Oliver Hi-Cap N Series User manual

Hi-Cap N Series
Destoners
Version 1.0 | 1/5/23
Oliver Manufacturing Company •27151 Harris Road •La Junta, CO 81050 •(888) 254
-
7814 •olivermanufacturing.com
Operations manual

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Safety Considerations
Important Safety Precautions for using the Hi-cap Stoner
•Always follow applicable safety standards and protocols when performing
maintenance or service.
•Always ensure that the stoner and components are electrically grounded.
•Always de-energize and lock out the electrical panel before working inside the
stoner cabinet or inside of the stoner.
•Always wear proper PPE - face shields, hard hats, safety shoes, insulating
(rubber) gloves with protectors, insulating sleeves, and flame-resistant (FR)
clothing when work must be performed in a live or energized electrical panel.
•Always wear proper PPE - safety glasses, hard hats, safety shoes, respirator
and gloves when inspecting the stoner or performing maintenance.
•Never operate the stoner with the air filters removed.
•Never operate the stoner with the deck removed.
•Never operate the stoner with missing or worn parts.
•Never operate the stoner with worn or damaged decks.
•Never use the stoner as a table or workstation.
•Never stand on the stoner and/or dust hood.
•Always wear ear protection when operating the stoner.
•Always keep machine clean and properly adjusted.
•Periodically inspect the Stoner, for wear and correct operation, in accordance
with Oliver Manufacturing’s maintenance recommendations.

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Contents
I. INTRODUCTION .........................................................................................................................................6
II. INSTALLATION ......................................................................................................................7
2.1 De skidding/Uncrating................................................................................................7
2.2 Foundation and Space Requirements ...................................................................7
2.3 Electrical Requirements and Precautions...........................................................9
2.4 Clean Air Source/Exhaust .......................................................................................10
2.5 Warranty Clause.......................................................................................................... 10
III. FUNCTIONAL OPERATION OF THE STONER..........................................................11
3.1 The Process of Stratification.................................................................................. 11
3.2 The Theory in Practice .............................................................................................12
3.3 Guidelines for Use of Stoner................................................................................... 15
IV. CONTROL COMPONENTS OF THE STONER.............................................................16
4.1 The Deck......................................................................................................................... 16
4.2 The Four Basic Adjustments ..................................................................................17
Feed Rate ..........................................................................................................................18
Tilt .......................................................................................................................................19
Eccentric Speed..............................................................................................................19
Air Adjustment............................................................................................................... 20
4.3 EXHAUST AIR ADJUSTMENT .......................................................................21
4.4 HIGH END PNEMUATIC GATE CONTROL ..............................................22
V. START UP AND OPERATION .......................................................................................... 23
5.1 Initial startup Procedure.........................................................................................23
5.2 Stoner Operation ........................................................................................................24
5.3 Increasing Capacity ...................................................................................................25
5.4 Separation Troubleshooting .................................................................................26

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VI. APPENDICES .......................................................................................................................................... 26
Appendix A: Maintenance and Basic Troubleshooting........................................... 32
A.1 Recommended maintenance Items ....................................................................33
A.1.1 Deck..............................................................................................................................33
A.1.2 Belts and Sheave .....................................................................................................34
A.1.3 Bearings......................................................................................................................34
A.1.4 Air Filters(non-heat)............................................................................................. 34
A.2 Machine Troubleshooting....................................................................................... 35
A.2.1 Blinded Deck.............................................................................................................35
A.2.2 Dirty Air Filters/Obstructed Air Flow............................................................ 35
A.2.3 Inadequate Foundation........................................................................................35
A.2.4 Belt Slipping..............................................................................................................35
A.2.5 Wrong Machine Settings ......................................................................................36
Appendix B: The ABB ACS380 VFD..................................................................................26
B.1 Getting to know the VFD keypad..........................................................................27
B.2 Programming the VFD from the keypad ........................................................... 30
B.3 VFD parameter list....................................................................................................31
Appendix C: Timer manual.................................................................................................26
C.1 Getting to know timer operation..........................................................................27
C.2 Timer dip switch selection .....................................................................................30
Appendix D: Electrical and Dimensional drawings ..................................................32
D.1 Hi-cap N Stoner 480V Electrical drawing .....................................................34
D.2 Hi-cap N Stoner Dimensional drawing...........................................................36
A.1.2

