Almex SG1 Operating Manual
Operating Manual
SG1 Vulcanizer Switchgear Control Box
ORDER NUMBER: BAT-SG1-001
Revised - April 2014
This manual was prepared to present the correct methods
and procedures of operating and maintaining your
ALMEX SG1 SWITCHGEAR CONTROL BOX
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 SG1 delivered to you.
READ THIS MANUAL CAREFULLY BEFORE OPERATING YOUR SWITCHGEAR CONTROL BOX
49900-038
Table of Contents
1. SAFETY 3
1.1. Safety Symbols 3
1.2. Definition of Pictograms 3
1.2.1. Caution 3
1.2.2. Electrical Hazard 3
1.2.3. Burning Hazard 3
1.3. Work Area Safety 3
1.3.1. Keep Work Area Clean 3
1.3.2. Keep Visitors Away 3
1.4. Personal Safety 3
1.4.1. Stay Alert 3
1.4.2. Never Alter or Remove Safety Devices 4
1.4.3. Use Safety Equipment 4
1.5. Service and Maintenance Safety 4
1.5.1. Use Authorized Service Only 4
1.5.2. Use Only Authorized Replacement Parts 4
1.5.3. Never Use a Defective or
Abnormally Operating SG1 4
1.6. Limitation of Use 4
2. PRODUCT OVERVIEW 4
3. HARDWARE OVERVIEW 5
3.1. WiFi Antenna 6
3.2. Platen Set 1 and Platen Set 2 Switches 6
3.3. Auxiliary Switch 6
3.4. USB Cable Receptacle 6
3.5. Reset Button 6
3.6. Warning Alarm 6
3.7. Tablet Power Receptacle 6
3.8. Thermocouple Receptacles 6
3.9. Temperature Set Point Indicator 6
3.10. Platen Set 1 and 2 Temperature
Indicators 6
3.11. Platen ON LED 6
3.12. Set Point Reached LED 6
3.13. LCD User Interface 7
3.14. Wireless Pressure Sensor Antenna 7
3.15. Network Master Indicator 7
3.16. Left and Right Auxiliary Receptacles 7
3.17. Upper and Lower Platen Receptacle
(Set 1 & 2) 7
3.18. SG1 Networking Receptacle 7
3.19. Power Main Input Receptacle 7
3.20. Wireless Pressure Sensors and
Schrader Valves 7
3.21. Spare Fuses 7
3.22. Power Cable 7
3.23. Front Panel Dust Cover 7
3.24. Thermocouple Cables 7
3.25. Networking Cables 8
4. SETTINGS 8
4.1. Network Settings 8
4.2. Control Settings 8
4.2.1. Auto-Tuning Support 8
4.2.2. Temperature Offset 8
4.3. Alarm Settings 8
4.3.1. Maximum Pressure 8
4.3.2. Temperature Range 8
4.3.3. Minimum Current 9
4.3.4. Platen Disconnection 9
4.4. Interface Settings 9
4.4.1. Temperature Units 9
4.4.2. Language 9
4.4.3. Sounds 9
5. SENSOR READINGS 9
5.1. Pressure Readings 9
5.2. Pressure Sensor Registration Procedure 9
5.3. Current Readings 9
5.4. Thermocouple Readings 10
6. PREPARATION 10
6.1. Unpacking 10
6.2. Connection Assembly 10
7. OPERATION 11
7.1. Heating the Vulcanizer 11
7.1.1 Automatic Heating 11
7.1.2. Manual Heating 11
7.1.3. Cooling 11
7.1.4. Splice Resume 11
8. OPERATION WITH MULTIPLE SG1s 11
8.1. Description 11
8.2. Preparation 12
9. MAINTENANCE AND REPAIR 13
9.1. Replacing Fuses 13
9.1.1 Opening the SG1 13
9.1.2 Fuse Replacement 14
9.1.3. Closing the SG1 14
10. TROUBLESHOOTING 15
10.1 No Reading on Platen Set 1 and/or
Platen Set 2 Temperature Indicators 15
10.1.1 Power Supply or Cable is Faulty. 15
10.1.2. Control Circuit Fuse has Opened 15
10.2 “Err” Displayed on Platen Set 1 and/or
Platen Set 2 Temperature Indicators 15
10.2.1. Platen not Connected 15
10.2.2. Loose Connection in Cable or
Platen Connector 15
10.2.3. RTD Temperature Sensor is Faulty 15
10.3. Platens Not Heating 15
10.3.1. Power Supply or Cable is Faulty 15
10.3.2. Platen Switch Off 15
