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SATAKE
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.
E-D0371001-00-02
CONTENT
1. LIMITED WARRANTY................................................................................................................. 4 2. SAFETY...................................................................................................................................... 5 2.1 Warning / Caution Types and Meanings ....................................................................... 6 2.2 General Instructions ...................................................................................................... 7 2.3 Special Precautions....................................................................................................... 9 2.4 Warning Stickers ......................................................................................................... 10 2.5 Location of Warning Stickers....................................................................................... 11 3. SPECIFICATIONS .................................................................................................................... 13 4. DIMENSIONS........................................................................................................................... 14 5. CONSTRUCTION..................................................................................................................... 15 6. INSTALLATION........................................................................................................................ 16 6.1 Rigging Method of the Machine .................................................................................. 16 6.2 Confirmation of Levelness ........................................................................................... 17 6.3 Position setting ............................................................................................................ 17 6.4 Selection of Floor......................................................................................................... 18 6.5 Maintenance Space..................................................................................................... 18 6.6 Installation of Feeding Pipe ......................................................................................... 19 6.7 Motor Pulley Size ......................................................................................................... 19 6.8 Component Parts of Weight and Installation ............................................................... 20 6.9 Fitting the Motor........................................................................................................... 21 7. PREPARATION FOR OPERATION ........................................................................................... 22 7.1 Inspection of Belt Tension and Milling Chamber......................................................... 22 7.2 Inspection in No-Load Operation ................................................................................ 22 7.3 Belt Tension Adjustment.............................................................................................. 23 7.5 Air Flow Rate Adjustment ............................................................................................ 24 7.6 Initial Adjustment of Abrasive Rollers .......................................................................... 24 8. OPERATION............................................................................................................................. 26 9. ADJUSTMENT OF RESISTANCE PLATE.................................................................................. 28 10. MAINTENANCE AND INSPECTION....................................................................................... 30 10.1 Periodical Check ..................................................................................................... 30
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10.2 Periodical Clean ...................................................................................................... 30 10.3 Maintenance of Abrasive Roller Surface ................................................................. 31 10.4 Inspection................................................................................................................ 32 10.5 Rotation and Replacement of Screen...................................................................... 33 10.6 Replacement of Abrasive Roller.............................................................................. 35 10.7 Replacement of Resistance Plate............................................................................ 36 11. TROUBLESHOOTING............................................................................................................ 37 12. LIST OF CONSUMABLE PARTS ............................................................................................ 39 EMERGENCY ADDRESS AND TELEPHONE ............................................................................... 41
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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.
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(3) Damages & losses because of disasters (fire, flood, storm and earthquake etc.), pollution, unusual voltage & damaged by sea air(rust). (4) Damages & losses which you moved or dropped the machine after setting. (5) Damages & losses which use of unauthorized spare parts or repair at unauthorized agency or factory. 3. 4. We will supply parts of the machine for 7 years after stop of production. But within this period some special parts are exceptional. Basically, We will stop to supply parts in 7 years after discontinued to produce. But if you have a request to order the parts, We will discuss about it. All warranty informations, machine features and specifications are subject to change without notice.
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2. SAFETY
WARNING
Do not carry out any operation, maintenance or inspection until you have read and well understood the contents of this instruction manual.
Keep this manual at hand for reference whenever any operation,
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Satake shall not be responsible for any injury, loss or damage
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. 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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WARNING
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injury, damages of the equipment / machinery or misconduct in material or product.
CAUTION
NOTE
to be noticed.
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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.
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(4) Do not fail to ground the machine in order to protect a person from being involved in electric accidents and to prevent fires from occurring due to current leaks. (5) Never touch the live parts inside the machine after turning on power. (6) Do not permit any person who has not been properly trained to operate or service the machine. (7) Keep out any person other than those permitted by the operator. Never let children come close to the machine. (8) Do not fail to inspect the machine before starting operation. When carrying out any inspection work, always power off and clearly indicate that the machine is under inspection or maintenance both in the control room and control panel at the work shop.
