Beruflich Dokumente
Kultur Dokumente
02103/951-0
Förderband-Ausrüstung Fax. 02103/951-199
Reisholzstraße 15 e-Mail info@nilos.de
D - 40721 Hilden Internet www.nilos.com
08.03.2018/Hi A17-126508_aen.docx
NILOS GmbH & Co. KG Tel. 02103/951-0
Förderband-Ausrüstung Fax. 02103/951-199
Reisholzstraße 15 e-Mail info@nilos.de
D - 40721 Hilden Internet www.nilos.com
Certification
The NILOS GmbH & Co. KG enterprise has been certified to ISO 9001: 2008.
Warranty
The warranty period and the scope of warranty have been set in the contractual terms
and the general terms and conditions of delivery.
• If the operator independently makes repairs to the unit or has them made by third
parties.
Copyright
These operating instructions (as a paper or an electronic document) are subject to the
copyright of the NILOS GmbH & Co. KG enterprise. The contents of the texts,
drawings etc. may only be copied with our approval.
08.03.2018/Hi A17-126508_aen.docx
Scope of Supply
1 Assembly Scheme / Installation Plan
2 Safety
Vulcanizing Press
3 Operating Instructions
8 Vulcanizing Plates
9 Digital Thermometer
7
6
5
4
10
8
9
3
2
1
1
Cross Beams complete = NJL151X00A
2
Cross Beams complete = NJL120X01B
3
Vulcanizing Plates complete = NJL213000C01
4
Vulcanizing Plates complete = NJL457000C01
05.02.2018/Hi LU_A17-126508_aen.docx
SCOPE OF SUPPLY
additional parts
5
for assembly variant belt width 1200-1400 mm
6
for assembly variant EMU-Air
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SCOPE OF SUPPLY
7
for assembly variant EMU-Liquid
05.02.2018/Hi LU_A17-126508_aen.docx
ASSEMBLY SCHEME
principle sketch
02.03.2015/Hi AS_EMU-Air_een.docx
ASSEMBLY SCHEME
principle sketch
20.02.2014/Hi AS_EMU-Liquid_DWA-stationaer_cen.docx
INSTALLATION PLAN
EMU-Liquid-Air
Belt Width: 1200-1400 mm / 800-1000 mm page 1/4
H4 H1
H H3 H5
H5
H2 H1
GB
Wk
Th
PL Dk
=
L1
St L4
1
Wk Wk
2 St
B2
L5 Dk
Th
Wk
L2
L5
B3
principle sketches B1 B1
L3
St Plug
Wk Water cooling
Dk Pressure bag connection
Th Thermometer
05.02.2018/Hi ABP_NJL213R00C+R01C_aen.docx
INSTALLATION PLAN
EMU-Liquid-Air
Belt Width: 1200-1400 mm / 800-1000 mm page 2/4
Vulcanizing Press
GB 1200-1400 mm Belt width
PL 1200 mm Press length
H 700 mm Press height (approx.)
16.7° Vulcanization angle
7 Quantity of cross beams
L3 x L4 1850 x 1670 mm Space requirements for press installation (approx.)
Attention! EMU-Liquid
• max. set pressure at the pressurized water unit (NJD036000A) 9 bar
• specific surface pressure at the belt 90 N/cm²
• 7 pairs of cross beams (NJL120X01B) with a pressing force of each 216 kN
Attention! EMU-Air
• max. set pressure at the pressure bag (NJZ155000A/NJZ852000B) 7 bar
• specific surface pressure at the belt 70 N/cm²
• 7 pairs of cross beams (NJL120X01B) with a pressing force of each 168 kN
05.02.2018/Hi ABP_NJL213R00C+R01C_aen.docx
INSTALLATION PLAN
EMU-Liquid-Air
Belt Width: 1200-1400 mm / 800-1000 mm page 3/4
principle sketches
H4
H H3 H1
H1
H2
GB
Wk
Th
PL
= Dk
L1
L4
St
Wk
B2
L5
L2
B3
B1
L3
St Plug
Wk Water cooling
Dk Pressure bag connection
Th Thermometer
05.02.2018/Hi ABP_NJL213R00C+R01C_aen.docx
INSTALLATION PLAN
EMU-Liquid-Air
Belt Width: 1200-1400 mm / 800-1000 mm page 4/4
Vulcanizing Press
GB 800-1000 mm Belt width
PL 1200 mm Press length
H 490 mm Press height (approx.)
16,7° Vulcanization angle
8 Quantity of cross beams
L3 x L4 1420 x 1550 mm Space requirements for press installation (approx.)
Attention! EMU-Liquid
• max. set pressure at the pressurized water unit (NJD036000A) 9 bar
• specific surface pressure at the belt 90 N/cm²
• 8 pairs of cross beams (NJL151X00A) with a pressing force of each 135 kN
Attention! EMU-Air
• max. set pressure at the pressure bag (NJZ155000A) 7 bar
• specific surface pressure at the belt 70 N/cm²
• 8 pairs of cross beams (NJL151X00A) with a pressing force of each 105 kN
05.02.2018/Hi ABP_NJL213R00C+R01C_aen.docx
PHOTO OF SCOPE OF SUPPLY
EMU-Liquid/Air: NJL213000C01
NJL457000C01 page 1/2
09.03.2018/Hi AF_A17-126508_aen.docx
PHOTO OF SCOPE OF SUPPLY
EMU-Liquid/Air: NJL213000C01
NJL457000C01 page 2/2
09.03.2018/Hi AF_A17-126508_aen.docx
SAFETY
Table of Contents:
1. About these operating instructions ..................................................................1
2. Basic safety instructions .................................................................................2
1.0 Terminology
Vulcanizing Press:
1.1 Purpose
These operating instructions are part of the system and describe the safe, proper use
in all operating phases.
• Keep the operating instructions during the entire service life of the system.
1.2 Scope
These operating instructions apply only to the system specified on the cover sheet.
Target groups of these operating instructions are the owner and technical personnel
entrusted with work on the system.
19.07.2016/Hi Si_EMU_aen.docx
SAFETY
Symbol Meaning
Danger to persons
DANGER
Failure to observe will result in death or serious injuries
Danger to persons
WARNING
Failure to observe can result in death or serious injuries
Danger to persons
CAUTION
Failure to comply may result in minor injury
1.5 Illustrations
The illustrations in these operating instructions are used to explain the function,
installation and commissioning of the system and can vary from the characteristics of
the delivered system.
The system has been built in accordance with state-of-the-art technology and the
recognized safety rules. Nevertheless, their use can present a danger to the life and
limb of the user or others or impairments of the system and other tangible assets.
• Only use the system in perfect technical condition and properly in a safety and
danger-conscious manner while observing the operating instructions.
• In particular, faults that may affect the safety of the device must be repaired
immediately.
19.07.2016/Hi Si_EMU_aen.docx
SAFETY
EMU-Liquid: splicing of steel cord conveyor belts with a specific surface pressure of
up to 140 N/cm2 and should only be connected to a pressurized water
unit.
