Summary of Contents for Oliver DVX
- Page 1 Operations manual Fluidized Bed Dryer Automated (GVX) Version 1.0 | 1/5/23 Oliver Manufacturing Company • 27151 Harris Road • La Junta, CO 81050 • (888) 254-7814 • olivermanufacturing.com...
- Page 2 DVX Fluidized Bed Dryers - Reference Manual Version V Revision Table Section Revision Date Main Section: Introduction to Installation and Functional Operation Setting Up Machine from HMI 3/6/2020 Modes of Operation Appendix A: The PanelView Plus Appendix B: CompactLogix 5370 L2 PLC...
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Page 3: Table Of Contents
Contents Installation and Functional Operation 1 Installation 1.1 Foundation Requirements ..................3 1.2 Handling ......................3 1.3 Protecting the Deck ..................3 1.4 Electrical Requirements .................. 4 1.5 Clean Air Source ..................... 4 2 Functional Operation of the Fluidized Bed Dryer 3 Control Components of the FBD 4 Safety Considerations Setting Up the Machine from the HMI... - Page 4 6.1.5 Heater Controls ......31 6.1.6 Start Button ......32 6.1.7 Dust Hood Light .
- Page 5 List of Tables Model Voltages and Total Amp Draws ............4...
- Page 6 List of Figures Putting particles on the deck and adjusting (a) Particles drying early (b) and drying at the end of the deck (c) .............. 7 2.2 Putting particles on the deck and adjusting (a) Particles drying early (b) and drying at the end of the deck (c) .............. 8 The Programmable Logic Controller (PLC) CompactLogix L2 .......
- Page 7 5.32 Blend Door Calibration ................. 24 5.33 Machine Hand ....................24 5.34 Mode Selection ..................... 27 Control Panel....................29 6.2 Airchest Controls Area.................. 29 6.3 Fan Controls Area ..................30 6.4 Deck Controls Area ..................30 6.5 Deck Eccentric Pause Button ................ 30 6.6 Deck End Raise Controls ................
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Page 8: Installation And Functional Operation
Part I Installation and Functional Operation... - Page 9 This manual contains several different sections. The first section will describe the installation procedure for the machine. Next, the functional operation and initial setup of the machine will be described. Then the operation of the machine in its various modes will be discussed.
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Page 10: Installation
1.2 Handling The DVX Fluidized Bed Dryer weighs several thousand pounds depending on the model and accessories ordered with it. Be sure that the handling equipment is adequate for the load. -
Page 11: Electrical Requirements
1.4 Electrical Requirements The DVX Fluidized Bed Dryer comes with a complete electrical cabinet that is wired to all of the electrical components such as the motors, hydraulic cylinders sensors, and dust hood light. -
Page 12: Functional Operation Of The Fluidized Bed Dryer
Functional Operation of the Fluidized Bed Dryer The DVX family of Fluidized Bed Dryers (FBD) is based on Olivers legendary Voyager and Maxi- Cap Gravity Separators. Unlike the gravity separator, which is designed to separate like particles of different specific gravities, the FBD is designed to remove moisture, and possibly heat, from the particles on the deck. - Page 13 product will dry. For normal use with ambient air, the typical operation of the machine is to set the fans at 100% and then to adjust the deck speed until all of the heavier particles are able to enter into the quasi-fluidic state, and then to adjust the End Raise until the product is just dry at the end of the deck.
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Page 14: Putting Particles On The Deck And Adjusting (A) Particles Drying Early (B)
Figure 2.1: Putting particles on the deck and adjusting (a) Particles drying early (b) and drying at the end of the deck (c) -
Page 15: Putting Particles On The Deck And Adjusting (A) Particles Drying Early (B) And Drying At The End Of The Deck (C)
Figure 2.2: Putting particles on the deck and adjusting (a) Particles drying early (b) and drying at the end of the deck (c) -
Page 16: Control Components Of The Fbd
Chapter 3 Control Components of the FBD The DVX Fluidized Bed Dryer is an automated machine, which means that instead of having dials or mechanical devices to control the air flow, deck speed, and other compo- nents that have to be individually controlled in a mechanical way the entire process is done via a Human Machine Interface (HMI) and a Programmable Logic Controller (PLC). - Page 17 Figure 3.2: The Human Machine Interface (HMI) – PanelView Plus HMI Figure 3.3: The Variable Frequency Drive (VFD) – PowerFlex 525...
