NovaTec NovaWheel NW Series User manual

Document#:
IM
N
W400-2000
_
10-07-08
Novatec, Inc
222 E. Thomas Ave.
Baltimore, MD 21225
Telephone: [phone]
Fax: [phone]
Parts Email: [email protected]
Website: www.novatec.com
Service Email: [email protected]
NovaWheel™
DESICCANT WHEEL DEHUMIDIFYING DRYER
INSTRUCTION MANUAL
NW Series with ‘NovaTouch’ Touch Panel PLC
Models: NW-400, NW-600, NW-800, NW-1000, NW-1300 & NW-2000

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TABLE of CONTENTS
SECTION PAGE
FOREWORD…………………………………………………………………....3
1. SALES AND SERVIC………………………………………………………….3
2. SHIPPING AND INSPECTION………………………………………………..3
3. PRINCIPLE OF OPERATION………………………………………………....4
Product familiarization
4. INSTALLATION………………………………………………………………...6
4.1 LOCATION
4.2. CUSTOMER PIPING CONNECTIONS
4.3 ELECTRICAL CONNECTIONS
4.4 PRE-COOLER CONNECTIONS
5. CONTROLS………………………………………………………………………9
5.1 PROCESS TEMPERATURE CONTROL
5.2 REACTIVATION TEMPERATURE CONTROL
5.3 PROCESS FILTER, AIR PRESSURE SWITCH (PPS1)
5.4 PRESSURE AND REACT AIR PRESSURE TRANSMITTER
6. OPERATING INSTRUCTION………………………………………………….10
7. NOVATOUCH CONTROLLER INSTRUCTIONS…………………………...11
8. MAINTENANCE INSTRUCTION
8.1 MOTORS
8.2 FILTERS
8.2.1 PROCESS FILTERS
8.2.2 REACTIVATION FILTER
8.3 GASKET
8.4 HOSES
8.5 ROTOR SEALS
8.6 CHAIN AND SPROCKETS
8.7 DESICCANT ROTOR
9. PREVENTIVE MAINTENANCE PROGRAMMED…………………………..24
9.1 BI-WEEKLY BASIS
9.2. MONTHLY BASIS
9.3. QUARTERLY BASIS
9.4 ANNUAL BASIS
10. ROTOR REPLACEMENT…………………………………………………….27
11. SEAL REPLACEMENT……………………………………………………….28
12. DRIVE MOTOR REPLACEMENT…………………………………………...28
13. MOTOR ROTATION SIGNAL………………………………………………..28
14. TROUBLE SHOOTING……………………………………………………….29
WARRANTY………………………………………………………………………...32

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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 insure 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: [phone] ●[email protected]
Technical Service Department: 1-800-938-6682 ●[email protected]
2. SHIPPING AND INSPECTION
Although NOVATEC uses reputed carriers to deliver products, it has no control over the
products once it leaves the manufacturing facility. Upon receiving the products, 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..

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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 400°F. (205°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.
Product familiarization
The major components and their locations are shown in fig-1. Fig-2 indicates the system flow
diagram.

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SPECIFICATIONS - NovaWheelTM Dryer
Model NW-400 NW-600 NW-800 NW-1000 NW-1300 NW-2000
Max Material Flow - Lbs./Hr) 375
(170
kg/hr)
500
(227
kg/hr)
750
(340
kg/hr)
1000
(454
kg/hr)
1250
(567
kg/hr)
2000
(907
kg/hr)
Voltage – Phase - Hz 460-3-60 460-3-60 460-3-60 460-3-60 460-3-60 460-3-60
Water Required - Nominal (GPM): 3 6 10 15 15 16
Customer Water Line Size (min): 1/2” id
(20 mm)
5/8” id
(20 mm)
3/4” id
(20 mm)
1” id
(25 mm)
1” id
(25 mm)
1” id
(25 mm)
Wheel Speed - nominal
(revolutions per hr):
10 10 10 10 10 10
Process Air dew Point (nominal): -40ºF (-40°C)
Drying Temperature: 150-350°F (66-177°C)
4. INSTALLATION
CAUTION: FOLLOW ALL NATIONAL AND LOCAL ELECTRICAL AND MECHANICAL
CODES, AS REQUIRED. ONLY QUALIFIED AND TRAINED PERSONNEL
SHOULD INSTALL AND OPERATE THIS EQUIPMENT.
4.1 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.
4.2 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.

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Process air connections:
NW-400: 6 inches diameter
NW-600: 6 inches diameter
NW-800: 8 inches diameter
NW-1000: 8 inches diameter
NW-1300: 12 inches diameter
NW-2000: 12 inches diameter
4.3 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.
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 the 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.

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4.4 COOLING COIL CONNECTION
A Cooling Coil is installed in NW series dryers and is required to lower the hopper return
temperature and 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 below on page 6.

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5.0 CONTROLS
The NW Series-dryer comes complete with the following controls:
5.1 PROCESS TEMPERATURE CONTROL
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 and process return temperature safety, through
the NovaWheel controller, is provided for extra safety. (refer to the controller section). On
the NW-400, the process heater is in the “NW” dryer cabinet. On sizes NW-600 and
larger, the heater and the controls were supplied “loose” for installation on the hopper.
On central drying systems, the process heaters are located on the hoppers.
5.2 REACTIVATION TEMPERATURE CONTROL
The reactivation temperature is controlled by the NovaTouch PLC controller. In addition,
there is a reactivation high temperature limit thermostat, which provides extra safety. The
reactivation temperature is set at about 400°F. (205°C) and should not be changed.
5.3 PROCESS & REGENERATION AIR FILTER PRESSURE SWITCHES (PS)
Monitors the air pressure differential across the process filter and the regeneration filter,
to be alerted when these filters need to be changed. The NovaTouch display will alarm
and show what filter needs to be cleaned or replaced, when these switches are
energizes.
5.4 PROCESS AIR DEW POINT MONITOR
It measures the air dew point from the dryer.

