NovaWheel DESICCANT WHEEL DEHUMIDIFYING DRYER INSTRUCTION MANUAL

NovaWheel DESICCANT WHEEL DEHUMIDIFYING DRYER INSTRUCTION MANUAL NW Series with NovaTouch Touch Panel PLC Models: NW-600NC thru NW-2000NC Dedicated Dryers & NW-600NC-C through NW-2000 NC-C Central Dryers NW-1000NC NOVATEC, Inc. 2012 All Rights Reserved Document: NWLarge IM 11-8-2012

CRITICAL TECHNICAL BULLETIN It has come to our attention that operators of NovaWheel dryers are sometimes, mistakenly using the EMERGENCY STOP button to routinely turn these dryers OFF. EMERGENCY STOP should ONLY be used under TRUE EMERGENCY conditions. Repeated use of EMERGENCY STOP can cause dryer component failure. These dryers are intended to be turned ON and OFF on the touch screen control panel by pressing the or button located at the bottom of the QuickOp screen. We have added labels to the control panel to remind operators how the dryer should be turned on and off but please make sure they understand the importance of these instructions to avoid component failure and production interruptions. EMERGENCY USE ONLY WARNING: DO NOT turn dryer OFF with EMERGENCY STOP. Turn dryer ON & OFF at bottom of touch screen with button. EMERGENCY USE ONLY WARNING: DO NOT turn dryer OFF with EMERGENCY STOP. Turn dryer ON & OFF at bottom of touch screen with button. NWLarge IM 11-8-2012 Page 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: NWlarge IM 11-8-2012 For NW-600NC through NW-2000NC and NW-600NC-C through NW-2000NC-C 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. NWLarge IM 11-8-2012 Page 3

Table of Contents 1 SALES AND SERVICE... 5 2 SHIPPING AND INSPECTION... 5 3 PRINCIPLE OF OPERATION... 6 4 PRODUCT FAMILIARIZATION... 7 4.1 System Flow Diagram... 8 4.2 Specifications NovaWheel Dryer... 8 5 INSTALLATION... 9 5.1 Location... 9 5.2 Customer Piping Connections... 9 5.3 Electrical Connections... 10 5.4 Cooling Coil Connection... 10 6 FUNCTION CONTROLS... 11 6.1 Process Temperature Control (Drying Temperature)... 11 6.2 Regeneration Temperature Control... 11 6.3 Process & Regeneration Air Filter Pressure Switches (Ps)... 11 6.4 Process Air Dew Point Monitor... 11 6.5 Intelligent Regeneration... 11 7 PRE-OPERATING SYSTEM CHECK... 12 7.1 Starting The Dryer... 12 7.2 Checking Electrical Phase Using Blower Direction... 12 7.3 Changing From F to C... 12 8 NovaTouch CONTROL... 13 8.1 System Conventions:... 13 8.2 Screen Maps:... 15 9 DRYING MATERIAL... 16 9.1 Initial Dryer Startup... 16 10 PROGRAMMING OTHER DRYING FUNCTIONS... 19 10.1 Commonly Used Screens... 19 10.2 Other Helpful Screens... 22 10.3 Rarely Used Screens... 24 11 MAINTENANCE INSTRUCTIONS... 26 11.1 Suggested Maintenance Schedule*... 26 11.2 Process, Regeneration & Plasticizer Filters... 27 11.2.1 Draining Plasticizer... 28 11.3 Chain and Sprockets... 29 11.4 Desiccant Rotor... 29 11.5 Motor Rotation Signal... 30 11.6 Rotor Replacement... 30 11.7 Seal Replacement... 31 11.8 Drive Motor Replacement... 31 11.9 Seal Replacement... 32 11.10 Drive Motor Replacement... 32 11.11 Motor Rotation Signal... 32 12 TROUBLE SHOOTING and ERROR MESSAGES... 33 13 WARRANTY NOVATEC, INC. - Effective Date 6-12-2012... 35 NWLarge IM 11-8-2012 Page 4

