Almex T4PGF1 User manual

T4PGF1 INSTRUCTION MANUAL Page 1
SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
INSTRUCTION MANUAL
T4PGF1 30A GROUND
FAULT CONTINUITY CHECKING TEMPERATURE
CONTROL PANEL
WITH A PUMP RECEPTACLE.
This manual was prepared to present the correct methods and procedures of operating and
maintaining your ALMEX GROUND FAULT CONTINUITY CHECKING
TEMPERATURE CONTROL PANEL.
Read this manual carefully before operating your vulcanizer.
1.1. SHAW-ALMEX INDUSTRIES LIMITED
PO Box 430
Parry Sound, Ontario, Canada P2A 2X4
Phone: [phone] or 1-800-461-4351
Fax: [phone]
e-mail: [e-mail]

T4PGF1 INSTRUCTION MANUAL Page 2
SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
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. Electrical Hazard ............................................................................................................................ 5
3.1.2. Burning Hazard .............................................................................................................................. 5
3.2. Limitation of use...............................................................................................................................5
4. ASSEMBLY............................................................................................................................................................ 6
4.1. Unpacking ........................................................................................................................................6
4.2. Functional Diagram ..........................................................................................................................6
4.3. Connection Assembly ......................................................................................................................7
5. OPERATION........................................................................................................................................................... 8
5.1. Safety Features And How To Operate .............................................................................................8
5.2. Temperature Controller Settings ......................................................................................................9
5.2.1. Setting the Platen Temperature ................................................................................................................. 9
5.2.2. Setting Temperature Units to °C or °F...................................................................................................... 9
5.2.3. Setting the Over Temperature Alarm........................................................................................................ 9
6. HEATING THE VULCANIZER............................................................................................................................ 10
6.1. Heating Up ....................................................................................................................................10
6.1.1. Manual Heating .......................................................................................................................................10
6.2. Temperature Control ......................................................................................................................10
7. REQUIRED DAILY TESTING ............................................................................................................................. 11
7.1. Required Daily Testing Before Use................................................................................................11
8. MAINTENANCE................................................................................................................................................... 12
8.1. Opening the Control Cabinet..........................................................................................................12
8.2. Overload Protection .......................................................................................................................12
8.3. Temperature Calibration ................................................................................................................12
8.3.1. Auto Tune................................................................................................................................................13
8.3.2. Input Shift................................................................................................................................................13
9. TROUBLESHOOTING ........................................................................................................................................ 14
9.1. No Display on Temperature Controller...........................................................................................14
9.2. Error Display on Temperature Controller .......................................................................................14
9.3. Platens Not Heating .......................................................................................................................14
9.4. Vulcanizer Over Heating ................................................................................................................15
9.5. Controller will not maintain Set Point Temperature ........................................................................15
10. REQUIRED MAINTENANCE SCHEDULE ....................................................................................................... 16
10.1. Daily Inspection Check Sheet ........................................................................................................16
10.2. Maintanence Schedule Check Sheet .............................................................................................17
11. RECEPTACLE PIN CONFIGURATION ............................................................................................................ 19
12. SERVICE .............................................................................................................................................................. 20
12.1. Emergency Service ........................................................................................................................20
12.2. Return of Goods Authorization.......................................................................................................20
12.3. Guarantee ......................................................................................................................................20
13. WARRANTY CARD AND INFORMATION........................................................................................................ 21
14. PARTS INFORMATION ...................................................................................................................................... 22
15. ELECTRICAL DRAWAINGS .............................................................................................................................. 25

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SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
2. RECORD OF PURCHASE
Job Number
Date of Purchase
Model Number T4PGF1
Serial Number
Weight 45 lb. [21 kg}
Voltage 415 volt
Phase 3 phase
Cycle/Hertz 50/60
Amperage Maximum Per Platen 15 Amp
Total 30 Amp
Circuit Overcurrent Protection Required 30 Amp- 15 per platen, 10 amp pump
Temperature Sensor 100 Ωplatinum RTD
Index of Protection – with case closed IP 67
Design of Protection – with case open IP 66
Ancillary Items platen cables, power supply cable
Spare Parts Fuses: 3 x 10 Amp, 3 x 1 1/4 Amp
Operating Instructions June, 2014
Supplements Omron E5CN-H manual
Service Bulletins none
Warranty Card yes
Drawings Model T4PGF1 drawing W1158-02
Parts Diagrams T4PGF1 Main Assembly, T4PGF1 Internal Assembly

