Kakanj Air

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
Translation of the original instructions

Vulcanizing Press
Type EMU-Liquid / EMU-Air
Article No. A17-126508
Customer: "Industrija 4B" d.o.o. Kakanj

Obre b.b.
72240 Kakanj
BOSNIA AND HERZEGOVINA
Our Assignment No.: A17-126508
Belt width: 800 - 1400 mm
Voltage: 400 V, 50 Hz, 3~+N+PE
Nominal power: 8.5 kW each heating plate NJL213…C
3.1 kW each heating plate NJL457…C
Specific surface pressure: 90 N/cm² (EMU-Liquid)
70 N/cm² (EMU-Air)
Nominal temperature: 145°C (variable up to 175°C)
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.
Warranty is forfeited in the following situations:
• In the event of improper use of the unit.
• In the event of improper treatment or maintenance of the unit.
• In the event of high-handed alterations to the unit.
• If the operator independently makes repairs to the unit or has them made by third
parties.
• If parts which are not original NILOS parts are used.
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.
Before first commissioning, we recommend that you carefully read the

technical documentation in order to familiarize yourself with the
vulcanizing press and to prevent possible operating errors
08.03.2018/Hi A17-126508_aen.docx
Scope of Supply
1 Assembly Scheme / Installation Plan
2 Safety
Vulcanizing Press
3 Operating Instructions
4 Air Control Box
5 Pressurized Water Unit / Container
6 Pressure Bag / Pressure Bag Adapter
7 Switch Box / Cable
8 Vulcanizing Plates
9 Digital Thermometer
10 Test Certificates / Heating Diagram

SCOPE OF SUPPLY
Vulcanizing Press EMU-Liquid / EMU-Air

page 1/3
7
6
5
4
10
8
9
3
2
1
Assignments to the different bandwidths, see installation plans
Item Article-No. Description Designation Quantity

1 NJL295300A Spacing Rail, 7-fold 2
NJL363400A Spacing Rail, 8-fold 2
2,7 NJL017101B 1 Cross Beam Profile,, 170 kN 150x98x1450 mm 16
NJL029101B 2 Cross Beam Profile,, 375 kN 255x100x1900 mm 14
3
3,4 NJL213100C Top Vulcanizing Plate, 400V 1100x1200 mm, 16.7° 1
NJL213200C3 Bottom Vulcanizing Plate, 400V 1100x1200 mm, 16.7° 1
NJL457100C4 Top Vulcanizing Plate, 400V 400x1200 mm, 16.7° 1
NJL457200C4 Bottom Vulcanizing Plate, 400V 400x1200 mm, 16.7° 1
5 NJZ155000A Pressure Bag 1100x1200 mm, 16.7° 1
NJZ852000B Pressure Bag 400x1200 mm, 16.7° 1
6 NJL080001A Equalization Plate 1100x1200 mm, 16.7° 1
NJL457002A Equalization Plate 400x1200 mm, 16.7° 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

page 2/3
Item Article-No. Description Designation Quantity

8 NJL018102B1 Tension Bolt Unit M30x300, complete 16
comprised:
NJL018103B Tension Bolt M30x300
NJL001104B Tension Bolt Nut M30, right-hand thread
NJL001105B Tension Bolt Nut M30, left-hand thread
NJL043102C2 Tension Bolt Unit M45x350, complete 14
comprised
NJL043103B Tension Bolt M45x350
NJL356303A Tension Bolt Nut M45, right-hand thread
NJL356304A Tension Bolt Nut M45, left-hand thread
9,10 NJL213001A5 Equalization Plate 1500x1200x1.5 mm, 2
16.7°
additional parts
Article-No. Description Designation Quantity

NA164E40024A Switch Box, 400 V NA16 4E 40 024A 1
NG0400028B Cable Set 16 A 4 m long 4
EK1040152 CEE Coupling 400 V 5-fold, 63 A, IP67 1
NJZ085000C 6 Air Control Box 7 bar (100 psi) 1

6
NJZ085200A Connecting Hose 1-fold 1x2.0 m 2
6
NJZ085300A Connecting Hose 2-fold 1x1.5 m / 2x2.5 m 1
6
NJZ511000A Adapter Retrofit pressure bag 2
from EMU-Liquid to
EMU-Air
5
for assembly variant belt width 1200-1400 mm
6
for assembly variant EMU-Air
05.02.2018/Hi LU_A17-126508_aen.docx
SCOPE OF SUPPLY

page 3/3
Article-No. Description Designation Quantity

NJD036000A 7 Pressurized Water Unit, 400 V 1
NJD008000C7 Fluid Container 50 litre 2
NJD011000B7 Hose 2-fold 1x1.5 m / 2x1.5 m 1
NJD011000F7 Hose 2-fold 1x2.5 m / 2x2.5 m 1
NJD012000B7 Hose 1-fold 1x2.0 m 1
EK50101017 Can of Glycol 20 litre 2
NJZ497000A Handles for Vulcanizing Plates 8

NJZ095000C Hose Distributor 2-fold cooling water connection, 4
0.3 m long
K0771 Digital Thermometer GTH 1100/2 2
7
for assembly variant EMU-Liquid
05.02.2018/Hi LU_A17-126508_aen.docx
ASSEMBLY SCHEME
Vulcanizing Press EMU-Air

page 1/1
principle sketch
1. Compressor (optional) 6. Cooling water system

2. Switch box (optional)
3. Air control Box 7. Compressed-air hose
4. Digital thermometer 8. Connection cable (heating
plate / switch box)
5. Vulcanizing press
02.03.2015/Hi AS_EMU-Air_een.docx
ASSEMBLY SCHEME
Vulcanizing Press EMU-Liquid

page 1/1
principle sketch
1. Switch box 5. Container

2. Connection cable (heating 6. Cooling water system
plate / switch box) (optionally)
3. Pressurized water hose 7. Vulcanizing press
4. Pressurized water unit 8. Digital thermometer
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
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.)
Vulcanizing Plate  NJL213000C01
B1 x L1 x H1 1100 x 1200 x 50 mm Dimension of vulcanizing plate

L5 1148 mm Vulcanizing heating plate edge length
H3 35 mm Thickness of pressure bag NJZ155000A
H4 24 mm Thickness of equalization plate NJL080001A
Vulcanizing Plate  NJL457000C01

H3 35 mm Thickness of pressure bag NJZ852000B
H5 1,5 mm Thickness of equalization plate NJL213001A
Cross Beam NJL120X01B

H2 x B2 x L2 255 x 100 x 1900 mm Dimension of cross beam
B3 36 mm Edge distance
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
• 7 pairs of cross beams (NJL120X01B) with a pressing force of each 168 kN
INSTALLATION PLAN
EMU-Liquid-Air
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
INSTALLATION PLAN
EMU-Liquid-Air
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.)
Vulcanizing Plate NJL213000C01