FOREWORD This manual is dedicated to the principle that any engineered system will have many elements contributing to the smooth operation of the systems, and that these must be understood in order that installation and operation can proceed successfully. The electrical and mechanical components in the NW Series dryers have been manufactured, selected and assembled with care to give you excellent service. A wide range of NW series dryers have been introduced to enable our valued customers to select the right model for their application. This NW series dryer has been designed for use in closed loop resin drying systems. All components of your NW series dryers have been carefully engineered and manufactured and have been thoroughly inspected for quality, function and performance. Before installing this system, please read this manual, review the diagrams and the safety information. This should save valuable installation and operation time later and will help ensure safe operation and long life. 1 SALES AND SERVICE NOVATEC maintains qualified sales, engineering, and service personnel to assist in any way possible. If you have any questions concerning the types of equipment which NOVATEC manufactures that might improve your process, or any questions concerning service, we urge you to contact us. Sales: 1-800-BEST-DRY 1-800-237-8379 Fax: 410-789-4638 Sales@novatec.com Technical Service Department: 1-800-938-6682 Service@novatec.com 2 SHIPPING AND INSPECTION Although NOVATEC uses reputed carriers to deliver products, it has no control over the product once it leaves the manufacturing facility. Upon receiving the product, thoroughly inspect all equipment inside and out for damage that may have occurred during shipment. If any damage is found, a claim should be filed immediately with your carrier. NOVATEC thoroughly tests and inspects all products before shipment. You are to make the piping, and electrical connections for final installation and commissioning. If there any problems, shut down the equipment and contact the NOVATEC Technical Service Department. NWLarge IM 11-8-2012 Page 5

3 PRINCIPLE OF OPERATION The NW NovaWheel Series dryer was engineered and designed to effectively remove moisture (in the vapor state) from hygroscopic plastic resins. This process is accomplished by the continuously rotating 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 moisture, 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 adsorption. 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 entering back into the process to provide for better performance. The three air streams (process, regeneration and purge) are separated by special Teflon fabric coated silicon seals. The process air and regeneration air is compressed by using regenerative blowers. The dry air from the dryer is then is heated and the air temperature is controlled in an electric heater, located either in the NovaWheel cabinet on the smaller sizes or this heater is located at the drying hopper on larger sizes or on a central drying system with more than one hoppers. The hot dry air enters the hopper at the bottom and dries the resin in the hopper. The air from the top of the hopper is returned to the dryer, where it is filtered, cooled in a cooling coil and the process blower sends the air back to the dryer again to be dried. NWLarge IM 11-8-2012 Page 6

4 PRODUCT FAMILIARIZATION The major components and their locations are shown below. Connections to Hopper are Labeled Process Air to Hopper Return Air Filter From Hopper Filter Instruction Manual NWLarge IM 11-8-2012 Regeneration Air Outlet Air Outlet Filter Filter Desiccant Wheel Chain, Sprocket & Idler Bracket Filter Touch Screen Control Desiccant Wheel Drive Motor Regeneration Filter Access Process Filter Access Plasticizer Trap Drain LH SIDE FRONT Plasticizer Filter Access Regeneration Blower Internal Cooling Coil Process Blower RH SIDE NWLarge IM 11-8-2012 Page 7

4.1 System Flow Diagram PROCESS HEATERS AT HOPPERS IN CENTRAL DRYING SYSTEM PROCESS PROCESS HEATER HEATER 4.2 Specifications NovaWheel Dryer *Max Material Flow - Lbs./Hr. Kg/Hr. Model NW-600NC NW-800NC NW-1000NC NW-1300NC 600 90 800 136 1000 182 1300 227 Voltage Phase - Hz 460-3-60 460-3-60 460-3-60 460-3-60 Customer Water Line Size (min) O.D.: Water Required - Nominal (GPM): Wheel Speed - nominal (revolutions per hr.): 5/8 (16 mm) 3/4 (20 mm) *Reduce kg/hr. by 20% for 415/3/50 voltage. Kg/hr. for 575/3/50voltage same as above. Process Air dew Point (nominal): -40ºF (-40 C) Drying Temperature: 150-350 F (66-177 C) 1 (25 mm) 1 (25 mm) 6 10 15 15 10 10 10 10 NOTE: The ONLY difference on a Central dryer is that the Process Heater is Located at the Drying Hopper. NWLarge IM 11-8-2012 Page 8

5 INSTALLATION CAUTION: FOLLOW ALL NATIONAL AND LOCAL ELECTRICAL AND MECHANICAL CODES, AS REQUIRED. ONLY QUALIFIED AND TRAINED PERSONNEL SHOULD INSTALL AND OPERATE THIS EQUIPMENT. 5.1 Location Locate your NW Series dryer in a low traffic area, this will avoid disturbance of the hoses connecting your dryer to the hopper. Allow sufficient distance (at least 2 feet) from the surrounding equipment, so the access doors may be opened to perform routine maintenance on the dryer and for safe operation. There must be a grounded power source that will supply the correct voltage per the dryer nameplate. Water (tower or chilled at +45 to 85 F) must be supplied to the cooling coil using flexible hoses. 5.2 Customer Piping Connections Care should be taken while connecting the process air piping. If hoses are used, it should suitable for at least 350 F and silicone hose is recommended. On larger piping, hard piping with steel tubing should be considered. The piping should not block the access doors of the dryer. See below for the correct connection size from the dryer to the hopper. Process air connections: NW-600NC: NW-800NC: NW-1000NC: NW-1300NC: NW-1600NC : NW-2000NC: 6 inches diameter 6 inches diameter 8 inches diameter 8 inches diameter 8 inches diameter 8 inches diameter NWLarge IM 11-8-2012 Page 9

