NDB Dryers with NovaTouch PLC Control

Transcription

1 NDB Dryers with NovaTouch PLC Control NOVATEC, Inc All Rights Reserved NDB_NovaTouch PLC IM 15 MAY 2017 Page 1 of 2

2 NOTES: Please record the following information, which is specific to this piece of equipment, in the space provided. Our Parts/Service Department will need these numbers to properly respond to any of your requests. Instruction Manual: NDB_NovaTouch PLC IM 15 MAY 2017 Model #: Serial # DISCLAIMER: NOVATEC, Inc. shall not be liable for errors contained in this Instruction Manual nor for misinterpretation of information contained herein. NOVATEC shall not, in any event, be held liable for any special, indirect or consequential damages in connection with performance or use of this information. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 2

3 TABLE OF CONTENTS SECTION 1 INTRODUCTION Desiccant Dryer General Description Principle of Operation Adsorption Cycle 1.12 Regeneration 1.13 Pre-cooler SECTION 2 INSTALLATION Unpacking General Description Installing the Hopper Machine Mounted 2.22 Floor Mounted 2.3 Diffuser Cone or Diffuser Tube Installation Connecting the Hoses Regeneration Outlet Utility Connections Power 2.62 Water SECTION 3 OPERATION Initial Start-Up Drying the Desiccant Operating Procedure 9 SECTION 4 SENSORS High Temperature Mechanical Limit Switch Hygro Dew point Sensor Shaw Dew point Sensor 11 SECTION 5 The TP177M and S7-224 CONTROLLER Programming the Controller Power Up 13 NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 3

4 TABLE OF CONTENTS (continued) 5.3 System Controls Main Menu Dryer Operation a Dryer Operation b Dryer Operation c Dryer Operation System Keypad Screen Loader Operations Setup Menu a Temperature Setpoints 5.3.5b Dew point Setpoints 5.3.5c Second Setpoint Functions 5.3.5d Real Time Clock 5.3.5e Password Protection Autostart Menu Message Screen Password Screen 26 SECTION 6 ALARMS AND WARNINGS 6.1 Warnings Alarms Clearing Alarms 28 SECTION 7 ENGINEERING/SETUP Entry Procedure Machine Setup Menu Configuration a Configuration b Configuration Dryer Parameters Cycle Advance Input Bypass PID Setpoints 35 SECTION 8 COMMUNICATIONS 36 SECTION 9 MAINTENANCE AND INSPECTION SCHEDULE Trouble Shooting Guide 38 SECTION 10 WARRANTY 42 NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 4

5 SECTION 1 INTRODUCTION 1.0 Desiccant Dryer General Description The NDB/MPC/CDM Series dual-bed dryers are continuous-duty; desiccant dryers designed to supply an uninterrupted flow of constant, low dew point air. These units are completely automatic and require little maintenance to offer many years of trouble free service. 1.1 Principle of Operation 1.11 Adsorption Cycle The reduction of moisture is accomplished by the use of an adsorbent material called Molecular Sieves. The process blower draws humid air across the filter (and if supplied, through a pre-cooler) and passes it thorough the adsorbing desiccant tower. The desiccant material adsorbs water vapor from the flow, leaving the air extremely dry, (-40 deg. F dew point or below). The dry air is then directed over the Process Heater, where the air is heated to a desired preset and it is then ducted to the drying hopper. The dry air enters, and is forced through, the hopper. The warm, low dew point air fills the hopper, placing all of the entering material in a moisture free environment. This causes the moisture in the plastic material to migrate to the surface where it is picked up by the dry air. This humid air is taken back to the dehumidifier where the moisture is adsorbed by the desiccant. Before the desiccant reaches the saturation point, the 4-way valve automatically reverses and transfers the humid airflow to the opposite tower Regeneration While one tower is on adsorption, the opposite tower is on regeneration. The blower forces air through the regeneration heater and desiccant tower. The desiccant is heated to the temperature required to desorb the water adsorbed by the desiccant during the proceeding drying period. Water vapor carried from the tower by the air is discharged to the ambient through the regeneration outlet port. The heater is de-energized when the desiccant is dry, and the tower is cooled to the required adsorption temperature. Adsorption and regeneration alternate automatically between the two towers in a continuous cycle Pre-cooler OPTIONAL Pre-cooling the drying air returning from the hopper lowers the inlet temperature to below 150 deg. F., maintaining high desiccant efficiency. Pre-coolers also condense out unwanted contaminants, including plasticizer, which can be harmful to the desiccant. If plasticizer is being condensed, a drain trap will be supplied to collect the condensate from the pre-cooling coil housing. On initial startup this drain-trap should be filled with water to prevent ambient air from leaking into the system and also to allow the condensate to drain from the pre-cooling coil housing to the drain trap. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 5