Only the components listed in the scope of supply may be used for installation and
operation of the system (see register "Scope of Supply/Installation Plan").
The system can be used in workshops or outdoors. When used outdoors, the system
must be protected from moisture and dirt, e.g. with a tent.
Correct use includes the observance of these operating instructions and the
observance of the operating and limit values.
Misuse
The system may not be used in areas in which special requirements are placed on
explosion protection.
The main system parts can be identified using the attached type plates.
19.07.2016/Hi Si_EMU_aen.docx
SAFETY
Work on the system may only be carried out by reliable, qualified expert personnel.
Expert personnel are persons who, based on their education, experience, training and
knowledge of vigilant regulations and standards, accident prevention specifications
and operating conditions, are capable of executing the required tasks.
• Clearly define the responsibilities for the various activities as part of system
operation.
Organizational measures
• Ensure that all staff have read and understood these operating instructions.
• Regularly check that personnel are operating the device in a safe and risk-
conscious manner in accordance with the operating instructions.
• Designate a person who is responsible for the safety of the system and of work.
19.07.2016/Hi Si_EMU_aen.docx
SAFETY
The required personal safety equipment depends on the work environment and is to be
determined by the responsible work managers.
In order to avoid injury, at least the following safety equipment must be worn during all
tasks:
• protective gloves
• protective goggles
• protective shoes
• protective clothing
Transport
• Make sure that the load is securely fastened and is lifted horizontally.
19.07.2016/Hi Si_EMU_aen.docx
SAFETY
• Make sure that the transport route offers sufficient space and is clear of
obstacles.
The person responsible for the work must use a load analysis to evaluate the physical
work and must use the workforce accordingly.
• Use additional employees when working with a constrained posture (e.g. loading
or unloading).
• Only combine system parts in agreement with the scope of supply (see register
"Scope of Supply/Installation Plan").
• Assemble the vulcanizing press in accordance with the installation plan (see
register "Scope of Supply/Installation Plan"). Do not leave out parts, e.g. cross
beams, to prevent damage to the vulcanizing press.
• Comply with the type of pressurization and the maximum permissible pressure.
• Route the cables and hoses so that they do not form tripping hazards.
Normal operation
Maintenance
Malfunctions
19.07.2016/Hi Si_EMU_aen.docx
SAFETY
High voltages are present on parts in the switch box during operation. Touching these
parts can lead to serious or fatal injuries.
• Keep the switch box door closed during operation of the system.
• Only have work on electrical equipment carried out by authorized, qualified expert
personnel.
• Always disconnect the devices from the electrical system before working on
electrical equipment.
• Lock the switch box door and keep the key in a separate location after completing
the work.
Hoses for pneumatic pressurization are under high pressure. Compressed air or a
water/glycol mixture escaping abruptly can result in injuries.
• Check all hose connector systems regularly for damage and leaks. Rectify any
damage immediately.
During operation, the system reaches temperatures of over 150 °C / 300 °F. The
vulcanizing plate and adjacent components can therefore cause serious burns.
• Wear suitable protective gloves and protective clothing during all work.
• Allow the vulcanizing press to cool down below 40 °C / 100 °F prior to dismantling
and prior to cleaning and maintenance work.
19.07.2016/Hi Si_EMU_aen.docx
SAFETY
Water vapor develops during the cooling process. Hot water and escaping water vapor
can cause burns and scalding.
• All hose connections must be regularly inspected for damage and leakage. All
damage must be repaired immediately.
• Inform supervisor.
19.07.2016/Hi Si_EMU_aen.docx
OPERATING INSTRUCTIONS
Table of Contents:
1. General Remarks ............................................................................................1
2. Installation of the press ...................................................................................3
3. Vulcanization...................................................................................................7
4. Dismounting of the Press .............................................................................. 10
5. Maintenance ................................................................................................. 11
6. Storage ......................................................................................................... 11
7. Disposal ........................................................................................................ 12
1. General Remarks
Vulcanizing presses type EMU have been designed to connect and repair conveyor belts.
• Spacing rail elements to hold and guide the lower cross beam profiles
(accessories).
• Cross beam profiles and pressure bags to generate the pressure required to
operate the press.
• Switch boxes with connecting cables for power supply and temperature control.
• Equalization plate (made of wood) between pressure bag and upper cross beam
for pressure distribution.
• Tie bolt and nuts to connect upper and lower cross beams.
Optional:
30.11.2017/Hi BA_Presse-EMU_aen_C.docx
OPERATING INSTRUCTIONS
All EMU vulcanizing plates have been compactly constructed and contain the following
components:
• Pressed sheets made from high-quality aluminum alloys for cooling purposes.
• Silicone heating mats with a high calorific output and good temperature
distribution at a low energy consumption.
• Heat insulation plates to neutralize the thermal impact of cross beam profiles and
pressure bags.
NOTE
When using EMU vulcanizing presses with heating plates in combination all the heating
plate edges marked in red have a lower heating capacity. After assembling of the
heating plates, none of the edges marked in red should be visible any longer.
The cooling system consists of special cooling profiles which conduct the cooling water
through specially shaped cooling channels, thus reducing the surface temperature
effectively in a short time at low water consumption rates.
All pressed cooling sheets feature a standard equipment of input / output connections
with a quick shutter hose coupling.
The required pressure is generated by a system of pressure bags and cross beams.
The cross beams consist of special profiles featuring indentations to accommodate the
tie bolts. Upper and lower cross beams are identical and have additional bore holes for
intake the safety pins of the top traction bolt nuts.
A set of hoses connects the pressure bags which are installed in the upper half of the
press to a pressurized water system or a pump unit (accessories). The pressure bags
generate an almost even amount of pressure on all parts of the belt’s surface and
balance elastic distortions of the cross beams.
An equalization plate serves to distribute the pressure evenly to the upper cross
beams.
30.11.2017/Hi BA_Presse-EMU_aen_C.docx
OPERATING INSTRUCTIONS
CAUTION
Optionally, pressurized air with a maximum pressure of 7 bar (100 psi) can be applied
to the pressure bags. For this purpose, the pressurized air control box needs to be
interposed between pressurized air supply and pressure bag in order to limit the
pressure.
CAUTION
It is not permitted to apply pressurized air with a pressure in excess of 7 bar (100 psi).
Different types of pressure bags - depending whether they have been customized for
pressurized water or pressurized air applications – are equipped with different plug
connection systems and are therefore not interchangeable.
• Make sure that the substructure provided is designed so that the vulcanizing
press can be positioned to prevent it from falling over, i.e. as level as possible ad
with a load-bearing capacity for the total weight.
• If the substructure is slightly inclined, install the vulcanizing press so that the
connections for the cooling-water supply line on the heating plates are located on
the higher side.
• Make sure that there is sufficient space for the installation and for connecting the
system parts.
• If the vulcanizing press is used outdoors, it must be protected from moisture and
dirt, e.g. with a tent.
CAUTION
• Damage to the vulcanizing press in case of deviant installation (e.g. leaving out of
cross beams)!
