SATAKE INSTRUCTION MANUAL MILLING SEPARATOR SFI1000, 1500A-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.

E-D0382001-01-05

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 .................................................................................................................... 11 4. DIMENSION............................................................................................................................. 13 5. CONSTRUCTION..................................................................................................................... 15 6. INSTALLATION........................................................................................................................ 17 6.1 Notes for installation .................................................................................................... 17 6.2 Procedure for Installation............................................................................................. 19 7. PREPARATION FOR OPERATION ........................................................................................... 20 7.1 Checking and Inspection ............................................................................................ 20 7.2 Inspection in No-Load Operation ................................................................................ 22 8. OPERATION............................................................................................................................. 23 9. MAINTENANCE AND INSPECTION......................................................................................... 24 9.1 General........................................................................................................................ 24 10. TROUBLESHOOTING............................................................................................................ 28 11. LIST OF CONSUMABLE PARTS ............................................................................................ 29 11. LIST OF CONSUMABLE PARTS ............................................................................................ 30 EMERGENCY ADDRESS AND TELEPHONE ............................................................................... 31

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. 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. 4. We will supply parts of the machine for 7 years after stop of production. But within this period some special parts are exceptional. 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.

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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, there is some possibility of fatal or serious injury. This shows potential hazard. If you do not follow this,

WARNING

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.

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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.

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2.4 Warning Stickers !

How to handle Warning Stickers
Check if letters and illustration on the sticker are legible and if not,

NOTE

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.

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2.5 Location of Warning Stickers

T090123

T037213 Fig. 2-1 Location of Warning Stickers

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3. SPECIFICATIONS
Model Paddy (Long & medium grain) Capacity Brown rice (Long & medium grain) Wheat Power source Revolution Air capacity (m3/min.) Static pressure (KPa) Frequency (Hz) Net weight (Kg) Vertical dynamic loads (Kgf) Dimensions(mm) W L H Screen Round hole
2.0, 2.0, 6.0,

SFI 1000A-T 5 10 65 (Pre - cleaning) 16 (Cleaning) Vibratory motor 1.0 kW x 2 (also available 1.1 kW x 2 ) 1000 rpm 12 -0.2 50 1000 1200 1606 2423 1933 Pitch 3.5, T1.2 SUS304P Pitch 3, T0.8 SUS304P Pitch 9.0, T1.2, SUS304P Pitch 9.2, T2.0, SUS304P Pitch 10.0, T1.2, SUS304P Pitch 11.9, T1.4, SPCC Pitch 12.7, T1.4, SPCC Pitch 13.85, T1.2, SUS304P Pitch 13.85, T2.0, SPCC Pitch 16.7, T1.2, SUS304P Pitch 18.0, T1.2, SUS304P

SFI 1500A-T 10 15 100 (Pre - cleaning) 25 (Cleaning) Vibratory motor 1.1 kW x 2 (also available 1.5 kW x 2 ) 12 -0.2 50 1500 1800 2236 2423 1933

6.35, 7.5, 8.0, 9.5,

11.1, 11.1, 12.7, 14.3,

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Slot hole 6.0x20, Pitch 11x25, T1.2, SUS304P 6.0x20, Pitch 10.8x24.8, T1.4, SPCC 6.5x20, Pitch 11.5x25, T1.2, SUS304P 7.0x20, Pitch 12x25, T1.2, SUS304P 7.0x20, Pitch 11.8x24.8, T1.4, SPCC 7.5x20, Pitch 12.5x25, T1.2, SUS304P 7.5x20, Pitch 10x22, T1.2, SUS304P 8.0x20, Pitch 11.6x24.8, T1.2, SPCC Woven screen #2, 2 SUS #2, 0.6 SUS #9, 0.6 SUS Area of 60 Hz Use inverter to adjust frequency to 50 Hz. Remark 1. Condition of material. Material Paddy Brown rice Wheat Process Pre - checking Cleaning % of contamination of large and fine impurities Less than 2 % Less than 2 % Less than 3 % Less than 3 % Moisture content Less than 15 % Less than 15 % Less than 15 % Less than 15 %

Large impurities Bigger than 20 mm. of string, dust, glass and stone etc. Fine impurities Smaller than 2 mm. of string, dust, glass and stone etc. 2. Install the pre process machine (Such as Drum separator or Scalper) when % of contamination of large and fine impurities is higher than above table. 3. Take out Retarded or remove dust periodically (Once/day) to protect material being stucked in the machine when % of contamination of large and fine impurities is higher than above table and can not install pre-process machine before SFI even this condition.

