satake instruction manual paddy husker

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.
1
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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
2
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.
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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.”
4
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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.
WARNING
This shows potential hazard. If you do not follow this,
there is some possibility of fatal or serious injury.
This shows potential hazard. If you do not follow this,
CAUTION
there is some possibility of middle or minor class
injury, damages of the equipment / machinery or
misconduct in material or product.
NOTE
This is used for calling special attention to or
adding emphasis to a certain information required
to be noticed.
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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.
7
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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.
8
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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.
9
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2.5 Location of Warning Stickers
T070154
220283504
299001542
Fig. 2-1 Location of Warning Stickers (1)
10
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T037212
T019360
T070190
Fig. 2-2 Location of Warning Stickers (2)
11
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T037212
T037212
Fig. 2-3 Location of Warning Stickers (3)
12
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3. SPECIFICATIONS
Model
HU10FH-T(2)-T + HA10W(3)-T
For Basmati rice
Process Capacity
(Husking ratio 90%)
Basmati
Parboil rice
3.5-4.0 tons / hour (Paddy)
Non parboil rice
2.5-3.0 tons / hour (Paddy)
Husker HU10FH(2)-T + Aspirator HA10W(3)-T
7.5 kW – 6P, 52 kW + 3.7 kW – 4P, 0.1 kW
Power required
Main Shaft Speed
Husker
: HU10FH(2)-T
1150 rpm
Fan Shaft Speed
Aspirator
: HA10W(3)-T
1400 rpm
Coil spring (HU)
Robber roll
Net weight
8 mm. (Blue)
Ø
Size
Diameter : 10 inch ,Width : 10 inch
Hardness
87° ± 5°
Husker
: HU10FH(2)-T
588 kg
Aspirator
: HA10W(3)-T
588 kg
13
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For long grain (except Basmati rice)
Process Capacity
(Husking ratio 90%)
Long grain
(except Basmati rice)
Husker HU10FH(2)-T + Aspirator HA10W(3)-T
Power required
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
Coil spring (HA)
Robber roll
1100 rpm
1400 rpm
10 mm. (Black)
Ø
Size
Diameter : 10 inch ,Width : 10 inch
Hardness
Net weight
5.0 ~ 6.0 tons / hour (Paddy)
87° ± 5°
Husker
: HU10FH(2)-T
588 kg
Aspirator
: HA10W(3)-T
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
15
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5. CONSTRUCTION
Tank
Shutter
Sensor
Valve
Feeder
Chute
Adjusting bolt
CHUTE
UP
DOWN
Rubber roll
Control box
Valve D
Valve E
Screw Conveyor
Valve A
Valve B
Screw Conveyor
Screw conveyor
Valve C
Husked rice outlet
Husk outlet
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.
Remove safety cover
Fig. 6-1
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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.
Set Levelness
Fig. 6-2
Then bolt the machine securely with the bolts.
6.3 Position setting.
Fig. 6-3
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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
COVER
Fig. 6-5 Assembly procedure (1)
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(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.
Angle
Fig. 6-7 Assembly procedure (3)
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(4) Attach the Top Covers.
TOP COVER
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.
21
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Rotation direction
Motor7.5kW-4P
Motor pulley
Timing belt
600DS8M2304
Movable shaft pulley
Tension Pulley
Main shaft pulley
Husk screw pulley
Geared motor 0.1kW
Dividing screw
Fan shaft pulley
V Belt A-62
Rotation
direction
Motor 3.7kW-4P
Motor pulley
Mixed grain screw pulley
V-belt A-47
V-belt (50Hz)B-68 2 Pcs.
(60Hz)B-66 2 Pcs.
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
22
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(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.
From previous process
Fig. 6-11 Sketch of the piping (1)
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Set the piping angle from husked rice outlet to the subsequent process at 40° or more.
To Paddy Separator
Fig. 6-11 Sketch of the piping (2)
(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.
Control box
Compressed air supply
Fig. 6-12 Sketch of the piping (3)
24
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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.
