mould rubber vulcaniser · 2018-03-28 · the mould –to be cut in two halves– out of the mould...

TEKNİK DÖKÜM

TEKNİK DÖKÜM Kaplama Malzemeleri Sanayi ve Ticaret A.Ş. Peykhane Sk. Büyük Birol İş Hanı Zemin Kat Çemberlitaş / İstanbul

Tel: (0212) 638 67 27-28 Faks: (0212) 638 33 13 Kuyumcukent, Atölye Bloğu, Zemin Kat, 1.Sok. No:1, Yenibosna - Bahçelievler

Tel: (0212) 603 01 43-50-53 Faks: (0212) 603 01 40 www.teknikdokum.com e-mail: [email protected]

OPERATING MANUAL

MOULD RUBBER VULCANISER

MODEL :

VP-02

VP-03

Seri No : This manual is an essential part of the mould rubber vulcaniser. It should be preserved within the immediate vicinity of the operator; in case the operator of vulcaniser has been replaced by someone else, the manual should be handed over to her/his successor.

TEKNĐK DÖKÜMTEKNĐK DÖKÜMTEKNĐK DÖKÜMTEKNĐK DÖKÜM

CONTENTS 1- INTRODUCTION 2- ISSUES CONCERNING SAFETY PRECAUTIONS

2.1- Used Safety Marks

2.2- Precautions to Be Taken to Prevent the Burns 2.3- Precautions to Be Taken to Prevent the Electric Shocks 2.4- Precautions to Prevent Squeezing of Hands

3- INSTALLATION and OPERATION

3.1- Regulation of the Vulcanising Temperature 3.2- Regulation of the Vulcanising Time 3.3- Using Instructions for the Mould Frame

4- MAINTENANCE, TROUBLESHOOTING and

REMEDIES for the MALFUNCTIONS 4.1- Maintenance of the Vulcaniser

4.2- Troubleshooting and Remedies for the Malfunctions 5- TECHNICAL CHARACTERISTICS 6- PARTS LIST 7- ASSEMBLING SCHEME 8- OVERALL DIMENSIONS 9- ELECTRIC CIRCUIT 10- CE DECLARATION OF CONFORMITY


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1- INTRODUCTION The main objectives for the preparation of this manual and presenting it at the service of the end users are as follows :

• Primarily to prevent any work accidents likely to occur by protecting the health of the workers operating VP-02/VP-03 mould rubber vulcaniser and providing occupational safety;

• To provide practical working conveniences for the workers supposed to operate the VP-02/VP-03;

• To increase the working efficiency to the furthest possible extent during the operation of the apparatus;

• To enable to removal of any minor defects and malfunctions likely to occur, with the limited facilities of the workshop and without producing any adverse or destructive effect on the apparatus;

• To set forth and use a common jargon to be able to prevent any communication lapses likely to involve during the spare parts requisition and supply transactions, thereby providing convenience and saving time.

The contents of this operation manual cover all the adequate data excluding the minor details relevant to the materials science and manufacturing technology of VP-02/VP-03 and do not concern at all the third parties other than those who purchase and use the apparatus. The scope of mould rubber vulcaniser VP-02/VP-03 is preparation of the rubber molds used for reproduction of wax models used in lost-wax casting process. Teknik Döküm AŞ reserves the right to perform changes and innovations, at any moment and without notice, on the model, type and accessories of VP-02/VP-03.

2- ISSUES CONCERNING SAFETY PRECAUTIONS Please read and carry out carefully the instructions written in this manual before starting any operation with the VP-02/VP-03 mould rubber vulcaniser, with particular regard to ensure the safety and health of the workers. The use of VP-02/VP-03 will not cause any hazard concerning the health and safety, as long as the safety precautions and instructions written below have been noticed, assured and borne in mind. Therefore, our company will not be assuming any responsibility in terms of compensating any damages or deficits originating from negligence of the precautions to be taken and from the delinquencies committed in the obedience to the instructions. Any damages, defects and deficits likely to arise from misuses or abuses shall definitely not be covered by the terms of warranty undertaken by our company.