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4. DIMENSION
Unit: mm
36 M8

360 210

185 1616 325 325

201 (Inner Dia.)

132

193

100 4- 17 1444 1604 2423 95 261

1009 1240 1428 1450 1606

336

Fig. 4-1 Dimensional Drawings (SFI1000A-T)

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542.5

518

156

140

1933(12INTAKE) 1768(6)

25(INTAKE) 20

12 6

Unit: mm
36 M8 (120) 360 185 (INTAKE) 210

375

2236 375

201

(Inner Dia.)

132

518 (578)

193

100 4- 17 336 1444 2423 (2453) 95 261

1509 1740 1928 1950 2106

Fig. 4-2 Dimensional Drawings (SFI1500A-T)

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542.5

156

140

1933(12 INTAKE) (1768(6 )

25 (INTAKE) (20 )

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5. CONSTRUCTION

(SFI1000A-T)
Material N H K

O P

I J Q Fine impurities Clean grain Larger impurities

Fig. 5-1 General Assembly

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The sieve body (A) of the milling separator is a steel fabrication containing two inlets (B), one exhaust (C) and four outlets. The sieve body is supported by four springs (D). The fixed inlets and the sieve body are connected with the filter cloth (E). Mounted on both sides of the sieve body are the vibratory motors (F). The stock can be observed through the inspection windows (G) on the top of the sieve body. Inside the sieve body are the top (H) and bottom (I) sieve decks. The ball cleaners (J) equipped on the sieves prevent choking of the material. The rubber plates (K) are fitted above the top sieves to prevent good grain from bouncing over into the tailings. The top and bottom sieves are clamped by the clamp levers (L) and clamp covers (M). The grains are evenly scattered across the width of the upper sieve by the wear plate (N) and directed to the top sieves. The top sieve screen is perforated with round holes and slot holes. The grains, which pass through the perforated screens, fall down onto the bottom sieves while the over tails are directed to the outlets (O) on the left and right sides of the sieve body. Fine impurities pass through fine woven screens of the bottom sieve and is directed to the outlet (Q) and clean grains are guided to the outlet (P).

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6. INSTALLATION
6.1 Notes for installation ! WARNING

Install the machine in a level, stable place for optimal machine performance. Ensure the level of the installation site and secure the machine with bolts.

(1) machine should be used with a suction dust collector. Provide a static pressure adjustment inhibitor in the line so as to ensure that a static pressure is maintained at 10 to 20 mmAq. (2) Allow a space in front of the machine as shown below in order to remove the screens.

1500mm

Fig. 6-1 Maintenance Space

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(3) As this machine comprises a vibratory body, install it on a rigid basement or floor which withstands such vertical dynamic loads as specified in the specifications. (See 2.SPECIFICATIONS) (4) Use shims at the bottom of the machine to correctly level the top surfaces of the machine and secure the machine with bolts.

WARNING

Before to operation, be sure to remove the transit lock.

(5) The vibratory body is locked by a transit lock to prevent damages during transit. Never fail to remove the transit lock before starting operation. (6) When the machine is used in a 60Hz area, use the inverter provided with the machine for conversion to 50Hz.

Fig. 6-2 Transit Lock

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WARNING

Prior to performing electrical installation, isolate the

machine from the power supply.

Have the electrical installation done by qualified

electricians.

CAUTION

Be sure to ground the machine to ensure safety.