6 SECTION Unpacking INSTALLATION Caution should be exercised to see that the equipment is not damaged during handling. The crate must be removed carefully. The machine must not be used to pry against when removing the crate. The dryer is usually shipped completely assembled and requires no further assembly prior to installation. Do not tilt the desiccant section at angle single at an angle greater than 30 degrees during unpacking or installation because the desiccant may get into the valve assembly. 2.1 General Description When the unit is unpacked, make a visual inspection looking for missing parts or damage which may have occurred during shipment. Some parts, such as thermometers, hoses, and hose clamps are packed inside the hopper. All electrical and mechanical connections should be checked for tightness because vibration during transit may cause them to loosen. 2.2 Installing the Hopper The inside of the hopper and the perforated spreader cone or diffuser tube should be thoroughly cleaned to remove all dust and oil that may have accumulated during shipment to your plant Machine Mounted If the drying hopper is to be mounted directly to the process machine, it should be mounted in a vertical position. Secure the hopper with bolts through the bottom flange. Use braces or guy wires as necessary to assure a safe installation Floor Mounted Locate the hopper stand and install where desired. Bolt the stand to the floor. The hopper should be bolted to the stand in a vertical position, secure as required. 2.3 Diffuser Cone or Diffuser Tube Installation After the hopper has been installed and secured, the perforated diffuser cone or diffuser tube should be installed in the hopper. The cone rests on a flange inside the hopper near the bottom of the straight side (just below the clean out door if applicable) where it joins the outer hopper cone. This cone maybe installed either thorough the clean out door (if supplied) or by removing the hopper lid. Be certain the diffuser cone is seated firmly to the flange inside the hopper. The diffuser tube is installed by pressing it into the hopper inlet tube from inside the hopper. Either a perforated diffuser cone or diffuser tube (not both) is supplied depending on the size and design of the hopper. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 6

7 2.4 Connecting the Hoses The "Dry Air Outlet" duct should be connected to the bottom duct of the drying hopper, or to the inlet of the heater in a hopper mounted heater configuration. The "Humid Air Outlet" duct on the lid of the hopper should be connected to the return air inlet of the dryer. Dryers from NOVATEC are shipped with flexible hose and clamps for this purpose. The lengths of the hose should be as short as possible cut away any excess. It is vital that the system is airtight. We recommended the use of insulation on process airlines that are heated. Hose insulation is available from NOVATEC. 2.5 Regeneration Outlet Do Not Insulate the return air hose! The regeneration outlet duct discharges hot, humid air. In some cases ducting the air may be desirable. Extreme caution must be given to the length of duct so, as to not cause backpressure to the regeneration blower. Contact the factory if the duct length will exceed four feet. If ducting outside, the reactivation air duct should be slanted down to prevent rain and moisture from entering the dryer. A trap for condensation should be located at the lowest point. 2.6 Utility Connections Field Wiring The specific electrical wiring schematics supplied with the CD/CDM and HB/HBM equipment should be reviewed and completely understood before initiating installation. If there is any ambiguous or conflicting information, contact the NOVATEC Technical Service Department before attempting to install the equipment. Dryer/HB Interlock Wiring Each HB has an interlock relay installed in its control box. The coil of this relay is connected in parallel to the dryer process motor starter coil. Should the dryer process blower shut off (i.e.; bed changeover, process blower motor overload), the HB interlock relay will power down the HB blower and heater. Typically the coil wires are labeled A and B on the terminal strip of the HB and dryer. Failure to interlock the HB relay with the dryer will not allow operation of the HB unit. Multiple HB s can have the A and B wires daisy chained from one unit to the next. Usually the interlock voltage is 115Vac Power NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 7

8 Connect the proper power supply through a main line disconnect switch (field supplied). Connect the green wire to earth ground. Because the Controller and various sensors are sensitive to 'Industrial Noise' the system must be properly connected to 'true' earth ground. The correct power supply requirements can be found on the specification sheet. Appendix A, or on the nameplate attached to the dryer. Local or national electrical codes should be followed as required. This is the only power connection necessary as the system is completely pre-wired and supplied with a control transformer to supply the necessary 115- vac control voltage Water If the unit is equipped with a pre-cooler, the proper water supply (see specification sheet, Appendix A) should be connected to the pipes marked "inlet" and "outlet" on the side of the pre-cooler. If the pre-cooler is used to remove plasticizer or other condensates, the condensate drain (called the drain-trap) should be connected to suitable drainage. On initial start-up, this drain-trap should be filled with water to prevent ambient air from leaking into the system and also to allow the condensate to drain from the precooling coil housing to the drain trap. The drain trap must be full at all times. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 8

9 SECTION 3 OPERATION 3.0 Initial Start Up After the drying system has been fully installed and power connected, check that the master off/on switch is on. Verify that the TP177M Touch Panel is on. Press NOVATEC logo screen to continue. The TP177M will change to the Main Menu Screen. Press the Operation pad and the TP177M will change to the system display screen. Press the Start Pad. The dryer should now be running. Adjust the process temperature by pressing the 3D Process Setpoint will appear. Enter desired setpoint temperature and press. pad. A full keypad No further adjustments are required to run the dryer. However, if you wish, you may step through all of the parameters to verify or change any values entered at the factory. See SECTION 5 for a complete description of programming the TP177M/S7-224 controller. 3.1 Drying the Desiccant When first put on-line, or when it is deemed necessary, the desiccant should be thoroughly dried. To do this, reduce the process air setpoint to a level below ambient temperature so that the heater does not come on. Check the blower for proper rotation by observing the rotation of the motor at the end facing the control box. The proper rotation is indicated with an arrow on the blower housing. Allow the unit to dry-cycle for 24 hours. This will allow the moisture adsorbed by the desiccant during transit or inactivity to be discharged. Failure to dry cycle the unit may cause drying problems with the material. The dryer will achieve its lowest dew point after the 24- hour period. However, if your process is such that it does not require as low a dew point as possible, material may be dried after a minimum of four hours of dry cycling. Don't forget to raise the process setpoint to the temperature recommended for drying your material. The material must be at its drying temperature for its residence time period (usually 2 to 4 hours) before the material is dry enough to process. 3.2 Operating Procedure After the initial residence period is complete, the material is dry and ready for processing. As dry material is withdrawn from the bottom, wet material should be added to the hopper at the same rate. (NOTE: It is extremely important to keep the hopper as full as possible for proper drying). If any special options were ordered with your dryer refer to APPENDIX B for details and start-up procedures. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 9