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List of Tables
Table 1 –Electric Requirements and Precaustions................................................. 9
Table 2 –Fan and Eccentric VFD parameter list ................................................... 31
List of Figures
Figure 1 –Destoner installation ............................................................................. 8
Figure 2 –Stratification process........................................................................... 12
Figure 3 –Stoner Top ideal view .......................................................................... 12
Figure 4 - Sectional view of stoner deck operation .............................................. 14
Figure 5 –Stoner deck overview ...........................................................................16
Figure 6 –Stoner Controls ................................................................................... 17
Figure 7 –Stoner console......................................................................................18
Figure 8 –Dusthood Pressure Gauge on the Console ........................................ 420
Figure 9 –Gate Timer Open and Closed on the Cabinet....................................... 21
Figure 10 –Gate 3-way swtich on the Console..................................................... 22
Figure 11 –Stoner Opeartion Step 1 .................................................................... 24
Figure 12 –Stoner Opeartion Step 2 .................................................................... 24
Figure 13 –Stoner Opeartion Step 3 .................................................................... 25
Figure 14 –Stoner separation patterns................................................................ 31
Figure 15 –New deck vs. worn deck .................................................................. 24
Figure 16 –VFD keypad overview...................................................................... 24
Figure 17 –VFD keypad display ......................................................................... 25
Figure 18 –VFD keypad status line..................................................................... 31
Figure 19 –VFD Faults and Warnings ............................................................... 24
Figure 20 –Changing VFD parameters............................................................... 24

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I.INTRODUCTION
CONGRATULATIONS! You have just purchased a well-built machine that can
earn substantial profits for you, if you take time right now to understand the
Oliver Stoner N and how it works. Please take a few minutes to read the
following document.
The Hi-cap Stoner N-Series is designed to separate particles of similar size
that differ in weight, eliminating heavy trash and stones. The Stoner
should not be used as a cleaning machine to remove dust, dirt, sticks and
other refuse frequently found in harvested crops. In all processing
situations, the best results are obtained from the stoner when the product has
been thoroughly pre-cleaned and sized, using the proper equipment for these
purposes. Under these conditions, the stoner is then able to show what it can
really do!

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II.INSTALLATION
This section explains the installation requirements for the Stoner. All Oliver
Stoners have been tested per Oliver Manufacturing’s protocols, at our facility, to
ensure the quality of the machine. Stoners are operated on test blocks at the factory
for a minimum of five hours. During and after operation, the drive mechanism and
controls are checked to ensure that they will operate satisfactorily when you set
them up at your factory.
2.1 De-Skidding and Uncrating
Although Oliver is built to give years of service, it can be damaged while
uncrating. First the top of the crate should be carefully removed. Then take off the
sides. After the top and sides are withdrawn, the Oliver Stoner can be disengaged
from the bottom of the crate by removing the four 3/8" bolts located on the
mounting flanges of the stoner. While removing the crate, do not put anything on
the separating deck. If the deck is damaged, good separations are impossible. Also,
be careful not to puncture the filter screens located on the sides of the machine. If
the filter screens are damaged, dirt may be sucked into the machine and may plug
the deck.
Immediately after uncrating your Oliver Stoner, inspect for shipping damage.
If the machine is impaired in any way, it was caused in transit and a claim should
be filed with the carrier.
The feed hopper, mounting brackets and discharge hoppers are attached to
the inside of the crate or the inside of the stoner. All items securely fastened inside
the stoner may be removed by opening the filter screens and cutting the tie wires.
2.2 Foundation and space requirements
Foundation Requirement: A solid foundation is required for your Oliver
Stoner. False vibrations from flooring can ruin the separation quality of the
machine. A six-inch concrete slab makes an ideal platform but is not essential. Many
customers operate Oliver Stoners on wooden floors with no problems. If you feel
that your floor is insecure, please contact the factory for recommendations.

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Location. The selected location for the installation must also have sufficient space
around the equipment for proper ventilation. Do not block the equipment airflow
filters. The selected location must have sufficient space around the Electrical cabinet
(if equipped) for working clearance as prescribed by the National Electric Code
Selection 110-26 or local Authority Having Jurisdiction.
When locating your stoner, be sure that you leave adequate clearance to
operate the controls and to remove the deck for changing or cleaning. Tooperate
the controls and provide normal maintenance, we recommend a minimum of 4 ft.
clearance. A space approximately equal to the dimensions of the deck is adequate
for deck removal from the heavy end. Please refer to our layout print at the end of
these instruction manual for dimensional information.
MINIMUM 4 FT
CLEARANCE
Figure 1: Destoner
installation
CLEARANCE TO OPEN
ELECTRICAL CABINET DOOR