• Observe scope of supply and installation plan (see chapter "Scope of Supply /
Installation Plan").
30.11.2017/Hi BA_Presse-EMU_aen_C.docx
OPERATING INSTRUCTIONS
CAUTION
NOTE
Only use pressure bags with the corresponding hose connectors.
WARNING
In the event of the transport by crane or any other lifting / hoisting device, these
articles must not be subjected to any load-bearing stress, e.g. by attaching them
directly to the hooks and ropes of the lifting devices.
• Prepare the belt in compliance with the instructions issued by the belt
manufacturer.
30.11.2017/Hi BA_Presse-EMU_aen_C.docx
OPERATING INSTRUCTIONS
The entire surface of the vulcanizing plates must be lined. For this purpose, edge
rails or old belts may be used.
CAUTION
If this is not properly done, the vulcanizing plates will bend or deform and become
unfit for further use.
• Lay down the upper heating plate(s) (pos. 4) with the pressed cooling sheet
facing the belt, in congruence with the position of the lower vulcanizing plate.
• Use the connecting cable to connect the vulcanizing plates with the switch box:
Versions 1 / 2
The plug connections of the vulcanizing plates are fitted with a forced locking
system (A).
version 1 version 2
30.11.2017/Hi BA_Presse-EMU_aen_C.docx
OPERATING INSTRUCTIONS
Version 3
• Lay down the pressure bags (pos. 5) on top of the upper vulcanizing plate and
use the set of hoses to connect it to a pressure supply system. Follow the
Operating Instructions of either pressurized water system or air control box, in
line with the pressure supply system used.
CAUTION
CAUTION
• Lay down the equalization plate (pos. 6) on top of the pressure bag in exact
congruence with its position. Make sure that all surfaces are clean.
• Enable the cooling water supply. Make sure that both input and output
connections have been linked up with the correct sets of hoses.
30.11.2017/Hi BA_Presse-EMU_aen_C.docx
OPERATING INSTRUCTIONS
WARNING
• Put on the upper cross beam profiles (pos. 7) and align them with their lower
counterparts.
• Insert all traction bolts (pos.8) as far as possible into the indentations at the ends
of the cross beams, so that the corresponding bore holes of the top traverse
profiles take up the safety pins of the top pressure and pull them evenly tight.
Additional circlip rings at both ends of the traction bolts prevent the bolts from
being screwed out of the pressure nuts. Make sure that all cross beam pairs have
the same distance between upper and lower cross beam profile once the tie bolts
have been tightened.
NOTE
• If a tension bolt unit is inserted the wrong way around, the locking pin is
pressed out.
• Press in the locking pin and insert the tension bolt unit correctly.
3. Vulcanization
Preparation
• The mains voltage must comply with the voltage specified on the name plate of
the switch box.
• Connect the switch boxes with the power supply.
Start
• Turn on the vulcanizing press by using the switch in the switch box (see
"Operating Instructions for Switch Box"). The heating stage has now begun.
30.11.2017/Hi BA_Presse-EMU_aen_C.docx
OPERATING INSTRUCTIONS
WARNING
• Danger of electrocution!
• Keep switch box door closed during press operation.
• Always disconnect the switch box from the electrical system before working
on electrical equipment.
• When the electronic temperature controls have been activated, the vulcanizing
plates will heat up until the TARGET temperature entered into the electronic
system (175° C [350° F] max.) has been reached (see "Operating Instructions
electronic temperature control system"). If technical problems occur in the
electronic temperature control system, the vulcanizing plates can be operated
manually by turning the switch in the switch box to the respective position. In this
case a permanent temperature reading by means of thermometers as an option
and manual control at an additional measuring point are absolutely necessary.
CAUTION
If the maximum temperature of about 175° C (350° F) is exceeded, the silicone
heating mats inside the vulcanizing plates will be irreparably damaged.
CAUTION
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OPERATING INSTRUCTIONS
NOTE EMU-AIR
• The pressure in the pressure system can increase when the temperature
increases.
During the heating-up phase the temperature might pass over the set-point for a
short moment, but comes down to the set temperature during the controlled
period. In case an additional measuring instrument is used parallel to the regular
measuring instrument, differences of temperature indication are unavoidable which
become smaller resp. are adapting to the set temperature.
• During the heat-up phase and vulcanizing process, check the pressure on
the compressed air control pressure gauge and charge the pressure bag with
more compressed air if necessary.
• Do not exceed the maximum pressure in the pressure bag and the resulting
surface pressure.
NOTE EMU-LIQUID
• The pressure in the pressure system can increase when the temperature
increases.
During the heating-up phase the temperature might pass over the set-point for a
short moment, but comes down to the set temperature during the controlled
period. In case an additional measuring instrument is used parallel to the regular
measuring instrument, differences of temperature indication are unavoidable which
become smaller resp. are adapting to the set temperature.
If the maximum setting pressure is exceeded by approx. 1 bar, a safety valve
opens and the pressure drops.
By switching on the pressurized water unit again, the pressure begins to build up
again up to the maximum setting pressure.
• Do not exceed the maximum pressure in the pressure bag and the resulting
surface pressure.
• Follow the instructions issued by the belt manufacturers regarding heating times.
End
• After the vulcanization has been successfully completed, the heating power must
be switched off at the selection switch at the switch box (switch position 0), and
the cooling water supply needs to be activated. If you want to monitor the cooling
process on the electronic temperature control system, you cannot turn the press
off at the main switch inside the switch box.
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OPERATING INSTRUCTIONS
WARNING
Danger of scalding by escaping water vapor or hot water!
• Safely drain off the cooling water.
• Once the temperature has gone down sufficiently to allow the press to be safely
opened, slowly deflate the pressure in the system before you switch off the press
at the main switch of the switch box.
NOTE
Pressure Bags with air pressurization:
• Pull off the compressed air hoses only in the depressurized state.
• Before depressurizing the press, switch off the compressor and/or shut off the
supply of compressed air.
• Disconnect compressed-air hose between air control box and pressure bag to vent
pressure bag
• Make sure that pressure bag is completely vented, as otherwise it may not be
possible to open vulcanizing press.
If the press is used to vulcanize PVC belts, special cooling ledges and pressed sheets
must be used as temperature discharge zones in compliance with the installation plan.
These articles are available on request as optional accessories.
CAUTION
Danger of burns on the heating plates and on the adjacent components!
• Allow vulcanizing press to cool down below 40° C/100° F.
CAUTION
Flying sparks can lead to connector parts being burned!
• Make sure that the main switch on the switch box is switched off.
• Only disconnect the connection cables of the heating plates when deenergized.
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OPERATING INSTRUCTIONS
• Remove tension bolt units and take off cross beams, equalization plate, pressure
bag and upper heating plate.
CAUTION
Freezing water or increased vapor pressure with closed cooling ducts can
destroy the heating plates!
• Completely remove residual water and soiling from the cooling channels, e.g. with
compressed air.
• When not in use provide the connection cable (heating plate / switch box) with its
protective caps.
