Table of Contents
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USER GUIDE
NovaWheel
Dry-Convey Dryers
MODELS:
NWB- DC+ Series, With NovaTouch™
7" Color Touch Panel PLC
>
MODELS NWB-25-DC+ through
NWB-300-DC+
NWB-DC Series, With NovaTouch™
4" Color Touch Panel PLC
>
MODELS NWB-25-DC through
NWB-200-DC
NWB-DC & DC+ UG 18 JULY 2019
©2019 NOVATEC, Inc. All Rights Reserved
Portable
™
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Table of Contents
Troubleshooting
Related Manuals for NovaTec NovaWheel NWB- DC+ Series
Summary of Contents for NovaTec NovaWheel NWB- DC+ Series
- Page 1 NWB- DC+ Series, With NovaTouch™ 7” Color Touch Panel PLC > MODELS NWB-25-DC+ through NWB-300-DC+ NWB-DC Series, With NovaTouch™ 4” Color Touch Panel PLC > MODELS NWB-25-DC through NWB-200-DC NWB-DC & DC+ UG 18 JULY 2019 ©2019 NOVATEC, Inc. All Rights Reserved...
- Page 2 Serial Number(s): Model Numbers: NOTES DISCLAIMER: NOVATEC, Inc., shall not be liable for errors in this instruction manual. Information can change without notice. Novatec makes no warranty of any kind concerning the information contained herein, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.
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Page 3: Table Of Contents
3.0 UNPACKING for NovaWheel™ NWB-DC & DC+ DRY/CONVEY MODELS 3.1 Unpacking 3.1.1 Tools You Will Need for Unpacking: 3.1.2 Unpacking Instructions: 3.1.3 List of UNPACKED CONTENTS: 4.0 BASIC COMPONENTS OF NOVATEC NWB-DC DRYER ASSEMBLY 4.1 Differences in Layout for -300 model 5.0 ASSEMBLY INSTRUCTIONS 5.1 Prepare/Assemble Machine Mount Receiver 5.2 Mount Hopper Receiver & Connect Flex Hose and Pickup Wand 5.3 Positioning the NWB-DC... - Page 4 13.1 Process Temperature Control (Drying Temperature) 13.2 Regeneration Temperature Control 13.3 Process & Regeneration Air Filter Pressure Switches (PS) 13.4 Process Air Dew Point Monitor 13.5 Intelligent Regeneration 13.6 Conveying Control 14.0 PRE-OPERATING SYSTEM CHECK 14.1 Starting The Dryer 14.2 Checking Electrical Phase 14.3 Changing From F° to C° 15.0 NovaTouch™ CONTROL 15.1 System Conventions: 15.2 Screen Map 16.0 INITIAL DRYER STARTUP 16.1 Dryer Pre-Check 16.2 Explanation of Password Levels 16.3 WELCOME Screen Pressing METRIC will change °F to °C. 16.4 Verify/Set Time & Date 16.5 Auto Start/Stop (Level 2) 16.6 Maintenance Schedule (setup) 16.7 Installation Checklist (setup) 17.0 SETTINGS SCREEN (Any level can view) 17.1 Dryer Alarm Settings (level 2) 17.2 Users Management 17.3 Advanced Options (level 2 & up)
- Page 5 18.0 DRYING MATERIAL 18.1 Quick Op Screen 18.2 Hopper Loader Setup 18.3 Machine Loader Setup 18.4 Resin Menu 18.5 Dryer Status Screen 18.6 Message Screen – Alarms 19.0 INSTRUCTIONAL TROUBLESHOOTING SCREENS 20.0 MAINTENANCE INSTRUCTIONS 20.1 Suggested Maintenance Schedule* 20.2 Filters 20.3 Process and Regeneration Filters 20.4 Conveying Air Filter 20.5 Draining Plasticizer 20.6 Chain and Sprockets 20.7 Desiccant Rotor 20.8 Motor Rotation Signal 20.9 Rotor Replacement 20.10 Seal Replacement 20.11 Drive Motor Replacement 21.0 TROUBLE SHOOTING and ERROR MESSAGES 22.0 WARRANTY FOREWORD This manual is dedicated to the principle that any engineered system will have many elements contributing to the smooth operation of the system, and that these must be understood in order that installation and operation can proceed successfully. The electrical and mechanical components in the NWB-DC Series dryers have been manufactured, selected and assembled with care to give you excellent service. A wide range of NWB-DC series dryers have been introduced to enable our valued customers to select the right model for their application. These NWB- DC (NovaWheel™ Dry/Convey) series dryers have been designed for beside-the-...
