Almex Pro Bedienungsanleitung

Pro, Solo

INSTRUCTION MANUAL Page 1

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

INSTRUCTION MANUAL

Pro

Solo

CONVEYOR BELT VULCANIZER

This manual was prepared to present the correct methods and procedures of operating and

maintaining your ALMEX VULCANIZER.

At the time of writing this manual, the instructions were up to date. However, some of the

information or appearance of the component parts may vary slightly from the vulcanizer

delivered to you.

Read this manual carefully before operating your vulcanizer.

SHAW-ALMEX INDUSTRIES LIMITED

P.O. Box 430

Parry Sound, Ontario, Canada P2A 2X4

Phone: 705-746-5884 or toll-free 800-461-4351

Fax: 705-746-9484

E-Mail: [email protected]

Web: www.almex.com

Pro, Solo

INSTRUCTION MANUAL Page 2

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

Table of Contents

RECORD OF PURCHASE .................................................................................................................. 3

DECLARATION OF CONFORMITY................................................................................................... 4

SAFETY ................................................................................................................................................ 5

3.1.

Definition of Pictograms ................................................................................................. 5

3.1.1.

Safety Alert ..................................................................................................... 5

3.1.2.

Crushing Hazard .............................................................................................. 5

3.1.3.

Burning Hazard ............................................................................................... 5

3.1.4.

Electrical Hazard ............................................................................................ 6

3.2.

Limitation of use ............................................................................................................. 6

3.3.

Hazardous Materials and Products ................................................................................ 6

3.4.

Safe Handling................................................................................................................. 6

ASSEMBLY .......................................................................................................................................... 7

4.1.

Unpacking ...................................................................................................................... 7

4.2.

Pro and Solo Features ................................................................................................... 7

4.3.

Functional Diagram ........................................................................................................ 7

4.4.

Basic Assembly and Splice Preparation ........................................................................ 8

4.5.

Assembling Presses Side by Side on a Splice............................................................... 8

4.6.

Changing Handle Position.............................................................................................. 8

OPERATION......................................................................................................................................... 9

5.1.

Pressurizing with Air....................................................................................................... 9

5.2.

Heating the Vulcanizer ................................................................................................... 9

5.3.

Cooling the Vulcanizer ................................................................................................. 10

5.4.

Depressurize ................................................................................................................ 10

MAINTENANCE ................................................................................................................................. 11

6.1.

Routine Maintenance ................................................................................................... 11

6.2.

Replacing the Pressure Bag ........................................................................................ 11

6.3.

Replacing Heating Element.......................................................................................... 11

6.4.

Replacing the Temperature Sensor (RTD Sensor)...................................................... 12

TROUBLESHOOTING ...................................................................................................................... 13

7.1.

Vulcanizer Not Heating................................................................................................. 13

7.2.

Vulcanizer Over Heating .............................................................................................. 13

7.3.

No Pressure or Loss of Pressure................................................................................. 13

SERVICE............................................................................................................................................. 14

8.1.

Emergency Service ...................................................................................................... 14

8.2.

Return of Goods Authorization..................................................................................... 14

8.3.

Guarantee .................................................................................................................... 14

Pro, Solo

INSTRUCTION MANUAL Page 3

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

1. RECORD OF PURCHASE

Job Number

Date of Purchase

Model Number

Serial Number

Platen Size

Bias

Weight Total

Top Frame with Platen

Platen Only

Operating Pressure

Voltage

Phase

Cycle/Hertz

Amperage Per Platen

Total

Element Construction

Element Resistance: Coils Connected

Coils Open

Temperature Control Panel Model

Calibration Temperature

Ancillary Items 2 x 1/4 NPT Cooling Tee, 2 x Stem Thermometer

Optional Items

Spare Parts

Operating Instructions 49908-042

Supplements

Service Bulletins

Warranty Card

Drawings

Parts Diagrams PRO Series or SOLO Series / AC3

Pro, Solo

INSTRUCTION MANUAL Page 4

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

2. DECLARATION OF CONFORMITY

We, Shaw-Almex Industries Limited,

of P.O. Box 430, Parry Sound, Ontario, Canada,

declare that the machinery:

Product: Vulcanizer

Model:

Pro / Solo

Year of Certification: 2000

has been manufactured using the following transposed harmonized European Standards:

EN 60204-1 Safety

EN 50081-1 Emissions (EN55011)

