Catalyst Tunnel Manual
Contents
1. After the injection is completed the system will be flushed with water 19 Catalyst SOFTROL The LCD will display SOFTROL CATALYST mi croPul se Software amp Control for Automation CONTROL STATION 128 Catalyst Inject Waiting for Chemical System to Flush Machine B 003 1 uk 7 y E 0 CLR NO While the controller is idle and waits for an injection request the LCD alternates between the two displays below eg DI Pali N mi croPul se Softwers amp Control for Automation C O N T R O L STATION The Catalyst Injection System Softrol Systems Inc c 1988 2001 1 2 3 ENT S SINS 1 S I 4 YES 0 CLR NO 20 Catalyst CONTROL STATION Waiting for Chemical Injection Request Depress YES key to Select Formula Software amp Contro for Automation i Illu uk S I 8 YES 0 C2. Low Pressure SOFTROL Chemical Pumps Catalyst sore 5 A a YA H H H 108x88 Sa itiliiftik D 1 2 3 4 6 Se o _ o ile GA A UG 2 SLO 24V DR 24AE RED G gt lt ee mn ARCFIBER all SOLI kl B SLOT 6 o A 2 E Q 9 pp H pA 7 ES FLOWMEMA p p AAA Tei 5 5 5 Mo ia 1B ic Ha er CIE Pilze 38 3c peal 4a ap ap d i o el j mT a 29 er SLOT 5 z a2 A E CE a g gt o AAA FARAO RA AAA Wr venu 21 19 1A 1B 1C fx 2A 2B 2c x 2 34 3B 3c 4A 4B 4c n e a H Bi la HSM TI IS l e SLOT 4 ta 2 HSN 14 OT TY LIT HSNI4 60 19 Ed SN LO Ei
3. ARCRAM CARD FOR RG62 ARCNET Catalyst SOFTROL ee Typical Electrical Layout JU Li 7 a e NI ar N 7 DI Ur HSM14 ar nr fa E HSNTH Il IS a K ba a 2 HSATH OT IS Sa ood vil LJ U Ur menu 60 1 iS ko SLOT 6 IN fal aavdy HO S Ly NI Tee Ca f GE ST dWNd 0 294 fia 25 10 pes ar ec Ee ar 7 5 SLOT 5 Ly NI wl WA
4. YA 8 CA 90 psi 7 SCFM 73 Hose Barb Connection for Water on units with integrated flush tank Make the electrical and air connections as explained below 10 Air Connections A 1 line of clean dry air at 90 psi minimum is required for the system The system uses about 7 SCFM maximum 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 also requires 120 VAC at 5 Amps These circuits should be dedicated for the chemical system use only Water Connections The Catalyst requires 5 GPM water at 70 110 deg F The unit has a 1 2 hose barb connection for the water supply This is found on the Catalyst itself on units with an integrated flush tank On units with a separate flush stand this connection will be at the flush stand Catalyst SOFTROL SOFTROL CATALYST Chemical Connections The chemical feed lines should be run from the 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 1 2 tubing for the small pump and 44 tubing for the large pump It might be necessary to use reinforced t
5. SOF IROL Software amp Control for Automation SIs iep e 0a Eep o SR ir SI iep o Flush4 jo CATALYST TUNNEL Installation and Operation Manual Softrol Systems Inc 4867 N Main St Acworth GA 30101 770 974 2700 1 Catalyst SOFTROL SOFTROL CATALYST Catalyst SOFTROL SOFTROL CATALYST Table of Contents Chapter Description Page 1 Introduction to System 5 Components 6 2 System Installation Configuration 9 Utilities 10 Network 14 System Configuration 15 Interface Configuration 18 3 Getting Started 19 System 20 Interface 25 4 Calibration 27 Flowmeter Calibration 28 H Factor Calibration 29 Errors 31 Checking Calibration 32 5 Configure Pulsenet 35 6 Programming Pulsenet 39 7 Programming the Tunnel 43 8 Maintenance Troubleshooting 45 3 Catalyst SOFTROL SOFTROL CATALYST Catalyst SOFTROL SOFTROL CATALYST Chemi Chem 2 Chem 3 Chem 4 Chem 5 Flush 1 Flush 2 Flush 3 Flush 4 Chem6 Chem 7 Chem 8 Chem 9
6. om ll WAH tal N3HI 90 29 SbOT 3 CI ES e D a H H D H H A H SE A A AA A H H G II vl WAHO e Wana a CS fa U Uae LI WIH fet cb i i 3 4 5 8 15 16 bi El Wel et bbbbEbM i DE eil W3HI LIT Z 4 di dae Ei e e _ a TT WAHO la OT WIHI c0 2S DUTIS x pi ae A AAA A AA AoC FAAAAA AAR tal O WAHI A SHO Il 23 i l 873 4 5 67 CSIs io ui 12 13 14 e la 6 W4HI la 8 dWNd 80 19 ei DEIER HH EI EI EI EI ET P SLOT 1 fy NI 80 13 WI W3HO 20 18 a N3HI 20 19 8 HSNI4 21 25 LI 6 W3HI SO TS o S proci Pet g la 9 W3H3 90 19 2 HSNIH 11 29 2 WaPo 20 19 r E3 PRO K4 AND WE H3HO So 1g HSNT4 01 23 go B co E 7 ji kal f W3HO 70 19 235 WC w nz Bo gt L 14 0U1 U a O LI 2 W4HI 20 19 O i 1 O D 54