5. Maintenance
6. Storage
When storing over a longer period, take the following measures to prevent harmful influences:
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OPERATING INSTRUCTIONS
Make sure that the storage location meets the following conditions:
• Vibration-free
• Frost-free
• Completely remove residual water and soiling from the cooling ducts of the
heating plates, e.g. with compressed air.
7. Disposal
Recycle or dispose of system parts, electrical and electronic components of one kind in
accordance with the local regulations.
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OPERATING INSTRUCTIONS
Table of Contents:
1. Function ..........................................................................................................1
2. Connections, operating and display elements.................................................1
3. Implementation ...............................................................................................2
4. Pneumatic plan ...............................................................................................3
1. Function
The device is connected to the pressurized air supply of the customer (10 bar / 140 psi
max.) and reduces the operational pressure – which can be monitored on a gauge – to
a maximum of 7 bar / 100 psi for the pressure bag.
A built-in safety valve monitors the pressure in the pressure bag and shuts the
operation down at about 7.5 bar / 107 psi.
EIN / ON
Lufteinlass Luftauslass
AIR INLET
4 3
Item. Component Description
1 Rocker valve • Position ON: Pressurize pressure bag with
compressed air
• Position OFF: Interrupt compressed-air supply
2 Pressure gauge Indicates the pressure in the pressure bag
3 Air outlet Connection to pressure bag
4 Air inlet Connection to compressed-air supply
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OPERATING INSTRUCTIONS
3. Implementation
• Connect the air control box to the pressurized air supply of the customer
(10 bar / 140 psi max.) (connection 1 / air intake).
• A stop valve should be interposed between the pressurized air supply and the air
control box.
NOTE
Only cleaned and dried pressurized air must be used. Ideally, a filter with a
separator for oil and water will be installed.
• Connect the pressure bag with the air control box (connection 2 / air outlet). Open
the stop valve (if applicable) in the pressurized air supply system of the customer.
• Move the tilting lever valve (HV) into position "ON" and supply the pressure bag
with pressurized air. The pressure control (DR) limits the maximum operational
pressure for the pressure bag to 6.8 bar / 97 psi. The pressure can be monitored
at the gauge (M1).
• A rise in the temperature can cause an increase of the pressure in the pressure
bag. A built-in safety valve (SV) in the air control box limits the maximum
pressure in the pressure bag to 7.5 bar / 107 psi and must not be adjusted.
• To deflate the pressure, move the tilting lever valve into the position OFF.
Remove the air from the pressure bag by disconnecting the hose connections
between the pressurized air control system and the bag.
CAUTION
Before opening a vulcanizing press, always make sure that the pressure bags
have been deflated.
Before depressurizing the press, switch off the compressor and/or shut off the
supply of compressed air. Pull off the compressed air hoses only in the
depressurized state.
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OPERATING INSTRUCTIONS
4. Pneumatic plan
Luftauslass
Air Outlet 2
M1
HV
SD
7.5 bar / 107 psi
max. 6,8 bar / 97 psi
SV
Lufteinlass
Air Inlet 1 DR
kundenseitig
max. 10 bar / 140 psi provided by customer
Druckluftversorgung
compressed air supply
Abbreviation Meaning
HV Lever valve
M1 Pressure gauge
SD Muffler
SV Safety valve
DR Compressed-air regulator
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SPARE PARTS LIST
7,13
EIN / ON
Lufteinlass Luftauslass
AIR INLET
9 10 5,6,14 12 7,8 15 15 16
A
3,4
13 2
11 11
principle sketches
NJZ085000G
NJZ085000C
NJZ085000D
NJZ085000E
NJZ085000F
27.02.2015/Hi EL_NJZ085_aen.docx
SPARE PARTS LIST
NJZ085000G
NJZ085000C
NJZ085000D
NJZ085000E
NJZ085000F
27.02.2015/Hi EL_NJZ085_aen.docx
OPERATING INSTRUCTIONS
Table of Contents:
1. Technical Description ......................................................................................1
2. Safety..............................................................................................................2
3. Assembling and Commissioning .....................................................................2
4. Maintenance ...................................................................................................4
5. Faults and Remedies ......................................................................................5
6. Ventilation of the System ................................................................................6
1. Technical Description
1 Supply pump
4S 4P 7 2 Coupling
3 Electrical motor
6 4 4 Control block
16
S
P 4S Suction connection (to the
fluid reservoir)
1 4P Pressure connection (to
5
the pressure bag)
2 5 Pressure control valve
8 working pressure
The pressurized water system is used for providing the necessary operating pressure
in case of vulcanizing presses with pressure bags. A supply pump (1) with electrical
motor (3), an attached control block (4) with suction and pressure connection (4S+4P),
two pressure-control valves (5+6), drain valve (7) and pressure gauge (8), form a
compact unit.
The supply pump (1), including electrical motor (3) and attached structures, as well as
the electrical control (16), are assembled on a wood mounting board (15) and are
protected by a surrounding tubular frame.
13.01.2015/Hi BA_DWA-stationaer_cen_C.docx
OPERATING INSTRUCTIONS
Pressurized water system, hose connector system and fluid reservoir, in connection
with the pressure bags, form a closed pressurized system.
2. Safety
CAUTION
The non-observance of the notes on safety can lead to personal injury and material
damage, as well as to the voiding of possible guarantee claims.
• Do not pump any inflammable or explosive liquids. Do not employ the pumps in
explosive atmospheres.
• Ensure that all movable parts, such as shaft and couplings, are covered properly
and protected before the system is switched on.
• Disconnect the pressurized water system from the electrical network before
maintenance operations.
• Set up pressurized water system and fluid reservoir on a flat underground which
is stable.
• Mount the hose connector between the pressurized water system (control block;
suction connection "S") and fluid reservoirs.
Mount hose connectors on the pressurized water system for pressure bags
(control block; pressure connection "P").
Ensure that all hose connectors are secured after the venting.
• Check liquid level on the fluid reservoir. The fluid reservoir must be completely
filled before the operational start-up.
• Check the glycol concentration. The glycol mixture is used for the valve lubrication.
13.01.2015/Hi BA_DWA-stationaer_cen_C.docx
OPERATING INSTRUCTIONS
NOTE
The glycol concentration must not fall below 40 %, since otherwise the pressurized
water system will be damaged.
• Close drain valve, since the pressure builds up only with closed drain valve.
• It is to be ensured that the mains voltage agrees with the voltage information on
the type designation plate of the pressurized water system.
Caution
• When the required pressure is reached, switch off the pressurized water system.
The pressure in the pressure bags is maintained.
• During the heating period, the pressure must be checked on the pressure gauge.
CAUTION
The maximum preset pressure is adjusted in the works for the respective
vulcanizing press on the pressure control valve, and must not be changed under
any circumstances, since otherwise the vulcanizing press will be damaged.
• After ending the vulcanization, the drain valve is to be opened so that the pressure in
the system can reduce. The water-glycol mixture runs back into the fluid reservoir.