EN 50082-1 Immunity (EN61000-4-2/3/4/5)

and is in conformity with the following Directives:

73/23/EEC Low Voltage Directive + amendment 93/68/EEC

89/336/EEC EMC Directive + amendment 92/31/EEC

89/392/EEC Machinery Directive

Signed in: Parry Sound, Ontario, Canada

Name: Mark Dudas

Position:: Manager of Engineering

Pro, Solo

INSTRUCTION MANUAL Page 5

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

3. SAFETY

Your vulcanizer has been designed to provide safe, efficient, trouble-free service for many years. Component design

and material selection have been carefully considered to ensure operator safety and our manufacturing procedures

provide a consistent, high-quality product.

The material that is presented in this operating manual has been compiled to provide direction for operating

personnel so that the maximum effectiveness of the vulcanizer can be achieved and so that there is a complete

understanding of correct operating procedures.

PLEASE READ CAREFULLY

The following safety precautions should be read carefully and understood thoroughly before you set-up or operate

your vulcanizer. Failure to follow these precautions may result in personal injury and/or equipment damage. All

operating personnel should be trained in the proper method of handling and operating the vulcanizer.

The risks associated with operating the vulcanizer are identified throughout this manual with pictograms.

Safety Alert Crushing Hazard Burning Hazard Electrical Hazard

3.1. Definition of Pictograms

3.1.1. Safety Alert

1. Never operate the press while unattended.

2. The upper frame must be securely assembled to the lower frame before pressurizing vulcanizer. Do not lean

against or over top of the vulcanizer during operation. Since high stress levels are resident in the frame and

pressure bolts during operation, component failure can result in a sudden movement of the frame and could

cause injury. A safety feature that has been added to the pressure bolt is a retention collar on the top nut that will

prevent the nut from being projected upward in the case of a bolt failure.

3. Do not connect the vulcanizer to a continuous pressure supply. In the event of component failure, it is important

for the pressure to drop to a safe level.

4. Do not tamper with the pressure relief valve. It is factory preset to prevent the vulcanizer from operating at

unsafe pressures.

5. Use hoisting provision provided on larger frames.

3.1.2. Crushing Hazard

1. Fingers must not be placed between platen surfaces when the vulcanizer is pressurized or injury will result.

2. There is a crushing hazard when assembling the press if the top frame is lowered onto the bottom frame.

3.1.3. Burning Hazard

1. The platen surfaces typically operate at or above 300°F (150°C). Touching these surfaces will result in a burn.

Pro, Solo

INSTRUCTION MANUAL Page 6

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

2. The cooling water may discharge from the platen initially as steam creating a burning hazard. Ensure the cooling

water discharge is not directed at any person or injury could result.

3. Improper use or component failure could result in the vulcanizer overheating. Always use an Almex temperature

controller when operating the vulcanizer and never leave the vulcanizer operating while unattended.

3.1.4. Electrical Hazard

1. A qualified electrician should perform all maintenance of the electrical components of the vulcanizer.

2. All of the electrical components contain live circuits. Do not open or service any of the electrical equipment

without disconnecting the main power supply.

3. Incorrect voltage and phase may result in component damage and create a fire hazard. Refer to the serial plate

for power specifications.

4. Equipment power supplies must be properly grounded or a severe shocking hazard may result.

5. Avoid using equipment in wet surroundings or a severe shocking hazard may result.

6. If any cable or connectors are damaged, they must be replaced or a fire and shock hazard may result.

3.2. Limitation of use

This equipment has been designed to vulcanize conveyor belts. Applying a combination of heat and pressure on the

product for a certain period of time accomplishes the vulcanizing process. The Pro 60 press operates up to 60 psi

(420 kPa), the Pro 100 and Solo operate up to 100 psi (700 kPa). There is a safety pressure valve built into the air

control assembly that must be used. A continuous pressure supply must not be connected to the press. The platens

can be operated at temperatures up to 325 °F (165 °C). The press is to be connected to an ALMEX temperature

control panel that is supplied complete with platen electrical cables. The press must never be allowed to operate

while unattended. Hoses have been provided to connect a cooling supply to the press. Other use is not allowed

without the written permission of Shaw-Almex.

3.3. Hazardous Materials and Products

The cooling water may discharge from the platen initially as steam creating a burning hazard. Ensure the cooling

water discharge is not directed at any person or injury could result.

