This can be level 1 thru 7 111111 or 777777 Press UP Arrow to take the formula to the end Changing a Formula If the incorrect formula has been started on the machine and the operator desires a new formula the best option is to Cancel the formula on the interface This will not give the credit for the incorrect formula in PulseNet and will show up as a canceled load Note f this is not done and the machine is restarted on the new formula the interface will switch to the new formula and the old formula will be credited with a run The machine must be restarted from the very beginning of the formula to identify the new formula to the interface 74 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Interface Board Problems Memory Card May Be Corrupt This may be displayed when the memory chip in the interface has been reinitialized To correct this do the following o Press CLR then 777777 ENT 0624577 o Press 777777 o Select 1 for machine setups o Enter valid setups From interface configuration If this does not correct the problem replace the memory chip or the entire OPT PRO board Replacing the OPT PRO Disconnect the power to the interface Remove the FPD Power IIC and I O cables Remove the EEPROM chip and insert into new board Remove the OPT ARC
91. puts to the interface are wired to the chemical outputs of the washer If there are not 8 outputs the last output should be wired to the input 8 of the Interface To identify the formula the washer needs to be programmed to give the corresponding binary number followed by a latch Example Formula Outputs 1 1 8 2 2 8 3 1 2 8 7 1 2 3 8 63 1 2 3 4 5 6 8 The outputs should be programmed to turn on for 5 seconds The Latch output should be programmed to turn on last This will cause the interface to read all inputs that are on or that were on during a specified time period 55 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Once the formula is identified to the interface the washer should be programmed to identify the chemical step that is desired The chemical step is identified in the same binary manner however the latch is not called for The maximum number of chemical steps is 16 Example Chemical Step Outputs 1 1 2 2 3 1 2 4 3 5 1 3 To signal the end of the formula the washer should be programmed to turn on the Latch input for 5 seconds There should not be any other binary inputs to the interface on at this time Some washers require a water level to turn on any chemical outputs in this case the end of the formula signal should be programmed before the extract step The number of formulas depends on the number of outputs available from the washer Additionally some machines require that chemical be use
92. r a unit input A typical test formula is shown below 0001 Check Alkali 0002 Set Chemical Flush 0 0003 Add 0 Oz of Alkali 0004 Wait to Satisfy 0005 Run Time 0 00 0006 END FORMULA Go ahead and program the formula by yourself If you run into problems take another look at the other formula examples Refer to the PulseNet User s Manual for additional information 53 Catalyst SOFTROL www Softrol com SOFTROL CATALYST 54 Catalyst SOFTROL www Softrol com SOFTROL CATALYST 7 Programming the Washers Washers with Softrol controllers can be programmed by PulseNet and can interface directly with the Catalyst unit The section on Programming from PulseNet describes how to create washer formulas The chemical additions are simply programmed with the chemical name and the desired amount Note The injection must be followed by a Wait to Satisfy in order for the machine to hold while chemical is being injection Softrol controllers only Non Softrol controlled washers will require an interface to work with the Catalyst chemical system The interface reads signals from the washer s chemical outputs and determines the formula that is being run and the step that it is at See the section on Programming from PulseNet for information on how to program washers with Softrol controls The interface has 8 inputs that correspond to the binary formula identifier Input 1 2 3 4 5 6 7 8 Binary 1 2 4 8 16 32 64 Latch The in
93. r in a level 4 password or higher and then press YES to resume If the Catalyst does not answer the chemical request then there might be a problem with the Catalyst or the network Call Maintenance Chem watchdog Chemical 1 Also check the chemical watchdog time in the setups This time should be 4 to 10 min Invalid Formula This will be displayed when the interface receives an input that indicates a formula that is not currently programmed To clear the formula press CLR NO ENT To select the correct formula use the arrow keys e Check the machine programming and chemical outputs to verify proper operation Formula Number 63 Not Assigned Use arrows to scroll ENT Accept NO Exit Invalid Formula Request This will be displayed when the interface in the waiting for formula state receives the latch input without a valid formula number To clear the formula press CLR NO ENT To select the correct formula use the arrow keys Check the machine programming and chemical outputs to verify proper operation Invalid Injection Request This will be displayed when the interface in the waiting for formula state receives binary inputs without the latch To clear the formula press CLR NO ENT To select the correct formula use the arrow keys Check the machine programming and chemical outputs to verify proper operation Catalyst Formula Number
