Intralox ThermoDrive Belt Splicing System v. 2.0 User Manual

Intralox ThermoDrive®

Belt Splicing System v. 2.0 User Manual

For use with TD 8026/8126 beltsTD 8050 belts

TERMS OF USEBuyers of Intralox equipment may not decompile, reverse engineer, copy, or transfer proprietary assembly designs, software, or documents in whole or in part except to the extent permitted by applicable law. Applying the proprietary information to non-Intralox products is prohibited.

Do not modify the equipment, components, or equipment assemblies. Do not remove or modify any factory-installed safety features without the written consent of Intralox. Intralox is not responsible for failures due to incorrect usage of the equipment.

For product warranty details, refer to the Terms and Conditions statement on your sales confirmation order. Contact Intralox Customer Service for more information. See contact numbers on the manual back cover. See www.intralox.com to view related documents.

PATENTSThermoDrive technology combines flat, homogeneous, thermoplastic material, and the positive drive feature of modular plastic belting (MPB) with a unique, patented drive engagement solution. This patented combination creates a one-of-a-kind tensionless belt system.

Intralox, L.L.C. manufactures ThermoDrive products under the following patents: 7850562; 8464862; 8596622; 8695790; 9097332; 9151357; 9242801; 9296565; 9359141; 9527672; 9555971; 9751695; 9796135; 9914591; Other U.S. and foreign patents pending.

For a current list of patents, visit www.intralox.com/pat/.

DOCUMENT The content of this document is proprietary to Intralox L.L.C., cannot not be disclosed to anyone else by the recipient without the written consent of Intralox, and can only be used in connection with Intralox products. Intralox can make changes without notice to both this document and to products described by this document. See the latest documents at www.intralox.com or contact Intralox Customer Service with questions about document content.

The original version of this document is written in English. Any version in a language other than English is a translation of the original document.

Last User Manual update: September 13, 2018 6:27 pm

Intralox is a registered trademark of Laitram, L.L.C.

SAFETY

S
AFETY
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 thisequipment.

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.

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.

Safety InformationANSI/ISO harmonized labels and symbols are included on this equipment and in its docu-ments 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 under-standing of warnings provided with this equip-ment. Do not ignore this information. It is included for your protection.

Imbedded WarningsThis is a general warning sign. It is used throughout this manual to alert you to hazards you can encounter during specific operating, trouble-

shooting, or servicing procedures. Read the corresponding information.

Belt Splicing System v. 2.0 1

SAFETY

2

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 SymbolsA 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

SAFETY

Belt Splicing System Hazards

Figure A: Heat Wand and Temperature Control Box hazards

Figure B: Belt cutting and trimming hazards

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

Contact with hot Heat Wand or Stand causes skin burns; use of heat-resistant gloves and sleeves that withstand consistent temperatures up to 500°F (260°C) is recommended.

Keep Heat Wand in Stand between each splice.

Belt Splicing System v. 2.0 3

SAFETY

4

Figure C: Clamping Fixture hazards


TABLE OF CONTENTS

TABLE OF CONTENTS
SAFETYSafety Information ................................ i-1Imbedded Warnings.............................. i-1Hazard Severity Panels ......................... i-2Safety Symbols .................................... i-2Belt Splicing System Hazards ............... i-3
TABLE OF CONTENTS

LIST OF FIGURES

1 EQUIPMENT OVERVIEWSystem Use......................................... 1-1

System Components ........................... 1-1Top Clamps/Cut Guides..................... 1-1Clamping Fixture ............................... 1-1Heat Wand with Temperature Control Box................... 1-1Accessories...................................... 1-2

2 SPLICING SYSTEM COMPONENTSAccessories ........................................ 2-1

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

Heat Wand and Temperature ControlBox ..................................................... 2-4

STANDARD PROCEDURES3 SET UP THE SPLICING SYSTEMCollect Needed Supplies ...................... 3-1

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

Prepare Clamping Fixture ..................... 3-2Secure Clamping Fixtureto Conveyor ...................................... 3-2Attach Crank Handle.......................... 3-2

Prepare the Heat Wand ........................ 3-3Make Power Connections.................. 3-3Adjust Temperature Setpoint ............. 3-4Allow Heat Wand to Pre-heat ............. 3-5

4 PREPARE BELT ENDSBelt 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 ENDSPrepare 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 BELTPrepare 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 BELTTrimming 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 UPShut Down & Clean............................. 8-1