H3 35 mm Thickness of pressure bag NJZ155000A
Cross Beam NJL151X00A

H2 x B2 x L2 150 x 98 x 1450 mm Dimension of cross beam
B3 30 mm Edge distance
Attention! EMU-Liquid
• max. set pressure at the pressurized water unit (NJD036000A) 9 bar
• 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
• 8 pairs of cross beams (NJL151X00A) with a pressing force of each 105 kN
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
Vulcanizing press EMU

page 1/8
Table of Contents:
1. About these operating instructions ..................................................................1
2. Basic safety instructions .................................................................................2
1. About these operating instructions
1.0 Terminology
Vulcanizing Press:
System: Vulcanizing press and components (for example switch box,

Air Control Box resp. pressurized water system)
1.1 Purpose
These operating instructions are part of the system and describe the safe, proper use
in all operating phases.
• Please read the operating instructions carefully before commencing work,

especially chapter 2. Basic safety instructions.
• Keep the operating instructions during the entire service life of the system.
• Make the operating instructions accessible to the personnel at all times.
• Pass on the operating instructions to all subsequent owners or users of the

system.
• Insert all supplements received from the manufacturer.
1.2 Scope
These operating instructions apply only to the system specified on the cover sheet.
1.3 Target groups
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

page 2/8
1.4 Symbols and markings
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
CAUTION Information for preventing damage
NOTE Notes to understand or optimize work processes
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.
2. Basic safety instructions
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.
SAFETY

page 3/8
2.1 Proper use
The vulcanizing press is intended exclusively for:
EMU-Air: splicing of fabric conveyor belts with a surface pressure of up to

70 N/cm2 and should only be connected to a compressed air supply.
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").
Any other usage is considered improper.
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 vulcanizing press is not suitable for:
EMU-Air: splicing of steel cord belts
EMU-Liquid: splicing of fabric belts.
The system may not be used in areas in which special requirements are placed on
explosion protection.
2.2 System part identification
The main system parts can be identified using the attached type plates.
2.3 Structural changes, repairs
• Do not make any changes, attachments or modifications to the system without

the manufacturer's explicit approval.
• Only original replacement parts supplied by the manufacturer may be used.
SAFETY

page 4/8
2.4 Owner's duties
Staff Selection and qualification
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.
• The legally stipulated statutory age for personnel must be observed.
• Only trained or instructed personnel may be used.
• Clearly define the responsibilities for the various activities as part of system
operation.
• Only allow personnel to be trained, instructed or those in training to work on the

system under the constant supervision of an experienced person with the right to
issue directives.
• Only allow work on electrical equipment to be carried out by a trained electrician

or by instructed persons under the direction and supervision of a trained
electrician in accordance with the rules of electrical engineering.
• Only allow work on pneumatic or hydraulic equipment to be carried out by expert

personnel with special knowledge and experience in the field of pneumatics.
• Only have the system transported by personnel instructed accordingly.
Organizational measures
• Ensure that all staff have read and understood these operating instructions.
• In addition to these operating instructions, all applicable general legal stipulations

and other mandatory regulations concerning accident prevention and
environmental protection must be observed and instructed.
• Regularly train the personnel in the safe use of the system.
• 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.
• Provide personal safety equipment.
SAFETY

page 5/8
2.5 Duties of personnel
• Observe the safety precautions and warnings listed in these operating

instructions and the safety precautions and safety symbols attached to the
system.
• Personal safety equipment must be worn whenever necessary or required by law.
2.6 Safety symbols on system
Safety Symbol Meaning Location
Danger from hot surfaces Heating plate
Danger from electrical voltage Switch box
2.7 Personal safety equipment
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
2.8 Safety measures for certain operating phases
Transport
• Only have the system transported by personnel instructed accordingly.
• Secure the system parts against falling prior to transport.
• Make sure that the load is securely fastened and is lifted horizontally.
SAFETY

page 6/8
• Make sure that the transport route offers sufficient space and is clear of
obstacles.
• Send persons standing around out of the danger area.
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).
• Do not transport the vulcanizing press while assembled.
Installation and connection
• 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.
• Only use pressure bags with the corresponding hose connectors.
• Route the cables and hoses so that they do not form tripping hazards.
Normal operation
• All unsafe work procedures are strictly prohibited.
• Only operate the system when in a safe, operational condition.
• Never leave the system to work unsupervised.
Maintenance
• All mandatory cleaning and servicing procedures must be carried out.
Malfunctions
If the electronically controlled temperature control fails, vulcanizing can be continued

with manual temperature regulation of the vulcanizing plates.
• Have the fault eliminated immediately after completing the vulcanizing.
SAFETY

page 7/8
2.9 Residual risks
Dangers from electrical energy
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.
Dangers from pressurized components
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.
• Never aim compressed air at persons.
Risk of injury from small flying objects (e.g. chips, dust).
Dangers of hot surfaces
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.
SAFETY

page 8/8
Dangers from sharp-edged threads
Abb. 1 Sharp-edged threads on tension bolt
The threads [1] of the tension bolt can cause lacerations.
• Wear suitable protective gloves.
• Only touch the tension bolt in the center.
• Do not touch the threads of the tension bolt.
Danger due to escaping water vapor
Water vapor develops during the cooling process. Hot water and escaping water vapor
can cause burns and scalding.
• Safely drain off the cooling water.
• Please ensure the proper connection of all cooling water hoses.
• All hose connections must be regularly inspected for damage and leakage. All
damage must be repaired immediately.
2.10 Behavior in an emergency
• Inform supervisor.
• Decide whether to terminate the vulcanization process. If yes:
• Disconnect power supply.
• Release pressure and dismantle press. Danger of burns on the

vulcanizing plate and on the adjacent components!
OPERATING INSTRUCTIONS
EMU Vulcanizing Press

page 1/12
rev. C
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.
Two different pressure systems are available:

• Pressure bags fitted to be connected to a pressurized water system or a pump
(additional pressure up to 14 bar/200 psi max.)
• Pressure bags fitted to be connected to a pressurized air supply (additional

pressure up to 7 bar/100 psi max.).
The vulcanizing presses comprise:
• 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.
• Hot plate / cooling plate to generate the vulcanization temperature.
• 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.
• Individually customized pressure supply system (accessory).
Optional:
• Equalization plates (made of stainless steel)
• Edge bar clamping device.
30.11.2017/Hi BA_Presse-EMU_aen_C.docx

page 2/12
rev. C
1.1 Heating system
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.
1.2 Cooling system
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.
1.3 Pressure system
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.

page 3/12
rev. C
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.
2. Installation of the press
2.1 Requirements for installation location
• 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.
2.2 Installing and connecting vulcanizing press
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").

page 4/12
rev. C
CAUTION
• Damaging of vulcanizing press when pressure is exceeded!

