Please Operation and Maintenance Manual Page 1

OPERATION AND MAINTENANCE MANUAL

Please
SECTIONAL VULCANIZING MACHINE

This manual has been prepared to present the correct methods and procedures.
of operation and maintenance of ALMEX VULCANIZERS.
The information contained in this manual is up to date as of its printing date.
However, due to the continuous improvements in the design of the vulcanizer, it is
It is possible that some information or appearance of a component may vary.
slightly regarding the team that has been delivered to him.

Read this manual carefully before operating your vulcanizer.

SHAW-ALMEX INDUSTRIES LIMITED

P.O. Box 430
Parry Sound, Ontario, Canada P2A 2X4
1-705-7465884
Fax: 1-705-7469484
E-mail sail@almex.com
Web: www.almex.com

SHAW-ALMEX INDUSTRIES LIMITED 49909-010 January 2002

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Index

1. PURCHASE REGISTER........................................................................................3
2. DECLARATION OF CONFORMITY .....................................................................4
5
3.1. Definition of Pictograms........................................................................... 5
3.1.1. Security Alert ................................................................................. 5
3.1.2. Impact Risk ................................................................................... 6
3.1.3. Surface by Hot Surface. Fire Risk............................ 6
3.1.4. Electrical Risk ....................................................................................... 6
3.2. Limitations of use ........................................................................................ 6
3.3. Hazardous Materials and Products.............................................................. 7
3.4. Safe Handling............................................................................................ 7
4. ASSEMBLY ..........................................................................................................8
4.1. Dimensions ............................................................................................... 8
4.2. Splicing Principles.............................................................................. 8
4.3. Unpacking ............................................................................................... 9
4.4. Functional Diagram.................................................................................... 9
4.5. General Assembly.................................................................................. 10
4.6. Assembly of Multiple Plates................................................................ 13
5. OPERATION ...........................................................................................................15
5.1. Pressurization ............................................................................................ 15
5.2. Heating of the Vulcanizer........................................................... 16
5.3. Vulcanizer Cooling.............................................................. 17
5.4. Depressurization ...................................................................................... 18
6. MAINTENANCE...................................................................................................18
6.1. Routine Maintenance .......................................................................... 18
6.2. Removal and Replacement of the Plate Insert.......................................... 20
6.3 Temperature Sensor Replacement (RTD Probe) .............................. 20
6.4. Insulation Replacement............................................................................. 21
6.5 Removal and Replacement of the Heating Element ......................... 21
7. SERVICE FAILURES...........................................................................................23
7.1. The Plates Do Not Heat Up............................................................... 23
7.2. The Plates Do Not Heat Evenly.................................................. 24
7.3. Overheated Plates............................................................................ 24
7.4. No Pressure or Pressure Loss....................................................... 24
7.5. The Plates Do Not Cool
8. SERVICE ................................................................................................................26
8.1. Emergency Service ............................................................................ 26
8.2. Authorization for Material Return ................................................ 26
8.3. Warranty

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PURCHASERECORD

Work Order No.

Purchase Date
Model No.
Serial No.

Plates Game 1 Game 2 Game 3 Game 4

Length: in. [mm] [ ] [ ] [ ] [ ]
Width: in. [mm] [ ] [ ] [ ] [ ]
Bias Angle
Voltage
Phase
Cycle
Amperes
Ohm's Open Circuits
Connected circuits
Element # E E E E
Weight: lb. [kg]
Cross Bars Game 1 (x) Game 2 Game 3 Game 4
Type
Pressure psi [kPa] [ ] [ ] [ ] [ ]
Length: in. [mm] [ ] [ ] [ ] [ ]
lb. [kg] [ ] [ ] [ ] [ ]
Pressure Bags Size 1 (x) Size 2 Size 3 Size 4
Length: in. [mm] [ ] [ ] [ ] [ ]
Width: in. [mm] [ ] [ ] [ ] [ ]
Bias Angles
Bag #

Total Weight lb. [kg]

Temperature Controller Model
Calibration Temperature°F [°C] 300 [150]
Pressure Control Model
Spare Parts
Operating Instructions
Supplementary Information
Service Bulletins
Warranty Card
Drawings
Part Diagrams Sectional Model: SVP, Plates, Type E Bars

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2. DECLARATIONOFCONFORMITY

We : Shaw Almex Industries Limited

Located in: P.O. Box 430, Parry Sound, Ontario, Canada.

We declare that the team:

Product: Vulcanizer
Model: Please
Year of Construction: 2003

It has been manufactured according to the following European standards:

EN 60204-1 Safety

EN 50081-1 Emissions (EN 55011)

EN 50082-1 Immunity (EN 61000-4 - 2/3/4/5)

In accordance with the following guidelines:

73 / 23 / EEC Low Voltage Directive and Corrections 93/68/EEC

89 / 336 / EEC EMC Directive and corrections 92 / 31 / EEC.

89 / 392 / EECDirective of Machining.

Signed in: Parry Sound, Ontario, Canada.

Nombre Lawrence B. Woolner / P. Eng.

Position: Engineering Manager.

