Intralox ThermoDrive Instruction Manual

Download

Intralox ThermoDrive®

Belt Splicing System v.2.0

Instruction Manual

For use with TD 8026/8126 belts TD 8050 belts

SAFETY

Safety Information

Avoid Injury.

Wear personal protective equipment (PPE) to operate, troubleshoot, or service this equipment (safety glasses, heat-resistant gloves, etc.).

Read manual instructions before trying to operate, troubleshoot, or service this equipment.

Keep children, people with impaired physical, sensory, or mental abilities, or people with limited experience or knowledge clear of the splicing system, especially during use. Impaired or inexperienced users must receive proper supervision or training by a person responsible for their safety.

Only personnel properly trained in the safe operation of the splicing system should use the equipment.

Only authorized Intralox service providers should service the Splicing System.There are no user-serviceable Splicing System components.

Never cut, drill, or otherwise modify the Heat Wand or Temperature Control Box. Modification may cause additional shock and burn hazards.

ANSI/ISO harmonized labels and symbols are included on this equipment and in its documents to help all operators use the equipment safely.

Some sections of this manual include a list of safety messages that apply to all procedures described in the section. Other safety messages are imbedded into specific procedures to remind you of mandatory actions or hazards specific to that procedure.

Review the label and symbol information that follow to ensure a quick and complete understanding of warnings provided with this equipment. Please do not ignore this information. It is included for your protection.

Imbedded Warnings

This is a general warning sign. It is used throughout this manual to alert you to hazards you may encounter

during specific operating, troubleshooting, or servicing procedures. Please read the corresponding information.

Refer to safety labels affixed to the equipment and shown in the documentation for detailed safety instructions.

If you have any questions about safety or your ability to perform tasks using these practices, contact Intralox before proceeding.

Belt Splicing System v.2.0

SAFETY

Hazard Severity Panels

DANGER indicates a hazard with a high level of risk. If you do not avoid this hazard, it will result in death or serious injury.

WARNING indicates a hazard with a medium level of risk. If you do not avoid this hazard, it could result in death or serious injury.

CAUTION indicates a hazard with a low level of risk. If you do not avoid this hazard, it could result in minor or moderate injury.

Safety Symbols

A black symbol inside a black-banded yellow triangle indicates a safety hazard you should avoid.

A black symbol inside a red-banded circle with a red diagonal line indicates an action that is prohibited.

A white symbol inside a blue circle indicates a required action to perform to avoid a hazard.

Belt Splicing System v.2.0

Belt Splicing System Hazards

Request assistance when moving or splicing with the 42" Splicing System.

Contact with hot Heat Wand or Stand will cause skin burns; use of heat-resistant gloves and sleeves that withstand consistent temperatures up to 500°F is recommended.

Keep Heat Wand in Stand between each splice.

Figure A: Heat Wand and Temperature Control Box hazards

SAFETY

Figure A: Belt cutting and trimming hazards

Belt Splicing System v.2.0

SAFETY

Figure B: Clamping Fixture hazards



Belt Splicing System v.2.0

SAFETY

Safety Information ..................................

Imbedded Warnings................................ 1

Hazard Severity Panels ........................... 2

Safety Symbols ...................................... 2

Belt Splicing System Hazards ................. 3

TABLE OF CONTENTS

LIST OF FIGURES

1 EQUIPMENT OVERVIEW

System Use.........................................

1-1

System Components ........................... 1-1

Top Clamps/Cut Guides .................... 1-1

Clamping Fixture ............................... 1-1

Heat Wand with Temperature

Control Box....................................... 1-1

Accessories...................................... 1-2

2 SPLICING SYSTEM COMPONENTS

Accessories ........................................

2-1

Clamping Fixture.................................. 2-2

Heat Wand and Temperature

Control Box .........................................

2-4

STANDARD PROCEDURES

4 PREPARE BELT ENDS

Belt End Situations..............................

4-1

Preparation Overview .......................... 4-1

Clean Belt Ends................................... 4-2

Cut Belt Ends ...................................... 4-2

Inspect Belt Ends ................................ 4-4

5 ALIGN AND SECURE BELT ENDS

Prepare to Align ..................................

5-1

Align Belt Ends.................................... 5-1

Lightly Secure Belt Ends...................... 5-2

Check Alignment & Tightly Secure

Belt Ends ............................................

5-3

Inspect Tension .................................. 5-4

Inspect Alignment ............................... 5-4

6 SPLICE THE BELT

Prepare to Splice.................................

6-1

Splice the Belt Ends ............................ 6-2

Allow the Belt to Cool.......................... 6-4

Inspect the Splice ............................... 6-4

7 TRIM & INSPECT THE BELT

Trimming Overview.............................

7-1

Trim First Weld Bead........................... 7-1

3 SET UP THE SPLICING SYSTEM

Collect Needed Supplies ......................

3-1

Prepare the Conveyor .......................... 3-1

Prepare Clamping Fixture ..................... 3-2

Secure Clamping Fixture to Conveyor 3-2

Attach Crank Handle.......................... 3-2

Prepare the Heat Wand ........................ 3-3

Make Power Connections.................. 3-3

Adjust Temperature Setpoint ............. 3-4

Allow Heat Wand to Pre-heat............. 3-5

Belt Splicing System v.2.0

Trim Second Weld Bead...................... 7-2

Trim Belt Edges .................................. 7-2

Inspect the Belt ................................... 7-3

8 SHUT DOWN, COOL, & PACK UP

Shut Down & Clean.............................

8-1

Cool Down.......................................... 8-1

Pack the Storage Case ........................ 8-1

TOC

TABLE OF CONTENTS

TROUBLESHOOTING

10 TROUBLESHOOT

Troubleshooting Overview..................

10-1

Procedures & Inspections.................. 10-1

Faulty Cuts & Splices......................... 10-1

Repeat Cuts .................................... 10-1

Repeat Splices................................ 10-1

Table of Equipment/Facility Problems. 10-2 Table of Preparing and Aligning

Belt Ends Problems ...........................

10-4

Table of Faulty Splice Problems ......... 10-7

Table of Belt Failures........................ 10-15

SPECIAL PROCEDURES

11 SPECIAL PROCEDURES

Set Up at the Returnway ....................

Make Belt Tabs.................................. 11-1

Shim for Belt Top Surface

(Vertical) Alignment ...........................

Trim the Second Weld Bead—

Alternative Technique.........................

Inspect the Clamping Fixture .............. 11-3

12 NUB TOP STYLE SPECIFICS

11-1

11-2

11-3

14 S8126 BELT SPECIFICS

S8126 Overview ................................

14-1

Preparing Belt Ends............................ 14-2

Shim the Smooth Edges to

Secure Belt Ends............................. 14-2

Use Thin Belt Tabs to

Secure Belt Ends............................. 14-2

Repeatedly Inspect Alignment before

Cutting............................................ 14-3

Hold the Cut Guides when

Fully Tightening Thumb Knobs......... 14-3

Add the Second Cut Guide to

Secure Belt for Cutting..................... 14-3

Inspect Cuts for Squareness............ 14-3

Align & Secure Belt Ends.................... 14-4

Remove any Belt Tension ................ 14-4

Check for Shims and Belt Tabs........ 14-4

Repeatedly Inspect Alignment.......... 14-4

Control Crank Handle During

Alignment ....................................... 14-4

Hold the Cut Guides when

Fully Tightening Thumb Knobs......... 14-5

Splice the Belt Ends ........................... 14-5

Control the Crank Handle

for 25 Seconds of Melting ............... 14-5

Close Decks Gently for Cooling........ 14-5

Trim & Inspect the Belt....................... 14-6

Nub Top Overview .............................

Remove Nubs.................................... 12-1

Prepare Silicone Spacers for Use ....... 12-1

Use Silicone Spacers......................... 12-2

13 TROUGHING GROOVES SPECIFICS

Troughing Groove Overview ...............