7. 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 eliminate 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 47 Invalid memory copy This occurs when the Catalyst reads a invalid formula number of a 0 formula from the interface To fix this problem enter the main menu on the Catalyst and select 1 Setup Select 3 Compartment formulas and change the 0 or invalid formula to a valid formula You will also need to change the formula on the interface Check the programming of the tunnel for errors Catalyst SOFTROL 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 Check chemical level replace if necessary 2 Press CLR 3 Press 777777 4 Press Yes to restart chemical injection If syst
8. 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 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 S7 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 card 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 in a password Enter the level
9. from the menu you can select 2 for Chemical setups This is typically configured on the computer under Edit chemical assignments See section 5 Chemical name This is the name of the chemical Chemical Units This is the units which the chemical is metered These must be given a name in the Vocab section first Sensor This tells the Catalyst which sensor the chemical is assigned to If the sensor is 0 then the chemical is not used 3 Comp Formula s This allows for manual entry of the formulas that are in the tunnel washer This typically only needs to be entered on start up The screen will display Current Formula Compartment 1 Key in Formula Enter Accept No Exit 17 Catalyst SOFTROL SOFTROL CATALYST Key in the formula number and press Enter to accept the formula number and go to the next compartment There are 20 compartments Each compartment must have a valid formula It cannot 20 Configuration Machine Interface 18 a i D Machine Power ON Catalyst wazaa Power Interuption During Formula ei Formula Timer Enabled Yes To Resume 12 3 poe Formula Timer On Hold 4 5 SET AT 7 D 9 IL 0 JI Blinking Calling for Chems fer 22 LAT Steady Receiving Chems YES The tunnel interface detects the binary code from the tunnel to determine the formula that is currently being run The interface k
10. 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 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 9 Catalyst SOFTROL SOFTROL CATALYST Utility Connections 120 VAC ELECTRICAL 5A 3 PTC AIR CONNECTION
11. more manifolds than the LT then a separate flush tank and stand is necessary 6 Catalyst SOFTROL SOFTROL CATALYST Flow Box Detail Manifold 1 Manifold 2 Manifold 3 Manifold 4 Each Manifold is dedicated to a specific module The svstem can have up to 8 individual manifolds The manifold can have up to 4 chemicals Chemical Manifold Detail Flush Valve Chemical Valve Flow Meter KK K oj lo o o o lo S CHEM 2 CHEM 3 CHEM 4 FLUSH 1 CHEMI Outlet to Calibration Outlet to Tunnel 7 Catalyst SOFTROL SOFTROL CATALYST Catalyst SOFTROL SOFTROL CATALYST 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
12. same procedure in step 17 28 Press 0 to exit to the main menu 29 Close the Calibration valve on the back of the unit Open the machine valve 30 Enable the system by holding down the ENT key and pressing YES Once you are finished with the calibration be sure to thoroughly flush the calibration port y Open Machine Valve Close Calibration Valve O O O O Os Rear View 30 Catalyst SOFTROL SOFTROL CATALYST Calibration Errors e Ocannot be entered in for a Calibration e lf No counts or low counts gt 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 31 Catalyst SOFTROL SOFTROL CATALYST 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 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 starting with formula 100 For example formula 101 checks chemical 1 If chemical 1 is Alkali formula 101 should
13. 4 different 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 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 VES button will allow pump to turn on and ignore the watchdog Release the VES button when the pump is primed See the next section for more details 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 Catalyst Call Maintenance Sensor Flush Watchdog Sensor 1 SOFTROL SOFTROL CATALYST Flush