5.3 Electrical Connections The NW Series dryer comes from the factory with all control circuits wired and the dryer needs to be connected to the proper power source. Electrical Drawings are included with this package. CAUTION: All electrical connections must be made by qualified electricians, per national and local electrical codes. Disconnect and lock out the main power source before making the electrical connection. Procedure: 1) Turn disconnect on the door to the OFF position, lock out the main power source and open the electrical enclosure. 2) Per the electrical diagram, install the main power wire to the main disconnect switch holder and install the ground wire. 5.4 Cooling Coil Connection A Cooling Coil is installed in NW series dryers and is required to lower the hopper return temperature when drying temperatures are above 225 F. This increases the efficiency of dryer. Tower, city or chilled water is required at between 40 to 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 on page 8. Water connections for NW-600NC through NW-2000NC Plasticizer Filter Drain NOTE: An external process air cooling coil is required when drying resins at under 170 F (77 C). NWLarge IM 11-8-2012 Page 10

6 FUNCTION CONTROLS The NW Series dryers come complete with the following controls: Instruction Manual NWLarge IM 11-8-2012 6.1 Process Temperature Control (Drying Temperature) The Temperature Control is a part of the NovaWheel NovaTouch PLC controller and controls the process outlet temperature as per the set value. In addition, there is a process high temperature limit thermostat that is provided for extra safety. (Refer to the controller section). 6.2 Regeneration Temperature Control The regeneration temperature is controlled by the NovaTouch PLC controller. In addition, there is a regeneration high temperature limit thermostat, which provides extra safety. The regeneration temperature is set at about 380 F. (190 C) and should not be changed. 6.3 Process & Regeneration Air Filter Pressure Switches (Ps) The air pressure differential across the process filter and the regeneration filter is monitored and the NovaTouch display will alarm and show when a filter needs to be cleaned or replaced. These are factory set but often need to be adjusted in the field once the customer loads resin in the hopper. Fig. 1 Fig. 2 Process Filter Pressure Switch Regen Filter Pressure Switch Access pressure switches through after removing the back panel from the dryer. Remove Phillips screw that holds clear cover in place (Fig. 1). Turn knob clockwise or counterclockwise to either increase or decrease 6.4 Process Air Dew Point Monitor It measures the process air dew point from the dryer. 6.5 Intelligent Regeneration Intelligent Regen constantly monitors the regeneration inlet and outlet temperatures and controls them to optimize the energy and dew point performance of the dryer. NWLarge IM 11-8-2012 Page 11

7 PRE-OPERATING SYSTEM CHECK Once material, vacuum hose, water and electrical connections are made, the NWDC Series dryer should be given a final checkout. 7.1 Starting The Dryer Turn the main disconnect switch to ON position to power the dryer. To start the dryer depress the ON/OFF button on the controller. The blowers and heaters are now energized and the desiccant wheel will begin turning and start to dry the return air. It will take several minutes and a couple revolutions of the wheel, for the dew point to get down to the -40 dew point. WARNING: E-STOP should only be used in True Emergency conditions. Repeated use of emergency stop can cause dryer component failure. Always use to turn dryer ON or OFF. 7.2 Checking Electrical Phase Using Blower Direction Remove a side panel on the dryer that allows you to view either the Process or Regeneration blower. Stop the dryer by depressing ON/OFF on the controller as above. As the blowers slow down, compare direction of the blades to the arrow on the blower. (A flashlight may be necessary) If the blowers are found to be rotating in the wrong direction, disconnect the main power supply, reverse any two power supply leads to the dryer, reconnect power supply and check again. WARNING: Any wiring procedure should only be done by a qualified electrician familiar with three phase electrical wiring. 7.3 Changing From F to C Degrees can be set to C or F on the NOVATEC SCREEN Basic Machine Configuration. (See page 24) NOTE: All dryers are set to display temperatures in degrees F when shipped. If you change the control to display degrees C, you must also change the DIP switch located on Siemens module 231-7PD22-OXAO located behind the electrical panel access door. DIP switch to change from Fahrenheit to Centigrade NWLarge IM 11-8-2012 Page 12