Shim the Grooved Deck ..................... 13-1

Trim the Tape .................................... 13-2

TOC

12-1

13-1

PREVENTIVE MAINTENANCE

15 PERFORM PREVENTIVE MAINTENANCE

Belt Splicing System v.2.0

LIST OF FIGURES

SAFETY

Figure A: Heat Wand and Temperature

Control Box hazards ...........................................3

Figure B: Belt cutting and trimming hazards ........3

Figure C: Clamping Fixture hazards.....................4

LIST OF FIGURES

1 EQUIPMENT OVERVIEW

Figure 1A: Splicing System............................ 1- 1

2 SPLICING SYSTEM COMPONENTS

Figure 2A: System accessories

(generic photo) ............................................. 2- 1

Figure 2B: Storage case ................................ 2- 1

Figure 2C: Clamping Fixture........................... 2- 2

Figure 3E: Check voltage requirements .......... 3- 3

Figure 3F: Check voltage requirements........... 3- 4

Figure 3G: Turn Power on.............................. 3- 4

Figure 3H: Check Control Box display ............3- 4

4 PREPARE BELT ENDS

Figure 4A: Clean belt ends ............................. 4- 2

Figure 4B: Pull the belt across BOTH decks,

and align the drive bars with grooves............. 4- 2

Figure 4C: Belt drive bar

engagement/alignment .................................. 4- 3

Figure 4D: Place Cut Guide on belt................. 4- 3

Figure 4E: Tighten Cut Guide in place............. 4- 3

Figure 4F: Check setup before cutting ............ 4- 3

Figure 2D: Top Clamp/Cut Guide set.............. 2- 3

Figure 2E: Heat Wand components................ 2- 4

STANDARD PROCEDURES

3 SET UP THE SPLICING SYSTEM

Figure 3A: Clamping Fixture on horizontal

conveyor ...................................................... 3- 2

Figure 3B: Add clamps ahead of

Clamping Fixture on an inclined conveyor ...... 3- 2

Figure 3C: Attach Crank Handle ..................... 3- 2

Figure 3D: Latch Heat Wand in Stand............. 3- 3

Figure 4G: Hold the utility knife against

the Cut Guide Edge........................................ 4- 4

Figure 4H: Inspect cut belt ends..................... 4- 4

Figure 4I: Inspect cut..................................... 4- 4

5 ALIGN AND SECURE BELT ENDS

Figure 5A: Align belt ends on Grooved Deck... 5- 2

Figure 5B: Belt ends extending....................... 5- 2

Figure 5C: Lower Cut Guide on Grooved Deck 5- 2

Figure 5D: Position and tighten thumb knobs .5- 2

Belt Splicing System v.2.0

LOF

LIST OF FIGURES

Figure 5E: Close the Clamping Fixture............ 5- 3

Figure 5F: Align right and left belt edges......... 5- 3

Figure 5G: Secure second belt end ................ 5- 3

Figure 5H: Clamping Fixture closed–but

not locked..................................................... 5- 4

Figure 5I: Inspect for gaps and horizontal

alignment...................................................... 5- 4

Figure 5J: Inspect belt surface vertical

alignment...................................................... 5- 5

6 SPLICE THE BELT

Figure 6A: Clean residue from the

Heat Wand.................................................... 6- 1

Figure 6B: Latch Heat Wand in Stand............. 6- 1

Figure 6C: Remove the Heat Wand from

the Stand ...................................................... 6- 2

7 TRIM & INSPECT THE BELT

Figure 7A: Secure the belt.............................. 7- 1

Figure 7B: Separate the weld bead

from the belt ................................................. 7- 1

Figure 7C: Remove the first weld bead........... 7- 1

Figure 7D: Remove the second weld bead ..... 7- 2

Figure 7E: Trim and skive ..............................7- 2

Figure 7F: Trim flash from belt edges............. 7- 2

Figure 7G: Trim rough edges or small corners 7- 2

Figure 7H: Create a smooth edge and

discard debris ............................................... 7- 3

Figure 7I: Check pitch at splice ...................... 7- 3

Figure 7J: Inspect for splice faults

(e.g., bubbles shown here)............................ 7- 4

Figure 6D: Wand Rest at one end .................. 6- 3

Figure 6E: Close Clamping Fixture on

Heat Wand.................................................... 6- 3

Figure 6F: Remove Heat Wand ...................... 6- 3

Figure 6G: Close Grooved Decks as

Heat Wand is lifted ........................................ 6- 3

Figure 6H: Heat Wand removed and

belt cooling................................................... 6- 3

Figure 6I: Wipe residue from the Heat Wand .. 6- 4

Figure 6J: Small, even weld bead................... 6- 4

8 SHUT DOWN, COOL, & PACK UP

Figure 8A: Pack main components ................ 8- 1

Figure 8B: Secure the twist latches ................ 8- 2

TROUBLESHOOTING

10 TROUBLESHOOT

LOF

Belt Splicing System v.2.0

LIST OF FIGURES

SPECIAL PROCEDURES

11 SPECIAL PROCEDURES

Figure 11A: Place the Clamping Fixture on a flat,

stable surface ............................................. 11- 1

Figure 11B: Make a Belt Tab........................ 11- 1

Figure 11C: Apply tape at Deck edge ........... 11- 2

Figure 11D: Trim away excess tape ............. 11- 2

Figure 11E: Replace the belt end.................. 11- 2

Figure 11F: Bend belt back onto Cut Guide... 11- 3

Figure 11G: Open Clamping Fixture.............. 11- 3

Figure 11H: Close Clamping Fixture and

ensure metal pads touch ............................. 11- 3

12 NUB TOP STYLE SPECIFICS

Figure 12A: Nub Top Samples ..................... 12- 1

Figure 12B: Remove nubs from

splicing area ............................................... 12- 1

13 TROUGHING GROOVES SPECIFICS

Figure 13A: Troughing groove samples........ 13- 1

Figure 13B: Center tape at Grooved

Deck edge................................................... 13- 1

Figure 13C: Trim tape width......................... 13- 2

Figure 13D: Trim tape length........................ 13- 2

Figure 13E: Finish belt end alignment........... 13- 2

14 S8126 BELT SPECIFICS

Figure 14A: S8126 Samples........................ 14- 1

Figure 14B: Trim tape at the belt edges ........ 14- 2

Figure 14C: Choose Belt Tabs thinner

than belt...................................................... 14- 2

Figure 14D: Place Belt Tabs on

Grooved Decks ........................................... 14- 2

Figure 14E: Inspect with square edge........... 14- 3

Figure 14F: Clamp belt edges securely......... 14- 3

Figure 12C: Spacers for

42" Clamping Fixture ................................... 12- 1

Figure 12D: Place Cut Guide on

Silicone Spacer........................................... 12- 2

Figure 12E: Align Silicone Spacer with

Deck edge................................................... 12- 2

Figure 14G: Secure the second Cut Guide

in place....................................................... 14- 3

Belt Splicing System v.2.0

LOF

LIST OF FIGURES

Figure 14H: Inspect cut ............................... 14- 3

Figure 14I: Place thin Belt Tabs on

Grooved Decks ........................................... 14- 4

Figure 14J: Inspect with square edge........... 14- 4

Figure 14K: Inspect touching ends............... 14- 4

Figure 14L: Clamp belt edges securely ........ 14- 5

Figure 14M: Maintain control of the

Crank Handle .............................................. 14- 5

Figure 14N: Inspect drive bar alignment ....... 14- 6

PREVENTIVE MAINTENANCE

15 PERFORM PREVENTIVE MAINTENANCE

LOF

Belt Splicing System v.2.0

EQUIPMENT OVERVIEW

System Use

1 EQUIPMENT OVERVIEW

System Components

The Intralox ThermoDrive Splicing System quickly and reliably splices Intralox ThermoDrive® conveyor belts.

All Splicing System v.2.0 models operate the same way. Melting time and temperature depend on the material being spliced.

The Splicing System requires only standard electric power for use.

The Splicing System contains a Clamping Fixture with Cut Guides and a Heat Wand with Temperature Control Box. Several accessories are also included with your system.

Top Clamps/Cut Guides

After the belt length is finalized to run without tension (contact Intralox for assistance as needed), use the 8026 or 8050 Cut Guide and a utility knife to prepare the belt ends.

Clamping Fixture

Align prepared belts on the Grooved Decks to hold belt ends together for melting. Once melted, remove the Heat Wand and close the Grooved Decks gently, but quickly, to join the belt ends.

Heat Wand with

Figure 1A: Splicing System

Temperature Control Box

Use the Heat Wand to melt the belt ends in the Clamping Fixture. The Temperature Control Box regulates Heat Wand temperature and may ONLY be used with the Intralox ThermoDrive Splicing System. Several splices can be completed in quick succession if plastic residue is removed from the Heat Wand between each splice.

Belt Splicing System v.2.0

1-1

1 EQUIPMENT OVERVIEW

NOTE

Accessories

The following accessories come with the above components: a storage case, Silicone Spacers, Teflon tape, Pitch Gauge, trim tools, a stopwatch, and Belt Tabs.

For details about components and voltage

requirements, see SPLICING SYSTEM COM-

PONENTS on page 2-1.



1-2

Belt Splicing System v.2.0

Silicone Spacers

Trimmers

Teflon tape

Skiver

Pitch Gauge

utility knife

stopwatch

Belt Tabs

Use caution when handling knives and trim tools.

SPLICING SYSTEM COMPONENTS

Trimmers: Sharp nippers with rubber-covered

Accessories

handles used to remove flashing on the belt edge and perform other trimming tasks

(Xcelite Silicone Spacers: Two (2), reusable, rectangu-

lar strips of rubber used to securely clamp certain belt ends; stored in white, cylindrical can; details for use in Special Procedures

storage case: Sturdy, cushioned, locking case to hold the Splicing System and accessories; designed with wheels and side handle for pulling

trimmers or similar)

2 SPLICING SYSTEM COMPONENTS

Figure 2A: System accessories (generic photo)

Pitch Gauge: Metal plate with notches to test belt pitch accuracy

Skiver: Handled tool with a u-shaped blade used to trim the weld bead from spliced belts (Flexco™ rough-top Skiver or similar)

Belt Tabs: Small pieces of ThermoDrive belt used on Grooved Deck ends to ensure even clamping pressure across the belt during splicing; replacements available from Intralox

Figure 2B: Storage case

Teflon

resistant, adhesive tape stopwatch: Digital timing device with large dis-

play utility knife: Self-retracting safety knife with a

1 Retractable Safety Knife model #99152 or similar)

tape: 5-yard (4.572 m) roll of heat-

3/4" two (2)-sided replaceable blade (Medoc

Belt Splicing System v.2.0

2-1

2 SPLICING SYSTEM COMPONENTS

NOTE

Wand Rest (between decks) Locating pin

Carrying handles

Grooved Decks

Locating Pins

Wand Rest (between decks; barely visible)

Shaft tether Crank Handle

Pivoting Studs

(& thumb knobs)

Locating pin

Frame edge

Carrying handles

Pivoting Studs

(& thumb knobs)

Clamping Fixture

Figure 2C: Clamping Fixture

Clamping Fixture: All-metal fixture designed to hold prepared belt ends in proper alignment during melting; includes 8026/8050 Top Clamp/Cut Guides and Crank Handle

The 8026/8050 Top Clamp/Cut Guide set does not

provide correct pitch with metal lacing. Contact

Intralox with questions about metal lacing.

Carrying Handles: Plastic rounded parts used to lift and carry the Clamping Fixture

Crank Handle: Removable, metal handle used to open and close Grooved Decks; attaches to the protruding shaft with retaining pin and tether

Frame edges: Curved, metal portion of the fixture frame on the right and left of the Grooved Decks designed to smooth belt movement onto the decks

2-2

Belt Splicing System v.2.0

2 SPLICING SYSTEM COMPONENTS

NOTE

recesses

(not visible)

Cut

Guide Edge

metal rail

locating

holes

locating holes

Cut Guide Edge

metal rail

recesses

Keep hands and fingers clear of Frame edges when opening/closing Grooved Decks.

Grooved Decks: Aluminum plates designed to move the belt ends together for splicing; grooved surface engages the drive bars to ensure proper alignment

Locating Pins: Fixed metal posts that correspond to the Cut Guide locating holes; designed to properly align Cut Guides on the Grooved Decks

Pivoting Studs: Metal studs with thumb knobs designed to hold the Cut Guides in place and secure the belt ends; a pivoting stud and thumb knob are at each end of each Grooved Deck

Shaft: Main crankshaft of the Clamping Fixture on which the Crank Handle fits

Wand Rests: Two (2) metal brackets that support the Heat Wand during splicing; located below the Grooved Decks and visible with the Clamping Fixture open

8026/8050 Top Clamp/Cut Guide Set: Pair of anodized aluminum metal plates (one red and one blue) that provide a guide for preparing belts for splicing; also secures belt ends on the Clamping Fixture Grooved Decks; designed only for use with ThermoDrive belts and Splicing Systems

Use the blue Cut Guide engraved with 8026

to prepare belts with 26 mm pitch.

Use the red Cut Guide engraved with 8050

to prepare belts with 50 mm pitch.

Cut Guide Edge: Steel edge on each Cut Guide designed to ensure a straight, even guide to prepare belt ends for splicing

Locating hole: Oval cut area at each end of the Cut Guides designed to align with the Clamping Fixture Locating Pins

Metal rail: Fencing attached to the Cut Guides designed to simplify handling the part

Recess: Curved cut at each end of the Cut Guides designed to engage the Clamping Fixture Pivoting Studs

Figure 2D: Top Clamp/Cut Guide set

Belt Splicing System v.2.0

2-3

2 SPLICING SYSTEM COMPONENTS

NOTE

Contact with hot Heat Wand or Stand will cause skin burns.

Place the Wand Stand on a hard, heatresistant surface (NOT a belt) during use.

Keep Heat Wand in the Stand when not in use.

Heat Wand

Stand

Temperature

Control Box

Electric Cord

Power Switch

Heat Wand and Stand

Wand Cord

Heat Wand and Temperature Control Box

Figure 2E: Heat Wand components

Heat Wand: Electrically operated, heating platen used to melt Intralox ThermoDrive belt ends for splicing; designed to be connected to the Temperature Control Box and used with the Clamping Fixture; designed to maintain setpoint temperature for a series of splices covered with Teflon tape to allow easy removal of melted plastic residue

Use the Heat Wand in temperatures above 40°F

(5°C) to produce quality splices. To use the

Splicing System below 40°F (5°C),

see TROUBLESHOOT on page 10-1.

Stand: Metal guard designed to hold the Heat Wand upright, allow handle access during use, and prevent accidental contact with the Wand; also protects work surfaces that might be burned by the Wand; Heat Wand should be returned to Stand after each splice

Connect the Heat Wand to the Temperature

Control Box BEFORE connecting the Temperature

Control Box to an electric outlet.

2-4

Belt Splicing System v.2.0

Temperature Control Box: Electric device that

NOTE

Always use ground fault protection/ residual current protection when operating in damp or wet conditions.

controls the Heat Wand temperature via thermocouple signals to and from the Wand; includes an Electric Cord with three-pronged plug

Electric Cord: Cord connected from the Temperature Control Box provided with a three-prong plug for use in a grounded outlet

Connect the Heat Wand to the Temperature

Control Box BEFORE connecting the Temperature

Control Box to an electric outlet.