10 SECTION 4 SENSORS 4.0 High Temperature Mechanical Limit Switch The NDB/MPC process heater is fitted with a mechanical temperature limit switch as a standard feature. It is a cartridge type thermostat with a range of -100 to 600 F. This switch is preset at the factory and under normal conditions it should never trip. In the event that a malfunction occurs and the temperature exceeds the preset limit this mechanical switch will open, shutting down the system and preventing any damage to the process or the equipment. The switch may be field adjusted if necessary. To change the temperature setting, remove the cover from the switch housing and turn the adjustment screw. A clockwise rotation lowers the setpoint and a counterclockwise rotation increases the setpoint. Each full revolution of the setpoint adjustment screw changes the temperature setpoint approximately 90. If the dryer is shutdown while the process temperature is elevated, an over temperature alarm may occur due to the increase in temperature without proper airflow. You should wait several minutes for the temperature to drop below the limit level before starting the dryer. You may also jumper the high temperature limit switch temporarily to cool the heater. 4.1 Hygro Dew Point Sensor The HYGRO Dew point Sensor is the standard sensor for NDB/MPC/CDM applications. The Sensor may also be called a White or Model M Sensor. It has a sensing range of -40 to +15 F. The electronics for this sensor are incorporated in the Hygro board assembly. The calibration has been done at the factory and no field calibration should be necessary. The HYGRO Sensor is a lithium chloride type. The sensor is installed in its sensing chamber when the dryer is shipped from NOVATEC. Even though the sensor does not read below - 40 F, the dryer is still capable of lower dew points. If it is desired to know the actual dew point below 40 F the optional SHAW dew point sensor should be used. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 10

11 4.2 Shaw Dew Point Sensor The SHAW Dew point Sensor is an option for the NDB/MPC/CDM series dryer. It has a sensing range of -112 F to +32 F. An additional circuit board is required for its operation. The sensor is calibrated at the factory-it can be field calibrated if necessary. To calibrate expose the sensor to ambient air for several minutes by removing it from its sensing chamber. It may be necessary to hold the sensor in the closed palm of your hand on extremely dry days (less than +32 F dew point). The moisture from the ambient air or your hand will allow you to adjust the sensor. With the coaxial cable attached, adjust the "pot" on the dew point sensor board marked "sensitivity" or "cal". Adjust until the dew point displayed is +31 F. Re-install the sensor into its holder. Calibration is complete. The SHAW Sensor is a capacitance type (metal core coated with a hygroscopic dielectric and covered with a porous gold film) that measure moisture independently of temperature. The Shaw sensor is shipped in a separate container that has been placed inside the control box. The sensor should be removed from its container and screwed into its sensing chamber. Inside the control box is a coaxial cable with plug that should be connected to the SHAW Sensor. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 11

12 SECTION 5 SYSTEM CONTROLS The TP177M (touch panel) and S7-224 PLC are both sophisticated Micro-controlled designs provided entirely by Siemens. Siemens is a name known worldwide for its electrical and electronic products. It is a standard controller with a custom program written by NOVATEC to make the NDB/MPC/CDM dryer the most dependable, flexible dryer available. The TP177M has 10 screens available for the control of the NOVATEC NDB/MPC/CDM dryer. DISPLAY: STATUS: Provided by System Status message block on the Dryer Operation Screen NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 12

13 DATA ENTRY: Provided for by 3D data entry pads. alarm FUNCTION: Use to start/stop the dryer, enter setup mode, and to control various functions. The TP177M and S7-224 has been fully programmed by NOVATEC. Just enter the process temperature setpoint and any custom functions that you wish. 5.1 Programming the Controller Programming the Controller is accomplished through a simple menu navigation scheme. Any 3 dimensional figure represents a control point whether it is a switch or a data entry point. 5.2 Power Up At power up the TP177M will run a self-test and then pass through to the third. The screens will automatically transfer after an internal time out or may be forced through by pressing the proper pad. The factory default screen is Main Menu. Press the START pad to bypass NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 13

14 5.3 System Controls Main Menu The systems parameters are divided into 5 different areas. The screens may be accessed from the Main Menu screen. Each screen will contain displays and the parameter entry points for proper operation. The display lines on the Main Menu screen will include the current day, date, and time based on the system real time clock, machine type, touch calibration, contrast + and and clean screen. It will also include the station number from the optional PROFIBUS communications module. If the number is zero, there is no ProfiBus module in the system. Depress this pad to go to Dryer Operation 1, 2, 3. (Section 5.3.2) Depress this pad to go to the Loader Operation. (Section 5.3.4) Depress this pad to go to the Setup Menu. (Section 5.3.5) Depress this pad to go to the Autostart Menu. (Section 5.3.6) Depress this pad to go to the Message Screen. (Section 5.3.7) NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 14