Compressed air is generally used to pressurize the press. Never direct compressed air flow at a person. Never

connect the vulcanizer to a continuous air supply.

3.4. Safe Handling

Handling the machine does present some residual hazard. The weight of the components is marked on the serial

plate. Handles are provided on the frames. For the bigger presses, hoisting equipment is needed to position the top

frame in place. Hoisting provision is on the frame.

Wear protective footwear when handling the press.

Connection of cables and hoses must be made in such a way that no tripping hazard is created.

Pro, Solo

INSTRUCTION MANUAL Page 7

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

4. ASSEMBLY

4.1. Unpacking

Carefully unpack vulcanizer from the crate and inspect for damage. Any damages or shortages should be reported to

the carrier and / or Shaw-Almex Industries Limited.

4.2. Pro and Solo Features

•The press is supplied with a separate top frame and bottom frame so that it is very easy to handle in most field

applications. There are handles on the ends that can be relocated to the sides of the frames and can be removed

for getting into tight places.

•The platen guards and platen covers are removable so that two presses can be placed side by side on a belt and

the platens will butt tightly together.

•The pressure bolts can be lowered to the horizontal position for positioning the vulcanizer between the conveyor

structure and the belt. The bolts can also be fully lowered so they do not interfere with work at the end of the

frame by removing the bolt position pins.

•On Pro models the air pressure control is attached to the frame with a unique fastening pad, and the air hose is

inside the frame. The control can be removed from the frame and there is sufficient air hose to hold the control

in a convenient location when pressurizing the frame. When the splicing is finished, the air hose is pushed back

into the frame and the air control is fastened to the frame.

•On Solo models the air control is connected to a quick coupler mounted on the bottom frame.

•Smaller presses can be operated on a single-phase power supply and they are available with a frame-mounted

temperature control panel. The power of the heater has been maximized to keep heat up time to a minimum. As

a result, the frame-mounted controls require a separate power supply for the top and bottom platens.

•Three-phase presses are connected to a T3 remote temperature control panel.

•The platens can be easily removed from the frame while the platen remains fully assembled. This makes the

platens very versatile as they can be used without the frame at lower temperatures to warm a belt and they can be

easily interchanged with a custom frame on special applications.

4.3. Functional Diagram

Air Pressure Control

Removable Handles

Removable Platen Guards

Platens

Cooling Fittings

Bolt Pos

ition Pins

Lift Ring

Temperature Control

(T1F models)

Serial Plate

Cooling Hoses

Figure 1

Pro, Solo

INSTRUCTION MANUAL Page 8

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

4.4. Basic Assembly and Splice Preparation

Safety: The vulcanizer should be assembled and operated on a flat, level and stable surface so there is no

danger of falling.

1. Lower the pressure bolts and lift top frame from the bottom frame.

2. Prepare the splice as required.

3. Position splice on lower platen. It is good practice to use platen covers between the belt and the top and bottom

platens.

4. Position top frame on the bottom frame, aligning the top and

bottom frame.

5. Raise the pressure bolts onto the top frame. They will be safely

in position when the top of the nut bears on the bearing cap and

the shoulder is under the edge of the frame, figure 2.

Safety: Failure to engage the pressure bolt properly could

result in over stroke damage to the vulcanizer and injury when

pressure is applied.

6. When using frame mounted temperature controls, connect the

panels to two separate power supply circuits. The temperature controller will illuminate, but the platen will not

start heating until the switch is on (1A-on, automatic or 1M- on, manual). See temperature control manual.

Safety: Each platen may have to be connected to a separate

circuit to avoid exceeding the current carrying capacity of the power

supply.

7. When using remote temperature controls, connect the top and

bottom platen electrical cables to the platen connectors and

connect the panel to a power supply. The temperature controller

will illuminate, but the platen will not start heating until the switch is turned to 1A (on, automatic) or 1M (on,

manual). See temperature control manual.

8. Connect the top and bottom platen cooling supply and drain hoses. To disconnect the hoses, pull back on the

collar on the quick connect plug.

4.5. Assembling Presses Side by Side on a Splice

All Pro and Solo presses can be positioned side by side

with their platens touching in order to make a larger platen

area.

1. Remove the platen guard from the side(s) of the presses

to be used together by loosening the platen guard

assembly bolts.

2. Remove the platen covers by removing the screws from

the side of the platens.

