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TABLE OF CONTENTS

Belt Splicing System v.2.0

TOC

SAFETY

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

Imbedded Warnings................................

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

Safety Symbols ......................................

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

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

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

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

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

TABLE OF CONTENTS

Содержание ThermoDrive

Страница 1: ...Intralox ThermoDrive Belt Splicing System v 2 0 Instruction Manual For use with TD 8026 8126 belts TD 8050 belts...

Страница 2: ...burn hazards 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 usi...

Страница 3: ...uld 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 insi...

Страница 4: ...igure A Belt cutting and trimming 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...

Страница 5: ...SAFETY 4 Belt Splicing System v 2 0 Figure B Clamping Fixture hazards...

Страница 6: ...e 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 4 PREPARE BELT ENDS Belt End Situations 4...

Страница 7: ...Spacers 12 2 13 TROUGHING GROOVES SPECIFICS Troughing Groove Overview 13 1 Shim the Grooved Deck 13 1 Trim the Tape 13 2 14 S8126 BELT SPECIFICS S8126 Overview 14 1 Preparing Belt Ends 14 2 Shim the S...

Страница 8: ...re 3C Attach Crank Handle 3 2 Figure 3D Latch Heat Wand in Stand 3 3 Figure 3E Check voltage requirements 3 3 Figure 3F Check voltage requirements 3 4 Figure 3G Turn Power on 3 4 Figure 3H Check Contr...

Страница 9: ...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...

Страница 10: ...rom splicing area 12 1 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 13 TROUGHING GROOVES SPEC...

Страница 11: ...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...

Страница 12: ...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 Clampi...

Страница 13: ...ries The following accessories come with the above components a storage case Silicone Spacers Teflon tape Pitch Gauge trim tools a stop watch and Belt Tabs NOTE For details about components and voltag...

Страница 14: ...g tasks Xcelite trimmers or similar Silicone Spacers Two 2 reusable rectangu lar strips of rubber used to securely clamp cer tain belt ends stored in white cylindrical can details for use in Special P...

Страница 15: ...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...

Страница 16: ...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...

Страница 17: ...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 t...

Страница 18: ...grounded outlet NOTE Connect the Heat Wand to the Temperature Control Box BEFORE connecting the Temperature Control Box to an electric outlet Power Switch Switch that enables power to the Temperature...

Страница 19: ...STANDARD PROCEDURES STANDARD PROCEDURES...

Страница 20: ...s if you are installing new belts and any needed carryway and returnway replacement components 4 Ensure the facility temperature is above 40 F 5 C to produce proper splices If splicing area is below 4...

Страница 21: ...amping Fixture at the conveyor frame Place clamps on Clamping Fixture ends on a horizontal conveyor Ensure Crank Handle can rotate 360 Place clamps ahead of the Clamping Fix ture on an inclined convey...

Страница 22: ...11 3 Prepare the Heat Wand 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 availa...

Страница 23: ...ure in green Figure 3G Turn Power on Adjust Temperature Setpoint 1 Choose the setpoint based on belt material discontinued 2 Press or to change the setpoint if needed Figure 3H Check Control Box displ...

Страница 24: ...moving 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 NOTE Release Stand latches before trying to remove the Heat Wand Contact w...

Страница 25: ...ess belt is too long cut away the excess belting and prepare belt ends using instructions here Existing Belt Cut away the damaged or excess belting then prepare belt ends using instruc tions here NOTE...

Страница 26: ...igning Use a clean lint free cloth or alcohol wipes Cut Belt Ends Prepare each belt end to be spliced on the Clamping Fixture with drive bars face up or down using these instructions FABRICATION TIP C...

Страница 27: ...To properly secure S8126 belts for cutting see S8126 BELT SPECIFICS on page 14 1 5 Place each Pivoting Stud in a Cut Guide recess and finger tighten the thumb knobs to hold the belt end securely Figu...

Страница 28: ...s Ensure the prepared belt end cuts meet these requirements Belt ends are square or perpendicular to the belt top surface and the belt edges Figure 4H Inspect cut belt ends Belt ends are straight not...

Страница 29: ...lt Ends FABRICATION TIP These instructions provide the most common cutting procedures If you are aligning S8126 belt ends a belt with troughing grooves or a belt with nubs see SPECIAL PROCEDURES 1 Ope...

Страница 30: ...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 th...

Страница 31: ...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 2 Adjust the belt ends horizontally until they are aligned...

Страница 32: ...s the Clamping Fix ture 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...

Страница 33: ...e Figure 5J Inspect belt surface vertical alignment FAIL If belt ends do NOT meet these require ments troubleshoot until requirements are met See TROUBLESHOOT on page 10 1 PASS When belt ends meet all...

