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.

Utility Connections
Make all the electrical, air and water connections as explained below.

Water Connections
The Catalyst requires water > 3 GPM at a temperature no greater then 110oF or less than 80oF. (This can be either tempered water, or hot and cold with a mixing valve- valve is not supplied) The supply line should be valved 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 should be no more than 45 psi.

Air Connections
A ½” 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 DI) 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 requires 120 VAC at 5 Amps. These circuits should be dedicated for the chemical system use only.

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 ½” tubing for the small pump and ¾” 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 inlet lines to the pumps must have adequate strainers (#12 Mesh minimum). 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 easier cleaning.

Chemical Pumps
The chemical pumps should be tightened to the proper torque range before use. The proper torque is 70 in.-lbs.

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 DI, there should be multiple lines to each washer or the 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.

Check Valve Assembly for multiple DI systems or more than 2 redundant Catalyst systems.

Drain Connection
There are 2 drain connections for the Catalyst with 1/2 “ NPT connections. The back-flush outlet should be hooked up at the very minimum. Since this outlet can be pressurized, the drain line does not have to be a gravity drain. The overflow is for the flush 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.

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
Selection? 0=exit

Select 1=Setups

1=Watchdogs/Setups
2=Chemical Setups

Select 1=Watchdogs/Setups

1=Machine Setup
2=Maintenance Setup
3=Clear Ram Vocabs
4=Passwords 0=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.

·Press the [ENT] key to accept the answer.
·Press only the [ENT] key to accept the default or keep the previously programmed value.
·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.
·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.

·AutoChem Flush
This setup answered in seconds is 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. Answer No if the Catalyst will process with automatic chemicals 1 thru 8 only.
·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.
·Flow Sensors
This setup tells the Catalyst to use the flow sensor input
·Chemical Watchdog
This is the time in mm:ss the user defines is sufficient for a Catalyst to hold itself while dispensing the chemical.
·Prompt Weight
This indicates whether the operator wishes to prompt the weight of the load before the start of each manual formula. This allows the operator to use ratio metric chemical additions. This will most likely be set to NO.
·ArcNet Node
This allows the user to define if the Catalyst is in an ArcNet networking system.
·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.
·Full Baud Rate
Y/N this is used only when a RS 232 port network is active on the REMK4A card.
·Multidrop Net
Y/N this is used only when a RS 232 port network is active on the REMK4A card.
·LAN Member ID #
This is the ID of the machine. This should be set the same as the Arcfiber card and the same as the machine outlet valve that it is connected to.
·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.
·Preferred ID Lo
This setup is used to assign the lowest 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.
·Preferred Range Hi
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.

Installation: Machine Interface
Mount the Machine Interface Boxes on or near each washer. Use nuts and bolts for a machine mount, and lags and screws for a wall mount. The interface should be connected to the washer controller with 15-conductor wire. The 24 VAC transformer should be mounted in the washer control panel. 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.

Configuration: Machine Interface

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? 0=exit

Select 1=Setups

1=Watchdogs/Setups
2=Chemical Setups

Select 1=Watchdogs/Setups

1=Machine Setup
2=Maintenance Setup
3=Clear Ram Vocabs
4=Passwords 0=exit

Select 1=Machine Setup

The setups that affect the interface are:
·AutoChem Flush- (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.
·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.
·LAN ID- (1-254) This is the ID of the machine. This should correspond to the machine outlet valve to which the machine is plumbed.

Installation: ArcNet Network
·The ArcNet cable is run as a bus system with the lines from an active hub run in a daisy chain fashion or star topology.
·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.

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 in one daisy chain.