8 NovaTouch CONTROL 8.1 System Conventions: All information and data displays will appear two dimensional in configuration and flat. All data entry points or operational features will appear three dimensional in configuration and raised or depressed in appearance depending on their operational position. Numerical Entries: When you touch an IO field on the HMI device touch screen that requires only a numerical entry (Password, Temperature, number of seconds etc.) the following keyboard will appear. 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. The numerical screen keyboard opens and displays the current value. 2. Set the value. You can only operate keys which are visualized in 3D format. The type to be entered determines whether a key is enabled or disabled. of value The following options for entering values are available: The current value is deleted when you enter the first character. Enter the value again. Use the and keys to move the cursor within the current value. You can now edit the characters of the current value or add characters. Use the key to delete the character to the left of the cursor. Use the key to change the sign of the value. Select to view the info text of the IO field. Select to confirm your entries or cancel them with. Both actions close the screen keyboard. NWLarge IM 11-8-2012 Page 13

Multiple choice inputs will use the DOWN arrow to alert you to a drop down menu. Pressing the associated display window will cause the drop down menu to appear. The keyboard is automatically hidden again when input is complete. The condition of a switch or display will be displayed in both language and the international ON/OFF icon. Example: [?] or an may appear on any screen, or in any alarm message. This is the indication that there is additional information available. By pressing the symbol, an information page will appear on the screen. The information page will be removed by pressing the X in the upper right hand corner of the page. Each time you exit a screen via the touch pad, the PLC EEPROM is programmed with the new information. The exception to this function is the Real Time Clock. Other symbols will include: Automatic start is on. Automation 2 nd set point is on. Language on screen is U.S. English as indicated on Main menu by en-us. NWLarge IM 11-8-2012 Page 14

8.2 Screen Maps: For all operational functions available to processor: The NOVATEC screen map defines all of the screens provided for all engineering functions: (Available with NOVATEC level password only) NWLarge IM 11-8-2012 Page 15

3 Instruction Manual NWLarge IM 11-8-2012 9 DRYING MATERIAL 9.1 Initial Dryer Startup NOTE: Assure voltage, connection and phasing are correct, cooling water is supplied (For dying over 225 F) and thermocouple is inserted in hopper. Turn main electrical disconnect switch to ON position. (Main Disconnect Switch) Quick Op screen (below) will appear. 1 Press OFF Button to turn dryer & process heater ON. WARNING: Always use for ON/OFF. Only use E-STOP in True Emergency Conditions. Repeated use of EMERGENCY STOP can cause component failure. QUICK OP SCREEN 3 2 1 2 2 Press box under PROCESS SETPOINT, Numeric keypad will appear. Enter PROCESS SETPOINT (Drying Temperature) and press If you want to read temperature in C - see page 12. 3 4 NW-1000NC While waiting for dryer to reach temperature and achieve -40 dew point, press MENU on QuickOp screen, above. Now press DRYER SETUP. NWLarge IM 11-8-2012 Page 16

Press Process Menu 5 Instruction Manual NWLarge IM 11-8-2012 as alternate way to enter drying temp and deviations. 6 5 6 Press Real Time Clock 8 7 7 Check the pre-sets. Press Gray button to enable changes. 8 Press each button where a change is required and keypad will appear. Make entry, then press after each entry. Continue until all fields are correct. Enable Daylight Savings Correction if applicable. 7 Press Monitor Mode - Press to Program to start clock. NWLarge IM 11-8-2012 Page 17

Press the dryer. button, then Auto-Start Menu if you want to program automatic Start/Stop times for 8 9 Mode 10 0 0 Mode 7 7 8 9 10 7 Press Gray button at bottom of screen to enable changes. Enter Dryer Start Time by pressing the Day Button and choose day from Dropdown menu. In first row, press Hours Button, enter start time and then press Same procedure for Minutes Button Enter Dryer Stop Time by choosing the Day and entering the hours and minutes using the second row. Press Disabled Press to Enable to activate Start/Stop function. Press button, then QuickOp Menu if you want to see drying temperature and dew point. It usually takes 2-4 hours for first hopper load of material to be sufficiently dry for processing.. NWLarge IM 11-8-2012 Page 18

10 PROGRAMMING OTHER DRYING FUNCTIONS 10.1 Commonly Used Screens Instruction Manual NWLarge IM 11-8-2012 The Quick-Op is the starting page for the dryer. Once the control is programmed it will display an overview of drying and conveying operations. STEP#1 Depress MENU button to program the Drying and Conveying Functions. Depress this button to enable and disable the process heater. Depress this button to go to the Main Menu for Dryer Set Up & more. Depress this button to go to the alarm list there is a tutorial there that explains the alarms in more detail. This shows the wheel speed it should be between 6 and 12 rph. Depress this button to start the dryer. Press to Change Process Setpoint NW-1000NC Main Menu: From here you can access: Quick-Op Screen Dryer Setup Dryer Operation Status View Message Screen (Alarms) Clean Screen Contrast Adjustments En-US = English US NWLarge IM 11-8-2012 Page 19