15 5.3.2 Dryer Operation Screens 5.3.2a Dryer Operation 1 The system has default setting to the Dryer Operation 1 screen. This start up sequence can be changed and is explained in the Engineering/Setup section of the manual. This screen includes message displays for System Status, Bed Status; Minutes left in the current stage, Process #1 Temperature, and Dew Point. The data entry points on the screen are the Process Setpoint #1 pad, Manual 2 nd. Setpoint, Main Menu, Next Screen and the Start/Stop pad. Depressing this pad will either START or STOP the system. When the System is not running, the pad will display Press to Start and the System Status line will display the message System Off. When the system is running, the pad will appear depressed and display Press to Stop. The System Status line will display several different messages depending upon conditions within the system. To change the PROCESS SETPOINT press the screen directly over The system will then change the display to the System Keypad. See SYSTEM KEYPAD (section 5.3.2) The system may be manually set to operate using the Manual 2 nd. Setpoint pad. When this is depressed the Second Setpoint is moved into the Setpoint #1 display, and the pad will display ON. The input may now be used to change the Second Setpoint value in the same way it was used to change the Process Setpoint. Depress the Next Page pad to go to Dryer Operation 2. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 15

16 5.3.2b Dryer Operation 2 Dryer Operation 2 includes message displays for System Status, Dew point Change Over Setpoint, and Dew Point Change Over Status, optional second process heater control, The data entry points on the screen are the Dew Point Change Over Setpoint, Process Setpoint #2 pad, Next Screen, Manual 2 nd. Setpoint, Main Menu, Return, Next Screen, and the Start/Stop pad. To change the Changeover Setpoint, press the screen directly over The system will then change the display to the System Keypad. See SYSTEM KEYPAD (section 5.3.2) The Dew point Changeover Status will display either ON or OFF and may be changed on the Dew point screen. Optional Second Process Heater: If the Second Process Heater is not installed, the displays for the Temp #2 and Setpoint #2 will read 0 (zero). If the Second Process Heater is installed, the Displays will read the second process heater temperature and the setpoint. This option may be added in the field. (See Engineering/Setup Section.) The system may be manually set to operate using the Manual 2 nd. Setpoint pad. When this is depressed the Second Setpoint is moved into the Setpoint #1 display, and the pad will display ON. The input may now be used to change the Second Setpoint value in the same way it was used to change the Process Setpoint. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 16

17 5.3.2c Operation Screen 3 Dryer Operation 3 includes message displays for System Status, Bed Status, Process #1 Temperature, System Dew Point and Moisture Manager dew point. The data entry points on the screen are the Process Setpoint #1 pad, Main Menu, Return, Next Screen, and the Start/Stop pad. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 17

18 5.3.3 System Keypad The System Keypad will appear and is common to all data entry requirement pads. The buttons available for operation on the system keyboard are dependent on the type of value to be entered. Buttons that are available for operation are 3D, and those that are not simply appear as flat keys. The following table explains the significance of each of the pads on the System Keypad. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 18

19 5.3.4 Loader Operation The Loader Operation screens will not be available if the unit was purchased as an NDB/MPC/CDM, however it can be reconfigured in the field to operate in DCS mode. (See Engineering/Setup Section.) Setup Menu All system parameters may be accessed from this menu Depress this pad to go to Temperature Setpoints. (Section 5.3.5a) Depress this pad to go to Dew point Setpoints. (Section 5.3.5b) Depress this pad to go to Second Setpoint Functions. (Section 5.3.5c) Depress this pad to go to Real Time Clock. (Section 5.3.5d) Depress this pad to go to Password Protection. (Section 5.3.5e) NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 19

20 5.3.5a Temperature Setpoints This screen has all of the temperature control set points for the system. The Process Setpoints set the temperature for the process heaters. The High Dev. And Low Dev. determines the High and Low Process alarm. Second Setpoint sets the temperature for the machine during Second Setpoint Operation. The Over SP is a software, first level, over temperature limit switch. A fault will cause the machine to drop out of run mode b Dew pointsetpoints This screen has all of the dew point control set points for the system. The Dew point Change Over Setpoint determines at what dew point the bed will shift. This extends the time that the bed is in Process mode. The Dew point Alarm Setpoint sets the alarm value for the system. The Bed Shift on Dew point may be turned On or Off on this screen. The text block will display the status. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 20

21 5.3.5c Second Setpoint Functions The Second Setpoint screen provides all of the necessary data inputs for the second setpoint operation. The dryer will allow for an ON and OFF time once a day or any combination of times throughout the week. Daily Start/Stop Example: Using the arrow pads, bring the day to START and STOP the Second Setpoint into the display. The day will be displayed in standard text (i.e. Sunday, Monday etc.) Set the START time in hours and minutes. As this is a 24 hour clock, 00:00 would be midnight, 12:00 would be noontime and after noon adding the hour to 12 would give you the correct 24 hour designation (i.e. 5: hrs = 17:00) Depress the Mode pad until the desired operation appears in the text block. You can select START, STOP or NO-OP. NO-OP is an abbreviation for NO-OPeration. For the purposes of the example, START should appear in the text block. Set the STOP time in hours and minutes. As this is a 24 hour clock, 00:00 would be midnight, 12:00 would be noontime and after noon adding the hour to 12 would give you the correct 24 hour designation (i.e. 5: hrs = 17:00) Depress the Mode pad until the desired operation appears in the text block. You can select START, STOP or NO-OP. NO-OP is an abbreviation for NO-OPeration. For the purposes of the example, START should appear in the text block. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 21

22 Making the settings active: Clearing the Settings: Depress this pad to enable the Second Setpoint settings. The display will read OFF when they are disabled. The pad will read Enabled and the display will read ON when the settings are active. Depress this pad to clear all of the settings. This will set all times to 00:00 and all modes to return to NO-OP. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 22