2 SPLICING SYSTEM COMPONENTS

Power Switch: Switch that enables power to the Temperature Control Box; display appears when Power is set on

Wand Cord: Cable that transfers electricity and thermocouple signals between the Temperature Control Box and the Heat Wand; plugs are provided at the cord ends for connection to both devices



Belt Splicing System v.2.0

2-5

STANDARD PROCEDURES

Request assistance when moving or splicing with the 42" Splicing System.

3 SET UP THE SPLICING SYSTEM

SET UP THE SPLICING SYSTEM

3. Collect new sprockets (if you are installing new belts) and any needed carryway and returnway replacement components.

Avoid Injury.

Use caution when handling knives and trim tools.

Contact with hot Heat Wand or stand will cause skin burns; use caution.

Do NOT submerge equipment or expose it to direct spray.

Always use ground fault protection/ residual current protection when

operating in damp or wet conditions.

Collect Needed Supplies

1. Bring Splicing System storage case and these shop items to the conveyor.

4. Ensure the facility temperature is above 40°F (5°C) to produce proper splices. If splicing area is below 40°F (5°C), see TROUBLESHOOT on page 10-1.

Prepare the Conveyor

See the ThermoDrive® Belting Conveyor Belting Installation and Maintenance at the

Intralox website or contact Intralox for complete assembly and disassembly instructions.

1. Disconnect power to the conveyor.

2. Remove or disable components as needed to

prevent accidental tensioning.

3. Remove components that may cause excess backbends.

4. Replace worn components being careful not to create drive bar snags.

• heat-resistant gloves and sleeves (rated for continuous use up to 500°F (260ºC)

• safety glasses and cut-resistant gloves

• tape measure

• soft, clean, dry, oil-free cloths or paper towels

• detergent (without ammonia or bleaches) to remove used belt dirt and residue

• alcohol to sanitize and dry belt

• multiple F- or C-clamps

• spare two (2)-sided utility knife blades

2. Unload the Splicing System storage case contents near required electric power and the belt to be spliced.

5. Install new sprockets with new belting.

6. String the belt on the conveyor and follow

correct pulley wrap configuration. Avoid conveyor cross braces, legs, and other snags.

7. Trial-fit and mark the belt for length. Leave enough catenary sag so the belt NEVER runs under tension.

8. Place marked belt area or ends where the Splicing System can be easily and safely used.

Belt Splicing System v.2.0

3-1

3 SET UP THE SPLICING SYSTEM

FABRICATION TIP

Request assistance when moving or splicing with the 42" Splicing System.

retaining pin Crank Handle tether

1. Push Handle onto shaft 2. Insert retaining pin

Prepare Clamping Fixture

Secure Clamping Fixture to Conveyor

1. Choose a location to set up the Clamping Fixture.

Use the conveyor carryway frame when

possible. For returnway setup, see Set Up at the

Returnway on page 11-1.

• Place clamps ahead of the Clamping Fixture on an inclined conveyor to prevent sliding.

Figure 3B: Add clamps ahead of Clamping Fixture on an inclined conveyor

2. Place the Clamping Fixture on the conveyor frame under the two (2) belt ends or belt section to be removed.

Figure 3A: Clamping Fixture on horizontal conveyor

3. Use F- or C-clamps to secure the Clamping Fixture at the conveyor frame.

• Place clamps on Clamping Fixture ends on a horizontal conveyor.

Attach Crank Handle

1. Align the Crank Handle slot to the Clamping Fixture shaft and push the handle toward the Fixture frame.

Ensure the tether and its fastener face away

from the Clamping Fixture.

• Ensure Crank Handle can rotate 360°.

3-2

Figure 3C: Attach Crank Handle

Belt Splicing System v.2.0

2. Insert the tethered retaining pin into the hole

FABRICATION TIP

NOTE

on the shaft to secure the Handle in place.

3 SET UP THE SPLICING SYSTEM

Prepare the Heat Wand

Ensure the tether and fastener face outward.

If there are any concerns about adequate Fixture

operation, see Inspect the Clamping Fixture on

page 11-3.

Make Power Connections

1. Place the Heat Wand in the Stand and latch in place.

Figure 3D: Latch Heat Wand in Stand

2. Ensure the equipment voltage requirements match the available facility power voltage. If voltage does not match, see TROUBLESHOOT on page 10-1.

Figure 3E: Check voltage requirements

3. Connect the Wand Cord to the Heat Wand, then to the Temperature Control Box. Latch connections together.

Each Wand Cord connection fits into

only one component.

Do not force connections together.

Belt Splicing System v.2.0

3-3

3 SET UP THE SPLICING SYSTEM

NOTE

Do NOT submerge equipment or expose it to direct spray.

Always use ground fault protection/ residual current protection when operating in damp or wet conditions.

current setpoint

temperature temperature

4. Plug the Temperature Control Box Electric Cord into a facility electric outlet.

Adjust Temperature Setpoint

1. Choose the setpoint based on belt material.

Belt Material Setpoint

Temp.°F/°C

Polyurethane 8x26/8x50

XT 8026*

450° F/232° C 485° F/252° C

Figure 3F: Check voltage requirements

Ensure the outlet is close enough for the Heat

Wand to reach the Clamping Fixture.

5. Set the Temperature Control Box Power to ON. The Display shows the last setpoint temperature in green.

XT 8050

Cold Use 8050

HTL 8050

*discontinued

2. Press ▲ or ▼ to change the setpoint if needed.

475° F/246° C 500° F/260° C 500° F/260° C

Figure 3G: Turn Power on

3-4

Figure 3H: Check Control Box display

Belt Splicing System v.2.0

Allow Heat Wand to Pre-heat

NOTE

Contact with hot Heat Wand or Stand will cause skin burns. Using heatresistant gloves and sleeves is recommended.

Place the Stand on a hard, heat-resistant surface (NOT a belt) during preheat.

1. Allow the Heat Wand 10-20 minutes to reach the temperature setpoint and stabilize before removing it from the Stand.

2. While the Heat Wand pre-heats in the Stand, prepare the belt ends. See PREPARE BELT ENDS on page 4-1.

3 SET UP THE SPLICING SYSTEM



Release Stand latches before trying

to remove the Heat Wand.

Belt Splicing System v.2.0

3-5

NOTE

FABRICATION TIP

NOTE

4 PREPARE BELT ENDS

PREPARE BELT ENDS

Existing Belt: Cut away the damaged or excess belting, then prepare belt ends using instructions here.

Cut Hazard

Wear safety glasses and use caution when preparing belt ends.

Belt End Situations

The minimum sag requirement must be met to run

the belt without tension. Review the

ThermoDrive® Belting Conveyor Belting

Installation and Maintenance or contact Intralox

to determine correct belt length

BEFORE cutting any belt.

New Prepared-end Belt: New belts should arrive with two (2) prepared ends. If the belt is too long, cut away any excess belting and prepare belt ends using instructions here.

New Endless Belt: New endless belts arrive in a pre-spliced loop. If ordered correctly, you do not need to shorten a new belt. If the endless belt is too long, cut away the excess belting and prepare belt ends using instructions here.

Contact Intralox to order replacement belt sections

for splicing as needed.

Preparation Overview

Once a length of belt is confirmed to run without tension (meets the sag requirement), prepare belt ends for splicing.

Proper preparation is critical for correct drive bar pitch and contamination-free splicing.

Instructions for preparing belt ends can differ

by belt series, style, and troughing groove type.

These instructions provide the most

common cutting procedures. For S8126 belt,

see the SPECIAL PROCEDURES section of the

manual.

The 8026/8050 Cut Guide set is NOT for use

with metal lacing.

Contact Intralox with questions about metal lacing.

Belt Splicing System v.2.0

4-1

4 PREPARE BELT ENDS

FABRICATION TIP

Clean Belt Ends

1. If used belt has not been severed into belt ends, clean the belt area—top, bottom, and edges—where the belt will be severed.

2. If the belt is severed into two ends or the belt is new, clean the top, bottom, and edges of the belt ends for at least three (3) drive bars.

Use a food-safe detergent (without ammonia or

bleaches) and/or alcohol. Any cleaning agent

residue contaminates the splice.

Cut Belt Ends

Prepare each belt end to be spliced on the Clamping Fixture with drive bars face up or down using these instructions.

Complete all splicing procedures with drive

bars face down whenever possible. Completing

procedures on the returnway (drive bars face down) often requires more setup time and an

additional operator.

1. Choose the correct Cut Guide based on belt drive bar pitch.

Red (8050): 50 mm drive bar pitch Blue (8026): 26 mm drive bar pitch

2. Pull the belt end across both Grooved Decks until at least 1" (25 mm) of material is past the second Grooved Deck.

Figure 4A: Clean belt ends

3. Wipe dry before aligning. Use a clean, lintfree cloth or alcohol wipes.

Figure 4B: Pull the belt across BOTH decks, and align the drive bars with grooves

4-2

Belt Splicing System v.2.0

4 PREPARE BELT ENDS

FABRICATION TIP

Drive bars engaged in Grooved Deck grooves

Drive bars aligned with Grooved Deck grooves and engaged in Cut Guide

Wear safety glasses and use caution when handling knives and trim tools.

Belt end to Hold blade against Cut through belt to be prepared Cut Guide Edge Grooved Deck

3. Engage the drive bars in the Grooved Decks, if drive bars face down. Align the drive bars with the grooves on the Grooved Deck, if belt drive bars face up.

Figure 4C: Belt drive bar engagement/alignment

4. Lower the Cut Guide onto the Grooved Deck while holding the belt in place. Align the Locating Pins and holes. Ensure the recesses are under the Pivoting Stud thumb knobs.

5. Place each Pivoting Stud in a Cut Guide recess and finger-tighten the thumb knobs to hold the belt end securely.

Figure 4E: Tighten Cut Guide in place

Ensure the Cut Guide Edge faces

the belt end to be cut. The Grooved Deck

should extend past the Cut Guide Edge.

Figure 4D: Place Cut Guide on belt

To properly secure S8126 belts for cutting, see

S8126 BELT SPECIFICS on page 14-1.

Belt Splicing System v.2.0

Figure 4F: Check setup before cutting

4-3

4 PREPARE BELT ENDS

6. Hold the utility knife blade on the stainless cut surface of the Grooved Deck before the belt and vertically against the Cut Guide Edge.

Figure 4G: Hold the utility knife against the Cut Guide Edge

Inspect Belt Ends

Ensure the prepared belt end cuts meet these requirements.

 Belt ends are square, or perpendicular, to

the belt top surface and the belt edges.

7. Make several straight, identical, scoring cuts (rather than one deep cut) across the width of the belt. Any other belt scoring must be cut away.

8. When the belt is cut through, remove it from the Grooved Deck.

Figure 4H: Inspect cut belt ends

 Belt ends are straight, not wavy or jagged,

and do not contain scoring cuts that could hold contaminates.

For example, inspect the prepared end by holding it against the straight Cut Guide.

Figure 4I: Inspect cut

 Belt ends are dry and free of oils, residue,

debris, and liquid.

FAIL: If belt ends do NOT meet these requirements, troubleshoot until requirements are met. See TROUBLESHOOT on page 10-1.

4-4

PASS: When belt ends meet all requirements, align them for splicing. See ALIGN AND SECURE BELT ENDS on page 5-1.



Belt Splicing System v.2.0

FABRICATION TIP

Keep hands and fingers clear of fixture frame when opening the Clamping Fixture.

ALIGN AND SECURE BELT ENDS

Align Belt Ends

Avoid Injury.

Keep hands and fingers clear of Frame edge when opening the Clamping Fixture.

