T1 - Omron Control INSTRUCTION MANUAL Page 1
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
INSTRUCTION MANUAL
T1
Omron Control
T1R2 Remote and T1F2, T1F3 Frame Mount Models
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 INDUSTRIES LIMITED
PO Box 430
Parry Sound, Ontario, Canada P2A 2X4
Phone: 705-746-5884 or 1-800-461-4351
Fax: 705-746-9484
E-mail: [email protected]
T1 - Omron Control INSTRUCTION MANUAL Page 2
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
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.
Temperature Control Panel Features..................................................................................6
4.3. Functional Diagram .............................................................................................................6
4.4. Connection Assembly..........................................................................................................7
5.
OPERATION ......................................................................................................................................7
5.1. Temperature Control Settings .............................................................................................7
5.1.1. Setting the Platen Temperature................................................................................................7
5.1.2. Applying and Removing Protection to Settings ......................................................................7
5.1.3. Setting Temperature Units to °C or °F ....................................................................................8
5.2. Heating the Vulcanizer ........................................................................................................8
5.3. Manual Override ..................................................................................................................8
5.4. Temperature Control ...........................................................................................................8
6.
MAINTENANCE.................................................................................................................................9
6.1. Opening the Control Cabinet (T1R2 Models)......................................................................9
6.2. Removing Control Panel from the Frame (T1F2, T1F3 Models).........................................9
6.3. Temperature Calibration......................................................................................................9
6.3.1. Auto Tune.............................................................................................................................10
6.3.2. Temperature Offset................................................................................................................10
7.
TROUBLESHOOTING ....................................................................................................................11
7.1. No Display on Temperature Controller..............................................................................11
7.2. Error Display on Temperature Controller ..........................................................................11
7.3. Vulcanizer Not Heating......................................................................................................11
7.4. Vulcanizer Over Heating ...................................................................................................12
7.5. Controller will not maintain Set Point Temperature...........................................................12
8.
Service..............................................................................................................................................12
8.1. Emergency Service ...........................................................................................................12
8.2. Return of Goods Authorization ..........................................................................................12
8.3. Guarantee..........................................................................................................................12
T1 - Omron Control INSTRUCTION MANUAL Page 3
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
1. RECORD OF PURCHASE
Job Number
Date of Purchase
Model Number
Serial Number
Weight 2 lb. (1 kg)
Voltage
Phase Single
Cycle/Hertz 50/60
Amperage Maximum 15
Circuit Over current Protection Required
Temperature Sensor 100 Ω platinum RTD
Index of Protection IP 54
Ancillary Items none
Spare Parts none
Operating Instructions 49900-030, R05/2005
Supplements OMRON E5GN
Service Bulletins none
Warranty Card yes
Drawings
Parts Diagrams 49950-022- T1R2, T1F2, T1F3
T1 - Omron Control INSTRUCTION MANUAL Page 4
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
2. DECLARATION OF CONFORMITY
We, Shaw-Almex Industries Limited,
of P.O. Box 430, Parry Sound, Ontario, Canada,
declare that the machinery:
Product: Temperature Control
Model: T1
Year of Design: 2001
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:
73/23/EEC Low Voltage Directive + amendment 93/68/EEC
89/336/EEC EMC Directive + amendment 92/31/EEC
89/392/EEC Machinery Directive
Signed in: Parry Sound, Ontario, Canada
on
Name: Lawrence B. Woolner, P.Eng.
Position:: Manager of Engineering
T1 - Omron Control INSTRUCTION MANUAL Page 5
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
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 the electrical equipment
without disconnecting the main power supply.
3. Incorrect voltage and phase may result in component damage and create a fire hazard. Refer to serial plate
for power specifications.
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 a single platen of an ALMEX conveyor belt
vulcanizer. Applying a combination of heat and pressure on the product for a certain period of time does the
process of vulcanizing.
The T1 temperature control panel operates within a range of 0 °C to 163 or 200 °C (32 °F- 325 or 400 °F)
depending on the press model. Refer to the vulcanizer manual for platen limitations.
T1 - Omron Control INSTRUCTION MANUAL Page 6
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
Two panels can be used on a vulcanizer. Depending on the amperage of the platens, it may be necessary to
connect each panel to a separate circuit.
The frame mounted control panels (T1F2, T1F3) should not be operated for more than three hours without
platen cooling because the frame temperature will increase and may cause the controls to malfunction. Use a
remote panel for continuous operation.
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.
4. ASSEMBLY
4.1. Unpacking
Carefully unpack temperature control panel from the crate and inspect for damage. Report any damages or
shortages to the carrier and / or Shaw-Almex Industries Limited.
4.2. Temperature Control Panel Features
The T1 temperature control panel is designed to control the temperature of a single platen in a vulcanizer. Two
T1 panels are used for independent control of top and bottom platens of a vulcanizer.
Saftey: Each control panel may have to be plugged into a separate circuit to avoid exceeding the
amperage capacity of the circuit.
