RC3-LOG & RC3P-LOG INSTRUCTION MANUAL Page 1
SHAWALMEX-EUROPE BV RC3-LOG & RC3P-LOG INSTRUCTION MANUAL SEPT 2018
INSTRUCTION MANUAL
RC3-LOG & RC3P-LOG
DATALOGGING TEMPERATURE CONTROL PANEL
This manual was prepared to present the correct methods and procedures of operating and
maintaining your ALMEX TEMPERATURE CONTROL PANEL.
Read this manual carefully before operating your vulcanizer.
SHAW-ALMEX EUROPE BV
DE BOLDER 54
9206 AR, Drachten, The Netherlands
Phone: +31 652 667 301
e-mail: info@shawalmex.eu
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SHAWALMEX-EUROPE BV RC3-LOG & RC3P-LOG INSTRUCTION MANUAL SEPT 2018
Table of Contents
1. RECORD OF PURCHASE .................................................................................................................... 3
2. DECLARATION OF CONFORMITY .................................................................................................... 4
3. SAFETY .................................................................................................................................................. 5
3.1. Definition of Pictograms ....................................................................................................... 5
3.1.1. Electrical Hazard ..................................................................................................................... 5
3.1.2. Burning Hazard ........................................................................................................................ 5
3.2. Limitation of use ................................................................................................................... 5
4. ASSEMBLY ............................................................................................................................................ 6
4.1. Unpacking ............................................................................................................................ 6
4.2. Functional Diagram .............................................................................................................. 6
4.3. Connection Assembly .......................................................................................................... 7
5. OPERATION .......................................................................................................................................... 7
5.1. Temperature Controller Settings ......................................................................................... 7
5.1.1. Setting the Platen Temperature ................................................................................................ 7
5.1.2. Protecting Temperature Controller Settings...............................................................................
5.2.1. Set the Timer ......................................................................................................................... 10
5.3. Heating the Vulcanizer ....................................................................................................... 11
5.3.1. Manual Heating ..................................................................................................................... 12
5.4. Temperature Control ......................................................................................................... 12
6. MAINTENANCE .................................................................................................................................. 12
6.1. Opening the Control Cabinet ............................................................................................. 12
6.2. Overload Protection ........................................................................................................... 12
6.3. Temperature Calibration .................................................................................................... 12
6.3.1. Auto Tune .............................................................................................................................. 13
6.3.2. Input Shift .............................................................................................................................. 10
7. TROUBLESHOOTING ....................................................................................................................... 13
7.1. No Display on Temperature Controller .............................................................................. 13
7.2. Error Display on Temperature Controller ........................................................................... 13
7.4. Platens Not Heating ........................................................................................................... 14
7.5. Vulcanizer Over Heating .................................................................................................... 14
7.6. Controller will not maintain Set Point Temperature ........................................................... 15
8. Service ................................................................................................................................................ 15
8.1. Emergency Service ............................................................................................................ 15
8.2. Return of Goods Authorization .......................................................................................... 15
8.3. Guarantee .......................................................................................................................... 15
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1. RECORD OF PURCHASE
Job Number
Date of Purchase
Model Number RC3-LOG & RC3P-LOG
Serial Number
Weight 15 kg
Voltage 380-420 volt
Phase 3
Cycle/Hertz 50/60
Amperage Maximum Per Platen 16 Amp
Total 32 Amp
Circuit Overcurrent Protection Required 32 Amp
Temperature Sensor 100 platinum RTD
Index of Protection IP 54
Ancillary Items
Spare Parts Fuses: 3 x 2 Amp
Operating Instructions 49900-028
Supplements NANODAC manual
Service Bulletins none
Drawings MWD
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2. DECLARATION OF CONFORMITY
We, Shaw Almex Europe BV
of De Bolder 54, 9206AR, Drachten The Netherlands
declare that the machinery:
Product: Temperature control panel
Model: RC3(P)-LOG
Year of Construction: 2018
has been manufactured using the following transposed harmonized European Standards:
EN 60204-1 Safety
EN 50081-1 Emissions (EN55011)
EN 50082-1 Immunity (EN61000-4-2/3/4/5)
and is in conformity with the following Directives:
2006/95/EC Low Voltage Directive + amendment 93/68/EEC
2004/108/EC EMC Directive + amendment 92/31/EEC
2006/42/EC Machinery Directive
Signed in: Drachten, The Netherlands
On September 17th, 2018
Name: C. Jongkind
Position:: Managing Director
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SHAWALMEX-EUROPE BV RC3-LOG & RC3P-LOG INSTRUCTION MANUAL SEPT 2018
3. SAFETY
Your ALMEX Temperature control panel has been designed to provide safe, efficient, trouble-free service for
many years. Component design and material selection have been carefully considered to ensure operator safety
and our manufacturing procedures provide a consistent, high-quality product.