14. Chem 10 1 Introduction The Catalyst Tunnel System The Catalyst Tunnel System is a chemical metering and injection system that delivers liquid chemicals to multiple modules of a tunnel washer The system is flexible and can be customized to serve up to eight modules with a possible sixteen chemicals The Catalyst System offers precise chemical deliveries with consistent results The system has the ability to interface with various types of controllers and production data may be gathered for a variety of tunnel washers Formula entry is simplified with a with the PulseNet PC software and all formulas are stored in the Catalyst Control Individual flowmeters for each module insure accurate chemical delivery 5 Catalyst SOFTROL SOFTROL CATALYST The major components of the Catalyst Tunnel system WA Flow Box Control Box l 8 Calibration Outlet Chemical Pumps H K Ger Flush Pumps ko a o Chem1Chem2 chem3 Chem4 Chem5 o Flush 1 Flush 2 Flush 3 Flush 4 _ Flush Tank J 0 Chem6Chem7 Chem8 Chem9 Chem 10 The Tunnel system can have up to 16 chemicals and 8 manifolds The Tunnel LT system can have a maximum of 10 chemicals and 5 manifolds If the system has
15. KO 9 dind ERR Gil WAHI S0 2S nr JET W3HO WC WHO pane IIA KA Let naho LU WHO suor 4 olf U a TT W3HO H W3HO nr Lg OT W3HO MIE ET Ee Da GI W3HO WS hd J U I 8 W3HO 80 19 Java NERE DA Le 4 wako 20 19 8 HSATA 21 24 EEEE OK A H 9 waho 90 IdIZ neu i fia 9 4 5 6 7 oH Cll n vie 1a el E aun Ss EI EE ry I S H3HO SO 19 9 HSMI4 Il 2 EE N LI e WaHO vo ISf HSn 60 29 PROCL by o WHO o E3 PRO K4 AND IN aa S ate di A A A IL la 2 W3HO 20 19 Ny A le T 10 15 Kk 8 B z q H rs 1 E LE ya A Ly NI o IT bee eee KGA L kd O Il Vl CHAT HAI HTFHFAHATHC_FFITFLFFRILIITFITHAFT_F_ITFCI_HTFFCAHAFXT_AX_A NS NE NO NI NE NE NE NIE NY ar NI NI SI SI NI NA NI NIN NA NI SENSE NES D gas sa B g J si z e s za za 4 a gt l S p a 2 i A gt AMP CIRCUIT BREAKER SWITCH SOFTROL Catalyst 53 CATALYST Card 7 Input Output SOFTROL Card Communication Flowmeter Card Sensors 1 4 Flowmeter Card Output Card Output Card Card Cage
16. LR NO C Pi SOFTROL The Main Menu SOFTROL CATALYST Software amp Control for Automation CONTROL STATION 1 Setup 2 Program 3 Maint 4 Calib 5 Totals 6 Clock Selection O Exit 1 2 JIS JIET SJ 7 WENE es TO T eval i sa 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 1 111111 Level 2 222222 Level 3 333333 Level 4 444444 only 21 Level 5 555555 Level 6 666666 Level 7 777777 Level 8 888888 freezes the timer Catalyst SOFTROL 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 a
17. 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 Chemical Injection Formula Editor IB x File Edit Tunnel Utilities Misc Help a Ar Bath Mat s Wht 0002 Add 2 Oz of Det 2 0003 Add 6 Oz of Alkali 3 0004 Add 15 Oz of Bleach 0005 Add 2 Oz of AfC 16 0006 Add 3 Oz of Soft 16 0007 Add 2 Oz of Sour 16 0008 Run Time 0 00 001 0000 00 0009 END OF FORMULA Formula 5 Bath Mats wht MANAGER 07 12 2006 15 53 Estimated Run Time 0 00 Empirical Run Time 1 24 Group 1 Milnor Tunnel Class Unassigned Yield 0 Lbs Count 0 1 620 bytes free CWT 0 00 39 Catalyst SOFTROL SOFTROL CATALYST Programming an Injection Formula At the main screen of PCIM 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 select 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
18. Timer Enabled 1 2 3 power Formula Timer On Hold 4 5 6 ENABLE 7 8 9 E Blinking Calling for Chems II a e n RI Steady Receiving Chems YEs Q ctR chem J The interface does not require much manual interference for normal operation When the tunnel transfers a binary signal is detected by the interface This signal corresponds to the goods that have entered module 1 The interface keeps the last 20 formulas in queue When a new formula is received the interface transmits the list of 20 formulas to the Catalyst Manual input is limited to manually changing the formulas The yellow power button indicates that the tunnel is powered and capable of producing If the light is off then the interface will display Tunnel Off line And the interface will have the hold output on The timer will not accrue at this time so if the tunnel is stopped for an extended time the avg transfer time will not be distorted he green enable button indicates that the tunnel is able to transfer The red hold button indicates that the tunnel is prevented from transferring 25 Catalyst SOFTROL 26 Catalyst SOFTROL CATALYST SOFTROL 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 va