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SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
3. DECLARATION OF CONFORMITY
We, Shaw-Almex Industries Limited,
of P.O. Box 430, Parry Sound, Ontario,
Canada, declare that the machinery:
Product: Temperature Control
Panel Model: T4PGF1
Year of Design: 2014
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)
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
and has been designed and assessed to comply with the following, in part or full where relevant:
•AS/NZS 3000:2007 - Electrical Installations (Australian/New Zealand Wiring Rules)
•AS/NZS 3007:2013 - Electrical equipment in mines and quarries (Surface installations and associated
processing plant)
•AS/NZS 2081:2011 - Electrical protection devices for mines and quarries
•AS/NZS 4871.1:2012 - Electrical equipment for mines and quarries (General requirements)
•AS/NZS 4871.4:2010 - Electrical equipment for mines and quarries (Mains powered electrical mobile
machines)
•AS 4242-1994 - Earth-moving machinery and ancillary equipment for use in mines (Electrical wiring
systems at extra-low voltage)
•MDG15:2012 - Guideline for Mobile and Transportable Equipment for Use in Mines
•MDG41:2010 - Guideline for fluid power systems safety at mines
Signed in: Parry Sound, Ontario, Canada
on
Name: Mark Dudas, Eng.
Position: Manager of
Engineering

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SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
4. SAFETY
Shaw Almex Highly recommends that all operators be properly trained by an Almex representative before using
any Almex equipment. This guarantees the full understanding of all safe operating procedures and functions of
the equipment. 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 temperature control panel can be achieved and
so that there is a complete understanding of correct operating procedures. There is a key required to operate the
control panel and it should be in the possession of a qualified person. Unqualified personnel must not open or
work on these units. Any unauthorized work or adjustments immediately VOIDS warranty.
PLEASE READ CAREFULLY
The following safety precautions should be read carefully and understood thoroughly before you set-up or
operate your temperature control panel. Failure to follow these precautions may result in personal injury and/or
equipment damage. All operating personnel should be trained in the proper operation of the temperature control
panel.
The risks associated with operating the temperature control panel are identified throughout this manual with
pictograms.
4.1. Definition of Pictograms
Electrical Hazard Burning Hazard
4.1.1. Electrical Hazard
1. A qualified electrician should perform all maintenance of the electrical components of the temperature
control panel.
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. Check the serial
plate for ratings.
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.
4.1.2. Burning Hazard
There is not a burning hazard with the temperature control panel itself, however, improper use or component
failure could result in the vulcanizer overheating. Always use an Almex temperature control panel when
operating the vulcanizer and never leave the vulcanizer operating while unattended.
4.2. Limitation of use
This equipment has been designed to control the temperature of an AS/GF ALMEX conveyor belt vulcanizer
with the letters AS/GF in the model. The process of vulcanizing is done by applying a combination of heat and
pressure on the product for a certain period of time.
The T4PGF1 temperature control panel operates within a range of 32°F (0°C) to a maximum of 325 °F (163°C).
Refer to the vulcanizer manual for platen limitations. An Almex temperature control panel must be used with an
Almex AS/GF vulcanizer and the vulcanizer should never be allowed to operate while unattended. Other use is
not allowed without the written permission of Shaw-Almex.

