Paddy Husker HR10FH T Satake Husker Specs

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    E-D0774001-00-001

    SATAKE

    INSTRUCTION MANUAL

    PADDY HUSKER WITH ASPIRATOR

    HU10FH(2)-T, HA10W(3)-T

    WARNING

    Do not carry out any operation, maintenance or inspection of themachine until you have read and well understood the contents of this

    instruction manual.

    Keep this manual at hand whenever any operation, maintenance orinspection of the machine is being carried out.

    SATAKE (THAILAND) CO., LTD.

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    2

    CONTENT

    1. LIMITED WARRANTY................................................................................................................. 3

    2. SAFETY...................................................................................................................................... 4

    2.1 Warning / Caution Types and Meanings ....................................................................... 5

    2.2 General Instructions ...................................................................................................... 6

    2.3 Special Precautions....................................................................................................... 8

    2.4 Warning Stickers ........................................................................................................... 9

    2.5 Location of Warning Stickers....................................................................................... 10

    3. SPECIFICATIONS .............................................................................................................. ...... 13

    4. DIMENSIONS........................................................................................................................... 15

    5. CONSTRUCTION..................................................................................................................... 16

    6. INSTALLATION ........................................................................................................................ 17

    7. WIRING AND AIR PIPING........................................................................................................ 30

    8. CONTROL BOX ....................................................................................................................... 31

    8.1 Names and Function of Terminal Base in Control Box. ............................................... 31

    8.2 Names and Function of Each Part of Control Box. ...................................................... 32

    9. AUTOMATIC OPERATION FLOWCHART ................................................................................ 37

    10. PREPARATION FOR OPERATION ......................................................................................... 38

    11. OPERATION........................................................................................................................... 44

    12. MAINTENANCE AND INSPECTION....................................................................................... 48

    13. TROUBLESHOOTING............................................................................................................ 64

    14. CONSUMABLE PARTS LIST .................................................................................................. 67

    EMERGENCY ADDRESS AND TELEPHONE ............................................................................... 68

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    E-D0371002-003

    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 withinlimited 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 withinthis period some special parts are exceptional.

    4. Basically, We will stop to supply parts in 7 years after discontinued to produce. But ifyou 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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    E-D0371004-005

    2.1 Warning / Caution Types and Meanings

    Hazard warning in this instruction manual and warning stickers attached on the machine

    main body are classified into the following three kinds, depending on the degree of risk of

    accident.

    Operator must recognize the importance of the warnings, and carefully follow the

    instructions given in this manual.

    This shows potential hazard. If you do not follow this,WARNING

    there is some possibility of fatal or serious injury.

    This shows potential hazard. If you do not follow this,

    there is some possibility of middle or minor classCAUTION

    injury, damages of the equipment / machinery or

    misconduct in material or product.

    This is used for calling special attention to orNOTE

    adding emphasis to a certain information required

    to be noticed.

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    E-D0371005-006

    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 shoesthat 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 inelectric 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 childrencome close to the machine.

    (8) Do not fail to inspect the machine before starting operation. When carrying out anyinspection 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 appropriatelock 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 restorethe cover after the checking.

    (11) Check for any damages on power cords and wire cables. Also, check for anylooseness or disconnection of connectors and plugs.

    (12) Operate the machine with all covers attached. Do not attempt to remove any coverduring 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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    E-D0371007-018

    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 inthis 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 tomalfunction and failure of the machine.

    (6) Keep alert to the machine, If any abnormality is found, stop the operation and checkthe 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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    E-D0371008-009

    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.

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    E-D0775002-0010

    2.5 Location of Warning Stickers

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

    220283504

    T070154

    299001542

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    E-D0775003-0011

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

    T070190

    T019360T037212

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    E-D0775004-0012

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

    T037212T037212

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    E-D0774002-0013

    3. SPECIFICATIONS

    Model HU10FH-T(2)-T + HA10W(3)-T

    For Basmati rice

    Parboil rice 3.5-4.0 tons / hour (Paddy)Process Capacity

    (Husking ratio 90%)Basmati

    Non parboil rice 2.5-3.0 tons / hour (Paddy)

    Power requiredHusker HU10FH(2)-T + Aspirator HA10W(3)-T

    7.5 kW 6P, 52 kW + 3.7 kW 4P, 0.1 kW

    Main Shaft Speed

    Fan Shaft Speed

    Husker

    Aspirator

    : HU10FH(2)-T

    : HA10W(3)-T

    1150 rpm

    1400 rpm

    Coil spring (HU) 8 mm. (Blue)