19. al Assignments Tunnel Edit Chemical Assignments E Group 1 Milnor Tunnel Cost Unit Units Lb Sensor Alkali 2 Det 2 Peroxide 2 Alkali 3 Det 3 Peroxide 3 de ERIN MM SS mm Je ven EA Each Oz of gesit contains cme 7 Edit Delete BR cen H ap 37 Catalyst SOFTROL 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 38 Catalyst SOFTROL SOFTROL CATALYST 6 Programming from PulseNet The Tunnel 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
20. atalyst Tunnel System with a 1 2 NPT connection This a gravity fed drain from the flowbox area as well as overflow from the flush tank 13 Catalyst SOFTROL SOFTROL CATALYST Installation ArcNet Network CAT 5e 2pr STRANDED Cable l Interface To Arcnet Hub or Computer ba EES e The ArcNet cable is run as a bus system with the lines from the interface to the Catalyst e If there is a single tunnel in the plant then a hub will not be used e The maximum number of nodes machines interface computer or Catalyst on the line is 10 e The last node on each end of the line should have a 93 ohm terminator e 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 14 Catalyst SOFTROL 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 Au
21. ated cylinder underneath it Press CLR Manifold 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 1 Calibrate Chems Use the t and arrows to scroll through the available chemical numbers until the chemical to be calibrated is displayed on line 1 of the LCD display 8 Press the ENT key to select that chemical 9 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 11 1f the small graduated cylinder is used dispense about 200 mL If the large cylinder is used dispense 500 1000 mL 12 The Catalyst screen will display the counts from the flowmeter These should be about 18 30 counts per oz 13 Close the valve at the end of the calibration line Place the graduated cylinder on a level surface and accurately read the amount of chemical in the graduated cylinder w SE The small cylinder has graduations in 2 ml increments To convert ml to Oz divide by 29 57 Be sure to measure ci the chemical only and not foam This will result in more ai accurate injections Example 226 ml 29 57 7 6 Oz 28 Catalyst SOFTROL SOFTROL CATALYST 14 Press ENT to accept the counts The controller will display a suggested amount based on the previous calibration Press CLR an
22. 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 1 004 Run Time 0 00 005 END FORMULA To run the check formula do the following 1 Atthe Waiting for Chemical Injection screen on the Injection Controller disable the system by pressing No 8 ENT This will prevent the system from receiving chemical requests from machines Open the calibration port and place the graduated cylinder underneath it Press YES and then enter in the formula number Press ENT to begin The controller will then ask you to key in the desired amount Then press YES to begin the dispensing of the chemical The controller will display the desired amount as well as the received amount The received amount should be counting up to the desired amount Once the injection is complete measure the amount of chemical that has been dispensed 8 To determine the amount of error subtract the measured amount received from the amount desired Divide this number by the amount desired and then multiply by 100 This will give you the percentage error o ob WD N Example Desired 64 Oz Received 62 Oz 64 62 2 2 64 03125 03125 X 100 3 125 error 32 Catalyst SOFTROL SOFTROL CATALYST If any calibrations are outside the desired tolerance normally 1 5 recalibrate the chemical Taking a painstaking approach to the
23. 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 described in the calibration section and press ENT amp YES to enable the Catalyst to resume pumping 33 Catalyst SOFTROL ML to Oz Conversion T able 690 23 3 900 30 4 960 325 SOFTROL CATALYST Catalyst SOFTROL 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 set up 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 Plant Name Address 1490 Bay Street City State Zip St Thomas USVI 0000 Plano 1 H Da e Configure Ports This should already be done if the computer was received from Softrol If not this will need to be completed per the PulseNet manual e Configure Groups There will be a group for each tunnel Ca
