Oliver DVX User 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
Operations manual

i
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
Modes of Operation
V
3/6/2020
Appendix A: The PanelView Plus
Appendix B: CompactLogix 5370 L2 PLC
Appendix C: Power flex 525 Variable Frequency Drive

ii
Contents
I Installation and Functional Operation 1
1 Installation 3
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 5
3 Control Components of the FBD 9
4 Safety Considerations 11
II Setting Up the Machine from the HMI 12
5 Choosing theMachine Options 13
5.1 Fan VFDs ..................................................................................................... 15
5.1.1 Fan Speed Scaling.............................................................................. 16
5.1.2 Fan Current, DC Bus Voltage, and Temperature alarm limits ............ 18
5.2 Deck Eccentric VFD ..................................................................................... 19
5.2.1 Deck Eccentric Speed Scaling ............................................................ 19
5.2.2 Deck Eccentric Current, DC Bus Voltage, and Temperature alarm
limits ................................................................................................. 20
5.3 Deck End Raise ............................................................................................ 21
5.4 Temperature Range ...................................................................................... 22
5.5 Blend Door ................................................................................................... 23
5.6 Machine Hand .............................................................................................. 24
5.7 Machine IP Addresses................................................................................... 25
III Modes of the Machine 26
6 Auto Mode 28
6.1 Continous Mode ........................................................................................... 28
6.1.1 Fan Controls...................................................................................... 29
6.1.2 Deck Eccentric Controls .................................................................... 30
6.1.3 Deck End Raise Controls ................................................................... 31
6.1.4 Sensor Readouts................................................................................ 31

iii
6.1.5
Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
6.1.6
Start Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
6.1.7
Dust Hood Light . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
6.2
Batch
Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
6.2.1
Batch Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
6.2.2
End Raise Cycle Timer . . . . . . . . . . . . . . . . . . . . . . . . .
34
6.2.3
Deck Shake Timer . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
6.2.4
Current Timer Readouts . . . . . . . . . . . . . . . . . . . . . . . .
36
6.2.5
Differential Temp Alarm . . . . . . . . . . . . . . . . . . . . . . . .
37
6.3 Local and Remote Mode ............................................................................... 38
6.4 Clean Out .....................................................................................................38
6.5 Trim ..................................................................................................................... 39
6.6 Changing Recipes........................................................................................ 40
7 Diagnostic Mode 44
7.1 Start Buttons for the Fans and Deck Eccentric............................................45
7.2 Deck End Raise Feedback ................................................................................. 45
7.3 VFD Graphs and Readout............................................................................46

iv
List of Tables
1.1 Model Voltages and Total Amp Draws............................................................4

v
List of Figures
2.1 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
3.1 The Programmable Logic Controller (PLC) CompactLogix L2.......................9
3.2 The Human Machine Interface PanelView Plus HMI ..................................... 10
3.3 The Variable Frequency Drive (VFD) –PowerFlex 525 ................................. 10
5.1 Menu Bar ..................................................................................................... 13
5.2 Logging in as theengineer user ..................................................................... 14
5.3 Navigating to the Dryer Options Screen from the Control Panel ................... 14
5.4 Dryer’s installedoptions screen..................................................................... 15
5.5 Dryer’s installed options screen top menu buttons ........................................ 15
5.6 Selecting the Fan VFD Options..................................................................... 16
5.7 Fan options pop up window .......................................................................... 16
5.8 Fan scaling options ....................................................................................... 16
5.9 Fan scaling Example for Dryer with no heat ................................................. 17
5.10 Fan scaling Example for Dryer with heat ...................................................... 17
5.11 Changing Fan 1 speed command for Example 2 ............................................ 18
5.12 Setting output current (A) limits for Fan 1 ................................................... 18
5.13 Setting output current (A) limits for Fan 1 Example..................................... 19
5.14 Selecting the Deck VFD Options................................................................... 19
5.15 Deck options popup window ........................................................................ 19
5.16 Deck scaling options ..................................................................................... 19
5.17 Deck scalingoptions Example....................................................................... 20
5.18 Changing Deck speed command for typical setup.......................................... 20
5.19 Setting output current (A) limits for Deck Eccentric..................................... 21
5.20 Setting output current (A) limits for Deck Eccentric Example ...................... 21
5.21 Selecting the Deck End Raise Options .......................................................... 21
5.22 Deck End Raise Options Screen .................................................................... 21
5.23 Inputing Voltage Limits for Deck End Raise ................................................. 22
5.24 Forcing the Deck up and Down ..................................................................... 22
5.25 Voltage Feedback .................................................................................................22
5.26 Selecting the Temperature Range settings and alarms................................... 23
5.27 Temperature Range popup ........................................................................... 23
5.28 Temperature Range Settings......................................................................... 23
5.29 Navigating to the Blend Door calibration...................................................... 23
5.30 Blend Door popup screen.............................................................................. 23
5.31 Blend Door pulses input boxes...................................................................... 24