The material that is presented in this operating manual has been compiled to provide direction for operating
personnel so that the maximum effectiveness of the temperature control panel can be achieved and so that there
is a complete understanding of correct operating procedures.
PLEASE READ CAREFULLY
The following safety precautions should be read carefully and understood thoroughly before you set-up or
operate your temperature control panel. Failure to follow these precautions may result in personal injury and/or
equipment damage. All operating personnel should be trained in the proper operation of the temperature control
panel.
The risks associated with operating the temperature control panel are identified throughout this manual with
pictograms.
3.1. Definition of Pictograms
Electrical Hazard
Burning Hazard
3.1.1. Electrical Hazard
1. A qualified electrician should perform all maintenance of the electrical components of the temperature
control panel.
2. All of the electrical components contain live circuits. Do not open or service any of the electrical equipment
without disconnecting the main power supply.
3. Incorrect voltage and phase may result in component damage and create a fire hazard.
4. Equipment power supplies must be properly grounded or a severe shocking hazard may result.
5. Avoid using equipment in wet surroundings or a severe shocking hazard may result.
6. If any cable or connectors are damaged, they must be replaced or a fire and shock hazard may result.
3.1.2. Burning Hazard
There is not a burning hazard with the temperature control panel itself, however, improper use or component
failure could result in the vulcanizer overheating. Always use an Almex temperature control panel when
operating the vulcanizer and never leave the vulcanizer operating while unattended.
3.2. Limitation of use
This equipment has been designed to control the temperature of an ALMEX conveyor belt vulcanizer. The
process of vulcanizing is done by applying a combination of heat and pressure on the product for a certain
period of time. The RC3(P)-LOG temperature control panel operates within a range of 32 F- 400 F (0 C to
200 C) though a maximum of 325 F (163C) is recommended for long life of most heating elements. Refer to
the vulcanizer manual for platen limitations. An Almex temperature control panel must be used with an Almex
vulcanizer and the vulcanizer should never be allowed to operate while unattended. Other use is not allowed
without the written permission of Shaw-Almex.
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4. ASSEMBLY
4.1. Unpacking
Carefully unpack temperature control panel from the box and inspect for damage.
Any damages or shortages should be reported to the carrier and / or SHAW ALMEX EUROPE BV.
4.2. Functional Diagram
4.3.
Figure 1.: Functional Diagram
Figure 2. : Backside RC3P-LOG Figure 3: Side RC3P-LOG
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4.4. Connection Assembly
Safety: Ensure the voltage, phase and cycle on the temperature control panel is the same as the power supply.
Turn the A/M switch to the 0 (off) position.
1. Install a suitable electrical connector to the power supply cable. Refer to the electrical specifications
indicated on the serial plate and in the record of purchase. Ensure the green wire is connected to earth.
2. Lift the covers on the platen connectors on the back panel of the temperature control panel and connect the
platen cables. Press the plugs firmly into the receptacles and rotate the latches to secure the plugs. When the
cables are removed, close the covers to protect the connector from water and dirt.
3. Connect the temperature control panel to the power supply. Refer to the electrical specifications indicated
on the serial plate and in the record of purchase. The temperature controllers should indicate the actual
platen temperature and the set point temperature.
5. OPERATION
The RC3(P)-LOG temperature control panel has one
datalogging temperature control unit, which controls
the temperature of the upper platen and the lower
platen. The average user need only adjust the
temperature set points for top and bottom platen. The
temperature controller has many other settings that
have been set by the factory.
The operator interface consists of a display screen and
four navigation push buttons.
PAGE BUTTON
From any
non-configuration page,
pressing
this
push button causes
the top
level
menu
(figure 4:) to
ap
pear.