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Page 6: Sales And Service
Sales: 1-800-BEST-DRY ●1-800-237-8379 NOTE: The Hopper Receiver should be set on the floor Fax: 410-789-4638 ● Sales@novatec.com with the bottom inside the round fiber tube (supplied) so the bottom flapper is protected by the tube. Technical Service Department: 1-800-938-6682 Service@novatec.com 3.1.3 List of UNPACKED CONTENTS: 2.0 SHIPPING AND INSPECTION • Dryer/Hopper Assembly Although NOVATEC uses reputed carriers to deliver • Machine Mount Receiver (with sight glass) products, it has no control over the products once it • Hopper Receiver on Fiber Tube (with flapper valve leaves the manufacturing facility. Upon receiving the underneath) products, thoroughly inspect all equipment inside and out • 5’ Long Pickup Wand for damage that may have occurred during shipment. If any damage is found, a claim should be filed immediately • Photo Eye Level Sensor with your carrier. -
Page 7: Basic Components Of Novatec Nwb-Dc Dryer Assembly
4.0 BASIC COMPONENTS OF NOVATEC NWB-DC DRYER ASSEMBLY... -
Page 8: Differences In Layout For -300 Model
5.1 Prepare/Assemble Machine Mount Receiver 4.1 Differences in Layout for -300 model NOTE: As you proceed with assembly, make sure that all bolts and hose clamps are securely fastened to ensure that there are no air or material leaks in the system. Do not use excessive flex hose but avoid sharp turns as this will hurt the efficiency of the system operation. 5.2 Mount Hopper Receiver & Connect Flex Hose and Pickup Wand 2-A: Remove cover plate from top of Material Hopper (save bolts and washers) then, after removing mask- ing tape from flapper, place Hopper Receiver in hole. Align inlet stub to face direction from where material will be pulled. Fasten the Receiver to the Hopper using the saved ¼” x 20 bolts and washers. 2-B: Place hose clamp over one end of flex hose and push end of the hose on to the material inlet stub on the side of the receiver. Fasten hose clamp securely. 2-C: Cut the flex hose to a length that will allow the 5’... -
Page 9: Positioning The Nwb-Dc
Hopper Receivers with Blowback are supplied with a 3-A Bolt the Machine Mount Receiver to the process male/female twist lock plug to which 115/1/50-60 VAC machine throat with user-supplied bolts. should be wired. A clean source of 80-120 psi com- 3-B Push one end of the flex hose all the way onto the pressed air should be connected to the supplied FNPT material inlet stub on the side of the receiver and fitting. (3/8” on the VR-5 and ¼” on the VR-12) fasten it securely with a hose clamp (supplied). 5.3 Positioning the NWB-DC 3-C String flex hose to the vacuum purge take-off (at- Roll the NWB-DC into position next to the process ma- tached to the bottom of the hopper) cut it to length chine it will be serving. and fasten securely with a hose clamp. NOTE: LOCATION 3-D Attach one end of flex hose to the vacuum inlet stub Position your NWB-DC Series dryer in a location where on top of the Machine Mount receiver and fasten it material and vacuum hoses will not be disturbed. Allow securely with a hose clamp. String the flex hose to sufficient distance (at least 2 feet) from the surround-... -
Page 10: Electrical Connections
6.0 ELECTRICAL CONNECTIONS Full size electrical drawings are included with this Instruction package for the voltage of the dryer you The NWB-DC+ Series dryers come from the factory ordered with all control circuits wired and a 10’ power cord. NOTE: 3 Phase detection is included on this model. If A quick-connect plug should be installed if moving the connection is not correct, a pop-up alarm will appear the NWB-DC+ to other process machines is antici- on the touch screen upon startup. -
Page 11: Pre-Cooler Water Connections
7.0 PRE-COOLER WATER CONNECTIONS 9.0 HOPPER EXTENSIONS A Cooling Coil is installed in NWB-DC+ series dryers and If you ordered a hopper extension, it will be a bolt-on is required to lower the hopper return temperature and type. The extension will be installed at the factory if the this increases the efficiency of dryer IF THE DRYING overall height of the unit fits into a standard height truck TEMPERATURE IS ABOVE 225°F . for shipping. If the unit is too tall for the extension to be factory-mounted, it will be shipped in a separate contain- Tower, city or chilled water is required at between 40 to er and must be installed at the processor’s plant. 85°F. Connect the cooling water supply and return using flexible hose that is at least 2 feet long, to allow for easy removal of the cooling coil for cleaning. The water flow rates and the required customer connection sizes for different models are shown in the chart below. 10.0 ADJUSTABLE DIFFUSER CONE POSITIONING IMPORTANT FOR PROPER DRYING Models NWB-XX-DC -100 -150 -200 -300 We have found that processors can improve the efficien- NWB-XX-DC+... -
