paddy husker hr10fh t
TRANSCRIPT
E-D0774001-00-00 1
SATAKE INSTRUCTION MANUAL
PADDY HUSKER WITH ASPIRATOR
HU10FH(2)-T, HA10W(3)-T
WARNING
• Do not carry out any operation, maintenance or inspection of the machine until you have read and well understood the contents of this instruction manual.
• Keep this manual at hand whenever any operation, maintenance or inspection of the machine is being carried out.
SATAKE (THAILAND) CO., LTD.
2
CONTENT
1. LIMITED WARRANTY................................................................................................................. 3
2. SAFETY...................................................................................................................................... 4
2.1 Warning / Caution Types and Meanings ....................................................................... 5
2.2 General Instructions ...................................................................................................... 6
2.3 Special Precautions....................................................................................................... 8
2.4 Warning Stickers ........................................................................................................... 9
2.5 Location of Warning Stickers....................................................................................... 10
3. SPECIFICATIONS .................................................................................................................... 13
4. DIMENSIONS........................................................................................................................... 15
5. CONSTRUCTION..................................................................................................................... 16
6. INSTALLATION ........................................................................................................................ 17
7. WIRING AND AIR PIPING........................................................................................................ 30
8. CONTROL BOX ....................................................................................................................... 31
8.1 Names and Function of Terminal Base in Control Box. ............................................... 31
8.2 Names and Function of Each Part of Control Box. ...................................................... 32
9. AUTOMATIC OPERATION FLOWCHART ................................................................................ 37
10. PREPARATION FOR OPERATION ......................................................................................... 38
11. OPERATION........................................................................................................................... 44
12. MAINTENANCE AND INSPECTION....................................................................................... 48
13. TROUBLESHOOTING............................................................................................................ 64
14. CONSUMABLE PARTS LIST .................................................................................................. 67
EMERGENCY ADDRESS AND TELEPHONE ............................................................................... 68
E-D0371002-00 3
1. LIMITED WARRANTY
The machine was produced under quality control and inspection. But, if there are any problems under normal use the limited warranty for the machine extends for the first year beginning on the date of purchase of the machine.
1. Please contact our agency or sales office to repair. If there is a problem within limited warranty period, We will repair for free (only under normal use condition). After the warranty period, repair fee would be billed.
2. It will be charged during limited warranty period following conditions. (1) Damages & losses misuse of improper or operated installation with no care. (2) Damages & losses unauthorized modification or unauthorized repair. (3) Damages & losses because of disasters (fire, flood, storm and earthquake
etc.), pollution, unusual voltage & damaged by sea air(rust). (4) Damages & losses which you moved or dropped the machine after setting. (5) Damages & losses which use of unauthorized spare parts or repair at
unauthorized agency or factory. 3. We will supply parts of the machine for 7 years after stop of production. But within
this period some special parts are exceptional. 4. Basically, We will stop to supply parts in 7 years after discontinued to produce. But if
you have a request to order the parts, We will discuss about it. All warranty informations, machine features and specifications are subject to change without notice.
E-D0371003-00 4
2. SAFETY
WARNING Do not carry out any operation, maintenance or inspection until you have read and well understood the contents of this instruction manual.
• Keep this manual at hand for reference whenever any operation, maintenance or inspection of the machine is being carried out.
• When you operate, maintain or inspect the machine, you are requested to follow instructions and warnings as stipulated in this manual. If you have any questions or indistinct points, you should suspend operation of the machine or your work until you can clarify it with the Satake office listed at the end of this manual for inquiries about the machine.
• Satake shall not be responsible for any injury, loss or damage caused by failure to observe instructions stipulated in this manual, by misuse or modification without our permission.
This chapter describes the definition of hazard signal words as well as safety precautions to be observed at the time of operation, maintenance or inspection as detailed and classified in the “General Inspections” and “ Special Precautions.”
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2.1 Warning / Caution Types and Meanings Hazard warning in this instruction manual and warning stickers attached on the machine main body are classified into the following three kinds, depending on the degree of risk of accident. Operator must recognize the importance of the warnings, and carefully follow the instructions given in this manual.
This shows potential hazard. If you do not follow this, WARNING there is some possibility of fatal or serious injury.
This shows potential hazard. If you do not follow this,
there is some possibility of middle or minor class CAUTION injury, damages of the equipment / machinery or
misconduct in material or product.
This is used for calling special attention to or NOTE adding emphasis to a certain information required
to be noticed.
E-D0371005-00 6
2.2 General Instructions
WARNING • The operator is supposed to pay attention to the following points to
ensure safety in operating, inspecting and serving the machine.
(1) Operator must contain long hair in a hair cover and neatly wear clothes and shoes
that are suitable for work. When carrying out any inspection or maintenance, wear appropriate protective gear such as helmet and safety shoes.
(2) Keep clean the surroundings and passages around the machine. (3) Do not pour water over the machine. Water in the machine shorts the electric
circuits, consequently causing the machine to break down. (4) Do not fail to ground the machine in order to protect a person from being involved in
electric accidents and to prevent fires from occurring due to current leaks. (5) Never touch the live parts inside the machine after turning on power. (6) Do not permit any person who has not been properly trained to operate or service
the machine. (7) Keep out any person other than those permitted by the operator. Never let children
come close to the machine. (8) Do not fail to inspect the machine before starting operation. When carrying out any
inspection work, always power off and clearly indicate that the machine is under inspection or maintenance both in the control room and control panel at the work shop.
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(9) Always power off before inspection and maintenance and follow the appropriate lock out procedure. After the inspection, make sure that there are no tools left.
(10) Check for any looseness or damage on bolts, nuts and belts. Make sure to restore the cover after the checking.
(11) Check for any damages on power cords and wire cables. Also, check for any looseness or disconnection of connectors and plugs.
(12) Operate the machine with all covers attached. Do not attempt to remove any cover during the machine operation.
(13) Always stop the machine before greasing the driving part of the machine. (14) Operator should well understand the power off procedure for a case of emergency. (15) When working with two or more persons, each person must confirm communication
with others before starting work.