Contact with hot Heat Wand or Stand will cause skin burns; use caution.

If you are aligning S8126 belt ends, a belt with

1. Open the Clamping Fixture fully.

These instructions provide the

most common cutting procedures.

troughing grooves, or a belt with nubs, see

5 ALIGN AND SECURE BELT ENDS

SPECIAL PROCEDURES.

Prepare to Align

Ensure these requirements are met before aligning belt ends.

• The belt is strung on the conveyor.

• The belt is following the proper belt path.

• The belt ends are on the carryway.

• The Clamping Fixture is stable or secured on the conveyor frame or platform under the conveyor belt.

2. Clear any dust, debris, or residue from the Grooved Deck tops and edge.

The following extra step helps equalize the

clamping pressure across the belt ends.

Gather four (4) Belt Tabs that match the belt

series and style you are splicing.

Place one Belt Tab at each Grooved Deck end

between the Locating Pin and the Pivoting

Stud. Ensure the drive bars engage the grooves.

Belt Splicing System v.2.0

5-1

5 ALIGN AND SECURE BELT ENDS

FABRICATION TIP

Drive bars engaged in Grooved Deck grooves

Drive bars aligned with Grooved Deck grooves and engaged in Cut Guide

belt end extends past Deck Edge

Lightly Secure Belt Ends

1. Center a belt end on the closest Grooved Deck so the drive bars engage the grooves. If belt drive bars face up, align the drive bars with the grooves on the Grooved Deck.

3. Hold the belt end in place and align the Locating Pins and holes to lower a Cut Guide onto the Grooved Deck and belt end.

4. Ensure the Cut Guide stainless edge faces outward and the recesses are under the Pivoting Stud thumb knobs.

Figure 5C: Lower Cut Guide on Grooved Deck

5. Place each Pivoting Stud in a Cut Guide recess and lightly tighten the thumb knobs.

Figure 5A: Align belt ends on Grooved Deck

2. Ensure the belt end extends past the Grooved Deck edge about 0.16" (4 mm). If the belt ends are much more or less than 0.16" (4 mm), see TROUBLESHOOT on page 10-1.

Figure 5B: Belt ends extending

Figure 5D: Position and tighten thumb knobs

Tighten thumb knobs evenly to keep belt top

surface even across the Grooved Deck.

Using optional Belt Tabs on Grooved Deck

ends prevents over-tightening. See page 5-1.

5-2

Belt Splicing System v.2.0

5 ALIGN AND SECURE BELT ENDS

NOTE

FABRICATION TIP

6. Place the second belt end on the other Grooved Deck so the prepared edges face each other.

7. Then, with the Cut Guide stainless edge facing outward as on the first belt end, lightly secure the belt in place.

Check Alignment & Tightly Secure Belt Ends

1. Close–but do not lock–the Clamping Fixture, and release the Crank Handle to inspect alignment. Gently open and close the Clamping Fixture as needed throughout alignment.

2. Adjust the belt ends horizontally until they are aligned directly across from each other and the belt edges align.

Figure 5F: Align right and left belt edges

If belt ends are slightly different widths, center

the narrow belt across from the wider one

and trim belt edge corners after splicing.

If belt widths are more than

1/8" (3.2 mm) different, contact Intralox.

Figure 5E: Close the Clamping Fixture

When decks are closed but not locked, you can

open them by lightly pushing the Cut Guide metal

rails apart. If you hear a “click” when closing the

decks, the decks are locked and can only be

opened with the Crank Handle.

3. When belt edges are aligned, evenly fingertighten the thumb knobs on each Cut Guide.

4. Adjust thumb knob tightness until the belt top surfaces are vertically flush. If belt top surfaces cannot be vertically aligned, See TROU- BLESHOOT on page 10-1.

Figure 5G: Secure second belt end

Belt Splicing System v.2.0

5-3

5 ALIGN AND SECURE BELT ENDS

FABRICATION TIP

belt edges belt ends belt edges

5. Open the Clamping Fixture.

Inspect Alignment

Once belt ends aligned and secured, do not

allow the Clamping Fixture to close

suddenly or with force.

Inspect Tension

With belt ends secured, close–but do not lock– the Clamping Fixture. The Clamping Fixture setup must meet the following requirement before belt end alignment inspection.

 The Clamping Fixture remains closed

when the Crank Handle is released.

With the prepared belt ends touching lightly, confirm belt ends meet requirements below and prepared end requirements. See Inspect Belt Ends on page 4-4.

 Belt ends are parallel to each other with

less than 1/32" (0.75 mm) gap at all points along the belt ends (about the width of a credit card).

 Belt edges are aligned, or the narrow belt

end is centered across from the wider belt end with an offset of less than 1/16" (1.6 mm).

Figure 5H: Clamping Fixture closed–but not locked

FAIL: If the belt weight pulls the Clamping Fixture open, troubleshoot until the requirement is met. See Table of Preparing and Aligning Belt Ends Problems on page 10-4.

PASS: When the Clamping Fixture meets the requirement, inspect belt alignment.

Figure 5I: Inspect for gaps and horizontal alignment

5-4

Belt Splicing System v.2.0

 Belt end top surfaces are flush within 1/

FABRICATION TIP

64" (0.5 mm). This is most easily assessed by sliding the Skiver tip across the belt ends to ‘feel’ for an uneven surface.

Figure 5J: Inspect belt surface vertical alignment

5 ALIGN AND SECURE BELT ENDS

FAIL: If belt ends do NOT meet these requirements, troubleshoot until requirements are met. See TROUBLESHOOT on page 10-1.

PASS: When belt ends meet all requirements, fully open the Grooved Decks to splice the belt. See SPLICE THE BELT on page 6-1.

Once belt ends are aligned and secured, do not

allow the Clamping Fixture to close suddenly

or with force.



Belt Splicing System v.2.0

5-5

FABRICATION TIP

NOTE

6 SPLICE THE BELT

SPLICE THE BELT

Release Stand latches before trying

to remove the Heat Wand.

Avoid Injury.

Keep hands and fingers clear of Frame edge when opening the Clamping fixture.

Contact with hot Heat Wand or Stand will cause skin burns; use caution.

Keep Heat Wand in Stand between each splice.

Do NOT submerge equipment or

expose it to direct spray.

Prepare to Splice

1. Ensure these requirements are met before preparing to splice the belt ends.

• The Splicing System is set up according to instructions. See SET UP THE SPLICING SYSTEM on page 3-1.

• The belt ends are correctly aligned according to instructions. See ALIGN AND SECURE BELT ENDS on page 5-1.

• The Clamping Fixture is fully open.

2. Once the temperature setpoint is reached, hold the Heat Wand handle(s) and wipe plastic residue from the Heat Wand. Use a clean, dry cloth. An assistant may be needed.

Figure 6A: Clean residue from the Heat Wand

3. Return the clean Heat Wand to the Stand and fasten the latches.

Shield the Heat Wand and Clamping Fixture

from air flow during pre-heating and splicing.

If there is cold or moving air

in the splicing area,

see TROUBLESHOOT on page 10-1.

Belt Splicing System v.2.0

Figure 6B: Latch Heat Wand in Stand.

6-1

6 SPLICE THE BELT

NOTE

FABRICATION TIP

Request assistance when moving or splicing with the 42" Splicing System.

Contact with hot Heat Wand or Stand will cause skin burns; using heatresistant gloves and sleeves is recommended.

Keep Heat Wand in Stand between each splice.

4. Choose the correct melting time based on belt material.

Splice the Belt Ends

Belt Material Setpoint

Temp.

Polyurethane 8x26/8x50

XT 8026*

XT 8050 Cold Use

8050

HTL 8050

*discontinued

Do not remove the Heat Wand from the Stand until

the temperature stabilizes within ± 2° of the set-

point for at least one (1) minute.

450° F 232° C 45 sec. 2 min.

485° F 252° C 45 sec. 2 min.

475° F 246° C 2 min. 2 min.

500° F 260° C 30 sec. 2 min.

500° F 260° C 75 sec. 2 min.

Melt time

Cool time

These instructions provide the most common

splicing procedures. If the belt is S8126, see

Splice the Belt Ends on page 14-5.

1. With the temperature stabilized, remove the Heat Wand from the Stand.

6-2

Figure 6C: Remove the Heat Wand from the Stand

Temperature fluctuates above and below the set point when the Heat Wand is removed from the

Stand. Perform steps 2-4 as the temperature is near the setpoint and rising rather than falling.

Belt Splicing System v.2.0

6 SPLICE THE BELT

NOTE

FABRICATION TIP

NOTE

2. With the Clamping Fixture fully open, set the Heat Wand on both Wand Rests.

Figure 6D: Wand Rest at one end

3. Prepare the stopwatch.

The Heat Wand temperature can

vary ±20°F (12ºC) from the setpoint

when removed from the Stand. If needed,

see TROUBLESHOOT on page 10-1.

4. Close the Clamping Fixture gently, but quickly on the Heat Wand until the Clamping Fixture locks, i.e., a “click” sound occurs.

5. When the melt time is reached, quickly open the Grooved Decks fully and remove the Heat Wand.

Figure 6F: Remove Heat Wand

Steps 5 and 6 should occur as fluid motions.

6. While holding the Heat Wand, close the Grooved Decks within 3 seconds to push the melted belt ends together without force before they begin to cool.

Figure 6E: Close Clamping Fixture on Heat Wand

Do not allow the Clamping Fixture to close

suddenly or with force.

Belt Splicing System v.2.0

Figure 6G: Close Grooved Decks as Heat Wand is lifted

Figure 6H: Heat Wand removed and belt cooling

6-3

6 SPLICE THE BELT

FABRICATION TIP

Contact with hot Heat Wand or Stand will cause skin burns; using heatresistant gloves and sleeves is recommended.

Keep Heat Wand in Stand between each splice.

Allow the Belt to Cool

1. While the splice cools, hold the Heat Wand handle(s) and wipe plastic residue from the Heat Wand. Use a clean, dry cloth. An assistant may be needed.

2. Return the Heat Wand to the Stand. Latch in place.

3. After two (2) minutes of cooling (in normal room temperature conditions), remove the Cut Guides from the belt and inspect the splice.

Inspect the Splice

Ensure these requirements are met before trimming the belt.

 Belt ends are joined with a bead of molten

material.

 Molten material appears as a small, even

bead on the top, bottom, and sides of the splice.

Figure 6I: Wipe residue from the Heat Wand

Wipe the Heat Wand even if plastic residue is

not visible. Residue can cause faulty splices.

6-4

Figure 6J: Small, even weld bead

FAIL: If the splice does NOT meet these requirements, troubleshoot until all requirements are met. See TROUBLESHOOT on page 10-1.

PASS: When the splice meets all requirements, trim and inspect the belt. See TRIM & INSPECT THE BELT on page 7-1.



Belt Splicing System v.2.0

FABRICATION TIP

weld bead Skiver

TRIM & INSPECT THE BELT

3. Move the rounded blade on the Skiver from side to side at the belt edge to separate the weld bead from the belt top surface.

Cut/Puncture Hazard

Wear safety glasses and use caution when handling knives and trim tools.

Trimming Overview

Thorough weld bead removal is critical for splicing success. Remaining weld bead or flash contacting sprockets or the conveyor frame strains the splice and causes premature belt failure.

Figure 7B: Separate the weld bead from the belt

4. Hold the Skiver blade flat against the top surface, and push forward to trim the visible weld bead from the belt.

7 TRIM & INSPECT THE BELT

Trim First Weld Bead

Start removing the weld bead within

three (3) minutes of closing

the Clamping Fixture.

After 10 minutes, the splice is too hard to trim.

