Manual VTA15AB (2) T
Manual VTA15AB (2) T
Manual VTA15AB (2) 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 on hand for reference whenever any operation, maintenance or inspection is being carried out.
CONTENTS
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 the Machine ....................................................................................................16 6.2 Confirming Levelness...................................................................................................17 6.3 Positioning ....................................................................................................................17 6.4 Floor Selection.............................................................................................................. 18 6.5 Maintenance Space .....................................................................................................18 6.6 Feeding Pipe Installation ..............................................................................................19 6.7 Motor Pulley Size ..........................................................................................................19 6.8 Installation and Weight Components ...........................................................................20 6.9 Fitting the Motor ...........................................................................................................21 7. PREPARATION FOR OPERATION ............................................................................................22 7.1 Inspecting Belt Tension and Milling Chamber .............................................................22 7.2 Inspection in No-Load Operation .................................................................................22 7.3 Belt Tension Adjustment...............................................................................................23 7.4 Air Flow Rate Adjustment .............................................................................................24 7.5 Initial Adjustment of Abrasive Rollers ...........................................................................24 8. OPERATION .............................................................................................................................26 9. RESISTANCE PLATE ADJUSTMENT ........................................................................................28 10. MAINTENANCE AND INSPECTION ........................................................................................30 10.1 Periodic Check .............................................................................................................30
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10.2 Periodic Cleaning ........................................................................................................30 10.3 Abrasive Roller Surface Maintenance .........................................................................31 10.4 Inspection Schedule ...................................................................................................32 10.5 Screen Rotation and Replacement .............................................................................33 10.6 Removing Feed Roller and Abrasive Roller ................................................................35 10.7 How to Detach Feed Roller from its Holder .................................................................36 10.8 Replacing the Resistance Plate ..................................................................................37 10.9 Grease Supply ............................................................................................................38 11. TROUBLESHOOTING.............................................................................................................39 12. LIST OF CONSUMABLE PARTS .............................................................................................41 CONTACT INFORMATION ........................................................................................................... 43
1. LIMITED WARRANTY
This machine was produced under quality control and inspection. The warranty of service for any problems under normal use for this machine shall extend for a period of one year beginning on the date of purchase. 1. Please contact your branch or sales office for repairs or service. All repairs within the warranty period will be carried out free of charge provided they occur under normal use conditions. Fees for any repairs after the warranty period will be billed to the customer. We shall be entirely free from any responsibility and/or liability in the case of any failure which is caused by the following: (1) Damages & losses caused by unauthorized modification or repair of the machine. (2) Damages & losses that are the result of disaster (fire, flood, storm and earthquake etc.), pollution, unusual voltage or damage by sea air (rust). (3) Damages & losses due to Relocation and/or transfer of equipment from the location where initially assembled, erected, constructed and/or installed by the client and/or user (4) Damages & losses due to the use of unauthorized spare parts or repair at an unauthorized agency or factory. 2. Supply of spare parts for this machine is limited to 7 years after discontinuance of production. Within that period, certain special parts may be accepted from the stated availability. The supply of spare parts for this machine will principally finish at the above limitation of supply; should the client desire spare parts after the limitation of supply, we may be able to submit a spare parts quotation. All warranty information, machine features and specifications are subject to change without notice.
3.
4.
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2. SAFETY
WARNING
Do not perform any operation, maintenance or inspection until you have read and fully understood the contents of this instruction manual. Keep this manual on hand for reference whenever any operation, maintenance or inspection of the machine is being carried out.
During operation, maintenance, or inspection, always follow all instructions
and warnings as stipulated in this manual. If you have any questions or require clarification on any point, suspend operation of the machine and contact the Satake office listed at the end of this manual.
Satake shall not be responsible for any injury, loss or damage caused by
failure to observe instructions in this manual, by misuse or by unauthorized modification of the machine.
This chapter describes and defines all hazard warnings as well as safety precautions to be observed during operation, maintenance, or inspection. Precautions are classified into two groups: General Instructions and Safety Precautions.
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WARNING
Shows a potential hazard. Failure to adhere to this warning may result In fatal or serious injury. Shows a potential hazard which follow this, presents the possibility of minor injury, damage to the equipment or mutilation of the product. This is used for calling special attention or adding emphasis to certain information requiring notice.