23 5.3.5d Real Time Clock The Real Time Clock (RTC) screen provides all of the necessary data inputs for S7-224 real time clock. When the Display pad is depressed, the RTC data will be sent to the screen. To set the (RTC) depress the Program pad. The display will stop updating and the new information may be entered. Set the RTC back to Display and the display will return with the new settings and begin to update. This PLC has no option for Daylight Savings Time. It must be reset e Password Setup The Password Setup Screen has listed 5 other screens with a space for passwords and a selector pad to either enable or disable the password. Any 6- digit number may be set as a password. To enable the password and protect the screen, enter the password and depress the associated pad. The pad will show Enabled and the protection will become active after leaving this screen. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 23

24 5.3.6 Autostart Menu The Autostart Menu screen provides all of the necessary data inputs for the second setpoint operation. The dryer will allow for an ON and OFF time once a day or any combination of times throughout the week. Daily Start/Stop Example: Using the arrow pads, bring the day to START and STOP the Second Setpoint into the display. The day will be displayed in standard text (i.e. Sunday, Monday etc.) Set the START time in hours and minutes. As this is a 24 hour clock, 00:00 would be midnight, 12:00 would be noontime and after noon adding the hour to 12 would give you the correct 24 hour designation (i.e. 5: hrs = 17:00) Depress the Mode pad until the desired operation appears in the text block. You can select START, STOP or NO-OP. NO-OP is an abbreviation for NO-OPeration. For the purposes of the example, START should appear in the text block. Set the STOP time in hours and minutes. As this is a 24 hour clock, 00:00 would be midnight, 12:00 would be noontime and after noon adding the hour to 12 would give you the correct 24 hour designation (i.e. 5: hrs = 17:00) Depress the Mode pad until the desired operation appears in the text block. You can select START, STOP or NO-OP. NO-OP is an abbreviation for NO-OPeration. For the purposes of the example, START should appear in the text block. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 24

25 Making the settings active: Clearing the Settings: Depress this pad to enable the Second Setpoint settings. The display will read OFF when they are disabled. The pad will read Enabled and the display will read ON when the settings are active. Depress this pad to clear all of the settings. This will set all times to 00:00 and all modes to return to NO-OP. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 25

26 5.3.7 Message Screen The Messages screen will contain the warning and error messages created by the system. The UP and DN pads will move the position of the message pointer. Messages will appear in the Message display in the order of occurrence. Pressing the Clear All Messages will remove all of the messages from the stack Password Screen The Password screen will appear whenever the system is directed to a screen that has password protection associated with it. If the password is enabled, the screen will remain up until the correct password is entered. If the password is not enabled, the screen will appear briefly before continuing to the selected screen. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 26

27 SECTION 6 ALARMS AND WARNINGS 6.1 WARNINGS The operator will be notified of System Warnings by a message in the display line. The operator may acknowledge the alarm by pressing the ALARM ACK pad at the right side of the display line. The message may be viewed at a later time in the message screen (See Section ) Acknowledging the alarm will clear the display and return the system status message. A System Warning is a failure or alarm that will not cause a catastrophic failure of the equipment. Under these conditions the machine will not shut down. The optional alarm horn will sound. Only those warnings that apply to your specific unit will be functional. These Warnings include the following: Communications Module Error Relay Module Error Setpoint Exceeds Limits Setpoint Exceeds High Alarm Process Temp #1 HIGH Dev. Alarm Process Temp #1 LOW Dev Alarm Process Temp #2 HIGH Dev. Alarm Process Temp #2 LOW Dev Alarm Process Dew point Alarm Moisture Manager Alarm Vacuum Loader No-Load Alarm Machine Hopper No-Load Alarm Low Material Level Hopper #1 *(Optional Equipment) *(Optional Equipment) *(Optional Equipment) *(Optional Equipment) *(Optional Equipment) *(Optional Equipment) NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 27

28 6.2 ALARMS This type of alarm will take the system out of the run mode whether it s in automatic or manual. The operator may acknowledge the alarm by pressing the ALARM ACK pad at the right side of the display line. The message may be viewed at a later time in the message screen (See Section ) Acknowledging the alarm will silence the optional horn. Only those warnings that apply to your specific unit will be functional. This type of alarm includes the following: Analog Module Error Thermocouple Module Error Coming Phases Reversed Process Motor Failure Regeneration Motor Failure Right Bed Shift Failure Left Bed Shift Failure Process LS 1 Open-Over Temp Process LS 2 Open-Over Temp Process #1 OVER TEMP SHUTDOWN Process #2 OVER TEMP SHUTDOWN *(System Dependent) *(System Dependent) *(System Dependent) *(System Dependent) *(System Dependent) 6.3 CLEARING ALARMS All Warnings and Alarms on this system will reset themselves if the failure corrects itself. In the case of a bad dew point, the system will send a warning. If the dew point comes within the parameters that have been setup, the alarm will reset and begin looking for the next occurrence. If the failure causes a system shutdown, all alarms are reset when the START pad is pressed. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 28

29 SECTION 7 ENGINEERING/SETUP 7.1 ENTRY PROCEDURE The ENGINEERING/SETUP section can be entered from any standard screen. The NOVATEC logo that is in the upper left corner is actually a screen transfer pad. Depress the NOVATEC logo and the password screen will appear. Enter the password and you will be passed through to the Machine Setup Menu. This password may only be obtained from NOVATEC Technical Service or Engineering. Depress the logo. 7.2 MACHINE SETUP MENU The NOVATOUCH software is designed to be re-configurable to any dryer in the NOVATEC line. This unit will configure to control all NDB/MPC/CDM dryers. All the necessary parameters are available in the 5 sub menus. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 29