94. rcnet Troubleshooting Catalyst Electronics Catalyst Pneumatics Pump Manual Catalyst Schematic Catapulse Schematic Catalyst www Softrol com SOFTROL www Softrol com Catalyst SOFTROL www Softrol com 1 Introduction The Catalyst System The Catalyst System is a chemical metering and injection system that delivers liquid chemicals to multiple washers The system is flexible and can be customized to serve up to twenty machines with a possible sixteen chemicals The Catalyst System offers precise chemical deliveries with consistert results The system has the ability to interface with various types of controllers and production data may be gathered for a variety of washers Formula entry is simplified with a with the PulseNet PC software and all formulas are stored in the Interface Box or on the microPulse washer controller 5 Catalyst SOFTROL Typical System Layout COMMUNICATION LINE MULTI CONDUCTOR LINE CHEMICAL DELIVERY LINE www Softrol com MACHINE INTER CONTROL FACE MACHINE HUB MACHINE CONTROL MACHINE COMPUTER MACHINE INTER CONTROL FACE MACHINE P CATALYST MACHINE INTER CONTROL FACE Ir MACHINE 6 Catalyst SOFTROL www Softrol com The S
95. roper operation of the system In this screen the name of the chemical is created as well as the units it is measured in if it can be used with steam and the units per pound if it is to be used with ratiometric processing Also the chemical supply is identified and corresponding amount is entered Note Most likely the bulk units are in gallons while the calibrated units are in ounces Then the amount of gallons per ounce would be entered as 007812 See page 22 of the PulseNet manual for examples 4T Catalyst SOFTROL www Softrol com SOFTROL CATALYST Once this page is completed save it and then change the Group ID to another group Now import the data from the first group into the new group and save Repeat this until all of the groups have been completed Finally enter the system defaults Menu and set the RSR to have an automatic time You will need to enter in the time the RSR will occur This should be at the end of a shift or the end of the day Note The machines interfaces and the computer need to be powered on to communicate to the totals to the computer Also check the box to also upload history This will allow the plant history reports to be viewed for specified time periods PulseNet is a very powerful software tool and has many features The above information is just the basic amount that needs to be entered to have the system function properly 48 Catalyst SOFTROL www Softrol com SOFTROL CATALYST
96. s of a heavy viscous surfactant will be quite different from those of a low viscosity acid Softrol Systems recommends that plant personnel become very familiar with the types of chemicals they will be handling and the potential hazards that are associated with each chemical This information is contained in the MSDS Material Safety Data Sheet supplied by the chemical vendors Softrol Systems also recommends that at the very minimum plant personnel be required to wear all protective equipment recommended in the MSDS Software amp Control for Aut amp Calibration Ball Valve _ Graduated Cylinder 49 Chem9 Chem 10 11 Chem 12 C C3 Ll 6 G woe whe MS woe n E T Chem5 Chem6 Chem7 Chem8 o Flush o 39 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Flow Meter Based Calibration To calibrate chemicals using
97. s the amount of time the Catalyst will flush the system with water after each chemical injection The Catalyst will read the time on the machine and use the time that is the greatest Chems 9 12 Auto If answered YES the Catalyst will turn on the chemical outputs for chemicals 9 through 12 e Chems 13 16 Auto If answered YES the Catalyst will turn on the chemical outputs for chemicals 13 through 16 Flow Sensors This setup tells the Catalyst to use the flow sensor input This should be set to YES Chemical Watchdog This is the time in mm ss the user defines is the maximum Catalyst inject time Prompt Weight This indicates whether the operator wishes to prompt the weight of the load before the start of each manual formula This will most likely be set to NO Signal Mute Time This is the time in mm ss the user defines how long a signal will be ignored when pressing the CLR key First Washer ID This setup informs the Catalyst the ArcNet networking ID of the first washer to be serviced Last Washer ID This setup informs the Catalyst the ArcNet networking ID of the last washer to be serviced e Preferred ID Lo Used for a redundant system This setup is used to assign the highest ArcNet networking ID that determines the preferable range for the Catalyst to inject chemicals Decisions by the Catalyst will be given preference according to the programmed range e Preferred ID Hi This setup is used to assign