E-D0371007-01 8
2.3 Special Precautions (1) Install the machine in a level and stable place. Unleveled and unstable installation
will cause vibration and poor performance of the machine. (2) Do not operate, inspect or maintain the machine with any part that is not specified in
this instruction manual. (3) Keep sufficient working space around the machine. (4) Before turning the power on, confirm the safety of the surroundings and passages
around the machine. (5) Handle the machine with care. Careless handling of the machine may lead to
malfunction and failure of the machine. (6) Keep alert to the machine, If any abnormality is found, stop the operation and check
the machine to ensure safe operation. (7) When using a ladder, it must be set in stable location. (8) In case the machine is used in a dusty place, wear a dust-proof mask and goggles. (9) If employees of a plant are unable to read or write, the owner of the plant must
explicitly draw their attention to any existing hazards and must give them special instruction.
E-D0371008-00 9
2.4 Warning Stickers
! NOTE How to handle Warning Stickers
• Check if letters and illustration on the sticker are legible and if not, remove dirt on the sticker or replace it.
• Use cloth, water or cleanser to remove dirt. Do not use organic solvent or gasoline.
• In case the sticker is damaged, lost, or illegible, replace it with a new one.
This machine is provided with warning stickers on certain locations where a special precaution is required. It is important for operators to know the location and contents of each stickers and follow the instruction on the sticker to prevent accidents.
E-D0775002-00 10
2.5 Location of Warning Stickers
Fig. 2-1 Location of Warning Stickers (1)
220283504
T070154
299001542
E-D0775003-00 11
Fig. 2-2 Location of Warning Stickers (2)
T070190
T019360 T037212
E-D0775004-00 12
Fig. 2-3 Location of Warning Stickers (3)
T037212 T037212
E-D0774002-00 13
3. SPECIFICATIONS
Model HU10FH-T(2)-T + HA10W(3)-T
For Basmati rice
Parboil rice 3.5-4.0 tons / hour (Paddy) Process Capacity (Husking ratio 90%)
Basmati Non parboil rice 2.5-3.0 tons / hour (Paddy)
Power required Husker HU10FH(2)-T + Aspirator HA10W(3)-T 7.5 kW – 6P, 52 kW + 3.7 kW – 4P, 0.1 kW
Main Shaft Speed Fan Shaft Speed
Husker Aspirator
: HU10FH(2)-T : HA10W(3)-T
1150 rpm 1400 rpm
Coil spring (HU) Ø8 mm. (Blue)
Size Diameter : 10 inch ,Width : 10 inch Robber roll
Hardness 87° ± 5°
Net weight Husker Aspirator
: HU10FH(2)-T : HA10W(3)-T
588 kg 588 kg
E-D0774003-00 14
For long grain (except Basmati rice)
Process Capacity (Husking ratio 90%)
Long grain (except Basmati rice) 5.0 ~ 6.0 tons / hour (Paddy)
Power required Husker HU10FH(2)-T + Aspirator HA10W(3)-T 7.5 kW – 6P, 52 kW + 3.7 kW – 4P, 0.1 kW
Main Shaft Speed Fan Shaft Speed
Husker Aspirator
: HU10FH(2)-T : HA10W(3)-T
1100 rpm 1400 rpm
Coil spring (HA) Ø10 mm. (Black)
Size Diameter : 10 inch ,Width : 10 inch Robber roll
Hardness 87° ± 5°
Net weight Husker Aspirator
: HU10FH(2)-T : HA10W(3)-T
588 kg 588 kg
NOTE
• Husking ratio depends on material quality and impurity high impurity material. May cause malfunction of machine.
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4. DIMENSIONS
Fig. 4-1 Dimensional Drawings
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DOWNUP
CHUTE
Sensor
TankShutter
Valve
Chute
Adjusting bolt
Control box
Valve DValve E
Screw Conveyor
Feeder
Rubber roll
Screw Conveyor
Husk outletValve CHusked rice outlet
Screw conveyor
Valve AValve B
5. CONSTRUCTION
Fig. 5-1
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6. INSTALLATION
6.1 Rigging Method of the Machine
WARNING • Use a wire having sufficient strength.
• Remove the safety cover for making work space during installation of husker
(fix the machine with body of aspirator).
• Use great care not to damage the body etc. when carrying and rigging work.
Fig. 6-1
Remove safety cover
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6.2 Confirmation of Levelness
CAUTION • If the machine is not set horizontally it may not be able to exhibit expected
capacity fully.
• Ensure the levelness of the machine and bolt it securely to the floor. Set the machine at the specified position and make sure that it is placed horizontal.
Fig. 6-2 Then bolt the machine securely with the bolts. 6.3 Position setting.
Fig. 6-3
Set Levelness
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COVER
6.4 Selection of Floor The Floor to be selected for installation must have enough strength. 6.5 When install the machine, Allow enough space around the machine for inspection jobs or passage as show in Fig. 6-4
Fig. 6-4 6.6 Process of Installation Comply with the following procedure to assemble the machine.
(1) Remove the top cover
Fig. 6-5 Assembly procedure (1)
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Angle
(2) Fit the husker onto the aspirator. Fix the bolts.
Fig. 6-6 Assembly procedure (2) (3) Remove the angle and fit the bolt on the body.
Fig. 6-7 Assembly procedure (3)
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(4) Attach the Top Covers.
Fig. 6-8 Assembly procedure (4) (5) Attach motors to the husker and the aspirator. (6) Fit timing belt to husker and V-belt to aspirator.
WARNING
• Caution must be exercised to prevent your fingers from being pinched at the pulley and belt.
CAUTION
• Securely fit the motor pulley.
• Fit the belts in accordance with Fig. 6-9, and sure to adjust the belt alignment.
TOP COVER
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V-belt (50Hz)B-68 2 Pcs.(60Hz)B-66 2 Pcs.
Dividing screw
directionRotation
Husk screw pulley
Motor pulleyMotor 3.7kW-4P
Fan shaft pulley
Tension Pulley
Timing belt600DS8M2304
directionRotation
Geared motor 0.1kW
Mixed grain screw pulley
V Belt A-62
V-belt A-47
Motor7.5kW-4PMotor pulley
Movable shaft pulley
Main shaft pulley
V-belt (50Hz)B-67 (High RPM) 2 Pcs.(60Hz)B-65 (High RPM) 2 Pcs.