30 The ONLINE/OFFLINE pad controls the TP177M communications to the S7-22x series PLC. When the display is ONLINE it is communicating screen information to and from the PLC. When the pad is depressed the display will change to OFFLINE and communications with the PLC will stop. The PLC will continue to operate normally without the display. The screen software may be reloaded at this time. Pressing the Up Load to Display pad will cause the TP177M to begin looking for a programming connection on the communications port. After a software download the screen will restart, reconnect to the PLC and return to normal operation. The Save Current Settings as New Default pad will take the adjustments to the parameters found in the setup menus and place them into the PLC onboard EEPROM. This will establish a custom baseline. After the save, the PLC will always start to these parameters regardless of whether the PLC has been off for an extended time or the battery backup has failed. The PLC will save the following list of parameters: Screen Temperature PID Values Dewpoint Passwords VL Parameters JIT Parameters Dryer Parameters Additional Parameters Save (all settings) (all settings) (all settings) (all passwords, all settings) (all settings) (all settings) (all settings) (all settings) Depress this pad to go to the Configuration Screens (Section 7.2.1) Depress this pad to go to Dryer Parameters (Section 7.2.2) NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 30

31 Depress this pad to go to Cycle Advance (Section 7.2.3) Depress this pad to go to Input Bypass (Section 7.2.4) Depress this pad to go to PID Setpoints (Section 7.2.5) CONFIGURATION 7.2.1a Configuration 1 This Screen allows you to configure the system and its properties. The Display Temp in C or F switch will only change the display and the calibration for the Dew Point. To actually change the temperature response to C requires a setting change on the dipswitch of the EM231-TC module. Switch position # 7 will be up for F. Place switch #7 down, turn the system off, and when the system is turned on it will display the true C temperature. The Display Date is US or EU will change the date display from MM/DD/YY to DD/MM/YY. The Dew point Sensor type will change the Dew point Calibration for the Hygro Sensor or the Shaw Sensor. The Shaw sensor on a new machine is 4-20ma output. The Shaw board is 100mv? Will allow those units with the older 100mv Shaw board to be retrofitted with the NovaTouch. The VL/JIT Control turns the material control subroutines on or off. A NovaTouch NDB/MPC can be retrofitted in the field to a DCS. The 2 nd Process Heater? turns the second process heater subroutines on or off. A NovaTouch NDB/MPC can be retrofitted in the field for a second process heater. Re-Start Dryer on Power Up? The will restart the dryer after a power failure. This will restart the dryer into run mode regardless of whether the dryer was Started or Stopped before the power failure. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 31

32 7.2.1b Configuration 2 This Screen allows you to configure the rest of the system and its properties. Using the arrow pads move the Type of Dryer into the display. This will set up the default timing for the system and set the title on the main screen. Using the arrow pads move the Start Up Screen into the display. This will determine which screen the system will display when power is applied The Offset for Thermocouple will allow you to enter an Offset for each thermocouple in the system. Use a positive number if the associated thermocouple read out is low and a negative number if the associated thermocouple read out is high. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 32

33 7.2.2 DRYER PARAMETERS The Dryer Parameters Screen has the balance of the internal setup parameters that makes this control system configure to the NOVATEC dryers. The Regen Cycle Time, Regen Heating Time, Dynamic Cooling Time, Alarm C/O, Blower C/O, Process Heater Off Before, Process Heater Off After, And Maximum Time In Dew Point C/O are all in default. They may be adjusted to improve performance as required. Returning to the Configuration 2 screen will return the timing values to the factory default. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 33

34 7.2.3 CYCLE ADVANCE The Cycle Advance screen is set up to allow the user to advance the cycle of the dryer and still have all the pertinent information available. System Status, Minutes Left in REGEN Stage, and Process Temperature are all displayed. Each time the Cycle Advance pad is depressed the dryer will advance to the next stage. The stage information and time left will be displayed each time. The Analog Offset/Gain Calibration Point is used in conjunction with the Analog Module. See Simatic S7-200 Programmable Controller System Manual # 6ES FA21-8BH0 for calibrations details and procedures INPUT BYPASS The Input Bypass screen is set up to allow the user to turn system component tests on or off. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 34

35 7.2.5 PID SETUP This screen allows the user to tweak the PID settings as necessary to improve the process heater performance. Included are Proportional, Integral, and Derivative terms along with the Pulse Width. This will set the period of the Process Heater control pulse while the P, I, and D terms will set the duty cycle. The Temperature Filter Rate will flatten out the response on noisy thermocouples. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 35

36 SECTION 8 COMMUNICATIONS Siemens offers three types of communications modules. The first communicates using both MPI (Multi-Point Interface) and Profibus DP Slave simultaneously. The second module offers Modbus RTU Master/Slave, SMS Messaging Service Center (Cell Phone, Pager, Fax), 33.6 kbaud modem, and Peer to Peer communications. The third communicates via Industrial Ethernet. All of these units provide for direct connection to the PLC program via Siemens Micro/Win Programming Software. Contact NOVATEC Engineering to see which type of module or network would best serve your requirement. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 36

