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Oliver Platinum Series Operation Manual

Gravity separators
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Operations manual
Platinum Series
Gravity Separators
Version 1.0 | 1/5/23
Oliver Manufacturing Company
•
27151 Harris Road
•
La Junta, CO 81050
•
(888) 254-7814
•
olivermanufacturing.com

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  • Page 1 Operations manual Platinum Series Gravity Separators Version 1.0 | 1/5/23 Oliver Manufacturing Company • 27151 Harris Road • La Junta, CO 81050 • (888) 254-7814 • olivermanufacturing.com...
  • Page 2 - Reference Manual Version I Voyager GVX Gravity Separators Revision Table Section Revision Date Main Section: Introduction: Installation and Functional Operation Setting up the Machine from HMI October 2012 Modes of Operation Appendix A: The PanelView 800 October 2018 Appendix B: MicroLogix 1400 Programmable Logic Controller October 2012 Appendix C: Variable Frequency Drive PF525 October 2020...
  • Page 3 Important information about the Operating Instructions The Voyager GVX Series of Gravity Separators is comprised of three different models: GVX1040, GVX1050, and GVX1060. The primary difference between them is the number of fans that supply the air flow and the length of the deck. The GVX1040 has three fans, the GVX1050 has four fans and the GVX1060 has five fans.
  • Page 4 Please take a few minutes to read the instructions to help eliminate many of the problems frequently encountered. Keep in mind at all times that the Oliver Gravity Separator is not a "cure-all" for the processor’s problems. The gravity separator is a specialized piece of machinery designed to separate particles of similar size that differ in specific density.

  • Page 5: Table Of Contents

    I. Introduction: Installation and Functional Operation ..............9 I. Installation ........................9 I. Foundation Requirements ..................... 9 II. Handling ........................9 III. Protecting the Deck ....................9 IV. Electrical Requirements ....................9 V. Clean Air Source ......................10 II. Functional Operation of the Voyager GVX Gravity Separator ..........11 I.
  • Page 6 V. Starting the Machine ....................36 VI. Faults ........................36 VII. Faulting on Power Cycling the Machine ..............38 VIII. Deprecated Screens – The Deck, Fan, and Actuator screens ........39 II. Recipes ........................40 I. Loading a Stored Recipe ................... 41 II.
  • Page 7 Figure 19: Voyager and Maxi-Cap Machine Option Choices ............25 Figure 20: Selecting Gate Options ..................26 Figure 21: Oliver User going from Login to Deck Calibration Screen ..........28 Figure 22: Deck Calibration with Hydraulics on................. 29 Figure 23: Login to Actuator Calibrate ..................30 Figure 24: Actuator Calibration Screens ..................
  • Page 8 Figure 46: Altering a stored recipe step 2 ................45 Figure 47: Selecting Recipe to Delete ..................46 Figure 48: Highlighting the recipe to delete ................46 Figure 49: Are you sure you want to Delete? ................47 Figure 50: Main Screen in Manual Mode .................. 48 Figure 51: Maintenance screen when not faulted.
  • Page 9 (This Page Intentionally Left Blank)

  • Page 10: Introduction: Installation And Functional Operation

    Therefore we recommend that the Voyager be firmly attached to the floor. Please contact the factory or your Oliver representative for recommendations. When positioning the Voyager, be sure that you leave adequate clearance to operate the controls, open the electrical cabinet and remove the deck for changing or cleaning.

  • Page 11: Clean Air Source

    If you need consultation on how to get clean air to your machine, please call the Oliver team.

  • Page 12: Functional Operation Of The Voyager Gvx Gravity Separator

    II. Functional Operation of the Voyager GVX Gravity Separator The Voyager GVX series of Gravity Separators is a new line of gravity separator from Oliver that takes the rugged base of previous separators and adds to it quieter fans and better balance as well as a never before seen automation package that make the Voyager the Cadillac of Gravity Separators.
  • Page 13 In addition to the air causing a lifting action to the particles, putting them into a quasi-fluidic state, the deck also vibrates. The vibration of the deck helps to stratify the particles by moving the particles that are lighter from around the heavier ones. Once the combination of the two mechanisms of air flow and deck vibration has stratified the material, only then can the particles be separated properly.

