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USER GUIDE
Rx SmartMed MVT Medical Vacuum Tanks MODELS:
>MVT-3 >MVT-5 >MVT-8
MVT-UG 20 AUG 2019 ©2019 NOVATEC, Inc. All Rights Reserved
User Manual: MVT-UG 20 AUG 2019
Serial Number(s):
Model Numbers:
In the space provided below you should record the model and serial number(s) of your equipment and the date the equipment was received.
In the event you would need aftermarket assistance our parts and ser- vice department uses this information, along with the manual number, to provide help for the specific equipment installed.
Please keep this instruction manual, any relevant addendums, engineer- ing prints and parts lists together for accurate documentation of your equipment.
NOTES:
DISCLAIMER: NOVATEC, Inc., shall not be liable for errors in this instruction manual. Information can change without notice. Novatec makes no warranty of any kind concerning the information contained herein, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.
©2019 NOVATEC, Inc. All Rights Reserved.
Table of Contents 1.0 SALES AND SERVICE ................................................................................................................................................................ 4
2.0 SHIPPING AND INSPECTION ................................................................................................................................................. 4
3.0 UNPACKING ............................................................................................................................................................................... 4
4.0 GENERAL INSPECTION............................................................................................................................................................ 4
5.0 VACUUM TANK STARTUP & CHECKLIST ........................................................................................................................... 5
6.0 QUICK OPS SCREEN ................................................................................................................................................................. 6
6.1 Quick Ops Screen Layout..................................................................................................................................................... 6
6.2 Quick Ops Screen Item Description .................................................................................................................................. 6
6.2.1 Tank Position ....................................................................................................................................................................... 6
6.2.2 Water Pump ......................................................................................................................................................................... 7
6.2.3 Puller Speed ......................................................................................................................................................................... 7
6.2.4 Puller Gap ........................................................................................................................................................................... 7 6.2.5 Vacuum Control .................................................................................................................................................................. 7
6.2.6 Tank Position ....................................................................................................................................................................... 7
6.2.7 Temperature Control ......................................................................................................................................................... 8
6.2.8 Tube OD ............................................................................................................................................................................... 8
6.2.9 GO TO STRING UP and GO TO HOT GAP Buttons ………………………………………………………………………………….8
6.2.10 Increase/Decrease (Jog) Buttons ................................................................................................................................. 8 6.2.11 Water Pump Pop-up Details ......................................................................................................................................... 8
6.2.12 Set TANK POSITIONS Control Pop-up ...................................................................................................................... 9
6.2.12.1 SET HOME POSITION Button ................................................................................................................................... 9
6.12.2.2 RESET DIE Button ........................................................................................................................................................ 9
6.12.2.3 Setting Die, Hot Gap and String Up (Fast Re- tract) Positions ........................................................................... 9
6.2.13 Selecting Maximum Vacuum ...................................................................................................................................... 10
7.0 DASHBOARD ........................................................................................................................................................................... 10
8.0 RECIPES (THIS PART IS STILL IN DEVELOPMENT) ........................................................................................................ 11
9.0 ALARM SCREENS ................................................................................................................................................................... 12
10.0 TRENDS……………………………………………………………………………………………………………………………………………………….12
11.0 SYSTEM SETTINGS SCREENS ........................................................................................................................................... 13
11.1 Tank Position (Z-Axis) Settings ..................................................................................................................................... 13
11.2 Water Pump Settings ...................................................................................................................................................... 14
11.3 Vacuum Control Parameters .......................................................................................................................................... 15
11.4 Temperature Control Parameters ................................................................................................................................. 16
11.5 Puller Speed & Gap .......................................................................................................................................................... 16
11.6 Miscellaneous Settings .................................................................................................................................................... 17
11.7 Maintenance Settings ...................................................................................................................................................... 18
11.7.1 User Management ........................................................................................................................................................ 18
11.8 MVT CONFIG. (Machine Configuration Screen) ....................................................................................................... 19
11.8.1 Installed Options ........................................................................................................................................................... 19
11.8.2 Sinamic Drive Parameters ........................................................................................................................................... 19
11.8.3 External Digital Vacuum Set Point Adjustment ..................................................................................................... 19
11.8.4 Maximum Vacuum Lookup ......................................................................................................................................... 19
12.0 MECHANICAL OPERATION .............................................................................................................................................. 20
12.1 Bessemer Rx SmartMed Overview .............................................................................................................................. 20
12.2 Linear Actuation ............................................................................................................................................................... 20
12.3 Higher Precision Vacuum Control - From the High Through the Low End ......................................................... 21
12.4 Externally Adjustable Roller Control ........................................................................................................................... 21
12.5 Water Diffuser System ................................................................................................................................................... 21
12.6 Dramatic Reduction of Flushing Time ......................................................................................................................... 21
12.7 Reduction of Pump Vibration Greatly Reduces Turbulence ................................................................................... 22
12.8 Internal Air Wipe .............................................................................................................................................................. 22
12.9 Easy, Tool-Free Cleanability ........................................................................................................................................... 22
12.10 Sanitary Tri-Clover Fittings Replace Threaded Fittings ........................................................................................ 23 12.11 Excellent Filtration - Standard .................................................................................................................................... 23
12.12 Non-contact Tooling ..................................................................................................................................................... 23
12.13 Contact Calibration Tooling ......................................................................................................................................... 24
12.14 Use As Vacuum Tank or Open Tank .......................................................................................................................... 24
13.0 WARRANTY ........................................................................................................................................................................... 25
4
FOREWORD This manual is dedicated to the principle that any engi- neered system will have many elements contributing to the smooth operation of the system, and that these must be understood in order that installation and operation can proceed successfully.