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SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
5. ASSEMBLY
5.1. Unpacking
Carefully unpack temperature control panel from the crate and inspect for damage.
Any damages or shortages should be reported to the carrier and / or Shaw-Almex Industries Limited.
5.2. Functional Diagram
T4PGF1 – Face Component Locations
1. Power Supply Connector (1REC) 2. Main Breaker (1CB)
3. Platen Switch (x2) (24-30SS) 4. Platen Temperature Control (x2) (18-25TC)
5. Platen Connector (x2) (5-11REC) 6. Alarm - over temperature audible (73ABU)
7. Emergency Stop Switch (23PB) 8. Keyed Reset / Start Switch (18PB)
9. Ammeter (AM1) 10. Phase Indicator Lights (PL1-3)
11. Pump Plug (39REC 12. Pump Earth Indication Light (PL80)
13. Platen Earth Indicator Light (PL79) 14. Earth Fault Test and Indication Light (47PB)
15. Face Plate Removal Handles (HN) 16. Face Mounting Screws, ( not shown )
See Page 22 For Parts List And Descriptions
Y

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SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
T4PGF1 – Internal Component Locations
1. Earth fault Current Transformer (9CT) 2. Control Power Transformer (12T)
3. Platen Contactors (22-39CON) 4. Platen Thermal Overloads (22-39CON)
5. Pump Contactor (22-39CON 6. Load Current Transformer (1AM)
7. Power Transformer and Phase Light Fuses (9FU) 8. Pump Fuses (39FU)
9. Terminal Blocks (*STER) 10. Ground/Earth Terminals (*GTER)
11. High Voltage Terminal Blocks (*TER) 12. Detecting Relays and Resistors (R85-104)
13. Power Transformer 120 to 12v DC (80PS) 14. Earth Leakage Detector Relay (47MON)
15. Terminal Locks (*LCK) 16. Transformer Output Fuse (15-82FU)
17. 12 DC Transformer Output Fuse (15-82FU) 18. Earth Leakage Fault Resistor and Base (9R)
19. Ground/Earth Lugs 20. Base to Face Aluminum Standoffs (*ST)
See Page 22 For Parts List And Descriptions.
5.3. Connection Assembly
SAFETY- Ensure the voltage, phase and cycle on the temperature control panel is the same as the power
supply.
Turn the top and bottom platen switches to the 0(off) position.
1. Install a suitable electrical connector to the power supply cable. Refer to the electrical specifications
indicated on the serial plate and in the record of purchase. Connect the GREEN and SILVER wire to earth.
2. Connect the power supply cable to the power supply receptacle on the center face of the temperature
control panel. This is an Arc Flash and Switch rated type of connector that is used for ground fault
protected Almex control systems.
3. The platen connectors are on the face of the temperature control panel. Connect the platen cables by
pressing the plugs firmly into the receptacles and rotate the latches to secure the plugs. Please note: GF
platen and cable male plugs will have pin #6 shorter than the rest. This allows the pilot circuit to break first
removing the power eliminating arc flash, power to disconnect second and earth or ground to disconnect
last.
4. Connect the temperature control panel to the power supply. The phase indication lights will show that
power is supplied to the lines lit. If all line Indicators do not illuminate, have a qualified person check the
problem.