98. should be no more than 45 psi Air Connections A 12 line of clean dry air at 90 PSI minimum is required for the system The system uses about 8 SCFM maximum 12 SCFM for the Catalyst at 90 PSI For multiple or redundant systems the supply line should be upsized accordingly The unit has a 3 8 OD flexible tubing connection Tubing not supplied Electrical Connections The Catalyst requires 120 VAC at 5 Amps The unit is supplied with a 15 US power cord The Active Hub not used on the Catalyst Lite also 1190 VAC Power requires 120 VAC at 5 cord Amps These circuits should be dedicated for WE s the chemical system use only E 378 RO cem ee _ Connection al 1 0 Water i Connection Chemical Connections chemical feed lines should be run from the Catalyst SOFTROL www Softrol com source Tank Drum Tote etc and connected to the appropriate pump The pump s inlet is at the bottom and the outlet to the chemical valves is at the top On the inlet of the pump use 4 tubing for the small pump and 37 tubing for the large pump It might be necessary to use reinforced tubing on some of the inlets if chemical is being drawn a long distance and or uphill The maximum distance for the pumps to draw depends on the chemical viscos
99. st Lite q l A 2 LL The Catalyst Lite System is a low cost flow metered chemical injection system capable of delivering up to eight 8 chemicals to a maximum of eight 8 washers in a compact all inclusive chemical resistant enclosure The Softrol designed and manufactured manifold systems with built in flow meter assures that precise delivery of chemicals is maintained during formula execution By using the standard Softrol Catalyst software package this unit delivers many of the features of the Catalyst Classic In order to provide a low cost solution for the automatic injection of chemicals Softrol has been able to engineer a system with slightly less automation primarily in the calibration of chemicals which is more automated on the upper line systems Additionally the Catalyst Lite incorporates an integrated 6 gallon flush tank providing immediate water for flushing the manifold This model is available as a redundant system 8 Catalyst SOFTROL www Softrol com Catalyst Classic The Catalyst Classic System is the industry standard for effectively automating the delivery of up to sixteen 16 chemicals to a maximum of sixteen 20 washers The freestanding non corrosive enclosure can be placed either in the chemical storage area or on the washroom floor for easy access By using multiple Softrol designed manifolds with built in flow meters this system is custom designed to deliver high flow precisely
100. t line 8 e e e Step 43 signals the interface to end the formula The Load Unload timer will start and run until the next formula is run 62 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Milnor Mark Formula 01 gt BAR TOWELS T Type of Step 0 End Formula 1 1 Way Wash 2 2 Way Wash Soak Wash 4 Pre Final Extract 5 Intermediate Extract 6 Final Extract 7 Double Ext Time Minutes 10 s Minutes 1 s Quarter Minutes FFF Bath Temperature Hot Water 02 Off 1 2 Raises Temp C Cold Water 02 Off 12On 3 Lowers Temp 3 3rd Water 0 Off 1 On B Bottom Fill O2 No 1 Yes L Liquor Level 0 No Water 1 Level1 2 Level2 3 S Steam 0 None 1 After Timer Run 2 Timer Stop Only 3 After Timer Stop 4 2 4 Early amp After Timer Run 5 Early Timer Stop 6 Early amp After Timer Stop CC Chemical Number 00 01 02 03 04 05 16 Signal Only NN Chemical Name 00 Same as Chemical Number W When to Inject 0 With Fill 1 Level 2 Level Temp OK SSS Seconds of Chemical Injection Signal with Chemical 0 No 1 Yes RPM Basket Speed in 96 of Normal D Drain 0 Standard 1 2 Way Wash Speed 2 Do Not Drain Stop w Drain 4 Stop w Fill 5 Stopw F amp D 6 F amp noD 7 D w 25 sec Spray Rinse R Drain Destination 0 Drain to Sewer 1 Drain to Reuse S Spray Rinse at End of Intermediate Extract 02 No 1 Yes
101. t to Satisfy 0019 Steam When Temperature lt 180 F Until Next Step 0020 Wait to Satisfy 21 Group 1 Dirty Laundry Eaters 22 905 bytes free Formula 1 LIGHT 5 MANAGER 10 01 1997 11 46 Class Blue Cotton Estimated Run Time 46 00 Yield 400 Lbs Count 200 Empirical Run Time 0 00 49 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Programming a Wash Formula At the main screen of PCPM click on Group Select Edit Formulas to bring up the editing screen Click on File on the menu then select Open Formula A list of Formulas will be displayed For this example please click on 001 Unassigned to select formula 1 The editing window will display two lines One line will be the unedited formula name and the other with END FORMULA instruction Click on the first line and press Enter Input the name of the formula In this case input Hot Wash The display will show the edited name Move the cursor to the END FORMULA line and press the Insert key A window with icons for all the available instructions will be displayed The set of instructions displayed will vary according to the type of controller used For this example we will be using a washer controller The display shows 10 icons one icon for each set of instructions X 8 2 Cancel Click on the rightmost icon on the top which depicts water faucet A list of all the selections will be displayed Cli