1. With the belt on the Clamping Fixture, move the weld bead to the stainless surface or other flat part of the Grooved Decks.

2. Secure the Cut Guide on the belt next to the weld bead.

Figure 7C: Remove the first weld bead

5. Remove the Cut Guide from the Clamping Fixture.

Collect all plastic remnants

and particles as they are created to avoid

product contamination.

Figure 7A: Secure the belt

Belt Splicing System v.2.0

7-1

7 TRIM & INSPECT THE BELT

FABRICATION TIP

Wear safety glasses and use caution when handling knives and trim tools.

Trim Second Weld Bead

The most common procedure for removing the

second weld bead is provided here.

For an alternate procedure,

see SPECIAL PROCEDURES on page 11-1.

1. If possible, remove the Clamping Fixture from the conveyor frame.

2. Have someone hold the belt up and away from the conveyor frame while holding the Cut Guide behind the weld bead.

Trim Belt Edges

1. Hold the Trimmers vertically against the belt edge and cut away any flash on either side.

Figure 7F: Trim flash from belt edges

2. Hold the Trimmers at the splice and cut diagonally toward the belt edge to trim rough spots or corners on belt edges.

Figure 7D: Remove the second weld bead

3. Use Trimmers to cut a small piece of the weld bead from the belt at the belt edge.

Figure 7E: Trim and skive

4. Place the Skiver blade under the cut weld bead and trim the entire weld bead from the belt.

Figure 7G: Trim rough edges or small corners

7-2

Belt Splicing System v.2.0

7 TRIM & INSPECT THE BELT

FABRICATION TIP

splice

3. Create a smooth belt edge without snags along the splice. Be sure not to puncture or score the belt.

Figure 7H: Create a smooth edge and discard debris

Collect plastic remnants

and particles as they are created, then

discard them away from belt and product.

Inspect the Belt

Ensure these requirements are met before running the belt.

 The belt top and bottom are smooth and

flat at the splice.

 Belt edges at the splice are smooth and

straight without any snags.

 The belt lies flat and smooth on the carry-

way without waves or bends.

 The drive bars on each side of the splice

engage Pitch Gauge notches. To inspect the drive bar pitch, use the cor-

rect side of the Pitch Gauge (8026 for 26 mm drive bar pitch and 8050 for 50 mm drive bar pitch) and inspect two (2) or more places along the splice.

Thorough weld bead and flash removal is critical for splicing success. Remaining weld bead or flash that contacts sprockets or the conveyor frame strains the splice and causes premature belt failure.

Allow the belt to cool at least five (5) minutes

before inspecting.

Figure 7I: Check pitch at splice

Belt Splicing System v.2.0

7-3

7 TRIM & INSPECT THE BELT

 When the belt is bent at the splice, the

splice has NO visible cracks or bubbles, and no more than two (2) small pits.

To inspect the splice, pull the belt edges together so the belt bends at the splice (as though it was around a 4" sprocket),

Figure 7J: Inspect for splice faults (e.g., bubbles shown here)

FAIL: If the belt splice does NOT meet all requirements, troubleshoot until all requirements are met. See TROUBLESHOOT on page 10-1.

PASS: When the belt meets all requirements, return the belt to production and shut down the Splicing System. See SHUT DOWN, COOL, & PACK UP on page 8-1.



7-4

Belt Splicing System v.2.0

NOTE

Request assistance when moving or splicing with the 42" Splicing System.

Heat Wand

and Stand

Coiled Cords

Temperature

Control Box

Clamping Fixture

with Cut Guides

SHUT DOWN, COOL, & PACK UP

5. Remove the Crank Handle from the Clamping Fixture and put it in the plastic bag.

6. Clean any accessories, PPE, or other compo-

Avoid Injury.

Contact with hot Heat Wand or Stand will cause skin burns; use caution.

Wear safety glasses and use caution when handling knives and trim tools.

nents and seal them in the plastic bag with the Crank Handle.

Cool Down

Let the Heat Wand and Stand cool completely (usually 15-20 minutes) in a safe place.

8 SHUT DOWN, COOL, & PACK UP

Consider completing the quarterly

Preventive Maintenance tasks

before shutting down the Splicing System.

Most of the tasks were already completed

during the Splicing process, see PERFORM

PREVENTIVE MAINTENANCE on page 15-1.

Shut Down & Clean

1. Set the Temperature Control Box Power to OFF and unplug it from the electric outlet.

2. Disconnect the Wand Cord from the Temperature Control Box and Heat Wand.

3. Coil and secure the Electric Cords.

4. Clean the Clamping Fixture with a clean, dry

cloth, close the Grooved Decks, and secure the Cut Guides in place.

Pack the Storage Case

1. With the storage case open, stand near the front latches and put the main components in using these instructions.

• Latch the Heat Wand in the Stand, then put the Heat Wand and Stand in the long compartment near the lid hinges.

• Put the Temperature Control Box in the middle compartment to the right.

Belt Splicing System v.2.0

Figure 8A: Pack main components

8-1

8 SHUT DOWN, COOL, & PACK UP

NOTE

• Put the coiled cords in the empty compartment next to the Temperature Control Box.

Storing Temperature Control Box with Heat Wand

cord attached can damage components.

• Put the Clamping Fixture in the long compartment near the hinges.

2. Put the plastic bag and any instructions or paperwork on top of the coiled cords.

3. Close the case and secure the recessed twist latches to prevent accidental opening and equipment damage.

The right twist latch includes a hasp

for extra security.

Figure 8B: Secure the twist latches

4. Store the case for future use.



8-2

Belt Splicing System v.2.0

TROUBLESHOOTING

NOTE

10 TROUBLESHOOT

TROUBLESHOOT

Procedures & Inspections

Avoid injury.

Contact with hot Heat Wand or Stand will cause skin burns; use caution.

Keep hands and fingers clear of fixture frame when opening the Clamping Fixture.

Use caution when handling knives and trim tools.

Do NOT attempt to cut, drill, or otherwise modify any electrical or mechanical components. Modifications may cause additional shock and burn hazards.

Troubleshooting Overview

This manual provides all procedures and instructions a facility maintenance technician needs to splice ThermoDrive belt ends together. Included here are troubleshooting tables with information about possible problems and suggestions for solving them.

Each problem appears in a gray box. Possible causes and solutions are listed under the gray box in order of likelihood. Use this information with the procedures and instructions in the manual text.

Multiple steps are required to complete a splice.

• System setup and inspection

• Belt end preparation

• Belt end alignment

• Splicing

• Trimming

Complete each task and inspect quality using checklists in the manual before starting the next task. Refer to the troubleshooting tables anytime an inspection is failed. Contact Intralox Technical Support with any questions.

Faulty Cuts & Splices

See the troubleshooting tables for detailed causes and remedies for faulty cuts and splices, but remember the requirements below.

Repeat Cuts

• Faulty prepared ends MUST be prepared again so the faulty end is cut away.

• Do NOT attempt to repair cuts.

Repeat Splices

• Faulty splices MUST be removed from the belt.

There are no user-serviceable components in the

Splicing System. Attempts to cut, drill, or

otherwise modify any electrical or mechanical

components voids the warranty.

Belt Splicing System v.2.0

• Do NOT splice the same prepared ends twice.

• Repeat the splicing procedure beginning with NEW prepared ends.

10-1

10-2

FABRICATION TIP

Contact with hot Heat Wand or Stand will cause skin burns. Using heat-resis- tant gloves and sleeves is recommended.

Place the Wand Stand on a hard, heat-resistant surface (NOT a belt) during pre-heat.

Table of Equipment/Facility Problems

Symptom & Possible Causes Action to Take

Voltage/Plug Mismatch

Error in ordering or shipping Contact Intralox Customer Service or Technical Support to correct error.

Temperature Control Box Display is blank or shows S.Err

Connection problem 1. Ensure equipment and facility voltages match.

2. Disconnect and reconnect all Control Box and Wand Cord connections inspecting for dam-

age. See Make Power Connections on page 3-3.

3. Set Control Box Power to on.

Internal damage Contact Intralox Technical Support for help.

Wand Cord is damaged/kinked

Wear or incorrect storage Contact Intralox Technical Support for replacement.

Continued use with damaged components can damage the Heat Wand and belt material.

Heat Wand tape is damaged

Wear or damage Contact Intralox Technical Support for repair instructions.

Heat Wand has plastic residue

Residue not removed after last splice

Belt Splicing System v.2.0

Remove residue before and after every splice. See Allow Heat Wand to Pre-heat on page 3-5.

Teflon tape damage Contact Intralox Technical Support for repair instructions.

Belt Splicing System v.2.0

NOTE

Heat Wand never reaches setpoint or varies erratically

Connection problem 1. Ensure equipment and facility voltage matches.

2. Disconnect and reconnect all connections inspecting for damage. See Make Power Connec-

tions on page 3-3.

3. Set Control Box Power to on.

Internal damage Contact Intralox Technical Support for help.

Heat Wand Temperature drops > 20°F/12ºC when out of Stand

Facility too cold High airflow in area

1. Increase facility temperature in splicing area if possible (above 40ºF/4ºC preferred)

2. Reduce air flow in splicing area if possible.

3. Shield splicing area from air flow with cardboard or similar.

4. Hold the Heat Wand in a controlled location outside of the Stand until it stabilizes at set point

before splicing.

5. Contact Intralox Technical Support for help.

Clamping Fixture not operating smoothly/easily

Mechanical problem 1. Remove visible debris from spring assemblies.

2. Apply gear lubricant to the moving parts at springs and linear bearings.

3. Contact Intralox Technical Support about bearing replacements or repair of bent frame,

Grooved Decks, or bearing shafts.

Do not disassemble the Clamping Fixture assembly. All components above are accessible

through Clamping Fixture openings. Attempts to cut, drill, or otherwise modify any

mechanical components voids the warranty.

Clamping Fixture not opening completely

Tool or clamp obstructing movement Ensure the Crank Handle can rotate 360º. Move any obstructions. Mechanical damage Contact Intralox Technical Support about possible bent components: Clamping Fixture frame,

10-3

Grooved Decks, bearing shafts, or spring linkage.

10-4

FABRICATION TIP

Symptom & Possible Causes Action to Take

Clamping Fixture metal pads do not touch when closed

Fixture closed improperly 1. Lock the Clamping Fixture closed.

2. Open the Clamping Fixture completely.

3. Repeat the inspection steps. See Ensure the tether and fastener face outward. on page 3-3.

Internal damage Contact Intralox for help.

Clamping Fixture does not stay closed unless locked

Belt tension too high 1. Clamp belt to conveyor frame near Clamping Fixture to eliminate pull on belt ends.

2. Adjust conveyor components to minimize tension.

Belt Tabs Lost/Missing

Belt Tabs lost or discarded • Make additional Belt Tabs from available belt material. See Make Belt Tabs on page 11-1.

• Contact Intralox Customer Service to order Belt Tabs.

Splicing with this issue can result in incorrect drive bar pitch.

Table of Preparing and Aligning Belt Ends Problems

Belt end not square (i.e., not perpendicular to belt top surface)

Repeat belt end preparation with attention to the following.

Cut technique • Hold blade vertically against Cut Guide Edge for entire cut.

• Make several identical, scoring cuts, NOT one deep cut.

Trim tool wear/damage Inspect knife for blade damage/wear. Repair/replace as needed.

Belt Splicing System v.2.0

Belt end wavy or curved

Repeat belt end preparation with attention to the following.

Cut technique • Make several identical, scoring cuts, NOT one deep cut.

• Hold blade vertically against Cut Guide Edge for entire cut.