• Observe maximum permissible pressure (see chapter "Scope of Supply /
Installation Plan").
NOTE
Only use pressure bags with the corresponding hose connectors.
• Put the spacing rail elements (if applicable; they can be 7

obtained as optional accessories) on a secure 6
base (pos. 1) and arrange them correctly. Attach
5
the lower cross beams with the right spacing and
align them correctly in vertical direction and
parallel to each other. The base must be able to 4
support the vulcanizing press safely and 10
securely. 8
9
• Assemble and align the bottom cross beam
profiles (pos. 2) in the spacing rails (pos. 1). 3
• Lay down the lower vulcanizing plate(s) (pos. 3) with the 2

pressed cooling sheet facing the belt. The accessory catalogue features 1
articles which allow the operators to lift the vulcanizing plates correctly.
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.
• Press with equalization plates (pos. 9):

Lay down the equalization plates onto the hot plates / cooling plates.
• Prepare the belt in compliance with the instructions issued by the belt
manufacturer.
• Press with equalization plates (pos. 10):

Lay down the equalization plates onto the conveyor belt.

page 5/12
rev. C
• Press with edge bars:

Assemble the edge bars - which should be slightly thinner than the belt - at each
side 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.
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
Connect connection cable to switch box and lock connector.

page 6/12
rev. C
Version 3
• Turn protective caps [A] to side.
• Pull off connector covers on connection

cables. B
• On one side unlock plug (position of rotating

handle: vertical).
• Connect connection cable to heating plates

and lock connector (position of rotating A
handle: horizontal [B]).
• Connect connection cable to switch box and lock connector.
• 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
• Damage to the pressure bag by foreign bodies!

• Before laying on the pressure bag, sweep off the surface of the heating plates and
of the pressure bag or clean with a damp cloth. Do not use cleaners containing
solvents.
• Do not carry or pull the pressure bag by the connection.
CAUTION
• Damage to hoses in case of overtemperature!

• Make sure that the hoses do not come into contact with the heating plates. The
hoses are heat-resistant up to a maximum of 120 °C/250 °F.
• 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.

page 7/12
rev. C
WARNING
• Danger of scalding by escaping water vapor or hot water!

• Ensure proper connections.
• Put on the upper cross beam profiles (pos. 7) and align them with their lower
counterparts.

Put the edge ledge pressure devices into their designated places (see installation
plan).
• 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.

page 8/12
rev. C
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.
• Vulcanizing presses with heating plates in combination:

The pressure supply is to be switched on with the achievement of 80 °C.
• Vulcanizing presses without heating plates in combination:

The pressure supply can already be switched on at the beginning of the heating-
up.

Apply an initial pressure of about 3 bar (43 psi) to the vulcanizing press. Press
the edge ledges against the edges of the belts by pulling the edge ledge pressure
devices tight, and apply the amount of pressure to the vulcanizing press which
has been identified in the installation plan.
• 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
• Danger of burns on the heating plate and on the adjacent components!

• Avoid touching.
• Wear personal safety equipment.

page 9/12
rev. C
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.

page 10/12
rev. C
WARNING
Danger of scalding by escaping water vapor or hot 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.
3.1 Vulcanization of PVC belts
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.
4. Dismounting of the Press
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.

page 11/12
rev. C
• Disconnect switch box from electrical system.
• Disconnect connection cable of heating plates: Unlock connector by turning

rotating handle and pull off.
• Disconnect hose connector for cooling water if present.
• Remove tension bolt units and take off cross beams, equalization plate, pressure
bag and upper heating plate.
• Remove conveyor belt.
• Remove lower half of vulcanizing press.
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
The EMU vulcanizing press is basically maintenance-free.

• The vulcanizing press has to be cleaned regularly and stored dry.
• The pressure bags must be checked for signs of damage and kept clean.
• The threads of the tie bolts must be greased regularly and checked for signs of damage.
• All electric cables must be checked for kinks and signs of damage.
• All hose connection systems must be checked for signs of damage and leaks.
When not used, they must be stored with their protective covers in place.
The maintenance instructions for the switch box, pressurized water unit or air control
box can be found in the respective operating instructions.
6. Storage
When storing over a longer period, take the following measures to prevent harmful influences:
• Protect with dry, dust-tight packing

page 12/12
rev. C
• Protect against high humidity by using desiccants
• Protect against direct sunlight and extremely high temperatures
• Protect against extreme cold
• Protect against corrosive environment (e.g. sea air)
• Protect against formation of condensed water
Make sure that the storage location meets the following conditions:
• Vibration-free
• Protected from dust
• Protected from water
• Frost-free
• Free of high temperature fluctuations
Comply with ambient conditions (see Tab. 1, page 12).
6.1 Vulcanizing press
• Protect the pressure bag from oily media.
• Completely remove residual water and soiling from the cooling ducts of the
heating plates, e.g. with compressed air.
• Grease the threads of the tension bolts.
6.2 Ambient conditions during storage
Reference Quantity Value

Temperature +5 °C up to +50 °C/+40 °F up to +120 °F
Relative humidity 65 % (Note: these values are favorable storage conditions)
Tab. 1: Ambient conditions
7. Disposal
Recycle or dispose of system parts, electrical and electronic components of one kind in
accordance with the local regulations.
Air Control Box

Article-No.: NJZ085000… page 1/3
rev. A
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.
2. Connections, operating and display elements

1 2
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
04.07.2016/Hi BA_Druckluftsteuerung-7bar-100psi_aen_A.docx
Air Control Box

rev. A
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.
Air Control Box

rev. A
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
SPARE PARTS LIST
Air Control Box

Article-No.: NJZ085000... page 1/2
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
Pos. Article-No. Description
2 x x x x x EK31127051 pressurized air control dial G1/4''

3 x x x x x EK3112316 cross distributor G1/4"
4 x x x x x EK3110225 safety valve 7.5 bar, G1/4"
5 x x x EK3112403 silencer G1/2"
x x EK3112404 silencer G1/2"
6 x x x x x EK3111573 hexagonal counter nut G1/2"
7 x x x x x EK3112233 toggle lever valve G1/4"
8 x x x x x EK3112710 push-in elbow fitting G1/4"
9 x x x EK3150020 pressure gauge 0-10 bar, ø 40
x x EK31500201 pressure gauge 0-150 psi, ø 40
27.02.2015/Hi EL_NJZ085_aen.docx
SPARE PARTS LIST
Air Control Box