102. that holds it in place 12 Reconnect all the plugs for the wires that connect to the mother board in the reverse order in which they were removed 13 Reconnect the cover and the power Once the unit is powered up you will need to do the machine setups and passwords These can be found in the installation and configuration section Download the formulas to the interface You may wish to run a test formula at this time To replace the Arcnet card Turn power off the interface Open the interface Remove the wires that go to the arcnet card Remove the retaining screw that holds the arcnet card in place Remove the card and replace with a new one Check the terminating jumper If the interface has only one communication line going to it it is at the end of the daisy chain then the jumper should be in place If not remove the jumper and discard Replace the retaining screw and reconnect the wires to the card The white wires go to terminal A and the colored wires go to terminal B Check the communications The red LED on the card should be on steady Terminating Jumper SOFTROL lt COC 0C 79 Catalyst SOFTROL www Softrol com SOFTROL CATALYST ArcNet Communications BNC Hub Softrol TP Hub Catalyst Hub 9 EN NL
103. the formula Low Air Pressure This happens when the air pressure drops below 65 psi during a chemical injection Once the air pressure is above 65 psi pressing the YES button will resume the formula The Catalyst will display low air pressure but will not alarm if it is not running a formula Chemical Watchdog This alarm occurs when the flow meter senses that it is out of chemical sensor is jammed or the injection took too long Use the password to reset this error If the system is out of chemical and needs to be Power Interruption During Formula Execution Press YES to Continue 128 Chemical Injection Alkali 005 000 Low Air Pressure Call Maintenance Chem watchdog Chemical 1 Chemical 2 primed holding the YES button will allow pump to turn on and ignore the watchdog Release the YES button when the pump is primed See the next section for more details e Sensor Flush This is similar to the Chemical watchdog however it occurs during the metered flush after the injection This should be corrected the same as a chemical watchdog 68 Catalyst Call Maintenance Sensor Flush Watchdog Sensor 1 SOFTROL www Softrol com SOFTROL CATALYST Flush Water Tank Not at Minimum Level This message will be displayed when the water level in the flush tank is not at the minimum level needed to start an injection This message will only display and not alarm when
104. the highest ArcNet networking ID that determines the preferable range for the Catalyst to inject chemicals Decisions by the Catalyst will be given preference according to the programmed range 22 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Installation Machine Interface Mount the Machine Interface Boxes on or near each washer Use nuts and bolts for a machine mount and screws for a wall mount The interface should be connected to the washer controller with 15 conductor wire 24 VDC will be supplied from the Catalyst for the power Refer to the interface schematic for specific wiring instructions Once the interface is powered the setups may be entered The setups in the interface are accessed in the same manner as the setups in the podium Wiring The interface comes pre wired with a 20 length of 15 conductor 18 gauge wire This wire should be cut to length and wired to the input converter The illustration above shows three Daisy Chains from the Catalyst The first one is machines 1 4 the second daisy chain covers machines 5 9 The third daisy chain is from the communication card of the Catalyst to the computer Machines 4 and 9 and the computer should have terminators If there are multiple Catalysts then the network will be wired in a similar fashion but a Hub will be used for communications Refer to the Catalyst manual for this layout 2 2 A UN OR AU