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3. SECURITY

Your vulcanizer has been designed to provide a safe, efficient, and fail-free service.
for many years.
The design of the components and the selection of materials have been carefully
considered to ensure the operator's safety and a strict manufacturing procedure
to provide a consistent and high-quality product.
The material presented in this manual has been gathered to provide guidelines to the staff.
operational in such a way that the maximum efficiency of the vulcanizer is achieved and understood
correctly the operational procedures.
PLEASE READ CAREFULLY
The following safety precautions must be read and understood carefully before
assemble and operate the equipment. Otherwise, it could cause harm to personnel and deterioration.
of the team.
All operators must be trained under the correct methods of handling and
operation of the equipment.
The risks associated with the operation of the vulcanizer are identified throughout the manual.
with these pictograms.

3.1. Definition of Pictograms

Security Alert Risk of Impact Fire Risk Electrical Risk

3.1.1. Security Alert

1. Never operate the vulcanizing machine if it is not under direct supervision.

2. Make sure all components are properly assembled before starting the
pressurization.
3. Make sure that the correct arrangement of the cross bars is carried out using the
bar spacing template provided with the vulcanizer.
4. Make sure that the entire surface of the plate rests on the band to be vulcanized.
so that the crossbars and the adjustment screws are loaded evenly
to prevent damage to the board.
5. Always use the supplied restriction system. The restriction bars and the
safety locks MUST be used simultaneously to reduce risks
potential consequences that may arise from the eventual failure of an adjustment screw.
6. Visually inspect all load components in order to detect deformation or
cracks. Replace any component if it shows damage.
7. The adjustment screws must be evenly tightened. THEY MUST BE TIGHTENED
ONLY BY HAND.

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8. Do not lean or rest on the vulcanizer during operation. Because there are
high voltage levels present in the frame and its assembly components,
during the operation, a component failure may occur causing the parts
they can be projected upwards or outwards.
9. Always use an ALMEX temperature control box. Do not exceed the maximum value of
operational pressure. Do not connect the vulcanizer to a continuous pressure source. In case of
If a component fails, it is important that the pressure can be reduced to a safe level.
Do not block the pressure relief valve. This valve has been previously adjusted in
factory to prevent the vulcanizer from operating under risky pressure conditions.

3.1.2. Impact Risk

There is a risk of impact when assembling the components of the vulcanizer.

3.1.3. Hot Surface, Burn Risk

The surfaces of the plates generally operate at 300°F (150°C) or temperatures
superiors. Touching these surfaces will pose a potential risk of burns.
2. The cooling water can be initially discharged from the plate in the form of steam.
thus creating a burn hazard. Make sure the water drainage of
Cooling should not be directed towards any person as it may result in personal injury.
3. Always use an Almex temperature control box when operating the vulcanizer.
Never leave it unattended while it is in operation. The use
inadequate or the failure of a component can result in overheating of the
vulcanizer.

3.1.4 Electrical Risk

A certified electrician must be the person responsible for carrying out all maintenance
the electrical components of the vulcanizer.
All electrical components contain live circuits. Do not open or perform
repairs on any electrical equipment without disconnecting the main supply source
current.
3. The application of an incorrect voltage and phase can result in damage to the
components and consequently create a potential fire hazard.
4. The power supply sources to the equipment must be properly grounded.
since it can pose a potential danger of electric shock.
5. Avoid using the equipment in wet environments as it may pose a potential hazard.
electric shock.
If a cable or connector is faulty, it must be replaced as it may result in a
potential electrical shock hazard.

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3.2. Limitation of Use.

This equipment has been designed to vulcanize conveyor belts.
The vulcanization process is carried out by applying a combination of heat and pressure to the
band during a specific period of time.
The Almex model SVP vulcanizer can operate up to a pressure of 200 psi (1380 kPa).
Refer to the label placed on each crossbar to know the maximum pressure.
applicable to her.
The vulcanizer has been designed to connect to an Almex pressure control device.
equipped with a complete pressure hose system.
The vulcanizer should not be connected to a continuous pressure source.

The recommended maximum operating temperature is 325.°F (165°C) in order to be able to ensure the
maximum lifespan of the heating element and the insulation sheet of the plate.
The vulcanizer is designed to connect to an Almex temperature control box.
equipped with plate cables.
Hoses have been supplied to connect the cooling source to the vulcanizer.
No other use of this vulcanizer is allowed without written permission from Shaw -Almex.

3.3. Hazardous Materials and Products.

The cooling water can be initially discharged from the plate in vapor form thereby creating
a potential burn hazard.
Make sure that the cooling water discharge does not point towards any person as
can result in personal injuries.
There could be potential risk associated with the use of the materials that make up the kit.
vulcanization.
Consult the supplier for the specifications of the splice materials for more details.