The
figure
shows
the
menu
for a user
logged
in with ‘Engineer’ level
access. Other access
levels
may
have fewer
menu items.
Within
configuration pages,
the Scroll
button
can
be used
as an
enter
key to
select
lower
menu
levels. In
such
cases
the
page button
is
used
to
reverse
this
action, moving
the user up
one
menu
level per
operation.
SCROLL BUTTON
From
trending pages, operation
of the scroll
push-button
scrolls
through
the
channels enabled
in the
group.
The
Faceplate
cycling
‘Off’
selection
can
be used
to
keep
a
particular channel
permanently displayed,
and
the scroll
pushbuttons
can
then be used
to
select channels
manually.
In
configuration pages,
the scroll key
operates
as an ‘enter’ key to
enter
the next
menu
level
associated with
the
highlighted
item.
Once
the
lowest menu
level is
reached, operation
of the
scroll key allows the value
of
the
selected
item to
be edited
by the
relevant means
(for
example,
the
raise/lower
keys, or a
keyboard entry).
The ‘Page’ key is
used
to
move
the user back up the
menu structure,
until the top level
menu
is
reached,
when
the scroll key can
be used again
to
return
to the
Home
page.
Figure 4: Operator Interface Home Screen
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RAISE/LOWER BUTTONS
Within
trending displays,
the Raise
and
Lower keys can
be used
to scroll
through
the
enabled
display
modes
in the
sequence:
vertical
trend, horizontal trend,
vertical
bargraph, horizontal
bargraph, numeric, vertical
trend... and
so
on.
Within
configuration pages, these pushbuttons
act as
cursor
keys,
allowing,
for
example,
the
user to
high-
light
menu items
for
selection using
the scroll
button, and
in many
cases allowing
the user to
select one from
a
number
of
alternative values
within
menu
items.
Theses
keys are
also
used
to
navigate through
the
virtual
keyboards
and number pads used
to
enter
text or
numeric strings.
5.1.1. Setting the Process Values
1. Starting at the home screen the following screens can be seen by pushing the page button and the lower
button:
2. Figure 5: Process Overview screen.
The setpoints of Upper and Lower Platen and the dwelltime can be adjusted in this screen.
3. Figure 6: Channel “cycling” screen
By default, the recorder scrolls through all the channels (Top platen, Bottom platen, Pressure and
Temperature Probe) in the display group, with each channel becoming the active channel in turn.
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4. Figure 7: Process values screen.
This screen gives a clear overview of the actual temperatures and the pressure.
5. Figure 8: control loop Top/Bottom Platen.
5.1.2. Set the Platen Temperatures
Push the page button untill the Process overview screen (Figure 5) is shown. Push the scroll button
and the raise/lower buttons to select the setpoint or dwelltime that needs to be changed:
The scroll button acts as the enter button to select the right value. The selected value will become yellow:
Change the value by entering the desired temperature. Push the page button and select yes to accept the changes.
The Bottom platen temperature has now been changed.
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Another option for changing the setpoints of the platens is by using the Control loop screens (figure 8)
Once the desired platen control loop screen is selected, push the scroll button 2 times and the temperature
will become black. By using the raise/lower buttons the temperature value can be set to the desired
value.
Once the desired value has been reached push the scroll button once more to enter the new value. Pushing
the page button will lock the new temperature value:
Important: The maximum recommended operating temperature is 325F (163C).
5.1.3. Setting the dwelltime
Push the page button untill the Process overview screen (Figure 5) is shown. Push the scroll button
and the raise/lower buttons to scroll to dwelltime. Once the dwelltime is selected pushing the scroll
button will activate the black up/down arrows and the dwelltime can be changed with the raise/lower buttons
:
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After having changed the dwelltime to the desired value it can be locked by pushing the scroll button
(enter) and the page button (back)
5.2. Heating the Vulcanizer
Safety: Never heat the vulcanizer unattended.
1. There are three positions on the platen switch as follows:
A - On Automatic. For automatic temperature control to SETPOINT VALUE.
0 - Off. Switches power to platens off. Controller remains energized.
M - On Manual. Override temperature controller and switch power to platen on. After having set the
switch to M the spring loaded red push buttons will power the heating to the platens..
