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.

E-D0774001-00-00

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

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.

2.

E-D0371002-00

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.

E-D0371003-00

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.

E-D0371004-00

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.

E-D0371005-00

(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-D0371006-00

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-D0371007-01

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.

E-D0371008-00

2.5 Location of Warning Stickers

T070154

299001542

220283504

Fig. 2-1 Location of Warning Stickers (1)

10

E-D0775002-00

T037212

T019360

T070190

Fig. 2-2 Location of Warning Stickers (2)

11

E-D0775003-00

T037212

T037212

Fig. 2-3 Location of Warning Stickers (3)

12

E-D0775004-00

3. SPECIFICATIONS
Model For Basmati rice Process Capacity (Husking ratio 90%) Power required Main Shaft Speed Fan Shaft Speed Coil spring (HU) Robber roll Net weight Size Hardness Husker Aspirator Husker Aspirator Basmati Parboil rice Non parboil rice 3.5-4.0 tons / hour (Paddy) 2.5-3.0 tons / hour (Paddy) HU10FH-T(2)-T + HA10W(3)-T

Husker HU10FH(2)-T + Aspirator HA10W(3)-T 7.5 kW 6P, 52 kW + 3.7 kW 4P, 0.1 kW : HU10FH(2)-T : HA10W(3)-T

1150 rpm 1400 rpm

8 mm. (Blue)

Diameter : 10 inch ,Width : 10 inch 87 5 : HU10FH(2)-T : HA10W(3)-T 588 kg 588 kg

13

E-D0774002-00

For long grain (except Basmati rice) Process Capacity (Husking ratio 90%) Power required Main Shaft Speed Fan Shaft Speed Coil spring (HA) Robber roll Net weight Size Hardness Husker Aspirator Long grain (except Basmati rice) 5.0 ~ 6.0 tons / hour (Paddy)

Husker HU10FH(2)-T + Aspirator HA10W(3)-T 7.5 kW 6P, 52 kW + 3.7 kW 4P, 0.1 kW Husker Aspirator : HU10FH(2)-T : HA10W(3)-T

1100 rpm 1400 rpm

10 mm. (Black)

Diameter : 10 inch ,Width : 10 inch 87 5 : 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.

14

E-D0774003-00

4. DIMENSIONS

Fig. 4-1 Dimensional Drawings

15

E-D0775006-00

5. CONSTRUCTION
Tank Shutter Valve Chute

Sensor Feeder

Adjusting bolt
CHUTE
UP DOWN

Control box

Rubber roll

Valve D Valve E Screw Conveyor Valve A Valve B

Screw Conveyor

Screw conveyor Husked rice outlet Valve C Husk outlet

Fig. 5-1

16

E-D0775007-00

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

17

E-D0775008-00

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

18

E-D0771009-00

6.4

Selection of Floor The Floor to be selected for installation must have enough strength. Allow enough space around the machine for inspection jobs or passage as show in Fig. 6-4

6.5 When install the machine,

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)

19

E-D0775009-00

(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)

20

E-D0775010-00

(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

E-D0775011-00

Rotation direction Timing belt 600DS8M2304 Tension Pulley

Motor7.5kW-4P Motor pulley Movable shaft pulley Main shaft pulley

Husk screw pulley

Dividing screw Fan shaft pulley

Geared motor 0.1kW 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 E-D0775012-00

(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)

23

E-D0775013-00

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

E-D0775014-00

(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.

25

E-D0771016-00

Motor Specification Voltare Frequency Amperage (V) 200 200 380 440 460 (Hz) 50 60 50 60 60 (A) 29.0 28.0 15.0 13.0 12.7 Thermal Relay Capacity (A) 29.0 28.0 15.0 13.0 12.7

Motor Specification Voltare Frequency Amperage (V) 200 200 380 440 460 (Hz) 50 60 50 60 60 (A) 33.0 30.0 17.0 14.5 14.5 Thermal Relay Capacity (A) 33.0 30.0 17.0 14.5 14.5

Table 6-1 - 7.5kW, 4P motor (TH1)