STEP #2: Depress Dryer Setup The Dryer Setup screen will direct you to the sub-menus that are necessary to control the functional operation of the dryer. Whenever you press a button that requires a numeric or alpha/numeric entry, a keyboard will appear as described under 8.1 System Conventions on page 13. STEP #3: Depress Real Time Clock Setup The Real Time Clock menu allows the operator to set the clock in the PLC. See complete instructions on page 17. Correct time is important for date/time stamps on ALARM messages and to allow Auto Start/Stop of the dryer. Remember to press: Monitor Mode Press to Program to enable changes AND press it AGAIN when changes are completed to start clock. STEP #4 Depress then AutoStart Menu The AutoStart Menu can be used to start or stop the dryer while unattended. When the system is enabled an icon will be displayed on the operations screens in the upper left corner. Complete instructions are on page 18. Remember to press Disabled Press to Enable to enable changes AND press it AGAIN when changes are completed to enable Auto Start/Stop. NWLarge IM 11-8-2012 Page 20

STEP#5: Depress then Password Menu The Password Menu Screen has listed 6 other screens with a space for passwords and a selector pad to either enable or disable the password. Any 5-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. Step #6: The Password Entry 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. Step #7: Depress then Process Menu Here, the Process values for hopper #1 can be set or adjusted. The high and low deviation, (range for the alarm,) second set point, and active set point values are available. Values must be entered as positive values. The Overtemp SP is the temperature, at which, the hopper blower and temperature control will shut down. NOTE: If you change the factory pre-set values (which are fine for just about any drying scenario) they will apply to every resin you dry so be sure to re-enter the factory pre-sets. NWLarge IM 11-8-2012 Page 21

Features Menu Process The Features #2 Menu displays settings for Set activated Points features including the set points for the Second Set Point Remote Delay, Auto Start and Receivers. This screen is only available if you have a 2- hopper system. Here, the Process values for hopper #2 can be set or adjusted. The high and low deviation, (range for the alarm,) second set point, and active set point values are available. Values must be entered as positive values. The Overtemp SP is the temperature, at which, the hopper blower and temperature control will shut down. NOTE: If you change the factory pre-set values (which are fine for just about any drying scenario) they will apply to every resin you dry so be sure to The Feature Menu displays settings for activated features including the set points for the Second Set Point Remote Delay, Auto Start and Receivers. 10.2 Other Helpful Screens NW-1000NC Other screens that can be accessed from the Main Menu include: Dryer Operation (Operation Screen 1) Status View Message Screen NWLarge IM 11-8-2012 Page 22

Dryer Operation Screen From the Main Menu if you select the Dryer Operation Screen, all of the dryer parameters can be monitored. Reactivation inlet and outlet temperature 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. Status View Screen -40 Actual Dew Point -40 Process Set Point 240 Actual Process Temp 238 From the Main Menu Screen you can set the status screen up to show selected items in a LARGE FONT On the Status View, all of the system responses can be monitored. The display is set on a 5 second loop. The can be changed to and the title of that display will become a drop down menu. Then you may select whichever status you want to display. This screen is typically used when viewing parameters from the ground if the dryer is on a mezzanine. Alarm Screen This icon will appear on all screens when there is an alarm. It will flash for an active alarm and show the count for how many alarms are active. It will disappear when the alarms clear or are cleared by operator intervention. Alarm messages will appear on the Main Menu when the Messages button is pressed. Alarm messages will appear as a dropdown box on any screen when the Alarm icon is pressed. NWLarge IM 11-8-2012 Page 23

NOVATEC Menu Changing From C to F NW-1000NC The NOVATEC MENU can be seen by touching the upper LH corner of any other screen. It can only be accessed with a NOVATEC password. The screen contains the software revision level (in the case of a standard) or the program number (in the case of a custom) for both the touch screen and PLC. The Runtime Control Panel releases the dryer program and goes to the touch panel set up program. Other touch buttons allow access to special set up screens. For instance, Calibrate Touch Screen allows set up of the touch pressure that will cause the screen to respond to the operator s finger. Changing from F to C is a common reason to access this screen. Obtain password from NOVATEC. Press in upper LH corner of any screen to view NOVATEC Menu. Enter NOVATEC Password. Press Basic Machine Configuration then Configuration Menu 1. Press F and it will change to C. Press 10.3 Rarely then Used to Screens exit. Rarely NOTE: Used If you Screens switch from F to C you must also adjust the dip switch on the PLC. See page 12 This screen allows you to install the options for 1 or 2 drying hoppers, whether they have active drying, offset the thermocouple if there is an error, and to filter the response if the thermocouple is noisy. On the thermocouple, entering a -5.0 will raise the reading 5 degrees. Entering a 5.0 will lower the reading 5 degrees. Valid entries for the filter are between 1.0 and 0.01. Contact Novatec Engineering before changing the settings. NWLarge IM 11-8-2012 Page 24