3. Cover the top and bottom platen area with a 1/8" thick

(3 mm) metal cover plate (aluminum, steel or stainless

steel).

4.6. Changing Handle Position

The handles can be located on the sides or the end of the frame. Tighten by hand only.

Safety: When changing the handle position, be sure the handles are threaded all the way in.

Top of Nut

Bearing Cap

Shoulder of Nut

Figure 4

Figure 2

Cover Plate

Platens touching

Figure

Pull to release

Pro, Solo

INSTRUCTION MANUAL Page 9

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

5. OPERATION

There are two essential requirements for perfect splicing of conveyor belting; Uniform Pressure and a controlled

Uniform Temperature. Both of these requirements are satisfied in the ALMEX Vulcanizer.

Uniform Pressure:

Full platen size pressure ‘bag’ applies uniform pressure over the entire platen area.

Important: This unique platen requires support over its entire area or permanent distortion of the platen may occur.

Fill any unused portion of the platen area with material the same thickness as the belt.

Uniform Temperature:

The heating element is a silicone rubber ‘blanket’ which covers the total platen surface.

5.1. Pressurizing with Air

The air control on Pro models is attached to the frame with an industrial type of

fastening pad. Remove the air control from the frame and pull out sufficient hose to

pressurize away from the end of the frame. The air control on Solo models is

separate and must be connected to the fitting on the bottom frame.

Safety: Do not lean against the vulcanizer when pressurizing. Component

failure can result in a sudden movement of the frame and could cause injury.

Safety: The Air Release/Pressure Relief valve is preset to blow off slightly

above operating pressure. Do not override this safety device or injury could result.

1. Turn the safety relief valve toggle so it is at a right angle with the valve.

2. Apply air (using compressed air or a hand / foot pump) until the desired air

pressure is reached as indicated on the gauge. Make sure air is actually entering

the pressure bag before commencing to heat the platens.

3. To de-pressurize, turn the toggle on the pressure relief valve so it is in line with

the body of the valve.

5.2. Heating the Vulcanizer

Safety: Never heat the vulcanizer while unattended.

1. Adjust the set point value of the temperature controller. If not familiar with the temperature controller, refer to

the manual supplied with the temperature controller for instruction.

2. Turn the switches on the temperature controller to the on position (1A-on, automatic or 1M- on, manual).

Safety: The platens will get hot.

3. Heat to set point temperature and then time the cure according to the belt manufacturer’s specification. Monitor

the platen temperature with the stem thermometers as well as the controller display.

Note: There are holes on the end of the platen opposite the electrical connector for inserting a stem thermometer. It

is good practice to verify the platen temperature with stem thermometers.

Tip: The use of different platen cover plates will affect the heat up time and may cause a difference between the

controller temperature reading and the actual temperature of the product. Cure temperatures and times may have

to be adjusted to compensate for this difference.

4. When the cure is finished, turn the switches on the temperature controller to the off position (0).

Figure 5

Air

Bag

Hose

Safety Relief

Valve Toggle

Pro, Solo

INSTRUCTION MANUAL Page 10

SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012

5.3. Cooling the Vulcanizer

Safety: The cooling water may discharge from the platen initially as steam creating a burning hazard. Ensure

the cooling water discharge is not directed at any person or injury could result.

1. When the cure time has been completed and the temperature controllers are switched to the off position (0), turn

on the water supply to cool the upper and lower platens. Leave the power supply connected to temperature

control panel so the platen temperature can be monitored.

2. When the platens have cooled to an acceptable temperature, the cooling water can be turned off. A typical cool

down temperature for a good splice result and safe handling of the belt without the risk of a burn is 150°F

(65°C).

3. The water must be blown out with air before the platens are reheated. Water remaining in the cooling channels

will reduce platen temperature uniformity, increase the heat-up time and may cause the elements to overheat.

Important: If water remains in the platens and the vulcanizer is stored at temperatures below freezing the platens

may be severely damaged.

Tip: The standard cooling hoses and fittings on the Pro and Solo vulcanizer are of the highest quality and have been

selected for their durability and their ability to cool the platens quickly with a minimal amount of water. The

passages in the hoses and fittings may become restricted if there is any solid matter in the cooling water, and this

will affect the cooling rate. Always use clean water for cooling and clean the fittings if the cooling time becomes

excessive.

5.4. Depressurize

1. To depressurize the vulcanizer, turn the safety relief valve toggle on the air control so it is in line with the valve.

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