    Size Diameter : 10 inch ,Width : 10 inch

    Robber roll

    Hardness 87 5Net weight

    Husker

    Aspirator

    : HU10FH(2)-T

    : HA10W(3)-T

    588 kg

    588 kg

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    E-D0774003-0014

    For long grain (except Basmati rice)

    Process Capacity

    (Husking ratio 90%)

    Long grain

    (except Basmati rice) 5.0 ~6.0 tons / hour (Paddy)Power required

    Husker HU10FH(2)-T + Aspirator HA10W(3)-T

    7.5 kW 6P, 52 kW + 3.7 kW 4P, 0.1 kW

    Main Shaft Speed

    Fan Shaft Speed

    Husker

    Aspirator

    : HU10FH(2)-T

    : HA10W(3)-T

    1100 rpm

    1400 rpm

    Coil spring (HA) 10 mm. (Black)

    Size Diameter : 10 inch ,Width : 10 inch

    Robber roll

    Hardness 87 5Net weight

    Husker

    Aspirator

    : HU10FH(2)-T

    : HA10W(3)-T

    588 kg

    588 kg

    NOTE

    Husking ratio depends on material quality and impurity high

    impurity material. May cause malfunction of machine.

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    E-D0775006-0015

    4. DIMENSIONS

    Fig. 4-1 Dimensional Drawings

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    E-D0775007-0016

    DOWNUP

    CHUTE

    Sensor

    Tank

    Shutter

    Valve

    Chute

    Adjusting bolt

    Control box

    Valve DValve E

    Screw Conveyor

    Feeder

    Rubber roll

    Screw Conveyor

    Husk outletValve CHusked rice outlet

    Screw conveyor

    Valve A

    Valve B

    5. CONSTRUCTION

    Fig. 5-1

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    E-D0775008-0017

    6. INSTALLATION

    6.1 Rigging Method of the Machine

    WARNING

    Use a wire having sufficient strength.

    Remove the safety cover for making work space during installation of husker

    (fix the machine with body of aspirator).

    Use great care not to damage the body etc. when carrying and rigging work.

    Fig. 6-1

    Remove safety cover

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    6.2 Confirmation of Levelness

    CAUTION

    If the machine is not set horizontally it may not be able to exhibit expected

    capacity fully.

    Ensure the levelness of the machine and bolt it securely to the floor.

    Set the machine at the specified position and make sure that it is placed horizontal.

    Fig. 6-2

    Then bolt the machine securely with the bolts.

    6.3 Position setting.

    Fig. 6-3

    Set Levelness

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    E-D0775009-0019

    COVER

    6.4 Selection of Floor

    The Floor to be selected for installation must have enough strength.

    6.5 When install the machine,Allow enough space around the machine for inspection jobs or passage as show in

    Fig. 6-4

    Fig. 6-4

    6.6 Process of Installation

    Comply with the following procedure to assemble the machine.

    (1) Remove the top cover

    Fig. 6-5 Assembly procedure (1)

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    Angle

    (2) Fit the husker onto the aspirator. Fix the bolts.

    Fig. 6-6 Assembly procedure (2)

    (3) Remove the angle and fit the bolt on the body.

    Fig. 6-7 Assembly procedure (3)

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    E-D0775011-0021

    (4) Attach the Top Covers.

    Fig. 6-8 Assembly procedure (4)

    (5) Attach motors to the husker and the aspirator.

    (6) Fit timing belt to husker and V-belt to aspirator.

    WARNING

    Caution must be exercised to prevent your fingers from being pinched at the

    pulley and belt.

    CAUTION

    Securely fit the motor pulley.

    Fit the belts in accordance with Fig. 6-9, and sure to adjust the belt alignment.

    TOP COVER

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    E-D0775012-0022

    V-belt (50Hz)B-68 2 Pcs.

    (60Hz)B-66 2 Pcs.

    Dividing screw

    directionRotation

    Husk screw pulley

    Motor pulleyMotor 3.7kW-4P

    Fan shaft pulley

    Tension Pulley

    Timing belt600DS8M2304

    directionRotation

    Geared motor 0.1kW

    Mixed grain screw pulley

    V Belt A-62

    V-belt A-47

    Motor7.5kW-4PMotor pulley

    Movable shaft pulley

    Main shaft pulley

    V-belt (50Hz)B-67 (High RPM) 2 Pcs.