3.4. Safe Handling

The handling of the vulcanizer presents certain potential hazards.
The weight of the components is marked on them.
Cranes or lifting systems may be required to position the plates and bars.
crossbeams in their place, in which case appropriate slings will be needed.
Use safety boots while operating the vulcanizer.
Cable and hose connections must be made in such a way that no risk is created.
potential flow interruption

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4. ASSEMBLY

4.1 Dimensions

Figure 1: Dimensions
Protective Laminate of
Type of Cross Bar pressure bag
EA EAX EB EC E380
flea mm tick mm lice mm louse mm bug mm Pressure Bag
W 22 559 27.5 699 32.5 826 32.5 826 36.5 927 Upper Plate
W
X 9.75 248 12.5 318 15 381 15 381 17 432 Band
Y 7.75 197 10.5 267 13 330 13 330 15 381 Lower Plate
X
Z 7 178 7 178 6 152 6.5 165 6.5 165 Y

4.2. Splicing Principles

There are two essential requirements for achieving a perfect splice in a conveyor belt:
Uniform Pressure and Controlled Uniform Temperature.
Both requirements are met with the ALMEX Vulcanizer.

Uniform pressure:
Inflatable pressure bags apply uniform pressure over the entire surface of the plate.
The plates are flexible in such a way that when pressure is applied to them, they mold or
they contour the worn profile of the band.

Important:
Due to its unique design, the Almex plate requires support on its entire surface to prevent occurrence.
a permanent distortion in it.
Fill all unused portions of the plate area with strips of the same thickness as the band.
that is being vulcanized.

Figure 2: Uniform Pressure

Before Pressurizing After Pressurizing

Uniform temperature:
The heating element is made up of an electric resistance embedded in a casing.
made of silicone rubber, designed to cover the entire surface of the plate.

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4.3. Unpacking

Carefully unpack the vulcanizer from its container and check for any damage.
Any breakdown or missing part must be reported to the transport company or to Shaw - Almex.
Industries Limited.

4.4. Functional Diagram

Figure 3: General Assembly of a Multi-Plate Vulcanizer.
(The SV6P model is shown containing 6 sets of plates)

Source of
Nutrition
Box of
Control of
Temperature

Distributor of Entry Exit

Cooling

Connector of
the Plate

Connector
of the Bag
Pressure

Distributor
of Pressure
Bar
Transversal

Pump of Screw of
Pressure Adjustment

Tank
Additional

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4.5. General Assembly

Safety: The vulcanizer must be assembled and

operated on a flat, leveled, and stable surface of
Figure 4: Templates
in a way that there is no potential danger of falling.

Remove the rollers from the conveyor to provide

space for the assembly of the vulcanizer. Use the
assembly template and the general layout drawing
to adjust distances.

2. With the tips of the band Figure 5: Cross Bars

carrier bent backwards,
place the template in the position of the Bar Screw of
splice. The templates ensure the Transversal Adjustment
correct spacing between the bars
transversals and establish the angle of
appropriate splice (bias). See Figure
4: Templates
Template
3. Position the crossbars on the
template. If the end of only one of the
the bar has the manufacturing cut-out to secure the pressure screw,
make sure that the notch is positioned at the top. See Figure 5: Crossbars.

Safety: Use secure slings to manually move very heavy components.

4. Install the lower restriction bars. With the terminal bolt removed from one end,
Slide the restriction bar along each crossbar and install the end bolt.
Both terminal bolts must be installed
approximately ¾” (18mm) away from the bar
outermost transversal. Figure 6: Lower Plate and Loops

Clamp Wing of
Bars of the Plate
5. Install the wings of the plates (or the rings of
Restriction
elevation) manually screwing them inside Plate
the holes located on an edge of the plate Inferior
inferior. See Figure 6: Lower Plate and Loops.
6. Raise and position the bottom plate over the bars
inferiors. Make sure the plate is centered.
in both directions on the bars

Safety: Never attempt to use the plate handles.

to elevate the plate over no one.
Remove the plate handle because it can cause cold spots on the plate.
8. If the orientation of the plates can cause the electrical connections and the connections of
Cooling systems should be located underneath the band, install them right at this moment.
cooling hoses and the cables of the boards.

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9. Prepare the splice on the bottom plate. It's good.Figure 7: Steel Edge Bar
It is common practice to place a sheet of wood over the board.
lower while preparing the splice in order to prevent
damage to the surface of the plate.
Suggestion: A wooden platform can be built at
be positioned around the plate to increase the
size of the work table.
Caution: Due to its unique design, the Almex plate requires Band

support on its entire surface to prevent it from suffering

Border Bar
permanent deformation or distortion. Fill in any
unused portion of the board with scraps of the same band
thickness of the band to be vulcanized.
10. Install the cooling hoses on the plates Figure 8: Upper Plate
inferior. It can be difficult to install the connectors of
cooling after placing the bar in position
from the edges and the upper plates.
11. When using the edge bars, install them on the
lower plate positioning them along the edges Plate
from the band. See Figure 7: Steel Edge Bar. Superior

Plate Wing
Suggestion: Edged Steel Bars must have
slightly less thickness (0.015", 0.5 mm) than the thickness of the band to be vulcanized.

12. Use the plate handles to lift and position the upper plate over the joint.
Make sure that the top plate is centered with the bottom plate. Make sure that the
cable connections are on the same side. See Figure 8 Upper Plate.

Safety: Never attempt to use the plate handles to lift the plate above anything.
person.