Fig. 6-9 Belt Routing and Belt Sizes (7) Dust – Suction piping
Note the following points when installing the dust – suction piping. 1) Intake airflow of 3 m3 /min. is required. 2) Number of bends as well as the piping lengths should be minimized with the dust – --removing 3) Put the dumper for adjusting air – volume of each machine.
Dust direction
Dust direction
Fig. 6-10
E-D0775013-00 23
(8) Adjust the tension of belts and be sure to fit safety covers.
CAUTION • Once the tension has been adjusted, be sure to fit safety covers.
• Be careful to avoid any excessive belt tension. Securely fit the motor pulley. Adjust the tension of belts so that they deflect 10-20 mm when pressed at the center. (9) Piping of mixed grain outlet.
Set the piping angle from the previous process to husker at 60° or more. If the piping angle is less than 60°, it causes the decrease of capacity due to bad paddy flow. Maximum input capacity is depends on variety of material etc,. may need to adjust angle of piping.
Fig. 6-11 Sketch of the piping (1)
From previous process
E-D0775014-00 24
Set the piping angle from husked rice outlet to the subsequent process at 40° or more.
(10) Control air piping Route the air piping to the coupler under the control set supply air pressure to the coupler about 0.5 MPa.
To Paddy Separator Fig. 6-11 Sketch of the piping (2)
Fig. 6-12 Sketch of the piping (3)
Control box
Compressed air supply
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(11) Electric Wiring
WARNING • Ensure that the main power is turned OFF when connecting any wiring work.
CAUTION • Make sure to close the cover of the control box after the wiring work.
• If the cover of the control box is forgotten to close, the electronic parts may damage by dust.
• Fit the elector – magnetic breaker for each motor.
• Make the electric wiring to stop the paddy supply in case that the distribution motor stops by the overload for some reason.
(1) Must use protective device such as contact breaker, electromagnetic contactor or thermal relay to each motor. Suggested thermal capacity is as rated in the table below. Confirm amperage with the name plate of motor and set the thermal relay capacity.
Table 6-1, 6-2 and 6-3 - Motor of paddy husker. Table 6-4 - Motor of paddy aspirator. Table 6-5 - Geared motor of paddy aspirator.
E-D0771054-00 26
Motor Specification
Voltare Frequency Amperage
(V) (Hz) (A)
Thermal Relay
Capacity (A)
200 50 29.0 29.0
200 60 28.0 28.0
380 50 15.0 15.0
440 60 13.0 13.0
460 60 12.7 12.7
Table 6-1 - 7.5kW, 4P motor (TH1)
Motor Specification
Voltare Frequency Amperage
(V) (Hz) (A)
Thermal Relay
Capacity (A)
200 50 33.0 33.0
200 60 30.0 30.0
380 50 17.0 17.0
440 60 14.5 14.5
460 60 14.5 14.5
Table 6-2 - 7.5kW, 6P motor (TH1) (for HU10FH model only)
Motor Specification
Voltare Frequency Amperage
(V) (Hz) (A)
Thermal Relay
Capacity (A)
200 50 45.0 45.0
200 60 42.0 42.5
380 50 22.5 22.5
440 60 19.5 19.5
460 60 19.0 19.0
Table 6-3 - 11kW, 4P motor (TH1)
Motor Specification
Voltare Frequency Amperage
(V) (Hz) (A)
Thermal Relay
Capacity (A)
200 50 15.0 15.0
200 60 14.2 14.2
380 50 7.7 7.7
440 60 7.1 7.1
460 60 6.8 6.8
Table 6-4 - 3.7kW, 4P motor (TH2)
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Motor Specification
Voltare Frequency Amperage
(V) (Hz) (A)
Thermal Relay
Capacity (A)
200 50 29.0 29.0
200 60 28.0 28.0
380 50 15.0 15.0
440 60 13.0 13.0
460 60 12.7 12.7
Table 6-6 - 0.1kW (TH3)
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TH2
MC2 MC3
TH3 TH1
MC1
K k
TH1TH2TH3
MC3
MC3
MC2
MC2
MC1
MC1PB3 PB2 PB1
PB1PB2PB3
PB
FUSEPL
LIS PS HRSV
IN2IN1 SWU V
CR2 CR3
CR1DRY1 CR4
*Local wiring (Refer to next pape)
NFB(non-fuse circuit breaker) if the power source is any voltageother than 200 V,make it to 200 V
Electro-magnetic contactor
Thermal relay
L l
CurrenttransformerAmmeter
Single phaseAC 200V
(Control box)
(Control box) Emergency stop
Stop Stop Stop
Run Run Run
Fig. 6-13 Wiring Instructions <On – site wiring>
• In case that the husker is not engaged with paddy separator. (1) Remove the jump wire between the terminal No.8 and No.9. (2) Connect the auxiliary terminal of thermal relay of the distribution motor with the terminal No. 8 and No.9.
E-D0771018-00 29
Fig. 6-14 Terminal Base of Control Box (One Part)
• In case that the husker is engaged with paddy separator:
(1) Remove the jump wire between the terminal No. 8 and No. 9 (2) Connect the auxiliary terminal of the thermal relay of the distribution motor with the external sensor in series and then connect them with the terminal No.8 and No. 9.
Fig. 6-15 Terminal Base of Control Box (One Part)
E-D0775016-00 30
7. WIRING AND AIR PIPING
WARNING • Ensure that the main power is turned OFF when performing any wiring work.
CAUTION • Make sure to close the cover of the control box after the wiring work.
• If the cover of the control box is forgotten to close, the electronic parts may damage by dust.