37 SECTION 9 MAINTENANCE AND INSPECTION SCHEDULE It is recommended that maintenance and inspection is done on a scheduled basis. Maintenance requirements will naturally vary widely for each installation and specific operating conditions. It is suggested that a complete inspection be performed with necessary maintenance at the end of the first, the first three months, and the first six months. These inspections will be indicative of how often future maintenance will be necessary. REMOVE POWER BEFORE SERVICING THE UNIT EVERY MONTH A. Inspect air filters. Clean or replace as required. Replace if cartridge is broken. The time interval for inspection should be shortened if experience indicates unusual dust loading. B. Check system for air leaks or flow obstructions and correct as required. EVERY 3 MONTHS A. Units equipped with sleeve bearing motors should be lubricated with SAE 20 oil. B Units equipped with ball bearing motors are factory greased and should be relubricated with high-grade ball bearing grease. NOTE: Most units are shipped with permanently lubricated bearings and no lubrication is required. All motors should be examined on an individual basis. C. Check heater amperage (See Specification Sheet) D. Check motor amperage (See Specification Sheet). E. Check all electrical connections to make sure that they have not become loose, especially those connections at contactors, motor starters, and heater elements. ONCE EVERY YEAR Check dehumidifier valve linkage and operation of valves. Check valve wiper seals for wear and tear. EVERY 2 YEARS or as NEEDED Remove top covers of dryer towers and replace desiccant. Inspect the high temperature silicon gasket and renew if necessary. (See Specification Sheet for the amount of desiccant). Warning: Tower lids and heater boxes may be extremely hot use caution when working with these parts. NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 37

38 9.1 Trouble Shooting Guide Most drying problems are the result of dirty filter(s), air leaks, desiccant contamination and/or malfunctioning regeneration heaters. It is seldom that other components fail. PROBLEM Machine Won't Start Inadequate or No Regeneration Heat Inadequate or No Process Heat Inadequate or No Adsorption Air Flow Inadequate Dew point INVESTIGATE A, B, C, N E, F, G, H, I, K D, E, G, H, I, J, K B, D, G, H, I, J, K E, F, G, H, I, K, L, M Changeover Temp. too high F, I, J, K CODE CHECK CONDITION SOLUTION A POWER SUPPLY NO VOLTAGE OR INCORRECT VOLTAGE CHECK FIELD INSTALLED VOLTAGE B MOTOR STARTER OVERLOADS TRIPPED RESET C D E F G H I TRANS- FORMER BLOWER MOTOR HEATER AMPERAGE REGEN MOTOR VALVE POSISTION VALVE MOTOR BLOWER ROTATION NO VOLTAGE ON PRIMARY NO VOLTAGE ON SECONDARY NO VOLTAGE AT MOTOR VOLTAGE AT MOTOR INCORRECT AMPERAGE VOLTAGE CORRECT AMPERAGE INCORRECT NO VOLTAGE AT MOTOR VALVE POSITION INCORRECT NO VOLTAGE AT MOTOR VOLTAGE AT MOTOR, VALVE MOVES FREELY BY HAND INCORRECT SEE CODE A CHECK FUSE, IF OK, REPLACE TRANSFORMER CHECK OUTPUT FROM CPU REPLACE MOTOR REPLACE HEATER SEE CODES B, D CHECK VALVE LINKAGE CHECK PROCESS HEATER LIMIT SWITCH, CHECK OUTPUT FROM CPU BOARD REPLACE VALVE MOTOR REVERSE PHASING NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 38

39 J FILTER FILTER DIRTY REPLACE OR CLEAN ELEMENT K AIR DUCT OBSTRUCTED REMOVE OBSTRUCTION L M N LEAKS IN SYSTEM DESICCANT HIGH TEMP LIMIT SWITCH AIR LEAKING IN OR OUT OF SYSTEM CONTAMINATED SATURATED TRIPPED (OPEN) REPLACE GASKETS, REPAIR LEAKS AS NECESSARY REPLACE DESICCANT DRY CYCLE FOR 24 HOURS WAIT FOR UNIT TO COOL OR ADJUST SWITCH AS NECESSARY NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 39

40 NDB/MPC/CDM PARAMETERS FACTORY PRESETS Parameter Pre- Set Units Parameter Pre-Set Units PROCESS SETPOINTS REGENERATION PARAMETERS Process 1 Setpoint 180 F Varies with dryer size. See chart for a Process 2 Setpoint 180 F listing of parameters Dew point High Alarm -10 F Bed Changeover Dew point -20 F PROCESS HIGH/LOW DEVIATIONS Process 1 Low Temp Deviation Process 2 Low Temp Deviation Process 1 High Temp Deviation Process 2 High Temp Deviation Process 1 Second Setpoint Process 2 Second Setpoint SECOND SETPOINTS Process 1 Second SP Delay Process 2 Second SP Delay DRYER OPERATING PARAMETERS Set Current Time 4:30 * PM Day of Month 11 * NA 10 F Set Month 4 * NA Set Year 95 * NA 10 F Daylight Savings Time NA NA Process Blower Delay 30 Sec C/O 10 F Dryer Changeover Time NA Mode Dew point Sensor Type Hygro NA 10 F Horn Resound Delay 15 Min Process Heat off before 1 Min c/o Auto Start at Power Up Allowed NA Temperature Display F Units 60 F Unit ID (SPI) 1 NA 60 F Comm Baud Rate BPS TUNING AND CALIBRATION Proc 1 SP2 Start Time Temperature 0 F Adjustment Proc 1 SP2 Stop Time Proportioning Band 6.3 NA Proc 2 SP2 Start Time Integral Constant 4.1 NA Proc 2 SP2 Stop Time Derivative Constant.15 NA AUTO START/STOP MODE Start Time * The actual Date and Time the dryer was Stop Time tested parameters are used. Start Days Pulse Width 20 Sec Stop Days Temperature Filter Rate 1.00 NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 40