13. Remove the plate handles. Figure 10: Pressure Bag and Protective Sheet

14. Position the pressure bag and its sheet Lamina

protector
protector over the upper plate. Locate the Plate Bag
hose coupling at the site most
convenient for the air connection or of
fluid. Try to position the bag in such a way
that its coupling is on the opposite side of the
electrical connections of the plates. See the
Figure 10: Pressure bag and its sheet Pressure Bag
protector

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15. Remove the dust cover from the Figure 9: Connection of the Plate
connectors of the boards and install the sockets
of the board cables. The configuration of the Stopper
pins allow the plug to be installed in a Plug
only form.
See Figure 9: Board Connection.
Activate the insurance to open the connection

Push the male connector firmly.

inside the female connector.
Sure Dust Protector
Loosen the screw to maintain the connectors. Open
in a closed and contact position.

Closed Insurance

Figure 11 Plate Cable

Suggestion: The two terminal ends of
the plate cables of the vulcanizer model
SVP–T4 can be connected during the
storage and transportation to protect
the contact pins of humidity, of dust
and deterioration. See Figure 11: Plate Cable.

Safety: Make sure to disconnect the main power supply before

connect the board cables.
Figure 12

16. Position the upper crossbars over Calibrated Pass

the protective sheet of the pressure bag. The bars
superior transversals must be aligned Restriction Bar
with the lower crossbars and
remain parallel with the ends of the
edges of the plates. See Figure 12. Screw of the
Belt buckle
Retention

Screw of
Union of the
Bars

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17. Install the adjustment screws. The square head of the adjusting screw must support
perfectly on the rectangular section of the seat at the ends of the bars. The
Adjustment screws must be uniformly tightened only by hand until the nut
sits on top of the bar.
Caution: Under no circumstances should you use a wrench to tighten the adjustment screws. If the
nuts do not turn freely by hand, inspect, repair or replace the screw.
18. Install the lower restraint bars. With the terminal bolt removed from one end,
slide the restriction bar along each crossbar and install the terminal bolt.
Both terminal screws should be placed approximately ¾" (18mm) away from
the outermost crossbar.
19. Install the retaining pins of the adjustment screws through the remaining holes.
from the upper and lower bars.

Safety: The restraining bars, end pins, and safety pins of

The adjustment screws are safety components of the vulcanizer. When such
components used together will protect the equipment against risks that may result
in occasional failures of the adjustment screws.
20. Adjust the edge steel bars.
21. Position the temperature control box and the pressure control device in the area of
splice.
22. Make the electrical, pressure, and cooling connections as indicated in
the drawing of General Arrangement included at the end of this manual. If you are not familiar with this
procedure, refer to the temperature control box manual and the manual of the
pressure control device.
23. Connect the wires from the lower plate and the upper plate to their respective controllers.
control box temperature. Connect the control box to the power supply.
See the temperature control box manual.
24. Connect the cooling hoses to the lower plate and the upper plate.

4.6. Multiple Plate Assembly.

The sectional multiple plate vulcanizers Figure 13: Union of the Bars
they are designed in such a way that the plates can be Restriction
placed side by side in order to create a plate of
largest warming. The procedure of
assembly is the one described earlier with the
following additions: Union of the
Bars of
More than one template will be provided for areas of
Restriction
splices larger than 96" (2.40 m).
More than one restriction system will be provided.
for splicing areas greater than 96" (2.40m). In
In this case, I executed the union of the sections of the
different restriction bars using the joint that Fastener of
it is indicated in this manual. The union will be Restriction of the
appropriately installed when the closing spring Bar

is under load inside the coupling device. Install the restraining bars.
lower as the crossbars are positioned, otherwise this
the operation could be difficult if the crossbars are not of the same height.

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3. Install the lower plates on the lower crossbars making sure that the
the edges of the plates should be completely aligned.
Suggestion: It is suggested to use steel sheets of 1/8” (3mm) thickness, of the same size as
the total area of available plate. A sheet is placed on the surface of the lower plates and
the other sheet on the top part of the band (underneath the upper plates).
These steel plates will ensure that there is no rubber flow through the gaps between the
union of the plates.
Always try to position the pressure bags in such a way that the joint between bags does not coincide with
the union between the plates.
4. Install the upper plates aligned with the lower plates and with their edges.
tightly pressed together. The area on the top of the plate (counter-laminated +
protective metal sheet) has been designed slightly smaller than the area of the
bottom part of the board (plank), to ensure that the edges of the board planks
adjacent ones are closely connected and there is perfect heat transfer by
thermal conductivity.
Make sure that the separation distance between the upper parts of adjacent plates does not
exceed 3/8" (9 mm) or the bag will try to expand within the gap.
5. Install the pressure bags so that their valves are on the same side and if possible
nearby. Always try to place the pressure bags in such a way that the joint between bags does not
it coincides with the union between plates.

When in a multiple board design all the boards have the same dimensions, they
They will supply two half-bags so that the bag-plate joints do not match.
6. Install the protective sheets over the bags of pressure bags in such a way that the joint
between sheets does not match the junction between bags.
7. More than one restriction system will be provided for splice areas greater than 96 inches.
(2.40m). In this case, execute the joining of the sections of the different restriction bars.
using the gasket indicated in this manual.
8. When using more than one temperature control box, connect the power cable.
Connect the principal of each control box to an appropriate power supply.