    (60Hz)B-65 (High RPM) 2 Pcs.

    Fig. 6-9 Belt Routing and Belt Sizes

    (7) Dust Suction piping

    Note the following points when installing the dust suction piping.

    1) Intake airflow of 3 m3/min. is required.

    2) Number of bends as well as the piping lengths should be minimized with the dust

    --removing

    3) Put the dumper for adjusting air volume of each machine.

    Dust direction

    Dust direction

    Fig. 6-10

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    E-D0775013-0023

    (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 60or more. If the piping

    angle is less than 60, it causes the decrease of capacity due to bad paddy flow.

    Maximum input capacity is depends on variety of material etc,. may need to adjust angle

    of piping.

    Fig. 6-11 Sketch of the piping (1)

    From previous process

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    Set the piping angle from husked rice outlet to the subsequent process at 40 or more.

    (10) Control air piping

    Route the air piping to the coupler under the control set supply air pressure to the coupler about

    0.5 MPa.

    To Paddy Separator Fig. 6-11 Sketch of the piping (2)

    Fig. 6-12 Sketch of the piping (3)

    Control box

    Compressed air supply

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    (11) Electric Wiring

    WARNING

    Ensure that the main power is turned OFF when connecting any wiring work.

    CAUTION

    Make sure to close the cover of the control box after the wiring work.

    If the cover of the control box is forgotten to close, the electronic parts may

    damage by dust.

    Fit the elector magnetic breaker for each motor.

    Make the electric wiring to stop the paddy supply in case that the distribution

    motor stops by the overload for some reason.

    (1) Must use protective device such as contact breaker, electromagnetic contactor orthermal 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

    Voltare Frequency Amperage

    (V) (Hz) (A)

    Thermal

    Relay

    Capacity (A)

    200 50 29.0 29.0

    200 60 28.0 28.0

    380 50 15.0 15.0

    440 60 13.0 13.0

    460 60 12.7 12.7

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

    Motor Specification

    Voltare Frequency Amperage

    (V) (Hz) (A)

    Thermal

    Relay

    Capacity (A)

    200 50 33.0 33.0

    200 60 30.0 30.0

    380 50 17.0 17.0

    440 60 14.5 14.5

    460 60 14.5 14.5

    Table 6-2 - 7.5kW, 6P motor (TH1)

    (for HU10FH model only)

    Motor Specification

    Voltare Frequency Amperage

    (V) (Hz) (A)

    Thermal

    Relay

    Capacity (A)

    200 50 45.0 45.0

    200 60 42.0 42.5

    380 50 22.5 22.5

    440 60 19.5 19.5

    460 60 19.0 19.0

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

    Motor Specification

    Voltare Frequency Amperage

    (V) (Hz) (A)

    Thermal

    Relay

    Capacity (A)

    200 50 15.0 15.0

    200 60 14.2 14.2

    380 50 7.7 7.7

    440 60 7.1 7.1

    460 60 6.8 6.8

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

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    Motor Specification

    Voltare Frequency Amperage

    (V) (Hz) (A)

    Thermal

    Relay

    Capacity (A)

    200 50 29.0 29.0

    200 60 28.0 28.0

    380 50 15.0 15.0

    440 60 13.0 13.0

    460 60 12.7 12.7

    Table 6-6 - 0.1kW (TH3)

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    TH2

    MC2 MC3

    TH3 TH1

    MC1

    K k

    TH1

    TH2

    TH3

    MC3

    MC3

    MC2

    MC2

    MC1

    MC1

    PB3 PB2 PB1

    PB1PB2PB3

    PB

    FUSEPL

    LIS PS HRSV

    IN2IN1 SW

    U V

    CR2CR3

    CR1DRY1 CR4

    *Local wiring (Refer to next pape)

    NFB(non-fuse circuit breaker)

    if the power source is any voltageother than 200 V,make it to 200 V

    Electro-magnetic contactor

    Thermal relay

    L l

    Currenttransformer

    Ammeter

    Single phaseAC 200V

    (Control box)

    (Control box) Emergency stop

    Stop Stop Stop

    Run Run Run

    Fig. 6-13 Wiring Instructions

    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.