vi
5.32 Blend Door Calibration................................................................................. 24
5.33 Machine Hand .............................................................................................. 24
5.34 Mode Selection ............................................................................................. 27
6.1 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 .............................................................................. 31
6.7 Airchest Sensors ........................................................................................... 31
6.8 Dusthood Sensors......................................................................................... 31
6.9 Heater Controls ............................................................................................ 32
6.10 Start Button - Machine Off........................................................................... 32
6.11 Start Button - Machine On andrecipe running ............................................. 32
6.12 Dust Hood Light Button - Light Off ............................................................. 32
6.13 Dust Hood Light Button - Light On.............................................................. 33
6.14 Control Panel in Batch Mode........................................................................ 33
6.15 Inputing Batch Timer settings for Batch Time length ................................... 34
6.16 Inputing Batch Timer settings for End Raise Cycle....................................... 34
6.17 End Raise Cycle Limts Example ................................................................... 35
6.18 End Raise Timer 5Seconds Example............................................................ 35
6.19 Deck Shake Timer......................................................................................... 36
6.20 Deck Shake Timer Example for 2 seconds on, 10 seconds off, repeated
through a 30 secondbatch cycle.................................................................... 36
6.21 Time Remaining ........................................................................................... 37
6.22 Time Remaining Deck Off............................................................................. 37
6.23 Navigating to the differential temp alarm settings......................................... 37
6.24 Differential Temp AlarmPopup Screen......................................................... 38
6.25 Clean Out Screen.......................................................................................... 38
6.26 Loaded Values Clean Out Screen .................................................................. 39
6.27 Time Elapsed for each stage.......................................................................... 39
6.28 Trim Settings................................................................................................ 40
6.29 Trim Settings Fan1 Example at 40% to 55% trim settings............................. 40
6.30 Navigating to the Recipe screen from the Control Panel ............................... 41
6.31 Recipe Setup Screen as anOperator user...................................................... 41
6.32 Recipe Setup Screen as a Supervisor user...................................................... 42
6.33 Recipe List with a new Recipe ...................................................................... 43
6.34 Recipe Setup Screen with Update Recipe and Cancel buttons....................... 43
7.1 Control Panel in Diagnostic Mode ................................................................ 44
7.2 Control Panel in Diagnostic Mode with Start Buttons Highlighted................ 45
7.3 Control Panel in Diagnostic Mode with Deck End Raise Feedback Highlighted 46
7.4 Graphs for Amperage (A), Voltage (V), and Temperature and the readout
for the VFD frequency in diagnostic mode .................................................... 46

1
Part I
Installation and Functional
Operation

2
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. Finally, several attached appendices will be provided for description of
related functions such as programming the PLC and HMI.