2.1- Used Safety Marks

Electric Hazard

Hot Area Attention

Preventive Grounding

Danger of Squeeze

Wear Safety Gloves


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2.2- Precautions to Be Taken to Prevent the Burns

Such external metallic parts of the vulcaniser as the upper and lower heater plates, etc.,

may be subjected to overheating. Therefore, any inadvertent contact of the skin with the metallic parts may cause epidermal burns. Minimising this risk down to the lowest level possible necessitates the following precautions to be taken :

• Do not ever touch the heater plates (05 and 11) with bare fingers; wear safety gloves!

• Work with extreme care and always avoid skin contact with the metallic parts of

the vulcaniser.

2.3 - Precautions to be Taken to Prevent the Electric Shocks

Whilst working with VP-02/VP-03 which has been designed to be power supplied by the city electricity network, following precautions must definitely be taken in order to prevent electric shocks :

• The apparatus should be properly grounded against the hazard of any current leakage likely to occur over the chassis. A grounding line has already been placed within the power cable (42) of VP-02/VP-03 for this purpose. Do not ever cancel the grounding line.

• Disconnect the apparatus from the electricity network by simply pulling off the plug of the mains supply cord (42), before starting with any electrical maintenance or repair treatment, whenever the VP-02/VP-03 has to be disassembled for any reason.

• In case the main cable (42) gets damaged, it should be replaced by our technician or by a qualified electrician, in order to avoid any risks and hazards.

2.4- Precautions to Prevent Squeezing of Hands You may have your fingers squeezed between the upper (11) and lower (05) heater

plates if you close – by turning the hand wheel (26) – the distance between them in the absence of a vulcanising frame. Do not insert your fingers between the upper and lower heater plates.

3- INSTALLATION and OPERATION VP-02/VP-03 Mould Rubber Vulcaniser may be utilised by simply placing the apparatus on a work bench, or by anchoring it to the work bench, as well, by supplying 4 proper bolts of compiling length relevant to the thickness of the working bench and reciprocating to the thread size of the bolts (50) of 4 rubber pods (48) placed underneath the pedestal lid (47). Once the mains cable (42) was plugged on to the socket of city electricity network of 230 V / 50-60 Hz (do have a look at the electric circuit of VP-02/VP-03 seen in Figure 4), installation of apparatus has already been accomplished and the vulcaniser is at your disposal for service. VP-02/VP-03 Mould Rubber Vulcaniser is designed to be used indoors. Do not in any case use it outdoors.


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3.1- Regulation of the Vulcanising Temperature The most proper and recommended vulcanising temperature of the moulding rubber is

around 160 ºC; however, the vulcanising temperature may vary depending on the trade mark, type and model of the rubber.

Heat up the vulcaniser first by activating the timer (39a) by turning the timer knob (39) clockwise, before placing the mould frame, and try to maintain the temperature at a constant level after reaching to the desired vulcanisation point. Temperature of VP-02/VP-03

may be regulated by pressing on right side pushbuttons, placed on the digital display, respectively, as seen in Figure 1. To set desired

temperature, press button. You will see on the screen, green “SV” light turns on & pre-adjusted temperature value. Adjust the desired temperature

Figure 1- Digital Temperature Controller

by pressing or buttons. Right after, press button and save the value.

After the vulcaniser has reached to a constant level of temperature of the desired vulcanisation point, place the mould frame between both heater plates (05 and 11).

Do not neglect to wear safety gloves after the vulcaniser has been heated up! And

tighten both heater plates (05 and 11) simply by turning the hand wheel (26) clockwise. Check the temperature of the vulcaniser after three minutes and squeeze the mould frame a bit tighter on, if it necessitates.

Always try to avoid over-squeezing the mould frame, particularly, whilst working with delicate, brittle, fragile and vulnerable model objects that are likely to get damaged.