10.3.3. Temperature Set Improperly 15
10.3.4. No Continuity Between
SG1 and Platen 15
10.3.5. Loose Connection in the
SG1 Control Panel 15
10.3.6. Faulty RTD Temperature Sensor
in Platen 15
10.3.7. Faulty Heating Element in Platen 15
10.3.8. Faulty Contactor in SG1 Control Panel 15
10.3.9. Loose Connection in Cable
or Platen Connector 15
10.3.10. Faulty Temperature Controller
in SG1 Control Panel 15
10.4. Vulcanizer Overheating 16
10.4.1. Temperature Set Improperly 16
10.4.2. Faulty Contactor in SG1 Control Panel 16
10.4.3. Faulty RTD Temperature Sensor
in Platen 16
10.4.4. Faulty Temperature Controller in
in SG1 Control Panel 16
10.5. Unit Fails to Create SG1 Network 16
10.5.1. Improper Network Configuration 16
10.5.2. Faulty Network Connectors 16
10.5.3. Faulty Communication on
SG1 Motherboard 16
11. SG1 PARTS LIST 17
12. SERVICE 18
12.1. Emergency Service 18
12.2. Return of Goods Authorization 18
12.3. Guarantee 18
13. SCHEMATIC DIAGRAMS 18
Revised - April 2014 49900-038
22
Shaw Almex Industries | 1.800.461.4351 | www.almex.com
SHAW ALMEX INDUSTRIES LIMITED
323 Glover Road, Stoney Creek, ON Canada L8E 5M2
Phone: 905-643-7750
toll free 800-418-2400 (Canada and US only)
Fax: 905-643-7788
Email: sail@almex.com
Web: www.almex.com
1. Safety
Your ALMEX SG1 Switchgear Box 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. Our manufacturing procedures pro
vide a consistent, high-quality product.
The material presented in this operating manual has been com
piled to provide personnel with a complete understanding of
correct SG1 operating procedures.
PLEASE READ CAREFULLY
The following safety precautions should be read carefully and
understood thoroughly before you set-up or operate your SG1.
Failure to follow these precautions may result in personal injury
and/or equipment damage. All personnel should be trained in
the proper operation of the SG1.
Risks associated with operating the SG1 are identified through
out this manual with safety symbols.
1.1 SAFETY SYMBOLS
These international safety symbols are used to identify and
call attention to specific safety matters. The risks associated with operating the switchgear control are identified
throughout this manual with these symbols.
CAUTION
ELECTRICAL
HAZARD
BURNING
HAZARD
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1.2 DEFINITION OF PICTOGRAMS
1.2.1. CAUTION
Indicate[s] a hazardous situation which, if not avoided,
could result in minor or moderate injury. CAUTION
[signs] without a safety alert symbol may be used to alert
against unsafe practices that can result in property dam
age only.
1.2.2. ELECTRICAL HAZARD
1. A qualified electrician should perform all maintenance
of the electrical components of the switchgear control
box. Service or maintenance performed by unqualified
personnel could result in risk of injury and will void war
ranty.
2. 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 com
ponent damage and create a fire hazard.
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 cables or connectors are damaged, they must
be replaced or a fire and shock hazard may result.
1.2.3. BURNING HAZARD
There is not a burning hazard with the switchgear control
itself; however, improper use or component failure could
result in the vulcanizer overheating.