Security:
Do not connect a power supply cable to the pump power receptacle located at the
the back part of a control box. This electrical circuit does not have sufficient capacity to
bear the load coming from the plate game.
9. When using more than one bag, several fluid pressure pumps, and multiple plates, use the
pressure distributor supplied by Almex with the vulcanizer to achieve a distribution
pressure uniformity in all bags.

5. OPERATION

The following procedure describes the operation of the vulcanizer once it has been
The splice is prepared and the vulcanizer has already been assembled.
In addition to this manual, separate operating instructions and
maintenance for the temperature control box and for the pressure control device.

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5.1. Pressurization
The vulcanizer can be pressurized with air up to 100 psi (690 kPa).
For safety reasons, if the vulcanizer must operate at a pressure greater than 100 psi (690
kPa), THE fluid pressure pump must be used.
Always use the Almex pressure control device to pressurize the vulcanizer.
Refer to the Air Control Device Manual or the Fluid Pressure Pump Manual
in case you are not familiar with its operation.
Generally, the pressurization time is much shorter with air than with water, but in
In both cases, the vulcanizing machine will require a few minutes to pressurize internally. Meanwhile
the larger the vulcanizer, the longer the pressurization operation will take.
When air is used, the pressure will begin to increase rapidly after flow is applied.
When water is used, the hydraulic pump will discharge fluid at a certain flow rate and by
Consequently, the bag must fill its entire volume before the increase in pressure begins.
It may take a few minutes for the pressure to start increasing, but once
Filling the bag will rapidly increase the operating pressure.
Carefully observe the pressure gauge when pressurizing.
Once the vulcanizer is pressurized, the crossbars and plates will deform.
in a visually imperceptible proportion depending on the magnitude of the applied pressure,
of the length of the bar and the design of the bars.
With the use of the unique ALMEX flexible plate design with pressure bag, the deformation of the
bars and the plates will not negatively affect the desired effect of the application of
uniform pressure for obtaining a durable joint.
Important:
Make sure that both the vulcanizer and the restraint system are correct.
assembled before pressurizing.
If the bars tend to deform or the assembly tends to be unstable, release the pressure and check.
the alignment of the components.

Security:
Do not lean on the vulcanizer while it is being pressurized. Because there are high
tension levels present in the frame and in the assembly components, during the
operation could result in a potential failure of some component causing the parts to be able to
to be projected upwards or outwards.
It is important for the staff to clear the area when the vulcanizer is operating.

Security:
Do not connect the vulcanizer to a continuous pressure source. In case of failure of a
component, it is important that the pressure can be reduced to a safe level.

Security:
The pressure relief valve of the air control device has been previously adjusted to
factory to vent at pressures slightly higher than the operating pressure shown on the plate
device serial number.

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The pressure relief valve of the fluid pressure pump has been previously adjusted at
factory to vent at 25 p.s.i (170 kPa) above the operating pressure shown on the serial plate
the bomb.
Do not tamper with this safety device as it may result in damage to the equipment and injuries.
to the staff.

Security:
Do not place your fingers between the surfaces of the plates when the vulcanizer is pressurized.
The omission of this standard may result in harm to personnel.
1. Connect the pressure control hose to the pressure bag connection.
2. Pressurize the vulcanizer to the operating pressure. Ensure that the air or fluid fills the
pressure bag before starting the heating of the plates. A simple practice to
make sure that each bag is being pressurized by slightly loosening the adjustment screws.
These screws will not move if the bag is effectively being pressurized.
3. To depressurize the vulcanizer, slowly open the pressure relief valve.

5.2. Heating the Vulcanizer

If you are not familiar with the operation of the temperature controller, please refer to the manual.
respective.

Safety: Never leave the vulcanization machine operating without direct supervision.

Important: There should be no residual water on the plates before heating them. Otherwise
there will be no uniform heating on the plates.
Important: The lifespan of the heating element will be significantly reduced if the
The vulcanizer is heated without being properly assembled and pressurized.

1. Adjust the set point value of the temperature controller. It may be necessary to cycle
OFF / ON the power supply to the temperature controller to reset the value of
temperature adjustment point. Check the temperature controller manual.
2. Place the temperature controller switches in the ON position. This position
must be indicated as AUTO(Mark VIII) or 1A(T4).

Safety: The plates will heat up.

3. Heat to the set temperature value and then measure the curing time.
according to the specifications supplied by the kit manufacturer's splice. Check the
plate temperature on the controller screen both with rod thermometers or with
thermocouples inserted into the beveled holes located at the edge of the plate.
4. When the curing period has ended, turn the switch of the temperature controller to
the OFF position.

5.3. Cooling of the Vulcanizer

The plates can cool naturally to the environment after having been turned off. The
natural cooling can take several hours so this method is only recommended in the
in case the cooling time is not important.

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Similarly, the plates can be cooled with compressed air, which is a faster method.
even though it will take several hours.

The preferred cooling method is to pump water through the plates.