3.2- Regulation of the Vulcanising Time

Adjust the timer (39a) to the desired period of vulcanising duration by turning the timer knob (39), clockwise, placed on the right side of digital displayer as seen in Figure 1. The most proper and recommended vulcanising time is an average of 7½ minute per each layer of moulding rubber supposed to be moulded. For instance, if six layers of rubber has been placed within the moulding frame (three layers underneath the prototype model and the other three above), the moulding rubber should then be vulcanised for a period of a length of 6 × 7½ = 45 minutes. The vulcanising time may vary depending on the trade mark, type and model of the rubber, as well.

3.3- Using Instructions for the Mould Frame

The prototype model to be moulded may be of any material likely to endure to a pressure yielded by only muscle force and to the temperature of a mere 160 ºC, as well as of metallic materials like gold, silver, copper, etc. Coating of the prototype model by a film of rhodium is preferably and fashionably recommended in recent applications, in order to obtain much smoother surfaces on both male (prototype) and female (rubber) moulds.

Place the prototype model amidst and between the pre-cut sandwiches of moulding rubber. If the model is of large and thick in size, then fill the blanks with waste (but clean!) clippings of pre-cropped rubber. The less the volume of voids that you have left within the cold natural rubber, the better and more precise vulcanising results you can obtain.


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As soon as the vulcanising time expires, leave the vulcaniser to cool down for a while and excise the mould frame squeezed between both heater plates (05 and 11). Then take off the mould –to be cut in two halves– out of the mould frame by utilising hand tools.

The rubber mould excised from the mould frame may be cut by surgical blades, along the most convenient and proper demarcation line. Do pay extreme care and attention, whilst cutting the rubber mould by special surgical blades. When the cutting treatment has once been accomplished and the rubber mould is parted in two halves, excise the prototype model out of the female nest. The mould is now at your disposal for wax injection and reproducing wax patterns.

An alternative method of halving the mould to challenge the conventional cutting practice is also available by preparing a mould in two pre-parted halves insulated from each other by a film of talcum powder, before starting to the vulcanising process. Coat the surfaces of both halves of the female mould nest supposed to host the prototype model by a film of talcum powder.

Connect two halves of natural moulding rubber by 4 metallic rivets –of a proper length not longer than the total thickness of two halves– placed at each one of four corners of the mould, and then apply the same vulcanising procedure as described above.

At the end of the vulcanising period apply the same cooling and excising ceremony and then part the mould in two halves simply by pulling off from the same corner by two pincers. Interface of two mould halves insulated from each other by a film of talcum powder will readily be apart from each other and no cutting treatment will be needed then.

4- MAINTENANCE, TROUBLESHOOTING and

REMEDIES for the MALFUNCTIONS 4.1- Maintenance of the Vulcaniser

Excess of the un-vulcanised rubber to be oozed from the mould frame may stick to the surfaces of both heater plates (05 and 11) and remain over there. Do not ever try to rasp these vulcanised rubber residues, for you may scrape and damage the surface of the heater plates (05 and 11), as well. Some solvent liquids like thinner and gasoline would rather be preferable for cleaning the surfaces of heater plates (05 and 11).

Do not neglect to lubricate the jack screw (19) evenly, with the grease or with some

other oil less viscose than grease, at least once a year. VP-02/VP-03 does not require any further maintenance.

4.2- Troubleshooting and Remedies for the Malfunctions

The heating element placed within both heater plates (05 and 11) may get broken off,

even if this malfunction occurs very occasionally. In such a case, when the vulcaniser may eventually fail in performing the heating function, just disconnect the apparatus from the city electricity network by simply plugging off the mains cable (42) and acknowledge the situation to our company by one of the telecommunication means that has been written on the front cover of this operation manual. All sorts of malfunctions within the scope of the warranty terms will be remedied.