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SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
5. Turn the RESET Key Switch and the temperature controllers will indicate the actual platen temperature and
the set point temperature. The platens cannot be switched on until the MAIN BREAKER is switched fully
OFF and then ON. The system is set to trip at or below 30 ma of current leakage in under 50 ms.
6. OPERATION
6.1. How to Operate and Understand the Safety Features
When power is connected to the panel L1, L2, L3 pilot lights will illuminate. The box will need to be reset
using the keyed reset switch. Once reset a qualified person should take possession of the key so the control box
cannot be randomly reset in the case of an earthing failure. If a failure occurs only qualified personnel can
examine repair or diagnose and reset the control box. The MAIN BREAKER can then be reset. The earth
condition indicators will illuminate and show one of three colours.
Switch the MAIN BREAKER fully OFF (0 or green) with some force and then back ON (1 or red) to reset.
There are 2 indicator lights, one for the platens and one for the pump. If either indicator shows Red there is a
ground wire short. This means a wire has crossed and is giving a false earth signal. The earth connection is not
confirmed as proper. If either indicator shows Yellow, a cable or ground wire may be disconnected or
registering too high a resistance to be sensed properly. This could occur if the pump or platen cable is not
plugged in or if an earth wire is not attached or corroded. If the cables are plugged in and this Yellow indicator
is showing shut down the press and inspect immediately. If a Yellow or Red indication is on the affected plugs
will have power removed immediately by the safety circuits of the T4P-GF box. Power will not be supplied to
the plugs until a Green indicator light is associated with the plug, or plugs. If either indicator shows Green the
system is ready to go. If a pump is not used the pump indicator will show Yellow or no earth/ground attached.
On the face is a Red push button. This is used to test the earth fault system by producing a 30ma signal to
ground. This should trip the earth fault system and turn the main breaker off. Once tripped the push button
will light up Red to indicate an earth fault problem and the power will be removed in under 55ms. If the earth
fault system does not trip, LOCK this box out and have it repaired immediately. This should be checked every
time the T4P-GF system is used. If the system has been tripped on its own and the main breaker is turned off
and/or the push button is illuminated Red, an earth fault condition has occurred. Stop use immediately and have
a qualified person check the problem.
The T4PGF1 temperature control panel has two solid state temperature controllers, one for the top platen and
one for the bottom platen. If one platen cable becomes disconnected, both platens and temperature indicators
will switch OFF. The MAIN BREAKER will remain ON.
The T4PGF1 also has a single auxiliary receptacle for operating an HPP20-4 GF pressure pump. The
connections and coding block will be designed to accept only the voltage the GF box has been built to. The
receptacle is designed to have no power supplied to it unless a properly grounded HPP20-4 GF pump has been
installed and the ground continuity check shows the pump system is functioning properly by indicating a Green
light.
Each temperature controller displays the process value (PV) which is the actual platen temperature, and the set
value (SV) which is the desired temperature. As the platens are heating and coming up to temperature the
controllers will indicate this by running with a Green colour display. As the platen temperatures come close to
the set point they will change to an Amber colour to signify that attention should be paid to the temperatures. If
the platen temperature set point is exceeded the controllers will show a Red display colour and sound a 90 dB
alarm to signify a problem. Correct the problem immediately before damage occurs to the belt splice, or
equipment.
IMPORTANT: The platens must be ground fault ready as identified by an AS/GF in the model type (e.g. SVP-
AS/GF or RAB4-AS/GF) or the T4PGF1 control panel will not function. Most Almex vulcanizer platens can be
easily converted to work with the T4PGF1 control panels. Contact Shaw-Almex Service for information.
The control system is factory set to trip in the case of an earth fault failure below 30ma at or less than 55ms. If
resistance to the earth increases to an unsafe level, the system is designed not to allow power to the platens and
or pump. Each circuit is fused or thermally protected to the appropriate load capability of the parts. “Do not
replace with larger fuses”. The main breaker is rated at 30 amps. The pump is protected at 10 amps. Platen
plugs are protected at 15 amps each.

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SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
6.2. Temperature Controller Settings
The average user need only adjust the temperature set point. The temperature
controller has many other settings that have been set by the factory. All
adjustments other than temperature set point can be protected to avoid making
adjustments that might adversely affect the operation of the controller. See
Protecting Temperature Controller Settings.
In the description of temperature controller settings, the display key is
described with the ↵symbol.
6.2.1. Setting the Platen Temperature
1. The SET VALUE indicator on each controller displays the set point
temperature of the platen. You may change this setting for your
application by pressing the ∧or ∨key to raise or lower set point. This can
be changed anytime but should be done before beginning to heat.
2. After changing the SET VALUE, Turn the RESET Switch to off then back
on. Failure to do this may cause the temperature to overshoot the set point.
Important: The maximum recommended operating temperature for most belts is 325°F (163°C).
6.2.2. Setting Temperature Units to °
°°
°C or °
°°
°F
1. Press and hold the Level key for at least three seconds until IN-t appears in the PV display.
2. Press the Mode key momentarily until d-U appears in PV display.
3. Press the ∧
∧∧
∧or ∨
∨∨
∨key to select C (Celsius) or F (Fahrenheit) in the SV display.
4. Press and hold the Level key until the Operation level screen appears. The setting will be maintained
6.2.3. Setting the Over Temperature Alarm
This feature of the controller will give the operator an audible alarm if the platen temperature rises 20 °F (11°C)
above the SET VALUE. Use the following procedure on each controller:
1. From the Operation level press the Mode key until AL-2 appears in the PV display.
2. Press the ∧or ∨key to set 20 °F or 11 °C in the SV display.
3. Press the Mode key until the Operation screen appears. The setting will be maintained.