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Motor Specification
Motor Specification
(V)
(Hz)
(A)
Thermal
Relay
Capacity (A)
(V)
(Hz)
(A)
Thermal
Relay
Capacity (A)
200
50
29.0
29.0
200
50
33.0
33.0
200
60
28.0
28.0
200
60
30.0
30.0
380
50
15.0
15.0
380
50
17.0
17.0
440
60
13.0
13.0
440
60
14.5
14.5
460
60
12.7
12.7
460
60
14.5
14.5
Voltare Frequency Amperage
Voltare Frequency Amperage
Table 6-1 - 7.5kW, 4P motor (TH1)
Table 6-2 - 7.5kW, 6P motor (TH1)
(for HU10FH model only)
Motor Specification
Motor Specification
(V)
(Hz)
(A)
Thermal
Relay
Capacity (A)
(V)
(Hz)
(A)
Thermal
Relay
Capacity (A)
200
50
45.0
45.0
200
50
15.0
15.0
200
60
42.0
42.5
200
60
14.2
14.2
380
50
22.5
22.5
380
50
7.7
7.7
440
60
19.5
19.5
440
60
7.1
7.1
460
60
19.0
19.0
460
60
6.8
6.8
Voltare Frequency Amperage
Voltare Frequency Amperage
Table 6-3 - 11kW, 4P motor (TH1)
Table 6-4 - 3.7kW, 4P motor (TH2)
26
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Motor Specification
(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
Voltare Frequency Amperage
Table 6-6 - 0.1kW (TH3)
27
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Emergency stop
PB
TH1
(Control box)
MC2
MC3
MC1
Electro-magnetic contactor
TH2
TH3
TH1
Thermal relay
(Control box)
L
K
TH2
TH3
Stop
PB3
l
k
Current Ammeter
transformer
MC3
Stop
PB2
Run
PB3
MC2
Stop
PB1
Run
PB2
MC1
MC2
MC3
Run
PB1
MC1
*Local wiring (Refer to next pape)
LIS
PS SV
HR
DRY1
CR1
CR2
CR3
IN1IN2 PL
CR4
U V
SW FUSE
Single phase
AC 200V
if the power source is any voltage
NFB
(non-fuse circuit breaker) other than 200 V,make it to 200 V
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.
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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)
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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.
External
sensor
Ball valve
Sensor
PS
LIS
Hour meter
HR
SV
Feeder
controller
Air cylinder (shutter)
Air cylinder (roll)
DRY1
CR1
CR2
CR3
Control
box
Solenoid valve
IN1 IN2
Speed
controller
(in)
PL
SW
FUSE
Compressed Air(inlet)
Speed
controller
(out)
(out)
Regulator
(for regulating the control pressure)
Air (outlet)
CR4
lamp Selector
switch
PE
Fuse Single Earth
phase
pressure gauge
(in)
Filter
Fig. 7-1 Wiring Instructions
Actuator valve
Regulator (for roll pressure)
Air (outlet)
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8. CONTROL BOX
8.1 Names and Function of Terminal Base in Control Box.
Timer relay
Hour meter
Relay
Socket
Changeover switch
Fig. 8-1
Electro
Sensor magnetic valve
External
Hour meter
sensor
(Jump wire)
LIS
SV
HR
CR1
DRY1
CR2
P2
P1
PS
Feeder external
signal
CR4
CR3
U V
IN1 IN2
Power
for feeder
PL
Pilot
lamp
SW
FUSE
Selector
switch
Fuse
PE
AC200V
Earth
Fig. 8-2 Control Box (Side View)
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8.2 Names and Function of Each Part of Control Box.
Hour meter
Pilot lamp
Fuse (2A)
Changeover switch
Feeder controller
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)
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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.
33
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8.3
Names and Function of Each Parts of Feeder Controller.