Trim tool wear/damage Inspect knife for blade damage/wear. Repair/replace as needed. Cut Guide wear Check Cut Guide Edge for curves or waves. Contact Intralox Technical Support for equipment

damage.

Belt end diagonal (i.e., not parallel to drive bars)

Repeat belt end preparation with attention to the following.

Cut technique Make several identical, scoring cuts, NOT one deep cut. Alignment problem • Clean any debris from belt ends.

• Clear debris from grooves in Deck and Cut Guide.

• Check drive bar engagement before securing belt ends.

For S8126 belts, see S8126 BELT SPECIFICS on page 14-1.

Belt moved during cut • Clean any debris from belt ends.

• Clear debris from grooves in Deck and Cut Guide.

• Engage drive bars in Cut Guide or Grooved Deck before securing.

• Fully secure belt to Clamping Fixture.

For S8126 belts, see S8126 BELT SPECIFICS on page 14-1.

Belt end has jagged cut

Repeat belt end preparation with attention to the following.

Trim tool wear/damage Inspect knife for blade damage/wear. Repair/replace as needed. Cut technique • Begin cut at belt edge (not on belt).

• Cut full width of belt each time.

10-5

10-6

FABRICATION TIP

Symptom & Possible Causes Action to Take

Difficult to pull belt onto the Fixture

Belt tension too high 1. Ensure belt is cut to proper length.

2. Clamp belt to conveyor frame near Clamping Fixture to eliminate pull on belt ends.

3. Adjust conveyor components to minimize tension.

Drive bars snagging on Clamping Fixture or C- or F-clamps

• Angle cardboard from Clamping Fixture edge to conveyor frame to allow the belt to slide

onto Fixture.

• Adjust clamps as needed.

• Request assistance for handling wide belts.

Belt end extends too far/too little past Grooved Deck edge

Drive bars not engaged 1. Clean debris from belt ends.

2. Clear debris from grooves in Deck and Cut Guide.

3. Engage drive bars in Cut Guide or Grooved Deck before securing.

Wrong Cut Guide used Repeat belt end preparation using the blue S8026 Cut Guide for 26 mm pitch belt or red S8050

Cut Guide for 50 mm pitch belt.

Belt end edges are offset (horizontal misalignment)

Ends different widths • If belt end widths are within 1/8" (3 mm) of each other, center the narrow belt end across

from the wide belt end.

• If belt end widths are more than 1/8" (3 mm) different from each other, contact Intralox Tech-

nical Support.

Slight dimension differences, within 1/16" (1.5 mm) on each edge

(or 1/8" (3 mm) total belt width), are acceptable when splicing belts.

Belt Splicing System v.2.0

Belt end top surfaces are offset (vertical misalignment)

Thumb knobs not tightened evenly Adjust thumb knobs to increase or decrease Cut Guide pressure on belt ends until belt top sur-

faces are flush.

Belt Splicing System v.2.0

Clamping Fixture secured to uneven surface causing vertical offset of Grooved Decks

Troughing grooves cause belt end sag If the belt has troughing grooves, shim the Grooved Decks with Painters’ tape. See TROUGH-

S8126 belt needs shimming For S8126 belt, see S8126 BELT SPECIFICS on page 14-1.

Table of Faulty Splice Problems

Splice area not smooth after trimming

More trimming needed Within five (5)-10 minutes of cooling time, complete the following steps.

Trim tool wear/damage • Inspect Skiver for blade damage/wear. Repair/replace as needed.

If one belt end is lower than the other across the full belt width, shim the lower Deck with Painters’ tape. See Make Belt Tabs on page 11-1.

ING GROOVES SPECIFICS on page 13-1.

• Trim away all weld beads and flash using the Skiver and Trimmers within 10 minutes.

• Feather offset belt edges together to eliminate snags. If belt ends are offset more than 1/16"

(1.5 mm), repeat the splice. If belt widths are more than 1/8" (3 mm) different, contact Intralox Technical Support.

See TRIM & INSPECT THE BELT on page 7-1.

• Inspect Trimmers for damage/wear. Repair/replace as needed.

10-7

Weld bead/flash too cool to trim After about 10 minutes of cooling, the splice is too hard to trim properly.

1. Cut the splice completely from the belt and repeat the full splicing procedure.

2. Do not allow splice to cool more than three (3) minutes before beginning to trim.

Belt ends or edges are offset See Splice Offset at . . . symptom below.

10-8

Contact with hot Heat Wand or Stand will cause skin burns. Using heat-resis- tant gloves and sleeves is recommended.

Place the Wand Stand on a hard, heat-resistant surface (NOT a belt) during pre-heat.

Contact with hot Heat Wand or Stand will cause skin burns. Using heat-resis- tant gloves and sleeves is recommended.

Place the Wand Stand on a hard, heat-resistant surface (NOT a belt) during pre-heat.

Symptom & Possible Causes Action to Take

Splice burned or damaged

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Temperature or time set too high • Adjust setpoint to recommended temperature.

• Melt belt ends for recommended time.

See Splice the Belt Ends on page 6-2.

Plastic residue on Wand during splice

Remove residue before and after every splice. See Allow Heat Wand to Pre-heat on page 3-5.

Wand Cord damage If Control Box actual temperature display is much higher than set point, contact Intralox Tech-

nical Support.

Splice has uneven melting/weld bead

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Plastic residue on Wand during splice

Remove residue before and after every splice. See Allow Heat Wand to Pre-heat on page 3-5.

Dirt or residue on belt ends 1. Clean belt ends with a food-safe detergent (without ammonia or bleach).

2. Sanitize and dry ends with isopropyl alcohol and a clean lint-free rag.

Belt Splicing System v.2.0

3. Avoid direct hand contact within 2 drive bars of prepared end.

Belt Splicing System v.2.0

Ends wavy, diagonal, or not square • Inspect knife for blade damage/wear. Repair/replace as needed.

• Clean debris from belt surfaces.

• Clear debris from grooves in Deck and Cut Guide.

• Check drive bar engagement before securing belt ends.

• Fully secure belt in Clamping Fixture.

For S8126 belt, see S8126 BELT SPECIFICS on page 14-1.

• Hold blade vertically against Cut Guide Edge for entire cut.

• Make several identical, scoring cuts, NOT one deep cut.

Ends moved/not secure • Clean debris from belt surfaces.

• Clear debris from grooves in Deck and Cut Guide.

• Check drive bar engagement before securing belt ends.

• Fully secure belt in Clamping Fixture.

For Nub Top belt surfaces, see NUB TOP STYLE SPECIFICS on page 12-1. For S8126 belt, see S8126 BELT SPECIFICS on page 14-1.

Clamping Fixture slammed shut for cooling

Maintain control of the Crank Handle when closing the Clamping Fixture for splice cooling. Allowing Grooved Decks to slam closed causes molten splash and possible misalignment.

Splice has little/no melting (e.g., no weld bead)

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Wrong Cut Guide used Repeat belt end preparation using the blue S8026 Cut Guide for 26 mm pitch belt or red S8050

Cut Guide for 50 mm pitch belt.

Temperature or time set incorrectly • Adjust setpoint to recommended temperature.

• Melt belt ends for recommended time.

See Splice the Belt Ends on page 6-2.

Heat Wand not pre-heated Allow Heat Wand 10-20 minutes to reach setpoint and stabilize before splicing.

Splice has little/no melting (e.g., no weld bead) continued on next page

10-9

10-10

Symptom & Possible Causes Action to Take

Splice has little/no melting (e.g., no weld bead) continued from previous page

Facility too cold High airflow in area

1. Increase facility temperature in splicing area if possible (above 40ºF/4ºC preferred).

2. Reduce air flow mechanically if possible.

3. Shield splicing area from air flow with cardboard or similar.

4. Hold the Heat Wand in a controlled location outside of the Stand until it stabilizes at set point

before splicing.

5. Contact Intralox Technical Support for suggestions.

Ends moved/not secure • Clean debris from belt surfaces.

• Clear debris from grooves in Deck and Cut Guide.

• Check drive bar engagement before securing belt ends.

• Fully secure belt in Clamping Fixture.

For Nub Top belt surfaces, see NUB TOP STYLE SPECIFICS on page 12-1. For S8126 belt, see S8126 BELT SPECIFICS on page 14-1.

Equipment damage Review possible equipment problems. See Table of Equipment/Facility Problems on page 10-

Splice has faulty drive bar pitch

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Wrong Cut Guide used Repeat belt end preparation using the blue S8026 Cut Guide for 26 mm pitch belt or red S8050

Cut Guide for 50 mm pitch belt.

Cut alignment technique Splice alignment technique

• Clean debris from belt ends.

• Clear debris from grooves in Deck and Cut Guide.

• Check drive bar engagement before securing belt ends.

For S8126 belts, see S8126 BELT SPECIFICS on page 14-1.

• Ensure proper procedure is being used for the series, style, and type belt being aligned.

Belt Splicing System v.2.0

Splice technique Ensure proper procedure is being used for the series, style, and type belt being aligned. See

SPLICE THE BELT on page 6-1.

Belt Splicing System v.2.0

Belt tension too high 1. Clamp belt to conveyor frame near Clamping Fixture to eliminate pull on belt ends.

2. Adjust conveyor components to minimize tension.

Clamping Fixture not properly closing • Clear any debris between Grooved Decks.

• Clamping Fixture damaged. See Table of Equipment/Facility Problems on page 10-2.

Splice breaks when bent

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Wrong Cut Guide used Repeat belt end preparation using the blue S8026 Cut Guide for 26 mm pitch belt or red S8050

Cut Guide for 50 mm pitch belt.

Temperature or time set incorrectly • Adjust setpoint to recommended temperature.

• Melt belt ends for recommended time.

See Splice the Belt Ends on page 6-2.

Bet splice not cool enough • Move spliced belt as gently as possible as it cools.

• Do not bend splice for inspection until the belt has cooled at least five (5) minutes at normal

room temperature.

Clamping Fixture slammed shut for cooling

Maintain control of the Crank Handle when closing the Clamping Fixture for splice cooling. Allowing Grooved Decks to slam closed causes molten splash and possible misalignment.

Splice has visible bubbles or pits

Some pitting is expected in used belt ends, but must be minimal. Large pits or consecutive small pits indicate a faulty splice. Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Temperature or time too high • Adjust setpoint to recommended temperature.

• Melt belt ends for recommended time.

See Splice the Belt Ends on page 6-2.

Splice has visible bubbles or pits continued on next page

10-11

10-12

Contact with hot Heat Wand or Stand will cause skin burns. Using heat-resis- tant gloves and sleeves is recommended.

Place the Wand Stand on a hard, heat-resistant surface (NOT a belt) during pre-heat.

Symptom & Possible Causes Action to Take

Splice has visible bubbles or pits continued from previous page

Dirt or residue on belt ends 1. Clean belt ends with a food-safe detergent (without ammonia or bleach).

2. Sanitize and dry ends with isopropyl alcohol and a clean lint-free rag.

3. Avoid direct hand contact within 2 drive bars of prepared end.

Plastic residue on Wand during splice

Remove residue before and after every splice. See Allow Heat Wand to Pre-heat on page 3-5.

Clamping Fixture slammed shut for cooling

Maintain control of the Crank Handle when closing the Clamping Fixture for splice cooling. Allowing Grooved Decks to slam closed causes molten splash and possible misalignment.

Clamping Fixture not properly closing • Clear any debris between Grooved Decks.

• Clamping Fixture damaged. See Table of Equipment/Facility Problems on page 10-2.

Belt tension too high 1. Clamp belt to conveyor frame near Clamping Fixture to eliminate pull on belt ends.