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(9) Always power off before inspection and maintenance and follow the appropriate lock out procedure. After the inspection, make sure that there are no tools left. (10) Check for any looseness or damage on bolts, nuts and belts. Make sure to restore the cover after the checking. (11) Check for any damages on power cords and wire cables. Also, check for any looseness or disconnection of connectors and plugs. (12) Operate the machine with all covers attached. Do not attempt to remove any cover during the machine operation. (13) Always stop the machine before greasing the driving part of the machine. (14) Operator should well understand the power off procedure for a case of emergency.
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(15) When working with two or more persons, each person must confirm communication with others before starting work.
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(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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(6) Keep alert to the machine, If any abnormality is found, stop the operation and check the machine to ensure safe operation.
NOTE
solvent or gasoline.
In case the sticker is damaged, lost, or illegible, replace it with a
new one.
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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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T037214
T037212
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299001524
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T037213 299001524 T037213 Fig. 2-2 Location of Warning Stickers (2)
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3. SPECIFICATIONS
Model Input Capacity Required Power Revolution of Main Shaft Size of Bran Suction Outlet Air Volume & Static Pressure Net Weight (without motor) Noise VTA5AA-TA 2 ~ 5.5 tons/hr. 22kW, 4P or 30kW, 4P 570 ~ 660 RPM 8 inch Dia. 30 m3 / min, -80 ~ -100 mmAq Approx. 900 kgs
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Approx. 80 dB (A)
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4. DIMENSIONS
Unit : mm
680
499 815
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25
135
4 inch
612
1765
8 inch
2309
2x3 25
726
227
612 1719
767
Fig. 4-1
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882
815
5. CONSTRUCTION
Inlet
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Motor Outlet Lower front cover V-belt V-pulley
Fig. 5-1
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6. INSTALLATION
6.1 Rigging Method of the Machine CAUTION
Use a wire having sufficient strength because the machine weight without motor about 900 kgs.
Use the four plates attached to the machine when transferring or installing the machine. Use great care not to damage the side cover, etc. when carrying and rigging work.
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Plate
Fig. 6-1
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Set the machine at the specified position and make sure that it is placed horizontally. If not, insert a liner at the position of bolt to adjust levelness of the machine. Then, securely fix the machine with the insulation pads for vibration.
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6.3 Position setting
Unit : mm
815
69 25
612
767
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815
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1000 1000 1000 Maintenance space 1000 500
Fig. 6-3
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1500
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Fig. 6-4 Feeding Pipe Connection
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may drop from the control lever when assembling it into the control lever and setting it in position, assemble with care. 6.8.1 Component parts of weight
Screw Spring Steel ball Weight
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Fig. 6-5 Fig. 6-6 Weight assembly
Fixed two levers on shaft as shown in Fig. 6-6. Install weight on lever.
Adjust spring as follow : (1) Turn the screw clockwise to make the spring stronger, using a minus-screw driver. (2) Slide the weight on the control lever to check the strength of spring. (3) Turn the screw clockwise further when it is not strong enough, and counterclockwise when it is too strong.
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Motor
Make an opening
Safety cover
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Fig. 6-7
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Turn off the power switch and the breaker first before starting
examination of the rice milling chamber, and display sign board indicating UNDER INSPECTION.
Turn the pulley with a hand slowly and examine the internal.
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(1) Maintain proper tension of V-belt. Weak tension of V-belt will cause slip, and excessive tension may adversely affect the durability of bearing and the V-belt with resultant failures and accidents on the rice whitener. (2) Inspect the inside of the rice milling chamber for any foreign matters such as bolts and nuts.