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2.3 Electrical Requirement: After your stoner is mounted on a secure
foundation, you are ready to make electrical connections. The Stoner comes with a
complete electrical cabinet that is wired to all the electrical components, such as the
motors, reference keypads and dust hood light. Typical voltages would be 230V and
460V, three-phase, at 60 Hz, however other voltages can be accommodated.
Cable Size
AWG or kcmil
Terminal Torque Requirements
Lbs - in
N-m
Lbs - in
N-m
18-10
35
4.0
80
9.0
8
40
4.5
80
9.0
6 - 4
45
5.1
165
18.6
3
50
5.6
275
31.1
2
50
5.6
275
31.1
1
50
5.6
275
31.1
1/0 - 2/0
50
5.6
385
43.5
3/0 - 4/0
50
5.6
500
58.5
250 - 350
50
5.6
650
73.4
400
50
5.6
825
93.2
500
50
5.6
825
93.2
600 - 700
50
5.6
1000
113.0
Always ensure that all applicable national and local electrical standards are
followed during installation. For field connections, refer to the electrical schematics
provided inside of the electrical cabinet. When penetrating the electrical cabinet for
field wiring the electrician must enter the cabinet from the bottom. Failure to do this
will result in voiding the factory warranty on the electrical cabinet.
OVERCURRENT AND PROTECTIVE DEVICE (OCPD) Sizing. Short circuit and
overload protection must be provided upstream of the power quality equipment.
Fused disconnects should be sized no less than 135% of the rated capacitor current.
Tocheck for proper belt tension, first turn the machine off. Then apply pressure
to the side of the belt midway between the pulleys. The belts should deflect
Table 1: Electrical Requirements and Precautions

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approximately 1/2 inch. After the machine has operated for 8 to 10 hours, check the
belts again. It is normal for new belts to stretch slightly, so the belt tension may have
to be adjusted. When belts are too loose, they will slip. This will cause the belts and
pulleys to overheat and shorten their life.
Be sure that the shafts are running in the proper direction. All shafts, motor
shaft, fan shaft and eccentric shaft, should run counterclockwise when viewed from
the side of the machine where the motor is installed. Proper fan rotation is very
important and at least half of the problems with new stoners can be traced back to
incorrect rotation.
2.4 Clean Air Source/Exhaust
Supply air source should be clean and free of cross drafts or obstructions to
interfere with intake. Supply intake should be properly screened to prevent
foreign objects from entering the system. Some customers need to bring in clean
outside air rather than to draw dusty plant air through the filters installed on the
machine. The clean air source should have a filter area not less than the area of
the deck surface.
After the stoner is installed and the motor wired so the fans rotate in the
proper direction, familiarize yourself with the theory behind stoner operation and
the proper usage of the controls before attempting to make a separation. Oliver
advice to the customer is to follow local code and regulation for exhaust system.
2.5 Warranty Clause
Failure to follow any or all the Installation requirements previously set forth by this
manual will result in a void of the factory warranty. Any damage incurred during
transportation or installation of the N series Stoner will not be covered under the
factory warranty.

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III. FUNCTIONAL OPERATION OF THE STONER
This chapter explains the functionality and operation of the Stoner, how they
work, and how they are operated. Do not attempt to operate the Stoner without an
understanding of how and why it works. Proper adjustment of all the controls is
necessary to obtain the best possible results. All gravity separators and stoners
utilize the same principles to affect a separation. Once these principles are
understood, it is usually a simple step to adjust a stoner to produce an optimum
separation. About 250 B.C., Archimedes discovered the law of specific gravity,
which is "ALL BODIES FLOATING IN OR SUBMERGED IN A LIQUID ARE BUOYED
UP BY A FORCE EXACTLY EQUAL TO THE WEIGHT OF THE LIQUID THEY
DISPLACE." The specific gravity of a particle is the ratio of its density to some
standard substance, the standard usually being water with a unit of 1. Particles
having a specific gravity of less than 1 will float and particles with a specific gravity
greater than 1 will sink.
Oliver stoners use air as a standard rather than water. Since air is lighter than
water, the relative difference between particles of differing weights is widened. For
this reason, the stoner is a very, sensitive machine and, when operated correctly, can
produce a very precise separation.
3.1 The Process of Stratification
Air is used as the separating medium for the process of stratification.
Stratification occurs by forcing air through the particle mixture so that the
particles rise or fall by their relative weight to the air. Figure 1 below represents
a cross section of the stoner directly over a fan. A particle mixture has been
introduced on top of the screen deck with the fans off.
In Figure 2 the fan has been turned on so that the heaviest particles rest on the
surface of the deck and the lightest particles are completely free of the surface of the
deck. Proper regulation of the air flow at this time is critical or all particles will be
blended and lifted free from the separating surface by excess air (Figure 3).