1.3 WORK AREA SAFETY
1.3.1 KEEP WORK AREA CLEAN
Cluttered areas and benches invite injuries.
1.3.2 KEEP VISITORS AWAY
Do not let visitors contact power cables or platen cables.
All visitors should be kept away from work area.
1.4 PERSONAL SAFETY
1.4.1 STAY ALERT
Watch what you are doing and use caution when operating
the SG1. A moment of inattention while operating power
equipment may result in serious personal injury or death.
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49900-038Revised - April 2014
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1. Safety CONTINUED
2. Product Overview
1.4.2 NEVER ALTER OR REMOVE SAFETY DEVICES
1.4.3 USE SAFETY EQUIPMENT
Always wear eye protection. Dust mask, hard hat or hearing
protection must be used for appropriate conditions. Nonskid, steel-toe safety shoes are required for safe operation,
due to the SG1’s weight.
1.5 SERVICE AND MAINTENANCE SAFETY
1.5.1 USE AUTHORIZED SERVICE ONLY
Service must be performed only by qualified personnel.
Service or maintenance performed by unqualified
personnel could result in risk of injury and will void warranty.
Contact your Almex representative to determine if service
is required by an Almex technician.
1.5.2 USE ONLY AUTHORIZED REPLACEMENT PARTS
When servicing SG1, use only identical replacement
parts. The use of unauthorized parts or failure to follow
“Maintenance Instructions” may result in electric shock or
injury.
1.5.3 NEVER USE A DEFECTIVE OR ABNORMALLY
OPERATING SG1
If the SG1 appears to be operating unusually, making a
strange noise or appears defective in any way, stop using
it immediately and make arrangements to have it repaired
by an Almex Technician.
1.6 LIMITATION OF USE
This equipment has been designed to control the temperature
of an ALMEX conveyor belt vulcanizer. The SG1 Switchgear
Control Box operates within a range of -30ºC to 45ºC (-22ºF to
113ºF). An ALMEX Switchgear Control Box must be used with
a ALMEX vulcanizer. The vulcanizer should never be allowed
to operate while unattended. Only use the SG1 for what it
is designed for, other use is not allowed without the written
permission of Shaw Almex.
The Almex SG1 Switchgear Control Box is the most advanced
vulcanizing control system in the world. It incorporates control of four
platens and has input for eight thermocouple leads so that redundancy
in temperature monitoring and recording is accomplished. It also
utilizes wireless sensors to record pressure bag readings.
The SG1 follows a user specified splice recipe that maintains a
dwell and cure temperature at a specified dwell time and cure
time. Using an advanced control method called PID, the SG1
reduces the effect of temperature overshoot by turning the platens
on and off in pulses. The splice can be started and stopped using
an ALMEXPAD or using the LCD display on the front panel of
the SG1.
Once begun, a splice continues automatically and does not
require intervention until the cure is finished and cooling
commences. The stages of the splicing process are displayed. (See
FIGURE 1) When no splice is specified and no heating or cooling is
taking place the splice-info screen will read “status: ready”.
When splice parameters are input and a splice starts, the device
starts in the “To Dwell” phase. When all connected platens reach the
dwell temperature, the platen begins the “At Dwell” phase. In this
phase of operation the SG1 maintains the set temperature for a set
time. Remaining dwell time can be viewed on the LCD display in the
“Splice Info” menu or on the ALMEXPAD Splice Monitor screen.
When the “At Dwell” phase is completed, the SG1 enters the
“To Cure” phase and heats up until all platens rise to meet the specified cure temperature called the “At Cure” phase. In this phase the
SG1 maintains the set temperature for a set time. (See FIGURE 1)
Once the Cure time elapses, the SG1 enters a “Cooling” state. At
this point, operators may pump coolant into the platens to speed
up the cooling phase with an ALMEX pressure pump. (See FIGURE
2) After all platens cool below the Cooling temperature, the splice
is complete.