6.2 Procedure for Installation

(1) Check and ensure the level of the machine and secure it on the basement and the floor. (2) Remove the transit lock. (3) Install the inlet, the suction duct and connect piping. (4) For use in 60Hz area, install the provided in your power panel. If a power panel is not available, prepare a box to enclose the inverter. (5) Carry out electrical installation. When used with the inverter, read the operators manual for the inverter.

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7. PREPARATION FOR OPERATION

! WARNING

Turn off the power switch and the breaker and display a UNDER INSPECTION.

7.1 Checking and Inspection

(1) Clean the machine and ensure that no toll, bolts, nuts or loose articles stays in the machine. (2) Check to see that the screens are secured with the clamp lever and the clamp cover. (3) Check to see that the inclination of the screen is 12 for pre-cleaning and 6 for cleaning. (4) Check to see that the vibratory motor is installed at an angle of 25 for pre-cleaning and 20 for cleaning.

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For pre-cleaning, set the rubber spring base at the top position. Inclination of the screen: 12 For cleaning, set the rubber spring base at the bottom position. Inclination of the screen: 6 For pre-cleaning, the motor should be installed as shown by For cleaning, the motor should be installed as shown by Fig. 7-1 (Motor inclination : 25 ) (Motor inclination: 20 )

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7.2 Inspection in No-Load Operation ! WARNING

The operator is supposed to pay attention to the following points to ensure

safety in operating, inspecting, and servicing the machine. (1) After checking and preparation is complete, check to see the rotation of each motor is correct. (As shown in the rotation sticker adhered on the vibratory motor.) (2) Keep no-load operation for a while to ensure that no irregular vibration is found. (3) The bolts and nuts on the vibratory body may be loosened due to vibration. After no-load operation, isolate the machine from the power supply and tighten securely the bolts and nuts on the vibratory body. Check and tighten the fixing bolts for the vibratory motor to a torque of 17Kgfm.

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8. OPERATION
(1) Start up the dust-collecting device. (2) Turn on the power supply. (3) Start material feeding. (4) The material flow rate should be adjusted at the prior process so as to feed material within a flow rate range specified in 2. SPECIFICATIONS.

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9. MAINTENANCE AND INSPECTION

! WARNING

Prior to cleaning or inspecting parts, turn off the power switch and breaker, and

display on UNDER INSPECTION notice.

Carry out inspection or maintenance work you confirm a complete stop of the

machine.

9.1 General
The following information is for maintaining this equipment. Periodic maintenance, when carried out as specified, will help to prevent premature failure of the equipment. It is recommended that all tasks in Table 9-1 are carried out as specified.

Item
First 15 min. First hour Weekly

Frequency
Monthly 3 monthly 6 monthly Annually

Noise & vibration Sieve Front clamp Sleeve Seal Toggle clamp Retarder Spring Spring buffer Fastener Table 9-1 Periodic Maintenance Schedule

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(1) Excessive noise and Vibration Check for unfamiliar noises and excessive vibration once a week indicate such items as sieve clamps, toggle clamps or fasteners are working loose or the vibratory motor is worn or damaged. After identifying the noise/vibration source, take appropriate measures. (2) Sieve Check the sieve frames, sieve covers and felt seals for wear, tear or damage. Replace as necessary. (3) Front clamp Check the sieve and the front clamp for wear and damage and for security of clamping every week. If necessary, adjust the front clamps by turning the bolts M12 so that the front clamp holds the sieve securely. (4) Sleeve Check the sleeves for damages every month. Replace as necessary. (5) Seal (Seals for front clamp, toggle clamp and inspection cover) Check all seals every 3 months for damage, particularly where stock leakage is evident. Replace as necessary. (6) Clamp Check Clamps for looseness and wear every 3 months.

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Fig. 9-1 Toggle Seal and Clamp (7) Retarder Check the retarders for damage every 3 months. Replace as necessary. (8) Spring Check the springs annually for damage and replace as necessary. (9) Spring buffer Check the spring buffers for wear and damage every 6 months. Replace as necessary.