2. Adjust conveyor components to minimize tension.

Splice has visible cracks

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Wrong Cut Guide used Repeat belt end preparation using the blue S8026 Cut Guide for 26 mm pitch belt or red S8050

Cut Guide for 50 mm pitch belt.

Cut technique or alignment problem • Make several identical, scoring cuts, NOT one deep cut.

• Hold blade vertically against Cut Guide Edge for entire cut.

• Engage drive bars in Cut Guide or Grooved Deck before securing.

Belt Splicing System v.2.0

• Fully secure belt to Clamping Fixture. For S8126 belts, see S8126 BELT SPECIFICS on page 14-1.

Belt Splicing System v.2.0

Equipment damage • Inspect knife for blade damage/wear. Repair/replace as needed.

• Check Cut Guide Edge for curves or waves. Contact Intralox Technical Support about equip-

ment damage.

Clamping Fixture not properly closing • Clear any debris between Grooved Decks.

• Clamping Fixture damaged. See Table of Equipment/Facility Problems on page 10-2.

Belt not lying flat on Carryway

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Cut technique • Clean belt ends with a food-safe detergent (without ammonia or bleach).

• Clear debris from grooves in Deck and Cut Guide.

• Check drive bar engagement before securing belt ends.

For S8126 belts, see S8126 BELT SPECIFICS on page 14-1.

• Make several identical, scoring cuts, NOT one deep cut.

Poor alignment • Clean debris from belt surfaces.

• Clear debris from grooves in Deck and Cut Guide.

• Check drive bar engagement before securing belt ends.

• Fully secure belt in Clamping Fixture.

For Nub Top belt surfaces, see NUB TOP STYLE SPECIFICS on page 12-1. For S8126 belt, see S8126 BELT SPECIFICS on page 14-1.

10-13

Belt tension too high 1. Clamp belt to conveyor frame near Clamping Fixture to eliminate pull on belt ends.

2. Adjust conveyor components to minimize tension.

10-14

FABRICATION TIP

Symptom & Possible Causes Action to Take

Splice offset at edges (horizontal misalignment)

Belt ends not properly aligned Belt ends different widths

• If belt edge offset is greater than 1/16" (1.5 mm), the splice is faulty. Cut the faulty splice

from the belt and repeat the splicing procedures with careful attention to alignment.

• If belt edge offset is 1/16" (1.5 mm) or less, trim off snags and use trim tools to smooth belt

edges before the splice fully cools.

• If belt end widths measure more than 1/8" (3 mm) different from each other, contact Intralox

Technical Support.

Slight dimension differences, within 1/16" (1.5 mm) on each edge

(or 1/8" (3 mm) total belt width), are acceptable when splicing belts.

Splice offset at top surfaces (vertical misalignment)

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Belt top surfaces not properly aligned • Adjust thumb knobs to increase or decrease Cut Guide pressure on belt ends until belt top

surfaces are flush.

• If one belt end is lower than the other across the full belt width, shim the lower Deck with

Painters’ tape. See Make Belt Tabs on page 11-1.

• If the belt has troughing grooves, shim the Grooved Decks with Painters’ tape. See

TROUGHING GROOVES SPECIFICS on page 13-1.

• For S8126 belt, see S8126 BELT SPECIFICS on page 14-1.

Equipment damage Cut Guides are bent. Contact Intralox.

This is often caused by over-tightening thumb knobs causing the Cut Guides to bow or warp.

Belt Splicing System v.2.0

Table of Belt Failures

Splice Tears in Production

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Splice was not inspected before running See TRIM & INSPECT THE BELT on page 7-1.

Weld bead/flash snagging on conveyor frame

Too much belt removed during trimming Skive raised weld bead from the flat belt surfaces; do not create a channel at the splice. Wrong Cut Guide used Repeat belt end preparation using the blue S8026 Cut Guide for 26 mm pitch belt or red S8050

Temperature or time set incorrectly • Adjust setpoint to recommended temperature.

1. Check trim tools for damage or wear.

2. Skive both top and bottom weld beads.

3. Be sure to smooth snags or offsets from belt edges.

Cut Guide for 50 mm pitch belt.

• Melt belt ends for recommended time. See Splice the Belt Ends on page 6-2.

Belt not engaging sprockets

Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.

Drive bar pitch faulty Inspect drive bar pitch at splice with Pitch Gauge. If pitch does not meet inspection, repeat

splicing procedure with special attention to the following:

• Clean debris from belt ends.

• Clear debris from grooves in Deck and Cut Guide.

• Engage drive bars in Cut Guide or Grooved Deck before securing.

• Use the blue S8026 Cut Guide for 26 mm pitch belt or red S8050 Cut Guide for 50 mm pitch

belt.

Belt not engaging sprockets continued on next page

10-15

10-16

Symptom & Possible Causes Action to Take

Belt not engaging sprockets continued on next page

Sprockets are misaligned on shaft See ThermoDrive® Belting Conveyor Belting Installation and Maintenance at the Intralox

website.

Belt tension too high See ThermoDrive® Belting Conveyor Belting Installation and Maintenance at the Intralox

website.



Belt Splicing System v.2.0

SPECIAL PROCEDURES

NOTE

Wear safety glasses and use caution when handling knives and trim tools.

SPECIAL PROCEDURES

Avoid Injury.

Keep hands and fingers clear of Frame edge when opening the Clamping Fixture.

Contact with hot Heat Wand or Stand will cause skin burns; use caution.

Wear safety glasses and use caution when handling knives and trim tools.

Set Up at the Returnway

11 SPECIAL PROCEDURES

3. Ensure there is adequate space above and around the Clamping Fixture for Heat Wand movement.

Make Belt Tabs

If Belt Tabs are lost or missing, use scrap belt, a utility knife, and Cut Guide to make new ones.

1. Cut a 1" (25 mm) strip from a belt end using the belt end preparation procedure.

When it is difficult or impossible to splice on the carryway, the Splicing System can be set up to splice the belt at the returnway using these steps.

Returnway splicing may require more assistance.

1. Place the Clamping Fixture on a sturdy, flat, portable surface.

2. Position the Clamping Fixture and supporting surface under the conveyor frame returnway near the belt ends.

All Belt Tabs must have one drive bar.

Figure 11B: Make a Belt Tab

2. Lay the strip on a flat, solid surface and cut it into 0.5" (13 mm) pieces. At least four are used for each splice.

Figure 11A: Place the Clamping Fixture on a flat, stable surface

Belt Splicing System v.2.0

11-1

11 SPECIAL PROCEDURES

FABRICATION TIP

NOTE

Grooved Deck edge (under tape)

first groove

Wear safety glasses and use caution when handling knives and trim tools.

Shim for Belt Top Surface (Vertical) Alignment

If the Cut Guide thumb knobs have been adjusted, but one belt top surface is higher than the other, shim with Painters’ tape.

If top surface alignment is intermittent, see

TROUGHING GROOVES SPECIFICS on page

13-1. If splicing S8126, see S8126 BELT SPE-

CIFICS on page 14-1.

Shim the Grooved Deck on the lower side using these steps.

1. Cut a length of tape wider than the belt width.

2. Center the tape on the Grooved Deck next to the first groove so it extends past the Deck edge and press it in place.

3. Use the utility knife to trim the tape at the Deck edge.

Figure 11D: Trim away excess tape

4. Replace the belt end in the Clamping Fixture using normal alignment procedures.

Figure 11C: Apply tape at Deck edge

11-2

Figure 11E: Replace the belt end

Tape layers can be added and removed in areas as

needed until belt top surfaces are aligned.

Belt Splicing System v.2.0

11 SPECIAL PROCEDURES

Trim the Second Weld Bead— Alternative Technique

If working alone or with low clearance, consider this alternative technique for removing the second weld bead from the belt splice.

1. After the first weld bead is removed, leave the Clamping Fixture in place.

2. Place the Cut Guide rail between the Grooved Decks, and bend the belt back so it lies on the flat Cut Guide base.

Inspect the Clamping Fixture

Ensure the Clamping Fixture meets the following requirements before aligning belt ends.

 The Clamping Fixture Grooved Decks

open smoothly when the Crank Handle is turned counter-clockwise.

Figure 11G: Open Clamping Fixture

 The Clamping Fixture closes smoothly

when the Crank Handle is turned clockwise, then locks closed at the “click.”

Figure 11F: Bend belt back onto Cut Guide

3. Use Trimmers to cut a small piece of the weld bead from the belt at the belt edge.

4. Place the Skiver blade under the cut weld bead and trim the weld bead from the belt.

5. To finish trimming and inspecting the belt, see Trim Belt Edges on page 7-2.

 Ensure the pads on each end of the

Clamping Fixture touch. Middle Clamping Fixture pads do not have to touch.

Figure 11H: Close Clamping Fixture and ensure metal pads touch

Belt Splicing System v.2.0

11-3

11 SPECIAL PROCEDURES

If the Clamping Fixture does not meet these requirements, see TROUBLESHOOT on page 10-1.



11-4

Belt Splicing System v.2.0

NUB TOP STYLE SPECIFICS

Remove Nubs

Use the Skiver to remove all nubs within 0.5"

Avoid Injury.

Keep hands and fingers clear of Frame edge when opening the Clamping

Fixture.

Contact with hot Heat Wand or Stand will cause skin burns; use caution.

Wear safety glasses and use caution when handling knives and trim tools.

Nub Top Overview

(12 mm) of each belt end.

Figure 12B: Remove nubs from splicing area

12 NUB TOP STYLE SPECIFICS

Nubs can hinder secure belt end clamping and make belt trimming difficult.

Figure 12A: Nub Top Samples

When splicing belts with a Nub Top surface, include these steps in the procedure for best results.

• Before aligning belt ends, remove nubs at belt ends to allow proper trimming after splicing.

• Before aligning belt ends, prepare the Silicone Spacers.

Prepare Silicone Spacers for Use

Cut four (4) 0.5" (12 mm) lengths of Silicone Spacer and ensure the remaining two strips fit between the Grooved Deck Locating Pins.

Figure 12C: Spacers for 42" Clamping Fixture

• When aligning belt ends, use Silicone Spacers to clamp belt ends securely.

Belt Splicing System v.2.0

12-1

12 NUB TOP STYLE SPECIFICS

FABRICATION TIP

belt end extends past Deck edge

Use Silicone Spacers

Position Silicone Spacer strips between belt nubs and the Cut Guides (or Grooved Decks, if drive bars face up) during alignment.

Figure 12D: Place Cut Guide on Silicone Spacer

Place Spacer strips on Belt Tabs, if used.

Ensure Spacer strips do not extend past Grooved Deck edges. Spacer strips should not contact the Heat Wand during splicing.

Figure 12E: Align Silicone Spacer with Deck edge



12-2

Belt Splicing System v.2.0

FABRICATION TIP

Grooved Deck edge (under tape)

first groove

TROUGHING GROOVES SPECIFICS

Shim the Grooved Deck

Avoid Injury.

Keep hands and fingers clear of Frame edge when opening the Clamping

Fixture.

Contact with hot Heat Wand or Stand will cause skin burns; use caution.

Wear safety glasses and use caution when handling knives and trim tools.

If belt top surfaces are not flush (vertically

misaligned) where troughing grooves meet,

shim the Grooved Deck with Painters’ tape.

Use these guidelines to shim Grooved Decks during belt end alignment.

Tape Length: Start with a piece of tape about the same length as the belt width.

13 TROUGHING GROOVES SPECIFICS

Troughing Groove Overview

A troughing groove can cause a slight sag in the belt top surface that can affect splicing quality.

Figure 13A: Troughing groove samples

When splicing belts with troughing grooves wider than 2" (50 mm), consider including these steps in the procedure at the beginning or if belt top surfaces are not aligned.