13.01.2015/Hi BA_DWA-stationaer_cen_C.docx
OPERATING INSTRUCTIONS
If necessary, the pressure bag can also be pumped empty. For this purpose, the hose
connector, which is assembled between pressurized water system and pressure bag,
is to be changed over on the connection block (change pressure connection (P) for
suction connection (S)).
CAUTION
NOTE
In case of the filling, operational start-up and draining of the pressurized water system, it
is to be ensured that the water-glycol mixture is collected only in the containers provided
for that, and is disposed of in accordance with the respective national stipulations,
where appropriate.
CAUTION
Pressurized water units are not determined for cooling the vulcanizing plates!
4. Maintenance
13.01.2015/Hi BA_DWA-stationaer_cen_C.docx
OPERATING INSTRUCTIONS
13.01.2015/Hi BA_DWA-stationaer_cen_C.docx
OPERATING INSTRUCTIONS
• If insufficient pressure builds up and other alternatives for remedying have not
provided any result (see "5. Faults and Remedies").
• Release the tube (E), which serves as the connection from the pressurized water
unit (A) to the pressure bag (D) from the pressure bag and connect it to the plug-
in nipple of the fluid reservoir (B).
• Switch on pump so that the air contained in the system can escape
• When the liquid is free of bubbles, the pump can be switched off.
• Disconnect hose (E) from the fluid reservoir (B) and re-connect it to the pressure
bag (D).
NOTE
In connection with fluid reservoir designs (B) without a plug-in nipple (F), re-airing must
be carried out by means of an open nozzle (NW7.2 øfem=13 mm) which is snapped on
to the quick-disconnect coupling (G). After removing the cover from the reservoir, the
hose must be held into the reservoir opening.
13.01.2015/Hi BA_DWA-stationaer_cen_C.docx
TECHNICAL DATA
Table of Contents:
1. Technical Data ................................................................................................1
2. Hydraulic plan .................................................................................................2
3. Wiring Plan......................................................................................................4
1. Technical Data
Dimensions
Reference Quantity Value
Length 520 mm
Width 305 mm
Height 640 mm
Tab. 2: Dimensions
Weight
Value
26.0 kg
Tab. 3: Weight
Parameter
Reference Quantity Value
Electric motor 0.37 kW
Pressure fluid Mixture of 50 % water and 50 % glycol
Flow rate approx. 9 liter/min.
28.09.2016/Hi TD_DWA-NJD036-WJD036_aen_A.docx
TECHNICAL DATA
WJD036000F
NJD036000G
NJD036000D
NJD036000N
NJD036000B
Nominal voltage 230 V
WJD036000G
WJD036000D
WJD036000A
NJD036000A
NJD036000F
Nominal voltage 400 V
NJD036000H
NJD036000L
NJD036000J
NJD036000K
NJD036000I
2. Hydraulic plan
P S
1 working pressure + 10 %
2 working pressure
28.09.2016/Hi TD_DWA-NJD036-WJD036_aen_A.docx
TECHNICAL DATA
3. Wiring Plan
L1 L2 L3 N PE L1 L2 L3 PE
Q1 1 3 5 Q1 1 3 5
2 4 6 2 4 6
U1 V1 W1 U1 V1 W1
M1 M1
M M
3 3
3~+N+PE 3~+PE
L1 N PE
Q1 1 3 5
2 4 6
U1 U2
M1
M
1
1~+N+PE
28.09.2016/Hi TD_DWA-NJD036-WJD036_aen_A.docx
SPARE PARTS LIST
2 1.7
1.6 1.4
3
P
S
1.1
1.5
1.2
1.8
1.3
principle sketches
WJD036000G
WJD036000D
WJD036000A
NJD036000A
NJD036000F
1
corresponding to the customer's mains supply
13.09.2016/Hi EL_DWA-400V-NJD036-WJD036_aen_A.docx
SPARE PARTS LIST
WJD036000G
WJD036000D
WJD036000A
NJD036000A
NJD036000F
13.09.2016/Hi EL_DWA-400V-NJD036-WJD036_aen_A.docx
SPARE PARTS LIST
Container
Specification: for pressure liquid page 1/2
rev. B
6 5 4 3 2
ø [mm] h [mm]
30 l 330 470
8 1
h
50 l 370 660
ø principle sketch
NJD008000C 50 l
NJD008000D 50 l
NJD009000D 30 l
22.12.2015/Hi EL_Behaelter_aen_B.docx
SPARE PARTS LIST
Container
Specification: for pressure liquid page 2/2
rev. B
NJD008000C 50 l
NJD008000D 50 l
NJD009000D 30 l
22.12.2015/Hi EL_Behaelter_aen_B.docx
OPERATING INSTRUCTIONS
Pressure bag
Specification: for connection to a pressurized page 1/2
water unit rev. A
Table of Contents:
1. General ...........................................................................................................1
2. Safety..............................................................................................................1
3. Storage ...........................................................................................................1
4. Maintenance ...................................................................................................2
1. General
Pressure bags are built to generate pressure in conveyor belt vulcanizing presses. The
pressure bags generate an almost even amount of pressure on all parts of the belt's
surface and balance elastic distortions of the pressure traverses.
2. Safety
The only pressurized liquid for pressurized water units that may be used is a mixture of
50 % water and 50 % glycol. The amount of liquid depends on the size and number of
pressure bags to be used and is stored in corresponding fluid containers (accessories).
Before the pressure bags can be applied, all surfaces of both pressure bags and
insulating plates need to be thoroughly cleaned in order to keep the pressure bags
from being damaged. Do not carry or pull the pressure bags at the connection.
The pressure in the pressure bag slowly increases due to the rise in temperature. In
this case the pressure must be regulated at the pressurized water unit.
3. Storage
The pressure bag has to be protected from the impact of direct sunlight and strong
artificial light. We commend a storage room with ordinary lighting as well as
Pressure bag
Specification: for connection to a pressurized page 2/2
water unit rev. A
4. Maintenance
The pressure bags must be subjected to a visual inspection on a six-monthly basis for
cracks, burns, leaks, damage etc. in order to make it possible to ensure fault-free
functioning.
07.07.2014/Hi BA_Druckkissen-Liquid_aen_A.docx
SPARE PARTS LIST
Pressure bag
Specification: fitted to be connected to page 1/1
an air control box / a pressurized water unit rev. A
5
4
12
2
13
3 1 1
Connection to Connection to
A air control box B pressurized water unit
13.12.2017/Hi EL_Druckkissen_aen_A.docx
RETROFITTING INSTRUCTIONS
Pressure bag
Retrofit: Pressure fluid to compressed Page 1/2
air Rev. B
with pressure bag adapter NJZ511000A
1. General
The pressure bag adapter is used to retrofit the pressure bags with connections for
water/glycol to pressure bag connections for compressed air.
2. Installing
Plug the pressure bag adapter for compressed air as per the figure onto the pressure
bag connection. Then connect the compressed air hose to the adapter.