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5- TECHNICAL CHARACTERISTICS The essential technical data relevant to VP-02/VP-03 has been compiled and summarised in the table given below :

Technical Characteristics of Mould Rubber Vulcanisers

VP-02 VP-03 Dimensions of Heater Plate 140 ×170 mm 200 ×250 mm Operation Temperature (maximum) 200 °C 200 °C Aperture Between the Plates (maximum) 70 mm 110 mm External Dimensions (width × length × height) 210 × 240 × 520 mm 320 × 350 × 630 mm Net Weight 16 kg 29 kg

Electrical Characteristics

Voltage 230 V AC 230 V AC Power 800 W 1000 W Frequency 50-60 Hz 50-60 Hz Current 3,5 A 4,3 A

Table 1- Technical Data of VP-02/VP-03 Mould Rubber Vulcaniser

6- PARTS LIST The spare parts of VP-02/VP-03, available for requisition and supplying on a delivery basis directly from the shelf, coded in the isometric assembly scheme seen in Figure 2 have been listed in the following table :

Part

№. Part Name Pcs.

Part

№. Part Name Pcs.

1 Pedestal 1 27 Washer Ø 12 1 2 Spiral Sleeve, lower 1 28 Capped Nut M12 1 3 Cable Sleeve 1 29 Spiral 1 4 Lower Insulating Plate 1 29a Heater Connection Cable 1

5 Lower Heater Plate 1 30 Transformer Fixation Plate 1

6 Pul Ø6 4 31 Spring Washer Ø 6 1

7 Allen Bolt M6 × 35 4 32 Allen Bolt M6 × 10 1

8 Lateral Shaft 2 33 Connector 1

9 Spring Washer Ø 12 (VP03: Ø 16) 2 34 Round Head Starbolt M3 × 15 2

10 Hexagonal Nut M12 (VP03: Ø 16) 2 37 Round Head Starbolt M3 × 10 1

11 Upper Heater Plate 1 38 Temperature Controller Escutcheon 1

12 Upper Insulating Plate 1 39 Timer Knob 1

13 Pressure Plate 1 39a Timer 1

14 Spiral Sleeve, Upper 1 40 Star Capscrew M3×7 2

15 Allen Bolt M6 × 35 6 41 Digital Temperature Controller 1

16 Lateral Shaft Fixation Bushing 2 42 Mains Cable 1

17 Fixation Bushing Nut 2 43 Cable Capped Sleeve 1

18 Jack Screw Washer 1 44 O-Ring 1

19 Jack Screw 1 45 Temperature Sensor PT100 1

20 Jack Screw Fixation Disc 1 46 Allen Bolt M5 × 10 4

21 Allen Bolt M6 × 35 3 47 Pedestal Lid 1

22 Bridge 1 48 Rubber Pod 4

23 Spring Washer Ø 12 (VP03: Ø 16) 2 49 Washer Ø 8 4

24 Capped Nu M12 (VP03: Ø 16) 2 50 Countersink Starbolt M6 × 25 4

25 Jack Screw Key 1

26 Hand Wheel 1

Table 2- Parts List of VP-02/VP-03 Mould Rubber Vulcaniser


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7- ASSEMBLING SCHEME The overall assembly of VP-02/VP-03 in the dismantled form and shown together with reciprocating part numbers listed in Table 2 have been illustrated in the figure seen below :

Figure 2- Exploded View of VP-02/VP-03 Mould Rubber Vulcaniser


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8- OVERALL DIMENSIONS Several measured views of VP-02/VP-03 are illustrated as follows :

Figure 3a- Frontal View Figure 3b- Lateral View

VP-02 VP-03

a 240 mm. 320 mm.

b 445 mm. 515 mm.

c 515 mm. 630 mm.

d 210 mm. 350 mm.