• The T1 is available for 115 volt or 230 volt, single phase, and 15 Amp.
• LED display of set point temperature and platen temperature. Maintains platen temperature at your preset
value until turned off.
• Three position switch for automatic control (1A) , manual override (1M) and heat off (0). It allows the
display to remain illuminated when the platen power is off.
• The remote panel is made from a lightweight but rugged ABS plastic that is dust proof and water resistant
to IP 54.
4.3. Functional Diagram
Figure 1
T1 R2
Remote Panel
T1 F3
Frame mount panel
A - temperature controller
B - switch
C - platen cable
D - power supply cable
A
C
B
A
C
D
B
D
T1 F2
Frame mount with
Auxiliary receptacle
T1 - Omron Control INSTRUCTION MANUAL Page 7
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
4.4. Connection Assembly
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.
2. Switch the control panel to the OFF position (0).
3. Connect the platen cables to the platen.
4. Connect the temperature control panel to the power supply. On T1F2 and T1F3 models, the power supply
cable is separate from the panel. Refer to the electrical specifications indicated on the serial plate and in the
record of purchase.
5. The temperature controllers should indicate the actual platen temperature and the set point temperature.
5. OPERATION
The T1 temperature control panel has a solid state temperature controller. The controller displays the process
value (No. 1 display) which is the actual platen temperature and set value (No. 2 display) which is the desired
temperature.
5.1. Temperature Control Settings
The average user need only adjust the temperature set point. The temperature controller has many other settings
that have been set by the factory and these can be adjusted. The controller settings can be protected to avoid
making adjustments that might adversely affect its operation.
5.1.1. Setting the Platen Temperature
Push the Up key or the Down key until the desired temperature is reached. This can be changed anytime but
should be done before beginning to heat.
5.1.2. Applying and Removing Protection to Settings
All controller settings except the set point adjustment can be protected so the settings can not be adjusted.
Applying protection:
1. Press the Level and Mode keys simultaneously for at least three seconds until oAPt
appears in the display.
2. Press the Up key until No. 2 display shows the number 2.
3. Press the Mode key to display iCPt
.
T1 - Omron Control INSTRUCTION MANUAL Page 8
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
4. Press the Up key until No. 2 display shows the number 2.
5. Press the Level and Mode keys simultaneously for at least one second to return to the temperature display.
Removing protection:
1. Press the Level and Mode keys simultaneously for at least three seconds until oAPt
appears in the display.
2. Press the Down key until No. 2 display shows the number 0.
3. Press the Mode key once and No. 1 display will show iCPt
.
4. Press the Down key until No. 2 display shows the number 1.
5. Press the Level and Mode keys simultaneously for at least one second to return to the temperature display.
5.1.3. Setting Temperature Units to °C or °F
1. Press the Level key for at least 3 seconds, until No. 1 display shows in-t
.
2. Press the Mode key until No. 1 display shows d-U
.
3. Press the Up or Down key until No. 2 display shows F
(Fahrenheit) or C (Celsius).
4. Press the Level key for at least 1 second to return to the temperature display.
5.2. Heating the Vulcanizer
Safety: Never heat the vulcanizer unattended.
1. The vulcanizer should be pressurized to at least 5 psi (0.3 kg/cm
2
) before heating.
2. Turn the switches to the 1A (On, Automatic) position to begin heating the vulcanizer. The OUT indicator
on the controller will light until the process value is close to the set value and then begin to flash. The
platen temperature indicator (no. 1 display) value will begin to increase as the platen temperature rises.
Safety: The platen will begin to get hot.
3. When the set point (no. 2 display) is reached, the OUT indicator will continue to flash on and off to
maintain set value temperature. Start timing the cure when set value is reached.
4. After the cure time, turn the controller switch to the OFF position.
5. For minimal overshoot on the next heating cycle, reset the controller by disconnecting from power.
5.3. Manual Override
The 1M position on the switch can be used to heat the platen while bypassing the temperature controller and the
temperature sensor. An insertion thermometer can be used to monitor the platen temperature if the controller
has failed. The switch must be held in the on position and it will return to the off position when released to
avoid accidental overheating.
5.4. 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) probe in each platen effects temperature control. The
controller should maintain temperature at the set point +-3 °F (2 °C) at 300 °F (150 °C).
2. The temperature controller incorporates a proportioning circuit that causes the platens to reach set point
temperature in a minimum of time with less than 2 °F (1.1 °C) of temperature overshoot. In operation, the
controllers will begin cycling off and on slightly below set point. During this initial cycling period, the
temperature will continue to rise to the set point as indicated by the temperature controllers. This early
cycling is a normal function of the controller and should not be reset, otherwise excessive temperatures will
occur.
T1 - Omron Control INSTRUCTION MANUAL Page 9
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
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 (T1R2 Models)
To access the circuits in the control panel, a Phillips head screwdriver is
required.
Safety: Disconnect the power supply.
1. Remove the screws from the cover.
2. Remove the cover.
6.2. Removing Control Panel from the Frame (T1F2, T1F3 Models)
To access the circuits in the control panel, a Phillips head screwdriver is required.