Page 12: Principle Of Operation
11.0 PRINCIPLE OF OPERATION 11.2 Resin Conveying A regenerative blower pulls resin from a bulk container The NWB-DC+ Series is designed to convey moisture through a pickup wand and flexible hose to an appro- laden resin from a source container, dry it, and deliver it priately-sized vacuum receiver where the material is fed to the throat of a process machine. into the drying hopper, as needed. As the material passes 11.1 Resin Drying through the drying hopper it is metered through a vac- The NWB-DC and DC+ NovaWheel Series dryers was uum takeoff valve to a machine mount vacuum receiver engineered and designed to effectively remove moisture mounted on the process machine, thereby maintaining a (in the vapor state) from hygroscopic plastic resins. This constant flow of dry material to the feed throat. process is accomplished by the continuously rotating 11.3 System Flow Diagram desiccant wheel and the three air streams (Process, Purge and Regeneration). The Process return air is exposed to an adsorbing media (desiccant wheel) in a sealed air stream, where the desiccant adsorbs the moisture from process air. After the desiccant has adsorbed the mois- ture, it is exposed to a Regeneration air stream which has been pre-heated to a temperature of about 380°F. (190°C). This causes the moisture to be driven out from the desiccant and prepares it for more moisture adsorp- tion. Now the desiccant media passes through third air stream called purge air stream. Here the desiccant media is cooled down by some of the process air before en- tering back into the process to provide for better per- formance. The three air streams (process, regeneration... -
Page 13: Function Controls
380°F. (190°C) and should not be changed. WARNING: Always use the Green/Red switch to START or STOP the dryer. The Power Disconnect switch should 13.3 Process & Regeneration Air Filter Pressure only be used in True Emergency conditions. Repeated Switches (PS) use of Power Disconnect can cause dryer component The air pressure differential across the process filter and failure. the regeneration filter is monitored and the NovaTouch 14.2 Checking Electrical Phase display will alarm and show when a filter needs to be cleaned or replaced. These are factory set but often need Your NOVATEC NWB-DC+ Dryer includes Phase De- to be adjusted in the field once the customer loads resin tection. This is particularly important for dryers that may in the hopper. be moved around the plant. When you turn the MAIN Disconnect switch to the ON position, a Pop-Up Alarm will appear on the screen if the connection is not correct. Process Filter Pressure Switch You should immediately correct this condition. Regen Filter Pressure Switch WARNING: Any wiring procedure should only be done by a qualified electrician familiar with three phase electrical wiring. -
Page 14: Novatouch™ Control
15.0 NovaTouch™ CONTROL current value. You can now edit the characters of the current value or add characters. 15.1 System Conventions: Use the key to delete the character to the left of the All information and data displays will appear two dimen- cursor. sional in configuration and flat. All data entry points or Use the key to change the sign of the value. operational features will appear three dimensional in configuration and raised or depressed in appearance depending on their operational position. Select to view the info text of the IO field. Numerical Entries: When you touch an IO field on Select to confirm your entries or cancel them with the HMI device touch screen that requires only a numerical entry (Password, Temperature, number of seconds etc.) the following keyboard will appear. Both actions close the screen keyboard. Alpha/Numeric Entries: When you are prompted to enter alphabetical and numerical data (Resin Names/ Numbers) this screen will appear: Proceed as follows: 1. Touch the relevant IO field on the screen. -
Page 15: Screen Map
15.2 Screen Map For all processor operations. -
Page 16: Initial Dryer Startup