Article-No.: NJZ085000... page 2/2
NJZ085000G
NJZ085000C
NJZ085000D
NJZ085000E
NJZ085000F
10 x x x x x EK3112712 push-in elbow fitting G1/8"

11 x x x x x EK3112711 push-in elbow fitting R1/4"
12 x x x x x EK3081802 hose ø8x1.25, 0.7 m
13 x x x x x EK3112470 sealing ring G1/4''
14 x x x x x EK3112461 sealing ring G1/2"
15.1 x x EK31101060 coupling DN7.2, G1/4
x x EK31101080 coupling DN7.2, G1/4
x EK3110093 coupling DN5, G1/4
15.2 x x x x x EK3112475 sealing ring G3/8''
16 x x x EK3110113 male connector DN7.2, ø13 mm
x x EK3110115 male connector DN7.2, ø13 mm
27.02.2015/Hi EL_NJZ085_aen.docx
Pressurized Water Unit

Specification: 230 V 1~, 230 V - 500 V 3~, page 1/6
50/60 Hz rev. C
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
17 6 Pressure control valve

working pressure + 10%
3 15 7 Drain valve
8 Pressure gauge
Fig. 1 Pressurized water system (principle sketch) 15 Mounting board
16 Electrical control
(not shown in Fig. 1)
17 Socket spanner
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.
Only a mixture of 50 % water and 50 % glycol may be employed as a pressure fluid.

The quantity of pressure fluid depends on the size and number of pressure bags to be
admitted and is kept in corresponding fluid reservoirs.
13.01.2015/Hi BA_DWA-stationaer_cen_C.docx

50/60 Hz rev. C
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.
• Do not exceed the maximum permissible pressure and max. operating

temperature under any circumstances.
• Ensure that all movable parts, such as shaft and couplings, are covered properly
and protected before the system is switched on.
• Check hoses for leakage and damage before every application.
• Note properly secured plug connections.
• Disconnect the pressurized water system from the electrical network before
maintenance operations.
3. Assembling and Commissioning
• 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").
• Vent the system (see Chapter "6. Ventilation of the System").
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.

50/60 Hz rev. C
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.
Connect the pressurized water system to the electrical network.
• Switch on the main power switch at the electrical control.
Caution
Damage by dry running!

• The pump must not run dry.
• 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.
On reaching the vulcanization temperature, the maximum valid pressure preset

for the vulcanizing press must be reached (see also installation plan).
If the maximum preset pressure is exceeded by approx. 1 bar, a safety valve

opens and the pressure falls below the maximum value. With renewed switching
on of the pressurized water system, the pressure again begins to build up to the
maximum preset pressure.
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.

50/60 Hz rev. C
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
Damage by dry running!

• Make sure that during pumping out of the pressure bags the pumps does not
run dry.
• Then the pressurized water system can be reduced in reverse order.
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
• The pressurized water system is to a large extent maintenance-free. The hose

connections are to be kept clean and provided with their protective caps when not
being used.
• The glycol concentration in the pressure fluid is to be checked regularly and
regenerated, where appropriate.
• Check the filter elements on the connection block regularly for dirt accumulation,
and clean.
• The shaft bearings of the pumps are to be lubricated every 50 hours operating
time, or at monthly intervals.
• The pressurized water system and its components are to be protected against
moisture, vibration, and increased ambient temperature through direct solar
radiation. They are to be cleaned regularly and kept dry.
• Repairs are to be carried out by authorized skilled personnel exclusively.

50/60 Hz rev. C
5. Faults and Remedies
Faults Possible cause Remedy

No pressure build-up Suction and pressure Check hose connections.
connection interchanged Fluid reservoir must be connected at
the suction connection and pressure
bag at the pressure connection.
Drain valve not closed Close drain valve
Pressurized fluid quantity Check liquid level in the auxiliary con-
not sufficient tainer. Maximum filling level must be
guaranteed before operational start-up.
Pump runs dry Switch off pressurized water system
immediately. Check liquid quantity
and filter elements.
Filter elements are dirty Remove filter elements on the
connection block and clean them.
Air in the system See chapter "6. Ventilation of the
System"
Pressure is not Safety valve has opened Bleed off pressure at the drain valve
maintained by 3 - 4 bar until valve closes again.
Leakiness in the Check pressure bags, hoses and
hydraulic system couplings for sealing.
Non-return valve does not Remove non-return valve (a) with
close socket spanner (b - see spare parts
b
list) and check for damage and/or
dirt accumulation
a
Fig. 2 Non-return valve dismantling

50/60 Hz rev. C
6. Ventilation of the System
A E G C A. Pressurized water unit

D B. Fluid reservoir
C. Vulcanizing press
D. Pressure bag
E. Hose to the pressurized
F
water system
F. Plug-in nipple
G. Quick-disconnect
B coupling
Fig. 3 Ventilation (principle sketch)
A ventilation of the system is necessary in the following cases:
• Before the pressurized water system is connected to the vulcanizing press.
• If insufficient pressure builds up and other alternatives for remedying have not
provided any result (see "5. Faults and Remedies").
The following operation steps are necessary:
• 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.
TECHNICAL DATA

Article No.: NJD036… / WJD036… page 1/4
rev. A
Table of Contents:
1. Technical Data ................................................................................................1
2. Hydraulic plan .................................................................................................2
3. Wiring Plan......................................................................................................4
1. Technical Data
Operating and limit values

Set pressure on the ≤ 12,0 bar
pressurized water unit
Pressure medium Mixture of 50 % water and 50 % glycol
Tab. 1: Operating and limit values
Dimensions
Length 520 mm
Width 305 mm
Height 640 mm
Tab. 2: Dimensions
Weight
Value
26.0 kg
Tab. 3: Weight
Parameter
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

rev. A
WJD036000F
NJD036000G
NJD036000D
NJD036000N
NJD036000B
Nominal voltage 230 V

Frequency 50 Hz x x x x
60 Hz x
Number of poles 1~+N+PE x x x x
3~+PE x
WJD036000G
WJD036000D
WJD036000A
NJD036000A
NJD036000F

Frequency 50 Hz x x x x x
Number of poles 3~+N+PE (CEE) x x x
3~+PE (CEE) x
6-pole (Harting) x WJD036000C
WJD036000B
NJD036000C
NJD036000H
NJD036000L
NJD036000J

Frequency 50 Hz x
60 Hz x x x x x
Number of poles 3~+N+PE x x x
3~+PE x x x
WJD036000E
NJD036000E
NJD036000K
NJD036000I
Nominal voltage 480 / 500 V