  • Page 14: What A Gravity Separator Can And Cannot Separate

    Figure 3: The Forces of Separation due to side tilt, air flow, and deck vibration. In general the product will be separated into three categories; (1) a heavy or acceptable product, (2) a light or reject product, and (3) a small middling product. If there are other heavy trash objects or dirt, these will be separated into a fourth product.

  • Page 15: Rule 2

    II. Rule 2 Particles of the same specific gravity but different sizes will be graded according to the size of the particles. Figure 5: Particles of same specific gravity but smaller size from left to right An example of this would be the elimination of shriveled corn kernels from the whole corn kernels of the same density.

  • Page 16: How The Voyager Controls Separation

    III. How the Voyager Controls Separation The main parts of the Voyager gravity table are the deck, the feeder, and the fans. Each one provides several degrees of freedom to the separation process. I. The Deck The Deck on the Voyager gives the most degrees of freedom to the separation process. Each controllable feature of the deck gives a different degree of control to the process.
  • Page 17 The End Raise, or the slope from the feed end to the discharge end, controls how fast the product moves down the deck. As will be seen, this is directly related to the feed rate. If there is not enough end raise, i.e the slope is too small, the product coming in on the feed end will bunch up and stratification will not occur well.

  • Page 18: The Feeder

    Figure 9: Effect of various Deck Speeds on separation with a constant Side Tilt The side tilt and end raise are controlled through hydraulic cylinders and valves. The Deck vibration is controlled by the eccentric motor which is driven by a Variable Frequency Drive. II.
  • Page 19 Figure 10: Air flow example Voyager 1050 -Figure 11: Effects of Air Speed on Separation...

  • Page 20: Increasing Capacity With The High Gates

    IV. Increasing Capacity with the High Gates The high gates, also referred to as cutout gates, can also be used to increase capacity. This is done by opening the cutouts slowly and allowing heavy particles of the product to go into the blender. This will allow more capacity to be put onto the deck through the feed rate.

  • Page 21: Removing Heavy Foreign Materials

    V. Removing Heavy foreign Materials The Rock Trap is located on the high side of the deck between the feeder and the first cutout gate. The primary purpose of the rock trap is for removal of a small percentage of heavy contaminant. Initially the rock trap was designed to remove dirt and stones from edible dry beans, hence the name rock trap.

  • Page 22: Control Components Of The Fbd

    Human Machine Interface (HMI) and a Programmable Logic Controller (PLC). Oliver has teamed up with Rockwell Automation and Allen Bradley to provide the user with the best interface possible. The HMI is a small touchscreen that allows the user to input desired settings, which are then transferred to the PLC, which then uses its internal programming to run the machine.
  • Page 23 PowerFlex 525 Figure 15: Variable Frequency Drive...

  • Page 24: Safety Considerations

    IV. Safety Considerations Important Safety Precautions for Using the Voyager GVX and Maxi-Cap Platinum Gravity Separators ● Always shut off the “lock- out” power when performing maintenance or service. ● Always insure that the dryer and components are electrically grounded. ●...

  • Page 25: Setting Up The Machine From The Hmi

    Figure 16: Main Screen to Login This will bring the user to the Login Screen. Here the user will have to log in as the Oliver user, which has the username and password of oliver. This is shown in Figure 17.
  • Page 26 Once the oliver user name and password have been entered, the username will appear in the upper right corner of the Login screen as OLIVER. Press the Machine Options button to go to the Machine Options screen once this has been done. This is shown in Figure 18.
  • Page 27 On the Machine Options screen, the Machine Type needs to be set to either a Voyager or a Maxi-Cap, depending on the gravity separator you have. . Note: On later editions of the code, the voyager and maxi-cap options will available. There will be no Dryer or Cooler options. The next step is to select the model number of the Gravity Separator.

  • Page 29: Calibrating The Machine

    This is shown in Figure 21. Figure 21: Oliver User going from Login to Deck Calibration Screen The first two things to notice from Figure 21 is that the deck should only be calibrated while the machine is turned off, whether in manual mode or automatic mode and the Hydraulics must be turned on.

  • Page 30: Calibrating Actuator Components

    Figure 22: Deck Calibration with Hydraulics on To calibrate the deck end raise, press the two arrow buttons on the far right. The up arrow is the one that extends the hydraulic cylinder for the end raise, and the down arrow is the one that retracts the hydraulic cylinder that the sensor is attached to.
  • Page 31 Figure 23: Login to Actuator Calibrate Figure 24: Actuator Calibration Screens...
  • Page 32 When you come to the actuator screen, there are 4 possible sets of actuators you might have. On a Maxi-Cap or Voyager, there are 4 low gates, which are the discharge gates and the feeders, and then there are four high gates including the rock trap and other gates along the deck. On some models none of these have been automated yet.