SensorBall valve
Air cylinder (shutter)
Air cylinder (roll)Control
box
(out)
(in)
Actuator valve
Air (outlet)
Regulator (for roll pressure)
Air (outlet)
valve
Regulator
Filter
Compressed Air(inlet)
(for regulating the control pressure)
pressure gauge
CR1
CR3
HR
FUSEIN1 IN2
PL SW
LIS
DRY1
CR2
PS SV
CR4
PE
Externalsensor
Feeder controller
Singlephase Earthlamp switchSelector Fuse
Hour meter
Solenoid
Speedcontroller
(out)
controller(in)
Speed
Fig. 7-1 Wiring Instructions
E-D0771020-00 31
CR1
CR3
HR
FUSEIN1 IN2
PL SW
LIS
DRY1
CR2
PS SV
VU
CR4
P2P1
PE
Externalsensor
AC200V EarthPilotlamp switch
Selector Fuse
Hour meter
Electromagnetic valveSensor
Feeder externalsignal
(Jump wire)
for feederPower
8. CONTROL BOX
8.1 Names and Function of Terminal Base in Control Box.
Fig. 8-1
Fig. 8-2 Control Box (Side View)
Hour meter Timer relay
Relay
Socket Changeover switch
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8.2 Names and Function of Each Part of Control Box.
Fig. 8-3 Control Box (Front View)
CAUTION • Make sure to close the cover of the control box after the wiring work.
• If the cover of the control box is forgotten to close, the electronic parts may damage by dust. • TP (Terminal Pin)
UV: Input power source AC 200V single phase
PE: Earth
LIS: HU tank paddy detection sensor
SV: Power of electro-magnetic valve
PS: For external sensor (PS)
Fuse (2A) Changeover switch
Hour meter
Feeder controller
Pilot lamp
E-D0771022-00 33
IN, IN 2: Power of feeder controller
E: Earth of feeder controller
P1, P2: External signal of feeder controller (Run, Stop signal)
• Timer relay --Set the waiting time from the detection of sensor to the start of husking. – Set range: 0~60 sec. (At factor shipment: 20 sec)
• Hour meter --Display the accumulated husking hour. (with zero setting function)
• Power lamp -- Light on when the power is ON. (AC 200V single phase)
• Fuse (2A) -- For protection of operation circuit.
• HAND/AUTO changeover switch - HAND: To open the supply valve, operate the feeder and pressurize the rolls. - STOP: To close the supply valve, stop the feeder and release the rolls. - AUTO: To perform the automatic operation by a sensor for the control. Automatic ----------- sequence to open the supply valve, operate the feeder, and pressurize the rolls or -------------- in reverse to close the supply valve, stop the feeder and release the rolls.
E-D0771023-00 34
8.3 Names and Function of Each Parts of Feeder Controller.
Fig. 8-4
Display lamp (RUN)
Display lamp (TRIP)
Frequency adjusting volume (FREQ)
Amplitude adjusting volume (V)
Second amplitude adjusting volume (V2)
Machine screw
Power switch
Machine screw
FRONT
Fuse holder
Power / voltage changeover switch
Input terminal base
Output terminal base
Terminal base for external input signal
External volume connection switch
INSIDE OF FRONT
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Fig. 8-5 Names of Each parts of Feeder Controller
• Display lamp (RUN)
- To light on during operation only. • Display lamp (TRIP)
- To light on and stop the output when the protection of over-voltage and over - current is functioned.
• Frequency adjusting volume (FREQ) - To use at the adjusting work of frequency.
• Amplitude adjusting volume (V) - To adjust the flow rate of paddy.
• Second amplitude adjusting volume (V2) - Not available.
BOTTOM
Grommet of output cable
Grommet of input cable
Grommet for external signal cable
Output connector for output frequency displayer
E-D0771025-00 36
• Power switch To turn ON and OFF the feeder.
• Terminal base for external input signal To connect the external input wire.
• Connecting switch of external volume Not available.
• Power / Voltage changeover switch To set AC 200V. (At factory shipment: AC 200V)
• Fuse holder To protect the feeder controller circuit.
• Input terminal base The power source for feeder controller.
• Output terminal base The power source for electro-magnetic coil of feeder.
• Grommet for external signal cable To pass the external signal cable.
• Output connector for output frequency displayer To connect the cable of a tachometer.
• Grommet for output cable To pass the output cable.
• Grommet for input cable To pass the input cable.
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START
Start operation of HU,HA and distribution motors.
Control boxSet the manual / auto switch at AUTO.
Any paddy in the HU hopper?Wait NO
Wait Is the PS hopper empty?Yes
HU hopper : empty ? PS hopper : full ? NONO
YES YES
Close the shutter and release the rolls. Close the shutter and release the rolls.
PS hopper : full ?YES
NO
YES
NO
Open the shutter and pressurize the rolls.
9. AUTOMATIC OPERATION FLOWCHART
Fig. 9-1 Automatic Operation Flowchart
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Tension bolt for
Motor 7.5kW
Motor 3.7kW
motorTension bolt for
belt
V-belt tension
Air pressure 0.5MPa or moreGear motor
10. PREPARATION FOR OPERATION
WARNING • Ensure that the main power is turned OFF when conducing any inspection
or maintenance work.
• After completion of inspections, be sure to fit safety covers back in space. 1. Check and adjust the following items (see Fig. 10-1) (1) Are the centers of pulley aligned ? (2) Any loosened pulley set bolts ? (3) Is the tension of belt correct ? (4) Is the control air pressure 0.5 MPa or more ? (5) Is the air pressure for rubber roll 0.2 MPa ?
Fig. 10-1
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CAUTION • Adjust air pressure at 0.2 MPa (for rubber roll)
• May occurred % of broken and cracked rice is increased even adjust rubber roll air pressure at 0.2 MPa need to check output.
• Adjust proper rubber roll air pressure (depends on material). Adjustment of rubber roll air pressure
a) Pull the handle of regulator.
b) Turn the handle and adjust air pressure. Clockwise – increase, Counter – clockwise - decrease
Fig. 10-2 Control box (front) and regulator
Regulator
Rubber roll air pressure
Supplied air pressure
Emergency stop switch Change over switch
Feeder Controller Pull the handle of regulator
then adjust air pressure.
E-D0775020-00 40
(2) Run the motor of the machine to check the direction of rotation and to check for any unusual noise or odor. After the check is over, stop the motor of the machine.