Safety: Disconnect the power supply.
1. On T1F2 models, disconnect the platen connector .
2. Remove the screws from the panel.
3. Slide the control assembly out the front opening of the frame.
4. On T1F3 models, disconnect the heating element wires form the relay
and the temperature sensor wires from the controller .
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.
Note: The temperature controller 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. Accurate calibration should still
be done on the vulcanizer using a portable temperature test meter with at least
two leads. An approved type of temperature meter may be purchased from Shaw-Almex.
The procedure is as follows.
1. Install a section of belting large enough to cover the platen area.
2. Install the temperature meter sensors above and below the belting approximately centered on the platen
faces. 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/cm
2
) maximum.
T1 R2 Figure 2
T1 F2, T1 F3 Fi
g
ure 4
Relay
T1F2
T1F3
Controller
Relay
T1 F2, T1 F3 Fi
g
ure 3
T1 - Omron Control INSTRUCTION MANUAL Page 10
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
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. Auto Tune the
controller as follows:
1. Connect the power supply and switch the platens to ON.
2. Press the Level key for less than one second and release. At
is displayed. If protection is on, it must be
switched off.
3. Press the Up key to switch no. 2 display from off to on. After 2 seconds, the At display will begin to flash.
The At display will flash until auto tuning is complete. After set point has been reached, it may take
approximately 10 minutes to complete auto tuning. It is not necessary to wait for the At display to stop
flashing before returning to the temperature display.
4. Press the Level key for less than one second to return to the temperature display. The no. 2 display (set
value) will flash until tuning is complete.
5. If the Process Value and the temperature on the test meter are different proceed to 6.3.2 Temperature
Offset to make adjustment.
6.3.2. Temperature Offset
If the external temperature meter reading and the temperature controller value are not the same after Auto
Tuning, the controller should be adjusted. Subtract the controller reading from the external temperature meter
reading and record this difference. Adjust the controller as follows:
1. Press the Level key for less than one second and release. At
is displayed. If protection is on, it must be
switched off.
2. Press the Mode key to show inS
(input shift) in the no. 1 display.
3. Press the Up or Down key to enter the temperature difference recorded above in the no. 2 display.
4. Press the Level key for less than one second and release to return to the temperature display. Notice that
the process value (no. 1 display) has changed by the amount you entered.
T1 - Omron Control INSTRUCTION MANUAL Page 11
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
7. TROUBLESHOOTING
This controller has many capabilities other than those used for the Almex Temperature Control. Adjust only
those settings described above. Other adjustments may result in the control panel being inoperable. For detailed
instruction of the E5GN controller, refer to the OMRON manual supplied with this temperature control panel.
7.1. No Display on Temperature Controller
FAULT CORRECTION
1. Power supply is faulty. 1. Check the supply cables and power supply connection.
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 probe as described in the vulcanizer
manual. The leads should be protected from moisture by
using a small amount of silicone in the back of the insert
terminal to seal the connection.
7.3. Vulcanizer Not Heating
FAULT CORRECTION
1. Platen switch OFF.
1. Turn platen switch to 1A or 1M.
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 or breakers and cable
connections.
4. Loose connection in control
panel.
4. Disconnect power supply, remove control panel cover
and check for loose wire connections.
5. Faulty temperature controller. 5. Refer to OMRON instruction manual.
6. Faulty relay.
6.
Disconnect power supply, and remove control panel
cover. Very carefully connect power supply and with
temperature controller OUT light on, check for power
between relay terminals 2-6 and 4-8. If full line voltage is
not measured, relay must be replaced.
7. Loose connection in cable or
platen connector.
7. Remove electrical connector insert from housing and
repair any loose connections.
8. Faulty RTD temperature
sensor.
8. 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.
9. Faulty heating element. 9. Measure the resistance between pins 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.
T1 - Omron Control INSTRUCTION MANUAL Page 12
SHAW-ALMEX INDUSTRIES LIMITED 49900-030 October 2000
Revised Mar03, Jun04, Aug04, Jun05
7.4. Vulcanizer Over Heating
FAULT CORRECTION
1. Temperature set improperly. 1. Ensure that controller set point is correct.
2. Faulty temperature controller. 2. Refer to OMRON instruction manual.
3. Faulty relay.
3.
Disconnect power supply, and remove control panel
cover. Remove the connectors from the power relay
check for continuity between relay terminals 2-4 or 6-8. If
there is continuity, relay must be replaced.
4. Faulty RTD temperature sensor. 4. 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.
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 OMRON instruction manual. Replace
temperature controller
8. Service
8.1. Emergency Service
Contact: Service Department
Telephone: 705 746 5884
1 800 461 4351 (Canada and U.S. only)
Fax: 705 746 9484
Mail: SHAW-ALMEX INDUSTRIES LIMITED
P.O. Box 430
Parry Sound, Ontario
Canada, P2A 2X4
E-mail: [email protected]
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.
/