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Page 18: Safety Considerations
Chapter 4 Safety Considerations Important Safety Precautions for Using the DVX Fluidized Bed Dryer • Always shut off the lock-out power when performing maintenance or service. • Always insure that the dryer and components are electrically grounded. • Always wear face and eye protection when inspecting or adjusting the dryer. -
Page 19: Setting Up The Machine From The Hmi
Part II Setting Up the Machine from the... -
Page 20: Choosing The Machine Options
See Figure 5.2. see Oliver’s training video entitled ”Menu Navigation” see Oliver’s training video entitled ”Logging in a User and Changing User Password”... -
Page 21: Navigating To The Dryer Options Screen From The Control Panel
Figure 5.2: Logging in as the engineer user Once the user is logged in as the engineer user, press the menu button marked Dryer Options on the right hand side to go to the installed options screen. See Figure 5.3 Figure 5.3: Navigating to the Dryer Options Screen from the Control Panel... -
Page 22: Fan Vfds
The installed options screen is shown in Figure 5.4. Figure 5.4: Dryer’s installed options screen The top of the screen has several menu buttons, see Figure 5.5, for navigation to the options for the subcomponents of the machine including the following items from left to right: •... -
Page 23: Fan Speed Scaling
Figure 5.6: Selecting the Fan VFD Options This will cause a popup window to open, as shown in Figure 5.7. Figure 5.7: Fan options pop up window The pop window will show the appropriate number of VFDs for the machine model. In this case Figure 5.6 shows the two fans for the DVX410 or DVX307 platforms. -
Page 24: Fan Scaling Example For Dryer With No Heat
100%, and Figure 5.11 shows that when the user attempts to change the commanded speed from the control panel that the min and max allowed values are indeed 50% and 100%. for further help see Oliver’s training video ”Setting up the Fan VFDs”... -
Page 25: Fan Current, Dc Bus Voltage, And Temperature Alarm Limits
Oliver’s training video ”Setting up the Fan VFDs”... -
Page 26: Deck Eccentric Vfd
Figure 5.13: Setting output current (A) limits for Fan 1 Example On the control panel, the alarms are indicated on the bar graph in Diagnostic mode. When the output current (or dc bus voltage or temperature) is within the specified limits, the bar will turn blue. -
Page 27: Deck Eccentric Current, Dc Bus Voltage, And Temperature Alarm Limits
RPM values in the grey boxes. The typical setup for a DVX Dryer is to allow the range of RPMs to go from 200 to 600 RPM. This normally corresponds to something close to 17 to 53 Hz, as shown in Figure 5.17. -
Page 28: Deck End Raise
Figure 5.19: Setting output current (A) limits for Deck Eccentric The grey input boxes to the right are used to indicate the full range of values the output current, in amps can take on. The boxes on the left are used to set values for the lower and upper alarm values, if needed. -
Page 29: Temperature Range
5.4 Temperature Range The DVX Dryer comes with the ability to set a generic temperature and humidity range and alarm limits for the airchest sections. The primary purpose of the settings are for Dryers that have a heating option. These settings will limit the maximum and minimum temperature that can be set for the heating option, and alarm levels for the temperature and humidity. -
Page 30: Blend Door
Gates on the Installed Options screen. See Figure 5.29. Figure 5.29: Navigating to the End gate calibration The End gate popup screen is shown in Figure 5.30. Figure 5.30: Blend Door popup screen see Oliver’s training video entitled ”Setting the heating unit temperature ranges”... -
Page 31: Machine Hand
See Figure 5.33 where the screen is HMI is set up for a left hand machine. Figure 5.33: Machine Hand see Oliver’s training video entitled ”Blend Door Calibration”... -
Page 32: Machine Ip Addresses
Note: The PLC IP address and port setting here will not change the actual PLC IP address or port number, but are only informing the HMI what address to look for the PLC at. see Oliver’s training video entitled ”Setting HMI and PLC IP addresses”... -
Page 33: Modes Of The Machine
Part III Modes of the Machine... -
Page 34: Mode Selection
The Dryer has several different modes. The two main modes are the Auto mode and the Diagnostic Mode. There are several submodes as follows: 1. Auto Mode (a) Continuous SubMode (b) Batch SubMode (c) Local SubMode (d) Remote SubMode 2. Diagnostic Mode The modes and submodes are chosen from the Control Panel screen through the use of dials. -
Page 35: Auto Mode
Continuous Mode Continuous Mode is the DVX Dryer’s mode for operating with a continuous fluidized bed of seed. The product is expected to come onto the deck in either a batch or continuous manner, and the product flows down the deck continuously and is driven off the deck discharge end by the deck eccentric motion, fan speed, and the end raise. -
Page 36: Fan Controls
Figure 6.1: Control Panel There are several different areas of interest on the Control Panel mode with the mode and submode selections that have been made. They are as follows: 1. Fan Controls 2. Deck Eccentric Controls 3. End Raise Controls 4. -
Page 37: Deck Eccentric Controls
. The deck eccentric has another control which allows for the pausing or starting of the deck. See Figure 6.5. Figure 6.5: Deck Eccentric Pause Button see Oliver’s training video entitled ”Changing the Fan Speed” see Oliver’s training video entitled ”Controlling the Deck Eccentric”... -
Page 38: Deck End Raise Controls
Figure 6.6: Deck End Raise Controls 6.1.4 Sensor Readouts Each DVX Dryer has a temperature and humidity sensor pair in both the airchest and dusthood for each zone. The number of zones is equal to the number of fan controls. -
Page 39: Start Button