16.0 INITIAL DRYER STARTUP 16.3 WELCOME Screen (setup username and password 4444 required for initial setup) 16.1 Dryer Pre-Check Pressing METRIC will change °F to °C. NOTE: Assure voltage, connection and phasing are cor- rect, cooling water is supplied (for drying over 225°F) and thermocouple is inserted in hopper. Connect material source to Hopper Loader Turn Main Disconnect Switch to “ON” position. On first start you should enter Information requested on WELCOME screen. NOTE: Username setup and password 4444 is required for initial setup. If the proper level of password protec- tion has not been entered prior to attempting changes, the alpha/numeric password entry keypad will appear, prompting the user to input the proper password before changes can be made. Setup username and password will not be required after Press the Forward Arrow to TIME and DATE initial setup except to change other usernames and 16.4 Verify/Set Time &... -
Page 17: Auto Start/Stop (Level 2)
16.6 Maintenance Schedule (setup) 16.5 Auto Start/Stop (Level 2) Press to page forward to set up maintenance Press and the AUTO START screen will appear. schedule. Choose days and enter times on numeric entry screen that will appear. Press after each entry and enter AUTO STOP days and times. Entries are optional. If you do not want to set Auto Start/Stop, simply press IGNORE. Choose the material condition that will be run and then the appropriate maintenance schedule for each task. NOTE: Performing maintenance on regular intervals will enhance dryer performance and life and minimize down- time. 16.7 Installation Checklist (setup) It is important that each of these things are checked before starting the dryer Pressing the FORWARD button one more time will open the Settings screen (next page). -
Page 18: Settings Screen (Any Level Can View)
17.0 SETTINGS SCREEN (Any level can view) This screen allows changes to be made to previous screens and also allows adjustments to be made to… Alarm Setpoints User Passwords Advanced Op ons Screen Se ngs NOTE: You will go directly to Quick Op screen (page 25) on all future starts. NOTE: From here on, these icons will appear at the bo‚om of every screen. -
Page 19: Advanced Options (Level 2 & Up)
17.3 Advanced Options (level 2 & up) OverDry Protection is Standard on DC+ models and can be activated for moisture sensitive resins like nylon. Water Saver can be activated when an external Cooling oil is employed. Moisture Manager is an option that must be ordered in advance. Alarm Settings are pre-set at NOVATEC but Level3 personnel can adjust the settings. No security to view these pages but Level 2 and up required to make changes 17.4 Touch Screen Settings You can calibrate “Touch”, Brightness and turn Sound ON or OFF. If the screen is dirty, a button allows you to clean it without disturbing the settings. Press to access Quick Op Screen . -
Page 20: Drying Material
18.0 DRYING MATERIAL Fill Time - the overall time, in seconds, 18.1 Quick Op Screen that material enters the convey air NOTE: Assure voltage, connection and phasing are correct, cooling water is supplied (for drying over 225°F) stream. It is the time the station T vacuum valve, and if equipped, the material purge valve, are open, allowing and thermocouple is inserted in hopper. Connect material material flow. This setting is relative to the size of the source to Hopper Receiver. Turn Main Disconnect Switch receiver and the flow characteristics of the material. to “ON” position. Default time is 10 seconds. Note that on receivers equipped with a proportioning valve this is the overall virgin and regrind loading time. Purge Time – (if equipped) is the time in seconds that the station T valve remains open while the material purge valve is closed to material flow. It allows for the purging of material from the conveying line after the Load Time has expired. This time is relative to the distance from the material purge valve to the receiver and how smoothly the material flows. Default time is 10 sec. Dump Time - this is the time that the material takes to fall from the receiver Process Temperature is factory set at 160°F. into the drying hopper, bin or machine after loading is Press temperature button to change temperature or completed. This time is determined by how smoothly or... -
Page 21: Machine Loader Setup
18.5 Dryer Status Screen 18.3 Machine Loader Setup This screen is widely used by processors Press each function and enter value on numeric screen. Press after each entry. Access by pressing the dryer image on the Quick Op screen or on ANY screen. Press to access Quick Op Screen . All of the dryer parameters can be monitored. Press on Machine Loader 1 screen and again on • Reactivation inlet and outlet temperature Hopper Loader 1 screen to return to Quick Ops screen. • Process inlet and outlet temperature • System dew point • Calculated desiccant wheel RPH The graphics on this screen will change appearance in accordance with the mode of operation. 18.6 Message Screen – Alarms 18.4 Resin Menu Access by pressing on QUICK OP screen. -