2. The vulcanizer should be pressurized to at least 5 psi (0.3 kg/sq.cm) before heating.
3. Press the blue TIMER RESET button at the timer. Setting the A/M button to A will start the heat cycle.
4. Turn the A/M switch to the A (on automatic) position to begin heating the vulcanizer. The Ammeter will
read the current for each platen as they are switched on. Depending on the screen that is chosen (figure
5,6,7 or 8) process information can be monitored.
Safety: The platen will begin to get hot.
5. Stem thermometers should be inserted into the hole in the platen edge as a secondary means of monitoring
the temperature. The temperature will not necessarily be the same as the temperature control because of
differences in calibration.
6. When the set point is reached, the dwell timer will start to run and the elapsed dwelltime can be seen on the
process overview screen.
7. When the dwelltime has been finished the heating will be switched of and the audio alarm be activated.
8. Press the time RESET button before the next heat cycle.
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5.2.1. Manual Heating
If there is a temperature controller malfunction or platen temperature sensor failure, the platen can be heated
manually by turning the platen switch to the M (on manual) position and push the red manual heating button.
These buttons have a spring return to off, a Safety Feature so the heat will shut off if the vulcanizer is left
unattended. When using this function, the platen temperature will have to be monitored by an external
temperature indicator such as a stem thermometer.
5.3. Temperature Control
1. A P.I.D (Proportional Integral Derivative) solid state temperature controller that senses the resistance
change in an RTD (Resistance Temperature Device) sensor in each platen effects temperature control. The
controller should maintain temperature at the set point +-3 F (2 C) at 300 F (150 C).
2. The temperature controller incorporates a proportioning circuit that causes the platens to reach set point
temperature in a minimum of time with less than 2 F (1.1 C) of temperature overshoot. In operation, the
controller will begin cycling off and on slightly below set point. During this initial cycling period, the
temperature will continue to rise to the set point as indicated by the temperature controller. This early
cycling is a normal function of the controller and should not be reset, otherwise excessive temperatures will
occur.
3. The parameters can be adjusted so that set point is reached in the fastest possible time (straight line heating)
but this will cause the temperature to overshoot the set point by several degrees. Alternatively, the
parameters can be adjusted so there is zero overshoot but the rate of heating will decrease as the set point is
reached. If you wish to fine tune your controller in either of these ways contact Shaw-Almex for advice.
6. MAINTENANCE
6.1. Opening the Control Cabinet
To access the circuits in the control box, a + blade screw driver is required.
Safety: Disconnect the power supply.
1. Remove the screws around the perimeter of the front panel.
2. The front panel can now be removed from the cabinet as one assembly.
6.2. Overload Protection
There is overload protection inside the control cabinet for
the platens . A fuse on the front plate protects the control
circuit.
The control circuit is protected with a 2 amp fuse (see figure
1), which is located in the center of the control panel front
plate.
The platens are protected with a 32 Amp circuit breaker.
The circuit breaker can be reset to one at the side of the
control cabinet (see figure 3) by opening the window and set
the switch to 1.
6.3. Temperature Calibration
After replacing a temperature controller, a platen temperature sensor or a platen heating element the temperature
controller should be calibrated to achieve the best performance. Failure to calibrate the controller with the
vulcanizer will result in temperature over shoot and the temperature control will be less precise.
Figure 9 Overload Protection
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Note: The temperature controller is a snap in module that can be replaced with a + blade screwdriver, and is a
recommended spare part. If you have ordered a spare controller, it will be factory set to an average value that
will control your platen reasonably well. Auto Tune should still be done as follows.
An external means of checking the platen temperature is required. A portable temperature test meter with at
least two leads is best to conduct the calibration tests. These may be purchased from Shaw-Almex.
1. Install a section of belting large enough to cover the platen area.
2. Install the temperature meter sensors above and below the belting, 8 inches (200 mm) from the electrical
connector. That is where the platen temperature sensor is located. Cut a groove in the belting to prevent
damage to both sensors and platens.
3. Assemble the vulcanizer and pressurize to 5 psi (0.3 kg/cm2).
6.3.1. Auto Tune
The temperature controller has an AUTO TUNE (AT) function that calibrates the controller with the heating
element and the temperature sensor. The controller has been calibrated at the factory and will not require
calibration unless the controller, the heating element or the temperature sensor is changed. Refer to the special
autotuning instructions for autotuning your RC3(P)-log controller.