This screen will allow you to turn on the water saver function and adjust the output response for whether your system has a N/O or N/C water saver solenoid. It is also used to turn the icons and functionality for the material control systems on or off. 10.3 Rarely Used Screens NO ENTRY REQUIRED Shipped Configured and Enabled Intelligent Regen constantly monitors the regeneration inlet and outlet temperatures and controls them to optimize the energy and dew point performance of the dryer. The control will lower (or raise) the regeneration inlet temperature by 5 F. (2.4 C) each time the desiccant wheel rotates to ensure that adequate, but not excess heat, is used to maintain the dryer dew point performance while insuring that no excess heat is used and wasted. Once the dryer has optimized itself, changes cease. The system insures the best dryer performance despite the materials processed, their moisture level or any changes in dryer processing rate thereby saving energy and improving performance. If there is an extended delay at the process machine, it is easier to re-set a reduced drying temperature or shut the Process Heater OFF on the QuickOp screen but this menu can be used to put or remove the dryer from second set point while unattended. When the system is enabled an icon will be displayed on the operations screens in the upper left corner. NWLarge IM 11-8-2012 Page 25

11 MAINTENANCE INSTRUCTIONS 11.1 Suggested Maintenance Schedule* CAUTION: Process, Regeneration and Plasticizer Filters MUST be Inspected and Cleaned per below AND Plasticizer MUST be Drained Into a Pan Every Two Weeks (more often if necessary) or poor drying and damage to the dryer will occur. Component Action Frequency Process Blower Motor Permanently lubricated - Reactivation Fan Motor X No Action required. Rotor Drive Motor Process Filter Regeneration Filter Clean with compressed air or replace as necessary. Every 2 weeks Plasticizer Filter Inspect & Clean as necessary Every 2 weeks Plasticizer Drain Drain plasticizer into pan Every 2 weeks Process Heater Hose. Tubing & Clamps Hopper Gaskets & Seals Pellet Screen Rotor Drive Chain & Sprockets Rotor Seals Rotor Rotation Compare process temperature setting to hopper inlet temperature to make sure they are comparable. If they are not - Contact NOVATEC Service Department. Check for leaks or holes. Tighten or replace as necessary. Check for leaks Repair or replace as necessary. Locate wire mesh at hopper return air outlet and clean with compressed air. Lubricate Do Not Disturb Except in an Emergency Preset at factory-no action required. Rotor speed should be 6-12 rotations/hour. If outside this parameter, make sure the limit switch hump is re-setting the limit switch. Every 2 weeks Every 2 months Every 2 months Every 2 months Every 6 months X X *This schedule may have to be varied depending on the dust level and abrasiveness of the materials you are processing and the number of hours you are operating the dryer each week. NWLarge IM 11-8-2012 Page 26

11.2 Process, Regeneration & Plasticizer Filters The filters shipped with the dryer are cleanable. The maintenance interval for the filters depends on the cleanliness of the surroundings and the dust/fines in plastic raw materials. A program should be established to ensure the filters are cleaned. Process Filter Access Regeneration Filter Access Plasticizer Filter Access TURN THE MAIN DISCONNECT SWITCH OFF 1- Turn 2 blue or yellow clamps to open filter access door. 2- Note which way arrows on filters point & pull flat Filters out of slots. 3- Clean with compressed air or replace, as necessary. 4- Slide filter elements back into slots being sure that arrows are pointing in the original direction. 5- Close access door and turn clamps to hold them closed. 6- Reconnect power and re-start dryer. Plasticizer Filter Drain EVERY 2 WEEKS Plasticizer Filter Process Air Filter NOTE: The best way to clean the plasticizer filter is to steam clean it, then wash with hot, soapy water and rinse thoroughly. A backup filter can be installed during this process. NWLarge IM 11-8-2012 Page 27

11.2.1 Draining Plasticizer Plasticizer Sight Glass EVERY 2 WEEKS Plasticizer Drain shown in normal (non-draining) position. To Drain Plasticizer: Place a pan under the valve exit. Push white cylinder towards dryer and turn the valve handle to the left. Plasticizer will drain into the pan. When finished draining, pull valve handle back to 12 o clock position. NWLarge IM 11-8-2012 Page 28