Remove the cover on the lower part of the machine, and conduct the following examination:
Cover
Fig. 7-1
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Turn off the power switch and the breaker at first before adjusting
the tension of belts and display a signboard notifying UNDER INSPECTION. (1) Shorten the distance between axes. Always shorten the distance between axes prior to attaching the belt. Give proper tension to the belt after completion of coupling of the belt. (2) Maintain proper tension on V-belt. Belt tension is measured by the amount of load to cause 1.6 mm flexion per 100mm belt span when it is pulled down by a spring scale perpendicularly at the center of span. Tense the belt so that flexion load becomes 5.9 kgs to 8.7 kgs (7.6 kgs in case of renewal of re-tensioning). The optimum belt tension is such that the belt does not slip against maximum load being given to it and yet the belt is tensioned as possible. It is important to maintain belt tension between 5.9 kgs. and 8.7 kgs. Excessive tension exceeding 8.7 kgs may shorten durability of belts and bearings, while weaker tension less than 5.9 kgs may cause slips. Span length 1.6 mm depth flexion per 100 mm span
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Load of flexion Fig. 7-2 Belt Tension
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After a proper tension is given to the belt, run the machine for a few minutes and make sure that no excessive looseness of the belt exists. For a sample test is given to the belt, touch the pulley and the bearing by hand and check their temperatures.
When the pulley is too hot : The belt tension may be too weak or the belt
may be slipping.
When the bearing part is too hot: :The tension of belt may be too tight.
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Display an UNDER INSPECTION sign. Adjust the air flow rate so that static pressure meter located on the back of the machine indicates -80~ -100mmAq at the fully closed state of secondary air inlet.
Turn off the power switch before conducting initial setting of abrasive rollers.
! NOTE
The breaking-in operation is carried out only to remove useless abrasive grain
stuck to abrasive rollers and to sharpen the surface of abrasive rollers, but also to check for leakage of rice grain or bran. In addition, it is for eliminating anticorrosive oil in the milling chamber. If the machine enters into a regular operation without a break-in operation, it may cause brans to stick to rollers surface, uneven rice whitening or accidents. Therefore, ensure to conduct a break-in operation before starting normal operation of the machine. Do not fail to carry out a break-in operation also when you operate the machine after a long absence or you have renewed the abrasive roller.
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Laying out a circulating line, and carry out breaking-in operation of the abrasive rollers using about 500kgs milled rice according to the following steps. (1) Put the milled rice into the tank. (2) Set smallest weights at the roots of control levers of the machine. (3) Start the motor of the machine after starting the rice bran fan. (4) Open the feeding valve gradually and adjust the rice flow rate. And operate finally at the rate of the flow stimulated in the specification. (5) Make the weight of control lever of the machine to operate at the rated electric power. (6) After about 10 minutes operation, discharge the rice grains outside of the machine.
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8. OPERATION
! WARNING
Do not open the cover during operation for safety. Never put your hand inside the machine without lock out the
motor before checking. It shall take about 5 minutes for main shaft to stop completely after electric power is switched off.
CAUTION
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(1) Turn on the rice-bran fan motor switch. (2) Turn on the machine motor switch at the closed position of feed valve. (3) Operate the machine at no load and check for unusual vibration or noise. (4) Adjust the air-volume damper to make the static pressure of -65 mmAq (in case duct diameter is 8 inch). (5) Set the smallest weight into the control lever, and open the feed valve. (6) The rice milling chamber becomes full with rice grains, milled rice begins to be discharged, then the flow of electricity stabilizes. After that, adjust the weight while paying attention to the electric current not to exceed the rated value specified.
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When the machine motor has tripped and is unable to rotate in spite of attempting re-start up, or when the operator wishes to discharge remaining of rice grains from the machine, follow the procedure of restoration as described below: Terminate the machine. (power off) Stop the suction. (or take off all the covers) Remove the cover of the residual grain discharging outlet located on the side of the machine and extract residual grains with a vacuum cleaner. If the rice grains are blocked in the milling chamber, and it is difficult to take them out, conduct inching-operations to loosen the cluster of rice grains and vacuum then out.
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Long-hour inching or repetitious inching may damage the magnetic contractor of motor. If the motor will not run despite of any inching efforts, power off the motor and dismantle the machine to take out residual rice grains.
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Turn off the power switch and the breaker first before starting
adjustment of plate, and display signboard indicating UNDER INSPECTION. (1) Remove the cover for Frame (Assy) and side covers of the machine. Then, remove the screens. (2) Loosen lock nut, and adjust the clearance between abrasive roller and resistance plate by turning the knobs to be 6 mm by using gauge for clearance.
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(3) Refer to Fig. 9-1, 9-2 and 9-3.