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

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

Belt Splicing System v. 2.0 TOC

TABLE OF CONTENTS

TOC

TROUBLESHOOTING10 TROUBLESHOOTTroubleshooting Overview.................. 10-1

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

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

Table of Equipment/Facility Problems. 10-2

Table of Preparing and AligningBelt Ends Problems ........................... 10-4

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

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

SPECIAL PROCEDURES11 SPECIAL PROCEDURESSet Up at the Returnway .................... 11-1

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

Shim for Belt Top Surface (Vertical) Alignment ........................... 11-2

Trim the Second Weld Bead—Alternative Technique......................... 11-3

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

12 NUB TOP STYLE SPECIFICSNub Top Overview ............................. 12-1

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

Prepare Flat Silicone Spacers for Use. 12-1

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

13 RIBBED V-TOP™ STYLE SPECIFICSRibbed V-Top Overview ..................... 13-1

Remove Top Surface Profile............... 13-1

Prepare SquareSilicone Spacers for Use.................... 13-1

Use Square Silicone Spacers ............. 13-2

14 TROUGH GROOVE SPECIFICSTrough Groove Overview ................... 14-1

Shim the Grooved Deck..................... 14-1

Trim the Tape.................................... 14-2

15 S8126 BELT SPECIFICSS8126 Overview................................ 15-1

Preparing Belt Ends........................... 15-2Shim the Smooth Edges toSecure Belt Ends ............................. 15-2Use Thin Belt Tabs to Secure Belt Ends ............................. 15-2Repeatedly Inspect Alignmentbefore Cutting ................................. 15-3Hold the Cut Guides whenFully Tightening Thumb Knobs......... 15-3Add the Second Cut Guide toSecure Belt for Cutting..................... 15-3Inspect Cuts for Squareness............ 15-3

Align & Secure Belt Ends................... 15-4Remove any Belt Tension ................ 15-4Check for Shims and Belt Tabs........ 15-4Repeatedly Inspect Alignment.......... 15-4Control Crank Handle DuringAlignment........................................ 15-4Hold the Cut Guides whenFully Tightening Thumb Knobs......... 15-5

Splice the Belt Ends .......................... 15-5Control the Crank Handlefor 25 Seconds of Melting ............... 15-5Close Decks Gently for Cooling........ 15-5

Trim & Inspect the Belt ...................... 15-6

PREVENTIVE MAINTENANCE16 PERFORMPREVENTIVE MAINTENANCE


LIST OF FIGURES

LIST OF FIGURES
SAFETY
TABLE OF CONTENTS

LIST OF FIGURES

1 EQUIPMENT OVERVIEWFigure 1A: Splicing System............................ 1- 1

2 SPLICING SYSTEM COMPONENTSFigure 2A: System accessories(generic photo) ............................................. 2- 1

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

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

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

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

STANDARD PROCEDURES3 SET UP THE SPLICING SYSTEMFigure 3A: Clamping Fixture on horizontalconveyor....................................................... 3- 2

Figure 3B: Add clamps ahead of ClampingFixture on an inclined conveyor ..................... 3- 2

Figure 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 on Power.............................. 3- 4

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

4 PREPARE BELT ENDSFigure 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 barengagement/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 4G: Hold the utility knife against theCut Guide Edge ............................................. 4- 4

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

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

5 ALIGN AND SECURE BELT ENDSFigure 5A: Align belt ends on Grooved Deck... 5- 2

Figure 5B: Belt ends extending pastGrooved Deck edge ....................................... 5- 2

Figure 5C: Lower Cut Guide onGrooved Deck ............................................... 5- 2

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

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

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

Figure 5G: Center belt ends............................ 5- 3

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

Belt Splicing System v. 2.0 LOF

LIST OF FIGURES

LOF

Figure 5I: Clamping Fixture closed–but not locked ............................................... 5- 4

Figure 5J: Inspect for gaps and horizontalalignment...................................................... 5- 4

Figure 5K: Inspect belt surface verticalalignment...................................................... 5- 5

6 SPLICE THE BELTFigure 6A: Clean residue from theHeat Wand.................................................... 6- 1

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

Figure 6C: Remove the Heat Wand fromthe Stand ...................................................... 6- 2

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

Figure 6E: Close Clamping Fixture onHeat Wand.................................................... 6- 3

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

Figure 6G: Close Grooved Decks asHeat Wand is lifted ........................................ 6- 3

Figure 6H: Heat Wand removed andbelt cooling ................................................... 6- 3