WARNING • When checking the direction of rotation, ensure that no one is present around the
adjustment. Be carefull not to touch the driving section.
• If any fault occurs, immediately shut off the power supply to stop driving the machine.
CAUTION • If the direction of rotation is wrong, machine performance will not be fully drawn, and
faults may result. Check the direction of rotation before starting any husking operations
• When operating without load, be sure to supply air, and ensure that the rolls are not mutually in contact.
Fig. 10-3 Rotation direction
E-D0775021-00 41
(3) Once the inspections complete, be sure to attach all safety covers. (4) Energize the control box to check the functions of machine components.
NOTE • Check the machine motor without running it.
• Keep the paddy hopper unload when conducting any check. [HAND] (1) Position the change over switch to “HAND”. (See Fig. 10-2) - Paddy feed valve will open. (See Fig. 10-2) - Feeder will vibrate. - Rubber rolls will be pressurized (brought into contact). (2) Restore the change over switch. - Paddy feed valve will close. - Feeder will stop. - Rubber rolls will be released (separated).
Fig. 10-4 Husker
Sensor
Feed valve
Manual Shutter
Feeder
Movable shaft
E-D0771031-00 42
[AUTO] Check following items when no paddy in the tank. (1) Position the change over switch at “AUTO”. (See Fig. 10-2) sensor detects no paddy in the
HU tank (LED stays ON). The machine does not act at all. (Since there is no paddy, the machine does not work after passing the setting time (at factory setting : 20 sec.) of a timer in the control box. Check the light out of LED by touching the tip of a sensor. At this state, wait till the setting time (at the factory shipment : 20 sec.) of a timer in the control box. - Paddy feed will vibrate. - Rubber rolls will be pressurized (brought into contact).
(2) Restore the change over switch to “STOP” (See Fig. 10-2) - Feeder will stop - Rubber rolls will be released (separate). Position setting
• Change – over switch : STOP
• Amplitude adjusting volume : 70
• Valve A : Middle
• Valve B : Middle
• Valve C : 2nd scale line from right
• Valve D : Middle
• Valve E :For long grain ->open, short grain -> close
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Valve C
Valve D
Feed valve
Valve BValve A
Amplitude adjustingvolume
Change over switch
CAUTION • Operate over the rated capacity may cause failure of the machine.
Fig. 10-5
Valve E
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11. OPERATION
NOTE • Trial run must be executed before operation.
11.1 Manual Operation (trial run) (1) Open the manual shutter then input paddy in the tank. (2) Confirm suction air in the suction pipe. (3) Turn power ON. (4) Run the machine motor. (5) Set at “HAND” the change over switch on the control box. (See Fig. 10-2)
(6) Adjust the roll pressure to set husking ratio at about 90% (See 10. PREPARATION FOR OPERATION “Adjustment of rubber roll air pressure”). Turn the knob clockwise increase. Counter – clockwise decrease.
(7) Adjust distribution by valve D and E. (8) Adjust wind sorting section by valve A, B and C.
NOTE • If the tank of paddy separator is full, set change over switch at
“STOP” (If the switch is set at “HAND”, the shutter will not be linked with the paddy separator hopper).
E-D0771034-00 45
11.2 Automatic Operation (1) Open the manual shutter then input paddy in the tank. (2) Confirm suction air in the suction pipe. (3) Turn power ON. (4) Run the machine motor. (5) Set at “AUTO” the change over switch on the control box (See Fig. 10-2). (6) Once the feed valve opens and feeder vibrates to start husking, adjust the roll - pressure to set the husking ratio at about 90%. (See 9. PREPARATION FOR - OPERATION, Adjustment of rubber roll air pressure) Turning the handle of - regulator clockwise to increase pressure (increase the husking ratio) and turning - it counter clockwise to decreases the pressure (decreases the husking ratio). (7) When the paddy sorting machine hopper becomes full. Feed valve will close, - and the roll gap will widen then will stop husking (only when it is linked with the - paddy separator hopper.) (8) Then, when the paddy separator hopper becomes empty, feed valve will open - after a timer of the timer setting to resume husking operation. (9) When the husker hopper becomes empty, feed valve will close, and the roll gap - widen to stop husking. (10) When any paddy comes, feed valve open after a time of the timer setting to - resume The husking operation.
NOTE • Adjust the feed rate of the husker to keep the fed valve open at
least 10 min. by amplitude adjusting volume at feeder controller. Need to observe the change in the husking ratio if the amplitude adjusting volume has been adjusted.
(11) Adjust the distribution by valve D and E. (12) Adjust the wind separation by valve A, B and C.
E-D0771035-00 46
11.3 Adjustment of open and closing speed of movable shaft and feed valve. (1) Adjustment of open and closing speed of movable shaft.
(2) Turn the adjusting screw to adjust open and closing speed of movable shaft. (set at 2 seconds and check it during operation). Turn the adjusting screw clockwise to slow down the air cylinder motion with the resultant increase tin the time from the feed valve opening to the moment the movable shaft roll touches the main shaft roll. On the contrary, if it takes too much time for the motion to start, turn the adjusting screw counter – clockwise.
(3) Once the adjustment completes, fix the adjusting screw using the lock nut.
Fig. 11-1 Adjusting the Speed controller
Speed controller (IN) – control air speed for closing rubber roll. Speed controller (OUT) – control air speed for opening rubber roll.
Adjusting screw
Speed controller
Lock nut
Decreaseair speed air speed
Adjusting screw
Increase
E-D0775023-00 47
Fig. 11-2 Speed Controller for Movable Shaft Opening / Closing
(2) Adjustment of open and closing speed of feed valve.
1) Loosen the lock nut of speed controller. 2) Turn the adjusting screw to adjust open and closing speed of feed valve.
Turn the adjusting screw – feed valve movement is slower. Turn it counter – clock wise feed valve movement is faster.
3) Once the adjustment completes, fix the adjusting screw using the lock nut.
Speed Controller (OUT)
Speed Controller (IN)
E-D0702031-00 48
12. MAINTENANCE AND INSPECTION
WARNING • Turn OFF the main power before conducting any cleaning or inspections of
machine components. Post a sign “UNDER INSPECTION” at the point of power shut-off.