The electrical and mechanical components in the MVT Series Medical Vacuum Tanks and Water Tanks have been manufactured, selected and assembled with care to give you excellent service. A full range of MVT series tanks have been introduced to enable our valued cus- tomers to select the right model for their application. All components of these tanks have been carefully en- gineered 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.
1.0 SALES AND SERVICE NOVATEC maintains qualified sales, engineering, and service personnel to assist in any way possible. If you have any comments concerning the types of equipment which NOVATEC manufactures that might improve your process, or any questions concerning service, we urge you to contact us. Please have your Model and Serial Number handy.
• Sales: 1-800-237-8379 • Fax: 410-789-4638 • [email protected]
Technical Service Department: 1-800-938-6682 • [email protected]
2.0 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 be- fore shipment. You are to make the piping, and electrical connections for final installation and commissioning. If there any problems, shut down the equipment and con- tact the NOVATEC Technical Service Department.
3.0 UNPACKING Caution should be exercised to see that the equipment is not handled roughly. The crate must be removed care- fully. Do not pry against the machine when removing the crate. Note any shipping damage on delivery receipt and report immediately to trucking company.
4.0 GENERAL INSPECTION When the unit is unpacked, make a visual inspection looking for missing parts or damage that may have occurred during shipment. Report any missing parts to Novatec immediately. All electrical and mechanical connections should be checked for tightness, as vibration during transit may cause them to loosen.
5
5.0 VACUUM TANK STARTUP & CHECKLIST Check before turning on: • The tank can move in all 3 axis. 1. +/-2” about 42” centerline vertically 2. +/-1” side to side horizontally 3. 12” along the length of the unit • All of the pump motors are wired for 460 VAC • All of the electronic overloads are set at the correct
current Startup up the system • Install the sealing end plates, close the drain valves,
open the spillover valves and open all of the lids. • Fill the tank reservoir system to the maximum fill level
(Note: Level will be marked) • Attach air supply at installed pressure regulator for air
wipe usage • Check for leaks in all steps of startup and testing. • Wait for the water level to reach the tubes going to the
recirculation pump. • Briefly turn on the recirculation pump to determine
the direction of rotation. Swap 2 wires at motor if it is incorrect.
• Turn on the recirculation pump. Ensure proper drain age of water from tank, choke flow if it looks like it will overflow.
• Turn on the vacuum pump(s) briefly to check the direction of rotation. Swap 2 wires at the motor if it is incorrect.
• Turn on the Vacuum Pump(s) • Open each spray bar valve fully so that it is in line with
the pipe. • Open each standpipe valve fully • Simulate operational clean-out of filter system to en-
sure check valves are working properly by draining fluid from bowl of non-used filter and remove bowl.
Vacuum Requirements and Leak Testing • Verify seal water flow regulator is functioning/installed
properly. • Close the Lids. The unit should seal within 3 seconds. • Vary the speed using the touch screen on regen blower
style tanks to vary the pressure • Under full water flow conditions, the maximum vacuum
read at the gauge should be as follows: • Regen Blower: 130” H2O • Observe full range under full flow conditions by varying
mechanical valves on each top section of tank. • There must be no air bubble leakage in the front
section windows.
6
Temperature control section.
Tank position (Z-Axis) section.
Screen navigation buttons
Increase value control buttons
Decrease value control buttons.
Puller speed and gap control sections
(optional)
Vacuum control section.
Diameter gauge
readout (optional)
Water Pump status section. Press to open
control pop-up.
Tank position animation
Tank “GO TO” position buttons
6.0 QUICK OPS SCREEN
6.1 Quick Ops Screen Layout The Quick Ops screen is divided onto three vertical sections (left, center and right).
The left section includes (from top to bottom): GO TO STRING UP position button, WATER PUMP status section and “decrease value” control buttons.
Center section displays tank position, PULLER SPEED and PULLER GAP sections, vacuum control section, TANK POSITION (Z-Axis) control section and TEMPERATURE CONTROL section.
Right section includes GO TO HOT GAP button, TUBE OD section and “increase value” buttons.
Bottom of each screen is occupied by the navigation buttons (NavBar) allowing quick access to the QUICK OPS, DASHBOARD, RECIPE, ALARMS, SETTINGS and TRENDS screens. Currently selected screen is indicated by the blue background color of the associated button on the NavBar.
NavBar section with Quick Ops screen selected.
6.2 Quick Ops Screen Item Description 6.2.1 Tank Position The TANK POSITION section (top, center part of the Quick Ops screen) shows the relative tank position in reference to the extruder and puller.
TANK POSITION section.
Tank Extruder Puller
7
6.2.2 Water Pump The WATER PUMP section displays water pump status (OFF – grey background, ON – green background, FAULT – red background), day (sun icon - production) or night (moon icon - circulation) mode of operation, filter’s UV light on indicator and actual PUMP SPEED (%). Pressing anywhere in that section will open pop-up that allows to turn on and off water pump as well as switch between day or night modes).
PULLER SPEED section.
6.2.3 Puller Speed The PULLER SPEED Control section shows actual pull- er speed and speed setpoint (setpoint can be modified). This is optional and currently available when the Novatec MedRx puller is networked. Touching anywhere in that section activates it (section’s color will change to brown) and allows fine puller speed adjustment using increase and decrease buttons. This section can be enabled (shown) or disabled (hidden) from the screen using the configuration screen.