9- ELECTRIC CIRCUIT The wiring diagram of the VP-02/VP-03 is shown below :

Figure 4- Electric Circuit of VP-02/VP-03 Mould Rubber Vulcaniser


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CE UYGUNLUK DEKLERASYONU

CE DECLARATION OF CONFORMITY

TEKNĐK DÖKÜMTEKNĐK DÖKÜMTEKNĐK DÖKÜMTEKNĐK DÖKÜM Teknik Döküm Kaplama Malzemeleri San. ve Tic. A.Ş.

Kürkçüler Pazarı Sok. No:20/2 Çarşıkapı - Đstanbul / Turkey Tel: +90 212 518 57 57 Fax: +90 212 638 33 13

email: [email protected] www.teknikdokum.com

Biz, TEKNĐK DÖKÜM Kaplama Malzemeleri San. ve Tic. A.Ş. olarak, deklere ederiz ki, We, TEKNĐK DÖKÜM Kaplama Malzemeleri San. ve Tic. A.Ş., herewith declare that,

PNÖMATĐK KAUÇUK KALIPLAMA PRESĐ VPP-20/25 PNEUMATIC MOLD RUBBER VULCANIZER VPP-20/25

PNÖMATĐK KAUÇUK KALIPLAMA PRESĐ VPP-17/20 PNEUMATIC MOLD RUBBER VULCANIZER VPP-17/20

KAUÇUK KALIPLAMA PRESĐ VP-02 MOLD RUBBER VULCANIZER VP-02 KAUÇUK KALIPLAMA PRESĐ VP-03 MOLD RUBBER VULCANIZER VP-03 KAUÇUK KALIPLAMA PRESĐ P-30 MOLD RUBBER VULCANIZER P-30

aşağıda verilen AB Uygunluk Direktiflerine (değiştirilmiş kurallar dahil) Uygundur: are in conformity with the following (including all applicable modification rules) Directives:

73/23/EEC Düşük Voltaj Direktifi - Low Voltage Directive 98/37/EC Makina Direktifi - Machinery Directive 89/336/EEC Elektromanyetik Uyumluluk - Electromagnetic compatibility (EMC)

Cihazlar aşağıdaki standartlara uygun olarak dizayn edilmiş ve üretilmişlerdir: The equipment has been designed and manufactured in conformity with the following specifications: EN 292-1 ;1991 EN 292-2 : 1991 EN 1050 : 1996 EN 60204-1 : 1997 EN 61000-6-3:2001

EN 55022:1998 EN 61000-3-2:2000 EN 61000-3-3:1995 EN 61000-6-1:2001 EN 61000-4-2:1995

EN 61000-4-3:1996 EN 61000-4-4:1995 EN 61000-4-5:1995 EN 61000-4-6:1996 EN 61000-4-11:1994

Biz, üretici firma olarak, burada listesi verilmiş bulunan cihazların yukarıdaki standartların ilgili maddelerine uygun olarak dizayn edilip üretildiklerini deklere ederiz. Cihazlar, belirtilen direktiflerin tüm gereklerini sağlamaktadır.

We, as the manufacturer, hereby declare that the equipment named above has been designed to comply with the relevant sections of the above specifications. The equipment satisfies all requirements of the Directives cited.

1- Bu deklarasyon belirtilen direktiflere uygunluğu belgeler. Özellikler ile ilgili garanti hakkı vermez This declaration demonstrates conformity with indicated directives but implies no warranty of properties.

2- Ürün ile birlikte verilen tüm güvenlik uyarıları, dokümanları ve işletim talimatlarına uyulmalıdır. All documentation, safety alerts, and operational instructions given with product shall be observed.

3- Tarafımızdan kabul edilmeyen, makinelerdeki herhangi bir değişiklik bu deklarasyonu geçersiz kılacaktır. Any revision on product, not agreed upon by us invalidates this declaration.

CEMAL APELĐGAN Genel Müdür, General Manager Istanbul, Türkiye / Turkey 30.09.2006

mould rubber vulcaniser · 2018-03-28 · the mould –to be cut in two halves– out of the mould...

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