105. to four 4 machines simultaneously two 2 machines simultaneously injections from each system or have the capability to deliver chemicals to machines while one of the units is shut down for preventative maintenance For Washrooms Requiring Single Machine Chemical Injections ChemPulse Express The ChemPulse Express flow metered system is an automated chemical injection system for individual machines This system does not employ a Queued First In First Out FIFO operation as in the ChemPulse Catalyst small systems but instead the ChemPulse Express system supplies chemicals immediately upon demand from the control The ChemPulse Express interfaces to a MicroPulse Machine Control or MicroPulse Machine Interface and allows the control of up to 32 chemicals per machine The system is completely modular so that maintenance or repairs may be completed for specific parts of the system without having to shut down an entire operation Chemicals are delivered to the ChemPulse Express system by either pressurized chemical headers or a Softrol engineered pump system After every injection the system is flushed with water to ensure the system s longevity and to guarantee complete injection of required volumes The unique feature of the ChemPulse Express is the feedback which it supplies to the MicroPulse controller In addition to monitoring volumes the controller uses the feedback received from the ChemPulse Express to obtain proof of injection and
106. tured above is the central piece of equipment that brings the all of the branches of the network together In normal operation the yellow RECON light should be off If this light is on steady or blinking then there may be a problem with the network If this light blinks occasionally once every 100 80 Catalyst SOFTROL www Softrol com SOFTROL CATALYST seconds then the network should be OK as this is the normal reconfiguration of ArcNet The ArcHub does not have this light All the red LEDs should be on steady If you suspect a problem with the Network try the following Communications can be verified from the Pulsenet computer by bringing up the multiple display feature If the front panel displays of all the machines that are turned on are shown then it is likely that communications are OK If there is a problem with communications remove one of the lines from the hub If the hub continues to reconfigure plug that line back in an unplug another Repeat this process until the network is stable You can then recheck communications at the computer to see which machines are causing the trouble Once the line that is causing the problems is identified the machine can usually be identified by the process of elimination To do this plug the line back into the hub and remove the tee from the first machine or node on that line Check to see if communications are restored Repeat this process until offending machine or the end of the li
107. uld be run perpendicular to the line 81 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Poorly grounded controllers and machines Cables run too close to Variable Speed Drives Coax Network SUFTRUL SYSTEMS INC XZ Jumpers for Coax Terminating PE ya sees ul Jumper BNC NETWORK JP JPL e et em der JP2 SET COMMUNICATION ID HERE IN NEG LOGIC BINARY VISHOWN FOR ID 1 0 JUMPER JP4 TO TERMINATE BNC NET 5 Catalyst Arcnet Card 82 Catalyst SOFTROL www Softrol com SOFTROL CATALYST Twisted Pair Network Terminating Jumper SOFTROL SYSTEMS INC GND C CataPulse Arcnet Card x 2 No N Z eee 5 SET COMMUNICATION ID j BINARY
108. with the 41 sleeve end first Duckbill is pointing down toward fluid cap cav ity 9 Position 19 O ring around 21 insert 10 Attach 34 manifold 36 swivel assembly to fluid cap Flow from Bottom to Top Inlet Bottom Outlet Top To reverse flow direction slide check valve assemblies into the 15 fluid caps backwards from whatis indicated in steps 2 and 7 In step 2 the 42 duckbills will be pointing down and in step 7 they will be pointing up VitonG Teflon and Hytrel are registered trademarks of the DuPont Company Kynar is a registered trademark of Penwalt Corp Flouraz is a registered trademark of Greene Tweed amp Co Inc Santoprene is a registered trademark of Monsanto Company licensed to Advanced Elastomer Systems Key Lube is a registered trademark of Key Industries oo 66605X X Page 3 of 8 www Softrol com PARTS LIST 66605X X FLUID SECTION 637140 FLUID SECTION SERVICE KITS include BALLS see BALL OPTIONS refer to XX in chart below DIAPHRAGMS see DIAPHRAGM OPTIONS refer to XX in chart below plus O ring items 2 19 20 33 and 93706 1 Key Lube grease SEAT OPTIONS BALL OPTIONS ITEM 21 ITEM 22 3 4 dia Service Kit XX XXX Seat Qty XXX Ball Qty Lax 95491 i fissi a 95961 im 931002 8 34 939610 y tl xx 4
109. www Softrol com SOFIROL Software amp Control for Automation 6 rd LL Q foy 9 9 g o o ur uw e o L n o PUMP PUMP 2 PUMP 3 PUMP 4 o PUMP 5 PUMP 6 PUMP 7 PUMP 8 m un S e Q 9 9 9l PUMP 9 PUMP 10 PUMP 11 PUMP 12 o FLUSH CATALYST Installation and Operation Manual Softrol Systems Inc 1100 North Point Parkway Acworth GA 30102 770 974 2700 www Softrol com Catalyst SOFTROL Chapter ONO Appendix Table of contents Description Introduction Installation System Utilities System Configuration Interface Installation Network Installation System Operation Passwords Priming the system Interface Operation Calibration Flow meter Based Calibration H Factor Calibrations Time Based Calibration Conversion Table PulseNet Configuration PulseNet Programming Washer Programming Maintenance and Troubleshooting Catalyst Alarms Interface Alarms A

Catalyst Manual - Softrol Support

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