The cooling time depends on many factors such as the initial temperature of the
plate, the final temperature of the plate, the temperature of the cooling water, the pressure of the water,
the flow resistance and the total plate area to be cooled.
Multi-plate arrangements require a longer cooling time due to the large area.
of the plate and the restriction in the cooling ports.
Generally, the vulcanizer will cool down to a safe handling temperature within a period of
five to ten minutes per plate game.
The cooling hoses should be connected to the plates during assembly of the
vulcanizer, since in this way the cooling ports are easily accessible and the
plates are not hot.
The cooling ports on the SVP plates are of the 1/8" NPT type.
The plates manufactured by Almex until 1994 generally have 1/4" NPT connectors such as
cooling ports.
Important: The plates should be cooled only while the vulcanizer is turned off.
pressure and as long as the heating of them has been stopped (OFF).

Safety: The cooling water can initially be discharged from the plate in shape
vapor creating a potential burn hazard. Make sure the water discharge
Cooling should not be directed at any person as it may result in injuries to personnel.
1. When the vulcanization time has been completed and the temperature controllers
they have placed it in the OFF position, open the water supply to cool the upper plate and
inferior. When using an automatic temperature control, leave the controller
temperature connected to the plates in such a way that the decrease can be monitored
temperature during the cooling cycle.
2. When using the pressure pump for cooling, refer to the pump manual.
3. When the plates have cooled to an acceptable temperature, the supply can be closed.
cooling water. A typical cooling temperature to achieve a splice
durable and at the same time to achieve a safe handling of the band without the risk of burning, it is
from 150°F (65°C).
4. The remaining water on the plates after a cooling cycle should be expelled with
compressed air before proceeding with a new heating cycle.
Important: The remaining water in the cooling channels will tend to reduce the distribution.
uniform temperature within the plate will increase its heating time and may cause
that the elements overheat. Likewise, if water remains inside the plates and the
vulcanizer is stored at temperatures below the freezing point of water, the plates
they may deteriorate severely.

5.4. Depressurization.
1. To depressurize the vulcanizer, slowly turn the handle on the relief valve.
pressure until it is aligned with the body of the valve.
2. When the pressure has dropped to zero and the flow has stopped, the source can be disconnected.
pressure supplier.

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Safety: Do not attempt to dismantle the vulcanizer until the pressure has been
completely released. The omission of this rule may result in damage to the equipment or injury
personal.

6. MAINTENANCE

Security: All maintenance must be carried out only when the vulcanizer is.
find des - energized and des-pressurized.
No special tools are required to perform maintenance on the equipment.

6.1. Routine Maintenance.

After every thirty (30) splice repairs, inspect the following components:
1. Visually inspect the crossbars, pressure screws, and pins.
safety to detect signs of cracking or deformation.
2. Visually inspect the straightness of the screws.
If the screw axis shows permanent deflection, it must be replaced.
Clean and inspect the screw thread with penetrant liquid every 200 curing cycles.
Make sure there are no cracks along the threaded length.
If there are cracks, remove the screw from service and contact Shaw Almex.
Apply some type of dry lubricant to the threads of the screws.
3. Visually inspect both ends of the bars on the rectangular section on which
the square head of the adjustment screw is supported.
Make sure there are no cracks along the edges of this section.
If there are cracks, the barrier must be replaced.
4. Check the continuity of the heating elements of the plates.
See the Purchase Record for the values of each resistor (ohms).
Use the measurements indicated in the column 'Ohm Reading - Circuit' as a reference.
Closed / Ohms Reading Coils Connected displayed in that record.
These measurements are the resistance readings of the plate receptacle between terminals 1-2,
2-3 and 1-3.
5. Check the continuity of the RTD probes on each board. See point 7.1.3 of the section.
titled 'The plates do not heat up'.

6. Examine the pressure bag(s), Figure 14: Board Connector

hoses and connectors for detecting damage
ELEMENT RESISTANCE
due to abrasion, cuts or any kind of
OF WARMING
deterioration that may cause leakage or failure when the
vulcanizer is under pressure.
Pay particular attention to the pressure bag to the
anchor base of the valve to the bag.

SHAW-ALMEX INDUSTRIES LIMITED

SENSOR RESISTANCE
RTD
Please operate and maintenance manual Page 19

7. Inspect all electrical cables for cuts, abrasion, and wear.

Inspect all the 'stress relief' points of the connections between cables and plugs.
to ensure the firm connection of the same.
If any electrical cable, hose, connector, or pressure bag shows signs of failure or damage,
it should be replaced or repaired.
8. The cooling circuit of the plates must be inspected for leaks and/or
blockage that could affect its operation.
An internal leak in the circuit can damage the insulation of the board and the element of
heating if it is not timely repaired.
9. Inspect the state of compression and/or mechanical resistance of the counter-lamination that
it serves as a thermal insulation system for the plate.
Check the degree of compression of the veneer, as the localized reduction of its
thickness can produce a thinner section and allow the heads in these sites to
the screws protrude from the exterior metal casing of the plate.
If this occurs, the insulation backing must be replaced.
Suggestion:
The threads of the adjustment screws of the Almex vulcanizers have been coated with a
protective compound to facilitate the removal and replacement of pressure nuts.
This compound will be progressively eliminated each time the vulcanizer is used.
Therefore, product No. 82351, antioxidant Chesterton No. 725 based on nickel, or
its equivalent must eventually be applied to the threads of each nut-bolt set to
prevent the screw-nut joint from welding together.
This application should be performed every three (3) months or more frequently under conditions
operational severities.
The surfaces of the screw threads must be free of oil, grease, moisture, and dust in order to
to apply the compound effectively and uniformly.
6.2. Removal and Replacement of the Plate Insert
The contact pins of the insert located inside
Figure 15: Board Connector
The plate receptacle must be inspected.
occasionally to detect damage resulting from
Adapter
wear, corrosion or electric arc. If the plugs
are damaged, the insert must be replaced. The Gasket
the protective cover of the receptacle must always be
used when transporting or storing the
Wrapping
plates in order to keep the insert clean.
Important: The plate insert is made from
made of a special material resistant to high temperatures.
Contact SHAW ALMEX for the appropriate spare part.
1. Remove the wrapping from the edge of the plate.Insert Cover
insert by releasing the four screws.
Carefully pull the packing, wrapping
and the insert outside of the plate.