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

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

7 TRIM & INSPECT THE BELTFigure 7A: Secure the belt ............................. 7- 1

Figure 7B: Separate the weld bead fromthe 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 anddiscard debris ............................................... 7- 3

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

Figure 7J: Inspect for splice faults(e.g., bubbles shown here)............................ 7- 4

8 SHUT DOWN, COOL, & PACK UPFigure 8A: Pack main components................. 8- 1

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

TROUBLESHOOTING10 TROUBLESHOOT

SPECIAL PROCEDURES11 SPECIAL PROCEDURESFigure 11A: Place the Clamping Fixture ona 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 andensure metal pads touch ............................. 11- 3

12 NUB TOP STYLE SPECIFICSFigure 12A: Nub Top Samples ..................... 12- 1

Figure 12B: Remove nubs fromsplicing area................................................ 12- 1

Figure 12C: Flat spacers for 42 inClamping Fixture ......................................... 12- 1


LIST OF FIGURES

Figure 12D: Place Cut Guide onspacer strip................................................. 12- 2

Figure 12E: Align flat spacer withDeck edge................................................... 12- 2

13 RIBBED V-TOP™ STYLE SPECIFICSFigure 13A: Ribbed V-Top samples.............. 13- 1

Figure 13B: Milling the Belt Ends ................. 13- 1

Figure 13C: Square Spacers for 24 inClampingFixture......................................................... 13- 1

Figure 13D: Align Ribbed V-Top belt end...... 13- 2

Figure 13E: Insert square Silicone Spacers .. 13- 2

Figure 13F: Align square Silicone Spacerflush with Deck edge................................... 13- 2

14 TROUGH GROOVE SPECIFICSFigure 14A: Trough groove samples ............ 14- 1

Figure 14B: Center tape at GroovedDeck edge................................................... 14- 1

Figure 14C: Trim tape width ........................ 14- 2

Figure 14D: Trim tape length ....................... 14- 2

Figure 14E: Finish belt end alignment........... 14- 2

15 S8126 BELT SPECIFICSFigure 15A: S8126 Samples........................ 15- 1

Figure 15B: Trim tape at the belt edges........ 15- 2

Figure 15C: Choose Belt Tabs thinner thanbelt ............................................................. 15- 2

Figure 15D: Place Belt Tabs onGrooved Decks ........................................... 15- 2

Figure 15E: Inspect with square edge .......... 15- 3

Figure 15F: Clamp belt edges securely......... 15- 3

Figure 15G: Secure the second Cut Guide inplace........................................................... 15- 3

Figure 15H: Inspect cut ............................... 15- 3

Figure 15I: Place thin Belt Tabs onGrooved Decks............................................ 15- 4

Figure 15J: Inspect with square edge........... 15- 4

Figure 15K: Inspect touching ends............... 15- 4

Figure 15L: Clamp belt edges securely......... 15- 5

Figure 15M: Maintain control of theCrank Handle .............................................. 15- 5

Figure 15N: Inspect drive bar alignment ....... 15- 6

PREVENTIVE MAINTENANCE16 PERFORMPREVENTIVE MAINTENANCE

Belt Splicing System v. 2.0 LOF

1 EQUIPMENT OVERVIEW

E1
QUIPMENT OVERVIEW System UseThe Intralox ThermoDrive Splicing System quickly and reliably splices IntraloxThermoDrive® 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.

Figure 1A: Splicing System

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

Top Clamps/Cut GuidesAfter 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 FixtureAlign 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 withTemperature Control BoxUse the Heat Wand to melt the belt ends in the Clamping Fixture. The Temperature Control Box regulates Heat Wand temperature and can ONLY be used with the Intralox ThermoDrive Splicing System. Several splices can be com-pleted 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

1-2

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

NOTEFor details about components and voltagerequirements, see SPLICING SYSTEM

COMPONENTS on page 2-1.


2 SPLICING SYSTEM COMPONENTS

A

S2
PLICING SYSTEM COMPONENTS ccessories
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 splic-ing; replacements available from Intralox

Trimmers: Sharp nippers with rubber-covered handles used to remove flashing on the belt edge and perform other trimming tasks (Xcelite® trimmers or similar)

Silicone Spacers: Kit containing reusable, flat strips and square strips of rubber used to clamp certain belts securely; stored in a white, cylin-drical tube

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

Figure 2B: Storage case

Teflon® tape: 5-yard (4.572-m) roll of heat-resistant, adhesive tape

stopwatch: Digital timing device with large display

utility knife: Self-retracting safety knife with a1.75 in two (2)-sided replaceable blade (Medoc Retractable Safety Knife model #99152 or similar)

Silicone Spacers

Trimmers

Teflon tape

Skiver

Pitch Gauge

utility knife

stopwatch

Belt Tabs

Use caution when handling knives and trim tools.