3
Chapter 1
Installation
This section explains the installation requirements for the Dryer. Your Dryer will have
been tested many hours of operation at our facility to ensure the quality of the machine.
Take care not to do anything that would damage it or compromise it.
1.1 Foundation Requirements
A solid, level foundation is required for safe and proper operation of the FBD. Vibrations
from flooring can cause damage to the machine. A six-inch concrete slab is ideal but not
essential. The FBD is fully counterbalanced to keep external vibrations to a minimum.
However, the accuracy of the counterbalancing system is affected by the weight of the
product on the deck and thus is dependent on the capacity and type of product being
dried. Therefore we recommend that the Dryer be firmly attached to the floor. Please
contact the factory or your Oliver representative for recommendations. When positioning
the Dryer, be sure that you leave adequate clearance to operate the controls, open the
electrical cabinet and remove the deck for changing or cleaning.
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. While handling the machine take extra care not to damage the deck, the air filters
or any other parts of the machine. The fork tubes are designed to be used with 8-foot
long forks (or fork extensions). Picking up the machine with shorter forks may damage
the tubes. The fan motors are mounted on the tubes so any damage can have serious
consequences for machine functionality. The machine isalso equipped with lifting lugs at
the corners of the mainframe which may be used to hoist the machine into place.
1.3 Protecting the Deck
The deck is the portion of the machine that actually contacts the product during the
drying process. Take extra care not to damage it. During construction and installation,
it is very common for contractors to use the surface of the deck as a work space or
storage space for items they do not need. Please discourage this practice! The deck is
designed to support a relatively uniform load of product over its entire surface. Storageof
concentrated loads on the deck has resulted in bentor broken deck frames and in damage

4
to the wire overcovers. We recommend that a non-combustible surface such as a sheet
of 16-gauge steel be placed over the deck to protect it until the Dryer is ready for to be
used. Do not weld anything to the machine as the sensitive control electronics could be
seriously damaged. If it is necessary to weld or cut above the machine during installation
take extra care to prevent damage from falling debris or sparks.
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. Typically the only wiring the electrician installing themachine needs to worry
about is the running of the power source to the electrical cabinet. Typical voltages would
be 230V and 460V, three phase, at 60Hz. Other voltages are possible, but need to be
addressed when the order is placed.
Machine
DVX304
DVX307
DVX410
DVX512
DVX616
208/230V
30 Amps
50 Amps
70 Amps
115 Amps
150 Amps
480V
20 Amps
30 Amps
50 Amps
70 Amps
80 Amps
Table 1.1: Model Voltages and Total Amp Draws
NOTE: As of November 1st 2012, the warranty covering the PLC and VFDs
will become void if the electrician enters the cabinet from the top. The PLC
and VFDs will suffer damage if dust or debris from drilling into the cabinet
enters the air ventson the units. The electrician must enter the cabinet either
from the bottom, or from the bottom of either side panel, below the vents on
the VFD. Failure to do this will result in voiding the warranty on the PLC
and the VFDs.
1.5 Clean Air Source
The FBD requires a clean air source in order to keep the deck from being contaminated
by dust blown in through the fans. The air chest comes supplied with air filters for a
machine is that is going to be bolted down to a solid slab foundation. For those who want
to use an external air filtration source, it is also possible to either raise the machine, or
to suspend it over a space where the air is being pumped in. If you need consultation on
how to get clean air to your machine, please call the Oliver team.

5
Chapter 2
Functional Operation of the
Fluidized Bed Dryer
The DVX family of Fluidized Bed Dryers (FBD) isbased on Olivers legendary Voyager and
Maxi-Cap Gravity Separators. Unlike the gravity separator, whichisdesignedtoseparate
like particles of different specific gravities, the FBD is designed to remove moisture, and
possibly heat, from the particles on the deck. Though the function is slightly different, it
works on a very similar concept as the gravity separator.
The FBD operates on a concept discovered by Archimedes, a Greek philosopher and
mathematician, who discovered that 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. In the case
of the FBD, the liquid is the air blown by the fans, and the bodies are the particles being
dried. What Archimedes was getting at is that we can use air to lift the particles on the
deck, and that the amount of air needed is related to the weight of the particles that need
to be lifted.
As the air moves past the particles it acts in the same way a swamp cooler does by
evaporating the water around the particles. Because it takes a large amount of energy to
change the state of the water from a liquid to a vapor, the surrounding air becomes cooler
as it passes the particles on the deck, as the energy needed to switch the state of the
water comes from the air, and from the particles themselves. Hotter air from the fans will
speed up the drying process because it has more heat that can be dissipated to the water,
increasing the rate at which the water changes state. This process of the water being
evaporated and the air being cooled as it passes through the seeds allows us to monitor
how dry the seed is as it passes over the deck. If the air is at the same temperature above
and below the particles, then there must not beany evaporation, and the seed is dry.
In order to move the seed along the deck, there must be a process that allows the seed
to propagate. This is done via the Deck Shake and the Deck End Raise. The Deck Shake
also helps with the lifting of the seed as it gives momentum to the particles, as well as
providing a mechanism for separating out the particles that are clumped together from
being wet. The Deck End Raise allows gravity to assist or resist the movement of the
particles on the deck.
With the combination of theair, the Deck Speed, and the Deck End Raise, the particles
will enter a quasi-fluidic state, meaning that the particles will almost act like a liquid,
moving along the deck. As the air is increased, the particles will start to move more
vertically in a layer, and the deck speed and end raise will drive the product down the
deck like a liquid. The faster the deck speed and the steeper the end raise from feeder
to discharge, the faster the particles will move. The higher the air speed the faster the