    SensorBall valve

    Air cylinder (shutter)

    Air cylinder (roll)Control

    box

    (out)

    (in)

    Actuator valve

    Air (outlet)

    Regulator (for roll pressure)

    Air (outlet)

    valve

    Regulator

    Filter

    Compressed Air(inlet)

    (for regulating the control pressure)

    pressure gauge

    CR1

    CR3

    HR

    FUSEIN1 IN2

    PL SW

    LIS

    DRY1

    CR2

    PS SV

    CR4

    PE

    Externalsensor

    Feedercontroller

    Singlephase

    Earthlamp switch

    SelectorFuse

    Hour meter

    Solenoid

    Speedcontroller

    (out)

    controller

    (in)

    Speed

    Fig. 7-1 Wiring Instructions

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    CR1

    CR3

    HR

    FUSE

    IN1 IN2

    PL SW

    LIS

    DRY1

    CR2

    PS SV

    VU

    CR4

    P2

    P1

    PE

    Externalsensor

    AC200VEarthPilot

    lamp switchSelector Fuse

    Hour meter

    Electromagnetic valveSensor

    Feeder externalsignal

    (Jump wire)

    for feederPower

    8. CONTROL BOX

    8.1 Names and Function of Terminal Base in Control Box.

    Fig. 8-1

    Fig. 8-2 Control Box (Side View)

    Hour meterTimer relay

    Relay

    Socket Changeover switch

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    8.2 Names and Function of Each Part of Control Box.

    Fig. 8-3 Control Box (Front View)

    CAUTION

    Make sure to close the cover of the control box after the wiring work.

    If the cover of the control box is forgotten to close, the electronic parts may damage by dust.

    TP (Terminal Pin)

    UV: Input power source AC 200V single phase

    PE: Earth

    LIS: HU tank paddy detection sensor

    SV: Power of electro-magnetic valve

    PS: For external sensor (PS)

    Fuse (2A)

    Changeover switch

    Hour meter

    Feeder controller

    Pilot lamp

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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.

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    Fig. 8-5 Names of Each parts of Feeder Controller

    Display lamp (RUN)

    - To light on during operation only.

    Display lamp (TRIP)

    -To light on and stop the output when the protection of over-voltage and over

    -current is functioned.

    Frequency adjusting volume (FREQ)

    - To use at the adjusting work of frequency.

    Amplitude adjusting volume (V)

    -To adjust the flow rate of paddy.

    Second amplitude adjusting volume (V2)

    -Not available.

    BOTTOM

    Grommet of output cable

    Grommet of input cable

    Grommet for external

    signal cable

    Output connector for output

    frequency displayer

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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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    START

    Start operation of HU,HA and distribution motors.

    Control boxSet the manual / auto switch at AUTO.

    Any paddy in the HU hopper?WaitNO

    Wait Is the PS hopper empty?Yes

    HU hopper : empty ? PS hopper : full ?NONO

    YES YES

    Close the shutter and release the rolls. Close the shutter and release the rolls.

    PS hopper : full ?YES

    NO

    YES

    NO

    Open the shutter and pressurize the rolls.

    9. AUTOMATIC OPERATION FLOWCHART

    Fig. 9-1 Automatic Operation Flowchart

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    CAUTION

    Adjust air pressure at 0.2 MPa (for rubber roll)

    May occurred % of broken and cracked rice is increased even adjust rubber

    roll air pressure at 0.2 MPa need to check output.

    Adjust proper rubber roll air pressure (depends on material).

    Adjustment of rubber roll air pressure

    a) Pull the handle of regulator.b) Turn the handle and adjust air pressure. Clockwise increase, Counter clockwise -

    decrease

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

    Regulator

    Rubber roll air pressure

    Supplied air pressure

    Emergency stop switchChange over switch

    Feeder Controller

    Pull the handle of regulator

    then adjust air pressure.

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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

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    (3) Once the inspections complete, be sure to attach all safety covers.

    (4) Energize the control box to check the functions of machine components.

    NOTE

    Check the machine motor without running it.

    Keep the paddy hopper unload when conducting any check.

    [HAND]

    (1) Position the change over switch to HAND. (See Fig. 10-2)

    - Paddy feed valve will open. (See Fig. 10-2)

    - Feeder will vibrate.

    - Rubber rolls will be pressurized (brought into contact).

    (2) Restore the change over switch.

    - Paddy feed valve will close.

    - Feeder will stop.

    - Rubber rolls will be released (separated).