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6. OPERATING INSTRUCTION
Before beginning final start up, check the correct blower rotation per the rotation arrows on
both the process and the regeneration blowers. If the blowers are found to be rotating in the
wrong direction, disconnect main power supply, reverse any two power supply leads to the
dryer, reconnect power supply and check again.
WARNING:
This process should only be done by a qualified electrician familiar with three phase
electrical wiring.
Once the hose and electrical connections are made, the NW-Series dryer is now ready for
operation.
To start the dryer:
1.0 Turn the main disconnect switch to “ON” position to power the dryer.
2.0 To start the dryer depress the “ON” on the NovaTouch controller (see the NovaTouch
Control - 7 below).
2.1 The blowers and heaters are energized and the desiccant wheel starts turning and
the dryer is starting to dry the return air. It will take some minutes and a couple
revolutions of the wheel, for the dew point to get down to the -40° dew point.
3.0 To stop the dryer, depress the “OFF” on the NovaTouch controller (see the NovaTouch
Control - 7 below).

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7. NOVATOUCH CONTROL
Permissions:
Some of the information contained in this manual is a reprint of Siemens Manuals. Novatec Inc
obtained written permission to reprint portions, as needed, for this manual in 2001.
Trademarks:
All names identified by ® are registered trademarks of the Siemens AG. The remaining
trademarks in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owner.
All names identified by TM are registered trademarks of Novatec Inc. The remaining trademarks
in this publication may be trademarks whose use by third parties for their own purposes could
violate the rights of the owner.
System Specifications:
All information on the TP177M touch screen and the S7-200 series PLC can be obtained from
the Siemens websites shown below. In general, these products have all the necessary
approvals in more than 15 countries.
Manuals are available in 5 different languages.
http://www.automation.siemens.com/simatic/portal/html_76/techdoku.htm
http://www.ad.siemens.de/simatic/portal/html_76/techdoku.htm
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.
When you touch an IO field on the HMI device touch screen, the numerical screen keyboard
will appear. The keyboard is automatically hidden again when input is complete.

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You can enter numerical and hexadecimal values character by character using the numerical
screen keyboard.
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 of value to be entered
determines whether a key is enabled or disabled.
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.
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.

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The condition of a switch or display will be displayed in both language and the international
ON/OFF icon.
Example:
On any screen, or appearing in any message, may be “[?]” or an . 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 2nd set point is on.
System Screen Map:
The following map defines all of the screens provided for all operational functions:

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Novatec Screen Map:
The following map defines all of the screens provided for all engineering functions:
The Quick-Op is the starting page for the dryer.
It will display the current time and date once the
Real Time Clock is properly set. It will also show
the communications Station ID (if so equipped.)
From here the dryer can be started and other
operational functions accessed.

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The Main Menu is the starting page for the dryer.
It will display the current time and date once the
Real Time Clock is properly set. It will also show
the communications Station ID (if so equipped.)
The contrast of the screen may be adjusted
using the associated touch pads. The Clean
Screen touch pad will turn off the actual touch
function of the screen so that it may be cleaned.
From here the dryer can be started and all other
operational functions accessed.
From the Operation Screen, all of the system
responses can be monitored. Reactivation
inlet and outlet temperature; process inlet and
outlet temperature; system dew point, and
calculated desiccant wheel RPH is
represented. The graphics on this screen will
change appearance in accordance with the
mode of operation.
From Operation Screen 2, the current status
of drying hopper #1 can be viewed. The
graphics on this screen will change
appearance in accordance with the mode of
operation.

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The Dryer Setup screen will direct you to
the sub-menus that are necessary to
control the functional operation of the
dryer.
From Operation Screen 3, the current status
of drying hopper #2 can be viewed. The
graphics on this screen will change
appearance in accordance with the mode of
operation.
On the Status Screen, 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.

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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.
The Real Time Clock menu allows the
operator to set the clock in the PLC.
To Program:
Set the clock to program mode via the
touch pad. Enter the year, month, day,
hours, minutes, and seconds, day of the
week, and the Daylight Savings Time
applicable for your local time zone. Set the
clock to monitor mode. The seconds
should start counting.
This time will be used for the time/date
stamp on any fault messages.
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.

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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.
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.
The Auto Second Set Point 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.

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The Password Setup 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.
On this screen, the alarm value for the system
dew point is set. It also has the settings for the
Moisture Manager. If the Moisture Manager is
turned on the reactivation temperature will be
decreased by 5 degrees per revolution of the
desiccant cassette. It will use the moisture
manager set point as a target and adjust the
system to stay between the high and low
alarm values.
The Features Menu holds the set points for
the Second Set Point Remote Delay,
Second Set Point Sleep Delay, all material
handling, and the Water Saver and Water
Saver Alarm values.

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The NOVATEC 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. Calibrate Touch Screen
allows you to set up the touch pressure that will
cause the screen to respond to the operator’s
finger. The Runtime Control Panel releases the
dryer program and goes to the touch panel set up
program. See the TP177M manual for details on
the operation in this mode. Basic Machine
Configuration and PID Values touch pads will take
you to the associated screens.
Using the associated drop down menus the
size of the dryer and dew point sensor can be
set. Set the Temperature Display for C or F as
required. This will re-calculate the set points to
either C or F and place them into memory.
Start Up Alarm Delay gives the system time to
stabilize before the temperature and dew point
alarms are activated. Alarm Recycle will re-
trigger all active, non-critical alarms based on
the time settings.
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.