Frequency 50 Hz x x
60 Hz x x
Number of poles 3~+N+PE x
3~+PE x x x
Tab. 4: Parameter
TECHNICAL DATA

rev. A
2. Hydraulic plan
P S
1 working pressure + 10 %
2 working pressure
TECHNICAL DATA

rev. A
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
SPARE PARTS LIST

Specification: 400 V, 50/60 Hz page 1/2
rev. A
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 x x x x x EK30300153 Pump HYPRO-5324 400 V, 50 Hz, 5-pole
comprised:
1.1 x x x x x EK3020171 Pump Hypro-5324C
1.2 x x x x x EK30300232 Coupling R19ST14-ED
1.3 x x x x x Electric motor 380-420 V, 50 Hz, 0.37 kW
resp. 1
380-480 V, 60 Hz, 0.37 kW
1.4 x x x x x EK30300233 Control block 6802130
with
EK30300137 non-return valve RVE-10
1.5 x x x x x EK3060428 Pressure limiting valve RDBA-LSN
1.6 x x x x x EK3060428 Pressure limiting valve RDBA-LSN
1.7 x x x x x EK30300134 Blow-off valve DV5E-01X
1
corresponding to the customer's mains supply
13.09.2016/Hi EL_DWA-400V-NJD036-WJD036_aen_A.docx
SPARE PARTS LIST

Specification: 400 V, 50/60 Hz page 2/2
rev. A
WJD036000G
WJD036000D
WJD036000A
NJD036000A
NJD036000F

1.8 x x x x x EK3150002 Pressure gauge 0-25 bar
2 x x x x x EK3050521 Filter element 500 bar
EK31100141 Plug-in nipple G1/2"
EA04526001 Protective cap
EK5200641 Key ring ø20
EK5580101 Chain ø1.6
3 x x NJD007E00B Electric control 400 V, 50/60 Hz, 5-pole, IP44
comprised pos. 3.1 - 3.3 and
EK1030107 Plug 400 V, 5x16 A, IP44
x NJD007E00E Electric control 400 V, 50/60 Hz, 5-pole, IP67
EK1030109 Plug 400 V, 5x16 A, IP67
x NJD007E00F Electric control 400 V, 50/60 Hz, 4-pole, IP44
EK1030039 Plug 400 V, 4x16 A, IP44
x NJD036E00B Electric control 400 V, 50/60 Hz
EK10301733 Hood M25
EK1030174 Male insert 500 V, 16 A
3.1 x x x x x EK1010307 Motor protective switch 1-1,6 A
3.2 x x x x x EK10711514 Reducing spout M25/M20
3.3 x x x x x EK1130152 Rubber-sheathed hose 4x1.5 mm2
4 x x x x x EK62603070 Socket wrench RVE 10
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
Item Article-No. Description

1 x EK7410201 Container 30 litre
x x EK74102060 Container 50 litre
2 x x x EA04102807 Sealing ring 17x22x2
EK3111581 Hexagonal counter nut G3/8"
EK5580101 Chain ø1,6
and pos. 2.1
2.1 x x EK3110014 Plug-in nipple G3/8"
x EK31100147 Plug-in nipple G3/8"
3 x x EK3060141 Drain valve G1/4"
EA04102808 Sealing ring 13x18x1.5
x EK30601411 Drain valve G1/4"
EA04102808 Sealing ring 13x18x1.5
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

4 x x x EK5200641 Key ring ø20
EA04102807 Sealing ring 17x22x2
5 x x EA04524131 Elbow connector G3/8"
x EK31120097 Elbow connector G3/8"
6 x x x EA04102807 Sealing ring 17x22x2
EK5580101 Chain ø1,6
and pos. 6.1
6.1 x x EK3110014 Plug-in nipple G3/8"
x EK31100147 Plug-in nipple G3/8"
7 x x x EA04524001 Hose nozzle G3/8", øi13
8 x x x EA04512001 Hose 1/2", øi=13
EK52006542 Hose clamp ø18.8-21.1
9 x EK74102101 Cover
x x Cover
-
22.12.2015/Hi EL_Behaelter_aen_B.docx
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.
Pressurized fluid (water-glycol-mixture) with a maximum pressure of 14 bar (200 psi)

can be applied to the pressure bags.
2. Safety
It is not permitted to apply pressurized air with a pressure in excess of

14 bar (200 psi).
Pay attention to the pressure details of the vulcanizing press.

The maximum pressure must not be exceeded under any circumstances.
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).
The pressure bags are heat-resistant at temperatures up to 75° C (165° F).The

pressure bags may not heat up above 75° C (165° F) and must be insulated against
the heating surfaces of the press.
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
storage temperature -10 °C up to +50 °C  15 °F up to 120 °F

relative humidity max. 65 %
07.07.2014/Hi BA_Druckkissen-Liquid_aen_A.docx
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.
The pressure bags have a limited service life of 6 years.
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
Item A B Article-No. Designation

1 x x pressure bag
2 x EK3112115 T-connection G3/8"
3 x EA04102807 sealing ring 17x22x2 mm
EK31101092 coupling DN 7.2, G3/8"
EA05218001 protective cap
4 x EA04102807 sealing ring 17x22x2 mm
EK3110804 reducing nipple G3/8"
5 x EK3110226 mini-safety valve G1/4", 7.2 bar
EA04102808 sealing ring 13x18x1.5 mm
12 x EK3112004 angle-connection G3/8"

13 x EK3110015 coupling, nipple type G3/8"
EA04526001 protective cap
EK5200644 key ring ø 25 mm
EK5580101 chain ø 1.6 mm
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.
Make sure the installation position is correct! The adapter is plugged

onto the pressure bag connection with the unlocked coupling; the
coupling is open on the hose end.
Hose end
Coupling open
Pressure bag end

Coupling unlocked
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
The pressure bag must be completely emptied before retrofitting from

fluid to compressed air.
The pressure in the pressure bag must be completely relieved before
pulling the adapter or the hose.
Hydraulic pressurization of more than 7 bar (100 psi) is forbidden.
A built-in safety valve at the pressure bag adapter limits the max.
pressure in the pressure bag to 7.2 bar (104 psi) and must not be
adjusted.
Only use the pressure bag adapter for compressed air.
4. Spare parts
Item Article no. Name Designation Quantity

1 EK31101070 Coupling, unlocked Nom. dia. 7.2, G3/8" 1
1a EK31101092 Coupling, open Nom. dia. 7.2, G3/8" 1
2 EK3112115 T screw connection G3/8" 1
3 EA04102807 Sealing ring 17x22x2 mm 3
4 EA05218001 Protective cap 2
5 EA04524131 Male connector G3/8" 1
6 EA04102808 Sealing ring 13x18x1.5 mm 1
7 EK3110804 Reduction nipple G3/8" 1
8 EK3110226 Mini safety valve G1/4", 7.2 bar 1
22.12.2017/Hi AA_Druckkissen-Umbau_Liquid-Air_ben_B.docx
Switch Box: 4-fold

page 1/4
rev. A
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.
Operator and display elements are placed behind a protective cover.
14.11.2014/Hi BA_Schaltschrank-4E-24_aen_A.docx
Switch Box: 4-fold

page 2/4
rev. A
The following elements are on the front side:
Main switch (1S1) Current supply ON
Electronic controller (4U7) Temperature control plates 1, 2, 3 ,4

