Sam Jackson Technical Staff & Network

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3 Sam Jackson Technical Staff & Network Access to the largest technical staff of cotton moisture control in the world is one call away. Our success depends on your success, so we staff our sales and support positions with technically trained personnel that are passionate about helping customers operate efficiently and maintaining a reputation for dependability and integrity. There are a lot of unknowns in the cotton ginning business. Our goal is to make sure that our customers know they can count on us. Below you will find contact information for our offices and our authorized resellers. Our customers have access to our entire staff and you are welcome to call any one of them (or all of them!) with your questions. Main Office - Lubbock, TX Toll-free: Phone: engineering@samjackson.com Factory/Shipping Address Samuel Jackson, Inc Upland Ave. Lubbock, TX Mid-South Office - Leland, MS Phone: casey@samjackson.com Paris Office Phone: +33 (0) serge@samjackson.com Dallas Field Office Phone: neil@samjackson.com Authorized Resellers These resellers have received special training and offer both new Sam Jackson products and technical support. Dixon Services (Sumter, SC) Rafe Dixon Phone: rafe@dixonservices.com Bradberry Services (Smyer, TX) Chris Bradberry Phone: bradberry@samjackson.com Gulf Coast Moisture Consulting (Edna, TX) Clay Whitley Phone: clay@samjackson.com

4 Table of Contents Drying Products Better Drying for Bigger Profits Series Gas-Fired Heaters Series Gas-Fired Heaters Series Oil-Fired Heaters... Hot Box III... Universal Collider Dryer... Air Control 8... Drying System Enhancements... Sam Jackson Engineered Systems Humidification Products Introduction to Moisture Restoration... Humidaire Features Explained... The Static Zapper... Gas-Fired Humidaire Comparison... Gas-Fired: The Humidaire King Mesa... Gas-Fired: The Humidaire Southwest... Glance at Humidaire History... Oil-Fired Humidaire Comparison... Oil-Fired: The Zephyr Humidaire... Oil-Fired: The Humidaire Sahara Lite... Oil-Fired: The Humidaire Sahara... Conditioning Hoppers... Lint Slide Grid... Steamrollers (General)... Steamroller I... Steamroller II Gas-Fired Auxiliary Heater Gas-Fired Auxiliary Heater Oil-Fired Auxiliary Heater... Moist Air Applicator Chart... Tex-Max Microwave Bale Moisture Sensor... A Common Sense Guide to Moisture Restoration

5 Table of Contents Measurement and Control Products Measurement and Control: It s Possible... Moisture Mirror Line... Mirror Comparison Chart... The Reflector... Moisture Mirror 1... Mirror X Software and Operating System... Moisture Mirror 2X... Moisture Mirror 3X... Moisture Mirror 4X... Moisture Mirror Upgrades... Mirror Sensors: The Sled II... Hot Box Inlet Sensor... Universal Sensor... Tex-Max Module Moisture... Seed Moisture Sensor... Tex-Max Bale Moisture... Flow Analyzers... Mirror Accessories: Bar Code Scanner and Printer... Remote Access... Mobile Mirror App... MoistureMirror.com... The Tool Box... Handheld Moisture Meters... Handheld Temperature Sensors... Air Tools... Introduction to Flow Control (Flow Tools)... Flow Tools... Introduction to Fire Tools... Fire Tools: Argus Detectors... Fire Tools: Pierce SawSavers Originally published February Information subject to change. Consult factory for latest details.

6 Your Product Pricing Options Price Points to Fit Any Need Your gin is like no other in the world. Use these symbols to help find the right options for it. Budget Saver Products Budget Saver products are your lowest first cost option. These products use basic and simple to use controls. As part of the cost control in providing these products, a limited inventory may increase delivery times and they do not include start-up services. In some cases, on-site technical service may be available for an additional charge. Gateway Products Gateway products have more features and power than Budget Saver products, but still provide an inexpensive price. Some of these products are eligible for upgrade programs, as the needs of your gin grow. Limited start-up services are provided with some of these products and in many cases, additional services are available at an additional charge. Fusion Products Fusion products feature a blend between good prices and good performance. Because of their wide appeal, these products are generally produced in larger runs, allowing faster delivery in most cases. Many of these products are eligible for upgrade programs. Start-up service is generally included for all domestic installations. Call for more details. Pinnacle Products Pinnacle products have the highest first cost, but also deliver the highest performance, resulting in your best return-on-investment option. These products feature sophisticated, yet easy-to-use controls, packed with features to deliver maximum results. Generous start-up, technical, and training services are included on all domestic installations. 6

7 Drying Products

8 Better Drying for Bigger Profits Drying performance can make or break a gin. Whenever there is talk about a gin, the usual questions are how many stands and what size, what kind of press and how may bales per hour do they run? The answer to the last one is typically reported based on peak speeds and good, dry, clean cotton. These things do matter. They matter a lot. But there is more to the story and overlooking it can be costly. The fact of the matter is that gins don t have the luxury of always ginning good, dry, clean cotton. How a gin performs on the more challenging cotton can determine if a gin thrives and in some cases, even whether or not it survives. DRY A strong drying strategy is your best weapon in ginning challenging cotton. Effective drying sustains higher production rates, resulting in more bales ginned per week and dramatically reducing operating expenses by reducing the time it takes to gin each season s crop. And when conditions and cotton are good, this arsenal of powerful drying weapons pay their way by reducing operating expense for each bale by saving on fuel and electric costs. As you look through this drying section, we hope to make you more familiar with the wide selection of products designed to deliver the benefits of good drying. Benefits like: Increasing your gin s production potential Optimizing your fuel usage Reducing your per bale operational costs Improving your turnouts Protecting grades through better cleaning and staple preservation Improving your drying can help you achieve all of that and there is nobody else in the business with more passion or a better reputation for helping you do it than Samuel Jackson. Give us a call. We would love to discuss the possibilities for your drying strategy. 8

9 1400 Series Gas-Fired Heaters Not just a heater. It s a Sam Jackson 1400 Series Heater. Some gins think all heaters are about the same. If it lights, they figure it s working. Once you try a Samuel Jackson Heater and experience the following benefits, don t be surprised if you never look at another heater the same way again. SimpleShed and SmartShed Technology - Jaw dropping fuel savings Moisture Mirror Compatible - Helps you take full advantage of Mirror features High Air Volume - The only true high air volume heater for gins High Turn Down Ratio - The highest in the industry Operator Friendly - Easy to run and easy to troubleshoot on those rare occasions when you have trouble Dependable - High reliability means very little down time Powerful, Yet Efficient - Fast and stable response gives you output when you need it and saves fuel when you don t DRY Main Line:

10 1400 Series Gas-Fired Heaters SimpleShed saves fuel and money. SimpleShed gives you greater control of your heaters and allows you to confidently gin without using drying fuel when you don t need it. Cotton arrives at your gin at a wide range of moistures. Traditional automatic temperature control from Samuel Jackson allows your heaters temperatures to automatically modulate up and down in response to changes in incoming moisture. SimpleShed offers the ultimate in fuel efficiency by allowing your heaters to automatically turn off when you are ginning dry cotton and automatically turn back on as soon as the moisture exceeds the threshold that you set. You can even define different thresholds for each heater! Look at the following two heater example. DRY There are many times an operator would be comfortable ginning with a heater off, if they only had the ability to quickly turn it back on when needed. SimpleShed gives your ginners this power and reduces your fuel consumption on a heater to zero when it is being automatically shed. ZERO! SimpleShed requires a Moisture Mirror 2X or higher. See the SimpleShed video in the on-line Sam Jackson Cinema for more details. 10

11 The Electrical Control Cabinet If you love unleashing the power of technology, Sam Jackson Heater cabinets are loaded with features giving you options for an unprecedented level of control. More importantly, the controls are designed to be easy to use and non-intimidating. It s a perfect blend of performance, flexibility and intuitive control, allowing you to achieve incredible results from day one. The upper portion of the control cabinet is dedicated to the electrical control components. The touch screen is integrated into the door, allowing all of its functions to be accessed, while the electronics remain protected. A unique mounting design allows the operator easy access to both the touch screen and the control components at the same time. This combined with on-board diagnostics and testing makes troubleshooting and setup easy. DRY Integrated Temperature Control Alarm & Error Display Alarm & Error History Temperature History Graphing Digital Air Flow Indicator Color Touch Screen Easy Field Software Updates Ethernet Communication Diagnostic Testing Easily Connects to Moisture Mirrors Sophisticated, yet simple. Main Line:

12 1400 Series Gas-Fired Heaters The Gas Train A rugged design means its ready for a long life. Refined operation means you ll want it around a long time, too. Self Diagnostics Monitor Valve Operation & Safety Onboard Diagnostics Allow Easy Testing of Valves & Switches Rugged Industrial Components Provide Reliable Operation Engineered Components are Part of the High Turn Down Ratio Design DRY Pressure Switches Report to the PLC Each Heater Has Its Own Gas Regulator Multiple Gas Pressure Gages Aid the Operator in Monitoring Performance In Line Filter Traps Contaminants Cabinet Design Allows Easy Conversion Between 4-Million and 8-Million Configurations 12

13 The Heater Bodies Generous cross-sectional area reduces pressure drop and turbo charges your high-air volume drying system. 4-Million Btu/hr Heater Body 8-Million Btu/hr Heater Body High-Air Volume Friendly Design Burner head designed specifically for cotton gin systems Rugged door features a design which provides easy & quick access DRY Tempered windows to keep an eye on flame quality You probably haven t given a lot of thought to your heater body. Don t worry... we have! The design insures they are simple to install, easy to maintain, and deliver superior results in operation. Don t let your heater be a weak point in your air handling system. Insist on genuine Samuel Jackson Heaters! Main Line:

14 1400 Series Gas-Fired Heaters Pull-Through Installations Our heaters are great for pull-through applications and you ll appreciate all of the thoughtful touches on our screen support design. Samuel Jackson Heaters can be equipped with Screen Support Stands for applications requiring pullthrough operation. These sturdy stands are made of stainless steel and have a generous screen surface area, increasing the minimum time in between cleaning. Screens also remove easily, without bolts or latches, for fast access to the burner heads. (Left: an HG Heater, below: two HG Heaters) DRY 14

15 Push-Pull Installations Versatile mounting options easily accommodate push-pull applications. Samuel Jackson Heaters can be equipped with a push fan kit, allowing them to be mounted on the outlet of a push fan. Push fan kits include an air diffuser sheet to reduce turbulent air flow across the burner head for more reliable lighting and operation. (Left: HG Heater in a basic push-pull installation, below: HG Heater pushpull installation with a plenum) The Push Plenum provides a more advanced installation option for push-pull systems, yielding many benefits. The Push Plenum reduces turbulence through the heater, improving turn-down and saving fuel. Plenum users also experience less trouble with flame rod and spark plug fouling and have easier internal access for those rare times when maintenance is required. DRY Main Line:

16 1400 Series Gas-Fired Heaters Premium Touch Screen Interface The touch screen interface lets the operator and the heater communicate and the conversation can be a simple or as deep as needed to get the job done! The home screen displays all of the heater s priority functions. When needed, heater setup functions are easily accessed and clearly laid-out. DRY Helpful instructions are easily accessed by pressing the question mark on most screens. A full battery of test functions are available for troubleshooting. 16

17 1100 Series Gas-Fired Heaters Solid Heater performance at a savings. The 1100 Series gas-fired heater models were originally introduced in the 1980s. They quickly developed a reputation for dependability and flexibility in the ginning industry. You will still find hundreds of these in service around the world. As a complementary product to the 1400 Series Heaters, we are offering the 1100 Series with a few 21st century touches. You will find the original numerical counter replaced with a much friendlier multiline LCD text display that changes color based on the severity of the warning message. Other features include: Guaranteed Moisture Mirror compatibility for automatic temperature control via analog signals Simple test program for easy setup and troubleshooting A wider operating range than most other heaters, offering fuel savings when lower temperatures are called for DRY Flexible control package allows the unit to be controlled from the cabinet or via an optional remote at the console Available in two models. The 1104 Model is rated at 4-million Btu/hr and the 1108 Model is rated at 8-million Btu/hr Budget friendly, but still loaded with features. Main Line:

18 1100 Series Gas-Fired Heaters 1100 Series Gas Heater Specifications What do you get when you cross your favorite features from our old school heaters with the friendlier interfaces possible with today s control options? A solid heater at a remarkable price. DRY Air volume capacity (max) Temperature control method Combustion sequencing Diagnostic display Temperature control points Operator type Remote control Electrical Fuel Maximum burner rating Air flow sensing Flame sensing Temperature sensor Test program Auto control options Diagnostics SimpleShed compatibility Programmable low fire Error/alarm history 14,000 CFM (1104 Model) 28,000 CFM (1108 Model) PID, 4-20 ma, Honeywell UDC-2500 PLC Backlit LCD multi color text display One included. Cascaded control optional Single oil-tight selector switch Not included. May be easily wired to most existing console controls/plcs 115 VAC, single phase Natural gas or propane 4-million Btu/hr (1104 Model) 8-million Btu/hr (1108 Model) Diaphragm switch, velocity pressure Flame rod Type J thermocouple, no transmitter Basic functions Moisture Mirror compatible (4-20 ma) Basic diagnostic messages on LCD No No 15 event, time stamped, FIFO stack 18

19 1100 Series Oil-Fired Heaters Oil-Fired Drying System Heaters The original HO oil-fired heater was first introduced in the mid-1980s. It had several sophisticated features as well as easy-to-use controls. It eventually made way for the 1200 Series heaters with a more sophisticated control system and a different design layout. In light of recent market trends, we have reintroduced the 1112 heater as an option for gins looking for a reliable oil-fired heater at an economical price. Don t let the term economical fool you, this heater has more features than any other brand of oil-fired heater on the market. Some features include: Industrial Grade Burner Package with a 20:1 turndown ratio for a wide operating range Can be used in a pull-through or pushpull drying system layout Flexible control package allows the unit to be controlled from the cabinet or via an optional remote at the console Guaranteed Moisture Mirror compatibility for automatic temperature control via analog signals DRY Simple test program for easy setup and troubleshooting (HO A Heater shown) The 1100 Series Oil-Fired Heaters are also available in a 7-Million Btu/hr model called the HO Main Line:

20 Hot Box III The multi-function machine for your front end. DRY There is so much more to a Hot Box than meets the eye. Not only does it perform several key functions and perform them well, it can be used to define a strategy for your entire front-end. The Hot Box eliminates the expensive costs and problems associated with a feed control. Or if you do use a feed control, why not fill it with cotton that has been passed through the advantages of a Hot Box first? It s a pick-up point. It s a dryer. It s a wad buster. * * With optional equipment installed. It s a junk separator. It s a moisture sensor. * It s a money saver! 20

21 What s new on the Hot Box III? What s the difference between the Hot Box II and the III? I liked my Hot Box II. I love my Hot Box III. Dewayne Couch Kiech-Shauver-Miller Gin, Monette, AR Specially designed to be tagfree, inlet door-stops keep the heavy door from resting on your belt, protecting it when fans are off. Improved trash gate seal and scroll to minimize jams from small rocks. The new seal is reversible when one edge becomes damaged. A kit is available to easily upgrade your existing Hot Box II to a Hot Box III in the field.* 100% heavier trash gate structural components made of plate steel instead of sheet metal used on earlier Hot Boxes. DRY Adjustable panels to reduce air leakage where the Hot Box III meets the belt conveyor. The trash gate has a 25% larger opening and a more aggressive angle to remove green bolls, trash, rocks and junk. * The Hot Box III Upgrade Kit fits most Hot Box IIs. Consult the factory for details. Main Line:

22 Hot Box III Options Get even more from your Hot Box III. Incoming Moisture Sensor Option The Hot Box cotton inlet gate can be equipped with an incoming moisture sensor. This rugged, stainless steel sensor measures the moisture of the cotton as it enters the Hot Box. Its mounting and design makes it self-cleaning. Since it eliminates the need for a Sled, it requires less belt space and allows a more compact installation. The Flail Option DRY Single-locked cotton dries and cleans better. Unfortunately, transforming a densely packed module into individual locks of cotton is no easy task. Cotton normally leaves the module feeder in clumps. Adding a flail to your Hot Box can help break up those clumps and improve your drying and pre-cleaning efficiency. The flail sits on the Hot Box outlet, where a series of heavy chains rotate at a high speed to break-up cotton as it flows through. (High speed photo of chains in action at left). 22

23 Universal Collider Dryer This dryer packs a huge punch. Based upon the design principles of the Collider Dryer, the Universal Collider is a powerful and flexible solution for gins trying to improve any existing drying system. Unlike the Collider, the Universal Collider doesn t have specific piping and fan requirements, which can save a significant amount of up-front costs on a new installation. Keep in mind that properly sized pipes, cyclones and fans will improve any system, but the Universal Collider lets your gin make these changes at your own pace. Designed to provide gins with an affordable and effective pull-through dryer, its flexible design allows it to perform well in a wide variety of system configurations. DRY In fact, its versatility and performance have helped it find a home in industries drying material other than seed cotton. Versatility and solid performance make the Universal Collider a great option. Main Line:

24 Universal Collider Dryer How the Universal Collider works. The Universal Collider uses several key elements to open and dry seed cotton. Seed cotton enters the Dryer through the splatter back transition. The transition spreads the cotton and breaks open wads. The cotton then splits and passes through the internal collider pieces. As the cotton exits the internal pieces, a high-speed collision occurs creating a single-locking effect on the fiber. There is one last point of slippage as the seed cotton exits the dryer through the bottom transition. The low-pressure drop design is conducive to high-air volume, high-speed collision drying and it can handle capacities of up to 30 bales per hour. Seed cotton traveling in a hot air line enters here. DRY Windows allow you to observe split and collision. A generous access door, allows easy access to the interior of the dryer for baffle adjustments and setup. Cotton and air are split here... and Collide here, which dries and fluffs the cotton. Dried and fluffed seed cotton exit here. 24

25 Construction and Upgradability The Universal Collider is constructed from mild-steel and powder-coated silver, giving it a durable and attractive finish. It ships knocked down, but is easily assembled. Because the entrance and exit transition requirements can vary, these items are not included with the price of the dryer. Drawings for these transitions will be supplied, so that you can have them made by your sheet metal provider. DRY For many users, the Universal Collider offers an intermediate step to a full Collider System. While none of the Universal Collider parts convert into a Collider, we offer two great upgrade options. The first option provides a generous trade-in allowance toward the purchase of a new Collider. The second option allows you to keep the Universal Collider and use it for an additional drying boost in your full Collider System, helping you better dry very challenging cotton. Either option you choose, you ll be pleased to know you preserved much of your initial investment, helping you meet the needs and capacity of your gin as it grows. But don t think you ll be suffering from mediocre drying in the mean time! In fact, don t be surprised if you fall in love with it and keep it around a long time. Main Line:

26 Air Control 8 Get more air and more drying when you need it! Did You Know? Centrifugal fans work hardest when your gin is idle and move the least amount of air when you need it the most...while you are ginning your fastest! A cotton gin s performance is heavily dependent on its air systems. Fans are the engines that drive air and cotton through your gin, but the amount of air a fan moves is inversely proportional to your ginning rate. It moves more air when you are idle than when you are ginning! The faster you gin, the less air your fan moves, depriving your drying and conveying systems of valuable air volume when you need it the most. Air Control 8 offers an easy way to get more out of your fans and increase your gin s production. Air Control 8 can boost your air by 30%! When it comes to drying, there is no disputing the advantages of maintaining a high air-to-cotton ratio - your cotton moves better, dries better and cleans better! DRY The Air Control 8 monitors the loads on your drying system and other key centrifugal fans. Whenever the load drops, the control either opens the Banjo or speeds up the variable frequency drive (VFD) on the fan, giving you more air. On drying systems, this can boost your hot air volume by 30%, giving you the benefits of a higher air to cotton ratio. Whenever there is a reduction or pause in your ginning rate, the Air Control 8 senses the increased load and adjusts the Banjo or VFD on the fan to reduce the airflow to a safe level to keep your fan motors from overloading. All of this happens automatically and continuously, keeping your airflow optimized and helping you gin faster and more efficiently. 26

27 Standard fans lose performance... The load and air volume of a standard fan falls as you gin faster, resulting in less air when you need it the most. But, with an Air Control 8... The fan motor load is constantly monitored. DRY The control adjusts the Banjo or VFD to maintain the set point. Your fans stay fully loaded (green line) even as your ginning rate increases. This gives your systems more air and all of the benefits that go along with it. Main Line:

28 Air Control 8 The Banjo II Option The Banjo II provides a mechanical method to control the load on your fan motor. Using a Banjo II, the fan speed stays constant. The specially designed Banjo outlet and internal vane work together to induce a swirling airflow into the fan. The direction of the swirl is the same as the fan s blast wheel. The more the vane tilts, the greater the swirl and the more the fan is unloaded because it is moving less air. When the vane is in the fully open position, there is no swirling action and the fan is allowed to move the maximum amount of air. This may lead you to ask, why not leave the vane open all of the time? The answer is because when your gin is idling or ginning at less than a normal rate, the fan motor would overload and trip out. With a Banjo II paired with an Air Control 8, your airflow can be continuously optimized to match your ginning rate. DRY Internal Vane Pneumatic Actuator Banjo Outlet/ Fan Inlet 28

29 The Variable Frequency Drive (VFD) Option An alternative to using a Banjo with the Air Control 8 is controlling the speed of the fan motor with a VFD. The operating principle is straightforward. The Air Control 8 continuously compares motor load with the operator set point and adjusts the speed of the fan up and down in response to changes in the system. The result is that you get faster fan speeds when you are ginning faster. When the gin is idling, the motor is kept from overloading by slowing the fan down. VFDs also offer the advantage of a true soft start, minimizing the demand spikes that occur when the motor is started. VFDs can be supplied by your local electrician. Just make sure they accept a 4-20 ma speed control input and offer an auxiliary output signal for power monitoring. For more details on selecting the right VFD, contact the Sam Jackson technical support team. Eight More Things to Know About Air Control 8 1. A color touch screen interface makes it easy to operate and adjust. 6. Banjos have replaceable outlet sections for easy repair of the most common wear point. DRY 2. Up to 8 fans can be controlled by a single panel. These fans can have any combination of either the Banjo or VFD option. 3. Banjos have over a ten year history of improving gin performance. 4. Equipped with Ethernet communications, the Air Control 8 can be monitored and adjusted on a Moisture Mirror 3X or 4X. 5. Banjos can prolong blast wheel life by promoting even wear patterns. 7. VFD technology has become much more affordable over the last decade, making their use in this application a good investment. 8. Not sure whether the Banjo option or the VFD option is the best for your gin? Both can be great choices. Call a Sam Jackson representative and we will be happy to discuss the pros and cons of each one. The only bad choice is not picking one! Call us today and let us help you boost your fans and your gin with an Air Control 8! Main Line:

30 Drying System Enhancements A Moisture Mirror can help you operate your drying system at peak energy and production efficiencies. The Moisture Mirror product line is much too large to adequately cover here, but no discussion on drying would be complete without at least mentioning it. On the most basic level, a Moisture Mirror can monitor both incoming and after-drying moistures. Once you have this information, the Mirror product line can help you use it in a number of ways, including automatic temperature control. Saves fuel with automatic temperature control Graphs drying data for training and grower feedback Helps avoid chokes Acts as a remote control * SimpleShed and SmartShed control functions * DRY Provides more consistent drying for better results Improves production Remote monitoring options * Several models and options to choose from, making it budget-friendly and flexible * Some models only See the Measurement Products section for more information 30

31 Air volume is critical to gin performance. Monitor it continuously with Air Tools. When it comes to air systems, most gins are operating blind and for good reason. There hasn t been a good online airflow indicator... until now! Disruptions to the air flow in your drying system can strike fast, resulting in a choke. Or air deficiencies can quietly and chronically eat away at your system s efficiency and performance. Either way, the Air Tools product line can help you deal with them and manage your drying air. For example, suppose an incline begins to overload, restricting air flow. Without Air Tools, you might not catch the problem in time to prevent a costly choke. With Air Tools, you have a constant monitor on air flow, alerting you to changes and giving you time to respond. Some options even provide the ability to automatically stop the incoming feed, reducing the size of the choke or preventing it altogether. DRY Easy to install, Air Tools static pressure ports can be mounted in any number of key airflow points in your system. Each port can be connected to one of three monitors, offering a wide range of price and automation options. Put one in every key point in your gin and see your air! on the Moisture Mirror and Air Tools product lines. Main Line:

32 Sam Jackson Engineered Systems Sam Jackson Drying Systems are used in the largest and fastest cotton gins in the world. Prolonged drought and raging floods can demand exceptional tactics in your ginning strategy. If you determine that a turn-key efficiency solution with detailed engineering and performance guarantees is called for, Samuel Jackson has a strong history in providing these services and continues to do so. Sam Jackson comprehensive systems offer the largest ratios of drying air to wet cotton utilized in cotton ginning operations worldwide. DRY Our systems will optimize drying fuel automatically, choosing only ambient air with no added drying energy and modulate through the full range of heating capacity as conditions warrant, maintaining robust capacity throughout the process. This frequently results in drying fuel savings of up to 50% or more over conventional gins and the financial return becomes even more significant when capacity improvements in wet conditions are taken into consideration. We provide the operator with views of mass flow through the process and regulate that mass flow automatically, ensuring that all gin stands operate to maximum efficiency. This feature alone normally increases a gin s weekly capacity by 7% or more while offering seasoned gin operators a mental break from the tedious nature of mass flow regulation by traditional methods. We offer automatic alerts when those unavoidable surprises arrive inside the cotton modules and stop the feed automatically to limit damage or chokes. 32

33 Our comprehensive systems record all system variables as well as critical operator settings. Database possibilities allow you to merge bale classing data with operations data and answer questions like, Which bales did we gin this week at speeds greater than our average? What was the module moisture content for those bales? What was the leaf grade for those bales? Even the best systems can develop fires from surprising and unexpected sources. Heat and spark sensors are utilized by our system designers to make sure that any fire that occurs is discovered and extinguished rapidly. This will get you back to the business of ginning cotton with minimal delay. Our systems can extend from one end of the gin to the other, including moisture restoration at key points to optimize press capacity and seed cotton conditioning before the gin stands for its many documented benefits. Of course, your complete system is only going to be as strong as the operators you have running it. Our services include generous field support and operator training for the first season. DRY On those occasions when we are not in your gin personally, we are there virtually through a high speed network that keeps a group of high level technical personnel at our Lubbock, Texas office aware of your system status and needs. Main Line:

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35 Humidification Products

36 Introduction to Moisture Restoration Adding moisture can add efficiency and value. We talk a lot about cotton moisture. But just to add variety to the same old fiber moisture explanation, let s take a look at another favorite ag product chocolate! When cocoa beans are harvested, their first step in becoming chocolate is to undergo a fermenting process where their moisture content is around 60%. If done incorrectly, the classic chocolate flavor will not develop. Next the beans must be dried down to a moisture content of about 7%. If it s too low, the beans are too brittle and break. Too high and they will mold in storage. Now the beans are ready to be shipped to the factory, where they will be dried further with roasting. Other processes follow, including milling, pressing, refining, tempering and molding. Each of these processes require a certain moisture range to produce desired results. Sound familiar? Cotton, like chocolate and virtually every other ag product, requires the control of moisture to maximize its value. In the previous section of this handbook, we discussed the needs and benefits of drying. But the benefits of moisture control do not stop after the drying and precleaning stage of the gin. HUMIDIFY There are two critical points in the gin where restoring moisture can yield efficiency gains for the gin and higher bale values for the growers. In the following pages you ll see the products we offer that are designed to deliver these benefits. If you are interested in obtaining the full advantages of moisture restoration in your gin, give us a call and we will work with you to find the best solutions for your operation. 36

37 Moisture restoration requires a Humidaire Unit and an Applicator. Humidaire Units Humidaire Units are used to safely and effectively restore moisture to cotton. They create moist or humidified air by heating ambient air; allowing it to absorb large amounts of moisture. Humidaire Units are often generically called moist air generators, humidifiers or simply moisture units. Each system usually requires a single Humidaire, but larger gins are reaching capacities where multiple units would actually be better in certain applications. There are several models of Humidaire Units with different levels of performance and control for your gin s specific needs. Moist Air Applicators Once the moist air has been generated by the Humidaire Unit, you need a moist air applicator. Applicators are separated into A King Mesa Humidaire Unit. two groups: those used to restore moisture to seed cotton and those used to restore moisture to lint. The two types of applicators differ by their location in the gin and more importantly their function as it relates to gin production, efficiency and fiber quality. Example applicators are shown below. HUMIDIFY A Conditioning Hopper for seed cotton moisture restoration A Lint Slide Grid for economical lint moisture restoration A Steamroller for powerful and efficient lint moisture restoration Main Line:

38 Introduction to Moisture Restoration Benefit from moisture at your gin stand feeders... A typical Conditioning Hopper System Seed Cotton Conditioning Systems Samuel Jackson Seed Cotton Conditioning Systems apply humid air to seed cotton between the conveyor distributor and each gin stand using an applicator called a Conditioning Hopper. Although each system will have a single Hopper above every stand, typically only one Humidaire Unit is required for the entire system. Seed Cotton Conditioning is used to prepare seed cotton for ginning. When the moisture level of seed cotton is raised before ginning, certain aspects of fiber quality are preserved. Seed Cotton Conditioning used alone has little effect on bale moisture content and is not a substitute for Lint Conditioning. Lint Conditioning Systems... and at your press HUMIDIFY Samuel Jackson Lint Conditioning Systems are found between the battery condenser and the tramper on a press. Generally, gins operating below 30 bales per hour use a Lint Slide Grid System and gins with capacities above 30 bales per hour use a Steamroller System. The purpose of restoring moisture to lint from a gin s perspective is to reduce the hydraulic pressures on the press. Conditioned lint presses easier, can improve press capacity and adds consistency to bale weights. Samuel Jackson Lint Conditioning Systems have no positive or negative effect on fiber quality A Steamroller II Lint Conditioning System

39 Humidaire Operation in 4 Easy Steps 4 Understanding the principles of operation of a Humidaire Unit is easiest when you break it down into the following four steps: Step 1: Ambient air is pulled in through the air inlet of the Humidaire Unit. Note: The air inlet screen has been removed for picture clarity. Step 2: The air passes through the burner head which raises the temperature of the air. Heated air will carry much more moisture than cool or ambient air. Step 3: The heated air enters the spray chamber where it mixes with a torrent of water that is circulated through the unit and sprayed out of nozzles. The air absorbs the moisture to become humidified air. HUMIDIFY Step 4: The moist air leaves the Humidaire Unit through a pipe connected to the top of the spray chamber and goes to the application point. The picture shows humidified air being exhausted from our Humidaire Test Stand as an example of the volume of moisture generated. In a gin, the humidified air would go to a seed cotton or lint moist air applicator. Main Line:

40 Introduction to Moisture Restoration Traditional Humidaire Control Step 1: The operator sets the air temperature. This controls the gas valve. Hotter air absorbs more moisture, so a higher air temperature will allow the Humidaire to generate more moisture output. Step 2: The operator sets the water temperature. This controls the water valve. The water valve adjusts the amount of water flowing through the nozzles. Adjusting the water temperature closer to the air temperature creates more moist air output. HUMIDIFY Note: This picture shows an example of the volume of moist air generated by a Humidaire Unit. In a gin, the moist air would be carried by pipe to an application point. Step 3: By balancing the air and water temperatures, the operator controls the amount of moisture the Humidaire Unit generates. 40