6
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. For example, consider Figure 2.1. Here particles, represented
by red dots, have been put onto the deck (a), and the FBD has been set to have 100%
Fan Speed, and perhaps the deck has been set at 500 RPMs, and the particles have been
put into a quasi-fluidic state and are moving up the deck (b). When the particles are
tested at the end of the deck, they are dry, but they are also dry at the center part of the
deck. This means that the deck end raise can be increased, moving the deck towards a
flat position and a slope from the Feeder to the Discharge End (c). This will increase the
speed of the particles across the deck, decreasing the drying and process time. The Deck
Speed can also be increased instead of the Deck Angle.
On the other hand, the particles might be introduced to the deck and the fans turned
up to 100% and the Deck Speed set at 500 RPMs, and the deck angle could be too steep
from the Feed End to the Discharge, keeping the particles from drying. See Figure 2.2.
The particles are put on the deck (a) and the deck is adjusted but the particles are not
drying at the end of the deck. The Deck End Raise should be decreased to hold the
particles on longer so that the particles will dry.

7
Figure 2.1: Putting particles on the deck and adjusting (a) Particles drying early (b) and
drying at the end of the deck (c)

8
Figure 2.2: Putting particles on the deck and adjusting (a) Particles drying early (b) and
drying at the end of the deck (c)

9
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
doneviaaHuman MachineInterface(HMI)andaProgrammableLogicController(PLC).
The HMI is a 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.
The PLC is like a small computer. It has a processor, memory, inputs, outputs, and a
small display for additional controls. It is the brains of the automated machine. One
additional component to the automated process is the Powerflex 40 Variable Frequency
Drive (VFD). It is what the PLC uses to give exact control over all of the fans and the
eccentric motor. It is critical to know and understand the difference between the three
when going through the guide.
Figure 3.1: The Programmable Logic Controller (PLC) CompactLogix L2

10
Figure 3.2: The Human Machine Interface (HMI) –PanelView Plus HMI
Figure 3.3: The Variable Frequency Drive (VFD) –PowerFlex 525

11
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.
• Never operate the dryer with the air filters removed.
• Never operate the dryer with the deck removed.
• Never operate the dryer with missing or worn parts.
• Never operate the dryer with the air chest boot removed.
• Never operate the dryer with worn or damaged decks.
• Never use the dryer as a table or work station.
• Never stand on the dryer.
• Always wear ear protection when operating the dryer.
• Always keep dryer clean and properly adjusted.
• Periodically inspect the dryer for wear and correct operation.

12
Part II
Setting Up the Machine from the
HMI

13
Chapter 5
Choosing the Machine Options
The main menu bar is the navigational tool for moving between the screens of the HMI,
and is located on the right side of the HMI screen(s). See Figure 5.1. The number
of buttons in the menu is based on which user is logged in i.e. operator, supervisor, or
engineer. The operator will only have access to the control panel and clean out menu
buttons. Thesupervisor will additionally haveaccess to the trim button. And the engineer
will have all of the supervisor options as well as the dryer options menu button used to
set up the available options for the dryer. 1
Figure 5.1: Menu Bar
Inorder toarriveatthe options forthedryer, theuser mustbeloggedinastheengineer
user. To do this, click on the current user hyperlink at the top right of the control panel
screen. This will take the user to the user security screen. From there, clickLoginbuttonand
enter engineer as the logged in user, and the password for the engineer user in the
password box and using the pop up keyboard to enter the password. See Figure 5.2. 2
1see Oliver’s training video entitled ”Menu Navigation”
2see Oliver’s training video entitled ”Logging in a User and Changing User Password”