Page 22: Instructional Troubleshooting Screens
19.0 INSTRUCTIONAL TROUBLESHOOTING SCREENS Examples are shown below. 20.0 ADDITIONAL TROUBLESHOOTING PROCEDURES 20.1 Material Is Not Being Conveyed If you need more information about a particular alarm, • If pulling material from a Gaylord, make sure the plastic press and a more detailed explanation of the alarm bag is not being pulled into the material lance. will appear, if available. Some even have photos with • Make sure the Vacuum receivers are not being over- instructions on how correct the issue. filled, causing the unit to dead-head. Press to see those screens • Adjust the overload setting on the 3MS motor starter for the conveying blower. Press to view possible solutions to resolve an alarm. Phoenix motor-starter configuration instructions The configuration sequence is as follows: 1. Stop the motor involved, you cannot adjust the set- point while the motor starter is active. 2. Press the reset button for more than 2 seconds (but less than 6) to show the current set- point. - Page 23 0.145 0.41 0.18 0.56 0.215 0.71 0.25 0.87 0.285 1.02 0.32 1.17 Press on any screen to access dryer status screen. 0.355 1.33 Call Novatec customer service and advise them of the 0.39 1.48 temperatures shown on the screen. 0.425 1.63 0.46 1.79 0.495 1.94 0.53 2.09 0.565 2.25 2.40 20.2 HTL Error Is Showing and Won’t Clear • High temp limit switch has tripped and has to be man- ually reset.
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Page 24: Maintenance Instructions
Plasticizer Drain Drain plasticizer into pan Every 2 weeks Clean with compressed air Receiver Filters Every 2 weeks or replace if necessary Compare process temperature setting to hopper inlet temperature Process Heater to make sure they are comparable. Every 2 weeks If they are not - Contact NOVATEC Service Department. Check for leaks or holes. Hose. Tubing & Clamps Every 2 months Tighten or replace as necessary. Check for leaks Hopper Gaskets & Seals Every 2 months Repair or replace as necessary. Locate wire mesh at hopper return air Pellet Screen Every 2 months outlet and clean with compressed air. -
Page 25: Filters
21.2 Filters 21.6 Chain and Sprockets The filters shipped with the dryer are cleanable. The maintenance interval for the filters depends on the clean- Chain liness of the surroundings and the dust/fines in plastic raw materials. A program should be established to ensure Tension the filters are cleaned. Assembly 21.3 Process and Regeneration Filters Chain and sprockets TURN THE MAIN DISCONNECT SWITCH OFF. Should be lubricated every 6 months. On All Models: Drive Turn the yellow knob, lift the filter access cover, remove Drive Sprocket Motor the lock nut and pull cartridge filter out from housing. -
Page 26: Motor Rotation Signal
1. Remove rotor from the cassette as explained in 20.10. 21.9 Motor Rotation Signal Check that the wheel rotor is rotating properly and each 2. Remove the old seal using knife. Also remove silicon time a signal goes to the controller, ensure that rotor sealant. complete its cycle and the limit switch hump has reset 3. Clean the plate surface. the limit switch provided near the rotor. If the hump is not resetting the limit switch, reset the limit switch 4. Apply fresh silicon sealant. toward the rotor. 5. Gently press the seal towards the plate, make sure the seal’s section does not get offset 21.10 Desiccant Rotor Replacement 6. After joining the seal to the plate, let it dry for 24 hrs. Desiccant rotor removal is accomplished as follows: 1. Remove the hex nuts on the Top Plate Assembly. 2. Remove the washers & spring from the Tie Rod. 3. Slide the Top Plate Assembly straight & upward gently. 4. Loosen the Supporting Tie Rod from where rotor is to be moved. 5. Remove the driven sprocket. 6. Slide the Rotor straight & upward, make sure that rotor does not get damaged. 7. Replace the desiccant rotor. Removing desiccant rotor To re-install rotor, reverse the above procedure. -
Page 27: Trouble Shooting And Error Messages