2-2

Clamping Fixture

Figure 2C: Clamping Fixture

Wand Rest(between decks)Locating pin

Carrying handles

Carrying handles

Grooved Decks

Locating Pins

Wand Rest (between decks;barely visible)

ShafttetherCrank Handle

Pivoting Studs(& thumb knobs)

Locating pin

Frame edge

Carrying handles

Pivoting Studs(& thumb knobs)

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

NOTEThe 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



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 corre-spond to the Cut Guide locating holes; designed to align Cut Guides properly 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

Figure 2D: Top Clamp/Cut Guide set

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 Splic-ing Systems

NOTEUse 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 Clamp-ing 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

recesses(not visible)

CutGuide Edge

metal rail

locatingholes

locating holes

CutGuide Edge

metal rail

recesses

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



2-4

Heat Wand and Temperature Control Box

Figure 2E: Heat Wand components

Heat Wand

Stand

TemperatureControl Box

Electric Cord

Power Switch

Heat Wand andStand

Wand Cord

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

NOTEUse the Heat Wand in temperatures above 40°F

(5°C) to produce quality splices. To use theSplicing 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 can be burned by the Wand; Heat Wand should be returned to Stand after each splice

NOTEConnect the Heat Wand to the Temperature

Control Box BEFORE connecting the Temperature Control Box to an electric outlet.

Contact with hot Heat Wand or Stand causes skin burns.

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

Keep Heat Wand in the Stand when not in use.



Temperature Control Box: Electric device that controls the Heat Wand temperature viathermocouple 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

NOTEConnect 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 Control Box; display appears when Power is set on

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

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


STANDARD PROCEDURES

STAN

DARD

PRO

CEDU

RES

3 SET UP THE SPLICING SYSTEM

S3
ET UP THE SPLICING SYSTEM
Avoid Injury.


Contact with hot Heat Wand or stand causes 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.

• 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.

3. Collect new sprockets (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 40°F (5°C), see TROUBLESHOOT on page 10-1.

Prepare the ConveyorSee the ThermoDrive® Belting Conveyor Belt-ing Installation and Maintenance at the Intralox website or contact Intralox for com-plete 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 can cause excess backbends.

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

5. Install new sprockets with new belting.

6. String the belt on the conveyor and follow correct pulley wrap configuration. Avoid con-veyor 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.




3-2

Prepare Clamping Fixture

Secure Clamping Fixtureto Conveyor1. Choose a location to set up the Clamping Fixture.

FABRICATION TIPUse the conveyor carryway frame when

possible. For returnway setup, see Set Up at the Returnway on page 11-1.

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 horizontalconveyor

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.

• Ensure Crank Handle can rotate 360°.

• Place clamps ahead of the Clamping Fix-ture on an inclined conveyor to prevent sliding.

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

Attach Crank Handle1. Align the Crank Handle slot to the Clamping Fixture shaft and push the handle toward the Fixture frame.

FABRICATION TIPEnsure the tether and its fastener face away

from the Clamping Fixture.

Figure 3C: Attach Crank Handle


retaining pin Crank Handle tether

1. Push Handle onto shaft 2. Insert retaining pin



2. Insert the tethered retaining pin into the hole on the shaft to secure the Handle in place.

FABRICATION TIPEnsure the tether and fastener face outward.

NOTEIf there are any concerns about adequate Fixture operation, see Inspect the Clamping Fixture on

page 11-3.

Prepare the Heat Wand

Make Power Connections1. Place the Heat Wand in the Stand and latch in place.

Figure 3D: Latch Heat Wand in Stand

2. Ensure equipment and facility voltages match. If voltage does not match, see TROU-BLESHOOT 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.

NOTEEach Wand Cord connection fits into

only one component.Do not force connections together.



3-4

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

Figure 3F: Check voltage requirements

NOTEEnsure 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 tem-perature in green.

Figure 3G: Turn on Power

Adjust Temperature Setpoint1. Choose the setpoint based on belt material.

IMPORTANT: See the ThermoDrive Splicing Temperatures and Times document at www.intralox.com for the latest recommenda-tions for all available belt materials and styles.