Display lamp (RUN)
Machine screw
Display lamp (TRIP)
Power switch
Machine screw
Frequency adjusting
volume (FREQ)
Amplitude adjusting volume (V)
Second amplitude adjusting
volume (V2)
FRONT
Power / voltage changeover switch
Terminal base for
external input signal
Fuse holder
Input terminal base
External volume
connection switch
Output terminal base
INSIDE OF FRONT
Fig. 8-4
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Grommet for external
signal cable
Grommet of output cable
Grommet of input cable
Output connector for output
frequency displayer
BOTTOM
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.
35
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•
•
•
•
•
•
•
•
•
•
•
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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9. AUTOMATIC OPERATION FLOWCHART
START
Start operation of HU,HA and distribution motors.
Control box
Set the manual / auto switch at AUTO.
Wait
NO
Any paddy in the HU hopper?
YES
Wait
Yes
Is the PS hopper empty?
NO
Open the shutter and pressurize the rolls.
NO
HU hopper : empty ?
NO
PS hopper : full ?
YES
YES
Close the shutter and release the rolls.
Close the shutter and release the rolls.
YES
PS hopper : full ?
Fig. 9-1 Automatic Operation Flowchart
37
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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 ?
Motor 7.5kW
Tension bolt for
belt
Air pressure 0.5MPa or more
Gear motor
Motor 3.7kW
Tension bolt for
motor
V-belt tension
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
Change over switch
Emergency stop switch
Supplied air pressure
Feeder Controller
Rubber roll air pressure
Pull the handle of regulator
then adjust air pressure.
Regulator
Fig. 10-2 Control box (front) and regulator
39
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(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
40
E-D0775020-00
(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).
Manual Shutter
Sensor
Feeder
Feed valve
Movable shaft
Fig. 10-4 Husker
41
E-D0775021-00
[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
42
E-D0771031-00
CAUTION
•
Operate over the rated capacity may cause failure of the machine.
Feed valve
Change over switch
Amplitude adjusting
volume
Valve D
Valve A
Valve B
Valve C
Valve E
Fig. 10-5
43
E-D0775022-00
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).
44
E-D0771033-00
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
•
(11)
(12)
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.
Adjust the distribution by valve D and E.
Adjust the wind separation by valve A, B and C.
45
E-D0771034-00
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.
Speed controller
Adjusting screw
Adjusting screw
Lock nut
Decrease
air speed
Increase
air speed
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.
46
E-D0771035-00
Speed Controller (IN)
Speed Controller (OUT)
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.
47
E-D0775023-00
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.
48
E-D0702031-00
(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
1/2
t
ones.
Main shaft rubber roll
Movable shaft rubber roll
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
49
E-D0771037-00
(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.
50
E-D0702033-00
(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
Plain Washer and Spring washer
= 2 ~ 5 mm.
B
M10 Fixing bolt
A
Rubber roll
Fig. 12-3
Rubber roll
A
C
Ball bearing 6309DDU
C
D
Retainer
Bearing cover
Detail D
Fig. 12-4
51
E-D0702034-00
(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.
Adjusting nut
Lock nut
Lock nut
Adjusting nut
Plate
Rubber roll
Knob
Front cover
Front cover
Fig. 12.5
Clearance
1 ~ 2 mm
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.
52
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(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.
Chute
Sticker (B)
Thic
Chute
s:T
k nes
Blue
Yellow
Red
Window B
Handle
(Limit area of rubber roll)
Sticker (A)
Blue
Yellow
Red
Window A
Movable rubber roll
Main 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
53
E-D0772025-00
2) Change the chute inclination by turning handle so that chute position sets on the
- same color of step though in section window B.
Window B
Chute
Blue
Sticker (B)
Red
s:T
knes
Thic
Yellow
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
54
E-D0771040-02
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.
Grease nipple
Grease nipple
Gylindrical bearing
Grease nipple
Cover
Bearing cover
Fig. 12-9 Grease nipple (1)
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.
55
E-D0775026-00
Driven side : Pour grease after removing safety cover.
Grease nipple
Grease nipple
Fig. 12-10 Grease nipple
(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.