    Fig. 10-4 Husker

    Sensor

    Feed valve

    Manual Shutter

    Feeder

    Movable shaft

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    [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 afterpassing 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 : 2ndscale line from right

    Valve D : Middle

    Valve E :For long grain ->open, short grain -> close

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    Valve C

    Valve D

    Feed valve

    Valve B

    Valve A

    Amplitude adjustingvolume

    Change over switch

    CAUTION

    Operate over the rated capacity may cause failure of the machine.

    Fig. 10-5

    Valve E

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    11. OPERATION

    NOTE

    Trial run must be executed before operation.

    11.1 Manual Operation (trial run)

    (1) Open the manual shutter then input paddy in the tank.

    (2) Confirm suction air in the suction pipe.

    (3) Turn power ON.

    (4) Run the machine motor.

    (5) Set at HAND the change over switch on the control box. (See Fig. 10-2)

    (6) Adjust the roll pressure to set husking ratio at about 90% (See 10.

    PREPARATION FOR OPERATION Adjustment of rubber roll air pressure). Turn

    the knob clockwise increase. Counter clockwise decrease.

    (7) Adjust distribution by valve D and E.

    (8) Adjust wind sorting section by valve A, B and C.

    NOTE

    If the tank of paddy separator is full, set change over switch at

    STOP (If the switch is set at HAND, the shutter will not be

    linked with the paddy separator hopper).

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    11.2 Automatic Operation

    (1) Open the manual shutter then input paddy in the tank.

    (2) Confirm suction air in the suction pipe.

    (3) Turn power ON.

    (4) Run the machine motor.

    (5) Set at AUTO the change over switch on the control box (See Fig. 10-2).

    (6) Once the feed valve opens and feeder vibrates to start husking, adjust the roll

    - pressure to set the husking ratio at about 90%. (See 9. PREPARATION FOR

    - OPERATION, Adjustment of rubber roll air pressure) Turning the handle of

    - regulator clockwise to increase pressure (increase the husking ratio) and turning

    - it counter clockwise to decreases the pressure (decreases the husking ratio).

    (7) When the paddy sorting machine hopper becomes full. Feed valve will close,

    - and the roll gap will widen then will stop husking (only when it is linked with the

    - paddy separator hopper.)

    (8) Then, when the paddy separator hopper becomes empty, feed valve will open

    - after a timer of the timer setting to resume husking operation.

    (9) When the husker hopper becomes empty, feed valve will close, and the roll gap

    - widen to stop husking.

    (10) When any paddy comes, feed valve open after a time of the timer setting to

    - resume The husking operation.

    NOTE

    Adjust the feed rate of the husker to keep the fed valve open at

    least 10 min. by amplitude adjusting volume at feeder

    controller. Need to observe the change in the husking ratio if

    the amplitude adjusting volume has been adjusted.

    (11) Adjust the distribution by valve D and E.

    (12) Adjust the wind separation by valve A, B and C.

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    11.3 Adjustment of open and closing speed of movable shaft and feed valve.

    (1) Adjustment of open and closing speed of movable shaft.

    (2) Turn the adjusting screw to adjust open and closing speed of movable shaft. (set

    at 2 seconds and check it during operation). Turn the adjusting screw clockwise

    to slow down the air cylinder motion with the resultant increase tin the time from

    the feed valve opening to the moment the movable shaft roll touches the main

    shaft roll. On the contrary, if it takes too much time for the motion to start, turn the

    adjusting screw counter clockwise.

    (3) Once the adjustment completes, fix the adjusting screw using the lock nut.

    Fig. 11-1 Adjusting the Speed controller

    Speed controller (IN) control air speed for closing rubber roll.

    Speed controller (OUT) control air speed for opening rubber roll.

    Adjusting screw

    Speed controller

    Lock nut

    Decrease

    air speed air speed

    Adjusting screw

    Increase

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    Fig. 11-2 Speed Controller for Movable Shaft Opening / Closing

    (2) Adjustment of open and closing speed of feed valve.

    1) Loosen the lock nut of speed controller.

    2) Turn the adjusting screw to adjust open and closing speed of feed valve.

    Turn the adjusting screw feed valve movement is slower.

    Turn it counter clock wise feed valve movement is faster.

    3) Once the adjustment completes, fix the adjusting screw using the lock nut.

    Speed Controller (OUT)

    Speed Controller (IN)

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    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.

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    (2) See through the access hole of the aspirator to check for straw or any other obstacles that

    may hamper the paddy flow.