*discontinued

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

Figure 3H: Check Control Box display


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

Belt Material SetpointTemp.°F/°C

Polyurethane 8x26/8x50 450° F/232° C

XT 8026* 485° F/252° C

XT 8050 475° F/246° C

Cold Use 8050 450° F/232° C

HTL 8050 500° F/260° C

Dura 8050 450° F/232° C

current setpoint temperature temperature



Allow Heat Wand to Pre-heat 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.

NOTERelease Stand latches before trying

to remove the Heat Wand.

Contact with hot Heat Wand or Stand causes skin burns. Using heat-resis-tant gloves and sleeves is recom-mended.

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


4 PREPARE BELT ENDS

4
PREPARE BELT ENDS
Cut Hazard


Belt End Situations

NOTEThe 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 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.

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

NOTEContact Intralox to order replacement belt sections

for splicing as needed.

Preparation OverviewOnce a length of belt is confirmed to run with-out tension (meets the sag requirement), pre-pare belt ends for splicing.

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

FABRICATION TIPInstructions for preparing belt ends can differ

by belt series, style, and belt machining options. These instructions provide the most common cutting procedures. For S8126 belt,

see the SPECIAL PROCEDURES section of the manual.

NOTEThe 8026/8050 Cut Guide set is NOT for use with

metal lacing.Contact Intralox with questions about metal lacing.


4 PREPARE BELT ENDS

4-2

Clean Belt Ends1. 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.

FABRICATION TIPUse a food-safe detergent (without ammonia or bleaches) and/or alcohol. Any cleaning agent

residue contaminates the splice.

Figure 4A: Clean belt ends

3. Wipe dry before aligning. Use a clean, lint-free cloth or alcohol wipes.

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

NOTEIf using the Hand-Held Belt Preparation Tool, see

the User Manual at www.intralox.com.

FABRICATION TIPComplete 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

extra 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 in (25 mm) of material is past the second Grooved Deck.

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


4 PREPARE BELT ENDS

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 Locat-ing Pins and holes. Ensure the recesses are under the Pivoting Stud thumb knobs.

Figure 4D: Place Cut Guide on belt

FABRICATION TIPTo secure S8126 belts properly for cutting, see

S8126 BELT SPECIFICS on page 15-1.

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

FABRICATION TIPEnsure the Cut Guide Edge faces the belt end to be cut. The Grooved Deck should extend past

the Cut Guide Edge.

Figure 4F: Check setup before cutting

Drive bars engaged in Grooved Deck grooves

Drive bars aligned with Grooved Deck groovesand engaged in Cut Guide


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


4 PREPARE BELT ENDS

4-4

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

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.

NOTETo prepare the second belt end, repeat steps 2-8

using the same cut guide.

Inspect Belt EndsEnsure 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 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 require-ments, troubleshoot until requirements are met. See TROUBLESHOOT on page 10-1.

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


5 ALIGN AND SECURE BELT ENDS

A5
LIGN AND SECURE BELT ENDS
Avoid Injury.

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

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

Prepare to AlignEnsure these requirements are met before align-ing 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.

Align Belt Ends

FABRICATION TIPThese instructions provide the most common

aligning procedures. If you are aligning S8126 belt ends, a belt with trough grooves, or a belt with nubs or Ribbed

V-Top, see SPECIAL PROCEDURES.

1. Open the Clamping Fixture fully.

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

FABRICATION TIPThe 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.

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



5-2

Lightly Secure Belt Ends1. 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.

Figure 5A: Align belt ends on Grooved Deck

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

Figure 5B: Belt ends extending past Grooved Deck edge

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 5D: Position and tighten thumb knobs

FABRICATION TIPTighten 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 Align Belt Ends on page 5-1.

Drive bars engaged in Grooved Deck grooves

Drive bars aligned with Grooved Deck groovesand engaged in Cut Guide

belt end extends past Deck Edge



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 fac-ing outward as on the first belt end, lightly secure the belt in place.

Check Alignment &Tightly Secure Belt Ends1. Close–but do not lock–the Clamping Fixture, and release the Crank Handle to inspect align-ment. Gently open and close the Clamping Fix-ture as needed throughout alignment.

Figure 5E: Close the Clamping Fixture

NOTEWhen 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.

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

FABRICATION TIPIf 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 in (3.2 mm) different, contact Intralox.

Figure 5G: Center belt ends

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

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

Figure 5H: Secure second belt end



5-4

5. Open the Clamping Fixture.

FABRICATION TIPOnce belt ends aligned and secured, do not

allow the Clamping Fixture to close suddenly or with force.

Inspect TensionWith 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.