Set temperature
Set vulcanizing time
RESET timer
Illuminated selector (5S2, 5S4, Operating mode (manual-off-automatic)

switch, green 5S6, 5S8) Illuminating function when the heating plates
are energized
Signal lamp, white (3H6) Main control voltage

Motor protective switch ON
Electronic buzzer (3H7) acoustic signal for end of vulcanizing time
The following elements are on the left-hand side:
CEE-type socket (1X3) Heating current to plate 1
CEE-type plug (1X1) Connector to mains supply
The following elements are on the right-hand side:
CEE-type socket (3X1) Connector to electric tools
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.
• If necessary connect additional electric tools to socket 3X1.

Switch Box: 4-fold

page 3/4
rev. A
• 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.
In case one phase of the mains supply is interrupted, the residual-current

operated circuit breaker (RCCB) is activated or the protective motor switch is
released, the white signal lamp 3H6 goes out and the switch box does not
function.
2.2 Vulcanization
• Adjust vulcanizing time and set temperature at electronic controller 4U7.
• 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.
• The heating procedure is started and is regulated to be led up to the set

temperature. Once the set temperature is achieved, the previously selected
vulcanizing time is started. The end of the vulcanizing time is displayed by a LED
on the electronic controller as well as an acoustic signal of the buzzer 3H7.
• 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
• The vulcanizing time can be disconnected by pressing the RESET button

on the electronic controller.
• In case of malfunction of the electronic temperature control, each heating

plate can be switched ON and OFF manually by setting the green selector
switches 5S2, 5S4, 5S6 + 5S8 in the manual switch position (key
position). For manual operation mode the illuminated selector switch must
remain in its position. Temperature control must take place with external
temperature measurement equipment.
Switch Box: 4-fold

page 4/4
rev. A
• 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.
• Repairs may only be carried out by approved electrical professionals.
5. Explanation of the pictograms

Phase control light, white
Mains voltage is required, motor protective switches are
switched on
Buzzer, yellow
Vulcanizing time expired
Selector switch; green

Selection: Manual control (key position)

Selection: Automatic control (lock position)

0 Heating plates in OFF mode
... Heating current channel (heating plate) 1 to…
Electronic controller:
Set vulcanizing temperature dial
Set vulcanizing time dial
Timer Reset push button – record malfunction
Electronic Controller "MultiControl Compact"

page 1/6
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.
1.1 Monitoring temperature differences

The unit is equipped with a system for monitoring temperature differences. At a temperature
difference of +/- 5°C between the channels, the heating in the relevant channel is disconnected
or the relevant channel is heated up so that all channels are led to the same approximate
target values.
25.06.2013/Hi BA_Regler-Multicontrol_aen.docx

page 2/6
2. Operational and display elements
17
2 3
1 4
6 7
8
12
9 13
10 14
11 15
16
Front view of the MultiControl Compact
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

page 3/6
2.1 LED explanations
LED (see illustration 1 on page 2) Display

8 or 10 Active control contact for channels 1-4
9 or 11 Achievement of a channel target value
12 The selected channel in automatic operation.
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
2.2 Display readout

Set target temperature
0 °C 200°C 0°C
Current actual
temperature in channels 0 °C 20Min 0°C
1-4
Units with timer function:

Display of the remaining
3. Different operation levels vulcanisation time
In operational mode
Operator level:
 Setting the vulcanization temperature (see

chapter 3.1 Vulcanization temperature operator
level)
 Setting the vulcanization time (see chapter 3.2

Vulcanization time operator level)

page 4/6
3.1 Vulcanization temperature operator level
The target value setting for the vulcanization temperature takes place with the vulcanization
temperature key.
In operational mode
Press briefly
Entry to the operator level and display of the

previous setting of the parameter value
Vulcanization temperature
120.0 °C
- + [X]
 Setting the parameter value
 Return to the operation mode without

acceptance of the changed value
 Accept the current or set parameter value

and return to the operation mode
   

page 5/6
3.2 Vulcanization time operator level
The target value setting for the vulcanization time takes place with the vulcanization time key.
In operational mode
Press briefly
Entry to the operator level and display of the

previously set parameter value
Vulcanization time
2 Min
- + [X]
 Setting the parameter value
 Return to the operation mode without

acceptance of the changed value
 Accept the current or set parameter value

and return to the operation mode
   

page 6/6
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.
SPARE PARTS LIST
Switch box 4-fold, 16 A

page 1/2
rev. A
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
3 4 5K1 5K5 5K3 5K7

5S6 4U7 5S8
1X6 2X6
3H6
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
EI1 Article-No. Description

1Q3, 1Q6, x x x x x x x EK10104111 motor protective switch 13-18 A
2Q3, 2Q6
3Q3 x x x x x x x EK1010401 motor protective switch 0.25-0.40 A
3Q1 x x x x x x x EA02337502 motor protective switch 4-6.3 A
5K1, 5K3, x x x x x x x EA02339941 contactor 18/32 A, 24 V, 50/60 Hz
5K5, 5K7
3K4 x EA02339813 contactor 230 V, 50/60 Hz
x x EK10101257 contactor 6 A, 400 V, 50/60 Hz
x x EK10102244 contactor 440 V, 50/60 Hz
x x EK10102248 contactor 500 V, 50/60 Hz
3F5 x x x x x x EK1020010 circuit breaker 1-pole, 6 A
x EK1020015 circuit breaker 1-pole, 4 A
1
Equipment identifier
04.05.2017/Hi EL_Schaltschrank-4E-24-16A_aen_A.docx
SPARE PARTS LIST
Switch box 4-fold, 16 A

page 2/2
rev. A
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
EI1 Article-No. Description