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Fig. 9-1
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!
of rice grain.
NOTE
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Fig. 9-2
Plate Resistance plate Gauge for clearance adjustment
Fig. 9-3
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complete stop of the machine. Be careful especially because the main shaft of the machine keeps running for about 5 minutes even after the stop button is depressed.
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Periodically check that fastening bolts are securely fastened.
The following positions are likely to gather bran, which should be cleaned on a regular basis. Parts to be cleaned periodically Frequency
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NOTE
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Be sure to lock out the motor before checking. (It shall take about
5 minutes for main shaft to stop completely after electric power is switched off). Item Bearing failures (noise / heat) Content
Run each equipment separately, and check for
Frequency
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Replace the bearing if any abnormal conditions
Once a month
V-belt tension
Once a week
Every 3 months
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Side cover
Fig. 10-1
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Frame ass'y Hex.Nut(M30) Loosen Fasten
Remove the screen from the machine. (3 pieces)
Loosen the Hex.Nut (M30) and take off the fixture from the frame assy. (3 sets)
Fixture
Fig. 10-2
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Screen Frame Fig. 10-3 Turn the existing screen in reverse of up and down and assemble the frame and its screen.
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Assemble in reverse turn as above , , , Fig. 10-4
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Fig. 10-5
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Spanner
After taking off the bolt (leftthread) remove the feed roller and the abrasive rollers and plate from the main shaft one by one. Assemble the new abrasive rollers.
Bolt
Fig. 10-6
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Fig. 10-7 (1) Loosen the Hex.socket head cap bolt and remove the resistance plate . . (2) Fix the new resistance plate by Hex. socket head cap bolt (3) Adjust the clearance between the abrasive roller and the resistance plate by turning the knobs . Refer to Fig. 9-2 and 9-3. (4) After finishing adjustment into desired clearance, fix resistance plate by turning the knob . . (Must fit with body). . (5) Adjust Support plate (6) Make the protection of looseness of resistance plate by fastening the Hex. nut (7) Assemble the remained part in reverse turn.
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11. TROUBLESHOOTING
! WARNING
Before maintenance the machine, isolate the machine from the power supply. Refit the safety cover after maintenance. If the troubles are not remedied even after taking measures following the
below instructions, contract your nearby distributor. See the contact address of Satake group companies at the end of this manual. Cause Action to Take 1. Insufficient flow rate. Foreign matter in the feed Valve. Remove the foreign matter.
Worn feed roller.
Conditions of Failure
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Replace the worn part. Replace the worn part. Check the material condition.
Worn abrasive roller. Worn resistance plate.
grains.
Decrease the flow rate to reduce the load. Decrease the resistance load. Replace the worn plate. dresser.
Indented surface or roughened. Rectify the surface with the Grooves of abrasive roller. Worn screen.
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Cause
Worn milling roller. Insufficient air flow rate. Inferior efficiency of screen,
Action to Take Replace the worn part. Adjust the air flow rate. Replace the worn part.
4. Insufficient whiteness.
abrasive of milling roller due to wear down. Adhesion of bran to screen frame Remove the bran stuck on or clogging thereof. the on the frame. Inferior whiteness of the material Check the whiteness of the grains. material.
Wear down of screen, abrasive or Replace the worn
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Adhesion of bran to screen flame Remove the bran on the
components. frame.
Remove the bran with wire brush. Replace the worn plate. Adjust the air flow rate.
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# 24P 261220440 261230530 Plate # 30P 261220410 # 36P 261220420 Abrasive roller # 30P is Standard 8 6
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Qty
Qty
(80, 0.9) 261230750 (80, 1.0) 261230760 (80, 1.1) 261230830 (85, 0.9) 261230800 (85, 1.0) 261230820 (85, 1.1) 261230810 Screen
261221050 Case 1
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3 261221360 Plate 1
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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
SATAKE
133 Moo 5 Bangkadi Industrial Park Tivanon Road Pathumthani 1200 Thailand Tel. 66-2-501-1180 Fax. 66-2-501-1188 E-Mail: eng-sth@sataketh.com Home Page : www.sataketh.com
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