Almex Pro User manual

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: [phone] or toll-free 800-461-4351
Fax: [phone]
E-Mail: [email protected]
Web: www.almex.com

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SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012
Table of Contents
1. RECORD OF PURCHASE .................................................................................................................. 3
2. DECLARATION OF CONFORMITY................................................................................................... 4
3. 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
4. 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
5. OPERATION......................................................................................................................................... 9
5.1. Pressurizing with Air....................................................................................................... 9
5.2. Heating the Vulcanizer ................................................................................................... 9
5.3. Cooling the Vulcanizer ................................................................................................. 10
5.4. Depressurize ................................................................................................................ 10
6. 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
7. TROUBLESHOOTING ...................................................................................................................... 13
7.1. Vulcanizer Not Heating................................................................................................. 13
7.2. Vulcanizer Over Heating .............................................................................................. 13
7.3. No Pressure or Loss of Pressure................................................................................. 13
8. SERVICE............................................................................................................................................. 14
8.1. Emergency Service ...................................................................................................... 14
8.2. Return of Goods Authorization..................................................................................... 14
8.3. Guarantee .................................................................................................................... 14

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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

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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
on
Name: Mark Dudas
Position:: Manager of Engineering

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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.

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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.

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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

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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
3
Pull to release

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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
In
Bag
Hose
Safety Relief
Valve Toggle

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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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SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012
6. MAINTENANCE
Safety: All maintenance must be done with the vulcanizer disconnected from the power supply and no
pressure in the bag.
There are no special tools required to maintain this equipment.
6.1. Routine Maintenance
The following items should be checked after every thirty cures.
1. Visually inspect the frames, welds, pressure bolts and hinge
pins for signs of cracking or deformation.
2. Check the continuity of the platen heating elements. Refer to
“Record of Purchase” for the resistance (ohms) values. Use the
figures from the “Ohms Reading Coils Connected” column. On
models with frame mounted controls, remove the control panel
to check the continuity.
3. Check the continuity of the platen temperature sensor. On models with frame mounted controls, remove the
control panel to check the continuity.
4. Check the platen pressure bag for damage due to abrasion, cuts or any type of damage that might cause a leak or
breakdown while under pressure. It can be checked quickly by removing the platen guards.
5. Check all cables for cuts, abrasion and wear and all “strain relief” fittings between cable and plugs for a secure
fit. If any cable, hose, fitting or pressure bag shows signs of damage they should be repaired or replaced.
6. The platen cooling should be checked for leaks and/or blockages that will affect their performance.
6.2. Replacing the Pressure Bag
1. Disconnect the platen electrical connector from the temperature control cable.
2. Remove the four lower platen-mounting bolts.
3. Remove platen.
4. Remove pressure bag, carefully pulling the hose through the
frame. Loosen the hose clamp at the bag and remove the hose
fitting from the bag valve.
5. Inspect the hose and replace if there are any signs of wear.
6. Install the fitting to new pressure bag and tighten the hose
clamp.
7. Position the new pressure bag onto the frame. On PRO models,
pull the air control at the same time to be sure the bag hose is
moving properly through the frame.
8. Install the platen and connect temperature control cable.
6.3. Replacing Heating Element
1. Remove the temperature control panel from the frame or the electrical connector insert from the housing and
disconnect the heating element and temperature sensor wires.
2. Remove the platen mounting bolts.
Element Resistance
3 Phase: Pins 1, 2, 3
Single Phase: Pins 1,3
RTD Sensor Resistance
Pins 4, 5, 6
Figure 7
Figure 6
Bag Valve
Hose Fitting
Clamp
Hose
Air Control