Страница 34: ...t ends are correctly aligned according to instructions See ALIGN AND SECURE BELT ENDS on page 5 1 The Clamping Fixture is fully open FABRICATION TIP Shield the Heat Wand and Clamping Fixture from air...

Страница 35: ...e the Heat Wand from the Stand FABRICATION TIP 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 setpoi...

Страница 36: ...lamping Fixture locks i e a click sound occurs Figure 6E Close Clamping Fixture on Heat Wand FABRICATION TIP Do not allow the Clamping Fixture to close suddenly or with force 5 When the melt time is r...

Страница 37: ...the Cut Guides from the belt and inspect the splice Inspect the Splice Ensure these requirements are met before trim ming the belt Belt ends are joined with a bead of molten material Molten material...

Страница 38: ...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 7A Secure the belt...

Страница 39: ...ure 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 tri...

Страница 40: ...me strains the splice and causes premature belt failure FABRICATION TIP Allow the belt to cool at least five 5 minutes before inspecting Ensure these requirements are met before run ning the belt The...

Страница 41: ...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 troubles...

Страница 42: ...clean dry cloth close the Grooved Decks and secure the Cut Guides in place 5 Remove the Crank Handle from the Clamp ing Fixture and put it in the plastic bag 6 Clean any accessories PPE or other compo...

Страница 43: ...can damage components Put the Clamping Fixture in the long com partment 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 t...

Страница 44: ...TROUBLESHOOTING TROUBLESHOOTING...

Страница 45: ...res and instructions in the manual text NOTE There are no user serviceable components in the Splicing System Attempts to cut drill or otherwise modify any electrical or mechanical components voids the...

Страница 46: ...ox Technical Support for help Wand Cord is damaged kinked Wear or incorrect storage Contact Intralox Technical Support for replacement FABRICATION TIP Continued use with damaged components can damage...

Страница 47: ...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...

Страница 48: ...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 a...

Страница 49: ...hnique 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...

Страница 50: ...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 bel...

Страница 51: ...g time complete the following steps 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 mor...

Страница 52: ...t 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 Se...

Страница 53: ...IFICS 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 cool...

Страница 54: ...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 Problem...

Страница 55: ...r 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 le...

Страница 56: ...ing 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 co...

Страница 57: ...que 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...

Страница 58: ...asure more than 1 8 3 mm different from each other contact Intralox Technical Support Splice offset at top surfaces vertical misalignment Cut the faulty splice from the belt and repeat the splicing pr...

Страница 59: ...g 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 recommende...

Страница 60: ...t 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 Se...

Страница 61: ...SPECIAL PROCEDURES SPECIAL PROCEDURES...

Страница 62: ...lat portable surface 2 Position the Clamping Fixture and support ing surface under the conveyor frame return way near the belt ends Figure 11A Place the Clamping Fixture on a flat stable surface 3 Ens...

Страница 63: ...hese 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 Figure 11C Apply tape...

Страница 64: ...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 Inspect th...

Страница 65: ...11 SPECIAL PROCEDURES 11 4 Belt Splicing System v 2 0 If the Clamping Fixture does not meet these requirements see TROUBLESHOOT on page 10 1...

Страница 66: ...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 Sil...

Страница 67: ...oved Decks if drive bars face up during alignment Figure 12D Place Cut Guide on Silicone Spacer FABRICATION TIP Place Spacer strips on Belt Tabs if used Ensure Spacer strips do not extend past Grooved...

Страница 68: ...eps in the procedure at the beginning or if belt top surfaces are not aligned FABRICATION TIP Splice on the carryway with drive bars face down for best results Shim the Grooved Deck FABRICATION TIP If...

Страница 69: ...im 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 Make Adjustments Adjust tape length place ment an...

Страница 70: ...RICATION TIP Use a 24 Splicing System and splice with drive bars face down for best results Prepare the Belt Ends When preparing S8126 belt ends include these steps in the procedure Shim the smooth ed...

Страница 71: ...pared end will be cut This allows you to leave tape in place for splicing 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...

Страница 72: ...h square edge 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 edg...

Страница 73: ...e Thin Belt Tabs to Secure Belt Ends on page 14 2 Figure 14I Place thin Belt Tabs on Grooved Decks Repeatedly Inspect Alignment Check Parallel Alignment Ensure the belt ends are visibly parallel to th...

Страница 74: ...ecks 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 pro...

Страница 75: ...8126 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 t...

Страница 76: ...PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE...

Страница 77: ...able replacement parts if needed x Ensure the Instruction Manual is in the storage case x Ensure safety labels are adhered per photographs in this manual See Belt Splicing System Hazards on page 3 Con...

Страница 78: ...ee 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 1...

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