24. d enter in the new amount Enter the amount to the tenths place Example 8 Oz 8 0 15 Press ENT The Catalyst will display Save Calibration As 1 Initial 2 H Factor 3 Update 4 V Factor 0 Discard and Exit 16 Select 1 to store the calibration as the initial calibration This is very important if it is not done the calibration will be lost 17 The controller will then return to the calibration menu 18 Press and hold CLR amp Manifold to flush the manifold for 5 seconds H Factor Calibrations This is used for greater accuracv for small dispense amounts lt 6 Oz If you do wish to do a H Factor calibration skip to step 27 19 Select 1 for calibrate chemicals 20 Select the same chemical as previously calibrated 21 Select 1 for Flow sensor calibration 22 Place the 250 ml graduated cylinder under the calibration port 23 Press and hold YES to dispense 200 220 mil it will contain mostly water 230 The small graduated cylinder is marked in 2 ml graduations Accurately read the amount and divide by 29 57 to convert to Oz Example 226 ml 29 57 7 6 Oz 24 Press ENT to accept the counts 29 Catalyst SOFTROL SOFTROL CATALYST 25 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 26 Select 2 H Factor 27 Flush the system by the
25. d 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 for 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 42 Catalyst SOFTROL SOFTROL CATALYST 7 Programming the Tunnel The tunnel is programmed to give a binary code when the goods first enter the tunnel The programming will depend on the wiring but the configuration below is the most typical Chem Binary Signal 1 1 CONDO WP CA N Latch Tunnel Transfer The binary code chems 1 7 should be programmed for 10 seconds and the latch chem 8 should be programmed for 5 seconds All the signals should be configured to start at the same time Once the latch turns off the interface will read the binary formula The interface will then send the 20 formulas in the Tunnel to the Catalyst for the injection 43 Catalyst SOFTROL 44 Catalyst SOFTROL CATALYST SOFTROL SOFTROL CATALYST 8 Maintenance Troubleshooting The Catalyst Chemical system will require periodic maintenance Doing a few simple p
26. eeps a queue of 20 formulas and transmits them to the tunnel Catalyst when the tunnel transfers The interface will prevent the tunnel from transferring until the chemicals have been received At start up the interface needs to have the current tunnel formulas entered into the memory To do this Press 777777 This will take the interface to the entry screen and will place the tunnel on hold Use the UP arrow to scroll to the compartment to be edited Press ENT to edit the formula Once the formula is changed to the desired number press ENT to save There cannot be any formula zeros in the interface This will cause the system to alarm If this happens enter in the password 77777 and change the zero formula Catalyst SOFTROL SOFTROL CATALYST O will exit and return the interface to operation During setup all 20 compartments of the interface will need to have valid formulas 3 Getting Started 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 ey EE WE TE mi croPul se Softwers 4 Control for Automation CONTROL STATION 128 Chemical Injection Alkali 064 018 Machine B 002 T 0 12 Step 0 00 Ee OIE 1 7 JIJILS IO JIL VES 0 CLR No
27. em alarms again Flush system by pressing the manifold amp CLR then enter in 777777 and retry the injection If the system continues to alarm check the flowmeter gears If the gears are not turning when the manifold is flushed then they are possibly blocked See the next section to disassemble the flow meter 48 Catalyst SOFTROL SOFTROL CATALYST Flowmeter Disassembly Remove all 8 bolts FLUSH 1 CHEM 1 CHEM 2 CHEM 3 CHEM 4 Close both valves before removing cover 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 MANIFOLD amp CLR for 20 seconds to flush the manifold with water e Place several rags or towels under the meter The manifold will be full of water e Close both the calibration valve and the machine valve located on the back of the system for the manifold 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 front of the flowmeter The gears should turn freely when in place e R