41 Humidaire Features Explained New Moisture Direct Control Makes it Easier Than Ever to Control Humidaire Output Our Humidaires have a strong reputation for performance and dependability. But controlling their output has always been a skill that required specialized instructions, experience in a variety of conditions and a knowledgeable touch until now! Moisture Direct Control makes getting just the right amount of moisture from your Humidaire Unit easier than ever. Traditional Humidaires measure temperature in the water tank and adjust moisture output by changing the amount of water being exposed to the hot air stream. Moisture Direct simplifies the control process by adjusting the water valve directly from the touch screen based on desired moisture output. Bump up the output percentage for more moisture or turn it down for less. It s that easy! In addition to making moisture control easier to use, Moisture Direct also gives Humidaire Units more precise output, a larger operating range and faster response. The key to successful Moisture Direct operation is a complex algorithm that is specially calibrated and unique to each Humidaire Unit. Every unit is carefully calibrated on our factory test stand prior to shipping. Should your unit ever need recalibrating, the complete procedure can be performed with the touch of a button and is completely automatic! We tend to agree with the old saying, It s easy to make something complicated, what s hard is keeping it simple. Our design team has done the hard work in making Humidaire control easy for all of your operators to get great results. HUMIDIFY Moisture Direct is a feature on all units with the 1600 Series Operating System. Main Line:

42 Humidaire Features Explained Introducing the 1600 Series Operating System After designing and manufacturing moisture equipment for over 50 years, we ve seen a number of machines that look like genuine Humidaire Units. While proven thermodynamic design is critical, experienced ginners will tell you a very important part of any moisture unit s performance is the operating system or controls. The Humidaire King Mesa closely resembles its popular predecessor, the Southwest Lite. That said, don t be quick to judge this book by its cover. The King Mesa introduces the biggest change in Humidaire controls technology in over 20 years. Moisture output is easier to adjust, faster to respond and more stable than ever! The new 1600 Series Operating System was specifically designed for the Humidaire King Mesa to support a number of new features including: Moisture Direct Control Moisture Mirror X remote compatibility Analog Water Pressure Monitoring Analog Gas Pressure Monitoring Improved Automatic Purge System Water Pump and Flame Settings for Gin Idle Output for Moist Air Fan VFD Advanced Real-Time Error Logging And more! The 1600 Series Operating System organizes all of these features on the Humidaire s local color touch screen so they are easy to find and use. Your operators will enjoy the simple and intuitive controls compared to previous moisture units. HUMIDIFY In addition to the Humidaire King Mesa, the larger, extreme-duty Humidaire Southwest also features the 1600 Series Operating System on all new units. Consult the factory for control upgrade options available for Southwest and Southwest Lite Humidaires. 42

43 1600 Series Features You Don t Want to Miss The 1600 Series operating system is loaded with new features. We can t cover them all here, but we wanted to highlight a few of them that you won t want to miss. Moisture Direct Control More analog inputs for advanced control and performance Detailed error reports and log Auto calibration procedure HUMIDIFY Flame idling More complete air monitoring Main Line:

44 Humidaire Features Explained Moisture Tunnel Technology Thermodynamically Speaking...It Sizzles! You can see the Moisture Tunnel in action as the fire and water interact inside the spray chamber. We ve all had our share of hamburgers. Cooked in a pan or a griddle they can be satisfying, but when you re really craving a good, make-your-mouth water burger, there is no substitute for flamegrilled. Letting that flame come in direct contact with the patty as it cooks does something special. Now you may be wondering what that has to do with Humidaires (other than this being written at lunch time). Well the classic Humidaire configuration uses griddle thermodynamics. The flame and the water are separated by a physical barrier and the water is heated indirectly. HUMIDIFY Humidaire models equipped with Moisture Tunnel Technology use flame-grilled thermodynamics, forcing the water into direct contact with the flame from a fuel-efficient, premium burner head. The results sizzle in more ways than one. As an example, the Humidaire Southwest is equipped with Moisture Tunnel Technology and can evaporate 100% more moist air using 10% less fuel than traditional moisture units. Moisture Tunnel Technology is available on the Humidaire Southwest, Humidaire King Mesa, Humidaire Sahara and Sahara Lite models. The Zephyr can be upgraded to the Sahara Lite. 44

45 Hydrocyclone Cleaning Option Clean Water Makes For Happy Humidaires and Humidaire Owners If you or one of your employees get stress relief from cleaning the mud and muck out of your Humidaire tank and pipes, then the hydrocyclone may not interest you. But if you d like a device that helps do that work for you, read on! Keeping the water circulating in your Humidaire clean helps it perform better, extends time between cleanings, makes cleaning the unit easier and adds life to your unit. The optional hydro-cyclone makes achieving cleaner water and its benefits possible. Similar in principle to the cyclones in your air systems, dirty water is swirled through the hydrocyclone. The dirt, sediment, lint and other junk entrained in the water gets separated out and exits the bottom of the cone. The cleaned water exits the top and is recirculated back into the bottom of the tank, where it sweeps the bottom of the tank clean, too. The Hydrocyclone Cleaning Option is available as a factory option or field retrofit on all HU-80 models. Compatible models come equipped with software controls that make it easy to setup and customize cleaning parameters. HUMIDIFY Ask your Sam Jackson rep for more information on how this option will work for you and improve your system. 45

46 Humidaire Features Explained Moisture Mirror Remote Control The Moisture Mirror 2X, 3X and 4X offer remote control of 1400, 1500 and 1600 Series Humidaires from your console. Mirror X Home Screens (2X shown) show the status of all connected Humidaires How would you like to take back a little real estate on your console? The Moisture Mirror 2X, 3X and 4X can remotely control up to four Humidaires and up to eight Heaters from a single touch screen. The Mirror allows you to start and stop the unit, change temperatures and even view performance statistics such as gallons evaporated per minute. If there is a problem at the unit, the Moisture Mirror will notify you at the console and offer possible solutions. You re not going to miss your old digital controllers! HUMIDIFY Connecting 1400, 1500 and 1600 Series products to the Moisture Mirror is easy. It only requires a single Ethernet cable from the Mirror to each product. If there s a communication problem, there is only one cable to check making troubleshooting a snap! Moisture Mirror Remote Compatibility is not available for the Static Zapper or Zephyr Humidaire Unit models. Each Humidaire has its own screen complete with start and stop buttons and operation statistics. 46

47 Water Watch Don t guess about Humidaire performance, watch for yourself. Water Watch meters are housed in the lower cabinet and help measure the ROI of moisture restoration at your gin. The relationship between temperature settings and Humidaire output can sometimes be difficult to understand. Water Watch makes it easier by displaying Humidaire performance as Fresh, Purge and Evaporated water in gallons per minute. By comparing the fresh water entering the unit with the purge water being removed, the amount of water evaporated is calculated as a running 30-minute average. Fresh and Purge totals are kept over the lifetime of the unit and resettable totals can be zeroed at the start of each gin season. Water Watch information is graphed over a 24-hour period. The graphing window displays a 30-minute time frame and defaults to the latest 30-minute interval. Graphing history is viewed by pressing the on-screen forward and back arrows. The Water Graph is especially helpful in identifying trends. Trends can be used to compare moisture system performance over time and highlight problems with Humidaire performance early. A malfunctioning water valve or float valve is easy to see when you look at the color-keyed graph. The Water Graph clearly defines a problem such as the malfunctioning purge valve in the example above. HUMIDIFY Water Watch comes standard on 1400, 1500 and 1600 Series Humidaire Units. Main Line:

48 The Static Zapper A Special Purpose Moisture Unit Many don t realize that the Humidaire was originally invented for the purpose of killing static. Success at that led to its use in other applications, giving benefits to press efficiency, ginning speed and protecting quality at the gin stand. With that history and the known power of moisture restoration, it s not surprising that interest in new applications for moist air continues to grow. Not all of those applications are suited for our traditional sized Humidaires. The Static Zapper offers an economical, easy-to-use moist air generator that is ideally sized for lower volume applications. Simple and straightforward to install, this unit is suited for special applications such as small capacity gins, spot conditioning, prototype testing and research trials. HUMIDIFY Available in gas or oil-fired configurations (gas-fired shown) 2 HP Water Pump 500-1,000 CFM 1-million Btu/hr rating Stainless steel water tank and spray chamber PLC controls Water flow controlled by VFD Output for fan speed control for constant air volume Evaporation rates of 60 gallons per hour Fast warm-up time Output is adjustable in 1% increments Easy installation Great alternative to boiler systems 48

49 Gas-Fired Humidaire Comparison Which model fits your needs? King Mesa Southwest Model # HU HU-SOUTHWEST-1680 Max. Evaporation 3.5 gallons/minute 4.2 gallons/minute Heating Efficiency 1,530 Btu per pound of water evaporated 1,530 Btu per pound of water evaporated Maximum Air Volume 4,000 CFM 5,000 CFM Water Pump Motor 5 HP 7.5 HP Stainless Steel Pump No Yes Burner Samuel Jackson Samuel Jackson Moisture Tunnel Technology Yes Yes Two side water tank access No Yes Access doors to tunnel Series Operating System Yes Yes Combustion Controls PLC PLC Air Temperature Control User Set-Point PID Controlled by User Set-Point PID Controlled by PLC PLC Water Temperature Control NEW! Moisture Direct NEW! Moisture Direct Operator Interface Touch Screen Touch Screen Ethernet Communications Yes Yes Moisture Mirror Remote Control Mirror 2X and higher Mirror 2X and higher Mirror Compatible for Target Bale Moisture Yes; Ethernet Yes; Ethernet Error/Alarm Interface Touch Screen Touch Screen Water Watch Diagnostics Yes Yes Purge System Automatic Automatic Hydrocyclone Filter Optional Yes Suggested Use Conditioning Hoppers, Moisture Condensers and Steamrollers Conditioning Hoppers, Moisture Condensers and Steamrollers HUMIDIFY Value Category Fusion Pinnacle Main Line:

50 Gas-Fired: The Humidaire King Mesa The Humidaire King Mesa has powerful moisture output, fuel efficient operation and user-friendly controls in one impressive package. Introduced in 2010, the Humidaire King Mesa can evaporate 75% more moisture using 10% less fuel compared to traditional moist air units. The improved performance and efficiency are byproducts of Moisture Tunnel Technology. The King Mesa is also the first Humidaire model to include Moisture Direct Control. Moisture Direct is the most stable and user-friendly Humidaire control system to date. More information on both Moisture Direct and the Moisture Tunnel can be found earlier in this section. The Humidaire King Mesa. The Humidaire King Mesa comes standard with several impressive features such as: HUMIDIFY A local color touchscreen for simple control and advanced diagnostics Improved! Automatic purge system to reduce cleaning needs Target Bale Moisture Control with any Mirror and a Tex-Max Remote control from any Mirror 2, 3 or 4 with Mirror X software Remote monitoring with an iphone or ipad using the Mobile Mirror App Easy access to the water tank during operation The King Mesa utilizes the Premium Touch Screen Interface that gives the operator in-depth performance statistics directly on the home screen. 50

51 PLC Controls Inside Cabinet The King Mesa can handle 4,000 CFM of air 6-inch Color Touch Screen Operator Interface Moisture Tunnel Technology equipped with the Samuel Jackson Burner Head HU-80 Thermodynamic Design Spray Chamber Window Water Tank Access Door Water Watch Meters and Dungs Gas Train Improved Heavy-Duty Purge Valves 5 HP Motor and Water Pump Moisture Direct Technology controls the water valve located on the backside of the Unit HUMIDIFY The Humidaire King Mesa is equipped with the NEW 1600 Series Operating System! Main Line:

52 Gas-Fired: The Humidaire Southwest An extreme-duty machine for top performance in the most demanding conditions. The Humidaire Southwest. Samuel Jackson engineers set out to design a Humidaire that s powerful, rugged, fuelefficient, easy to clean and operator-friendly. You will find all of these attributes and more in the Humidaire Southwest. Introduced in 2004, the Southwest is especially popular in Australia and the Western U.S. where extremely dry conditions demand it. The Southwest disputes all claims against the ability to restore moisture with humid air with its maximum evaporation capacity at over 4 gallons per minute. The impressive output of this unit can be attributed in part to Moisture Tunnel Technology which also improves its fuel-efficiency by 10% versus traditional Humidaires. HUMIDIFY The Southwest comes standard with a 7.5 HP motor and a stainless steel water pump. These components generate robust water pressure with some of the most challenging water sources in the world. The unusual looking device on the right side of the unit is a hydrocyclone water filter. If you ve got tough water, it can handle it. These features coupled with an almost entirely stainless steel body and touch screen controls make this one amazing Humidaire. If you need references, ask us about the gin that conditioned almost half-a-million bales at 60 bales per hour in the last four years with their Southwest. The Southwest utilizes the Premium Touch Screen Interface. It gives the operator a 30-minute graphing feature to view Humidaire performance. 52

53 All analog switches for advanced diagnostics PLC Controls Inside Cabinet HU- 80 Thermodynamic Design Southwest can handle 5,000 CFM of air 6-inch Color Touch Screen Operator Interface Spray Chamber Access Door Moisture Tunnel Technology equipped with the Samuel Jackson Burner Head Hydrocyclone Water Filter Water Watch Meters Located on the backside of the unit, the Southwest has a 7.5 HP stainless steel water pump Water Valve is controlled by a modulating motor on the backside of the Unit Waveless float chamber in water tank Spray chamber, water tank and windows are accessible on both sides of the Unit HUMIDIFY The Humidaire Southwest is equipped with the NEW 1600 Series Operating System! Main Line:

54 Glance at Humidaire History More than 55 years of Humidaire Progress The gas-fired models on the previous pages and the following oil-fired models represent the efforts of more than five decades of Humidaire research and development, bringing you the absolute in moist air technology for cotton gins. We always enjoy a look back at our roots and thought you might like to see a little Humidaire history, too. HUMIDIFY 54

55 Oil-Fired Humidaire Comparison Zephyr Sahara Lite Sahara Model # HU-80-ZEPHYR HU HU-SAHARA-1590 Max. Evaporation 1.5 US gpm 3.5 US gpm 4.8 US gpm Heating Efficiency 1,230 Btu/lb of water evaporated 1,170 Btu/lb of water evaporated 1,160 Btu/lb of water evaporated Maximum Air Volume 2,500 CFM 4,000 CFM 5,000 CFM Water Pump Motor 5 HP 5 HP 7.5 HP Stainless Steel Pump No No Yes Burner Beckett 2-Stage Burner Maxon Maxon Moisture Tunnel Technology No Yes Yes 1600 Controls No Yes Yes Combustion Controls Honeywell/ Relay-Based PLC PLC Air Temperature Control 2 - Stage Burner High and Low User Set-Point PID controlled by PLC User Set-Point PID controlled by PLC Water Temperature Control User Set-Point User Set-Point User Set-Point Operator Interface Selector Switches Touch Screen Touch Screen Ethernet Communications No Yes Yes Moisture Mirror Remote Control No Mirror 2X and higher Mirror 2X and higher Mirror Compatible for Target Bale Moisture Yes; Analog Yes; Ethernet Yes; Ethernet Alarm/Error Interface None Touch Screen Touch Screen Water Watch Diagnostics No Yes Yes Purge System Manual Automatic Automatic Hydrocyclone Filter No Optional Yes Upgradable Yes; to a Sahara Lite No No Suggested Use Conditioning Hoppers, Conditioning Hoppers, Conditioning Hoppers Moisture Condenser and Moisture Condenser and and Lint Slide Grid Steamrollers Steamrollers Value Category Gateway Fusion Pinnacle HUMIDIFY Main Line:

56 Oil-Fired: The Zephyr Humidaire A balance of power and simplicity. The Zephyr is a Humidaire hybrid with selector switch controls similar to the Static Zapper and the HU-80 frame of the more powerful Sahara Lite. This feature-mix creates a unit that s powerful and userfriendly for the novice operator. The HU- 80 frame allows the unit to be upgraded to a Sahara Lite as the gin s needs for powerful moist air output and sophisticated controls grow. A Zephyr Humidaire Unit. Key Features of the Zephyr: The Zephyr uses an oil-fired commercial grade burner that burns either kerosene or diesel. The burner can change from high fire to low fire with the flip of a switch. HUMIDIFY Moist air output is adjusted with the water valve that s located on the back side of the unit. With the selector switch interface, operators will have little trouble learning how to make changes based on climate and condition of the cotton. The Zephyr s Selector Switch Controls 56