Hose end
Coupling open
22.12.2017/Hi AA_Druckkissen-Umbau_Liquid-Air_ben_B.docx
RETROFITTING INSTRUCTIONS
Pressure bag
Retrofit: Pressure fluid to compressed Page 2/2
air Rev. B
with pressure bag adapter NJZ511000A
3. Safety
4. Spare parts
22.12.2017/Hi AA_Druckkissen-Umbau_Liquid-Air_ben_B.docx
OPERATING INSTRUCTIONS
Table of Contents:
1. Description ......................................................................................................1
2. Function ..........................................................................................................2
3. Safety..............................................................................................................4
4. Maintenance ...................................................................................................4
5. Explanation of the pictograms ........................................................................4
1. Description
1 2
1 0 0 2
I II I II
1X3 2X3
5S2 5S4
3 4
0 0
1 2 1 2
I II 1 2 3 4 I II
3 4
3 4
3 4
5S6 4U7 5S8
1X6 2X6
3H6
I
0 1S1 ...V ...A
3H7
3X1
1X1
principle sketch
The switch box with surrounding protective frame is designed for connection to a
3-phase power supply and equipped with CEE-type sockets to connect vulcanizing
plates and an additional socket to connect electric equipment.
The switch box is also equipped with main switch, electronic controller, motor
protective switch and residual-current operated circuit breaker (RCCB) for heating and
pilot current together with illuminated selector switches for automatic or manual
temperature control as well as an acoustic signal that indicates the end of the
vulcanizing time.
14.11.2014/Hi BA_Schaltschrank-4E-24_aen_A.docx
OPERATING INSTRUCTIONS
2. Function
Please also refer to the operation instructions for the "MultiControl Unit" and chapter 5.
Explanation of the pictograms.
2.1 Commissioning
• Create a connection to mains supply. Please pay attention that the mains supply
voltage matches the voltage data on the name plate of the switch box.
• Make connection between the heating plates and the switch box with the
connector cables provided.
• Switch the illuminated sector switches 5S2, 5S4, 5S6 + 5S8 to position "0".
• Switch on the main switch 1S1. The white signal lamp 3H6 lights up and the
switch box is ready for operation.
2.2 Vulcanization
• For automatic temperature control set the illuminated selector switch 5S2, 5S4,
5S6 + 5S8 to the automatic position (lock position). The green illuminated
selector switches display the operation of the heating plates.
• The temperature of the individual heating plates and the remaining vulcanizing
time are displayed on the electronic controller display.
• When the vulcanizing time has been completed, set back the electronic controller
by pushing the RESET button ; the vulcanizing time is set back and the buzzer
3H7 is turned off. Then turn off the heating plates by setting the illuminated
selector switches 5S2, 5S4, 5S6 + 5S8 at position "0”.
During the cooling down phase, the temperature of the heating plates can be
read at the display of the electronic controller.
• Malfunction
14.11.2014/Hi BA_Schaltschrank-4E-24_aen_A.docx
OPERATING INSTRUCTIONS
• After completion of the vulcanization, turn off the main switch 1S1. Cut off the
mains supply and disconnect the vulcanizing plates.
3. Safety
• The switch box is not protected against explosions. Do not operate the switch box
in areas in which specific requirements with regard to explosion protection are
required.
• The switch box must be protected against frost, moisture, dust, vibration excess,
environmental temperatures and direct sunlight.
4. Maintenance
• The switch box must be cleaned regularly and kept in a dry place.
Electronic controller:
Set vulcanizing temperature dial
Electronic controller:
Set vulcanizing time dial
Electronic controller:
Timer Reset push button – record malfunction
14.11.2014/Hi BA_Schaltschrank-4E-24_aen_A.docx
OPERATING INSTRUCTIONS
Contents:
1. General information ..................................................................................................1
1.1 Monitoring temperature differences...........................................................................1
2. Operational and display elements .............................................................................2
2.1 LED explanations......................................................................................................3
2.2 Display readout .........................................................................................................3
3. Different operation levels ..........................................................................................3
3.1 Vulcanization temperature operator level ..................................................................4
3.2 Vulcanization time operator level ..............................................................................5
4. Terminal plan ............................................................................................................6
5. Safety .......................................................................................................................6
1. General information
The electronic temperature controller „MultiControl Compact” is a four channel, two-point
heating controller with PID feedback.
• When switched on with a 24V AC supply voltage, the company logo appears.
• After approx. 5 seconds, the control turns to the operational mode.
The input points for the 4 channels are designed for PT100 double conductor and triple
conductor circuits.
The control contact output (NO switch) is a potential-free relay contact; max. contract load is
250V AC, 8A.
25.06.2013/Hi BA_Regler-Multicontrol_aen.docx
OPERATING INSTRUCTIONS
17
2 3
1 4
6 7
8
12
9 13
10 14
11 15
16
1 Minus button for key selection - graphic 12 LED start signal for channel 1 to channel 4
display
2 Plus button for key selection - graphic 13 LED timer is running
display
3 Key for key selection – return key for 14 LED timer expired
graphic display
4 Key for key selection on the graphic display Optional:
Entry to different levels
15 Cool down LED after timer expiry
Return key, confirm key
Start / stop signal 16 LED cooling temperature achieved
5 Reset timer key
6 Vulcanization time key 17 Graphic display for:
Actual value display for channels 1 to 4
7 Vulcanization temperature key
Target value display for the vulcanization
8/10 Heat LED channel key X temperature
Time display for the vulcanization time
9/11 LED target value for channel X achieved Symbol display with key selection
Parameter description / parameter value
25.06.2013/Hi BA_Regler-Multicontrol_aen.docx
OPERATING INSTRUCTIONS
Optional:
LED (see illustration 1 on page 2) Display
13 Expiry of the vulcanization time
14 End of the vulcanization time
15 Controller with cooling function: display of the cooling
process
16 Controller with cooling function: end of the cooling
process
0 °C 200°C 0°C
Current actual
temperature in channels 0 °C 20Min 0°C
1-4
In operational mode
Operator level:
25.06.2013/Hi BA_Regler-Multicontrol_aen.docx
OPERATING INSTRUCTIONS
The target value setting for the vulcanization temperature takes place with the vulcanization
temperature key.
In operational mode
Press briefly
Vulcanization temperature
120.0 °C
- + [X]
Setting the parameter value
25.06.2013/Hi BA_Regler-Multicontrol_aen.docx
OPERATING INSTRUCTIONS
The target value setting for the vulcanization time takes place with the vulcanization time key.
In operational mode
Press briefly
Vulcanization time
2 Min
- + [X]
Setting the parameter value
25.06.2013/Hi BA_Regler-Multicontrol_aen.docx
OPERATING INSTRUCTIONS
4. Terminal plan
The terminal plan contains of the possible terminals in the unit. The exact version of the unit
can be checked by referring to the identification label.