CAUTION
NOTE
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safety during operation, inspection, or maintenance of this machine. (1) Operator must have his hair cut short and wear clothes and shoes that are free of stray or loose fabric in order to protect from inadvertent contact with machinery. Always wear a helmet and safety shoes when carrying out any inspection or maintenance. (2) Ensure that passages around the machine, as well as all surrounding areas, are kept clean at all times. (3) Keep water and other liquids away from the machine. Contact with water or other liquids can short electric circuits, subsequently causing the machine to break down. (4) Always properly ground the machine in order to protect personnel from fires or electric accidents caused by current leaks. (5) Do not touch any live moving parts while the machine is powered on. (6) Keep the operating area clear of any people other than those permitted by the operator. Never let children near the machine. (7) Always 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 on the control panel. (8) Always power off before inspection and maintenance and affix an "Under Inspection" sign over the power switch. After the inspection, be sure all tools are picked up.
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(9) Check all bolts, nuts, and belts for any looseness or damage. Be sure to replace all covers after completing this check. (10) Check for any cuts or damage to power cords, wiring, and cables. Ensure that all connectors and plugs are seated properly (11) Operate the machine with all covers in place. Do not attempt to remove any cover while the machine is running. (12) Always stop the machine before adding grease. (13) All operators must familiarize themselves with the power off procedure in case of emergency. (14) When two or more persons operate the machine, each person must confirm readiness to the others before starting the machine. (15) Do not permit any person who has not been properly trained to operate the machine.
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gasoline. If a sticker is damaged, lost, or illegible even after cleaning, replace it with a new one. This machine is provided with warning stickers in locations where special precaution is required. It is important for operators to know the location and content of each sticker and to follow all instructions in order to prevent accidents.
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T037214
T037212
Fig. 2-1 Location of Warning Stickers
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T037213
T037212
3. SPECIFICATIONS
Model Input Capacity Required Power Revolution of Main Shaft Size of Bran Suction Outlet (option) 6 ~ 10 tons/hr. 55kW, 6P. or 75kW, 6P 450~500 RPM
VTA15AB(2)-T
12 inches
( 14 inches)
Air Volume & Static Pressure 70 M3/min, - 1.0 ~ - 1.5 KPa for outlet 12 (option) Net Weight (without motor) Shipping Volume (85 M3/min, - 1.0 ~ - 1.5 KPa for outlet 14) Approx. 1,750 kg Approx. 10 M3
Input capacity varies with rice variety and parboiling methods. Figures of Air Volume & Static Pressure are in no condition to mill the rice.
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4. DIMENSIONS
Unit: mm
808.5 25 822 50 25 950
O 12" or 14" O 6"
955
150
847
698
830 1782
952
427.5 1317.5
890
Fig. 4-1
14
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875
2265.4
5. CONSTRUCTION
Inlet Feed valve Abrasive roller Weight Control lever Motor Feed roller Screen
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6. INSTALLATION
6.1 Rigging the Machine CAUTION
Use a wire with sufficient strength to support the machine (weight
When transferring or installing, use the four plates attached to the machine. Take extra care not to damage the side cover or other parts.
Fig. 6-1
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M16 bolts. Set the machine in the specified position and make sure that it is horizontally level. If not, insert a liner at the bolt position to adjust the levelness of the machine, and then bolt it securely to the floor.
6.3 Positioning
Unit: mm
808.5 822
950
Fig. 6-2
17
955
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1000
1000
1500
1000
500
500
1000
500
Fig. 6-3
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19
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lever. Use care when attaching it into the control lever and setting its position. 6.8.1 Weight Components
(Screw) (Spring) (Bearing) (Weight)
A
Fig. 6-5
Fig. 6-6
Weight assembly Fix two levers on shaft as shown in Fig. 6-6. Install weights on levers. Adjust spring as follows: (1) Turn the screw clockwise to make the spring stronger, using a flat-head screw driver. (2) Slide the weight on the control lever to check the strength of spring. (3) Turn the screw further clockwise if it is not strong enough and counterclockwise if it is too strong.
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Motor
Make an opening
Safety cover
Fig. 6-7
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Cover
Fig. 7-1
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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. Adjust the tension of the belt after coupling of the belt. (2) Maintain proper tension on the 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 the span. Adjust the tension of the belt so that the flexion load is between 7.1 kgs and 10.6 kgs(9.2 kgs when re-tensioning an old belt). The optimum belt tension is that the belt should be as slack as possible, but still tight enough so that the belt does not slip when the maximum load is applied. It is important to maintain belt tension between 7.1 kgs and 9.2 kgs. Excessive tension exceeding 10.6 kgs may shorten durability of belts and bearings, while insufficient tension (less than 7.1 kgs) may cause slips.
Span length
Load of flexion
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After belt tension is properly adjusted, run the machine for a few minutes and make sure that the belt is not excessively loose. To test the belt tension, 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.
Display an UNDER INSPECTION sign. Adjust the air flow rate so that the static pressure meter located on the back of the machine indicates -1.0~ -1.5 KPa when the secondary air inlet is fully closed.