  • Page 33: Setting The Trim Options

    You will have to log in as the Oliver user. Once you have logged in, proceed to the Trim Values Screen by pressing the Trim Values button on the bottom right hand corner of the Login Screen, as shown in Figure 25.

  • Page 34: Language Selection

    other words Fan 1 can only be set from 50% to 60% while the corn recipe is loaded. The same thing holds true for the deck speed and end raise, except that deck speed will be in rpms, not in a percent value.

  • Page 35: Modes Of Operation

    III. Modes of Operation The Gravity Separator has three basic modes of operation: Automatic, Manual, and Remote. In Automatic mode, the machine is operated as a whole from a recipe or set of parameters. The Machine is started as a whole, and runs as a unit. In Automatic mode the machine can fault, meaning that it failed to operate as expected and the machine generally will stop running under these conditions.

  • Page 36: Machine Settings

    I. Machine Settings Figure 29: Controlling Auto Mode from Machine Settings The Machine Settings screen allows for all the parameters of the gravity to be changed in one place. If desired, the settings can be saved in a recipe to be called up later. The following sections will describe all of the parts of the settings used in the Automatic mode.

  • Page 37: End Raise Control

    II. End Raise Control The deck end raise, which controls how far the deck can be sloped relative to being flat, can also be set from 0 to 100. At zero percent end raise, the deck will be flat. At >0% the deck will be negatively sloped from the feeder to the discharge.
  • Page 38 drive the motors fail to respond to communication from the PLC in 60 seconds, and when a VFD reports that it has entered into various faulted states. So, how does the operator know the machine has faulted? All of the faults but two on the gravity will stop the machine totally when in automatic mode. The two faults that won’t shut the machine down are the faulting of the Deck End Raise and the Deck Side Tile.

  • Page 39: Faulting On Power Cycling The Machine

    Figure 33: Entire Machine Faulted with Indicators When the entire machine is faulted and has turned itself off, the machine will normally take the user to the Maintenance Screen. The Maintenance screen will also give the user an indication what has caused the gravity to fault and to shut off.

  • Page 40: Deprecated Screens - The Deck, Fan, And Actuator Screens

    VIII. Deprecated Screens – The Deck, Fan, and Actuator screens There are three other screens that can be reached from the Machine Settings screen. They are the Deck Screen, Fans Screen, and Actuator Screen. These are reached by pressing the Deck button or the Fan button from the Machine Settings Screen.

  • Page 41: Recipes

    Clicking on the Active Recipe button will take you to the Machine Recipes screen. If you are not logged in as a user, the keyboard will come up first, requiring you to log in, as shown in Figure 37. The username and the password is oliver, with no caps.

  • Page 42: Loading A Stored Recipe

    Figure 37: Entering user name and password for Recipes Figure 38: Machine Recipes Screen Notice in Figure 38 that there are 3 recipes listed. Depending on which recipes were loaded at the factory, you may have more or less recipes. There will always be a Clean Out Cycle 1 and 2 Recipe listed.

  • Page 43: Saving A New Recipe

    Figure 39: Changing Recipes Notice in Figure 39 that the Clean Out Cycle Recipe is still highlighted. In order to finish selecting the Wheat recipe, press the enter button as highlighted in Figure 40. Figure 40: Hitting enter to highlight recipe Notice that the Wheat recipe is now highlighted.
  • Page 44 Figure 41: Saving a new recipe Figure 42: Save Recipes Screen The values here will be the same current values you were using on the Machine Settings screen. Check to make sure they are the way you want them to be, and then click on the Insert NEW button. This will take you to the Save Recipe Screen, shown in Figure 43.
  • Page 45 Figure 43: Save New Recipe Screen Figure 44: Keyboard for naming recipe Once you have named the recipe what you want it to be, then press the Insert New button. This will finish saving the recipe, and will take you back to the Machine Settings Screen.

  • Page 46: Altering A Stored Recipe

    III. Altering a Stored Recipe If you find that you have been to change the parameters of a recipe slightly for better results, such as might happen in a different season with more or less humidity, then you will have to alter an already created recipe.