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Figure 2: Stratification process
3.2 Theory in Practice.
Figure 3 represents a top view of the ideal
situation in the operation of the seed mixture,
similar to Figure 1, falls from the feeder onto the
deck. The area immediately under the feeder is
called the stratification zone. In this area, the
vibration of the deck and the lifting action of the
air combine to stratify the material into layers
with heavier layers on the bottom and lighter
layers on the top as shown by Figure 2.
Separation cannot occur until the material
becomes stratified. The size of the stratification
area will depend on the difficulty of the
separation and on the capacity at which you are
processing. At no time should it exceed 1/3 of the
deck surface.
The more difficult the separation, the
greater is the area that is required to obtain
proper stratification. For example, the
stratification area is large when separating mud
clods from saleable beans, because there is relatively little difference in weight.
FIGURE
3

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However, the stratification area is small when removing rocks or stones from beans,
because there is a large difference in weight. Higher capacities likewise require
greater areas for stratification.
Once the material is stratified, the vibrating deck begins pushing the heavier
layers in contact with the deck uphill toward the stone discharge. At the same
time, the upper lighter layers, which do not contact the deck, begin to float
downhill toward the clean product discharge.
It should be noted that, since the stratification process is not instantaneous, some
of the heavier materials will be carried down the deck toward the discharge end
before they can sink to the bottom of the fluidized bed. This is normal and
acceptable as long as the heavy trash does not flow off the deck with the cleaned
product. When you are not making a proper separation, it is an indication of one
of the following problems:
1. Feed rate too high - stratification area too large.
2. Machine improperly adjusted -- improper stratification.
3. Material not suitable for separation on a stoner.
Each of the above is a distinct problem and will be discussed fully in this manual.

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Figure 4: Sectional view of stoner deck operation
This figure 4 above is a sectional diagram of what occurs on a stoner deck.
Compressed air forced through the mesh of the deck cover lifts the lighter particles
upward, while heavier particles sink against the air currents and come to rest on
the deck surface, providing the air is properly adjusted. The heavier particles are
forced to travel uphill by mechanical action, while the lighter particles float
downhill on a film of air.
While stoners have greater capacities than gravity separators, based on
square feet of relative deck area, there is a limit as to the amount of feed flowing
to the deck. As the feed is increased, the stratifying area is also increased. The
stratifying area should not occupy more than 1/3 of the entire deck area.
We have already stressed the need for earlier processing of products before
they are introduced onto the stoner. (See p. 1.). This pre-sorting enables
separations that are otherwise impossible. There are three guide- lines developed
by the late Oliver W. Steele that state what can be separated and what cannot be
separated on a gravity separator or stoner.

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3.3 Oliver’s Guidelines for Use of Stoner
Rule 1. PARTICLES OF THE SAME SIZE BUT DIFFERING SLIGHTLY IN SPECIFIC
GRAVITIES CAN BE SEPARATED.
A common example of this would be the separation of similar size stones from seed
where the stones are heavier than the seed.
RULE 2. PARTICLES OF THE SAME SPECIFIC GRAVITIES BUT DIFFERING IN THE
SIZE WILL BE GRADED ACCORDING TO THE SIZE OF THE PARTICLES.
Unlike the gravity separator, a stoner produces a two-way separation rather than a
continuous grade at discharge. Due to this two-way separation, sizing is not done on
a stoner, because the accuracy of separation is poor.
RULE 3. PARTICLES DIFFERING IN SPECIFIC GRAVITIES AND ALSO DIFFERING
IN SIZE CANNOT BE EFFICIENTLY SEPARATED.
An example of this would be the separation of adobe from pinto beans
where the particles are nearly the same size and the weight as well. In cases such
as this, the stoner must be operated at a lower capacity; and one should expect a
lower quality separation.