21.0 TROUBLE SHOOTING and ERROR MESSAGES Trouble Probable Reason Corrective Action 1. Unit not running Control main circuit breaker tripped. Reset the breaker. Main power off. Check line and main. Control power interrupted. Check per item as per electrical wiring diagram. 2. Material in hopper melts. Process temperature controller set too high Check set temperature for proper drying for material being dried. process temperature. Temperature probe not installed in process Ensure temperature probe is installed in the air stream. dryer outlet, or in the hopper inlet. Process blower rotating in wrong direction. Change blower rotation. Temperature sensor connection loose or Correct the connection. reversed. 3. -
Page 28: Warranty
12.0 WARRANTY NOVATEC, INC. - EFFECTIVE DATE 1 APRIL 2019 NOVATEC, INC. offers COMPREHENSIVE PRODUCT WARRANTIES on its use, whether based upon warranty, contract or negligence, shall not all of our plastics auxiliary equipment. We warrant each NOVATEC man- in any case exceed the cost of correcting defects in the equipment as ufactured product to be free from defects in materials and workman- herein provided. All such liability shall terminate upon the expiration ship, under normal use and service for the periods listed under “Warran- of said warranty periods. Novatec shall not in any event be held liable ty Periods”. The obligation of Novatec, under this warranty, is limited to for any special, indirect or consequential damages. Commodities not repairing or furnishing, without charge, a similar part to replace any part manufactured by Novatec are warranted and guaranteed to Novatec which fails under normal use due to a material or workmanship defect, by the original manufacturer and then only to the extent that Novatec within its respective warranty period. It is the purchaser’s responsibility is able to enforce such warranty or guaranty. Novatec, Inc. has not au- to provide Novatec with immediate written notice of any such suspect- thorized anyone to make any warranty or representation other than the ed defect. Warranted replacement parts are billed and shipped freight warranty contained here. Non-payment of invoice beyond 90 days will pre-paid. The purchaser must return the suspect defective part, freight invalidate the warranty. A renewed warranty can be purchased directly prepaid and with identifying documentation to receive full credit for from Novatec. the part returned. Novatec shall not be held liable for damages or delay Please note that we always strive to satisfy our customers in whatever caused by defects. No allowance will be made for repairs or alterations manner is deemed most expedient to overcome any issues in connec- without the written consent or approval of Novatec. tion with our equipment. - Page 29 Exclusions: Routine maintenance/replacement parts are excluded from the war- ranty. These include, but are not limited to: hoses, desiccant, filters, filter elements, wiper seals, gaskets, dew point sensors, infrared lamps, motors, internal solenoids, fuses and motor brushes. Use with abrasive materials will void the warranty of any standard product. Wear resistant options may be available to extend usable service life with abrasive ma- terials. Novatec reserves the right to limit the warranty if the customer installs replacement parts that do not meet the specifications of the original parts supplied by Novatec. *Specific Exclusions: 1. NovaDrier™ and NITROdry™ warranty is void if coalescing filters are not replaced on a 6-month or yearly basis (per instruction manual) and/or membrane has been exposed to ozone. 2. NovaVac Dryer -The ability of the canisters to hold vacuum will be compromised if the vacuum seal edge is damaged from mishandling. We do not warranty canisters damaged from improper handling. We do, however, warranty the seals. 3. LOAD CELLS on our WSB’s are covered by Novatec standard warran- ty as long as they have not been damaged from improper handling. 4. Desiccant Wheel Warranty will be void if the wheel has been exposed to plasticizer, dust or other contaminants as a result of negligence on the part of the processor. 5. DryTemp+ - We assume no responsibility from equipment failures resulting from untreated or improperly treated water. This warranty shall not apply to equipment: 1. Repaired or altered without written approval of NOVATEC unless such repair or alteration was, in our judgment, not responsible for the failure 2. Which has been subject to misuse, negligence, accident or incorrect...
- Page 32 Drying > Conveying > Blending > Downstream 222 East Thomas Avenue Baltimore, Maryland 21225 www.novatec.com Phone 410-789-4811 or 800-938-6682 24 Hour service: 800-938-6682 Fax: 410-789-4638 Email Parts: parts@novatec.com Service: service@novatec.com Sales: sales@novatec.com...
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