6.2.5 Vacuum Control The VACUUM CONTROL section. This section is always visible on the vacuum tank and hidden on the water tank (configuration is done from the HMI setup screen). This section controls the vacuum pump (ON/OFF button) and its status (OFF, ON, FAULT – grey, green, red background color of the ON/OFF button accordingly), current vacuum pump speed (%), current vacuum level, selected maxi- mum vacuum level and state of the automatic vacuum controller (MAN or AUTO). The vacuum controller can be toggled by sliding or double tapping MAN/AUTO switch. Actual controller state is indicated by orange MAN or AUTO text on the blue background. When controller is in MANUAL mode, vacuum control section additionally shows vacuum pump speed setpoint (%). Touching a pre-selected vacuum will open “SELECT MAX VACUUM” pop-up window where the user can select and activate different maximum vacuum level.
Touching anywhere on this section will change its color to teal indicating that fine control of the pump speed (when vacuum controller is in MANUAL mode) or vac- uum setpoint (when vacuum controller is in AUTOMATIC mode) can be done with increase/decrease buttons.
PULLER GAP section. 6.2.4 Puller Gap The PULLER GAP Control section shows actual puller gap and gap setpoint (setpoint can be modified). This is optional and currently available when the Novatec MedRx puller is networked. Touching anywhere in that section activates it (section’s color will change to purple) and allows fine puller gap adjustment using increase and decrease buttons. This section can be enabled (shown) or disabled (hidden) from the screen using configuration screen.
Vacuum Control section. 6.2.6 Tank Position The TANK POSITION (Z-Axis) section is always visible and displays the actual tank position in relation to the set gap (extruder) position, status of the position controller (OFF, ON – indicates movement, FAULT) and SET TANK POSITIONS button that opens pop-up for setting vari- ous position presets (home, die, hot gap and string up as well as reset die). Touching anywhere in this section will change its color to green indicating that tank can be jogged with increase/decrease buttons.
Tank Position (Z-Axis) control section.
Water Pump Motor
Actual Speed (%)
Water Pump Status
Water Pump Day/Night
Mode
Filter’s UV Light Status
Vacuum pump motor speed [%] Vacuum SETPOINT Actual vacuum
readout selector
Vacuum Pump ON/OFF
button and status
Maximum Vacuum (touch to open
selection pop-up)
Vacuum Controller Selector
PULLER GAP Setpoint
Actual PULLER GAP
PULLER SPEED Setpoint
PULLER SPEED Actual
8
Water pump ON/OFF button
and status.
6.2.7 Temperature Control The TEMPERATURE CONTROL section is always vis- ible and shows actual water temperature in the tank and temperature setpoint. When the heater and chiller are installed and enabled (from the HMI setup screen) temperature of the water reservoir is also shown. If the heater and chiller are not installed, the temperature setpoint value can be used to monitor water temperature and set deviation alarm (temperature deviation can be set in the Temperature Control section of the setup screen). Touching anywhere on this section will change its color to dark yellow and will activate fine control of the tempera- ture setpoint with the increase/decrease buttons.
section in the center of the screen (puller speed - brown, puller gap - purple, vacuum – teal, tank position – green, tank temperature – dark yellow) and amount of change for the selected item (amount of change can be configured by the user for each button and item individually from the HMI setup screen).
Decrease and Increase (jog) buttons (selected for vacuum adjustment indicated by teal background
and values in in H2O units). 6.2.11 Water Pump Pop-up Details
Water Temperature control section. 6.2.8 Tube OD The TUBE OD section will show the measured current product diameter when third party gauge (TBA) is in- stalled and connected to the tank or Novatec’s MedRx puller. It can be configured to be hidden from the screen (from HMI setup screen).
6.2.9 GO TO STRING UP and GO TO HOT GAP Buttons As the name suggests, those two buttons are used to move tank to the previously set STRING UP (typically away from the extruder) or HOT GAP (production position, at the ex- truder) positions.
6.2.10 Increase/Decrease (Jog) Buttons These buttons are used to adjust the tank position, vac- uum setpoint, vacuum pump speed, water temperature setpoint, puller speed and gap setpoints. Buttons on the left side of the screen are used to decrease and on the right side to increase selected items by small, normal or large values (indicated by one, two or three arrows point- ing left or right and in case of tank position section be- ing selected pointing up or down). All buttons will always have the same background color as selected by the user
Water Pump control pop-up window.
WATER PUMP pop-up can be open by touching anywhere in the Water Pump section on the Quick Ops screen. The pump can be turned on or off with a press of the button. Button background and text indicates current pump state (grey – OFF, green – ON, red – FAULT). If the water pump has a fault, it must be first reset, before the water pump can be started (use hardwired reset pushbutton located on the HMI panel). Water Pump operation mode can be toggled by sliding or double tapping the Day/Night mode slider. Day mode is intended for normal production (as the water pump typically is operated at faster speed), while Night mode is used to circulate water through the filter when tank is not in production. Water Pump is automat- ically switched to Day mode when the Vacuum Pump is started by the operator.
Day/Night mode switch
Actual Water Reservoir
Temperature
Water Temperature Setpoint
Actual Water Temperature
9
Day/Night mode slider states. 6.2.12 Set TANK POSITIONS Control Pop-up
Set Tank positions control pop-up.