B C D Inputs
Resistance thermometer
Inputs in accordance with
1 Operating voltage level
Relay outputs: K1 24 V AC Sensor 1
max. 250 V AC 2
max. 8 A E1 1 3
3 4
K2 E2 2
4 5
E3 3
5
K3 E4 4
6
E5 5 Sensor 2
E6 6 8
7
K4 E7
9
7
8 10
E8 8
9
K5 Common
9
10
11 Sensor 3
K6
12 13
14
15
13
SSR outputs for SSR 1 Choice of
controlling Channel 1 interfaces
contactor coils 14
24...240 V AC A 10
max. 1 A B 11 Sensor 4
15
TxD 12 18
SSR 2
Channel 2 RxD 13 19
16 +5 V DC 14 20
Update 15
17 GND 16
SSR 3
A Channel 3
18
PE 1
19
2 SSR 4
24 V AC,
3 Channel 4
50/60 Hz 20
Operating voltage
A B C D
5. Safety
Please pay attention!
• Check the version of the unit before installation!
• Check the supply voltage, the required supply voltage ratio and the bridges.
• For effect avoidance of disturbances, place the shield of the sensor or signal conductors onto
PE on the unit.
25.06.2013/Hi BA_Regler-Multicontrol_aen.docx
SPARE PARTS LIST
1 2
1 0 0 2
I II I II
1X3 2X3
3Q1 3Q3 1Q3 1Q6 2Q3 2Q6
5S2 5S4
3 4
0 0
1 2 1 2
I II 1 2 3 4 I II
3 4
3 4
I
0 1S1 ...V ...A 1F1 3T3
PE N
3H7
3X1 1S1
3F5
principle sketches
1X1
NA16 4E 50 024A
NA16 4E 50 124A
NA16 4E 44 024A
NA16 4E 44 124A
NA16 4E 23 124A
NA16 4E 40 024A
NA16 4E 40 124A
1
Equipment identifier
04.05.2017/Hi EL_Schaltschrank-4E-24-16A_aen_A.docx
SPARE PARTS LIST
NA16 4E 50 024A
NA16 4E 50 124A
NA16 4E 40 124A
NA16 4E 44 024A
NA16 4E 44 124A
NA16 4E 23 124A
NA16 4E 40 024A
04.05.2017/Hi EL_Schaltschrank-4E-24-16A_aen_A.docx
SPARE PARTS LIST
2 1 3
NG0400028H
NG0400028A
NG0400028B
08.07.2014/Hi EL_NG0400028_aen.docx
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OPERATING INSTRUCTIONS
Vulcanizing Plates
Specification: type EMU page 1/3
Table of Contents:
1. Technical description ......................................................................................1
1.1 Heating system ...............................................................................................1
1.2 Temperature control system ...........................................................................1
1.3 Cooling system ...............................................................................................2
2. Mounting of the vulcanization heating plate ....................................................2
3. Commissioning ...............................................................................................3
1. Technical description
All EMU vulcanizing plates have been compactly constructed and contain the following
components:
• Pressed sheets made from high-quality aluminum alloys for cooling purposes.
• Silicone heating mats with a high calorific output and good temperature
distribution at a low energy consumption.
• Heat insulation plates to neutralize the thermal impact of cross beam profiles and
pressure bags.
The vulcanization heating plates are equipped with resistance thermometers (double
PT100) for electronic temperature control. This is done electronically by means of a
PID temperature controller which is installed in the switch box.
25.06.2013/Hi BA_Heizplatte-EMU_Duolock-Harting_aen.docx
OPERATING INSTRUCTIONS
Vulcanizing Plates
Specification: type EMU page 2/3
The cooling system consists of special cooling profiles which conduct the cooling water
through specially shaped cooling channels, thus reducing the surface temperature
effectively in a short time at low water consumption rates.
All pressed cooling sheets feature a standard equipment of input / output connections
with a quick shutter hose coupling.
• Lay down the lower vulcanizing plate(s) with the pressed cooling sheet facing the
belt. The accessory catalogue features articles which allow the operators to lift
the vulcanizing plates correctly.
• Carry out the preparation of the belt splicing according to the guidelines specified
by the belt manufacturers in each case.
• Apply edge ledges (accessories) according to the strength of the belt. Add lining
underneath any part of the vulcanizing plate which is jutting out.
The entire surface of the vulcanizing plates must be lined. For this purpose, edge
rails or old belts may be used.
If this is not properly done, the vulcanizing plates will bend or deform
and become unfit for further use.
• Lay down the upper heating plate(s) with the pressed cooling sheet facing the
belt, in congruence with the position of the lower vulcanizing plate.
25.06.2013/Hi BA_Heizplatte-EMU_Duolock-Harting_aen.docx
OPERATING INSTRUCTIONS
Vulcanizing Plates
Specification: type EMU page 3/3
3. Commissioning
• Use the connecting cable to connect the vulcanizing plates with the switch box.
The plug connections of the vulcanizing plates are fitted with a forced locking
system (A).
version 1 version 2
• Enable the cooling water supply. Make sure that both input and output
connections have been linked up with the correct sets of hoses.
The safe discharge of the cooling water must be ensured. If the system
has not been sufficiently sealed, the operators run the risk of being
scalded by hot steam or hot water.
Please remove after the cooling process residual water and soiling from the
cooling canals. Frozen water or increased water steam pressure in the
blocked cooling channels can destroy the vulcanizing heating plate.
25.06.2013/Hi BA_Heizplatte-EMU_Duolock-Harting_aen.docx
REPAIR INSTRUCTIONS
Table of Contents:
1. Structure of the EMU vulcanization heating plate ...........................................1
2. Replacement of pin insert, temperature sensor PT100 and heating element....2
3. Pin wiring ........................................................................................................7
4. Alternative connections ...................................................................................8
2.1
1 Cover plate
2 Wooden insulation plate
2.1 Cover plate
10 3 Intermediate plate
4 Silicone heating element
5 Heating/cooling plate
6 Pin insert
6.1 Mounted socket
6.2 Built-in unit
6.3 Sealing
6.4 Covering
7 Earth connection for heating/cooling plate
8 PT100 temperature sensor
9 Earth connection for intermediate plate
10 Earth connection for heating/cooling and
intermediate plate
29.01.2015/Hi AA_Heizplatte-EMU_DuoLock_aen_B.docx
REPAIR INSTRUCTIONS
The replacement of plug connector, heating element and PT100 temperature sensor
necessitates the following work steps:
NOTE
3. Loosen connecting cables for PT100, heating element and earth connection at
the pin insert [6].
NOTE
For pin wiring see chapter 3 "Pin wiring" and chapter 4 "Alternative connections"
and the documentation supplied with the press.
CAUTION
29.01.2015/Hi AA_Heizplatte-EMU_DuoLock_aen_B.docx
REPAIR INSTRUCTIONS
CAUTION
Risk of damage!
If connected wrongly, the temperature sensor PT100 will not be connected to the
24 V supply but to the power supply of the press.
This will result in damage to the PT100 sensor as a result of the excess voltage
and can lead to burning, and in extreme cases, fire.
When all cables have been connected to the pin insert, the rear contacts must be
insulated with an insulating spray. Then assemble the pin insert.