56
E-D0775027-00
Regulator
Inlet air
Detali of inspection window
Air filter
Max.line
Baffle plate
Tube
Push
Fig. 12-11
(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.
Louver 2
Air separator
Cover
Fig. 12-12
57
E-D0775028-00
(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).
Power Switch
Digit meter
Amplitude adjusting Volume [V]
Frequency adjusting Volume (FREQ)
Fig. 12-13
58
E-D0775029-00
(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.
Trough mount
Magnetic coil
Hex. Bolt
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.
59
E-D0771045-00
(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.
Cover
Feed valve
60
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.
61
E-D0771047-00
Jump Wire
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.
LED
Sensitivity adjusting volume
Fig. 12-18 Sensor
62
E-D0775031-00
(16) Replacement method of tension guide and tension.
CAUTION
•
1)
2)
3)
4)
5)
6)
Turn OFF the power before the work.
Turn OFF the power. Push the emergency switch.
Remove the safety cover guide.
Remove V-belts.
Remove the tension. Make sure the positions of each tension.)
Remove the tension guide. Replace the tension and tension guide together.
Refit in reverse order after the completion of the replacement.
Refer to below figure on the position of the factory shipment.
Tension
Tension guide
Tension
V - Belt
Fig.12-19 Aspirator Driven Part
63
E-D0775032-00
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
1. Poor husking ratio. - Insufficient roll pressure.
- High water content of the paddy.
- If the main shaft roll is smaller in diameter than the
countershaft roll, exchange the right and left sides.
- Replace them with new ones.
- Decrease the feed rate sing the feed rate adjusting
handle.
- Tighten the tightener to the level where the belt bends
10-20 mm as pressed with fingers.
- Remove the foreign materials.
- Reinstall the piping.
- Worn rolls.
- Excessive feed rate.
- Belt slippage.
2. Unable to increase - Valve blocked by foreign
the feed rate.
materials.
3. Much husk
included in the
husked rice.
- 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.
- Measure the water content, and adjust it to a right level.
- Maladjusted wind-sorting section.
- Belt slippage.
- Husking is often interrupted.
- Too much feed rate.
- Blocked louver.
64
- 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-D0771050-00
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.
Fuse (2A)
Bind Head Screw
Fig. 12-1 Fuse position of feeder controller.
65
E-D0771051-00
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.
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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
HU
HA
Part No.
Part Name
Q’ty Condition of Replacement
220110085
220280440
220300510
0114021
TC110309
Plate
Plate (side plate)
Chute
Felt ring
Bearing
1
1
1
1
4
TD13A047
TD13A062
TD13B065
TD13B066
TD13B067
TD13B068
225131400
V – Belt A - 47
V – Belt A – 62
V – Belt B – 65
V – Belt B – 66
V – Belt B – 67
V – Belt B - 68
Conveyor Screw
1
1
2
2
2
2
1
T038106
225131250
225131420
225131410
Plate
Dividing Valve
Conveyor Screw
Conveyor Screw
2
1
1
225130540
Screw case
225130660
225130670
225131610
225133620
225133630
Screw case
Screw case
Tension
1
1
2
Tension guide
1
1
1
Remark
Worn out more than 2 mm.
Worn out more than 2 mm.
Paddy does not flow smoothly. Paddy is flown.
Dust leak
Have Vibration.
Main and
movable shaft
Worn out, slippage
Worn out, slippage.
Worn out, slippage.
Worn out, slippage.
Worn out, slippage.
Worn out, slippage.
Cannot distribute even valve is closed.
For dividing
Husked rice passes only at the center portion.
Husked rice cannot discharge.
Has no efficient distribution.
Has clogged due to lower capacity of conveyor For mixture
Cannot convey husk that is remained much
For husk
when seeing trough the inspection window.
No distribution by a big worn hole of screw
case.
Worn hole of screw case.
Worn hole of screw case.
Tension is much loose.
Husked rice side
Tension is much loose.
Husk side
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E-D0775033-00
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]
68
E-D0371039-00
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
69
E-D0371040-00