    (3) If the thickness of the main shaft rubber roll of the husker has decreased to about the half

    of that the movable shaft rubber roll, replace both main and movable shaft rubber rolls.

    Confirm whether the chute position is proper, when the rubber rolls replace into new

    ones.

    Fig. 12-1

    (4) Over a long period of use, the sorting plate may collect scum as from brown rice. Wash

    and clean it from time to time.

    (5) Use the rubber roll of less than 87C (chore) 5C (chore) hardness.

    Maximum hardness of the rubber roll shall be 92 degrees or less.

    (6) The fixing hole diameter of retainer of rubber roll is 116 mm. Dont use the rubber roll over

    the allowance of diameter (0 ~ +0.1 mm).

    Fig. 12-2

    Movable shaft rubber rollMain shaft rubber roll

    1/2

    t

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    (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.

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    (8) Selection of (M10) fixing bolt to join Rubber roll and Retainer 2-2022-0050 for various size

    of Rubber roll.

    CAUTION

    Minimum clearance C shall be more than 1 mm. If not follow this, the fixing

    bolt may touch against the bearing cover during operation. It will cause to

    damage bearing cover, bearings and shaft (Movable and Main shaft).

    Whenever install fixing bolt, do not forget to install plain washer and spring washer.

    A Size (mm) B Size (mm) Remark

    3.2 ~ 7.99 20 M10x20

    8 ~ 12.99 25 M10x25

    13 ~17.99 30 M10x30

    18 ~ 22 35 M10x35

    Fig. 12-3

    Fig. 12-4

    Rubber roll

    Retainer Bearing cover

    Ball bearing 6309DDU

    A

    C

    C

    D

    Detail D

    Rubber rollM10 Fixing bolt

    A

    Plain Washer and Spring washer= 2 ~ 5 mm.

    B

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    (9) Adjusting of plate

    CAUTION

    Never fail to adjust the clearance between plate and rubber roll to avoid

    accident whenever rubber rolls are replaced. It may cause the trouble of

    the burning of rubber roll or the coming off plate when the machine is

    operated in a contacted condition of palate and rubber roll.

    1) After replacement of rubber rolls, loosen the lock nut at the front cover by turning it

    counterclockwise and fasten the adjusting nut by 3 turnings clockwise. At this time,

    keep the front cover open.

    2) Close the front cover securely by fastening the knob.

    3) Loosen the adjusting nut until plate and rubber roll contact.

    After contacted fasten the adjusting nut by one turning clockwise.

    4) Lock the adjusting nut by fastening the lock nut.

    CAUTION

    It may cause the trouble of the burning of rubber roll or the coming off of

    plate when the machine is operated in a contacted condition of plate and

    rubber roll.

    Rubber roll

    Adjusting nut

    Knob

    Front cover

    Adjusting nut

    Lock nut

    Lock nut

    Front cover

    1 ~ 2 mm

    Clearance

    Plate

    Fig. 12.5

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    Window B

    Handle

    Chute

    (Limit area of rubber roll)

    Movable rubber roll

    Main rubber roll

    BlueYellow

    Red

    Blue

    Yellow

    Red

    Sticker (B)Chute

    Thick

    ness:T

    Window A

    Sticker (A)

    (10) Adjustment of chute

    NOTE

    For maintaining the performance of machine, conduct the adjustment of chute

    depending on the wearing (remaining thickness of rubber) of rubber roll.

    Fig. 12-6 Front View of Husker

    1) Check rubber roll thickness of main shaft side through inspection window A whether itis at red, yellow or blue of sticker (a).

    Fig. 12-7 Inspection Window A

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    Chute

    Thick

    ness:

    T

    Yellow

    Red

    Window B

    Sticker (B)Blue

    2) Change the chute inclination by turning handle so that chute position sets on the

    - same color of step though in section window B.

    Fig. 12-8 Inspection Window B

    3) Gradually, main shaft rubber roll turns the position of yellow and red by wearing (see

    window A). Confirm the chutes inclination also follow the color at window B.

    - (Chutes 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

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    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.

    CAUTION

    No pour of grease may cause the failure of machine like the

    wearing of bearing and occurrence of vibration.

    Pour genuine grease sufficiently till the grease comes out from the

    clearance.

    Fig. 12-9 Grease nipple (1)

    Bearing cover

    Gylindrical bearing

    Cover

    Grease nipple

    Grease nipple

    Grease nipple

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    Fig. 12-10 Grease nipple

    Driven side : Pour grease after removing safety cover.