2. Remove the insert from the envelope by releasing the four screws and
Carefully pull the wires through the packaging.

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3. Disconnect the RTD sensor, the element, and the ground wires from the insert.
4. Connect all the cables to the new insert. Connect the yellow sensor of the RTD probe to
Terminal 4 and the two white wires to Terminals 5 and 6.
5. Install the insert inside the wrapper.
6. Secure the cables and slide the packaging until it is flush with the wrapping.
7. Rotate the wrapping several times to position the wires inside the loose bundle and
Then carefully insert the cables into the adapter.
8. After ensuring that no cable is blocked, tighten the wrap around the adapter.

6.3. Replacement of the RTD Probe

1. Remove the insert from the plate. See point 6.2 Figure 16: RTD Probe
2. Disconnect the probe wires and pull.
RTD Probe
through the packing. The wiring can
stay connected.
3.Remove the RTD probe from the board. See
Figure 16: RTDProbe. If the probe does not come out with
ease, I made a ¼" (6 mm) hook in the
end of a thick wire and slide it in
from the channel to the bottom of the probe
approximately 8" or 200 mm. Then pull the
hook. If it is not possible to pull the probe, the channel
It must then be drilled with a ¼" drill bit.
(6mm) diameter and 9" (230 mm) long.
4. Adjust the cables in the new probe to the same
length they had in the old probe.
5. Insert the wiring of the RTD sensor through the appropriate holes in the packing.
in such a way that the yellow cable is aligned with Terminal 4 and the two white cables with
terminals 5 and 6.
Each cable of the probe must have a small metal casing attached at the end.
to ensure a better connection to the insert.
Adjust the wiring connections to the insert. Install the insert inside the housing. See the
section 6.2: Removal and Replacement of the Plate Insert
6. Apply a thin layer of a compound that facilitates on the new probe.
heat flow extraction (Heat Sink Compound).
Install the probe into the plate approximately 8" or 200mm deep.
The temperature controller will need to be calibrated after replacing the sensor.
of temperature. Refer to the Temperature Control Box manual.

6.4. Replacement of Counter-Laminating for Thermal Insulation.

1.Place the aluminum surface or heating side of the plate down.
The protective metal casing of the board must be positioned upwards.
2. Remove the screws from the metal housing of the board and remove the housing.
Remove the counter-laminate that acts as a thermal insulation system for the plate.

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Now the rear surface of the protective aluminum sheet of the element will be exposed.
of warming.
3. Install the new veneer sheet
Use the old veneer sheet to mark the gaps of the new sheet.
4. Correctly position the new veneer sheet, the protective aluminum sheet.
of the heating element and the plate casing.
Replace the screws using dry lubricant on their threads.

6.5. Heating Element Replacement

Place the aluminum surface or heating side of the plate facing down.
The protective metal casing of the plate must be positioned upwards.
2. Remove the screws from the metal casing of the board and take off that casing.
Remove the counter-laminate that acts as a thermal insulation system for the plate.
Now the rear surface of the protective aluminum sheet of the element will be exposed.
Heating element. See Fig. 17: Heating Element.
3. Remove all the screws from the protective aluminum sheet of the resistor element.
4. Vulcanizing machines with very large plate areas can have two or more elements of
plate heating.
This design allows for better temperature control and lower amperage per element.
Carefully lift the protective aluminum sheet from the resistance, removing it from the
plate.
Care should be taken in this operation, as the resistor element may be adhered to the
backing sheet.
In this case, use a knife carefully to separate the element until you free it.
5. Remove the insert from the receptacle of its protective cover.
Disconnect the conductors from the insert, noting their connection arrangement.
See Point 6.2: Removal and Replacement of the Plate Insert.
6. Remove the old element. Care must be taken in this operation, as the element
the resistor may be attached to the backing sheet.
Insert the new element in the space
corresponding on the solid plate (Plank). Mark Figure 17 Heating Element
about the element the holes for fixing the
plate screws. Cover of
Element
If it is necessary to cut the resistance, remove one.
equal amount of material on each side to center it Adapter
about the plate.
8. Using a leather punch or, failing that, a Element
similar tool, drill the holes in the
new element.
9. Place the new element on the Plank. Position
all the conductors in the adapter.

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10. Place the aluminum backing sheet of the element over it.
Replace the screws using dry lubricant on their threads.