Figure 5I: Clamping Fixture closed–but not locked

FAIL: If the belt weight pulls 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 belt alignment.

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

Belt ends are parallel to each other with less than 1/32 in (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 in (1.6 mm).

Figure 5J: Inspect for gaps and horizontal align-ment

belt edges belt ends belt edges



Belt end top surfaces are flush within 1/64 in (0.5 mm). This is most easily assessed by sliding the Skiver tip across the belt ends to ‘feel’ for an uneven surface.

Figure 5K: 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 requirements, fully open the Grooved Decks to splice the belt. See SPLICE THE BELT on page 6-1.

FABRICATION TIPOnce belt ends are aligned and secured, do not allow the Clamping Fixture to close suddenly

or with force.


6 SPLICE THE BELT

S6
PLICE THE BELT
Avoid Injury.

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




Prepare to Splice1. 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.

FABRICATION TIPShield 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.

NOTERelease Stand latches before trying to remove the

Heat Wand.

2. Once the temperature setpoint is reached, hold one or more Heat Wand handles and wipe plastic residue from the Heat Wand. Use a clean, dry cloth. An assistant can be helpful.

Figure 6A: Clean residue from the Heat Wand

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

Figure 6B: Latch Heat Wand in Stand.


6 SPLICE THE BELT

6-2

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

FABRICATION TIPExtreme ambient conditions can require an

increase or decrease in melting time.

IMPORTANT: See the ThermoDrive Splicing Temperatures and Times document at www.intralox.com for the latest recommenda-tions for all available belt materials and styles.

*discontinued

NOTEDo not remove the Heat Wand from the Stand until

the temperature stabilizes within ±2° of the setpoint for at least one (1) minute.

Splice the Belt Ends

FABRICATION TIPThese instructions provide the most common

splicing procedures. If you are splicing S8126 belt ends, a belt with trough grooves, or a belt with nubs or Ribbed

V-Top™, see SPECIAL PROCEDURES.

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

Figure 6C: Remove the Heat Wand from the Stand

FABRICATION TIPTemperature fluctuates above and below the

setpoint 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 Material Setpoint Temp.

Melt time

Cool time

Polyurethane8x26/8x50

450° F232° C 45 sec. 2 min.

XT 8026*485° F252° C 45 sec. 2 min.

XT 8050475° F246° C 60 sec. 2 min.

Cold Use 8050

450° F/232° C 30 sec. 2 min.

HTL 8050500° F260° C 75 sec. 2 min.

Dura 8050450° F232° C 40 sec. 2 min.


Contact with hot Heat Wand or Stand causes skin burns; using heat-resis-tant gloves and sleeves is recom-mended.

Keep Heat Wand in Stand between


6 SPLICE THE BELT

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.

NOTEThe Heat Wand temperature can

vary ±20°F (12ºC) from the setpointwhen 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.

Figure 6E: Close Clamping Fixture on Heat Wand

FABRICATION TIPDo not allow the Clamping Fixture to close

suddenly or with force.

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

Figure 6F: Remove Heat Wand

NOTEPerform steps 5 and 6 as a fluid motion.

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 6G: Close Grooved Decks as Heat Wand is lifted

Figure 6H: Heat Wand removed and belt cooling


6 SPLICE THE BELT

6-4

Allow the Belt to Cool

1. While the splice cools, hold one or more Heat Wand handles and wipe plastic residue from the Heat Wand. Use a clean, dry cloth. An assistant can be helpful.

Figure 6I: Wipe residue from the Heat Wand

FABRICATION TIPWipe the Heat Wand even if plastic residue is not visible. Residue can cause faulty splices.

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 SpliceEnsure these requirements are met before trim-ming 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 6J: Small, even weld bead

FAIL: If the belt splice does NOT meet all requirements, troubleshoot until all require-ments 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.

Contact with hot Heat Wand or Stand causes skin burns; using heat-resis-tant gloves and sleeves is recom-mended.



7 TRIM & INSPECT THE BELT

T7
RIM & INSPECT THE BELT
Cut/Puncture Hazard

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

Trimming OverviewThorough 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 fail-ure.

Trim First Weld Bead

FABRICATION TIPStart 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 7A: Secure 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.

Figure 7B: Separate the weld bead from the belt

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

Figure 7C: Remove the first weld bead

5. Remove the Cut Guide from the Clamping Fixture.

FABRICATION TIPCollect all plastic remnants and particles as

they are created to avoid product contamina-tion.

weld bead Skiver



7-2

Trim Second Weld Bead

FABRICATION TIPThe 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.