NOTE: At any time during the operational phase the splice can
be emergency stopped by going to the “Splice Info” menu and
selecting the “Stop Splice” option.
FIGURE 1 - SPLICE GRAPH
Revised - April 2014 49900-038
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FIGURE 2 - PRESSURE PUMP
3. Hardware Overview
FIGURE 3 -
SG1 FUNCTIONAL
DIAGRAM
Revised - April 2014
FIGURE 4 - SG1 FUNCTIONAL DIAGRAM
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49900-038
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3. Hardware Overview
SG1 FRONT PANEL
3.1. WIFI ANTENNA
Allows the SG1 Switchgear Box to connect wirelessly to
ALMEXPAD Senior and exchange data.
3.2. PLATEN SET 1 AND PLATEN SET 2 SWITCHES
The main heating controls are
located on the left side of the SG1
front panel.
Each control, can be
set in the AUTO, OFF, or
MANUAL position. In AUTO mode,
the SG1 controls the splice
according to the splice parameters
set using the ALMEXPAD or SG1
menus. Holding a platen switch
in the MANUAL position forces
the platens on without the
use of
the temperature controller.
(SEE FIGURE 5)
3.3. AUXILIARY SWITCH
Controls power to the auxiliary receptacles for an Almex Pressure Pump. Power is ON when set in the MANUAL position.
Note: The AUTO mode is non-operational at this time and
should not be used.
(SEE FIGURE 5)
3.4. USB CABLE RECEPTACLE
Allows the user to connect to the ALMEXPAD tablet. The connection
has a threaded cap to create a water-tight seal
3.5. RESET BUTTON
Restarts the SG1. (SEE FIGURE 6)
NOTE: The reset button does not need to be pressed to
prepare for the next heat cycle. This is handled automati
cally once a splice is completed.
3.6. WARNING ALARM
Indicates that the SG1 or attached press is operating outside of
recommended and/or desired operating conditions. The SG1
gives an audible signal if the splice is outside of a user specified
temperature range, current range, pressure range or if a platen
cable is disconnected. (SEE FIGURE 6) (For more information
SEE ALARMS, SECTION 4.3)
FIGURE 5 PLATEN SET
2 (TOP) AND
AUXILIARY
SWITCHES
(LEFT)
.
(SEE FIGURE 6)
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FIGURE 6 - FROM LEFT TO RIGHT - USB CABLE RECEPTACLE, TABLET POWER
RECEPTACLE, RESET BUTTON, WARNING ALARM
3.8. THERMOCOUPLE RECEPTACLES
Located on the right side of the SG1 front panel. These
receptacles serve as further inputs for tracking and recording
platen temperature. NOTE: Use K-Type thermocouples only.
(SEE FIGURE 7)
FIGURE 7 - THERMOCOUPLE RECEPTACLES
3.9. TEMPERATURE SET POINT INDICATOR
Displays the goal termperature of the splice recipe’s current
phase. (SEE FIGURE 8)
3.10. PLATEN SET 1 AND 2 TEMPERATURE INDICATORS
Displays the current temperature of the connected platens.
(SEE FIGURE 8)
3.11. PLATEN ON LED
Illuminates if the platen is on. (SEE FIGURE 8)
3.12. SET POINT REACHED LED
Illuminates if the platen has reached the set point for the
current phase. (SEE FIGURE 8)
3.7. TABLET POWER RECEPTACLE
Provides DC power to charge and run ALMEXPAD Senior or
Junior Tablets.
Revised - April 2014 49900-038
6
(SEE FIGURE 6)
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FIGURE 8 - BOTTOM LEFT - TEMPERATURE SET POINT INDICATOR
CENTRE TOP & BOTTOM - PLATEN SET 1 TEMPERATURE INDICATORS
RIGHT TOP & BOTTOM - PLATEN SET 2 TEMPERATURE INDICATORS
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