41 Regeneration Parameters Chart CDM NDB/ MPC INLET SETPOINT HEATING TIME DYNAMIC COOL ALARM DELAY CYCLE TIME ADVANCE CYCLE F 105 min 5 min 15 min 4.0 hrs. No F 90 min 5 min 15 min 4.0 hrs. No F 90 min 5 min 15 min 4.0 hrs. No F 90 min 5 min 15 min 4.0 hrs. No F 90 min 24 min 15 min 4.0 hrs. No F 90 min 24 min 15 min 4.0 hrs. No F 90 min 24 min 15 min 4.0 hrs. No F 90 min 24 min 15 min 4.0 hrs. No F 90 min 24 min 15 min 4.0 hrs. No F 90 min 24 min 15 min 4.0 hrs. No F 110 min 60 min 15 min 4.0 hrs. No F 110 min 60 min 15 min 4.0 hrs. No F 120 min 65 min 15 min 4.0 hrs. No F 90 min 60 min 15 min 4.0 hrs. No F 90 min 60 min 15 min 4.0 hrs. No NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 41

42 10.0 WARRANTY WARRANTY NOVATEC, INC. - Effective Date 8 MAY 2017 NOVATEC, INC. offers COMPREHENSIVE PRODUCT WARRANTIES on all of The provisions in equipment specifications are descriptive, unless our plastics auxiliary equipment. We warrant each NOVATEC manufactured product expressly stated as warranties. The liability of Novatec to the to be free from defects in materials and workmanship, under normal use and purchaser, except as to title, arising out of the supplying of the said service for the periods listed under Warranty Periods. The obligation of equipment, or its use, whether based upon warranty, contract or negligence, Novatec, under this warranty, is limited to repairing or furnishing, without shall not in any case exceed the cost of correcting defects in the charge, a similar part to replace any part which fails under normal use equipment as herein provided. All such liability shall terminate upon due to a material or workmanship defect, within its respective warranty the expiration of said warranty periods. Novatec shall not in any event be period. It is the purchaser s responsibility to provide Novatec with held liable for any special, indirect or consequential damages. immediate written notice of any such suspected defect. Warranted Commodities not manufactured by Novatec are warranted and guaranteed replacement parts are billed and shipped freight pre-paid. The purchaser to Novatec by the original manufacturer and then only to the extent that must return the suspect defective part, freight prepaid and with identifying Novatec is able to enforce such warranty or guaranty. Novatec, Inc. documentation to receive full credit for the part returned. Novatec shall not be has not authorized anyone to make any warranty or representation held liable for damages or delay caused by defects. No allowance will be other than the warranty contained here. Non-payment of invoice beyond 90 made for repairs or alterations without the written consent or approval of days will invalidate the warranty. A renewed warranty can be purchased directly Novatec. fromnovatec. Please note that we always strive to satisfy our customers in whatever manner is deemed most expedient to overcome any issues in connection with our equipment. Warranty Periods: Note: All warranty periods commence with the shipment of the equipment to the customer. 5-Year Resin Drying to Include NovaWheel Dryers * Dual Bed Dryers NovaDrier * NDM-5 Membrane Dryer Gas-Fired Process Heaters Gas-Fired Regeneration Heaters Drying Hoppers Central Drying Hopper Assemblies Heater/Blower Units and Hot-Air Dryer Silo Dehumidifiers NovaVac Dryers * Resin Blending and Feeding to Include WSB Blenders, MaxiBatch & Feeders * Gaylord Sweeper Systems Resin Conveying to Include GSL Series Vacuum Loaders GlassVu Loaders, Receivers and Hoppers Downstream Extrusion Equipment to Include C and NC Bessemer Series Cutters NPS Bessemer Series Pullers NPC Mini Puller/Cutter All NS Series Servo Saws All Cooling and Vacuum Tanks Manufactured by Novatec 3-Year When a Prophecy data plan is activated for VPDB and SVP pumps with PumpSense, Novatec automatically extends the warranty to 3 years. The data plan must be activated within 60 days after pump shipment, and remain active through the warranty period to maintain extended warranty eligibility. The first 6-months of data plan usage is free from Novatec. 2-Year Central System Controls to Include FlexTouch Series Controls FlexXpand Series Controls OptiFlex Series Controls PLC Communications Modules Greenboard Communications Modules LOGO! Mini PLC Moisture Measurement Equipment to Include MoistureMaster PET Resin Crystallizers 1-Year Resin Conveying and Systems Components to Include VL/VLP Series Loaders VRH, VR, VR-FL & VRP Series Receivers Compressed Air Loaders AL-B Barrel Loader Cyclone Dust Collectors Conveying System Accessories Surge Bins Valves and Accessories Electronic Metal Separators Quick Select Manifolds Tilt Tables Filter Dust Collectors Drawer Magnets Resin Conveying System Components to Include *VPDB Vacuum Positive Displacement Pumps *SVP Vacuum Pumps MVP Vacuum Pumps UltraVac Vacuum Pumps Vacuum Regenerative Blower Pumps Velocity Control Valves *See 3-Year Warranty above Central System Controls to Include MCS-600 Series Controls (Distributed I/O) MCS-400 Series Controls CL Silo Manager Infrared Dryers Custom Equipment of any kind unless otherwise specified Railcar Unloading Systems NDB_NovaTouch IM 15 MAY NOVATEC, Inc. All Rights Reserved Page 42