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.

Trim Belt Edges1. 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 diag-onally toward the belt edge to trim rough spots or corners on belt edges.

Figure 7G: Trim rough edges or small corners




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

FABRICATION TIPCollect plastic remnants and particles as they are created, then discard them away from belt

and product.

Inspect the BeltThorough weld bead and flash removal are crit-ical for splicing success. Remaining weld bead or flash that contacts sprockets or the conveyor frame strains the splice and causes premature belt failure.

FABRICATION TIPAllow the belt to cool at least five (5) minutes

before inspecting.

Ensure these requirements are met before run-ning 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 and inspect two (2) or more places along the splice.

Use 8026 for 26 mm drive bar pitch.

Use 8050 for 50 mm drive bar pitch.

Figure 7I: Check pitch at splice

splice



7-4

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 in 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 require-ments 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.


8 SHUT DOWN, COOL, & PACK UP

S8
HUT DOWN, COOL, & PACK UP
Avoid Injury.



NOTEConsider completing the quarterly preventive

maintenance tasks before shutting down the Splic-ing System. Most of the tasks were already completed during the Splicing process, see

PERFORM PREVENTIVE MAINTENANCE on page 16-1.

Shut Down & Clean1. Set the Temperature Control Box Power to OFF and unplug it from the electric outlet.

2. Disconnect the Wand Cord from the Tem-perature 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.

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

Cool DownLet the Heat Wand and Stand cool completely (usually 15–20 minutes) in a safe place.

Pack the Storage Case1. 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.

Figure 8A: Pack main components


Heat Wandand Stand

Coiled Cords

TemperatureControl Box

Clamping Fixturewith Cut Guides


8 SHUT DOWN, COOL, & PACK UP

8-2

• Put the coiled cords in the empty com-partment next to the Temperature Con-trol Box.

NOTEStoring 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.

NOTEThe right twist latch includes a hasp

for extra security.

Figure 8B: Secure the twist latches

4. Store the case for future use.


TROUBLESHOOTING

TROU

BLES

HOOT

ING

10 TROUBLESHOOT

T10
ROUBLESHOOT
Avoid injury.


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


Do NOT attempt to cut, drill, or other-wise modify any electrical or mechani-cal components. Modifications may cause additional shock and burn hazards.

Troubleshooting OverviewThis 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 sug-gestions 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.

NOTEThere are no user-serviceable components in the

Splicing System. Attempts to cut, drill, orotherwise modify any electrical or mechanical

components voids the warranty.

Procedures & InspectionsMultiple 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 any-time an inspection is failed. Contact Intralox with any questions.

Faulty Cuts & SplicesSee the troubleshooting tables for detailed causes and remedies for faulty cuts and splices, but remember the following requirements.

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.

• Do NOT splice the same prepared ends twice.

• Repeat the splicing procedure beginning with NEW prepared ends.


10 TROUBLESHOOT

Tabl

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Prob

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10-2 Belt Splicing System v. 2.0

10 TROUBLESHOOT

Hea

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ble

(abo

ve 4

0ºF/

4ºC

pre

ferr

ed)

2. R

educ

e ai

r flo

w in

splic

ing

area

if p

ossi

ble.

3. S

hiel

d sp

licin

g ar

ea fr

om a

ir flo

w w

ith c

ardb

oard

or s

imila

r.4.

Hol

d th

e H

eat W

and

in a

con

trolle

d lo

catio

n ou

tsid

e of

the

Stan

d un

til it

stab

ilize

s at s

etpo

int

befo

re sp

licin

g.5.

Con

tact

Intra

lox

Cus

tom

er S

ervi

ce fo

r mor

e in

form

atio

n.

Clam

ping

Fix

ture

not

ope

ratin

g sm

ooth

ly/e

asily

Mec

hani

cal p

robl

em1.

Rem

ove

visi

ble

debr

is fr

om sp

ring

asse

mbl

ies.

2. A

pply

gea

r lub

rican

t to

the

mov

ing

parts

at s

prin

gs a

nd li

near

bea

rings

.3.

Con

tact

Intra

lox

Cus

tom

er S

ervi

ce a

bout

bea

ring

repl

acem

ents

or r

epai

r of b

ent f

ram

e,

Gro

oved

Dec

ks, o

r bea

ring

shaf

ts.

N

OTE

Do n

ot d

isas

sem

ble

the

Clam

ping

Fix

ture

ass

embl

y. A

ll co

mpo

nent

s ab

ove

are

acce

ssib

leth

roug

h Cl

ampi

ng F

ixtu

re o

peni

ngs.