Set Tank position window can be accessed by pressing SET TANK POSITION button located in the Tank Position sec- tion on the Quick Ops screen. If a specific position was previously set, it is indicated by change of background col- or of the button from dark to light blue.
6.2.12.1 SET HOME POSITION Button Tank must be homed each time power to the tank control is turned on, which is always indicated by yellow flashing HOME NOT SET message in the TANK POSI- TION section on the Quick Ops screen. Without tank being homed first, it is not be possible to jog it (with increase/decrease buttons) nor move it (with GO TO STRING UP or GO TO HOT GAP buttons).
CAUTION! Initiating homing will cause tank to move away from the extruder all the way towards the puller. Make sure there is no other equipment (e.g. diameter gauge) placed on its way of movement. To home the tank, open Set Tank Positions pop-up and press SET HOME POSITION button. Tank will move to its me- chanical stop (home position) and stop there. If there is no fault, then HOME NOT SET status on the Quick Ops screen will be replaced with OFF status. Now tank can be manually jogged with increase/decrease buttons.
6.12.2.2 RESET DIE Button Pressing the RESET DIE button will reset previously stored die, hot gap and string up positions. This step may be necessary if the tank was physically moved between the extruder and the puller or extruder tooling was changed (to shorter than the one used previously).
CAUTION! After pressing RESET DIE button, the tank can be jogged manually towards the extruder, which may hit its tooling.
6.12.2.3 Setting Die, Hot Gap and String Up (Fast Re- tract) Positions Once tank is successfully homed, die, hot gap and string up (fast retract) positions can be set.
CAUTION! This step is necessary only once, as long, as the tank was not physically moved further or closer to the extruder or puller or in case when the extruder tool- ing size was replaced as stored die and hot gap position will be different for new tooling
CAUTION! If the tank was physically pushed, or the extruder tooling has been changed, pressing GO TO GAP button before new DIE and HOT GAP positions are set may cause damage to the extruder tooling, as the tank may travel to far towards the extruder. Pressing GO TO STRING UP before the new string up position is set, when the tank was physically moved closer towards the puller, may cause tank to hit equipment placed between the puller and the tank as it may traverse too far out- wards from the extruder.
The extruder’s die position is the first position to be set. Select (touch) TANK POSITION (Z-Axis) section on the Quick Ops screen (section’s background and jog buttons will turn green indicating that Tank Position section’s is selected). Next, use increase/decrease buttons to jog the tank to the extruder gap (use fine adjustment when close to the extruder, to prevent tank from travelling to far and damaging extruder’s tooling). Once the tank has been moved to the desired gap position, open SET TANK POSITION pop-up (press SET TANK POSITION button in the Tank Position section) and then press SET DIE button to set new die position. SET DIE button background will change its color to light green indicating that die position is set. Once this is done, tank’s tra- verse with jog buttons will be limited to the die position (this position acts as software limit switch in extruder’s direction to prevent accidental overtravel and possible damage to the extruder). If there is a need to change die position, reset die position (press RESET DIE) and then repeat this procedure.
Next step is to set hot gap (production) position. Select TANK POSITION (Z-Axis) section, then use increase/de- crease jog buttons to move tank to the desired produc- tion position. Once done, open SET TANK POSITION
Water Pump Night mode is selected
Water Pump Day (production) mode
is selected
10
pop-up and press SET HOT GAP button to store new production position. SET HOT GAP button’s background will change color to light blue indicating that hot gap position is set. After this step is completed, the tank can be moved to the stored set gap position by pressing GO TO HOT GAP button from the Quick Ops screen. Tank can be still jogged past hot gap position (up to the set die position).
Last step is to set STRING UP position. Select TANK POSITION section (Z-Axis) and use jog buttons to move as far from the extruder as needed. Open the SET TANK POSITIONS pop-up and press SET STRING UP FAST RETRACT button. The new string position (fast retract) will be stored. It is indicated by the SET STRING UP button background color turning light blue. After this procedure is completed, tank can be moved to string-up position by pressing GO TO STRING button from the Quick Ops screen or by activating one of two hardwired Fast Retract pushbuttons on the entry side or HMI panel of the tank.
6.2.13 Selecting Maximum Vacuum
Touch MAXIMUM VACUUM level status box in the VACUUM CONTROL section to open Select Maximum Vacuum pop-up. Select desired initial maximum vacuum level using up and down arrows and then press ACTI- VATE button to commit or X to cancel and close pop-up.
Initial maximum vacuum level dictates size of the open- ing of the vacuum relief valve and water pump speed.
CAUTION! Changing the maximum vacuum level will switch automatic vacuum controller to manual mode and lower vacuum pump speed to 10 [%].
Select Maximum Vacuum level pop-up.
7.0 DASHBOARD Press DASHBOARD button on the NavBar to access Dashboard screen.
Dashboard screen is used to display status of the tank and all connected and configured line components. All areas are oversized to make them easier to see from a distance. Specific sections (PULLER SPEED and PULLER GAP, TUBE OD and VACUUM PV (Process Value) and VACUUM SP (Setpoint) , in case of the water tank, can be disabled (hidden from the screen) by changing setting on the machine setup screens.
Dashboard screen
11
8.0 RECIPES (THIS PART IS STILL IN DEVELOPMENT)
Press RECIPE button on the NavBar to access Select Recipe screen.