Table 6-2 - 7.5kW, 6P motor (TH1) (for HU10FH model only)

Motor Specification Voltare Frequency Amperage (V) 200 200 380 440 460 (Hz) 50 60 50 60 60 (A) 45.0 42.0 22.5 19.5 19.0 Thermal Relay Capacity (A) 45.0 42.5 22.5 19.5 19.0

Motor Specification Voltare Frequency Amperage (V) 200 200 380 440 460 (Hz) 50 60 50 60 60 (A) 15.0 14.2 7.7 7.1 6.8 Thermal Relay Capacity (A) 15.0 14.2 7.7 7.1 6.8

Table 6-3 - 11kW, 4P motor (TH1)

Table 6-4 - 3.7kW, 4P motor (TH2)

26

E-D0771054-00

Motor Specification Voltare Frequency Amperage (V) 200 200 380 440 460 (Hz) 50 60 50 60 60 (A) 29.0 28.0 15.0 13.0 12.7 Thermal Relay Capacity (A) 29.0 28.0 15.0 13.0 12.7

Table 6-6 - 0.1kW (TH3)

27

E-D0771055-00

(Control box)

Emergency stop PB TH1 TH2 TH3

MC2 TH2

MC3 TH3

MC1 TH1

Electro-magnetic contactor Thermal relay (Control box) Current Ammeter transformer

L K l k

Stop PB3 MC3 MC3 Run PB3

Stop PB2 MC2 MC2 Run PB2

Stop PB1 MC1 MC1 Run PB1

*Local wiring (Refer to next pape) LIS DRY1 CR2 IN1 PL IN2 PS SV HR CR1 CR4

CR3 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.

28

E-D0775015-00

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)

29

E-D0771018-00

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
LIS PS SV

Sensor

Ball valve

Hour meter
HR

Feeder controller Air cylinder (shutter) Air cylinder (roll) Control box
CR2 CR3 DRY1 CR1 CR4

Solenoid valve

IN1 IN2

PL

SW

FUSE

Speed controller (out)

Compressed Air(inlet)
(out)

PE

Regulator (for regulating the control pressure) Air (outlet)

(in)

lamp Selector switch

Fuse Single Earth phase

Speed controller (in)

pressure gauge Filter

Fig. 7-1 Wiring Instructions

Actuator valve Air (outlet) Regulator (for roll pressure)

30

E-D0775016-00

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

PS

SV

HR
P1

DRY1

CR1

CR4

CR2

CR3 U V

IN1 IN2 Power for feeder

PL Pilot lamp

SW

FUSE

Selector switch

Fuse

AC200V

Fig. 8-2 Control Box (Side View)

31

P2

Feeder external signal

PE Earth

E-D0771020-00

8.2 Names and Function of Each Part of Control Box.

Hour meter

Pilot lamp

Changeover switch

Fuse (2A)

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)

32

E-D0775017-00

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

E-D0771022-00

8.3

Names and Function of Each Parts of Feeder Controller.

Machine screw Power switch Machine screw

Display lamp (RUN) Display lamp (TRIP) Frequency adjusting volume (FREQ) Amplitude adjusting volume (V) Second amplitude adjusting volume (V2)

FRONT

Terminal base for external input signal

Power / voltage changeover switch Fuse holder

External volume connection switch

Input terminal base Output terminal base

INSIDE OF FRONT Fig. 8-4

34

E-D0771023-00

Grommet for external signal cable

Grommet of output cable

Output connector for output frequency displayer

Grommet of input cable

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

E-D0771024-00

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.

36

E-D0771025-00

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 ? YES Close the shutter and release the rolls.

PS hopper : full ? YES Close the shutter and release the rolls.

NO

YES

PS hopper : full ? NO

Fig. 9-1 Automatic Operation Flowchart

37

E-D0771026-00

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

38

E-D0775018-00

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 Regulator Pull the handle of regulator then adjust air pressure.