Tape Placement: Center the tape along the length of the Grooved Deck. Adhere the tape next to the first Grooved Deck groove so it extends past the Deck edge.

Figure 13B: Center tape at Grooved Deck edge

Splice on the carryway with drive bars

face down for best results.

Belt Splicing System v.2.0

13-1

13 TROUGHING GROOVES SPECIFICS

Wear safety glasses and use caution when handling knives and trim tools.

Trim the Tape

Trim the tape along the deck edge to prevent tape contact with Heat Wand during Splicing.

Make Adjustments: Adjust tape length, placement, and layers as needed during alignment to ensure belt top surfaces align.

Figure 13E: Finish belt end alignment

Figure 13C: Trim tape width

Use the troughing groove(s) at the belt end as a guide to trim and remove tape from the areas with drive bars.

Figure 13D: Trim tape length



13-2

Belt Splicing System v.2.0

FABRICATION TIP

14 S8126 BELT SPECIFICS

S8126 BELT SPECIFICS

Use a 24" Splicing System and splice with

drive bars face down for best results.

Avoid Injury.

Keep hands and fingers clear of Frame edge when opening the Clamping

Fixture.

Contact with hot Heat Wand or Stand will cause skin burns; use caution.

Wear safety glasses and use caution when handling knives and trim tools.

S8126 Overview

The smooth edges on S8126 belting provide challenges when splicing. The thickness variations and limited drive bar engagement require special attention.

It is important to know the standard TD Splicing System operation and procedures before beginning. But, these techniques and guidelines are critical for successful splicing.

Read all instructions in detail before preparing, aligning, or splicing belt ends.

Prepare the Belt Ends: When preparing S8126 belt ends, include these steps in the procedure.

• Shim the smooth edges.

• Use thin Belt Tabs.

• Repeatedly inspect alignment.

• Hold the Cut Guides to secure the belt.

• Add the second Cut Guide.

• Inspect cuts for squareness.

Align & Secure Belt Ends: When aligning and securing S8126 belt ends to be spliced, include these steps in the procedure.

• Remove any belt tension.

• Check for Tape Shims and Belt Tabs.

• Repeatedly inspect alignment.

• Control Crank Handle during alignment.

• Hold the Cut Guides to secure the belt.

Splice the Belt Ends: When splicing S8126 belt ends, add controlling the Crank Handle and closing the Clamping Fixture gently to the procedure.

Figure 14A: S8126 Samples

Belt Splicing System v.2.0

Trim & Inspect the Belt: When trimming and inspecting S8126 belt splices, use special care when inspecting drive bar pitch and drive bar alignment.

14-1

14 S8126 BELT SPECIFICS

FABRICATION TIP

6 mm TD 8126 FT belt

5.3 mm Belt Tab

Preparing Belt Ends

Shim the Smooth Edges to Secure Belt Ends

Tape shims must raise the smooth belt edges so

they can be secured by the Cut Guide, but not

so much that the belt drive bars can not engage

the Grooved Decks.

With the belt drive bars face up, use these guidelines to layer Painters’ tape on the smooth edges before cutting or aligning.

• Adhere tape from the drive bar ends to the belt edges. Keep the tape edge at least 0.25" (6-7 mm) from where the prepared end will be cut. This allows you to leave tape in place for splicing.

Use Thin Belt Tabs to Secure Belt Ends

Use these guidelines to correctly place one (1) Belt Tab between each Pivoting Stud and Locating Pin before lightly securing belt ends.

• Use Flat Top Belt Tabs slightly thinner than the belt, e.g., use 5.3 mm Flat Top tabs for 6 mm S8126 Flat Top belt.

Figure 14C: Choose Belt Tabs thinner than belt

• Ensure the Belt Tab drive bars engage the grooves.

• Trim the tape at the belt edges. Do not

score the belt.

Figure 14B: Trim tape at the belt edges

• Stop layering tape as soon as the tape top surface is even with the belt surface between drive bars.

Figure 14D: Place Belt Tabs on Grooved Decks

14-2

Belt Splicing System v.2.0

14 S8126 BELT SPECIFICS

90°

Repeatedly Inspect Alignment before Cutting

To align the belt ends on Grooved Decks for cutting or splicing, use the following guidelines.

Check Parallel Alignment: Ensure the belt ends are visibly parallel to the Cut Guides when first placing belts and again just before splicing.

Check Perpendicular Alignment: Use a square edge to ensure each belt edge is perpendicular to the Cut Guide when placing belts and again just before splicing.

Figure 14E: Inspect with square edge

Add the Second Cut Guide to Secure Belt for Cutting

With the belt end properly aligned and tightly secured, place the 8050 Cut Guide on the second locked Grooved Deck. Hold the Cut Guide against the Belt Tabs and hand-tighten the thumb knobs.

Figure 14G: Secure the second Cut Guide in place

Inspect Cuts for Squareness

When the cuts are complete, inspect each prepared end for straight, square cuts. Hold it against the straight Cut Guide and use a square to check for 90° corners.

Hold the Cut Guides when Fully Tightening Thumb Knobs

Hold the Cut Guides against the Belt Tabs, while finger-tightening the thumb knobs evenly at each belt edge.

Figure 14F: Clamp belt edges securely

Figure 14H: Inspect cut

Belt Splicing System v.2.0

14-3

14 S8126 BELT SPECIFICS

FABRICATION TIP

90°

Align & Secure Belt Ends

For best results, use a 24" Splicing System and

align belts with drive bars face down.

To align and secure S8126 belt ends for splicing, include these steps in the procedure.

Remove any Belt Tension

To minimize pull on the belt ends, ensure adequate belt slack is provided on each side of the Clamping Fixture.

Check for Shims and Belt Tabs

1. Ensure tape shims are on belt smooth edges.

2. Ensure there is one (1) Belt Tab between

each Pivoting Stud and Locating Pin. If Belt Tabs are missing, see Use Thin Belt Tabs to Secure Belt Ends on page 14-2.

Repeatedly Inspect Alignment

Check Parallel Alignment: Ensure the belt ends are visibly parallel to the Grooved Deck when first placing belts, aligning belt ends, and just before splicing.

Check Perpendicular Alignment: Use a square edge to ensure each belt edge is perpendicular to the Cut Guide when placing belts, aligning belt ends, and just before splicing.

Figure 14J: Inspect with square edge

Control Crank Handle During Alignment

Figure 14I: Place thin Belt Tabs on Grooved Decks

Gently open and close the Clamping Fixture to inspect belt end alignment. Do not allow belt ends to touch.

Figure 14K: Inspect touching ends

Normal clamping force can

cause belt end misalignment. Maintain control

of Crank Handle at all times.

14-4

Belt Splicing System v.2.0

14 S8126 BELT SPECIFICS

FABRICATION TIP

Hold the Cut Guides when Fully Tightening Thumb Knobs

Hold the Cut Guides against the Belt Tabs, while finger-tightening the thumb knobs evenly at each belt edge.

Figure 14L: Clamp belt edges securely

Check for secure clamping by tugging gently

on the belt edges just before splicing.

Splice the Belt Ends

Because S8126 belting is difficult to clamp securely, even normal clamping force can shift the belt ends during splicing. When splicing belt ends, include these steps in the procedure.

Control the Crank Handle for 25 Seconds of Melting

Turn the Crank Handle gradually so melting belt ends maintain contact with the Heat Wand for the first 25 seconds, then lock the Clamping Fixture closed.

If the belt moves when pulled, consider adding

an additional tape layer to the tape shims. Do

not add so much that belt drive bars cannot

engage the Grooved Decks.

Figure 14M: Maintain control of the Crank Handle

Close Decks Gently for Cooling

When removing the Heat Wand, control the Crank Handle to close the Clamping Fixture completely, but gently.

Normal clamping force can

cause belt end misalignment. Maintain control

of Crank Handle at all times.

Belt Splicing System v.2.0

14-5

14 S8126 BELT SPECIFICS

NOTE

Trim & Inspect the Belt

To trim and inspect S8126 belt splices, add these steps to the procedure.

• Use special care when inspecting drive bar pitch.

• Use a square edge to ensure drive bar ends are aligned within 1/16" (1.6 mm) and are perpendicular to the belt edge.

Figure 14N: Inspect drive bar alignment

Remove tape shims before running the belt.



14-6

Belt Splicing System v.2.0

PREVENTIVE MAINTENANCE

15 PERFORM PREVENTIVE MAINTENANCE

PERFORM PREVENTIVE MAINTENANCE

Use caution when handling knives and trim tools.

Keep hands and fingers clear of Frame

Avoid injury.

Contact with hot Heat Wand or Stand will cause skin burns; using heat-resis-

tant gloves and sleeves is recommended.

Perform the following procedures quarterly to ensure the Splicing System is in good working order when you need it most.

edge when opening the Clamping Fixture.

Tech.

Initials

Maintenance Procedure to Perform

Ensure all components are in the Splicing System storage case. See SPLICING SYSTEM COMPONENTS on page 2-1. See the Intralox website or enclosed documents for a list of available replacement parts if needed.

Ensure the Instruction Manual is in the storage case. Ensure safety labels are adhered per photographs in this manual. See Belt

Splicing System Hazards on page -3. Contact Intralox or Clarion Safety for replacement labels if needed.

Set up the Splicing System and inspect for the following:

• Ensure the Clamping Fixture opens easily and smoothly. See Inspect the Clamping Fixture on page 11-3.

• Ensure blades and trim tools are sharp and intact.

• Ensure the Heat Wand Cord and connections are in working order.

• Ensure the Temperature Control Box display appears when powered on and the Electric Cord is in working order.

Monthly

Quarterly

Biannually

Annually

• Ensure the Heat Wand pre-heats when powered on. Secure any misaligned or loose components, etc.

Clean the Temperature Control Box display with minimal lens cleaning solution and a soft cloth.

Use a clean, dry cloth to remove dust or belt debris from each Splicing System component.



Belt Splicing System v.2.0

15-1

Contact

Intralox, L.L.C. USA, New Orleans, LA, +504-733-0463, Toll Free: 1-800-535-8848 Intralox, L.L.C. Europe, Amsterdam, The Netherlands, +31-(0)20-540 36 00, Toll Free: +0800-4687-2569 Intralox Shanghai LTD., Shanghai, China, North Toll Free: 10800-711-0100, South Toll Free: 10800-110-0100 Global Assembly Center Locations: Japan • United Kingdom • Australia • Brazil • India

Country- and industry-specific free phone numbers available at intralox.com

Intralox ThermoDrive Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

TABLE OF CONTENTS

TABLE OF CONTENTS

SAFETY

LIST OF FIGURES

STANDARD PROCEDURES

TROUBLESHOOTING

SPECIAL PROCEDURES

PREVENTIVE MAINTENANCE

LIST OF FIGURES

LIST OF FIGURES

SAFETY

TABLE OF CONTENTS

STANDARD PROCEDURES

TROUBLESHOOTING

SPECIAL PROCEDURES

PREVENTIVE MAINTENANCE

EQUIPMENT OVERVIEW

SPLICING SYSTEM COMPONENTS

SET UP THE SPLICING SYSTEM

PREPARE BELT ENDS

ALIGN AND SECURE BELT ENDS

SPLICE THE BELT

TRIM & INSPECT THE BELT

SHUT DOWN, COOL, & PACK UP

TROUBLESHOOT

SPECIAL PROCEDURES

NUB TOP STYLE SPECIFICS

TROUGHING GROOVES SPECIFICS

S8126 BELT SPECIFICS

PERFORM PREVENTIVE MAINTENANCE