Select recipe screen
Edit recipe screen
Copy selected recipe into the buffer
Display next 10 recipes
Paste recipe from the buffer onto selected recipe
Activate selected recipe
Display previous 10 recipes
Edit selected recipe Edit selected recipe
Display next 10 recipes
Display next recipe
Save edited recipe
Activate selected recipe
Display previous recipe
Selected recipe number
Display previous 10 recipes
12
9.0 ALARM SCREENS Press ALARMS button on the NavBar to access machine Alarms.
Alarm screen showing tank’s alarms and event messages in the alarm viewer.
10.0 TRENDS Press TRENDS button on the NavBar to access data Trends.
13
11.0 SYSTEM SETTINGS SCREENS Press SETTINGS button on the NavBar to access System Settings screen.
This screen allows the user to tweak parameters for each piece of equipment controlled from each section on the Quick Ops screen.
System settings screen with tank position section selected.
11.1 Tank Position (Z-Axis) Settings
Press TANK POSITION button to access Tank Position user settings.
Tank position user settings
The user can adjust jog values for the tank traverse (Z-Axis) by changing values in the white fields next to arrows. Three arrows indicate TANK POSITION TRIM VALUES for large jog increase/decrease buttons, two arrows indicate trim for normal jog increase/decrease buttons and one arrow indicates trim for fine jog in- crease/decrease buttons.
TK POS. OUT. LIMIT (Tank Position Outer Limit) value is a limit for outward traverse (maximum position tank can travel away from the extruder). In most cases it should be left at default setting of 0.00 [in].
Large traverse (jog) step
Fine traverse (jog) step
Tank Position Outer Limit
Normal traverse (jog) step
User settable values
Calculated (read only)
values
Section selection buttons
14
11.2 Water Pump Settings
Press WATER button to access Water Pump user set- tings.
On this screen, the user can change water pump day and night speed setpoints as well as reset water pump runtime hour counter.
Note, that once maximum vacuum setting is changed from the Quick Ops (via Maximum Vacuum pop-up) it will reset day (production) speed to the default value. After that, the user can increase or decrease water pump speed if needed again from this screen.
Water Pump user settings
Reset water pump’s run
hours
Water Pump night (circulation) speed
setpoint
Water Pump day (production) speed
setpoint
15
11.3 Vacuum Control Parameters
Press the VACUUM button to access Vacuum Control user settings.
Vacuum Control settings are only available for the vac- uum tank (not accessible for the water tank). Vacuum tank option must be enabled first in the MVT Configura- tion (typically set at the factory).
On this screen, the user can calibrate vacuum transducer (set zero, SET SPAN values), set large, normal and fine vacuum trim values for the increase/decrease jog but- tons and set value for the vacuum deviation alarm.
When vacuum deviation setpoint is set to the value greater than 0 deg., actual vacuum readout (VACUUM PV) field in the Vacuum Control section of the Quick Ops screen will indicate vacuum deviation alarm by changing its background color from white to red. Ad- ditionally, alarm will be logged and visible in the alarm viewer on the Alarm screen. Leaving vacuum deviation setpoint at 0 will disable deviation alarm monitoring.
• Enter readout from the vacuum gauge into SPAN VALUE field and press SET SPAN button
After calibration procedure is completed, the vacuum value shown on the HMI display should match vacuum gauge readout closely.
For the vacuum tank automation system to precisely control vacuum levels it is important to calibrate its vacuum transducer. To calibrate the vacuum transducer, follow steps below:
• Make sure that no water nor vacuum pumps are running
• Open vacuum chamber lid on the tank
• Press SET ZERO button
• Close vacuum chamber lid
• Start water pump
• Start vacuum pump, keep vacuum controller in manual mode, then keep increasing vacuum pump speed (with vacuum section selected, press increase buttons) until vacuum readout on the manual (magnahelic) gauge is as far as it possible above 0 [inH2O]
Vacuum control user settings
Vacuum transducer calibration:
set zero, set span
Normal vacuum trim
Normal vacuum trim
Vacuum span value
Large vacuum trim
Vacuum deviation setpoint
16
11.4 Temperature Control Parameters
Press TEMP. CONTROL button to access Temperature Control user settings.
On this screen, the user can set large, normal and fine vacuum trims for the increase/decrease jog buttons and set value for the temperature deviation alarm.
When temperature deviation setpoint is set to the value greater than 0 deg., actual temperature readout (TEMP PV) field in the Temperature Control section of the Quick Ops screen will indicate temperature deviation alarm by changing its background color from white to red. Additionally, alarm will be logged and visible in the alarm viewer on the Alarm screen. Leaving vacu- um deviation setpoint at 0 will disable deviation alarm monitoring.
Temperature control user settings
11.5 Puller Speed & Gap
Press TEMP. CONTROL button to access Temperature Control user settings.
Puller speed and gap settings are only available when Novatec MedRx puller is used and networked with the tank. It must be enabled first in the MVT Configuration.
The user can adjust large, normal and fine trim values for the puller’s gap or speed setpoint increase/decrease buttons when speed or gap sections are selected on the Quick Ops screen.
Puller speed and gap user settings.
Normal temperature
trim
Normal temperature
trim
Water temperature
deviation setpoint
Large temperature
trim
Fine puller gap setpoint trim
Fine puller speed
setpoint trim
Normal puller gap setpoint
trim
Normal puller speed
setpoint trim
Large puller gap setpoint
trim
Large puller speed
setpoint trim
17
11.6 Miscellaneous Settings
Press MISC button to access Miscellaneous user settings.