57 Selector Switch Operator Interface The Zephyr can handle 2,500 CFM of air HU-80 Thermodynamic Design Beckett 2-Stage Oil- Fired Burner Assembly Water Tank Access Door Zephyr can be upgraded to a Sahara Lite using existing frame 5 HP Motor and water pump Manually Adjusted Water Valve on the backside of the Unit Header Pipe Flush Valve HUMIDIFY Main Line:

58 Oil-Fired: The Humidaire Sahara Lite Our most popular oil-fired model. Do you need a powerful source of moist air for a moisture condenser or a Steamroller? How about Conditioning Hoppers? Or in smaller gins, one unit for both applications? The Sahara Lite will handle any of those applications with ease. It s also priced at over 40% less than the Sahara and has 100% more moist air output than the Zephyr. Combine price and performance with an elegant color touchscreen operator interface and tons of additional features and you ve got one impressive Humidaire. A Sahara Lite Humidaire Unit. The Sahara Lite comes standard with several user-friendly features: HUMIDIFY A color touchscreen for onboard diagnostics and troubleshooting Moisture Mirror 2X, 3X and 4X remote control capability Target Bale Moisture Auto Control with any Mirror and a Tex-Max Auto purge system to reduce cleaning The Sahara Lite utilizes the Premium Touch Screen Interface that gives the operator instant access to run times and real-time water statistics. Water tank access during operation 58

59 PLC Controls Inside Cabinet The Sahara Lite can handle 4,000 CFM of air 6-inch Color Touch Screen Operator Interface HU-80 Thermodynamic Design Spray Chamber Window Maxon Oil-Fired Burner Head Water Tank Access Door Water Watch Meters 5 HP Motor and water pump Water Valve is controlled by a modulating motor on the backside of the Unit HUMIDIFY Main Line:

60 Oil-Fired: The Humidaire Sahara The most powerful Humidaire in the world. Seeking to design an oil-fired Humidaire model with the same performance, durability and user-friendly features of the Humidaire Southwest, Samuel Jackson engineers created the Humidaire Sahara. Instead of getting a comparable unit, surprisingly, the Sahara is more powerful and efficient than its gas-fired counterpart. Sahara users will find no job too tough for this extreme duty unit. The Humidaire Sahara. The Sahara comes standard with all the features you would expect from the best Samuel Jackson has to offer: HUMIDIFY An onboard color touchscreen for diagnostics and troubleshooting Moisture Mirror 2X, 3X and 4X remote control capability Target Bale Moisture Auto Control with any Mirror and a Tex-Max Auto purge system to reduce cleaning Stainless steel water train and pump (except Hydrocyclone) A Hydrocyclone filter to handle the harshest water conditions Water tank access during operation Dual access to the spray chamber and an additional door to the mist eliminator for easy maintenance Wave-less float chamber to ensure optimum water level The Sahara utilizes the Premium Touch Screen Interface that informs the operator of performance problems and suggests multiple solutions. 60

61 6-inch Color Touch Screen Operator Interface PLC Controls Inside Cabinet HU- 80 Thermodynamic Design Sahara can handle 5,000 CFM of air Spray Chamber Access Door Maxon Oil- Fired Burner Head Located on the backside of the unit, the Sahara has a 7.5 HP stainless steel water pump Water Valve is controlled by a modulating motor on the backside of the Unit Water Watch Meters Waveless float chamber in water tank Hydrocyclone Water Filter on the backside of the Unit Spray chamber, water tank and windows are accessible on both sides of the Unit HUMIDIFY Main Line:

62 Conditioning Hoppers Everyone agrees gin stand moisture is important. Conditioning Hoppers provide the best solution to maintain optimum ginning moisture. HUMIDIFY Conditioning Hoppers in operation at a gin running at over 60 bales per hour. Over 50 years ago, Mr. Sam Jackson invented the first Humidaire Unit. At that time, the unit was used to reduce static electricity problems in dry seed cotton through an applicator similar to modern Conditioning Hoppers. Through later research, it was discovered that in addition to eliminating static electricity, restoring moisture to seed cotton before ginning also preserves fiber quality during fiber-seed separation. Within practical limits, increasing the moisture in seed cotton before ginning has a positive correlation to fiber quality characteristics such as length, strength, uniformity and lower short fiber content. Today, Hoppers are used in gins all over the world to combat problems with static electricity and fiber damage due to dry ginning conditions. 62

63 Researchers have studied the role of moisture in preserving fiber quality at the gin for many years. Below, you ll find excerpts from that research that are very impressive. You ll see that raising the moisture level of seed cotton before ginning can significantly impact fiber quality. If you re not using seed cotton conditioning in your gin, you are missing out on some great benefits. Cotton with a 3% moisture content going through two lint cleaners will have 40% more short fiber content than cotton at 5% moisture content. 1 Raising moisture content from 4% to 6% before ginning resulted in a 1/32nd increase in staple and a 2% decrease in SFC. 2 Results from a USDA - ARS study showed consistent increases in uniformity and strength as moisture increased from 4.1% to 8.4%. 3 Fiber length increases almost one full staple length with each 1% increase in moisture content. 4 Moisture contents below 5% are especially damaging to cotton fiber. 5 Fiber length is reduced from a 37 staple to a 35 staple when moisture was reduced from 7.4% to 3.4%. 5 Short Fiber Content increased from 4.6% to 8.7% when moisture decreased from 8.4% to 4.1%. 5 HUMIDIFY 1 Mangialardi and Griffin (1966) 2 Impact Of Ginning On Fiber Quality: The Best Ginning Practices, International Cotton Advisory Committee s Expert Panel on Ginning Methods 3 USDA-ARS Cotton Ginning Research Unit website 4 Rick K. Byler. Moisture Restoration for Seed Cotton, Two Approaches. 5 W. Stanley Anthony. Moisture Management Practices at Gins. Main Line:

64 Conditioning Hoppers Conditioning Hoppers moisturize dry, brittle fiber making it stronger and more valuable. Conditioning Hoppers are available in two styles: Classic-Entry and End-Entry. Alternative styles offer installation flexibility, but neither has been shown to differ in performance. On both styles, the moist air enters through two stainless steel valves that stop the flow of humid air when the feeder stops. These valves can also open and close automatically based on incoming moisture when used with a Moisture Mirror. This allows the humid air to be quickly diverted if incoming seed cotton moisture gets too high. HUMIDIFY A diagram of a Classic Entry Hopper. The humid air fills an internal chamber before passing through the galvanized injection plates and entering the seed cotton. This feature creates uniform moisture distribution along the entire width of the Hopper. The moisturized seed cotton is strengthened, giving it more protection from damage as it enters the gin stand for the rigorous fiberseed separation process. An End-Entry Conditioning Hopper. 64

65 Lint Slide Grid An economical and effective moisture restoration solution for capacities up to 30 bales per hour. This picture shows a typical Lint Slide Grid installation. It is taken from inside the lint slide looking up at the battery condenser. Invented in the 1970s, gins around the world continue to use the Lint Slide Grid as a simple and effective tool for lint moisture restoration. A Grid consists of overlapping stainlesssteel slats mounted in the bottom of the lint slide to create a 4-inch false bottom. Moist air travels in the false bottom and evenly escapes through each slat, penetrating the batt as it passes down the lint slide. HUMIDIFY The Lint Slide Grid is a great moist air applicator for many gins as it can be effective up to 30 bales per hour. It is also the most economical moist air applicator on the market today. Main Line:

66 Lint Slide Grid Easy to install, operate and maintain. HUMIDIFY The drawing above shows a typical Lint Slide Grid installation. Each system must have a Humidaire Unit, a fan for suppling moist air to the Grid and the Grid itself. Insulation along with a dedicated exhaust fan are highly recommended. Grids are available in different models designed for several different types of lint slides. A Grid begins to moisturize the batt as it leaves the battery condenser. A batt with fewer breaks and a longer lint slide will improve absorption of the moist air by the fiber. While there are many factors to consider, properly set up Grids can restore an average of 1.5% moisture per bale. Be aware that bale moisture is affected by several variables and can fluctuate. Any unused moist air can be piped back into the lint flue or exhausted outside. There are other options and enhancements for Lint Slide Grids that are available by viewing the manual. 66

67 Steamrollers Overview of Steamroller Technology Condensation. If you had to pick one word that inspired the development of the Steamroller, condensation might be the second best choice. Everyone sees condensation so often that most folks don t give it much thought. But then most folks aren t cotton ginners. On a cold glass of iced tea, water condenses from the air around it and forms water droplets. The more humid the air, the more droplets. In a gin, restoring moisture requires very humid air and when the weather is cold, condensation can become a big problem. Lint sticks to water droplets that form on parts of a lint slide grid system or in a moisture condenser and once that starts happening, you are well on your way toward a choke. Auxiliary heaters and insulation can help, but with both grid systems and moisture condensers the humid air is interacting with a much larger volume of cold air and eventually the cold air wins out. Frustrated by haired over condenser screens and being forced to run Humidaires at lower outputs, ginners were searching for a better way. These frustrations grew bigger as gins grew in speed and the demands on their presses grew greater. From this frustration, the Steamroller was born. The resulting design isolated the humid air from directly interacting with large volumes of cold air and protected key points from condensation with auxiliary heat to keep those surfaces warm. But if you think the Steamroller s advantages are just in the cold weather, you d be wrong. The Steamroller I & II s design makes them capable of restoring more moisture than any other applicator, making it easier for you to achieve the desired moisture in all conditions. This top performance is achieved using a lower humid air volume than other methods, meaning you ll save fuel costs. Easier to maintain target moisture, lower operating costs, faster press performance and less wear and tear on your press all add up to the best one word description behind the Steamroller. Efficiency. HUMIDIFY Main Line:

68 Steamrollers Comparison of Steamroller I and II Sam Jackson manufactures and supports both the Steamroller I and II. Both models share core technologies and offer the same level of efficiency and capability in the amount of moisture they can restore. However, there are some key differences in the two, which have led us to the decision to continue offering both models. This allows users to pick the model that offers them the advantages most important to them. The purpose of this page is to highlight those differences. The Steamroller I was introduced fifteen years ago and since then has conditioned over 70 million bales and improved the performance and life of 90 presses. Advantages of the Steamroller I include: Lower initial cost Better for short lint slides Suitable for wide range of ginning speeds Can be bypassed Eligible for upgrade program Factory refurbished units may be available The Steamroller II was introduced in 2008 equipped with features compiled from the wish lists of users of the original Steamroller. The result is a more forgiving, easier to maintain design. HUMIDIFY Reduced cleaning demands No plenum to accumulate pin trash More aggressive feeding reduces choke potential from large wads Easier to install Better suited for higher capacity gins Overshot drum provides more surface area for applying moisture The lint batt compressed only at exit Simple and easy to replace flashings Drum wiper brush cleans the drum Handles uneven batts better Better choice for gins handling rough, trashier cotton 68

69 How the Steamroller I works. The lint conditioning process starts as the batt feeds into the Steamroller from the battery condenser. Unlike moisture-type condensers, the Steamroller is a separate piece of equipment from the battery condenser. This means that the moist air used by the Steamroller isn t diluted by outside air which reduces efficiency and causes condensation and hairing problems. The batt passes under a rotating drum where moist air enters from underneath. The Steamroller is under slightly negative pressure pulling the moist air completely through the batt for uniform moisture application through the fiber. Excess air is exhausted by a dedicated fan piped into the lint flue. The conditioned batt is compressed by the feed-out roller as it exits the Steamroller and continues down the lint slide into the tramper. HUMIDIFY Typical Steamroller Lint Conditioning System layout. Main Line:

70 Steamrollers How the Steamroller II works. Like the original design, the Steamroller II isn t diluted by outside air, which reduces efficiency and causes condensation and hairing problems. But unlike the original, the batt passes on top of a rotating drum in an overshot fashion. The moist air enters from above, where it is pulled down through the lint. Because there is no plenum, there is no place for pin trash to accumulate and most of it is carried away in the exhaust air. Users report cleaning takes less than half the time of the original. The updated design also features aggressive doffing and compression rollers that do a superb job of handling wads, avoiding chokes and keeping the cotton flowing. Loaded with other design touches, the Steamroller II delivers the highest levels of performance with easier than ever maintenance. HUMIDIFY Typical Steamroller II Lint Conditioning System layout. 70

71 1501 Gas-Fired Auxiliary Heater A One-Million BTU/hr Heater in One Compact and Well-Designed Package Perfect for providing just enough heat to tame or avoid condensation issues on moist air applications, the HG Gas-Fired Heater can be the difference between achieving great results or battling chronic chokes. Without a dependable source of hot dry air at a consistent temperature, your moisture restoration system will either be crippled by the need to run at lower than ideal outputs or you will be at risk of condensation problems and the resulting chokes. The HG has an integrated fan, burner body, gas train and control panel mounted on a skid. Installation can be as simple as connecting pipe, three-phase power, a thermocouple and gas supply. Looking for something more sophisticated and able to provide more convenient operation? The control panel can connect to compatible Moisture Mirrors, providing remote functions such as start and stop commands, temperature set point control and error/ alarm monitoring. You can even set up the HG to automatically start and stop when your Humidaire does, ensuring it s ready when you need it. Whether you do a basic install or take advantage of the more advanced features, your HG will help your moisture restoration system perform at its best. So take the advice of one of our favorite ginning friends who counsels, You either need a good auxiliary heater or you need some stout ginners with big pipe wrenches. The problem with the last one is those aren t the kind of guys you want to make mad by having them clearing chokes a few times everyday. HUMIDIFY Main Line:

72 1142 Gas-Fired Auxiliary Heater Gas-fired auxiliary heater for special applications. The HG heater. The 1142 Features: Burner body that can handle 4,000 CFM of air Operator-friendly digital control Packaged burner lights quickly and reliably Low air flow and flame protection Suitable for a variety of drying applications HUMIDIFY The HG is an economical gas-fired heater with a maximum output of 1 million Btu per hour. Costs are kept low by using a packaged burner assembly and simple controls. Burner operation is fast and reliable as it automatically turns on and off to maintain a desired temperature set by the operator. The operator simply enters a set point on the single temperature controller mounted in the control cabinet door. When needed, a knob on the gas train permits fine tuning adjustments to the gas flow to influence the cycle period for heat output. The heater package includes the fan, motor and controls already mounted making installation fast and easy. Simple setup, an economical price and easy-to-use controls make the 1142 well-suited for a variety of applications. 72

73 1143 Oil-Fired Auxiliary Heater Dependable oil-fired auxiliary heat. The HO heater. The 1143 Features: Burner body that can handle 4,000 CFM of air Operator-friendly digital control Packaged burner lights quickly and reliably Low air flow and flame protection Suitable for a variety of drying applications The HO is an economical oil-fired heater with a maximum output of 700,000 Btu per hour. Costs are kept low by using a packaged burner assembly and simple controls. Burner operation is fast and reliable as it automatically turns on and off to maintain a desired temperature set by the operator. The operator simply enters a set point on the single temperature controller mounted in the control cabinet door. When needed, the oil fuel delivery system permits fine tuning adjustments to influence the cycle period for heat output. The heater package includes the fan, motor and controls already mounted making installation fast and easy. Simple setup, an economical price and easy-to-use controls make the 1143 well-suited for a variety of applications. HUMIDIFY 73

74 Moist Air Applicator Chart Typical Moist Air Volume (CFM) Typical Maximum Moisture Restoration Capability (pounds of moisture per bale) Typical Energy Consumed in a 40 BPH Gin (Btu per pound of moisture) Lint Slide Grid Low cost applicator No batt compression Moisture Condenser* Dual-purpose applicator/condenser Good batt compression Steamroller I & II* Most efficient applicator Best batt compression 2, , , ,125 (4 cents/pound) 5,000 (6.4 cents/pound)** 1,625 (2 cents/pound)** HUMIDIFY *Moisture Condensers and Steamrollers are often used with an auxiliary heater which will consume additional fuel, particularly in cold conditions. **Using natural gas at a cost of $1.29/therm. 1 therm = 1CCF 74