    (12) Discharge of drain

    CAUTION

    Turn off the power prior to the discharge of the drain.

    Be careful the compressed air does not exceed 0.95 MPa

    (9.5 kgf / m2) because the air control unit may break.

    Discharge the drain before it will reach at the baffle plate of air filter.

    If you fail to discharge the drain, the machine may cause the

    breakage.

    The air control unit is necessary to remove the dust and water in the compressed air and to keep

    the smooth movement of an air cylinder and a solenoid valve. The drain must be discharged

    before it will reach at the maximum line i.e. the baffle plate in the air filter. The discharge of drain

    is done to push up the lower tub of air filter as below figure.

    Grease nipple Grease nipple

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    (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 method1) Remove the cover (main body)

    2) Remove louver 2

    3) Remove air separator

    4) Clean the inside of the boy.

    Once cleaning is over, reverse the procedure to refit the cover. Make sure valve C

    can open and close smoothly, after reassembled louver 1.

    Inlet air

    Air filter

    Regulator

    Baffle plate

    Max.line

    Detali of inspection window

    TubePush

    Fig. 12-11

    Fig. 12-12

    Air separator

    Cover

    Louver 2

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    (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 Hzat factory shipment).

    4) Meet the frequency in case of except above situation.

    (1) Set amplitude adjusting volume [V] at50notch.

    (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 : 51Hz).

    Fig. 12-13

    Amplitude adjusting Volume [V]

    Frequency adjusting Volume (FREQ)

    Power Switch

    Digit meter

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    (14-2) Adjustment of clearance between magnetic coil and trough mount.

    1) Loosen the bolts of magnetic coil fixture base.

    2) Insert thickness gauge clearance between magnetic coil and trough mount and set

    -- clearance at 2.3 mm.

    3) Tighten the bolts of magnetic coil base.

    4) Confirm the clearance at 2.3 mm.

    Fig. 12-14

    (14-3) Adjustment of feeder setting position.

    1) Check the abnormal nose to contact with feeder if a contacting noise or abnormal

    - noise comes out from the feeder during the husking.

    2) Remove the cover under the feeder.

    3) Loosen four bolts of feeder.

    4) Adjust the clearance by moving the feeder. Check whether there is no contact point

    - or any smaller clearance by the above movement.

    5) Fix the feeder and cover.

    Trough mount Magnetic coil

    Hex. Bolt

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    60

    (14-4) Adjustment of feed valve setting position.

    1) Remove cover.2) Loosen the fixing bolts of feed valve.3) Adjust the position of feed valve so that the feed valve puts the trough as

    Fig.

    4) Fasten the fixing bolts to adjust clearance between both left and right side offeed valve and trough is the same.

    5) Fix the cover.

    Feed valve

    Cover

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    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.

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    Fig. 12-16 Sensor Fixing Fig. 12-17 Jump Wire

    Conduct the sensitivity adjustment, if there is any abnormality at the above points.

    (1)Check there is no paddy in the tank.(2)Turn the sensitivity adjusting volume of sensor counterclockwise until LED lightens on.(3)Check if LED lightens out when the paddy is fed into the tank. If LED does not lighten out,

    conduct the procedure from No. (1) again.

    Fig. 12-18 Sensor

    LED

    Sensitivity adjusting volume

    Jump Wire

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    (16) Replacement method of tension guide and tension.

    CAUTION

    Turn OFF the power before the work.

    1) Turn OFF the power. Push the emergency switch.

    2) Remove the safety cover guide.

    3) Remove V-belts.

    4) Remove the tension. Make sure the positions of each tension.)

    5) Remove the tension guide. Replace the tension and tension guide together.

    6) Refit in reverse order after the completion of the replacement.

    Refer to below figure on the position of the factory shipment.

    Fig.12-19 Aspirator Driven Part

    Tension

    Tension guide

    V - BeltTension

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    13. TROUBLESHOOTING

    WARNING

    Before maintaining the machine, isolate the machine from the power supply.

    Refit the safety cover after maintenance.

    If the troubles are not remedied even after taking measures following the

    below instructions, contact your nearby distributor. See the contact address

    of Satake group companies at the end of this manual.

    Conditions of Failure Cause Action to Take

    - Insufficient roll pressure. - Adjust the pressure.