Figure 6.9: Heater Controls 6.1.6 Start Button In continous mode, the start button will start the operation of the recipe for the entire machine. The start button has a power symbol on it indicating that when it is pressed and green the machine is energized, and when it is red, the machine is not energized. See Figure 6.10 and 6.11 Figure 6.10: Start Button - Machine Off Figure 6.11: Start Button - Machine On and recipe running... -
Page 40: Batch
Figure 6.13: Dust Hood Light Button - Light On 6.2 Batch Mode The batch mode of the Dryer is used for running batches that stay on the dryer for an extended amount of time, either on the full deck or on baskets at different positions along the deck. -
Page 41: Batch Timer
6.2.1 Batch Timer The batch timer is used to time an entire batch. At the current revision of the code, the batch timer will automatically control the opening and closing of the end gate when the entire deck is used for the batch. At the beginning of each batch cycle the gate will close, and it will re-open at the end of a batch cycle so adjustments can be made to the deck to bring the seed off of the deck. -
Page 42: Deck Shake Timer
For example, the limits migh be set such that the upper limit is 80% end raise, the lower limit 30% end raise, and the recipe setting being 50% end raise. Figure 6.17 Figure 6.17: End Raise Cycle Limits Example The second setting is to set the length of time between the stirs of the deck. That time does not include the amount of time it takes the deck to go all the way up, then down, and to return to its original position. -
Page 43: Current Timer Readouts
Figure 6.19: Deck Shake Timer For example, if the deck should start out on for 2 seconds, then off for 10 seconds, and repeat this cycle for the entire batch cycle of 30 seconds, then Figure 6.20 illustrates the settings that would need to be input into the appropriate grey input boxes. Figure 6.20: Deck Shake Timer Example for 2 seconds on, 10 seconds off, repeated through a 30 second batch cycle Note: The deck shake timer setpoint cannot be altered while a batch is... -
Page 44: Differential Temp Alarm
Figure 6.21: Time Remaining The timers will then count down until they reach zero, and then restart the cycle. When the Deck is off, then the Deck On Timer will change to a Deck Off Timer, then back to Deck On when the timer reaches zero. See Figure 6.22. Figure 6.22: Time Remaining Deck Off 6.2.5 Differential Temp Alarm... -
Page 45: Local And Remote Mode
Figure 6.24: Differential Temp Alarm Popup Screen The differential temperature and humidity are set in the appropriate grey input boxes. 6.3 Local and Remote Mode The last of the Auto Mode submodes is the selection between local and remote mode. The only function of this setting is to take the stop/start button off the HMI, and for the PLC to wait for the start/stop command from the plant SCADA. -
Page 46: Trim
Trim screen, log in as a supervisor, then press the trim settings menu button on the menu on the right side of the screen. The trim screen is shown in Figure 6.28. see Oliver’s training video entitled ”Using the Clean Out Function”... -
Page 47: Changing Recipes
Supervisor user. The recipe screen is navigated to by pressing the Loaded Recipe Hyperlink in the top right corner. See Figure 6.30. see Oliver’s training video entitled ”Using the Clean Out Function”... -
Page 48: Navigating To The Recipe Screen From The Control Panel
Figure 6.30: Navigating to the Recipe screen from the Control Panel For the Operator user, the Recipe Setup screen looks like Figure 6.31. Figure 6.31: Recipe Setup Screen as an Operator user From this screen recipes can be loaded and saved via the Load Recipe and the Save Recipe buttons. - Page 49 Control Panel, and then saved into the currently highlighted recipe with the Save Recipe button. The recipe name in the loaded recipe column can also be changed from the Recipe Settings Screen. Note: Make absolutely certain that the Loaded Recipe name and the recipe highlighted and shown in the saved recipe column are the same or that you intend to overwrite the name in the saved recipe highlighted, as the recipe name in the loaded recipe columns WILL overwrite the name of...
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Page 50: Recipe Setup Screen With Update Recipe And Cancel Buttons
Figure 6.33: Recipe List with a new Recipe Figure 6.34: Recipe Setup Screen with Update Recipe and Cancel buttons see Oliver’s training videos entitled ”Adding New Recipe and Deleting Old Recipe” and ”Loading and Saving Recipes”... -
Page 51: Diagnostic Mode
Chapter 7 Diagnostic Mode Unlike the Auto Mode, which uses a recipe to operate all of the machine’s components simultaneously, the diagnostic mode is used for troubleshooting purposes only and starts each component individually. In order to set the machine to the Diagnostic Mode, the user must be logged in as a Supervisor. -
Page 52: Start Buttons For The Fans And Deck Eccentric
Start Buttons for the Fans and Deck Eccentric In diagnostic mode the fans and the deck eccentric are started independently of each other. Each of them will have their own start button. See the areas marked with a red circle in Figure 7.2. Figure 7.2: Control Panel in Diagnostic Mode with Start Buttons Highlighted 7.2 Deck End Raise Feedback The deck end raise has a display for the voltage feedback for the deck. -
Page 53: Vfd Graphs And Readout
Figure 7.3: Control Panel in Diagnostic Mode with Deck End Raise Feedback Highlighted 7.3 VFD Graphs and Readout Each of the fans and the deck eccentric have readouts that display the voltage, amperage, temperature, and the output frequency in hertz of each drive. This can be used to diagnose the current condition of the drive, monitor the drive for excess voltage, amperage, and temperature, as well as make sure the drive is getting to the expected output frequency at different commanded speeds.