CAUTION • If the machine is help stopped for a long time, insert may built nests at various
corner. When restarting operation, check the machine for any nests of insect, and remove them if any.
• If any parts are worm or broken, or when the times has come to replace any consumable parts, contact the nearest sales office.
•
The use of rubber roll of poor quality, such as higher hardness, brittle rubber and larger fixing hole diameter, may cause the increase of broken rice and the damage of the bearing section.
Conduct the inspections and maintenance work on a regular basis (see the following).
The inspections and maintenance are also required when keeping the machine without being operated for a long time, or when restarting operation after a long time.
(1) Occasionally check the tension of transmission V-belts, hex.belts and scooped belts of the elevator, and adjust if it is necessary.
• Pay attention to the tension particularly after installation or replacement of the belts since the elongation will be large.
E-D0771037-00 49
(2) See through the access hole of the aspirator to check for straw or any other obstacles that may hamper the paddy flow. (3) If the thickness of the main shaft rubber roll of the husker has decreased to about the half of that the movable shaft rubber roll, replace both main and movable shaft rubber rolls.
※ Confirm whether the chute position is proper, when the rubber rolls replace into new ones.
Fig. 12-1
(4) Over a long period of use, the sorting plate may collect scum as from brown rice. Wash and clean it from time to time. (5) Use the rubber roll of less than 87C (chore) ± 5C (chore) hardness. Maximum hardness of the rubber roll shall be 92 degrees or less. (6) The fixing hole diameter of retainer of rubber roll is 116 mm. Don’t use the rubber roll over the allowance of diameter (0 ~ +0.1 mm).
Fig. 12-2
Movable shaft rubber rollMain shaft rubber roll
1/2t
E-D0702033-00 50
(7) Do not use the eccentric rubber roll and low quality rubber roll.
WARNING • If the following rubber roll is used, it may happen that the broken rice ratio
increases, the husking ratio decreases or the machine is damaged.
• Excess hardness than the specified one.
• The hole diameter of retainer is over the allowance range ( 0 ~ 0.1 mm.)
• Eccentric rubber roll.
• Low quality rubber material.
E-D0702034-00 51
(8) Selection of (M10) fixing bolt to join Rubber roll and Retainer 2-2022-0050 for various size of Rubber roll.
CAUTION • Minimum clearance C shall be more than 1 mm. If not follow this, the fixing
bolt may touch against the bearing cover during operation. It will cause to damage bearing cover, bearings and shaft (Movable and Main shaft).
• Whenever install fixing bolt, do not forget to install plain washer and spring washer.
A Size (mm) B Size (mm) Remark
3.2 ~ 7.99 20 M10x20
8 ~ 12.99 25 M10x25
13 ~17.99 30 M10x30
18 ~ 22 35 M10x35
Fig. 12-3
Fig. 12-4
Rubber roll
Retainer Bearing cover
Ball bearing 6309DDUA
CC
D
Detail D
Rubber rollM10 Fixing bolt
APlain Washer and Spring washer
= 2 ~ 5 mm.B
E-D0775024-00 52
(9) Adjusting of plate
CAUTION • Never fail to adjust the clearance between plate and rubber roll to avoid
accident whenever rubber rolls are replaced. It may cause the trouble of the burning of rubber roll or the coming off plate when the machine is operated in a contacted condition of palate and rubber roll.
1) After replacement of rubber rolls, loosen the lock nut at the front cover by turning it counterclockwise and fasten the adjusting nut by 3 turnings clockwise. At this time, keep the front cover open. 2) Close the front cover securely by fastening the knob. 3) Loosen the adjusting nut until plate and rubber roll contact. After contacted fasten the adjusting nut by one turning clockwise. 4) Lock the adjusting nut by fastening the lock nut.
CAUTION • It may cause the trouble of the burning of rubber roll or the coming off of
plate when the machine is operated in a contacted condition of plate and rubber roll.
Rubber roll
Adjusting nut
Knob
Front cover
Adjusting nutLock nut
Lock nut
Front cover
1 ~ 2 mmClearance
Plate
Fig. 12.5
E-D0772025-00 53
Window BHandle
Chute
(Limit area of rubber roll)
Movable rubber rollMain rubber roll
BlueYellowRed
BlueYellow
Red
Sticker (B)Chute
Thickness:T
Window A
Sticker (A)
(10) Adjustment of chute
NOTE • For maintaining the performance of machine, conduct the adjustment of chute
depending on the wearing (remaining thickness of rubber) of rubber roll.
Fig. 12-6 Front View of Husker
1) Check rubber roll thickness of main shaft side through inspection window A whether it is at red, yellow or blue of sticker (a).
Fig. 12-7 Inspection Window A
E-D0771040-02 54
Chute
Thickness:T
Yellow
Red
Window B
Sticker (B)Blue
2) Change the chute inclination by turning handle so that chute position sets on the - same color of step though in section window B.
Fig. 12-8 Inspection Window B 3) Gradually, main shaft rubber roll turns the position of yellow and red by wearing (see
window A). Confirm the chute’s inclination also follow the color at window B. - (Chute’s in inclination links wearing of rubber rolls).
(11) Grease Supply
NOTE • Turn off the main power before pouring grease into machine.
Pour grease into the fulcrum of cylindrical bearing of movable shaft every 150 hrs. These are two pouring places of grease at the operation side and the driven side of machine.
Brand / Model : Shell / Retinax EPX2 (Contains Molybdenum Di Sulphite, lead and Soduim Nitrite fee)
Also pour grease into bearing of each shaft every 300 hrs. Use SATAKE genuine grease.
Brand / Model : Trane / Super H.P. Multipurpose grease
E-D0775026-00 55
CAUTION • The SATAKE genuine grease is used when the machine is
shipped from the factory.
• Don’t mix the different brand grease to avoid deterioration of the quality of grease.
Operation side : Pour genuine grease after removing bearing cover.
CAUTION • No pour of grease may cause the failure of machine like the
wearing of bearing and occurrence of vibration.