11.3 Chain and Sprockets Chain Drive Motor Tensioner Assembly Drive Sprocket Chain and sprockets should be lubricated every six months. 11.4 Desiccant Rotor The state-of-the-art desiccant rotor supplied with NWDC series dryers will last very long under ideal conditions. Due to the nature of desiccant and honeycomb matrix they make very good filters. The life of desiccant is directly related to the air born contaminates passed through it. Avoid exposure to acidic gases or unusual amounts of dust. Although the desiccant rotor is considered a cleanable/washable media, the preferred method of cleaning is to blow dust out with low pressure compressed air and to reactivate the rotor at a maximum temperature of 380 F (190 C) for 15 minutes. Washing the rotor, although possible, is not recommended as wash water impurities may contaminate the desiccant. Proper filtration and preventing contact with chemicals will greatly improve the life of the desiccant. Inspect the face of the rotor to see that no surface damage has occurred. The rotor should turn smoothly upon the shaft. Desiccant Rotor. Drive Motor NWLarge IM 11-8-2012 Page 29

11.5 Motor Rotation Signal Check that the wheel rotor is rotating properly and each time a signal goes to the controller, ensure that rotor complete its cycle and the limit switch hump has reset the limit switch provided near the rotor. If the hump is not resetting the limit switch, reset the limit switch toward the rotor. 11.6 Rotor Replacement Desiccant rotor removal is accomplished bas 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. To re-install rotor, reverse the above procedure. NWLarge IM 11-8-2012 Page 30

11.7 Seal Replacement The top and bottom silicon PTFE coated fabric flat seals which separates the process from the reactivation purge compartments. Normally they do not require service or replacement. However, should damage occur, or if air leakage is suspected of causing poor performance, the seal should be replaced using the following procedure. 1. Remove rotor from the cassette as explained above. 2. Remove the old seal using knife. Also remove silicon sealant. 3. Clean the plate surface. 4. Apply fresh silicon sealant. 5. Gently press the seal towards the plate, make sure the seal s section does not get offset 6. After joining the seal to the plate, let it dry for 24 hrs. NOTE: The smooth Teflon coated side of the seal is always on the top side of the seal and there should not be any silicon sealant remaining on that side. 11.8 Drive Motor Replacement Desiccant rotor removal is accomplished as follows: 1. Remove the chain from the drive sprocket. 2. Remove the drive sprocket from the motor shaft. 3. Remove the screws of the motor from the plate. 4. Replace the drive motor. To re-install drive motor, reverse the above procedure. NWLarge IM 11-8-2012 Page 31

11.9 Seal Replacement The top and bottom silicon PTFE coated fabric flat seals separate the process from the reactivation purge compartments. Normally they do not require service or replacement. However should damage occur, or if air leakage is suspected of causing poor performance, the seal should be replaced adopting following procedure. 7. Remove rotor from the cassette as explained above. 8. Remove the old seal using knife. Also remove silicon sealant. 9. Clean the plate surface. 10. Apply fresh silicon sealant. 11. Gently press the seal towards the plate, make sure the seal s section does not get offset 12. After joining the seal let it dry for 24 hrs. NOTE: The smooth Teflon coated side of the seal should always on the top and there should not be any silicon sealant remaining on that side. 11.10 Drive Motor Replacement Desiccant rotor removal is accomplished by the following: 5. Remove the chain from the drive sprocket. 6. Remove the drive sprocket from the motor shaft. 7. Remove the screws of the motor from the plate. 8. Replace the drive motor. To re-install drive motor, reverse the above procedure. 11.11 Motor Rotation Signal To check that wheel rotor is rotating properly and each time a signal to the controller goes, to ensure that rotor complete its cycle and the limit switch hump has reset the limit switch provided near the rotor. If the hump is not resetting the limit switch, reset the limit switch toward rotor. NWLarge IM 11-8-2012 Page 32

12 TROUBLE SHOOTING and ERROR MESSAGES TROUBLE PROBABLE REASON CORRECTIVE ACTION 1. Unit not running Control main circuit breaker tripped. Main power off. Reset the breaker. Check line and main. 2. Material in hopper melts. 3. Reactivation (regeneration) temperature too high. 4. Reactivation (regeneration) heat too low (Rotor not fully reactivating.) Control power interrupted. Process temperature controller set too high for material being dried. Temperature probe not installed in process air stream. Process blower rotating in wrong direction. Temperature sensor connection loose or reversed. Reactivation temperature set too High. Reactivation thermostat setting too low Reactivation temperature controller set too Low Reactivation heaters faulty. Check per item as per electrical wiring diagram. Check set temperature for proper drying process temperature. Ensure temperature probe is installed in the dryer outlet, or in the hopper inlet. Change blower rotation. Correct the connection. Check set-temperature on NWDC controller. it should be 380 F (190 C) Adjust thermostat for proper reactivation heat at around 380 F (190 C) Check set temperature on NWDC microprocessor controller. it should be 380 F. (190 C) Replace heaters. NWLarge IM 11-8-2012 Page 33