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IV. CONTROL COMPONENTS OF THE STONER
Before starting to operate the machine, it is necessary to have a thorough
understanding of the controls and their location on the Oliver Stoner. PROPER
REGULATION OF CONTROLS IS THE KEY TO SUCCESSFUL STONER
SEPARATION, AND THE PROPER USE OF THESE CONTROLS SHOULD BE
UNDERSTOOD PRIOR TO ATTEMPTING AN ACTUAL SEPARATION.
4.1 THE DECK
The most important part of the
stoner is the deck, because it is the main
separating surface. It consists of a
carefully constructed metal frame to
counteract false vibrations with a
screen or polymer over cover that is the
surface on which the separation takes
place.
The highest or uphill end of the
deck is the stone discharge and the
lower or downhill portion of the deck is
the clean product discharge.
Oliver Stoners have one,
two or three stone discharge traps depending on the model. The Oliver Model 2448
N Stoner has one stone trap. The Model 3648 N Stoner has two stone traps, and the
Model 4848 and 6048 N Stoner each have three stone traps.
The features of the deck will be discussed further in these instructions, but
knowledge of their location is important as well as understanding the controls that
affect the four variable adjustments in the Oliver Stoner.
FIGURE
5

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4.2 STONER ADJUSTMENTS
All Stoners have four variable adjustments that must be properly adjusted
and balanced to obtain optimum separations. These are Feed Rate, Tilt, Eccentric
Speed and Air Control. We will discuss the controls for each of these variables in
turn. (Please refer to Figure 6.)
1. FEED CONTROL.
2. TILT ADJUSTMENT.
3. VFD AIR ADJUSTEMENT FOR AIR.
4. VFD ECCENTRIC SPEED.
5. DUST HOOD PRESSURE GUAGE.
6. EXHAUST BLAST GATE CONTROL.
7. START/STOP BUTTON
8. HIGH END PNEUMATIC GATE
9. HIGH END GATE 3-WAY SWTICH
FIGURE
6: STONER CONTROLS

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START/STOP BUTTON:
The START/STOP button controls the machine start and stop of this Nautilus stoner.
When start button is pressed, it will start air, eccentric motion, timer for the high-end
gate and activate the dust hood light. When stop button is pressed it will stop the
operation of the stoner completely.
FEED RATE:
The feed rate can be controlled with external feed bin or vibrating feeder. Built in
feeder with 6-inch round inlet located on top of the dust hood as shown in figure 8
and labelled with balloon 1. The external feeder controls the amount fed onto the
separating deck. You must supply your own feeder control or can be purchased as
option from the factory.
The feed rate, whether fast or slow, should be uniform and free of surges.
Surges in the incoming feed will show up in the discharge of the machine as a poor-
quality separation. We suggest the use of surge bins above the feeder, if processing
will be interrupted.
Generally, the average feed rate is determined by the average capacity of the
processing line of equipment. For optimum separation on your stoner, your feed
rate should be as low as possible without falling below the minimum feed rate at
FIGURE
7: CONSOLE

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which the deck can be fed and still obtain the necessary separation. When starting
your stoner, always start at the minimum feed rate; obtain your required
separation, then increase the feed rate to the desired capacity.
TILT:
Tilt is the difference in the elevation between the high end of the deck and the low
end of the deck. Increasing tilt will cause the material to shift toward the low end
of the deck. Decreasing tilt will cause the material to shift toward the high end of
the deck. Normally, the best separations are obtained when the tilt is set at or near
the maximum steepness. However, care should be taken not to set the tilt too steep.
The tilt is too steep when material cannot be made to flow toward the high end of
the deck by increasing the eccentric speed. Too little tilt is shown when all the
material moves toward the heavy side of the deck despite a slow eccentric speed. The
tilt is adjusted by loosening the two clamping handles (2) and moving the tilt
adjustment handle (2) in toward the machine for more tilt and away from the
machine for less tilt.
VFD AIR ADJUSTMENT : Air regulation is one of the most important adjustments
to be made on a stoner. The most common mistake in air regulation is the use of too
much air. Separation is not made by "blowing" the light material from the heavy but
by using a controlled air flow to create the stratified layers, which are then separated
by the vibrating action of the deck. Too much air will cause a boiling or bubbling
action lifting the heavier particles from the deck and mixing them with the lighter
top layers. Too little air will cause the material to appear sluggish and pile up on the
high end of the deck.
With proper air regulation, the bed of material will be almost fluid in
appearance. With the exception of the stratifying zone under the feeder, the
material on the surface should be agitated and free flowing. Bubbling should be
kept to a minimum, allowing the vibrating deck to make the separation.