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•On small presses, lift the platen and carefully remove platen adapter from the grommet. Remove the platen and
wires.
•On larger presses there is a label showing how the platen must be rotated before it can be removed. To remove
the platen in this case, the platen cover must be removed and the adapter bolts removed from the platen.
3. Remove the screws from the platen mounting plate and disassemble the platen.
4. Remove the element.
5. Using the old element as a pattern, punch the holes through the new element and carefully trim the edges to fit
the platen.
6. Replace the new element, feeding the wires through the adapter.
7. Assemble the platen. Do not distort the platen mounting plate when tightening the assembly screws.
8. Install platen to frame by carefully routing wires through the grommet and into the frame.
9. Fit the rubber sleeve on the grommet onto the adapter.
10. Connect the element wires to the temperature control panel or to the electrical connector insert and install the
insert to the hood.
6.4. Replacing the Temperature Sensor (RTD Sensor)
1. Remove the temperature control panel from the frame or the electrical connector insert from the housing and
disconnect the heating element and temperature sensor wires.
2. Remove the platen cover.
3. Remove the adapter bolts from the platen and separate the adapter from the platen enough to expose the wires
and pull the wires through. Carefully remove the adapter from the grommet.
4. Remove the RTD sensor from the platen. If the sensor does not come easily, make a ¼” (6mm) hook on the end
of heavy wire and slide it down the channel to the bottom of the sensor (approximately 8” or 200 mm) and pull.
5. Insert the new sensor in the platen approximately 8” (200 mm). Trim the wires on the new sensor to
approximately the same length as the element wires and strip the insulation back ¼” (6 mm).
6. Route element and sensor wires through the adapter and fasten the adapter to the platen.
7. Install platen to frame by carefully routing wires into frame and fitting the grommet to the frame.
8. Fit the rubber sleeve on the grommet onto the adapter.
9. Connect the element wires to the temperature control panel or to the electrical connector insert and install the
insert to the hood.
Platen cover
Platen
Element
Element cover
Insulation
Mounting plate
Pressure bag
Frame
Sensor
Adapter
Grommet
Figure 8

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7. TROUBLESHOOTING
7.1. Vulcanizer Not Heating
Refer to Temperature Control trouble shooting instruction first. If the fault is not found, use the following:
FAULT CORRECTION
1. Loose cable connection. 1. Ensure that cable connections are clamped together
properly.
2. Loose connection in cable or
platen connector.
2. Disconnect power supply, remove electrical connector
insert from housing and check all connections.
3. Faulty RTD temperature
sensor.
3. Measure the resistance between pins 4-5 and 4-6 on the
platen electrical receptacle or between the colored wire
and the other wires on the sensor. Depending on the platen
temperature, the resistance should be between 100-170
Ohms. See figure 6.
4. Faulty heating element. 4. Measure the resistance between platen electrical
receptacle pins 1-3 on single phase and 1, 2, 3 on three
phase. Compare the reading with the value in your Record
of Purchase, Element Resistance, Coils Connected. If the
values are not close and the connections are good, the
element must be replaced.
7.2. Vulcanizer Over Heating
Refer to Temperature Control trouble shooting instruction first. If the fault is not found, use the following:
FAULT CORRECTION
1. Faulty RTD temperature
sensor.
1. Measure the resistance between pins 4-5 and 4-6 on the
platen electrical receptacle (Figure 6). The resistance should
be between 100-170 Ohms.
7.3. No Pressure or Loss of Pressure
FAULT CORRECTION
1. Blocked air passage. 1. On Pro models, remove air control assembly from frame
and pull hose all the way out to make sure there are no kinks.
On Pro and Solo models, remove bag hose from air control
assembly. Using no more than 5 psi (0.35 kg/cm
2
), blow air
directly into the air control assembly and into the air bag to
find the blockage. Clean or replace parts to remove blockage.
2. Broken air line or leaking
valves or fittings.
2. Remove air control assembly from frame and check for
leaks by applying air pressure (maximum 5 psi, 0.35 kg/cm
2
)
and covering the valves and fittings with soapy water.
Bubbling will indicate leaks. Tighten fittings, clean or replace
leaking valves. Note: do not disassemble the safety relief
valve. If it is leaking it must be replaced.
3. Leaking pressure bag. 3. Remove the pressure bag and inspect for leaks. If no leak
is evident, inflate the bag (maximum 5 p.s.i./ 0.35 kg/ cm
2
) and
spray soapy water over the bag. Bubbling will indicate
escaping air and the bag should be replaced.

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SHAW-ALMEX INDUSTRIES LIMITED 49908-042 March 2012
8. SERVICE
8.1. Emergency Service
Contact: Service Department
Telephone: [phone] or Toll Free 800 461 4351
Fax: [phone]
E-mail: [e-mail]
Mail: SHAW-ALMEX INDUSTRIES LIMITED
P.O. Box 430
Parry Sound, Ontario
Canada, P2A 2X4
8.2. Return of Goods Authorization
The service department of Shaw-Almex Industries Limited MUST be contacted for the necessary authorization and
documentation prior to returning goods to the factory.
The service department may be reached at the above numbers.
8.3. Guarantee
Your ALMEX equipment is guaranteed against defective parts, material and workmanship for a period of twelve
months from the date of purchase. See WARRANTY CARD for complete details.