From Miscellaneous settings user can select to use US or metric units, access maintenance functions and tank configuration parameters.
To change between US and metric system, slide or dou- ble tap the SYSTEM UNITS slider.
Machine configuration parameters are set at the factory, hence require special authorization level and should be only accessed by qualified personnel.
Miscellaneous settings
Maintenance functions
Selection of the system units (slider)
Machine configuration
18
11.7 Maintenance Settings
Maintenance Functions Include:
• Set time and date
• Enable screen cleaning
• Exit HMI runtime application and enter Windows control panel
• User management (add/remove users, change pass- words)
• Save & restore recipes
• Import & export user management
HMI Maintenance Settings pop-up 11.7.1 User Management
Using user view on the User Management screen, users can be added, renamed or removed, and their passwords can be either set or changed.
HMI User Management screen
User management
Import user management
from the SD card
Restore machine configuration
from the SD card
Backup machine configuration to
the SD card
Export user management to
the SD card
User name User group
name
Password Automatic logoff time due to
inactivity
19
11.8 MVT CONFIG. (Machine Configuration Screen)
This screen is accessible from the System Settings Misc. Machine Config. and should be accessed by authorized personnel only.
It includes four sub-sections that can be accessed by pressing a button from the left navigation area.
11.8.1 Installed Options
MVT Config – Installed Options.
From this screen, the TANK TYPE can be configured as a water or vacuum tank (done at the factory, changing this setting requires service authorization). Also, SYS- TEM UNITS, PULLER GAP, PULLER SPEED, DIAMETER GAUGE (OD gauge) and TEMP. CONTROLLER features can be disabled (hidden from the Quick Ops and Dash- board screens) when not installed (typically set in the factory but available to the end user with setup autho- rization when their system is expanded, or the tank is upgraded).
Slide or double tap slider for the selected option to en- able (show) or disable (hide) it.
Select recipe screen
11.8.2 Sinamic Drive Parameters
This are service parameters for water and vacuum pump VFDs. Those parameters can be viewed by the user but can be modified by the authorized (Novatec) personnel only.
11.8.3 External Digital Vacuum Set Point Adjustment
This screen allows an authorized (setup level authori- zation) user to enable and configure external vacuum set point control using tank’s digital interface. Use slider (slide or double tap) to toggle enable or disable external vacuum set point control.
When controller is enabled, vacuum set point can be adjusted with two digital inputs of the tank PLC.
MVT Config – External Vacuum Adjustment
EXT. VAC. SP CHANGE VALUE defines by how much vacuum setpoint will be increased or decreased each time tank’s PLC sees pulse on its digital inputs.
EXT. VAC. SP CHANGE DELAY when greater than zero defines time (in seconds) after which tank’s PLC increase or decrease vacuum setpoint when it sees continuously request to increase or decrease vacuum setpoint on one of its digital inputs.
11.8.4 Maximum Vacuum Lookup
This screen is a service screen and it is intended for the Novatec’s engineer.
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12.0 MECHANICAL OPERATION 12.1 Bessemer Rx SmartMed Overview
• Features designed specifically for medical extrusions.
• Most popular lengths – 3, 5 and 8 feet
• All 316 stainless steel
• Every water contact surface is electro-polished
• Glass lids to prevent scratching and warping
• All corners rounded ease of cleaning and wipe down
• Elimination of as many threaded fasteners as possible
• Tri-clover fittings for ease of cleaning
• Unique re-circulation system with an upper reservoir, a vacuum reservoir below that and the water pump below those to minimize cavitation and for ease of flushing
• Total closed loop vacuum control
• Standard UV filter and .05 micron filter to remove dead germ bodies
• Programmable precise positioning of tank for home, stringing up and hot-gap placement
• Clear, tank-mounted touch screen control
• Hand-held tablet for use in conjunction with tank— mounted control
12.2 Linear Actuation
No more hand cranks for linear movement of the Besse- mer Rx SmartMed vacuum tanks. All linear movement is programmed by the user to precisely set whatever hot gap is required.
Now, a servo actuator, in conjunction with a simple touch screen control allows the tank to move to and from the face of the die in increments as low as 1/1000 inch at a time. Several positions, from Home to the string-up position to setting the hot gap can be easi- ly pre-programmed into the touch screen control and saved as a recipe so repeatability is guaranteed for each product that is produced. You can even set the acceler- ation and deceleration speeds to minimize water move- ment during travel.
Simply go to the recipe screen, choose the product being produced and your pre-programmed settings will be repeated to within 1/1000th of an inch, all with touch screen convenience.
Touch screen controlled linear actuator replaces typical hand cranks for linear positioning.
Home, string-up and hot- gap positions set to within 1/1000th inches for recall in customer-set recipe.
Customer sets linear positions and save in recipe for future repeatability to with 1/1000th of an inch.
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12.3 Higher Precision Vacuum Control - From the High Through the Low End The Bessemer Rx SmartMed vacuum tank is leading the industry in vacuum control. We start with a very good, very quiet, regenerative vacuum blower that has excellent operational characteristics. We have added a better drive on this vacuum blower and added a vacuum transducer that has about double the resolution of pre- vious units. Coupled with our closed loop control, you have significantly better control of the vacuum to within +/- 0.01 inches of water instead of 0.1 inches H2O and you can pick the vacuum level more precisely, using the touch screen.