28. eplace the O ring with a new one Replace the cover Tighten the bolts ina staggered manner The bolts should only be finger tight 10 12 in Ibs e Attach the cable Release the Emergency Stop Button e Restart the system and check flowmeter to make sure it is functioning properly The O ring should be checked whenever the cover is removed 49 Catalyst SOFTROL SOFTROL CATALYST ArcNet Communications i A E E E S amp a ER 2 HUB b LA il PWR fi PWR i i Aa z O TIMING EA e gt KO el mm Ma Ma mp DR ST 7 Sa G 1 1 e p A l EP EW KA wi 2 S it el CS jif All of the communications involved with the Catalyst are 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 Catalvst 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 t
29. g ID of the tunnel interface washer interface to be serviced Typically 201 204 e Sensor 1 Setups Sensor Assignment This is the module number that the manifold is plumbed to Flush Between Chemicals This is the amount of time the Catalyst will flush between chemicals Flush After Chemicals This is the amount of time that the Catalyst will flush the manifold after of the chemicals on this manifold have been injected 16 Catalyst SOFTROL SOFTROL CATALYST e Sensor 2 Setups Sensor Assignment This is the module number that the manifold is plumbed to Flush Between Chemicals This is the amount of time the Catalyst will flush between chemicals Flush After Chemicals This is the amount of time that the Catalyst will flush the manifold after of the chemicals on this manifold have been injected e Sensor 3 Setups Sensor Assignment This is the module number that the manifold is plumbed to f this is set to 0 then the sensor is not used and the following questions will not appear Flush Between Chemicals This is the amount of time the Catalyst will flush between chemicals Flush After Chemicals This is the amount of time that the Catalyst will flush the manifold after of the chemicals on this manifold have been injected The setups repeat until sensor 8 If the sensor assignment is 0 then the sensor is unused and remaining questions for that sensor will not appear 2 Chemical setups After selecting Watchdogs Setups
30. hemical Output Valves Priming the System At the Injection Controller screen Waiting for Chemical Injection Request Enter the Level 7 password factory default 777777 Press the 3 key for Maintenance at the Main Menu Select 1 for manual outputs Open the calibration port in back of the machine Close the machine port on the back of the machine Press the 1 key for Chemicals e Use the arrows to scroll to the chemical to be checked e 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 e Use the Stroke Limiting adjustment nut to adjust the flow through the valve Low flow 5 to 1 gpm High flow 1 3 gpm e Press the CLR Manifold keys to flush the system between each chemical injection e Repeat this procedure for each chemical Press the 0 key to exit 23 Catalyst SOFTROL SOFTROL CATALYST Key Strokes for the Tunnel Catalyst CLR ENT 1 CLR 2 CLR 3 CLR 4 CLR 5 CLR 6 CLR 7 CLR 8 CLR NO ENT YES ENT 24 Flush all Manifolds Flush Manifold 1 Flush Manifold 2 Flush Manifold 3 Flush Manifold 4 Flush Manifold 5 Flush Manifold 6 Flush Manifold 7 Flush Manifold 8 Disable the Catalyst Enable the Catalyst Catalyst SOFTROL SOFTROL CATALYST Interface Operation xi Catalyst sma Machine Power ON Power Interuption During Formula Execution Press Yes To Resume Formula
31. his 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 Configure Supply Inventory Data Num SupplyName i Cost Unit PI Bleach 1 1600 Antichlor Gal 6 0500 Sour Gal 8 2300 Alkali Gal 4 8000 Detergent Gal 9 9500 Chemical Supply 6 Unit Chemical Su 7 Unit Chemical Supply 8 Unit Chemical Supply 9 Unit v consona EA Z 1 2 3 4 5 6 7 8 9 36 Catalyst SOFTROL SOFTROL CATALYST 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 e 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 e Edit Chemical Assignments This setup is very important for proper operation of the system In this screen the name of the chemical is created as well as the units it is measured in the sensor it is assigned to 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 Edit Chemic