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10) Fasteners All fixing screws, nuts and bolts must be checked on installation to ensure that no slackening has occurred during transport. Repeat the check after one hour and after the machine has been running for one month, thereafter every 3 months. Particular attention should be given to the nuts and bolts securing the vibratory motor and the spring brackets. See the below list for the recommended tightening torque. Fastener size M12 M20 M24 (Vibratory motor) M30 (Vibratory motor) Table 9-2 Recommended tightening torque 100Nm (75 lbs ft) 340Nm (250 lbs ft) 390Nm (290 lbs ft) 600Nm (450 lbs ft)

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10. TROUBLESHOOTING
! WARNING

Before maintenance 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 1. Separation is not effectively perform.

Cause Too much material feeding.

Action to Take Reduce the rate of material feeding from the prior process. Clean the bag filter to remove choking. Clean the screens with soft cloth or air jet once a week.

Reduction in suction air

quantity or static pressure.

Choking of the top or bottom

screens.

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11. LIST OF CONSUMABLE PARTS

SFI1000A-T Part name

Part No. Remark 540162720 Spring 540162750 Sleeve 540162770 Spring buffer 540162780 Spring buffer 540166881 Retarder 540169010 Plate 540169020 Plate 540169106 Screen (0.6 P9) 540169306 Screen (8.0 9 mesh) 540169307 Screen (2.0 P3.5) 540169600 Ball 540161245 Seal 540169040 Seal FZ0200601 Seal 540169106 Screen (6.0, Pitch 9.0, T1.2, SUS304P) T038637 Screen (6.35, Pitch 9.2, T2.0, SUS304P) T038583 Screen (8.0, Pitch 11.9, T1.4, SPCC) T038649 Screen (9.5, Pitch 12.7, T1.4, SPCC) T038648 Screen (11.1, Pitch 13.85, T2.0, SPCC) T038651 Screen (12.7, Pitch 16.7, T1.2, SUS304P) T038653 Screen (14.3, Pitch 18.0, T1.2, SUS304P) T038619 Screen (7.0x20, Pitch 10x22, T1.2, SUS304P) T038569 Woven Screen (# 2, 2) SUS304 540169306 Woven Screen (# 9, 0.8) SUS304 Please tell the specification of screen to sales person when order screen other than above list.
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11. LIST OF CONSUMABLE PARTS

Part No.
540162720 540162750 540162770 540162780 540166881 540169010 540169020 540169106 540169306 540169307 540169600 540161245 540169040 FZ0200601 540179307 540179308 540179106 T043087 540179111 T043051 T043085 540179110 540179109 540179108 540179107 T043086 T043084 T043052

SFI1500A-T Part name

Spring Sleeve Spring buffer Spring buffer Retarder Plate Plate Screen (0.6 P9) Screen (8.0 9 mesh) Screen (2.0 P3.5) Ball Seal Seal Seal Screen (2.0, Pitch 3.5, T1.2, SUS304P) Screen (2.2, Pitch 3.0, T1.2, SUS304P) Screen (6.0, Pitch 3.0, T1.2, SUS304P) Screen (7.5, Pitch 10, T1.2, SUS304P) Screen (8.0, Pitch 12, T1.2, SUS304P) Screen (8.0, Pitch 11.9, T1.2, SPCC) Screen (12.7, Pitch 16.7, T1.2, SUS304P) Screen (6.0x20, Pitch 11x25, T1.2, SUS304P) Screen (6.0x20, Pitch 11.5x25, T1.2, SUS304P) Screen (7.0x20, Pitch 12x25, T1.2, SUS304P) Screen (7.5x20, Pitch 12.5x25, T1.2, SUS304P) Woven Screen (#8, 0.90, SUS304P) Woven Screen (#10, 0.5, SUS304P) Woven Screen (#12, 0.65, SUS304P)

Remark

Please tell the specification of screen to sales person when order screen other than above list.
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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: eng-sth@sataketh.com 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: kg-hiroshima@satake-japan.co.jp

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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: eng-sth@sataketh.com Home Page: www.sataketh.com

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