1F1 x x x EK1010282 residual-current operated circuit breaker (RCCB)
4 pole, 400 V, 63 A
x x x x EK10102961 residual-current operated circuit breaker (RCCB)
4 pole, 400/500 V, 63 A
3T3 x x x x x x x EK1000052 transformer 100 VA, prim. 230-500 V, sec. 24/48 V
4U7 x x x x x x x EK3240129 multi compact controller
1S1 x x x x x x x EK1010728 main switch 3-pole, 63 A, IP66
5S2, 5S4, x x x x x x x EK10803309 illuminated selector switch, head, green
5S6, 5S8 EK10803313 auxiliary switch block 24 V, LED green
3H6 x x x x x x x EK10803672 pilot light 24 V, LED white
3H7 x x x x x x x EK10603600 electronic buzzer 24 V, 85 dB
1X3, 1X6, x x x x x x x EK1040445 CEE-mounted socket 7 pole, 16 A, 500 V, IP44
2X3, 2X6
3X1 x EK1040285 CEE-mounted socket 4-pole, 16 A, 230 V, IP44
x EK1040288 CEE-mounted socket 4-pole, 16 A, 400 V, IP44
1X1 x EA025366 CEE-plug 5-pole, 63 A, 500 V, IP67
x EK10300770 CEE-plug 4-pole, 63 A, 230 V, IP67
... x x x x EA02111705 rubber-sheathed hose 4x16 mm2
x x x EA02111706 rubber-sheathed hose 5x16 mm2
04.05.2017/Hi EL_Schaltschrank-4E-24-16A_aen_A.docx
SPARE PARTS LIST
Cable connecting set

Specification: 16 A, 500 V page 1/1
2 1 3
NG0400028H
NG0400028A
NG0400028B

1 x EK1160210 rubber-sheathed hose 7x2.5 mm²
length 3 m
x EK1160210 rubber-sheathed hose 7x2.5 mm²
length 4 m
x EK1160210 rubber-sheathed hose 7x2.5 mm²
length 10 m
2 x x x EK1030183 CEE-plug 7-pole, 16 A, 500 V, IP44
3 x x x NG0100018A coupling 6x35 A, complete
comprised:
hood
female insert
screwed cable gland M25x1.5
locking left/right
08.07.2014/Hi EL_NG0400028_aen.docx
/

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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.
1.1 Heating system
The heating system comprises of silicone-heating mats, embedded between pressed

sheets and thermo insulating plate. The silicone-heating mats reach their heating
power by optimum temperature distribution and low power consumption.
The maximum temperature for silicone-heating mats amounts 175 °C.
1.2 Temperature control system
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.
The temperature detectors are designed as double PT100 resistance

thermometers. In the event of failure of one PT100 the second PT 100 is
put into operation by changing connections, using the red instead of the
white connecting leads.
In order to rule out any confusion, the connecting leads of the defective
PT100 are to be cut off.
Only when the second PT100 fails must the temperature detector be
replaced (see replacement instructions).
25.06.2013/Hi BA_Heizplatte-EMU_Duolock-Harting_aen.docx
Vulcanizing Plates
1.3 Cooling system
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.
2. Mounting of the vulcanization heating plate
see also operating instructions "EMU vulcanizing press"
• 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.
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.
• 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.
Vulcanizing Plates
3. Commissioning
see also operating instructions "EMU vulcanizing press"
• 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.
• In the event of failure of the electronically controlled temperature control system,

the vulcanization heating plates must be switched off manually when the
SETPOINT temperature is reached (disconnect from the mains supply).
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.
REPAIR INSTRUCTIONS
EMU-Vulcanizing Heating Plate

Plug connector, heating element and temperature sensor PT100 page 1/8
rev. B
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
1. Structure of the EMU vulcanization heating plate
2.1
6 6.1 6.2 6.3 6.4 9 8 7
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

rev. B
2. Replacement of pin insert, temperature sensor PT100 and heating element
The replacement of plug connector, heating element and PT100 temperature sensor
necessitates the following work steps:
2.1 Replacement of pin insert
2.1.1 Dismounting of pin insert
1. Loosen and remove screws at pin insert.
2. Pull out pin insert.
NOTE
Pay attention to the mounting position of the plug!
3. Loosen connecting cables for PT100, heating element and earth connection at
the pin insert [6].
2.1.2 Mounting of pin insert
1. Mounting in the reverse order.
NOTE
For pin wiring see chapter 3 "Pin wiring" and chapter 4 "Alternative connections"
and the documentation supplied with the press.
CAUTION
Danger of short circuits!

When connecting the cables make sure the pins are connected correctly.
REPAIR INSTRUCTIONS

rev. B
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.
2.2 Replacement of temperature sensor PT100
2.2.1 Dismounting of temperature sensor
1. Unscrew cover plate [1] and remove.
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.
4 Remove earth cable at temperature sensor [7].
5 Loosen slightly covering [6.4] from sealings [6.3].
6 Remove temperature sensor PT100 [8].
REPAIR INSTRUCTIONS

rev. B
2.2.2 Mounting of temperature sensor
1. Mounting in the reverse order.
NOTE
CAUTION

CAUTION
Risk of damage!
NOTE
CAUTION
REPAIR INSTRUCTIONS

rev. B
2.3 Replacement of heating element
2.3.1 Dismounting of heating element
1. Dismounting of pin insert [6] and

temperature sensor [8] (see chapter 2.2.1
Dismounting of temperature sensor).
Positions from 6.1 to 6.4

will not be dismounted.
8
6 6.1 6.2 6.3 6.4
2. Unscrew insulation plate [2] and remove.
3. Remove earth cable for intermediate plate [9].
4. Remove intermediate plate [3] and heating element [4].
2.3.2 Assembling of heating element
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].
REPAIR INSTRUCTIONS

rev. B
NOTE
CAUTION

CAUTION
Risk of damage!
NOTE
CAUTION
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].
REPAIR INSTRUCTIONS

rev. B
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
REPAIR INSTRUCTIONS

rev. B
4. Alternative connections
4.1 Three phase power supply
R1-Rn Platte R1-Rn Platte

Platen Platen
2x PT100 2x PT100
(L1) (L2) (L3)
(L1) (L2) (L3) WH WH WH WH WH WH
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
Single heating element Split heating element
4.2 Single phase AC power supply
Platte
R1-Rn Platen
2x PT100
(L1) (L1) (N) WH WH WH
X1 1 2 3 4 5 PE 6
Kabel/cable
7x2,5 mm²
1 2 3 4 5 PE 6
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 x x x NJL…..…… 1 silicone-heating element
1
2 x x x NJL……….. cover sheets for vulcanizing plates, top/bottom
3 x x x EK3051203 coupling nipple R3/8"
4 x x x EK2470133 plug M18x1.5
5.1 x x x NJL415300A socket holder complete
5.2 x x x NG0100017A male insert 35 A, 500 V, complete
comprises:
EK10301791 mounted housing
EK1030172 pin insert
5.3 x x x EK51306711 cylinder head screw M4x25
5.4 x x x EA07610201 spring washer ø4
6 x x x EK51730228 countersunk screw M6x40
7 x x x EK51307096 cylinder head screw M6x35
8 x x x EK5200123 knurled counter sunk nut M6x11.5
9 x x x NJL034103A protective cover for male insert
10 x x x EK3230165 temperature feeler 2 x PT100, 0.29 m long
11 x x x EK5580305 eye bolt M10
1
Article-No.:
Vulcanizing NJL213100C NJL457100C NJL620100A