The automated leak system allows the operator to choose the desired water level so the pump runs at the sweet spot on the CFM curve allowing the proper
12.4 Externally Adjustable Roller Control
The externally adjustable roller system, with clear win- dows, solves two issues. When using the vacuum as a drool-control and there is a fairly large gap around the tube, it is very important to not open to cover and adjust a roller. Every time the cover is opened vacuum is lost, water rushes out and the die can actually freeze off. An- other problem it solves is it keeps people’s hands out of the water, minimizing the probability of bacteria transfer.
amount of water to run over top of the tube which helps keep the water temperature equal both over and under the tube. This ensures concentricity for the very best
Externally adjustable roller system in combination with top windows.
No need to open cover because you can see exact result of your adjustments.
precision medical tubing.
Vacuum level can be controlled down to +/- 0.1 inches H2O.
Simple touch screen control allows easy control of vacuum level.
12.5 Water Diffuser System The water diffuser system improves how much water can be delivered. This is important because if there is insufficient water volume, heat transfer is not good and different temperature gradients are created within the tank. Even the water level adjustment is controlled by similar type of tri-clover fitting to adjust water level very precisely. Especially for free extrusion, the water level in relationship to the tube is very critical.
12.6 Dramatic Reduction of Flushing Time
The water pump purposely mounted below all the res- ervoir so the pressure of the water above the pump acts as a primer. As long as there is water in the reservoir it’s going to want to be drawn down and it will self-prime itself very quickly so there are minimal cavitation issues. There is also a 3-way valve down below so the pump can
Water drool aid can be chosen from can be easily controlled from touch screen dropdown.
be used to literally drain the entire system out in about 60-90 seconds.
The water tank is positioned below all other water reser- voirs so the entire system can be flushed in about 60-90 seconds by turning a 3-way valve.
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12.7 Reduction of Pump Vibration Greatly Reduces Turbulence Instead of just mounting isolation bushings under the water pump, the Rx SmartMed is fitted with an AC inverter which allows the RPM’s to be adjusted and that accomplishes a couple of important advantages.
First, the RPM’s can be adjusted to run in either a day- time or nighttime mode so water is constantly circulat- ing, thus eliminating stagnant water.
Second, at different vacuum levels, the RPM’s of the vacuum pump can be adjusted to the point where we get near zero vibration so both the vacuum system and the water system are being tuned.
This is important for critical products like medical extru- sion as well as free extrusion where water turbulence will tend to move tiny tubes.
12.8 Internal Air Wipe
An internal air wipe is included on our closed tanks as well as open tanks. Mounting it internally reduces noise and eliminates water from dripping on the floor.
The air wipe can be fitted with interchangeable inserts so you can actually size the air wipe for the particu- lar size of tubing being made which cuts down on the amount of air being used and, more importantly, ensures proper measuring of very precise tubing. Especially when dealing with thousandths of an inch, a laser will measure water beads on the tubing so a properly functioning air wipe is of great importance.
12.9 Easy, Tool-Free Cleanability
Everything about the Novatec Rx-SmartMED Series Vacuum Tanks is designed specifically for precision micro-bore medical tubing applications, even when it comes to cleaning.
All metal surfaces are stainless steel, electro polishing, rounded corners, tri-clover fittings, easily removeable heat exchangers and the vacuum section actually pulls out to allow the tank to be cleaned or serviced without any tools. Everything can be wiped down and easily re-assembled. Servicing time should be about half what other tanks require.
In addition to easy cleanability, by trying to have round- ed corners, trying to tig weld and electro-polish all contact surfaces and by using tri-clover fittings similar to those used in the dairy, wine and beer industry, the flushing procedure is enhanced because surface tension is reduced and there is no stagnation for bacteria and film build up.
Internal air wipe reduces noise and eliminates water spillage.
Using alternate inserts to fit specific tubing diameter reduces compressed air usage and ensures proper diameter measurement.
Easy open easy-clean tri-clo- ver Fittings similar to those used in the dairy industry.
Easy-to clean rounded corners reduce surface tension and eliminate stagnation
Closeup of tool-free tri-clover fittings.
Easy access to water reservoir for cleaning.
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12.10 Sanitary Tri-Clover Fittings Replace Threaded Fittings Typically, tank manufacturers use threaded water con- nections but they are a breeding ground for bacteria and nearly impossible to clean. Instead, the Rx Smart MED extrusion tanks use tri-clover fittings, also known a sanitary fittings, commonly used in the dairy and beer industry. They have no threaded contact surfaces. They are stainless steel, and the clamshell design is easily dis- assembled, without tools, and cleaned. In fact, the entire manifold is designed for easy dis-assembly and cleaning.
Top of sanitary tri-clover fittings Easy, no-tools dis-assembly
12.12 Non-contact Tooling
A wide range of bushings that require no tools are avail- able to suit a myriad of needs.
We use a series of plates that are removeable by hand to create the various types of bushings that are avail- able and each plate has a “O” ring in the back to so they will seal and not allow bubbles to get in the process. All plates are simply rotated manually for assembly and dis-assembly.
• Typical types of non-contact bushings include:
• Straight bushings
• Bushings with iris
• Split plate design
• Micro-press skinner design in 1” and 2.5’
• Bushing plus a bushing
• Iris plus an iris
• …and more
-no threaded contact surfaces. for cleaning. 12.11 Excellent Filtration - Standard
No more need to pay for optional “upgraded” filters. The Rx SmartMed vacuum tanks include, as standard, a UV filter which renders germs sterile. Then, a 0.5 micron filter removes them from the water stream instead of the usual 5 micron filters, supplied by others. These stan- dard, up-graded filters are necessary for medical grade tubing regardless of whether using tap water or deion- ized water.