32. ith 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 line is reached Things that can cause network trouble e 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 e 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 e Un terminated Line This will cause the network to reset This can be a card at the e
33. lt Enter gt 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 lt Insert gt 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 the correct instruction list the controller type should be set to Catalyst Plus Tunnel podium on the configure groups menu Instruction List Add Chemical by Unit Blank Line Wait to Satisfy The most common instruction used on the Tunnel Catalyst is the Add Chemical by Unit To create a formula simply insert this instruction select the appropriate chemical and enter in the desired amount Do this for all the chemicals that the goods should receive throughout the tunnel The last instruction should always be RUN 0 00 40 Catalyst SOFTROL Example formula SOFTROL CATALYST 0011 41 0007 0008 0009 0010 EHD OF 0001 Hand Tow 0002 0003 0004 0005 Add Add Add Add Add Add Add Run KWER 2 Oz 6 Oz 3 Oz 2 Oz 3 Oz 2 Oz Chemical Injection Formula Editor s Wht of Alkali 2 of Det 2 of Alkali 3 of Det 3 of Bleach of A C 16 of Soft 16 of Sour 16 Time 0 00 FORMULA 001 0000 00 Catalyst SOFTROL SOFTROL CATALYST Programming the Injection Controller Only calibration test formulas should be programme
34. nd 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 e 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 e Cables run too close to power wires If you must cross a power line the cable should be run perpendicular to the line e Poorly grounded controllers and machines e Cables run too close to Variable Speed Drives 51 Catalyst SOFTROL SOFTROL CATALYST RG62 CONNECTION ARCRAM 1995 Systems Inc Softrol ABBA L _ IF CARD IS END OF LINE D JPL PUT JUMPER ON JPI OR gt g USE BNC T WITH TERMINATOR db JP2 D IS END OF LINE ee UMPER ON CX T OR USE BNC T WITH TERMINATOR at ES wa Sa 25 Cc NA AD SA NA SA da Sa BB ce ELI DPTARC e SS SDFTROL SYSTEMS INC A GND C
35. nswer to a previous question press the ENT key to accept the current values to the remaining questions then restart the procedure 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 MicroPulse 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 e AutoChem Flush This setup answered in seconds is the minimum amount of time the Catalyst will flush the system with water after each chemical injection Typically 15 Sec e Chems 9 12 Auto If answered YES the Catalyst will turn on the chemical outputs for chemicals 9 through 12 Answer No if the Catalyst will process with automatic chemicals 1 thru 8 only e Chems 13 16 Auto If answered YES the Catalyst will turn on the chemical outputs for chemicals 13 through 16 Answer No if the Catalyst will process with automatic chemicals 1 thru 12 only e Flow Sensors This setup tells the Catalyst to use the flow sensor input Typically YES e Chemical Watchdog This is the time in mm ss for the maximum chemical injection Typically 45 Sec e 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 Typically 5 00 e ID of Tunnel Washer This setup informs the Catalyst the ArcNet networkin
36. ransmitted 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 If it is a single Catalyst the hub card will 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 Usuallv twisted pair For more information on the lavout of the network please see section 2 10 of Installation and Configuration Troubleshooting the network The active hub Pictured above is the central piece of equipment that brings the all of the branches of the network together In normal operation the vellow 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 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 50 Catalyst SOFTROL SOFTROL CATALYST 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 w