75 Tex-Max Microwave Bale Moisture Sensor Missing the mark on moisture could cost you a lot. The Tex-Max allows you to monitor every bale. A Tex-Max Bale Moisture Sensor. The Tex-Max is an online microwave moisture sensor built by Samuel Jackson using Vomax Microwave Technology. It scans each bale leaving your gin thousands of times and provides a single reading reflecting the average of those scans. The Tex-Max is highly repeatable as found in numerous studies including a 2008 Beltwide Cotton Conference paper on Vomax Technology. All current models of Moisture Mirrors and most Samuel Jackson Humidaire Units allow you to enter a Target Bale Moisture for Automatic Control. Do Not Use With Water Spray Devices A Tex-Max cannot protect you against problems from bales that have been subjected to water spray systems. Because water spray systems apply moisture unevenly, extreme wet spots can and do exist within a bale that has an average moisture of less than 7.5%. Problems from these wet spots can arise before the moisture can equilibrate throughout the bale. Samuel Jackson reserves the right to refuse sale of a Tex-Max to any gin using a water spray device. HUMIDIFY Main Line:

76 A Common Sense Guide to Moisture Restoration Restoring moisture to lint cotton is probably the most debated and most misunderstood ginning practice. Recent abuses have made the industry even more fractured on this matter and spawned even more misinformation. The following facts are educational and practical as good ginning guidelines to follow in your own operation. We hope you find them helpful... During storage, a bale will move toward and attain an equilibrium moisture content (EMC) in the warehouse in which it s stored. Without any moisture restoration at the gin, the typical moisture content of the lint is well below the EMC a bale will reach in storage. Simply put, the fiber after lint cleaning is very dry. HUMIDIFY There are significant benefits to a gin if they can raise the moisture in the lint prior to the press. In fact, for efficiently operating at modern ginning capacities, the ability to restore moisture is a necessity, not a luxury. Bale moisture sensors are intended to offer a useful display of lint moisture for a ginner skilled in evaluation and handling of cotton bales. It is recommended that an operator pay close attention to bale moisture conditions at all times and validate readings against oven moisture tests if they appear questionable. Always gin your cotton with wisdom and prudence. 76

77 Lint moisture restoration systems do not improve fiber quality. When considering this point, it s important not to confuse lint moisture restoration with seed cotton moisture restoration (seed cotton conditioning), which can positively impact fiber quality. Done properly, lint moisture restoration does not harm fiber quality. This requires the moisture to be applied uniformly and in moderation. Water spray systems do not apply moisture evenly throughout the bale. A mill buying a bale based on the receiving dock weight is paying for the moisture in that bale whether it was gained by the lint at the gin or in the warehouse. A mill can derive benefits from bales that were properly moisturized by the gin, including: bales opening to a uniform and more manageable height, fewer broken bale ties making handling easier, reduced tie forces making opening the bales safer, faster conditioning times in the mill s opening room (because proper fiber moisture is important for mill operating efficiency, too). Taking the above points into consideration, it s clear that there is some common ground on this issue. If a gin restores moisture to lint using a safe method and reasonable level, it can be mutually beneficial for both gins and mills. Growers benefit by having some of the weight lost during harvesting or gin drying restored to the bale. What is the best target bale moisture? This is not only a good question, it s also one of the most common asked. To answer it we first have to know the answer to two questions that are specific to your gin: 1. What bale moisture provides the best performance for your press (and strapper)? 2. How much weight would the bale regain in storage if it were ginned without the benefits of moisture conditioning? Those factors are used to determine the ideal target bale moisture for your gin. This target will help you gin faster and more efficiently, and it will help your growers get paid for the weight gain that would otherwise go to a middleman. HUMIDIFY Give us a call. We d love to help you determine and achieve your ideal bale moisture. Main Line:

78

79 Measurement & Control Products

80 It s Possible... Not just promises, but possibilities One of the best parts of our job is seeing our products in action at our customer s gins and there is nothing like watching the reactions on the day the equipment is started up for the first time. The second biggest smiles you have ever seen are on the gin crews faces when wet cotton hits the incoming sensor and the heaters immediately respond by turning up. The biggest smile is on the manager s face when the incoming cotton changes back to dry and the heaters not only turn down, but turn all the way off. It s an exciting time for our customers and something we always enjoy watching. An outsider would probably be a little perplexed by this whole scene. They would see a customer who bought some equipment with expectations of performance and wonder why there is so much excitement in it working as advertised. If that outsider knew of the many products pushed in our industry over the years that were long on promises and short on delivery, they would better understand that excitement of seeing equipment that actually does what it says it will do. And if they understood all of the control challenges in a gin, they would better understand how rare such products are and the amount of passion and dedication it takes to produce them. M & C At Sam Jackson, we know there is no substitute for seeing a product working like it should in your own gin. We appreciate the commitment you make when selecting one of our products and when you do, you can be sure of two things. First, we have a long track record and hard earned reputation for customer satisfaction. Second, we know that keeping that reputation means keeping our promises to you. After all, we will enjoy seeing our products in action in your gin almost as much as you will. 80

81 Do you wonder if you can......use automatic heater control to protect from wet surprises and save 30% or more fuel?...automate flow control to gin faster?...automatically control bale moisture?...record key statistics on how every bale was ginned in an easy to use database?...view current ginning data on-the-go on your iphone, ipad or computer? You can do these things and much more. Talk to your Sam Jackson rep today and see what really is possible. M & C Main Line:

82 Moisture Mirror Line Building the Perfect Mirror System for Your Gin Your gin is one of a kind and nobody knows its needs, people and budget better than you. That s why we make it easy for you to customize a Mirror system by choosing the options best for you. Step 1: Select Your Mirror Model There are four Moisture Mirror models, ranging from the budget-friendly Mirror 1 to the fullyloaded Mirror 4X. In addition to the Mirror A Moisture Mirror 2X operator interface. models, we offer the Reflector for those who simply need a display for a single moisture sensing point and an alarm contact. Use the comparison chart and talk to your Sam Jackson rep to see which model offers all the features you want. Step 2: Select Sensors and Options Depending on the Mirror model, you can choose a variety of input and output connections - moisture inputs, heater controls, Humidaire controls, motor loads, Air Control 8 integration, database logging, ipads, iphones and more! Information is power and the Mirror system provides you with many ways to gather and use information. M & C Step 3: Grow With Confidence Tired of the technology you buy today becoming outdated tomorrow? For over a decade our Mirror customers have avoided those costs and frustrations. As your needs grow, so can your Moisture Mirror system. We make it easy to add on additional sensors and options, as well as providing easy model upgrade options that preserve your original investment. 82

83 Moisture Mirror Comparison Chart Which model fits your needs? Reflector Moisture Mirror 1 Moisture Mirror 2X Moisture Mirror 3X Moisture Mirror 4X Model # A 81880A 81900A Touch Screen Size 6-inch 8-inch 10-inch 12-inch 15-inch Moisture Channel Inputs Flow Analyzer Inputs No Custom Inputs analog/1 digital 2 analog/2 digital Alarm Contact Yes Yes Yes Yes Yes Automatic Heater Temperature Control Ethernet Communications 1400, 1500 & 1600 Series Remote No Yes Yes Yes Yes No No Yes Yes Yes No No Yes Yes Yes Aux. Heater Remote No No No Yes Yes SR II Remote No No No Yes Yes Heater Banks Feature No No Yes Yes Yes Heater Idle Feature No Manual Automatic Automatic Automatic Automatic Drying Index No No Yes Yes Yes Shed Technology No No SimpleShed SmartShed SmartShed Automatic Control for Target Bale Moisture No Yes Yes Yes Yes Mobile Mirror App No No Yes Yes Yes Printer Option No No Yes Yes Yes PBI Auto Increment No No No Yes Yes Data Recording Option No No No Air Control 8 Monitoring and Control Compact Flash Card, CSV file MySQL Database on Mac Computer No No No Yes Yes Upgradable No Yes Yes Yes You ve got it all! Value Category Budget-Saver Budget-Saver Gateway Fusion Pinnacle M & C Main Line:

84 The Reflector A Reflector can alert you to high moisture seed. The Reflector is used to display the moisture reading from one sensor in your gin. Often coupled with a Sam Jackson Seed Moisture Sensor, the Reflector includes an alarm contact to perform a control action or simply notify the operator when moisture goes above a user-definable threshold. The Reflector graphs moisture readings for the past 24-hours allowing operators to look back at previous moisture data. A home screen view of the Reflector. Similar to the rest of the Moisture Mirror product line, the Reflector offers several customizable features including warning and alarm setup, password protection and three choices for home screen views. Technical Note: The Moisture Mirror 3X and 4X include an input for seed moisture and do not require the Reflector for seed moisture display. The Reflector s setup screen. M & C The Reflector can offer a useful display of cotton seed moisture for a ginner skilled in evaluation and handling of cotton seed. This information is intended to be fast and repeatable, but not always accurate. Samuel Jackson strongly recommends operator attention to actual seed conditions at all times and user validation of readings against oven moisture tests if readings appear questionable. Always gin your cotton with wisdom and prudence. 84

85 Moisture Mirror 1 Automatic Control for the 21 st Century New Bigger Screen! The Moisture Mirror 1 home screen (8-inch screen size). If you ve been around ginning for very long, you ve heard about automatic heater controls. There are several products out there, but they are either based on 20-year old technology or a custom product from a local electrician with limited product support or upgrade potential. The Moisture Mirror is different. When the Moisture Mirror entered the scene in 2001, a world of new options became available and heater controls have never been the same. The status quo for automatic heater controls had been a couple of big analog dials rigged up to gas valves on your heaters. Just the base model Mirror offers multiple moisture sensor options, automatic control of heaters and Humidaire Units, inputs for cotton flow sensors, graphing of Incoming, After-Drying and Bale moisture and more! If you haven t looked at automatic heater controls in a while, they ve changed! You owe it to yourself and your gin s budget to check out what the Moisture Mirror has to offer. M & C Main Line:

86 Moisture Mirror 1 Moisture Mirror 1 users commonly report savings of 30% on their fuel bill! The Moisture Mirror 1 is a good choice for even the smallest and most budget conscious gins. It s loaded with features and very economical. The feature most appreciated by ginners is Automatic Heater Temperature Control. The Mirror reads the incoming moisture and sets the heater temperature as a remote set point on the existing controllers. The Mirror sets low temperatures when cotton is dry and instantly asks for more heat when cotton becomes wet. This saves fuel and prevents chokes by catching wet surprises inside modules. Users commonly report a savings of 30% on their fuel bill! The Incoming Moisture Screen. M & C The Target Bale Moisture Screen. Automatic Humidaire Unit Control for Target Bale Moisture is another feature enjoyed by many Mirror users. The Mirror receives the bale moisture signal from a compatible sensor and adjusts the Humidaire s water temperature set point to meet the target bale moisture entered by the operator. This feature helps maintain optimum bale moisture, which improves bale weight consistency and proper press performance. 86

87 The Mirror 1 graphs all connected moisture sensor data for a 24-hour time period. This information is helpful for troubleshooting or monitoring moisture information from the previous shift. Flow Analyzers measure the real horsepower being used by a connected motor. When used on a module feeder or inclined cleaner, they help anticipate and prevent chokes. Moisture Mirror 1 Key Features and Benefits 8-inch color touch screen Inputs for Incoming, After-Drying and Bale Moisture Automatic Heater Temperature Control Automatic Humidaire Unit Control for Target Bale Moisture Automatic Control of Conditioning Hopper Valves Flow Analyzer inputs 24-hour moisture graphs Bale per hour indicators Programmable alarm contacts Heater Idle Button Saves fuel Helps preserve fiber quality Helps avoid chokes Heater idle input More consistent bale moisture Helps maintain optimum moisture throughout the gin Easy to install and use Ginner friendly M & C Main Line:

88 Mirror X Software and Operating System Meet the New Mirror X Line The operating core of the Moisture Mirror remained fundamentally the same for almost ten years, since the product s release in Back then, high speed Internet service at gins was rare, PLCs were less powerful, touchscreens had fewer options and we never used the word smart to describe a phone. A lot changed in ten years. So in 2011, our engineers performed a massive overhaul of the operating system and named it the Mirror X. This section will highlight some of the advantages and new features the Mirror X offers, as well as answer some frequently asked questions about this exciting new upgrade. M & C Moisture Mirror 4X Home Screen. 88

89 Friendlier, Faster and Mobile Mirror Compatible Some Mirror X Highlights This software is designed to make setup easier, provide you and your operators with easier access to information and gives you the advantages of the most advanced automatic controls. Mobile Mirror App compatible More shown on the Home screen, giving the information you need at a glance New bale moisture control algorithm for greater stability of bale moisture Faster and more robust communication to connected equipment Virtual stack light Ability to clear all errors and alarms with the press of one button No operational screen is more than two button presses away and most are just one Clear setup screens with features to make it easy to adjust settings and options More advanced production tracking, including per shift customization Additional inputs on Mirror 3X and 4X models (details in those sections) 1600 Series equipment compatible More than 60 other new features Not all features available on all models. Frequently Asked Questions: Can I upgrade my existing Mirror? Yes! Mirror X software is compatible with all existing Moisture Mirrors. What Mirror models can be upgraded to Mirror X software? Mirror X software is available for the Mirror II, III and IV. A Mirror I can be upgraded to a Mirror 2X, 3X or 4X. Will I need any additional parts? Your Mirror will require: Ethernet cards, a 260 PLC CPU, a compatible touch screen (normally applies to Mirror IIs purchased before 2006) and open ports on your network switch. Most Mirrors have some of these components already, but a Samuel Jackson representative can help you determine exactly what you need. How do I get data from the Moisture Mirror X in my gin to my iphone? All Mirror X models are compatible with the Mobile Mirror app, but your Mirror data needs to be securely transmitted to the Internet. See the Mobile Mirror App and Remote Access sections later in this Handbook for more details. M & C Main Line:

90 Moisture Mirror 2X The Mirror 2X is much more than a bigger screen... Now iphone compatible The Moisture Mirror 2X home screen (10-inch screen size). The Moisture Mirror 2X has been a popular model because it s packed with features and with the Mirror X software the feature list has gotten even longer. Ginners enjoy its larger 10-inch touch screen but it s what it does for you that s impressive. 1400/1500/1600 Series Remote Control, SimpleShed Technology and the Auto-Drying Index are the core features that have made this model a can t gin without product for many. M & C And now, add iphone compatibility to the already strong feature list, giving you the ability to connect to your Mirror through the Mobile Mirror App. Many of the most powerful Mirror functions are made possible with Ethernet communications and the Mirror 2X is the most economical Ethernet equipped model. Check out the following pages to learn about the Moisture Mirror 2X highlights that users enjoy most. 90

91 it features functions that you will not want to gin without. A detailed view of a King Mesa Humidaire control screen on the Mirror 2X touch screen. SimpleShed The basic heater temperature control offered by the Mirror 1 is a huge fuel saver. SimpleShed Technology takes fuel savings to a whole new level. The Mirror 2X can turn 1400 Series Heaters on and off in a matter of seconds. The ginner simply sets the Incoming Moisture Threshold and Time Delay on each heater and lets the Mirror do the rest. When incoming moisture is below the threshold, the heater is completely off and in Standby Mode. When it rises above the threshold, the heater lights in about 3 seconds. SimpleShed has saved gins as much as 45% on their fuel bill! Remote Control Functions The Mirror 1 can set the temperatures on your heater and Humidaire, but the Mirror 2X offers full remote control functionality. Ethernet allows the Mirror 2X to remotely control up to Series Heaters and /1500/1600 Series Humidaires. As a remote, the Mirror can start and stop each unit, adjust temperature set points, view diagnostics and clear error messages. Ethernet also makes SimpleShed possible, an incredible fuel saving technology for gins with 1400 Series Heaters. SimpleShed is easy to set up. Heaters can have separate thresholds staging the moisture content at which they shed on and off. For more on this extraordinary feature, see the 1400 Series Heater information in the Drying Products Section. Note: some highlighted inputs require optional sensors or hardware. M & C Main Line:

92 Moisture Mirror 2X Packed with the most common user requested features. The Auto Drying Index is easy to turn on and off and set a Target After-Drying Set point. Target After-Drying Control As the Mirror 1 gained popularity, the most often requested feature for the next model was fully automatic heater temperature control. The Mirror 2X answers, allowing the operator to set a target for the After-Drying Moisture. The Mirror automatically adjusts the Drying Index (red and blue bar) based on comparing the target to the actual moisture value. Incoming moisture is still monitored and fast-paced changes are made to the heater temperature set points accordingly. If the ginner wants to make adjustments, he can easily change the target or switch back to manual Drying Index control. M & C Heater Banks On the Moisture Mirror 1, all connected heaters receive the same temperature set point. This is a great improvement over manual control, but many times Mirror operators want to fine-tune their drying recipe even more. Heater Banks on the Mirror 2X allow operators to multiply the temperature set point by any number between 1 and 200%. Based on the multiplier, heaters will operate automatically at a constant percentage either higher or lower than the Mirror s standard set point. All three Heater Banks can be left at 100% for standard Mirror operation. The Heater Banks setup screen. 92

93 Auto Heater Idling When there s a small problem in the gin, heaters are often left running while the problem is quickly resolved. Many times, problems are not as small as they first appear and a few minutes turns into a few hours. If the heaters are left running at normal temperatures during this time, lots of fuel is wasted. The Mirror 2X can easily solve this problem by automatically idling heaters when cotton flow stops. When cotton flow resumes, the heaters resume normal operation. Auto Heater Idle setup screen. The Moisture Mirror 2X offers all the key features and benefits of the Mirror 1, plus: 10-inch color touch screen 1400/1500/1600 Series Remote Control SimpleShed Technology Target After-Drying Moisture Ethernet Communications Remote Access Option- Monitor your Mirror screen over the Internet from anywhere Auto Heater Idle Feature Cash Register Screen that tracks the impact of your moisture restoration system Ability to add a printer Heater Banks for greater heater temperature control Mobile Mirror App compatible M & C Main Line:

94 Moisture Mirror 3X The Moisture Mirror 3X: Serious Power More Power and Great Value! The Moisture Mirror 3X home screen (12-inch screen size). The Moisture Mirror 3X was designed to enhance 1400, 1500 and 1600 Series Sam Jackson equipment. Humidaires, Heaters, moisture sensors, Air Control 8, the Steamroller and more are right at your fingertips... and that s before you even press a button! M & C The Mirror 3X has improved features from previous Mirror models and has quite a few new capabilities of its own. Data recording, SmartShed Technology, Banjo and VFD monitoring with Air Control 8 and Seed Moisture measurement are a few of the most popular additions. Take a look at the next few pages for a more in-depth look at the most popular features. 94

95 Get the most from your 1400, 1500 and 1600 Series Sam Jackson Products. The Mirror 3X data file exported to a spreadsheet document. The compact flash memory card can store up to 40 data fields for over 100,000 bales. Data Recording The Mirror 3X is a completely integrated moisture management system offering data recording for all 1400, 1500 and 1600 Series products and sensors. The Mirror records every available moisture variable including Heater and Humidaire temperatures, all moisture sensor values, Flow Analyzer readings, ginning rate and ambient temperature and humidity. The data is stored on a compact flash memory card and can be retrieved for analysis through a networked computer or by using a compact flash card reader. SmartShed Like the Mirror 2X, the Mirror 3X has Shed Technology, but the latest version has a few new tricks up its sleeve. SmartShed Technology builds on the SimpleShed options offered by the Mirror 2X of a single moisture threshold and time delay for shedding heaters on and off. SmartShed allows the operator to set an incoming moisture threshold, a threshold for ambient temperature and humidity and even has the ability to turn heaters on and off based on cotton flow. SmartShed Technology is the ultimate in automatic heater control. M & C Note: some highlighted inputs require optional sensors or hardware. Main Line:

96 Moisture Mirror 3X M & C Banjo/Air Control 8 Connectivity The Electric Banjo and Air Control 8 have quietly developed a reputation for being the secret weapon in the world s most powerful drying systems. One reason Banjos were so secret is because they did their job of maintaining robust air flow from the fan room in the back of the gin or under the floor. The Banjo II and updated Air Control 8 are compatible with the Mirror 3X and 4X. Ginners can view Banjo or VFD operation and change set points from the comfort of the Mirror touch screen at the console. For more information, see the Air Control 8 section of this book. The Mirror 3X screen opens up in your Internet browser allowing you to watch your gin run from anywhere you are in the world. The Air Control 8 screen on the Mirror 3X supports 8 fans and has dynamic text for custom naming. Internet Viewable The Moisture Mirror 3X s Remote Access option lets you watch your Mirror from home... or anywhere else with Internet access. That might not sound appealing at first, but you ll want your whole gin to be Internet accessible the first time the Mirror 3X s Remote Access saves you a trip from home in the middle of the night. This information can also be viewed by Samuel Jackson personnel saving you time and money if your problem can be fixed remotely instead of having someone make a service call. The Remote Access option does require a good Internet connection at the gin, but managers that already rely on this option will tell you, It s worth it! 96

97 Auxiliary Heater Remote The Mirror 3X is not only a full function remote for 1400 Series and higher drying system heaters and Humidaires, but it can also connect to most 1401 and all 1501 Auxiliary Heaters. That makes it possible for your operators to monitor and adjust your auxiliary heater from right at the console. No more walking back to the heater to reset errors and more importantly, no more surprises caused by the heater going off without anyone noticing or struggling to maintain the desired temperatures undetected. Customizable Inputs Mirrors quickly become an indispensable mission command center for operators. So it makes sense that gins have requests for non-standard inputs. The Mirror 3X makes this possible, giving you two customizable input channels (one analog and one digital). You pick the critical points you want to monitor, such as a shaft speed, machine operating temperature, pressure or switch status. The 3X can display on screen alarms, helping you avoid trouble and gin faster. M & C Main Line:

98 Moisture Mirror 3X Seed Moisture Input Cotton seed is valuable and knowing the moisture content of that seed can help protect its value. Mirror 1 and 2X users have to buy a Reflector to monitor seed moisture. Mirror 3X users enjoy having these benefits built in, including the seed moisture reading, the display and the programmable alarm contact all in the same convenient place as their other Mirror information. Bales per Shift The quickest way to see how things have been running is to look at the production figures. The Mirror 2X displays current and average bales per hour, but the Mirror 3X does that and also keeps track of bale production per shift. You define the start and stop time for up to 3 shifts and the Mirror counts, displays and records the number of bales each shift produces, including the current and last shift(s). Monitors Temperature and Relative Humidity You know that ambient conditions affect ginning operations - make sure your Mirror knows what those conditions are. SmartShed utilizes the ambient temperature and relative humidity for advanced automatic heater control. Since this information is also logged, it can help when analyzing bale and performance data. M & C Bale ID Logging As you can see, the Mirror 3X is capable of collecting and recording a lot of valuable information. To tie the data to each bale ginned, the 3X is also capable of capturing every bale ID number. Receive questions about a particular bale? Look up the data for that bale and see the key information about how it was ginned. 98

99 Steamroller Remote Control Screen Steamroller I and II users with compatible control panels can connect them to their Mirror 3X. This allows operators to monitor the Steamroller from the console. The static pressure is continuously displayed, helping the operator keep an eye on exhaust air flow - an important operation parameter. Watching the static pressure can help indicate when cleaning is needed. The screen also shows the Steamroller status and speed. Consult with your Sam Jackson representative for compatibility details. How did we pack so many features into the Mirror 3X? The Mirror 3X offers a lot of capabilities and power beyond lower models - more than we could cram into a single panel. To offer all of these features, Mirror 3X and higher models include a second control panel that we refer to as the advanced panel. The advanced panel gives extra processing power and communication points to your Mirror system. This approach also makes it easier to install field upgrades from a Mirror 1 or 2X. Having more features requires more screen space to efficiently display information and controls to the operator. The Mirror 3X utilizes a 12-inch color touch screen to keep key information available to your ginners at a glance and all of the data and setup screens are never more than a touch or two away. The Moisture Mirror 3X offers all the key features and benefits of the Mirror 1 and 2X plus: 12-inch color touch screen Data storage on a compact flash memory card Data is network accessible Data is easily exported to spreadsheet software for analysis SmartShed Technology Custom input channels (1 analog/1 digital) Analog input for seed moisture Monitoring and control of Air Control 8 Steamroller monitoring Bales per shift monitor Temperature and Relative Humidity Sensor Input Bale ID Logging M & C Main Line:

100 Moisture Mirror 4X Look at your gin in ways never before possible. The Moisture Mirror 4X home screen (15-inch touch screen). M & C The principles behind the Mirror 4X are simple. First, knowledge is power. Second, the easier it is to access and the more ways it can be analyzed, the more powerful that knowledge becomes. The Mirror 4X combines those two basic truths to give you the most information, the most ways to view it, the most automatic controls and the most complete and usable database for creating performance reports. Simply the Best! 100

101 The Mirror 4X records ginning data in an easy to access premium online database. Have you ever wondered... how does my day ginning compare to my night ginning? how many bales left my gin under 7.0% moisture last season? how much do we slow down in wet cotton? is dry cotton hurting my staple? is overloading my pre-cleaning affecting leaf grades? Every Mirror 4X has its own website where you can search for information and create reports by any key variable on the Mirror. Search bales by permanent ID # Search bales by date ginned Search bales by Mirror variable One click reports for data averages by day, week or season Look What s Possible! With easy to find information at your fingertips, you ll never look at moisture control in your gin the same way again! M & C Main Line:

102 Moisture Mirror 4X Three Drying Loops for Gins With Multiple Incoming Feeders Some gins are setup with multiple module feeders and/or feed controls. Without the 4X, such gins would need additional Mirrors to provide separate drying control loops, but the 4X includes three independent drying control loops, making it ideal for such gins. Not only does each feeder have its own moisture sensor, but the drying indexes can be set independently, too. (Two loop setup shown). M & C...and Two Bale Moisture Control Loops for Gins With Two Presses The Mirror 4X also offers two independent bale moisture control loops, saving gins with two presses from needing to purchase two separate Moisture Mirrors. This allows for two independent targets, two bale moisture readings and the ability to control two Humidaires automatically. The screen also displays the last 16 bale moistures for each side, so that you see how well your moisture restoration systems matches the target. Note: some highlighted inputs require optional sensors or hardware. Users can choose between the three drying loops option or the second incoming moisture input, but not both at the same time

103 Second Incoming Moisture Input In some situations, a second incoming moisture sensor would provide faster response or help provide additional control stability. The Mirror 4X makes this possible, providing two inputs dedicated for incoming moisture signals. The automated control can be set to react to either reading, the average of the two readings or to the highest of the two readings. More Flow Analyzer Inputs All of the other Mirror models offer only three flow analyzer inputs. The Mirror 4X offers five inputs, making it possible for you to monitor loads on two additional key points. These points can also be configured to trigger an alarm contact, helping you avoid costly chokes and proactively identify potential problems. The Moisture Mirror 4X offers all the key features and benefits of the Mirror 1, 2X and 3X plus: 15-inch color touch screen Two additional flow analyzer channels for a total of five Input for hopper moisture in addition to after-drying moisture input Three independent automatic drying control loops for gins with multiple feeders Two independent automatic bale moisture control loops for gins with two presses Steamroller remote control functions Equipped with networkable Mac Mini Server for increased data storage Built-in premium database Data stored in full functioning MySQL database Capable of recording 1,000,000 bales of ginning data Dedicated website access to the database Database is searchable Data can be filtered to hone in on the variables you want to analyze One click reports for data averages for shift, day or season Custom reporting possible M & C Main Line:

104 Moisture Mirror Upgrades We make upgrading Mirror Models easy! Mirror I Mirror 2X Mirror 3X Mirror 4X As deals go, you ll be hard-pressed to find one like this in the ginning industry or anywhere else for that matter. Since the Moisture Mirror II was released in 2003, Samuel Jackson has made it our goal to allow Mirror users to retain 100% of their investment when upgrading their Mirror. On some models, that amounts to over a 50% savings versus buying new. Over 100 gins with Moisture Mirrors have already taken advantage of this offer. The Moisture Mirror upgrade is essentially a kit. All Mirrors have compatible wiring, so the upgrade usually consists of a larger touchscreen and new software. More advanced models include a second PLC and enclosure with the kit. All existing sensors are compatible with updated Mirror models assuring you that they can always be reused. M & C No other equipment in your gin preserves your capital like the Moisture Mirror. We hope you ll take advantage of this upgrade offer because it may not be around forever

105 Mirror Sensors: The Sled II Incoming moisture for gins without a Samuel Jackson Hot Box. The Sled II is a resistance-based sensor mounted on a pendulum frame above a conveyor belt that gives lightning fast, highly repeatable readings. The Sled II glides along the top of the seed cotton and reports instant readings back to the Moisture Mirror for automatic heater temperature control. The Sled II in action. The Sled II is most often employed at gins using a conveyor belt that do not have a Samuel Jackson Hot Box. The Sled II offers an earlier point for sensing moisture than a feed control, giving heaters more time to respond to fluctuations in moisture. The Sled is a very popular option for sensing incoming moisture with over 150 units sold since If you have a Sam Jackson Hot Box or are planning to get one, see the section on the Hot Box with Incoming Sensor. M & C A Sled I and a non-sam Jackson hot box. Main Line:

106 Mirror Sensors: Hot Box Inlet Sensor If you have a Sam Jackson Hot Box II or III, save money and space with a door mounted sensor. Mounting the incoming moisture sensor on the cotton inlet door was an idea born out of necessity for gins with limited conveyor belt length between the module feeder and the Hot Box III. With the cotton inlet door riding less than two inches off of the belt, the sensor is constantly submersed in seed cotton making it an ideal spot for moisture sensing. The Hot Box sensor constantly monitors the moisture content of incoming seed cotton. M & C The cotton inlet door of the Hot Box III is a very hostile environment. Modules often contain wrenches, concrete pieces, mesquite stumps and a number of other items that all end up at the Hot Box door. With such an abrasive environment, the rugged and durable stainless steel design of the Hot Box door sensor is a requirement. It sloughs off any debris that comes its way as it performs its daily duty of taking fast and repeatable moisture readings. The moisture sensor is mounted on the angled area at the bottom of the cotton inlet door putting it into direct contact with seed cotton

107 Mirror Sensors: Universal Sensor Universal Sensors are the most flexible option for measuring incoming or after-drying moisture. The Universal Resistance Sensor above a vacuum dropper. Incoming - Lots of gins don t have conveyor belts carrying cotton from the module feeder to an air pickup point. For those gins, the Universal Resistance Sensor is the best option for measuring incoming seed cotton moisture. This sensor can be placed anywhere cotton builds for a short period of time. Above vacuum droppers, feed works below a module feeder or a feed control bin are ideal locations, but the Mirror s peak hold feature allows flexibility in other locations, too. After-Drying - The Universal Resistance Sensor is also welldesigned for measuring after-drying seed cotton moisture. For gins that use seed cotton conditioning systems, the best location for this sensor is in the overflow hopper. Gins that do not use seed cotton conditioning have the option to locate the sensor between the conveyor distributor and the extractor feeder above the gin stand that receives the most cotton. M & C The Universal Resistance Sensor mounts discretely on the back of the transition between the distributor and the extractor feeder or the overflow bin (as shown). Main Line:

108 Mirror Sensors: Tex-Max Module Moisture Great for Second Incoming Moisture Sensor for Mirror 4X Users Our first recommendation for an incoming moisture sensor is a resistance sensor close to the pick-up point, such as a Sled II, a Universal Sensor in a feed control bin or a Hot Box sensor. These sensors are fast-responding and when paired with a Moisture Mirror, they are capable of reporting the highest moisture cotton passing across it. That makes them ideal for providing you with the incoming moisture signal you need for great automatic heater temperature control. If you can only have one moisture sensor, one of our resistance sensors is the way to go. But Moisture Mirror 4X users aren t limited to one incoming moisture input - they can have two! The Tex-Max Module Moisture sensor is ideal for making the most out of an additional incoming moisture input. The Tex-Max is mounted on the module feeder, where it scans through the middle of the module giving advanced notice of changes in module moisture. This means your ginner and your Mirror 4X can not only see the moisture of the cotton currently being fed into the gin, but also what is about to enter the gin, as well. Using these two sensor types in tandem allows you the advanced notice provided by the Tex-Max, while avoiding the shortcomings associated with microwave sensing at the module feeder. See the Mirror 4X section of this catalog for more details on using a secondary incoming moisture input. M & C 108

109 Mirror Sensors: Seed Moisture Sensor Help protect one of your most valuable assets. Your seed. The Seed Moisture Sensor is located in the seed plug access door. The Cotton Seed Sensor needs a display for its output signal. For gins with a Moisture Mirror 3X or 4X there is already an input for seed moisture. For gins with earlier Mirror models or no Mirror at all, the singlechannel Reflector is ideal for performing this function. Both the Mirror 3X, Mirror 4X and Reflector include a user-defined alarm contact to notify operators or perform a control action when seed moisture gets too high. For more, see the sections in this book on the Reflector and the Moisture Mirror 3X and 4X models. Cotton seed is an extremely valuable asset to gins because many gins are paid with seed and nothing else. Seed moisture is very important because wet seed can cause an extensive amount of damage in the form of mold and sometimes fires. The Cotton Seed Resistance Sensor mounts in your seed plug access door. As its name states, it is based on the same fast and repeatable resistance technology used in the Samuel Jackson seed cotton moisture sensors. A gin has a couple of options to serve as a display for the Seed Moisture Sensor. The seed moisture sensor and Reflector products are intended to offer a useful display of cotton seed moisture for a cotton ginner skilled in evaluation and handling of cotton seed. This information is intended to be fast and repeatable, but not always accurate. Many variables may affect accuracy of a resistance moisture sensor like the when used with cotton seed in a gin. Samuel Jackson recommends operator attention to actual seed conditions at all times and user validation of readings against oven moisture tests if readings appear questionable. M & C Main Line:

110 Mirror Sensors: Tex-Max Bale Moisture Know the moisture of every bale. The Tex-Max is a highly accurate and very repeatable online microwave-based sensor for reading final bale moisture. It works by taking approximately 1,000 overlapping scans per second as the bale moves at a constant speed through the transmitter and receiver. Each scan passes all the way through the bale and is not affected by bagging or tie materials. After the bale has passed through the Tex- Max, the average bale moisture is displayed on the LCD screen on the side of the unit. A 4-20 ma output for bale moisture content is also available for display and automatic Humidaire Unit control when connected to any Moisture Mirror model. The Tex-Max Bale Moisture Sensor. M & C Do Not Use With Water Spray Devices A Tex-Max cannot protect you against problems from bales that have been subjected to water spray systems. Because water spray systems apply moisture unevenly, extreme wet spots can and do exist within a bale that has an average moisture of less than 7.5%. Problems from these wet spots can arise before the moisture can equilibrate throughout the bale. Samuel Jackson reserves the right to refuse sale of a Tex-Max to any gin using a water spray device

111 Mirror Sensors: Flow Analyzers Monitor the flow of cotton through machinery. Flow Analyzers are used to monitor cotton as it flows through gin machinery. Consisting of a current transformer and shaft power monitor, Flow Analyzers measure the percent horsepower used by a connected motor. Unlike measuring only amperage, percent horsepower is representative of the actual work done by the motor. This allows Flow Analyzers to sense very small changes in cotton flow like module density, cotton moisture and trash content to name a few. Flow Analyzers do require a Moisture Mirror to display the signal from the shaft power monitor. The Flow Analyzer is normally installed near the motor starter. Flow Analyzers normally monitor the module feeder dispersing cylinders and the cylinders on the first stage inclined cleaners. As cotton enters the machine being monitored, the yellow bar graph on the Mirror changes according to flow. New Flow Analyzer Option for Module Feeders with Belts! The Cotton Height Sensor acts as an eye seeing wads before they enter your gin and become chokes. Ask your Sam Jackson Representative for details. Alarms can be setup for a control action such as pausing the module feeder or alerting ginners with a light or a buzzer. Flow Analyzers can also be used to idle heaters on Moisture Mirror models 2X, 3X and 4X. All Mirror models offer at least three flow analyzer inputs and the Mirror 4X offers two extra for a total of five flow analyzer inputs. Flow Analyzer channels can be programmed with custom alarms, allowing you to do things like pause the incoming feed if an incline reaches near overloading. M & C Main Line:

112 Mirror Accessories: Bar Code Scanner and Printer Economical tools for documenting moisture from module to bale. Bar Code Scanner - While the Moisture Mirror product line gives you an important window into your ginning process at a specific point in time, it s not until later when you sit down and look at the data that you re able to properly evaluate how well your operation ran over a period of time. The Moisture Mirror 2X, 3X and 4X have the ability to record gin level moisture control data by Permanent Bale ID using a Bar Code Scanner. The Scanner comes with a mounting arm for hands-free scanning or it can be used manually. The Bar Code Scanner is often mounted to the Tex-Max Bale Moisture Sensor frame. Printer - Moisture Mirror models 2X and higher are compatible with the Printer Option. The Printer provides a single line of information for each bale. With the appropriate sensors connected, this information includes: Permanent Bale ID, BPH, time of day, Incoming, After-Drying and Bale Moisture, three Flow Analyzer Channels, Drying Index Setting, After-Drying Target and Target Bale Moisture. The Printer Option records line by line bale data. M & C 112

113 Remote Access Securely connecting your data to the Internet. Sam Jackson products (depicted in red) in your gin stay connected via a local network. This allows the information to be conveniently displayed and shared among products for integrated performance. But there are times when you are away from the local gin network that you would like to view or share data on your ginning operations. Example devices include smart phones, computers or remote Sam Jackson support (depicted in green). The Remote Access option can securely make the data from your local Sam Jackson gin network available to you via the Internet. What is Remote Access? It s a fee-based Moisture Mirror network monitoring service. Provides you and technicians Mirror remote access for monitoring and troubleshooting. Saves service calls, which gets you back to ginning faster and saves you money. Required if Samuel Jackson is providing your network support. Requires a dedicated Internet connection for the Mirror. Pricing is reasonable and subject to Mirror model. Do it yourself option instructions are FREE. See: M & C Main Line:

114 Mobile Mirror App From the other side of the county to the other side of the world, your iphone can keep you connected to your gin. Moisture Mirrors have given ginners loads of key information that helps them run more efficiently, alert them to problems faster and help automate more processes to achieve consistent results. For gin managers, it also helps monitor system and crew performance. But gin managers wear a lot of hats and can t always be near a Mirror screen. But if they have an iphone, they can have the next best thing - a Mobile Mirror screen. With the Mobile Mirror App, over 70 gin variables are at your fingertips anywhere in your iphone service area. Have an ipad? The Mobile Mirror app works on that, too. The full Mobile Mirror app is available through the Apple App Store, but should only be purchased once you have the necessary system requirements, which include a Mirror 2X or higher, remote access and a dedicated Internet connection. Other specifications apply, so please visit with your Sam Jackson rep for full details. But you can check out a demo of the app for free! Search the App Store for Mobile Mirror Free and see the simulated ginning variables, try out the graphing feature and imagine all the ways you can make use of having this information in your pocket whenever you need it. M & C 114

115 Some variables monitored by the Mobile Mirror app: Mobile Mirror connects you to the data being displayed on the Moisture Mirror in your gin. Current BPH Average BPH Bales This Shift Bales Last Shift Bales This Season Incoming Moistures After-Drying Moisture Bale Moisture Seed Moisture Flow Analyzer Loads Heater Temps Drying Index Target After-Drying Heater Status Shed Status Target Mode Valve Position Humidaire Temps Humidaire Status Evaporation Rate Purge Rate Auxiliary Heater Steamroller Data Target Bale Moisture Air Control Set Points Air Control Loads Custom Channels Mirror Inputs Mirror Outputs Ambient Temp Ambient RH% Cash Counter Data *depending on your Mirror model and options M & C Main Line:

116 MoistureMirror.com Get the scoop on Web Access to Your Gin at M & C At MoistureMirror.com you can: Learn about Remote Access through a VPN Connect to demo online Mirrors at the Sam Jackson factory Conduct speed tests for your Internet connection Find detailed instructions for connecting via Windows, Mac or iphone Do It Yourself instructions for setting up your own Remote Access 116

117 The Tool Box When you have nice tools, you want a nice place to put them. Mirrors, advanced panels, Flow Tools, Air Tools, data concentrators, alarm relay panels - if you own several of these powerful products the good news is they will make a big impact on your operational efficiency and profitability. But each of these panels comes in its individual enclosure, making installation of several panels challenging. Space requirements, convenient access and inter-panel wiring are all complicated by using individual enclosures. So what do you do? We recommend that you take the same approach as you would in keeping any other high-end tool. Put them in a Tool Box! The Tool Box is a 60 x 48 x 10 steel enclosure can comfortably hold 4 standard panels, with plenty of room to keep wiring easy and neat. It can also house your Ethernet switch(es) and power supply back-up. An integrated light makes everything easy to see and panels are mounted at a comfortable working height. Doors open wide, keeping them from interfering with access when you need it. And it s equipped with a lock and key when you want to keep access away from others. Every time you need panel access, you ll be glad you have a Tool Box! M & C Main Line:

118 Handheld Moisture Meters Handheld Moisture Meters let you spot-check moisture anywhere within safe reach. Every gin needs a Moisture Mirror, but sometimes there are places that you need to check moisture outside of the gin. The 16001A Delmhorst C-2000 is a helpful tool that can travel with you to the warehouse, the seed house, the module yard or the field anytime you need to spot-check moisture levels. Samuel Jackson has been a U.S. Dealer for Delmhorst for many years and stands by their product s rugged and reliable operation. The C-2000 is even carried by Sam Jackson technicians in the field. The handheld unit is sold by itself, but requires one of the resistance-based sensor attachments for operation. These include: the 16867A Module Probe, the 16003A Seed Cotton Cup and the 16002A Bale Probe. C-2000 Meter M & C Module Probe Seed Cotton Cup Bale Probe 118

119 Handheld Temperature Sensor A diagnostic tool every gin should have. The Handheld Temperature Meter is a handy product to have in your gin s tool room. Even if you don t use it everyday, there s no substitute when you need it. The Meter does require one of the temperature probes for operation. The 5-inch long, Air/Water Temperature Probe is essential for diagnosing thermocouple problems on heaters or Humidaire Units. Many gins have infrared temperature meters, but they only measure surface temperature. That s great for troubleshooting failing electrical components, but accurately measuring air or water temperature requires immersion of a probe into air or water. Taking a reading near the suspect thermocouple can quickly tell you if it s working or not, saving time and headaches. Temperature Meter The Handheld Temperature Meter also supports a Module Temperature Probe. Air/Water Probe Module Probe Specifications and features include: 3.5-inch Digital LCD readout Displays in Fahrenheit or Celsius Temperature Range: -40ºF to 300ºF -40ºC to 150ºC Accuracy: 40ºC to 80ºC, ±1.5ºC 80ºC to 150ºC, ±2.5ºC -40ºF to 176ºF, ±3ºF 176ºF to 300ºF, ±4.5ºF Includes carrying case M & C Main Line:

120 Air Tools Why continuously measure your air? Everyday life is filled with sensors and indicators to make our lives better... We use them throughout the gin to monitor compressed air pressure, amps, hydraulic pressure, RPMs, temperature, moisture and more... We monitor these things to keep the gin running at its best. M & C The right air flow is critical to your gin running well. Air Tools can help you make sure it s right. Air Tools can help your gin run its best! 120

121 Save time and money by avoiding chokes. In a cotton gin, air is extremely important. It dries and restores moisture, cleans lint, batts fiber, doffs brushes and conveys material between machinery. For such a critical component in the ginning process, air has traditionally been difficult to keep a handle on. Air Tools uses online pressure ports connected to analog gauges or touchscreen displays to make air easier to see and understand. These pressure measurements act as windows into a gin s air systems showing changes as they happen throughout the entire ginning season. Air Tools let you see and prevent blockages that cripple your air systems and ultimately lead to chokes. Air Tools is like imaginary windows allowing you to look inside your air system!! Static Pressure Port installed in a pipe. M & C Main Line:

122 Air Tools The Static Pressure Port The 22420B Static Pressure Port. Every Air Tools measurement location requires a pressure port. The static pressure port measures static pressure inside a pipe or duct. Static pressure is especially useful because it is normally very stable and easy to monitor. When there s a problem, static pressure increases or decreases depending on whether the blockage is upstream or downstream from the port. Seeing this change early allows operators to pause ginning, go straight to the problem, fix it quickly and resume ginning. Air Tools allows ginners to detect small problems before they become large ones saving costly down time. The Static Pressure Port is made out of powder-coated cast iron making it durable and economical. It consists of three pieces and can be quickly installed from the outside of any round pipe or rectangular duct. M & C Suggested measurement locations include: Drying system pipes Cyclones Lint cleaner duct Lint flue Before or after inclined cleaners Fan inlets or outlets Other problematic choke points in your gin The inside view of the Static Pressure Port

123 The Velocity Pressure Probe Knowing the velocity pressure in your air lines can be very useful. Velocity pressure tells you how fast the air is moving and can be used to determine the actual air volume in your pipes. Pipes in a gin carry air, seed cotton, lint, trash and cotton seed. Because the Velocity Pressure Probe extends inside the pipe, it can only be used in air lines. The Velocity Pressure Probe. The Velocity Pressure Probe is made out of powder-coated steel making it durable and economical. It consists of two pieces including the probe and an adjustable clamp. The clamp allows the probe to be extended into an air line up to 14 inches. The tip of the Probe is where the measurement is taken. A good place to use a velocity pressure probe in a gin would be between a heater and the mix-point or any other clean air line where air volume or velocity is important. Need help picking between the static and velocity probes? We can help you pick the best one for your application and goals. The clamp allows adjustment up to 14 inches inside the pipe. M & C Main Line:

124 Air Tools Budget and Gateway options, because everyone needs an eye on their air flow. Budget-Saver Option - The Air Tools product line was designed to fit the budget and comfort level of any operation. The easiest way to setup an Air Tools monitoring point is by connecting the pressure port directly to a Analog Magnehelic Gauge. The Analog Gauge serves as a monitoring point, but offers no control action. The Magnehelic Gauge comes complete with a mounting bracket for quick installation. Gateway Option - The Photohelic Gauge keeps the simple Analog interface of the Magnehelic, but adds control action with a built-in relay contact. The set points are easy to adjust with the dials on the sensor s face. If the pressure reading trips either of these set points, the contact opens or closes depending on wiring. These could be used to turn on a warning light, kick a gin stand out, pause incoming feed or any of a number of other possibilities. M & C 124

125 Transducers and Concentrators put Air Tool readings at your fingertips. Air Tools Pressure Transducer. Pressure Transducers - Analog Gauges are inexpensive and good for a peek into your air systems. As with any system, looking at one part is helpful, but it really doesn t tell you the whole story. Air Tools can bring multiple monitoring points into a single touch screen. To accomplish this, a Pressure Transducer must be used to convert the pressure readings into electrical signals. One Transducer is required for every Pressure Port. The air tube from each Port plugs into a Transducer which is then wired into the Data Concentrator. Data Concentrator - A Data Concentrator is required for both Mini and Premium Air Tools. For the Premium Interface, a single Concentrator will support up to 12 monitoring points. Each additional Concentrator adds another 12 points of capacity up to a maximum of 36 points. Cables leaving the Pressure Transducers are wired into the Concentrator and then a single Ethernet cable connects the Concentrator to the Air Tools Touch Screen Interface. The Concentrator should be located as central to its monitoring points as possible. The Data Concentrator connects the Pressure Transducers to the Touch Screen Interface. M & C Main Line:

126 Air Tools Mini Air Tools: An affordable option for monitoring the most essential points in your air system. The Mini Air Tools includes an 8-inch touch screen that is easy to read and use. The Mini Air Tools Kit includes: an 8-inch color touch screen interface, 6 Pressure Ports, 6 Transducers and a single Data Concentrator to monitor pressure at the most essential points throughout your gin. The six points can be used anywhere there is air flow such as the drying system, lint cleaners, cyclone banks, etc. The Mini Air Tools Interface only supports 6 monitoring points, but the Data Concentrator, Transducers and Pressure Ports can be reused when upgrading to the Premium Interface. M & C Mini Air Tools was designed with all users in mind. The six monitoring channels fill the touch screen, so they are easy to read and use. Pressing any channel zooms to an individual monitoring and setup page. Setup is simple using an on-screen keypad to enter each warning and alarm value. The red, yellow and green scale adjusts instantly as changes are made. Mini Air Tools users also enjoy dynamic text for flexible naming of each monitoring channel. Each channel can be zoomed in to see short term graphs and setup parameters

127 Premium Air Tools: See the air at up to 36 points in your gin. The Premium Air Tools Interface with all 36 channels displayed. Unused channels can be hidden. Once you discover the power of Air Tools, you ll find there are lots of places in your operation that Seeing the Air could be beneficial. The Premium Air Tools Interface is capable of handling 36 different channels making it suitable for systems large and small. Premium Air Tools does require one data concentrator for every 12 monitoring points. This allows an operation to utilize the Premium Interface, but only purchase ports and concentrators as needed. The Premium Air Tools Interface has several user-definable features. There are two scales for each channel allowing the operator to set thresholds for flowing material and idled flow. This is helpful because these values can be significantly different and idled thresholds can alert the operator to problems before material is fed into the system. An early indicator could mean the difference between preventing a problem and digging one out of a choked piece of machinery. Each channel allows the operator to zoom in for a closer look. M & C Do you want more options for controlling your Air Tools system? The Alarm Relay Output Panel gives you 16 separate alarm outputs for control actions such as kicking out individual gin stands or pausing your module feeder. Main Line:

128 Introduction to Flow Control It s cotton flowing through your gin, A lot of factors go into determining a gin s bottom line, but aside from having cotton to gin, no factor matters more than how quickly that crop is ginned. When the topic of gin production gets discussed, how fast a gin can run gets a lot of attention. But the biggest of those numbers happen under the best conditions and can be deceptive in evaluating overall performance. What matters to a gin s bottom line is achieving their target production consistently. Our company s history has been built on delivering products that help gins with that goal across a wider range of conditions - not just the best conditions. But setting up your gin layout for consistent production is just one challenge, keeping it fed with the right amount of cotton is another. Knowing the importance of this challenge of flow control, we ve had a history of swings and misses working on it, too - mostly misses. Still, the advantages of consistent flow control were too great for us to give up. In 2007, we set out to address this challenge again with a mix of lessons learned from past attempts and new control tools with a fresh approach to custom tuning for each gin. Melding those elements were the seasoned talents of Mark Gentry, the lead product designer. If you ve met Mark, you know he has a knack for making the complex simple and a passion for helping customers become more efficient. The hard earned results reflect those qualities and from it we can now offer gins automatic flow control with Flow Tools. M & C 128

129 but it might as well be real money. How much is good flow control worth? To evaluate the importance of consistent flow control, think about your last gin stand. Out of every hour, how much time does it spend empty with the gin breast out? How much time does it spend running at less than full capacity? Those times add up to production losses and those losses eat up profits. To put some numbers to it, look at these examples. If you watched a 15 bale-per-hour stand for 10 minutes: Every 40 seconds that stand is out, it loses 1 bale-per-hour of production Every minute it is operating at 50% capacity it loses 3/4 bales-per-hour of production Scenario #1 40,000 Bale Season 32 bales-per-hour average without flow control 34 bales-per-hour average with flow control Production savings of more than $45,000 Scenario #2 100,000 Bale Season 43.5 bales-per-hour average without flow control 46 bales-per-hour average with flow control Production savings of more than $78,000 Flow Tools has helped customers achieve production increases in that range and in some cases even more. Note: The production savings are based off of a variable hourly ginning cost of $625 per hour. Our engineers will be happy to help you analyze potential returns based on costs specific to your gin. M & C Main Line:

130 Flow Tools: Fundamentals Your ginner accounts for a lot of variables to control the feed rate... Consider some of the variables that your ginner must factor in when setting the feed rate. These variables are always changing and aren t always easy to see. Even if he had all of the information, making adjustments to all of it would require constant tweaking of the control knob, which ties him up from taking care of the many other parts of his job. Incoming Moisture Slugging Module Density Disperser Load Module Toppled? Gin Stand Status Overflow Level Round or Conventional Module Size Incline Loads Cotton Type Problems at the Press M & C Conveyor Distributor Status 130

131 Flow Tools does, too. Flow Tools collects information from its own sensors and shares information from the Moisture Mirror via an Ethernet network. What type of information? Flow Tools monitors the same type of variables your ginner would use to adjust the incoming flow of cotton. Because these variables or their immediate effects are continuously monitored, Flow Tools can make fast adjustments in response to changes, resulting in more consistent production and freeing your ginner up to tend to the other things that keep your gin running smoothly. Our ginners spend less time adjusting the module feeder knob and more time ginning cotton. Jerry Harris King-Mesa Gin, Lamesa, TX Hear what Flow Tools customers are saying for yourself. Go to YouTube and visit the SamJacksonCinema channel or type in keywords Cotton Gin Flow Tools M & C Main Line:

132 Flow Tools Proven results from a design made for the way you gin Flow Tools is an innovative product that s easy to use and understand. The operator simply sets the Flow Tools Set Point Selector on a conventional dial near the touch screen. Flow Tools maintains that setting by combining the information it collects via sensors and the network with the user defined settings that are specific to your gin. The result allows for a completely automatic flow control solution for many gin layouts. Flow Tools even keeps track of the amount of time it is being operated in automatic. This feature helps you (and us) track how well it is performing. Real reports from gins utilizing Flow Tools show run times as high as 99.5%. Flow Tools Home Screen. Existing module feeder controls are not altered when integrating Flow Tools. Modifying a system that works creates unforeseen problems and confuses operators that are comfortable with their existing setup. Flow Tools sends a speed signal to the module feeder bed via two wires. Instead of the ginner setting a bed speed with a speed potentiometer or a touchscreen, Flow Tools does it automatically. All existing module feeder functions and features are preserved. M & C If you want to take the system out of automatic and switch back to manually setting the module feeder bed speed, all it takes is the flip of a switch. But once you see how well Flow Tools keeps your gin fed consistently, expect to be spending almost all of the time in automatic mode and the smiles that go with it Flow Tools works with a gin s existing module feeder controls.

133 Setup, training and people Flow Tools Setup Screen. As with any product in your gin, don t underestimate the people requirement for a Flow Tools System. Samuel Jackson requires that at least two people are trained by our technicians on Flow Tools setup, tuning and operation during commissioning. Flow Tools is a product that will ultimately require less ginner involvement with flow control, but understanding the system is the only way to get there. In the right hands, Flow Tools can significantly improve consistent cotton flow in your gin, allowing faster and more profitable ginning. Flow Tools includes many user-definable settings to customize the system for your gin. Sam Jackson technicians help you initially set up Flow Tools while teaching personnel how each parameter works. After the initial setup, Flow Tools will be operational, but there s no way to replicate cotton flow in your gin like real ginning. Fine tuning will be done by ginners through experience with the system. Every adjustment will move the system closer to seamless integration into your operation. The tuning period may take a few days to a couple of weeks depending on the operation and gin personnel. Ginner sets the Flow Tools Set Point. M & C Main Line:

134 Flow Tools What you need to know when considering if Flow Tools is right for your gin... We d love to tell you Flow Tools will work for any gin, but it won t. One of the principles behind our success is that we always strive to find the best fit of products for each of our customers and Flow Tools is no exception. Our engineers have identified some of the gin setup characteristics that contribute to a successful Flow Tools installation. If your gin meets these criteria, there is a good chance that Flow Tools could be right for you. Isolated Motor on Inclined Cleaner Cylinders Flow Tools requires accurate readings from the Flow Analyzers that provide it with inclined cleaner loads. For the accuracy needed, the motors must drive only the cylinders. If a motor drives both the cylinders and a vacuum, it will not provide a consistent or accurate enough signal. Belt Feed at the Module Feeder Cotton height measurement is a critical element in avoiding chokes in loosely packed modules and providing Flow Tools with a more comprehensive picture of the amount of cotton entering the gin. A belt feed going into a Hot Box provides us with a place to obtain that measurement. Adequate Sized Overflow Based on Gin Capacity Flow Tools utilizes information about the amount of cotton in your overflow to make a determination if the cotton flow is too high or too low. A small overflow decreases the amount of resolution in this information and reduces the margin for error. Flow Tools works best with 5 cubic feet of overflow for every bale per hour capacity. No Long Delays Between the Module Feeder and the Inclines Long time delays create a lag between measured variables that makes tuning difficult. Long belt conveyors, like those used on moving head module feeders, or dryers with long residence times are not Flow Tools compatible. M & C Responsive and Solid Drying Systems Flow Tools factors in incoming moisture, but for it to really shine it needs to be coordinated with responsive and effective drying system controls and equipment. Visit with us to find out more about Flow Tools and its potential to help you gin more efficiently

135 All gin stands running at full capacity. Ginners tending the gin instead of the feed control knob. Ginning faster with Flow Tools. M & C Main Line:

136 Fire Tools Cotton gin fires are costly... Downtime Safety Damage M & C 136

137 ...prevention and early detection are affordable. There s one word feared more than any other in a cotton gin: FIRE! Fire melts flashings, destroys electrical components, warps sheet metal and causes general havoc throughout the whole operation. While the costs of mid-season repairs of fire damaged equipment are extremely high, they are small in comparison to the costs of lost production due to down time. With fire related down times ranging from two hours to two weeks, Fire Tools can pay for themselves with the first fire they prevent! Fire Tools use fire detection sensors from Argus Fire Control and Pierce Electrical Construction. Sam Jackson is proud to offer both of these product lines as an Authorized Distributor. The Argus sensors detect sparks and can be located throughout the gin. Pierce sensors use infrared temperature measurement to detect tags at gin stands. For gins desiring more automation, Samuel Jackson has developed an auto-adjusting SawSaver model with ROC Technology. For even more automation and Ethernet connectivity, be sure to ask your Sam Jackson Representative about the Fire Tools Interface! M & C Main Line:

138 Fire Tools: Argus Detectors See one in action and you ll want several. The Argus Fire Prevention System consists of a Control Panel and Spark Detectors. Each Control Panel can support up to 10 zones when equipped with an equal number of zone cards. A zone is considered any location in the gin that sensors are monitoring and would typically consist of two to four sensors. Zone examples might be above the module feeder pick-up point, before the pre-cleaning system, behind individual gin stands, in the lint flue riser or any other spot that fires are prone to break out. A single Argus Infrared Spark Detector. Fires cost gins a lot more than a few pounds of charred cotton. A Argus Z-1 Control Panel is economical and easily expands to monitor up to 10 Zones. Spark Detectors mount flush to the side of a pipe or duct and monitor through a small sealed cutout. They use infrared technology to pinpoint single sparks at speeds up to 200 feet per second. By comparison, cotton typically flows at 75 feet per second in gin pipes. Upon detection, a control action can be used to contain spread of the spark in 1/20th of a second. The infrared field is produced at a ninety degree angle from the detectors giving it a very wide viewing area. Additional sensors can be added for better coverage and protection. M & C See Argus Detectors in action. View the demonstration video on the Sam Jackson Cinema page on our website

139 The cost of the Argus gear is so small compared to what they save in downtime and damaged machinery. I just don t think I can gin without them. Dennis Flowers Sudan Farmers Coop Association Protecting Your Gin With Argus Spark Detectors is as Easy as 1, 2, 3! Step 1 - Select the number of zones you want to monitor. A zone is any point in the gin that you want to monitor for sparks or fires. Examples include: after the cotton pick-up point, behind gin stands and lint cleaners, after the overflow, before and after precleaning equipment and the lint flue riser. A control panel is chosen for the desired number of zones with panels available from one zone (Z-1 Panel) to ten zones (Z-10 Panel). Any panel can be field upgraded to monitor additional zones. Step 2 - Select the number of detectors for each zone. Each zone can accept spark inputs from up to ten detectors. Most zones will require from two to four detectors for adequate coverage. Step 3 - Select the system accessories. Each Spark Detection System can be equipped with a Horn/Strobe Combo to alert the operator when an alarm has been tripped. Example: Let s say you wanted to equip your gin with a Spark Detection System with monitoring at: Step 1: the initial cotton pick-up = 1 zone the overflow return pipe = 1 zone the lint flue riser = 1 zone for a total of 3 zones, requiring a Z-3 Control Panel For each zone you need an adequate number of detectors:* Step 2: 3 - Detectors at the cotton pick-up zone 3 - Detectors at the overflow zone 6 - Detectors at the lint flue zone for a total of 12 detectors needed for your system. Select your system accessories: Step 3: Only one Horn Strobe Combo would be needed for the entire system. * Recommended number of detectors varies by pipe size. M & C Main Line:

140 Fire Tools: Pierce SawSavers If you don t like rib fires, this product is for you. In 1995, Pierce Electrical Construction developed an innovative device to address a problem that has plagued ginners for years... gin stand tags. Tags occur when lint sticks between two ribs in a gin stand breast. The resulting friction between the tag and gin saw cause the temperature to rise and a fire will result if left unattended. Pierce s solution, the SawSaver, uses temperature sensors to detect tags quickly. These downtime and money saving devices are now available from Samuel Jackson. An original Pierce SawSaver Controller. SawSavers use two infrared sensors to measure temperature across the gin stand. Sensors are precisely positioned to measure across the saw teeth at the ginning point. A controller on each stand displays the temperature and allows the ginner to set an alarm set point. When a tag occurs, the temperature rises quickly and trips this set point, which kicks out the respective gin breast. The ginner can quickly locate and remove the tag and continue ginning safely and fire free. M & C Sensor selection and mounting location are specifically designed for your gin stand

141 Get more from SawSavers with ROC Technology. In addition to offering the original Pierce SawSaver controls and sensors, Samuel Jackson has developed an automatic SawSaver control package with ROC Technology. ROC is an acronym for Reduced Operator Changes. The Samuel Jackson controls operate automatically instead of requiring ginner adjustment when there are fluctuations in ambient and system temperatures. The SawSaver with ROC Technology interface. Tag detection is visualized by indicator bars on both sides of the interface. When a bar rises quickly, a tag has formed between two ribs. The dotted line on the indicator bar is user definable and sets the responsiveness of the ROC Technology. When either bar crosses this line, the alarm is triggered, the gin stand kicks out and the interface turns red. An arrow also indicates which side of the stand the tag is located. The ginner can then safely remove the tag and press any button on the interface to clear the alarm and resume ginning. Ask About SawSavers for Sentinel Lint Cleaners. The SawSaver interface with the left side in an alarmed state. Upgrade Note: SawSavers with ROC Technology use a Samuel Jackson control package coupled with Pierce Electrical sensors. Original Pierce Electrical SawSavers can be upgraded with the Samuel Jackson controls package while retaining existing sensors. Contact your Samuel Jackson Representative for details. M & C Main Line:

142 Looking for more information, service manuals, product videos, savings calculators or other sources of information? Visit us online! The Samuel Jackson website is loaded with resources for both prospects and existing customers. Use the online calculators to help you determine a returnon-investment. Play the videos to train your personnel. Look up installation requirements in the product service manuals. You ll find all that and more available online, all the time for your convenience. Can t find what you are looking for or just want to go straight to the source? Call us and we will get you the information you need. Find it all at

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