TROUBLE PROBABLE REASON CORRECTIVE ACTION 5. Material in hopper Clogged Filters Inspect and clean/ replace all filters, as not getting dried necessary. properly. Drain plasticizer. Door gasket leaking or Check all gaskets (filter cover, hopper damaged. doors, and hopper lids) and repair or replace damaged gaskets. 6. High dew point in process air from dryer into hopper. Leak in hose. Hose connection loose. Wrong process temperature for material being dried. Hopper is running almost empty. See #6 below High inlet temperature to the wheel rotor (should be less than 150 F per the display). Leaks in the system. Replace hose Tighten hose connections. Add material to hopper and control the level higher. Check the cooling water is flowing to the cooling coil and make sure the temperature is below 85 F and at the proper flow. Check the dryer system & hopper for any air leaks & repair as required. 7. Process blowers not running. 8. Dew Point Sensor not working properly. 9. Wheel rotor turning but not indexing or showing a RPH speed. High moisture levels in plastic resin being dried in hopper, reducing the drying performance. Motor main circuit breaker tripped. Motor overload tripped. Not operating High or erratic dew point Rotor limit switch not aligned properly. Rotor drive motor defective. Reduce the moisture of the resin being loaded into the hopper. Keep the resin sealed until ready for use, to reduce the amount of moisture being picked up by the resin from the surrounding air. Reset main circuit breaker. Rectify fault reset overload and check motor AMPS are in limit. Check sensor wiring for tightness & breaks. Check sensor wiring and check tubing to the sensor & sensor for tightness and air leaks. Replace the dew point sensor as required (it should be replaced yearly) Align the limit switch it should be reset by limit switch hump on each rotation. Replace motor NOTE: When ALARM message is followed by a?, press the message for more information. NWLarge IM 11-8-2012 Page 34

13 WARRANTY NOVATEC, INC. - Effective Date 6-12-2012 Instruction Manual NWLarge IM 11-8-2012 NOVATEC, INC. offers COMPREHENSIVE PRODUCT WARRANTIES on all of our plastics auxiliary equipment. We warrant each NOVATEC manufactured product to be free from defects in materials and workmanship, under normal use and service for the periods listed under Warranty Periods. The obligation of NOVATEC, under this warranty, is limited to repairing or furnishing, without charge, a similar part to replace any part which fails under normal use due to a material or workmanship defect, within its respective warranty period. It is the purchaser s responsibility to provide NOVATEC with immediate written notice of any such suspected defect. Warranted replacement parts are billed and shipped freight pre-paid. The purchaser must return the suspect defective part, freight prepaid and with identifying documentation to receive full credit for the part returned. NOVATEC shall not be held liable for damages or delay caused by defects. No allowance will be made for repairs or alterations without the written consent or approval of NOVATEC. The provisions in equipment specifications are descriptive, unless expressly stated as warranties. The liability of NOVATEC to the purchaser, except as to title, arising out of the supplying of the said equipment, or its use, whether based upon warranty, contract or negligence, shall not in any case exceed the cost of correcting defects in the equipment as herein provided. All such liability shall terminate upon the expiration of said warranty periods. NOVATEC shall not in any event be held liable for any special, indirect or consequential damages. Commodities not manufactured by NOVATEC are warranted and guaranteed to NOVATEC by the original manufacturer and then only to the extent that NOVATEC is able to enforce such warranty or guaranty. NOVATEC, Inc. has not authorized anyone to make any warranty or representation other than the warranty contained here. Non-payment of invoice beyond 90 days will invalidate the warranty. A renewed warranty can be purchased directly from NOVATEC. 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 Period: Note: All warranty periods commence with the shipment of the equipment to the customer. NW Series NovaWheel = 2 Years Exclusions: Routine maintenance/replacement parts are excluded from the warranty. 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 materials. 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 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. Touch screen controls on NovaWheel dryers have a 2-year warranty. All other controls have a 1-year warranty 3. 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. 4. LOAD CELLS on our WSB s are covered by NOVATEC standard warranty as long as they have not been damaged from improper handling. 5. Velocity Control Valve warranty is voided if unit is placed in direct material flow. 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 wiring by others 3. Warranty is void if processing rates exceed manufacturer-recommended levels or if damage is caused by ineffective power isolation and/or power spikes/sags or incorrect installation. NOTE: All conditions and content of this warranty are subject to changes without notice. NWLarge IM 11-8-2012 Page 35