Standard UV filter renders germs sterile.
Standard 0.5 micron filters removes sterile germs from the water stream.
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12.13 Contact Calibration Tooling
Once again, all plates are simply rotated manually for assembly and dis-assembly. This type of tooling can actually be assembled off the tank and then installed manually. there a receiver, a housing. There is a calibrated bushing or sleeve, a cover plate for it and there is a piece that actually holds it all together.
12.14 Use As Vacuum Tank or Open Tank Most vacuum tanks do not work well as open tanks but the Bessemer MedRx vacuum tank conveniently serves as either type.
By putting the open reservoir as part of the tray and having the vacuum reservoir entirely below that actually creates some head pressure. So, when vacuum is not being used, that little bit of head pressure makes the wa- ter want to go from the open to the closed section very easily. Having the water pump entirely below that, for space savings, got rid of cavitation because it’s helping the pump prime so we’re not creating air bubbles that are typical when someone tries to use other vacuum tanks as an open tank. In addition, you still have all of the precision and ease of operation that is available in the vacuum tank.
This eliminates the need to change out the tank, which saves space and investment.
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13.0 WARRANTY NOVATEC, INC. offers COMPREHENSIVE PRODUCT WARRANTIES on all of our plastics auxiliary equipment. We warrant each NOVATEC man- ufactured product to be free from defects in materials and workman- ship, under normal use and service for the periods listed under “Warran- ty 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 suspect- ed 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 au- thorized 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 connec- tion with our equipment. Warranty Periods: Note: All warranty periods commence with the shipment of the equip- ment to the customer.
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 * Nitrodry Nitrogen Dryers DryTemp+
Central System Controls to Include: FlexTouch™ Series Controls FlexXpand™ Series Controls OptiFlex™ Series Controls PLC Communications Modules Greenboard Communications Modules LOGO! Mini PLC MCS-600 Series Controls – (Distributed I/O) MCS-400 Series Controls
CL Silo Manager
5-YEAR (Except 1-Year on Non-Novatec Buy-Out Items)
Resin Blending and Feeding to Include: WSB Blenders, MaxiBatch & Feeders * Gaylord Sweeper Systems
Downstream Extrusion Equipment to Include: C and NC Bessemer Series Cutters NPS Bessemer Series Pullers NPC Mini Puller/Cutter All NS Series Servo Saws Rx SmartMed Extrusion Products All Cooling and Vacuum Tanks Manufactured by Novatec
Resin Conveying and Systems Components to Include: GSL Series Vacuum Loaders GlassVu Loaders, Receivers and Hoppers VL/VLP Series Loaders VRH, VR, VR-FL, VRP & VRM 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
Moisture Measurement Equipment to Include: MoistureMaster®
PET Resin Crystallizers
Filter Dust Collectors Drawer Magnets Velocity Control Valves
Resin Conveying System Components to Include: ** VPDB Vacuum Positive Displacement Pumps ** SVP Vacuum Pumps ** MVP Vacuum Pumps ** Railcar Unloading Systems
3-YEAR
**5-Year Extended Warranty - When a MachineSense® data plan is activated for products with **, Novatec automatically extends the warranty to 5 years. The data plan must be activated within 60 days after product 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.
1-YEAR Infrared Dryers UltraVac Vacuum Pumps Vacuum Regenerative Blower Pumps Custom Equipment of any kind unless otherwise specified
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Exclusions: Routine maintenance/replacement parts are excluded from the war- ranty. These include, but are not limited to: hoses, desiccant, filters, filter elements, wiper seals, gaskets, dew point sensors, infrared lamps, motors, internal solenoids, fuses and motor brushes. Use with abrasive materials will void the warranty of any standard product. Wear resistant options may be available to extend usable service life with abrasive ma- terials. Novatec reserves the right to limit the warranty if the customer installs replacement parts that do not meet the specifications of the original parts supplied by Novatec.
*Specific Exclusions:
1. NovaDrier™ and NITROdry™ warranty is void if coalescing filters are not replaced on a 6-month or yearly basis (per instruction manual) and/or membrane has been exposed to ozone.
2. NovaVac Dryer -The ability of the canisters to hold vacuum will be compromised if the vacuum seal edge is damaged from mishandling. We do not warranty canisters damaged from improper handling. We do, however, warranty the seals.
3. LOAD CELLS on our WSB’s are covered by Novatec standard warran- ty as long as they have not been damaged from improper handling.
4. Desiccant Wheel Warranty will be void if the wheel has been exposed to plasticizer, dust or other contaminants as a result of negligence on the part of the processor.
5. DryTemp+ - We assume no responsibility from equipment failures resulting from untreated or improperly treated water.
This warranty shall not apply to equipment:
1. Repaired or altered without written approval of NOVATEC unless such repair or alteration was, in our judgment, not responsible for the failure
2. Which has been subject to misuse, negligence, accident or incorrect wiring by others
3. Warranty is void if processing rates exceed manufacturer-recom- mended 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.
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Drying > Conveying > Blending > Downstream
222 East Thomas Avenue Baltimore, Maryland 21225
www.novatec.com
Phone
410-789-4811 or 800-938-6682 24 Hour service: 800-938-6682
Fax: 410-789-4638
Parts: [email protected] Service: [email protected]
Sales: [email protected]