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 will eliminate anti-corrosive oil in the milling chamber. If the machine enters into a regular operation without a break-in operation, bran may to stick to the rollers, rice whitening may be uneven, or accidents may occur. Therefore, make sure to conduct a break-in operation before starting normal operation of the machine. Also, always perform a break-in operation when you operate the machine after a long absence or you have changed an abrasive roller.
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Lay out a circulating line, and perform the breaking-in operation of the abrasive rollers using about 300kgs milled rice according to the following steps. (1) Put the milled rice into the tank. (2) Set the 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. Ultimately, operate at the rate of the flow stipulated in the specifications. (5) Adjust the weight on the control lever so the machine operates at the rated electric power. Moving the weight further away from the machine body will increase the power used, and moving it closer will decrease the power used. (6) After about 10 minutes of operation, discharge the rice grains outside of the machine.
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8. OPERATION
WARNING
Do not open the cover during operation. Never put your hand inside the machine without first locking the motor. It
will take about 5 minutes for the main shaft to stop completely after the electric power is switched off.
CAUTION
There is a possibility of tripping the machine motor circuit breaker when
abruptly adjusting the rice flow rate or the weight on the control lever. (1) Turn on the rice-bran fan motor switch. (2) Turn on the machine motor switch with the feed valve in the closed position. (3) Operate the machine with no materials loaded and check for unusual vibration or noise. (4) Attach the smallest weight to the control lever, and open the feed valve. (5) The rice milling chamber fills with rice grains, milled rice is discharged, and the flow of electricity stabilizes. After that, adjust the weight while paying attention so that the electric current does not exceed the rated value specified.
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If the machine motor has tripped and is unable to rotate in spite of attempted re-start-up, or if the operator wishes to discharge the remaining rice grains from the machine, follow the restoration procedure described below: Terminate the operation (Power off). Stop suction and take off all 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 rice grains are blocked in the milling chamber and it is difficult to take them out, conduct inching operations (start and stop the motor in small increments) to attempt to loosen the cluster of rice grains. Then vacuum then out. Long-hour inching or repeated inching may damage the magnetic contractor of the motor. If the motor will not run despite inching efforts, power off and dismantle the machine to take out residual rice grains.
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plate; hang an Under Inspection sign over the power switch. (1) Remove the Frame cover and side covers of the machine, and then remove the screens. (2) Loosen the lock nut and adjust the clearance between the abrasive roller and the resistance plate by turning the knobs until the clearance is 6 mm according to the clearance gauge. (3) Refer to Fig. 9-1, 9-2 and 9-3.
Clearance wider Clearance between abrasive roller and resistance plate Cover for Frame (Ass'y)
Fig. 9-1
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NOTE
The clearance should be adjusted in accordance with the length of rice grain.
Fig. 9-2
Abrasive roller
Fig. 9-3
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6 mm
the machine has been completely stopped. The main shaft will continue to run for about 5 minutes after the stop button has been pressed.
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contact your distributor or Satake sales agent. (1) When the roller surface is clogged with bran, use a wire brush to clean the surface. (2) In case of an indented surface or roughened grooves on the roller, the problem must be rectified with a dresser. Contact your distributor or Satake sales agent.
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Be sure to lock the motor before inspecting. (It will take about 5 minutes for main shaft to stop completely after electric power is switched off). Content
Frequency
Run each mechanism separately, and check for any unusual noise. Check for any unusual heat at bearings after 10 minutes or more of continued operation. Replace the bearing if any abnormal conditions are found. The belt tension is appropriate when the belt deflects approximately 10 mm when pressed lightly with a finger. It can be used until it breaks or deforms. Replace the abrasive roller when it loses 6~10 mm of diameter. Replace it when the plate loses approximately 1/3 of its full width. Once a week Every 3 months Every 3 months Every 3 months Once a month
V-belt tension
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Knob bolt
Loosen the knob and remove the bolts from the covers.
Fig. 10-1
Fig. 10-2
Frame (Ass'y) Hex.Nut(M30) Loosen Fasten
Loosen the Hex. Nut (M30) and remove the fixture from the frame.
Fixture
Fig.10-3
33
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Screen Frame
Fig. 10-4
Turn the screen upside down and reassemble with frame. Reattach the screen, frame (Assy) and cover by reversing the directions on the preceding page.
Fig. 10-5
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Fig. 10-6 After unscrewing the bolt (left-hand thread), remove the feed roller (with holder) and the abrasive rollers from the main shaft one by one.
Spanner Bolt Washer Feed roller Abrasive roller
Mount the new abrasive rollers and re-assemble the remaining part in reverse order.