plates NJL213200C NJL457200C NJL620200A
Heating element NJL213101B NJL457101B NJL620101A
Cover Sheets NJL213106B NJL457106B NJL620106A
NJL213205B NJL457205B NJL620205A
29.01.2018/Hi EL_HPP-EMU-DuoLock-Staeubli-400V-rh_nen.docx
Digital-thermometer GTH 1100/2

for two feelers page 1/1
1. Technical data
feeler : feeler type K (NiCr-Ni)

feeler connection : 2-pole flat plug
measuring range : - 50 to 1150°C

display : 1°C
accuracy : 1% ± 1D
indicator : 13 mm high LCD - display

operating temperature : 0 to 45°C
electric power supply : 9 V battery type JEC 6F22
durability of battery : approx. 200 hours
change of battery signal : - BAT -
dimensions : 150 x 86 x 30 mm
weight : approx. 230 g (incl. battery)
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.
Switch positions: DIFF (variation between feelers 1 and 2)
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
Designation: Pressure Bag

Drawing No.: NJZ155000A
Comm. No.: A17-126508
Method of Testing
measuring tape x
visual check x
pressurised water unit x
compressor/pressure gauge
dimension pressure test bar

serial-no. according to type tightness
working remark
plate Lx Bx H minutes test
pressure
3535 1100X1200X35 9 45 OK
Hilden, date: 09.03.2018

release: B. Vogt (production Manager)
NILOS GmbH & Co. KG Tel. 02103/951-0 NILDS
revision I date
1 13.06.14
P_2_8_4_5_3
Test Certificate
Designation: Pressure Bag

Drawing No.: NJZ852000B
Comm. No.: A17-126508
Method of Testing
measuring tape x
visual check x
pressurised water unit x
compressor/pressure gauge
dimension pressure test bar

working remark
plate Lx Bx H minutes test
pressure
3534 400x1200x35 9 45 OK
Hilden, date: 09.03.2018

NILOS GmbH & Co. KG Tel. 02103/951-0 NILIJ5
Reisholzstralle 15 Fax. 02103/951-199
Revision I Date
1 13.06.14
P_2_8_4_5_9
Test Certificate
Designation: Pressurized Water Unit

Drawing No.: NJD036000A
Comm. No.: A17-126508
Method of Testing
visual check x
pressure gauge x
pressure test bar

serial-no. according tightness
working remark
to type plate nominal voltage minutes test
pressure
101254 400V 9 45 OK
Hilden, Date: 09.02.2018

NILOS GmbH & Co. KG Tel. 02103/951-0 NILD5
Revision I Date
1 13.06.14
P_2_8_4_5_6
Test Certificate
Designation: Air Control Box

Drawing No.: NJZ085000C
Comm. No.: A17-126508
Method of Testing
visual check x
compressor/pressure gauge x
pressure test
working remark
plate max. bar minutes test
pressure
100430 7 10 45 OK
Hilden, Date: 08.03.2019

HEATING DIAGRAM
Heating Plates: NJL213000C01 /

NJL457000C01 page 1/1
1. Heating Diagram
Belt width: 1400 mm

Press size: 1500 x 1200 mm / 16.7°
Voltage: 400 V, 50 Hz, 3~+N+PE
(Nominal) Heating power: 2 x 8.5 kW + 2 x 3.1 kW = 23.2 kW
(Nominal) Heating current: 2 x 12.3 A + 2 x 4.5 A = 33.6 A
Serial no. of heating plates: NJL213000C01 = 106000+106001
NJL457000C01 = 106002+106003
Temperature setting: 145 °C
heated: according to installation plan

Belt quality / Belt thickness: EP 400/3 – 4:2 cover / 10 mm
[°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

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Translation of the original instructions

Customer: "Industrija 4B" d.o.o. Kakanj

Warranty is forfeited in the following situations:

• In the event of improper use of the unit.

• In the event of improper treatment or maintenance of the unit.

• In the event of high-handed alterations to the unit.

• If parts which are not original NILOS parts are used.

Before first commissioning, we recommend that you carefully read the

4 Air Control Box

5 Pressurized Water Unit / Container

6 Pressure Bag / Pressure Bag Adapter

7 Switch Box / Cable

10 Test Certificates / Heating Diagram

Vulcanizing Press EMU-Liquid / EMU-Air

Assignments to the different bandwidths, see installation plans

Item Article-No. Description Designation Quantity

Vulcanizing Press EMU-Liquid / EMU-Air

Item Article-No. Description Designation Quantity

Article-No. Description Designation Quantity

NJZ085000C 6 Air Control Box 7 bar (100 psi) 1

Vulcanizing Press EMU-Liquid / EMU-Air

Article-No. Description Designation Quantity

NJZ497000A Handles for Vulcanizing Plates 8

Vulcanizing Press EMU-Air

1. Compressor (optional) 6. Cooling water system

Vulcanizing Press EMU-Liquid

1. Switch box 5. Container

Vulcanizing Plate  NJL213000C01

B1 x L1 x H1 1100 x 1200 x 50 mm Dimension of vulcanizing plate

Vulcanizing Plate  NJL457000C01

B1 x L1 x H1 400 x 1200 x 50 mm Dimension of vulcanizing plate

H5 1,5 mm Thickness of equalization plate NJL213001A

Cross Beam NJL120X01B

Vulcanizing Plate NJL213000C01

Cross Beam NJL151X00A

Vulcanizing press EMU

1. About these operating instructions

System: Vulcanizing press and components (for example switch box,

• Please read the operating instructions carefully before commencing work,

• Make the operating instructions accessible to the personnel at all times.

• Pass on the operating instructions to all subsequent owners or users of the

• Insert all supplements received from the manufacturer.

1.3 Target groups

Vulcanizing press EMU

1.4 Symbols and markings

CAUTION Information for preventing damage

NOTE Notes to understand or optimize work processes

2. Basic safety instructions

Vulcanizing press EMU

2.1 Proper use

The vulcanizing press is intended exclusively for:

EMU-Air: splicing of fabric conveyor belts with a surface pressure of up to

Any other usage is considered improper.

The vulcanizing press is not suitable for:

EMU-Air: splicing of steel cord belts

EMU-Liquid: splicing of fabric belts.

2.2 System part identification

2.3 Structural changes, repairs

• Do not make any changes, attachments or modifications to the system without

• Only original replacement parts supplied by the manufacturer may be used.

Vulcanizing press EMU

2.4 Owner's duties