• Pour genuine grease sufficiently till the grease comes out from the clearance.
Fig. 12-9 Grease nipple (1) Bearing cover
Gylindrical bearing
Cover
Grease nipple
Grease nipple
Grease nipple
E-D0775027-00 56
Fig. 12-10 Grease nipple
Driven side : Pour grease after removing safety cover. (12) Discharge of drain
CAUTION • Turn off the power prior to the discharge of the drain.
• Be careful the compressed air does not exceed 0.95 MPa (9.5 kgf / m2) because the air control unit may break.
• Discharge the drain before it will reach at the baffle plate of air filter. If you fail to discharge the drain, the machine may cause the breakage.
The air control unit is necessary to remove the dust and water in the compressed air and to keep the smooth movement of an air cylinder and a solenoid valve. The drain must be discharged before it will reach at the maximum line i.e. the baffle plate in the air filter. The discharge of drain is done to push up the lower tub of air filter as below figure.
Grease nipple Grease nipple
E-D0775028-00 57
(13) Cleaning of louver Periodically (once a week) check the louver (wind drum) of the aspirator for any accumulation of dust, paddy or rice grains. Any accumulation of dust, paddy or rice grains on the louver will increase contamination of paddy in the husked rice worsen the wind – sorting results.
(1) Louver cleaning method 1) Remove the cover (main body) 2) Remove louver 2 3) Remove air separator 4) Clean the inside of the boy. Once cleaning is over, reverse the procedure to refit the cover. Make sure valve C can open and close smoothly, after reassembled louver 1.
Inlet air
Air filter
Regulator
Baffle plateMax.line
Detali of inspection window
Tube Push
Fig. 12-11
Fig. 12-12
Air separator
Cover
Louver 2
E-D0775029-00 58
(14) Adjustment of feeder (14-1) Adjusting method - 1) Turn ON the power on the control box. 2) Turn ON the power switch of feed controller. 3) Check the present frequency by the digital meter (51 Hz at factory shipment). 4) Meet the frequency in case of except above situation. (1) Set amplitude adjusting volume [V] at 50 notch. (2) Position the change over switch at “HAND”. (3) Find out and confirm the frequency at widest vibration from the value of digital meter by turning frequency volume “FREQ” with touching the feeder trough (54~55 Hz). (4) Reduce 4 Hz from the frequency which check at step (3) (At factory shipment : 51 Hz).
Fig. 12-13
Amplitude adjusting Volume [V]
Frequency adjusting Volume (FREQ)
Power Switch
Digit meter
E-D0771045-00 59
(14-2) Adjustment of clearance between magnetic coil and trough mount. 1) Loosen the bolts of magnetic coil fixture base. 2) Insert thickness gauge clearance between magnetic coil and trough mount and set -- clearance at 2.3 mm. 3) Tighten the bolts of magnetic coil base. 4) Confirm the clearance at 2.3 mm.
Fig. 12-14 (14-3) Adjustment of feeder setting position. 1) Check the abnormal nose to contact with feeder if a contacting noise or abnormal - noise comes out from the feeder during the husking. 2) Remove the cover under the feeder. 3) Loosen four bolts of feeder. 4) Adjust the clearance by moving the feeder. Check whether there is no contact point - or any smaller clearance by the above movement. 5) Fix the feeder and cover.
Trough mount Magnetic coil
Hex. Bolt
60
(14-4) Adjustment of feed valve setting position.
1) Remove cover.
2) Loosen the fixing bolts of feed valve.
3) Adjust the position of feed valve so that the feed valve puts the trough as Fig.
4) Fasten the fixing bolts to adjust clearance between both left and right side of feed valve and trough is the same.
5) Fix the cover.
Feed valve
Cover
E-D0771047-00 61
6) Remove cover.
7) Loosen the fixing bolts of feed valve.
8) Adjust the position of feed valve so that the feed valve puts the trough as Fig.
9) Fasten the fixing bolts to adjust clearance between both left and right side of feed valve and trough is the same.
10) Fix the cover.
(15) Adjustment of level sensor
WARNING • Ensure that the main power turned OFF before the inspection
and maintenance work of each part. Confirm the following points if there is any abnormal sensor.
1) Check whether any fixing nuts of a sensor are fastened. • Fix the clearance at 1 mm between the acrylic plate.
2) Check if the distance between a sensor and the acrylic plate is 1 mm. If not, fix it at 1 mm distance.
3) Check if there is no abnormal wiring, such as the break of wiring in a sensor or control box.
• Replace the wiring in case of the break of wiring.
• Fit the wiring if there is the break. Take care of the wiring mistake.
4) Check if the jump wire in sensor is cut. If not, cut it by a nipper.
E-D0775031-00 62
Fig. 12-16 Sensor Fixing Fig. 12-17 Jump Wire
Conduct the sensitivity adjustment, if there is any abnormality at the above points.
(1) Check there is no paddy in the tank.
(2) Turn the sensitivity adjusting volume of sensor counterclockwise until LED lightens on.
(3) Check if LED lightens out when the paddy is fed into the tank. If LED does not lighten out, conduct the procedure from No. (1) again.
Fig. 12-18 Sensor
LED
Sensitivity adjusting volume
Jump Wire
E-D0775032-00 63
(16) Replacement method of tension guide and tension.
CAUTION • Turn OFF the power before the work.
1) Turn OFF the power. Push the emergency switch. 2) Remove the safety cover guide. 3) Remove V-belts. 4) Remove the tension. Make sure the positions of each tension.) 5) Remove the tension guide. Replace the tension and tension guide together. 6) Refit in reverse order after the completion of the replacement. Refer to below figure on the position of the factory shipment.
Fig.12-19 Aspirator Driven Part
Tension
Tension guide
V - Belt Tension
E-D0771050-00 64
13. TROUBLESHOOTING
WARNING • Before maintaining the machine, isolate the machine from the power supply.
• Refit the safety cover after maintenance.
• If the troubles are not remedied even after taking measures following the below instructions, contact your nearby distributor. See the contact address of Satake group companies at the end of this manual.