  • Page 47: Deleting A Stored Recipe

    IV. Deleting a Stored Recipe In order to delete a Recipe, select the recipe you wish to delete. In this case, let’s delete the wheat recipe. Use the up and down arrow keys to select wheat, and then use the enter key to highlight the wheat, as shown in Figure 47: Selecting Recipe to Delete Figure 48: Highlighting the recipe to delete...
  • Page 48 Figure 49: Are you sure you want to Delete? If the recipe name is correct, then press yes. If not, press the cancel button and go through the process again, correcting any errors made.

  • Page 49: Manual Mode

    The first thing to notice is that the Maintenance Screen is a diagnosis Screen. In the upper left of the screen, below the Oliver Logo, there is a current Status for the Fans and the Deck. When the machine is not in a faulted state, the screen will show a status of ok as shown in Figure 51. If the...

  • Page 50: Faults On The Maintenance Screen

    FBD were faulted, then the Maintenance Screen would look like Figure 52. Note that if only the Fans were faulted, only they would show a fault, and vice versa. Figure 52: Maintenance Screen When Machine is Faulted I. Faults on the Maintenance Screen If the Machine is faulted, it will look like Figure 52.

  • Page 51: Bearing Greasing Interval

    Figure 53: Various possible battery status screens The PLC battery is used for memory back up and retention. If the battery is removed while the PLC is not powered, the PLC will lose its internal memory and the PLC program. The same thing will occur if the PLC battery goes dead.

  • Page 52: Total Hours On Machine And Current Batch Time

    IV. Total Hours on Machine and Current Batch Time The PLC keeps track of how many total hours the machine has been run and how long the current batch has been running and displays it on the HMI screen. The Total Hours on Machines is a running total and is never reset.

  • Page 53: Starting The Fans

    I. Starting the Fans Notice for each fan there are two green buttons for starting and stopping the fan, a blue numeric entry for a commanded fan speed, and a read out for the amp draw of each fan. To start a fan, start by choosing how fast you want it to go.

  • Page 54: Fan Vfd Error Codes And Faults

    pulling amps. (The figure is only for reference. Your motor may pull a different current.) If the stop button is pressed the fan will stop running, and the buttons will go back to green and will return to their previous wording. All of the fans work in the same way. II.

  • Page 55: Deck Diagnostics

    III. Deck Diagnostics The next screen available from the Maintenance Screen is the Deck Diagnostics screen. To get there, press the deck diagnostics button on the Maintenance Screen. Figure 60: Going from Maintenance to Deck Diagnostics Figure 61: The Deck Diagnostics Screen I.

  • Page 56: Deck Shake Or Speed

    Notice that, as shown in Figure 61, that the Deck Diagnostics Screen can have the same red box marked with the Clear Fault. The Clear Fault box will only come up if the Deck End Raise is faulted. If it is not present the Deck End Raise is not faulted. The Deck End Raise must not be faulted in order for the deck to be moved.

  • Page 57: Hydraulics

    Figure 63: Deck Shake on Manual Mode The start button now indicates that the Gravity Separator Deck Shake is on, and the stop button now indicates that it must be pressed to stop. Notice that the amps read out indicates that the deck motor is now pulling amps.

  • Page 58: Remote Mode

    III. Remote Mode The final mode of the Gravity Separator is a remote one. The remote mode allows control of the machine to be passed to a Supervisory Control and Data Acquisition (SCADA) system. This control is not comprehensive. It is limited in functionality, both for safety reasons as well as quality of control reasons.

  • Page 59: Initial Setup And Startup

    IV. Initial Setup and Startup Now that you are familiar with the theory and the modes of operation of the Gravity Separator, it is time to do the initial startup of the machine. 1. Close the rock trap and the cut out gates on the machine. They will be set up after proper separation has been achieved.
  • Page 60 Gravity Separator Pre-Set Adjustments for initial setup Voyager Pre-Set Adjustments Model Deck Deck Deck Deck Fans Mesh Side Speed Raise Tilt 1040 10Ms 100% 1040 16Ms 1040 30Ms 1050 10Ms 100% 1050 16Ms 1050 30Ms 1060 10Ms 100% 1060 16Ms 1060 30Ms Maxi-Cap Platinum Pre-Set Adjustments...

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