IMPORTANT:
Make sure that the element, its backing sheet, and the Plank are completely clean
before assembly.
Sharp edges, aluminum or metal shavings will damage the heating element.
Cut the element's conductors to approximately 8" (200mm) in length.
Remove the insulating cover from the conductors by approximately 1/4" (6mm).
12. Through the appropriate holes in the packing, insert the conductors into the
terminals 1, 2, and 3 of the plate receptacle insert.
The drivers must be routed through the wrapping and secured to the insert with the
tighten the fastening screws.
The drivers must reconnect in the same arrangement in which they were disconnected.
If you have any questions regarding the connection sequence, refer to the wiring diagram.
Install the insert into the wrap.
See Point 6.2: Removal and Replacement of the Plate Insert.

13. Install the insulating veneer sheet and the casing over the aluminum sheet.
protector of the element.
Replace the screws using dry lubricant on their threads.
The temperature controller will need to be calibrated after replacing the
heating element.
Refer to the Temperature Control Box manual.

7. SERVICEFAILURES

Refer to the "Fault Detection" section of the control box as the first option.
temperature.
If you do not find the fault, follow the next procedure:

7.1. THE PLATES DO NOT HEAT UP.

FAILURE CORRECTION

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Loss of cable connection 1. Make sure the cable connections

They are properly joined.

2. Disconnect the power supply source,

2. Loss of connection in the board cable or in
remove the insert from its wrapper and press
the connector of the board.
all connections.

3. RTD temperature sensor failure 3. Measure the value of the resistance between the
pines 4-5 and 4-6 on the receptacle of the
plate. Depending on the temperature of the
the plate value should be between 100-
170 Ohms.
If negative, replace the RTD sensor.

4. Heating element failure 4. What is the resistance between pins 1, 2, and 3?

about the plate receptacle. Compare the
reading with the value indicated in the Register
Purchase / Element Resistant Coils
Connected.
If the values are not close and the
connections are good, the element of
heating must be replaced.
RESISTANCE ELEMENT
OF HEATING

SENSOR RESISTANCE
RTD

7.2. THE PLATES DO NOT HEAT UNIFORMLY.

Refer to the "Fault Detection" section of the control box as the first option.
temperature.
If you do not find the fault, follow the next procedure:

FAILURE CORRECTION
Residual cooling water in the Purge the water from the plate by blowing air.
plates. compressed through the channels of
cooling.

2. What is the resistance between pins 1, 2, and 3?

A portion of the element has burned.
about the plate receptacle. Compare
warming
the reading with the indicated value in the
Purchase Record / Element Resistant
Coils Connected.

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If the values are not close and the

connections are good, the element of
heating must be replaced.

7.3. OVERHEATING OF THE PLATES.

Refer to the 'Fault Detection' section of the control box as the first option.
temperature.
If you do not find the fault, follow the next procedure:

FAULT CORRECTION
RTD temperature sensor failure What is the value of the resistance between the
pins 4-5 and 4-6 on the receptacle of the
plate.
Depending on the temperature of the
the value should be between 100-
170 Ohms.
If negative, replace the sensor
RTD.

7.4. THERE IS NO INDICATION OF PRESSURE OR PRESSURE LOSS.

Refer to the 'Fault Detection' section of the pressure pump as the first option.
If you do not find the fault, follow the next procedure:

FAILURE CORRECTION
Blocked fluid passage. Inspect the pressure bag valve
and the obstruction hoses
Clean and replace the parts that are
necessary.

2. Leak in the pressure bag or in the

2. Remove the pressure bag and inspect
hoses
for leaks. If no leak is evident, use air
compressed to inflate the bag (maximum 5
psi = 0.35 Kg/cm2) and sprinkle water
soapy on the bag.
The bubbling will indicate the escape of air and in
in this case the bag must be replaced.

7.5. THE PANELS DO NOT COOL

Refer first to the "Fault Detection" section of the pressure pump.
If you do not find the fault, follow the next procedure:

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FAULT CORRECTION
Blocked fluid passage. 1. Remove the cooling hoses and
inspect for leaks and obstructions.
Clean and replace any parts that are
necessary.
Blow compressed air through the
cooling channels from a port
cooling and then, from the other, in order to
to check for obstruction within the plate.
If there is an obstruction, consult Shaw.
Almex for detailed service.

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8. SERVICE

8.1. EMERGENCY SERVICE:

CONTACTOS Service Department
EMAIL service@Almex.com
TELEPHONE: 1-705-7465884 1-800-4614351 Toll-free call
FAX: 1-705-7469484
EMAIL: SHAW ALMEX INDUSTRIES LIMITED
P.O. Box 430, Parry Sound, Ontario
Canada, P2A 2X4

8.2. AUTHORIZATION FOR MATERIAL RETURN

The Shaw Almex Industries Service Department MUST BE contacted for approval
and the processing of the necessary documentation before returning material to the factory.
The Department of Services can be contacted through the phone numbers above.
indicated.

8.3. GUARANTEE:
Your ALMEX vulcanizer is guaranteed against defects in components, materials
defective and poor workmanship for a period of twelve (12) months from the date of
dispatch.

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