Conditions of Failure Cause Action to Take
- Insufficient roll pressure. - Adjust the pressure. - Tighten the handle (2) (roll pressure adjustment) to increase the pressure as to set the husking ratio at about 90% without any damage on the grain skin.
- High water content of the paddy. - Measure the water content, and adjust it to a right level.
- Worn rolls. - If the main shaft roll is smaller in diameter than the countershaft roll, exchange the right and left sides. - Replace them with new ones.
- Excessive feed rate. - Decrease the feed rate sing the feed rate adjusting handle.
1. Poor husking ratio.
- Belt slippage. - Tighten the tightener to the level where the belt bends 10-20 mm as pressed with fingers.
2. Unable to increase the feed rate.
- Valve blocked by foreign materials.
- Remove the foreign materials. - Reinstall the piping.
3. Much husk included in the husked rice.
- Maladjusted wind-sorting section. - Belt slippage. - Husking is often interrupted. - Too much feed rate. - Blocked louver.
- Adjust the valve (see the manual). - Tighten the belt. - Use the valve to decrease the feed rate, and avoid any long duration of interruption wherever possible. - Clean the louver.
E-D0771051-00 65
Check list in manual operation. Checklist on Electrical and Air Systems in Manual Operation.
Condition of Failure Cause Action to Take
1. Does not power on (pilot lamp does not illuminate).
- The power switch of the paddy husker control panel is not turned on. - Boken cable. - Brown fuse (F1) on the front of the control box.
- Turn on the switch. - Check the conductance of the power cable. - Replace the fuse (2A).
2. Shutter does not open/close.
- No or insupplicient air feed. - Fault with the air cylinder (for shutter).
- Check valves etc. Ensure the air feed. - Replace the air cylinder.
3. Rolls do no open/ close. - Fault with the air cylinder (for rolls). - Faulty with the speed controller. - Faulty with the regulator. - Excessive tension of the driving hex belt, or wrong belt routing. - Fault with the air valve.
- Replace the air cylinder. - Replace the speed controller. - Replace the regulator. - Adjust the belt tension. Check the belt routing, and reinstall the belt if necessary. - Replace the air valve.
4. Neither shutter nor rolls function
- Fault with the HAND/AUTO change-over switch. - Blow fuse on the panel. - No or insufficient air feed. - Fault with the solenoid valve.
- Replace the switch. - Replace the fuse (2A). - Feed air (0.5 MPa or more). - Replace the solenoid valve.
Fig. 12-1 Fuse position of feeder controller.
Fuse (2A)
Bind Head Screw
E-D0771052-00 66
Check list is Automatic Operation. Checklist on Electrical and Air Systems in Automatic Operation Condition of Failure Cause Action to Take
1. Shutter does not open.
- No Paddy contained in the husker hopper. - The time set on the timer has not elapsed yet from the paddy began to accumulate. - The paddy separator hopper is full. - Fault with the husker hopper lower limit sensor. - Fault with the air cylinder. - Ball valve closed. - Low air pressure
- Supply the paddy. - Wait until the time comes. - Wait until the hopper becomes empty. - Repair the fault. - Replace the sensor. - Replace the air cylinder. - Open the ball valve. - Wait until the air pressure recovers.
2. Shutter does not close.
- Fault with the upper limit sensor of the paddy separator machine hopper. - Low air pressure. - Fault with the air cylinder and solenoid valve.
- Replace the sensor. - Check and adjust the air pressure. - Replace the air cylinder and solenoid valve.
E-D0775033-00 67
14. CONSUMABLE PARTS LIST
If any parts are worn or broken, or when the time has come to replace any consumable parts, contact the nearest sales office.
Model Part No. Part Name Q’ty Condition of Replacement Remark 220110085 Plate 1 Worn out more than 2 mm. 220280440 Plate (side plate) 1 Worn out more than 2 mm. 220300510 Chute 1 Paddy does not flow smoothly. Paddy is flown. 0114021 Felt ring 1 Dust leak
HU
TC110309 Bearing 4 Have Vibration. Main and movable shaft
TD13A047 V – Belt A - 47 1 Worn out, slippage TD13A062 V – Belt A – 62 1 Worn out, slippage. TD13B065 V – Belt B – 65 2 Worn out, slippage. TD13B066 V – Belt B – 66 2 Worn out, slippage. TD13B067 V – Belt B – 67 2 Worn out, slippage. TD13B068 V – Belt B - 68 2 Worn out, slippage. 225131400 Conveyor Screw 1 Cannot distribute even valve is closed.
Husked rice passes only at the center portion. For dividing
T038106 Plate 2 Husked rice cannot discharge. 225131250 Dividing Valve 1 Has no efficient distribution. 225131420 Conveyor Screw 1 Has clogged due to lower capacity of conveyor For mixture 225131410 Conveyor Screw
1 Cannot convey husk that is remained much when seeing trough the inspection window.
For husk
225130540 Screw case 1
No distribution by a big worn hole of screw case.
225130660 Screw case 1 Worn hole of screw case. 225130670 Screw case 1 Worn hole of screw case. 225131610 Tension 2 Tension is much loose. 225133620 Husked rice side
HA
225133630 Tension guide 1 Tension is much loose.
Husk side
E-D0371039-00 68
EMERGENCY ADDRESS AND TELEPHONE
Produced By SATAKE (THAILAND) CO.,LTD. 133 Moo 5 Bangkadi Industrial Park Tivanon Road Pathumthani 12000 Thailand Tel. 66-2-501-1180 Fax. 66-2-501-1188 E-Mail: [email protected] Home Page : www.sataketh.com Sold By SATAKE CORPORATION 2-30 Saijo Nishihonmachi Higashi-Hiroshima-Shi Hiroshima 739-8602 Japan Tel. 81-824-20-8539 Fax. 81-824-20-0865 E-Mail: [email protected]
E-D0371040-00 69
SATAKE (THAILAND) CO., LTD. 133 Moo 5 Bangkadi Industrial Park Tivanon Road Pathumthani 1200 Thailand Tel. 66-2-501-1180 Fax. 66-2-501-1188 E-Mail: [email protected] Home Page : www.sataketh.com