Fig. 10-2 Control box (front) and regulator

39

E-D0775019-00

(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

Feed valve

Feeder

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 Valve A Valve B Valve C Valve D Valve E

: 70 : Middle : Middle : 2nd scale line from right : Middle :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

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) (12)

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 Lock nut Decrease air speed

Fig. 11-1 Adjusting the Speed controller

Adjusting screw

Increase air speed

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

ones.
1/2 t

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. Dont 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) 3.2 ~ 7.99 8 ~ 12.99 13 ~17.99 18 ~ 22 B Size (mm) 20 25 30 35 Remark M10x20 M10x25 M10x30 M10x35

Plain Washer and Spring washer = 2 ~ 5 mm.

M10 Fixing bolt

Rubber roll

Fig. 12-3
Rubber roll A C Ball bearing 6309DDU C

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. Close the front cover securely by fastening the knob. Loosen the adjusting nut until plate and rubber roll contact. After contacted fasten the adjusting nut by one turning clockwise. Lock the adjusting nut by fastening the lock nut.
Adjusting nut Lock nut Plate

2) 3) 4)

Lock nut Adjusting nut

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

E-D0775024-00

(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
Thic s:T k nes

Sticker (B) Blue Yellow Red Window B (Limit area of rubber roll) Sticker (A)

Chute Handle

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 Red 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 chutes inclination also follow the color at window B. - (Chutes in inclination links wearing of rubber rolls). (11) Grease Supply

Blue Sticker (B)

s:T knes Thic

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. Dont 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

(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.

Fig. 12-11

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) 2) 3) 4) 5) Remove cover. Loosen the fixing bolts of feed valve. Adjust the position of feed valve so that the feed valve puts the trough as Fig. Fasten the fixing bolts to adjust clearance between both left and right side of feed valve and trough is the same. Fix the cover.

Cover

Feed valve

60

6) 7) 8) 9)

Remove cover. Loosen the fixing bolts of feed valve. Adjust the position of feed valve so that the feed valve puts the trough as Fig. 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

Turn OFF the power before the work.

1) 2) 3) 4) 5) 6)

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.
Cause Action to Take - 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. - 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. - 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.

Conditions of Failure

1. Poor husking ratio. - Insufficient roll pressure.

- High water content of the paddy. - 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. - Maladjusted wind-sorting section. - Belt slippage. - Husking is often interrupted. - Too much feed rate. - Blocked louver.

64

E-D0771050-00

Check list in manual operation. Checklist on Electrical and Air Systems in Manual Operation.
Condition of Failure 1. Does not power on (pilot lamp does not illuminate). Cause - 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. - No or insupplicient air feed. - Fault with the air cylinder (for shutter). - 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. - Fault with the HAND/AUTO change-over switch. - Blow fuse on the panel. - No or insufficient air feed. - Fault with the solenoid valve. Action to Take - Turn on the switch. - Check the conductance of the power cable. - Replace the fuse (2A). - Check valves etc. Ensure the air feed. - Replace the air cylinder. - 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. - Replace the switch. - Replace the fuse (2A). - Feed air (0.5 MPa or more). - Replace the solenoid valve.

2. Shutter does not open/close. 3. Rolls do no open/ close.

4. Neither shutter nor rolls function

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 1. Shutter does not open. Cause - 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 - Fault with the upper limit sensor of the paddy separator machine hopper. - Low air pressure. - Fault with the air cylinder and solenoid valve. Action to Take - 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. - Replace the sensor. - Check and adjust the air pressure. - Replace the air cylinder and solenoid valve.

2. Shutter does not close.

66

E-D0771052-00

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.
220110085 220280440 220300510 0114021 TC110309 TD13A047 TD13A062 TD13B065 TD13B066 TD13B067 TD13B068 225131400 T038106 225131250 225131420 225131410 225130540 225130660 225130670 225131610 225133620 225133630

Part Name
Plate Plate (side plate) Chute Felt ring Bearing 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 Plate Dividing Valve Conveyor Screw Conveyor Screw Screw case Screw case Screw case Tension Tension guide

Qty Condition of Replacement

1 1 1 1 4 1 1 2 2 2 2 1 2 1 1 1 1 1 1 2 1

Remark

HU

HA

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

67

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: 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

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

69

E-D0371040-00