Fig. 10-7
35
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Detach the feed roller from the holder by removing four Hex. Bolts.
Fig. 10-8
Fig. 10-9
36
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EAG08025 A Hex. socket head cap bolt 3-M8x25 261020560 Base 261020625 Screw 261021070 Pin 261020610 Boss 261020575 B Resistance plate 261020600 Spacer FM30H018 Stop ring H-18 ERBB30 Plain washer 2-M30 T025071 Hex.nut 2-M30xP2 ERBB10 Plain washer 2-M10 EBA012 Hex.nut 2-M10 EEC25016 Spring roll pin 2.5x16 EHGEKT050 C Knob EAG08020 Hex. socket head cap bolt 8-M8x20 261020535 Plate 261020510 Frame 261020640 Fixture EMU1025 E High nut 2-M10x25 FZ011611043 D Knob EAA10080 Hex.bolt M10x80 FZ000280121 SKN10 Super knob cap 118780 8-Sticker
Fig. 10-10 (1) Loosen the Hex. socket head cap bolt and remove the resistance plate .
(2) Fix the new resistance plate to the frame with the Hex. socket head cap bolt. (3) Adjust the clearance between abrasive roller and the resistance plate by turning the knobs. Refer to Fig.9-2 and 9-3. (4) After adjusting to desired clearance, fix the resistance plate by turning the knob. (5) Protect the resistance plate by fastening the tightening nut. (6) Re-assemble the remaining parts in reverse order.
37
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Never mix different greases to protect against grease deterioration. Main Shaft Trane super H.T or equivalent Once / 3 years, 100g
Fig. 10-11 (1) Remove the lower front cover from the main body. (2) Set a grease pump in an ancillary tool box. (3) Feed 100g of grease into the grease pump. (4) Move the lever after inserting the outlet of grease pump into grease nipple of main body. (5) Supply all grease inside grease pump into main shaft.
38
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11. TROUBLESHOOTING
WARNING
Isolate the machine from the power supply prior to maintenance. Refit all safety covers after maintenance. If errors are not remedied even after taking the measures outlined in the
following instructions, contact your nearest distributor. See the contact information for Satake group companies at the end of this manual. Conditions of Failure 1. Insufficient flow rate. Cause Action to Take Foreign matter in the Feed Valve. Remove the foreign matter. Replace the worn part. Worn feed roller. Replace the worn part. Worn abrasive roller.
Worn resistance plate.
Large amount of cracked grains. Check the condition of the material. Excessive flow rate. Excessive weight resistance. Worn resistance plate. Indented surface or roughened
Decrease the flow rate to reduce the load. Decrease the resistance. Replace the worn plate. Rectify the surface with the dresser-call your Satake sales agent. Replace.
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Cause Insufficient air flow rate. Inefficiency in screen, abrasive roller, or milling roller due to weardown. Adhesion of bran to screen frame or clogging thereof. 4. Insufficient whiteness. Inferior whiteness in the material grains. Wear-down of screen, abrasive roller or milling roller. Adhesion of bran to screen flame or clogging thereof. Clogging of abrasive roller. Conditions of Failure 3. Rice temperature too high.
Worn resistance plate.
Action to Take Adjust the air flow rate. Replace the worn part.
Remove bran stuck on the frame. Check the whiteness of the material. Replace the worn components. Remove bran stuck on the frame. Remove bran with wire brush. Replace the worn plate. Adjust the air flow rate. Lower the feed rate of grains to a normal level. Clean the screen.
Insufficient air flow rate. Excessive feed rate. Excessive feed rate.
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# 20P T025770 # 24P 261210440 # 30P 261210410 # 36P 261210420 Abrasive Roller # 30P is Standard.
261065530 Plate 8 8
Packing 2 Roller
41
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Qty
Qty
(80, 0.9) 261210750 (85, 0.9) 261210805 (85, 1.0) 261210820 Screen 1
42
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CONTACT INFORMATION
Produced By SATAKE (THAILAND) CO.,LTD. 133 Moo 5 Bangkadi Industrial Park Tivanon Road Pathumthani 12000 Thailand Tel. 66-2-501-1180 Fax. 66-2-501-1188 E-Mail: eng-sth@sataketh.com Home Page: www.sataketh.com
Sold By SATAKE CORPORATION 2-30 Saijo Nishihonmachi Higashi-Hiroshima-Shi Hiroshima 739-8602 Japan Tel. 81-824-20-8539 Fax. 81-824-20-0865 E-Mail: kg-hiroshima@satake-japan.co.jp
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SATAKE (THAILAND) CO., LTD. 133 Moo 5 Bangkadi Industrial Park Tivanon Road Pathumthani 12000 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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