7. TROUBLESHOOTING
This controller has many capabilities other than those used for the Almex Temperature control panel. Adjust
only those settings described above. Other adjustments may result in the control box being inoperable. For
detailed instruction of the ALMEX NANODAC controller, refer to the ALMEX NANODAC instruction
manual supplied with this temperature controller.
7.1. No Display on Temperature Controller
FAULT
CORRECTION
1. Power supply is faulty.
1. Check the supply cables and power supply connection.
2. Control circuit fuse has
opened.
2. Disconnect power supply, open the control cabinet,
correct the fault in the control circuit and replace the fuse.
7.2. Error Display on Temperature Controller
FAULT
CORRECTION
1. Loose connection in cable or
platen connector.
1. Remove electrical connector insert from housing and
tighten all connections.
2. RTD temperature sensor is
faulty.
2. Measure the resistance between pins 4-5 and 4-6 on the
platen electrical connector. Depending on the platen
temperature, the resistance should be between 100-170
Ohms. Replace sensor as described in the vulcanizer
manual. The wires should be protected from moisture by
using a small amount of silicone in the back of the insert
terminal to seal the connection.
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7.3. Platens Not Heating
1. Platen switch OFF.
1. Turn platen switch ON.
2. Temperature set improperly.
2. Ensure that controller set point is correct.
3. No continuity between power
supply and platen.
3. Check power supply, fuses (inside panel) and cable
connections.
4. Loose connection in control
panel.
4. Disconnect power supply, open the control cabinet and
check for loose wire connections.
5. Faulty temperature controller.
5. Refer to ALMEX NANODAC instruction manual.
6. Faulty relay.
6. Disconnect power supply, and open control cabinet. Very
carefully connect power supply and switch the platens on.
The temperature controller should be showing an output
to this channel.. To verify that power is getting to each
relay check for voltage between terminal "A1" and
terminal “A2” of the Power relays for the top and bottom.
If a particular relay is receiving incoming power and is
receiving a signal from the controller, but is not sending
outgoing power then that relay is faulty and must be
replaced.
7. Loose connection in cable or
platen connector.
7. Remove electrical connector insert from housing and
tighten all connections. The wires should be protected
from moisture by using a small amount of silicone.
8. Faulty RTD temperature
sensor.
8. Measure the resistance between pins 4-5 and 4-6 on the
platen receptacle. Depending on the platen temperature,
the resistance should be between 100-170 Ohms.
9. Faulty heating element.
9. Measure the resistance between pins 1-2, 2-3 and 1-3 on
the platen electrical receptacle. Compare the reading with
the value in your Record of Purchase, Element Resistance,
Coils Connected. If the values are not close and the wires
and connections are good, the element must be replaced.
The wires should be protected from moisture by using a
small amount of silicone in the back of the insert terminal
to seal the connection.
7.4. Vulcanizer Over Heating
FAULT
CORRECTION
1. Temperature set improperly.
1. Ensure that controller set point is correct.
Figure 2 Platen Connector
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2. Faulty temperature controller.
2. Refer to ALMEX NANODAC instruction manual.
3. Faulty RTD temperature
sensor.
3. Measure the resistance between pins 4-5 and 4-6 on the
platen electrical receptacle. Depending on the platen
temperature, the resistance should be between 100-170
Ohms.
7.5. Controller will not maintain Set Point Temperature
FAULT
CORRECTION
1. Controller not calibrated
properly.
1. Follow calibration procedure.
2. Faulty temperature controller.
2. Refer to ALMEX NANODAC instruction manual.
Replace temperature controller
8. Service
8.1. Emergency Service
Contact: Service Department
Telephone: +31 652 667 301
Fax: +31 842 202 967
Mail: SHAW ALMEX EUROPE BV
PO BOX 16
9247 ZN, Ureterp
The Netherlands
E-mail: info@shawalmex.eu
8.2. Return of Goods Authorization
The service department of Shaw-Almex Industries Limited MUST be contacted for the necessary authorization
and documentation prior to returning goods to the factory.
The service department may be reached at the above numbers.
8.3. Guarantee
Your ALMEX vulcanizer is guaranteed against defective parts, material and workmanship for a period of 12
months from the date of purchase. For complete details, refer to the Warranty Card.
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