37. rocedures 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 1 Week e Re torque all chemical pumps e Carefully inspect all connections for signs of chemical or water leaks If any leaks are found fix them immediately e 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 Use 7 16 nut driver Torque from 1 h we vii bolt head This is on the side of the Tighten ALL bolts air inlet Tighten all 6 bolts and nuts 45 Catalyst SOFTROL alarms while running They are SOFTROL ATALYST N Catalyst Alarms f 8 SOFTROL mi croPul se Softwere 4 Control for Aut tion CONTROL STATION Call Maintenance Chemical Watchdog Chemical 12 1 3 ENT AGC 8 ES 0 NO The Catalyst can have
38. rying specific gravity and viscosity The flow properties 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 777 Close Machine Valve y Open Calibration Valve Rear View 27 Catalyst SOFTROL SOFTROL CATALYST Flow Meter Based Calibration To calibrate chemicals using the flow meter please do the following Note For most tunnel injections lt 8 oz use the small 250mL graduated cylinder for calibration 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 valve on the back of the Flowbox Open the valve at the end of the calibration line and place the gradu
39. t 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 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 Press the NO key to exit 22 Catalyst SOFTROL SOFTROL CATALYST 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 e Press the NO amp ENT keys at the simultaneously to DISABLE the system e 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 C
40. talyst The controller must be selected as Catalyst Plus Tunnel Podium Configure Groups Cmc Members 1 Milnor Tunnel Rane 1 ren Add Delete PS a Formulas ho 1 128 C 512 T Off line Controller Type WARNING Delete groups will cause American Pioneer Platinum Plus Dryer PPD_ENG machine omissions in summarizing pre American Pioneer Platinum Plus Washer PPW_ENG Belt BLT_ENG S Catalyst Plus Podium CPP_ENG Edit Slave shuttles Catalyst Plus Podium Espanol CPP_ESP Catalyst Plus Podium Francais CPP_FRA Catalyst Plus Tunnel Podium CPT_ENG Catalyst Plus Tunnel Podium Espa ol CPT ESP es ti 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 35 Catalyst SOFTROL SOFTROL CATALYST 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 lf the units of measurement on the Catalyst are Oz Configure Supply Inventory Data 1 Bleach 2 Antichlor 3 Sour Gal 4 Alkali Gal 5 Detergent Gal 6 Chemical Supply 6 Unit 7 Chemical Su 7 Unit 8 Chemical Supply 8 7Unit7 9 Chemical Supply 9 Unit v unt comm EA H e Configure Plant Utility Data This is generally not used in a Catalyst only plant Please refer to the PulseNet Manual if t
41. toChem 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 i i 3 Maint 4 Calib e N 5 Totals 6 Clock E a Selection O exit SATR STATION 1 Setup e Program 3 Maint 4 Calib S Totals 6 Clock Select 1 Setups Slection 0 Exit 1 Watchdogs Setups ENGINE 2 Chemical Setups I 3 Comp Formula s Select 1 Watchdogs Setups 1 Machine Setup Ke j 2 Maintenance Setup OH A 3 Clear Ram Vocabs 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 15 Catalyst SOFTROL SOFTROL CATALYST 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 a
42. ubing on some of the inlets if chemical is being drawn a long distance and or uphill The inlet lines to the pumps must have fi adequate strainers 12 Mesh minimum lin 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 oN easier cleaning Z 3 4 Y Strainer 12 Mesh Im 1 3 4 Drum Wand 11 Catalyst SOFTROL SOFTROL CATALYST Chemical Pumps The chemical pumps should be tightened to the proper torque range before use The proper torque is 70 in Ibs Tighten all 6 bolts from front 12 Catalyst SOFTROL SOFTROL CATALYST Machine Connections The Catalyst Tunnel System has 1 2 hose barb for the machine delivery lines A minimum of 5 of tubing should be used even if the machine lines are hard piped The distance to the tunnel should be kept to a minimum lt 200 This will require less water to flush the chemical Also the vertical run should be less than 20 3 Machine connection e Drain Connection There is one drain connection for the C
Download Pdf Manuals
Related Search