NOTE
CAUTION
Take care when spraying the rear plug contacts, allowing the spray to dry for
around 15 minutes before assembling the plug.
If the pins on the plug are coated, this will lead to contact faults.
2 Dismounting of pin insert [6] (see chapter 2.1.1 Dismounting of pin insert).
3 Remove cover plate [2.1]: Screw in screw M8 into threaded hole and lift out cover
plate.
29.01.2015/Hi AA_Heizplatte-EMU_DuoLock_aen_B.docx
REPAIR INSTRUCTIONS
NOTE
For pin wiring see chapter 3 "Pin wiring" and chapter 4 "Alternative connections"
and the documentation supplied with the press.
CAUTION
CAUTION
Risk of damage!
If connected wrongly, the temperature sensor PT100 will not be connected to the
24 V supply but to the power supply of the press.
This will result in damage to the PT100 sensor as a result of the excess voltage
and can lead to burning, and in extreme cases, fire.
When all cables have been connected to the pin insert, the rear contacts must be
insulated with an insulating spray. Then assemble the pin insert.
NOTE
CAUTION
Take care when spraying the rear plug contacts, allowing the spray to dry for
around 15 minutes before assembling the plug.
If the pins on the plug are coated, this will lead to contact faults.
29.01.2015/Hi AA_Heizplatte-EMU_DuoLock_aen_B.docx
REPAIR INSTRUCTIONS
VORSICHT
Risk of damage!
When assembling the heating plate, take care to ensure that everything is
spotlessly clean.
All surfaces that come into contact with the silicon heating mat must be smooth,
dry, clean and free of any oil or grease.
Any sharp edges, such as scratches, must be removed; Foreign material will be
pressed into the heating mat and cause damage to it.
1. Lay the silicone heating element [4] on the heating/cooling plate [5].
2. Position the intermediate plate [3], and then connect the temperature sensor
PT100 [8] and the earth cable for the intermediate plate [9] and the
heating/cooling plate [10].
3. Connect pin insert [6].
29.01.2015/Hi AA_Heizplatte-EMU_DuoLock_aen_B.docx
REPAIR INSTRUCTIONS
NOTE
For pin wiring see chapter 3 "Pin wiring" and chapter 4 "Alternative connections"
and the documentation supplied with the press.
CAUTION
CAUTION
Risk of damage!
If connected wrongly, the temperature sensor PT100 will not be connected to the
24 V supply but to the power supply of the press.
This will result in damage to the PT100 sensor as a result of the excess voltage
and can lead to burning, and in extreme cases, fire.
When all cables have been connected to the pin insert, the rear contacts must be
insulated with an insulating spray. Then assemble the pin insert.
NOTE
CAUTION
Take care when spraying the rear plug contacts, allowing the spray to dry for
around 15 minutes before assembling the plug.
If the pins on the plug are coated, this will lead to contact faults.
4. Position the insulating plate [2] and hand tighten the screws supplied. The plug
cover should also be screwed on. Then lay down the cover plate [2.1] with the
groove down.
5. Screw the cover plate [1] onto the insulating plate [2].
29.01.2015/Hi AA_Heizplatte-EMU_DuoLock_aen_B.docx
REPAIR INSTRUCTIONS
3. Pin wiring
3.1 Three phase power supply
Heating mat Phase L1 Pin 1
Phase L2 Pin 2
Phase L3 Pin 3
PT100 Connecting lead 1, color white1 Pin 4
Connecting lead 2, color white1 Pin 5
1
Jumper Jumper plug contacts 5+6, color white
PE Connect earth cable for the intermediate plate and the heating/cooling plate to
the pin on the side.
3.2 Single phase AC power supply
Heating mat Phase L1 Pin 1 + 2
Neutral cable Pin 3
PT100 Connecting lead 1, color white1 Pin 4
1
Connecting lead 2, color white Pin 5
Jumper Jumper plug contacts 5+6, color white1
PE Connect earth cable for the intermediate plate and the heating/cooling plate to
the pin on the side.
1
Stand-by lead, colour red
29.01.2015/Hi AA_Heizplatte-EMU_DuoLock_aen_B.docx
REPAIR INSTRUCTIONS
4. Alternative connections
1 2 3 4 5 PE 6
X1 1 2 3 4 5 PE 6 X1
Kabel/cable Kabel/cable
7x2,5 mm² 7x2,5 mm²
1 2 3 4 5 PE 1 2 3 4 5 PE 6
6
Platte
R1-Rn Platen
2x PT100
X1 1 2 3 4 5 PE 6
Kabel/cable
7x2,5 mm²
1 2 3 4 5 PE 6
29.01.2015/Hi AA_Heizplatte-EMU_DuoLock_aen_B.docx
SPARE PARTS LIST
Vulcanizing Plates
Specification type EMU, 400 V, 3~ page 1/2
2 6
11
A-A
3, 4 9 7, 8 5 10
principle sketches
29.01.2018/Hi EL_HPP-EMU-DuoLock-Staeubli-400V-rh_nen.docx
SPARE PARTS LIST
Vulcanizing Plates
Specification type EMU, 400 V, 3~ page 2/2
NJL213100C/200C
NJL457100C/200C
NJL620100A/200A
1
Article-No.:
29.01.2018/Hi EL_HPP-EMU-DuoLock-Staeubli-400V-rh_nen.docx
OPERATING INSTRUCTIONS
1. Technical data
accuracy : 1% ± 1D
2. Operating instructions
Insert the two feelers into feeler sleeves 1 and 2. The requested temperature value of
feeler 1 or feeler 2 can be displayed by means of using the lateral slide switch.
ATTENTION!
The battery must be replaced upon display of - BAT - as otherwise measuring errors
may occur.
17.01.2013/Hi BA_Thermometer-Digital_aen.docx
NILOS GmbH & Co. KG Tel. 02103/951-0 NILDS
ReisholzstraBe 15 Fax. 02103/951-199
D-40721 Hilden e-Mail info@nilos.de
Internet www.nilos.com
revision I date
1 13.06.14
P_2_8_4_5_3
Test Certificate
Method of Testing
measuring tape x
visual check x
pressurised water unit x
compressor/pressure gauge
Test Certificate
Method of Testing
measuring tape x
visual check x
pressurised water unit x
compressor/pressure gauge
Test Certificate
Method of Testing
visual check x
pressure gauge x
Test Certificate
Method of Testing
visual check x
compressor/pressure gauge x
pressure test
serial-no. according to type tightness
working remark
plate max. bar minutes test
pressure
100430 7 10 45 OK
1. Heating Diagram
[°C]
Y1
Y2
[min]
X1 X2
Description Parameter
X1 End of heating-up 30 min
X2 Start of cooling-down 75 min
X2-X1 Curing time 45 min
Y1 Temperature at Start of vulcanizing 140 - 150° C
Y2 Temperature at End of vulcanizing 140 - 150° C
Tab. 1: Explanation of heating diagram
08.03.2018/Hi AD_A17-126508_aen.docx