    - Tighten the handle (2) (roll pressure adjustment) to

    increase the pressure as to set the husking ratio at about

    90% without any damage on the grain skin.

    - High water content of the paddy. - Measure the water content, and adjust it to a right level.

    - Worn rolls. - If the main shaft roll is smaller in diameter than the

    countershaft roll, exchange the right and left sides.

    - Replace them with new ones.

    - Excessive feed rate. - Decrease the feed rate sing the feed rate adjusting

    handle.

    1. Poor husking ratio.

    - Belt slippage. - Tighten the tightener to the level where the belt bends

    10-20 mm as pressed with fingers.

    2. Unable to increase

    the feed rate.

    - Valve blocked by foreign

    materials.

    - Remove the foreign materials.

    - Reinstall the piping.

    3. Much husk

    included in the

    husked rice.

    - Maladjusted wind-sorting section.

    - Belt slippage.

    - Husking is often interrupted.

    - Too much feed rate.

    - Blocked louver.

    - Adjust the valve (see the manual).

    - Tighten the belt.

    - Use the valve to decrease the feed rate, and avoid any

    long duration of interruption wherever possible.

    - Clean the louver.

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    Check list in manual operation.

    Checklist on Electrical and Air Systems in Manual Operation.

    Condition of Failure Cause Action to Take

    1. Does not power on (pilot

    lamp does not illuminate).

    - The power switch of the paddy husker control

    panel is not turned on.

    - Boken cable.

    - Brown fuse (F1) on the front of the control box.

    - Turn on the switch.

    - Check the conductance of the power

    cable.

    - Replace the fuse (2A).

    2. Shutter does not

    open/close.

    - No or insupplicient air feed.

    - Fault with the air cylinder (for shutter).

    - Check valves etc. Ensure the air feed.

    - Replace the air cylinder.

    3. Rolls do no open/ close. - Fault with the air cylinder (for rolls).

    - Faulty with the speed controller.

    - Faulty with the regulator.

    - Excessive tension of the driving hex belt, or

    wrong belt routing.

    - Fault with the air valve.

    - Replace the air cylinder.

    - Replace the speed controller.

    - Replace the regulator.

    - Adjust the belt tension. Check the belt

    routing, and reinstall the belt if necessary.

    - Replace the air valve.

    4. Neither shutter nor rolls

    function

    - Fault with the HAND/AUTO change-over switch.

    - Blow fuse on the panel.

    - No or insufficient air feed.

    - Fault with the solenoid valve.

    - Replace the switch.

    - Replace the fuse (2A).

    - Feed air (0.5 MPa or more).

    - Replace the solenoid valve.

    Fig. 12-1 Fuse position of feeder controller.

    Fuse 2A

    Bind Head Screw

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    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 Part No. Part Name Qty Condition of Replacement Remark

    220110085 Plate 1 Worn out more than 2 mm.

    220280440 Plate (side plate) 1 Worn out more than 2 mm.

    220300510 Chute 1 Paddy does not flow smoothly. Paddy is flown.

    0114021 Felt ring 1 Dust leakHU

    TC110309 Bearing 4 Have Vibration. Main and

    movable shaft

    TD13A047 V Belt A - 47 1 Worn out, slippage

    TD13A062 V Belt A 62 1 Worn out, slippage.

    TD13B065 V Belt B 65 2 Worn out, slippage.

    TD13B066 V Belt B 66 2 Worn out, slippage.

    TD13B067 V Belt B 67 2 Worn out, slippage.

    TD13B068 V Belt B - 68 2 Worn out, slippage.

    225131400 Conveyor Screw 1 Cannot distribute even valve is closed.

    Husked rice passes only at the center portion.

    For dividing

    T038106 Plate 2 Husked rice cannot discharge.

    225131250 Dividing Valve 1 Has no efficient distribution.

    225131420 Conveyor Screw 1 Has clogged due to lower capacity of conveyor For mixture

    225131410 Conveyor Screw1

    Cannot convey husk that is remained much

    when seeing trough the inspection window.

    For husk

    225130540 Screw case1

    No distribution by a big worn hole of screw

    case.

    225130660 Screw case 1 Worn hole of screw case.

    225130670 Screw case 1 Worn hole of screw case.

    225131610 Tension 2 Tension is much loose.

    225133620 Husked rice side

    HA

    225133630Tension guide 1 Tension is much loose.

    Husk side

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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: [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]

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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: [email protected]

    Home Page : www.sataketh.com