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SHAW-ALMEX INDUSTRIES LIMITED June 14 2017
7. HEATING THE VULCANIZER
7.1. Heating Up
Safety: Never heat the vulcanizer unattended and do the Pre-use Inspection before starting.
1. There are three positions on the platen switch as follows:
1A - On Automatic. For automatic temperature control to SET VALUE.
0- Off. Switches power to platens off. Controller remains energized.
1M - On Manual. Override temperature controller and switch power to platen on. This position has a
spring return to off, a Safety Feature so the heat will shut off if the vulcanizer is left unattended.
2. The vulcanizer should be pressurized to at least 5 psi (0.3 kg/sq.cm) before heating.
3. Turn the keyed RESET button to switch power on. Remove the key and have a qualified person hold it.
Then switch the MAIN BREAKER fully OFF (0 or green) with some force and then back ON (1 or red) to
reset. Then turn the keyed RESET button to switch power on. This sets the temperature controllers to
begin the heat cycle. The controllers display will turn Green.
4. Turn the switches to the 1A (on automatic) position to begin heating the vulcanizer. The Ammeter will read
the current for each platen as they are switched on. The OUT 1 light emitting diode on the controller will
light until the process value is close to the set value and then begin to flash. At this point the controllers
display will turn Amber. The platen temperature indicator value will begin to increase as the platen
temperature rises.
Safety: The platen will begin to get hot.
5. Stem thermometers should be inserted into the hole in the platen edge as a secondary means of monitoring
the temperature. The temperature will not necessarily be the same as the temperature control because of
differences in calibration.
6. When the set point is reached, the OUT 1 light emitting diode will continue to flash on and off to maintain
SET VALUE temperature. Start timing the cure when SET VALUE is reached.
7. After the cure time, turn the controller switches to the 0(off) position.
8. Turn the RESET Key Switch before the next heat cycle.
7.1.1. Manual Heating
If there is a temperature controller malfunction or platen temperature sensor failure, the platen can be heated
manually by turning the platen switch to the 1M (on manual) position.
Safety: This switch has a spring return to off, a Safety Feature so the heat will shut off if the vulcanizer is
left unattended. When using this function, the platen temperature will have to be monitored by an external
temperature indicator such as a stem thermometer.
7.2. Temperature Control
1. A P.I.D (Proportional Integral Derivative) solid state temperature controller that senses the resistance
change in an RTD (Resistance Temperature Device) sensor in each platen effects temperature control. The
controller should maintain temperature at the set point +-3 °F (2 °C) at 300 °F (150 °C).
2. The temperature controller incorporates a proportioning circuit that causes the platens to reach set point
temperature in a minimum of time with less than 2 °F (1.1 °C) of temperature overshoot. In operation, the
controllers will begin cycling off and on slightly below set point. During this initial cycling period, the
temperature will continue to rise to the set point as indicated by the temperature controllers. This early
cycling is a normal function of the controller and should not be reset, otherwise excessive temperatures will
occur.
3. The parameters can be adjusted so that set point is reached in the fastest possible time (straight line heating)
but this will cause the temperature to overshoot the set point by several degrees. Alternatively, the
parameters can be adjusted so there is zero overshoot but the rate of heating will decrease as the set point is
reached. If you wish to fine-tune your controller in either of these ways contact Shaw-Almex for advice.