Atte

mpt

s to

cut

, dril

l, or

oth

erw

ise

mod

ify a

ny

mec

hani

cal c

ompo

nent

s vo

ids

the

war

rant

y.

Clam

ping

Fix

ture

not

ope

ning

com

plet

ely

Tool

or c

lam

p ob

stru

ctin

g m

ovem

ent

Ensu

re th

e C

rank

Han

dle

can

rota

te 3

60º.

Mov

e an

y ob

stru

ctio

ns.

Mec

hani

cal d

amag

eC

onta

ct In

tralo

x C

usto

mer

Ser

vice

abo

ut p

ossi

ble

bent

com

pone

nts:

Cla

mpi

ng F

ixtu

re fr

ame,

G

roov

ed D

ecks

, bea

ring

shaf

ts, o

r spr

ing

linka

ge.


10 TROUBLESHOOT

Sym

ptom

& P

ossi

ble

Caus

esAc

tion

to T

ake

Clam

ping

Fix

ture

met

al p

ads

do n

ot to

uch

whe

n cl

osed

Fixt

ure

clos

ed im

prop

erly

1. L

ock

the

Cla

mpi

ng F

ixtu

re c

lose

d.

2. O

pen

the

Cla

mpi

ng F

ixtu

re c

ompl

etel

y.

3. R

epea

t the

insp

ectio

n st

eps.

See

Ensu

re th

e te

ther

and

fast

ener

face

out

war

d. o

n pa

ge 3

-3.

Inte

rnal

dam

age

Con

tact

Intra

lox

Cus

tom

er S

ervi

ce.

FABR

ICAT

ION

TIP

Splic

ing

with

this

issu

e ca

n re

sult

in in

corr

ect d

rive

bar p

itch.

Clam

ping

Fix

ture

doe

s no

t sta

y cl

osed

unl

ess

lock

ed

Belt

tens

ion

too

high

1. C

lam

p be

lt to

con

veyo

r fra

me

near

Cla

mpi

ng F

ixtu

re to

elim

inat

e pu

ll on

bel

t end

s.2.

Adj

ust c

onve

yor c

ompo

nent

s to

min

imiz

e te

nsio

n.

Belt

Tabs

Los

t/M

issi

ng

Belt

Tabs

lost

or d

isca

rded

• M

ake

addi

tiona

l Bel

t Tab

s fro

m a

vaila

ble

belt

mat

eria

l. Se

e M

ake

Belt

Tabs

on

page

11-

1.•

Con

tact

Intra

lox

Cus

tom

er S

ervi

ce to

ord

er B

elt T

abs.

Tabl

e of

Pre

pari

ng a

nd A

ligni

ng B

elt E

nds

Prob

lem

sBe

lt en

d no

t squ

are

(i.e

., no

t per

pend

icul

ar to

bel

t top

sur

face

)

Rep

eat b

elt e

nd p

repa

ratio

n w

ith a

ttent

ion

to th

e fo

llow

ing.

Cut t

echn

ique

• H

old

blad

e ve

rtica

lly a

gain

st C

ut G

uide

Edg

e fo

r ent

ire c

ut.

• M

ake

seve

ral i

dent

ical

, sco

ring

cuts

, NO

T on

e de

ep c

ut.

Trim

tool

wea

r/dam

age

Insp

ect k

nife

for b

lade

dam

age/

wea

r. R

epai

r or r

epla

ce a

s nee

ded.


10 TROUBLESHOOT

Belt

end

wav

y or

cur

ved

Rep

eat b

elt e

nd p

repa

ratio

n w

ith a

ttent

ion

to th

e fo

llow

ing.

Cut t

echn

ique

• M

ake

seve

ral i

dent

ical

, sco

ring

cuts

, NO

T on

e de

ep c

ut.

• H

old

blad

e ve

rtica

lly a

gain

st C

ut G

uide

Edg

e fo

r ent

ire c

ut.

Trim

tool

wea

r/dam

age

Insp

ect k

nife

for b

lade

dam

age/

wea

r. R

epai

r or r

epla

ce a

s nee

ded.

Cut G

uide

wea

rC

heck

Cut

Gui

de E

dge

for c

urve

s or w

aves

. Con

tact

Intra

lox

Cus

tom

er S

ervi

ce fo

r mor

e in

for-

mat

ion.

Belt

end

diag

onal

(i.e

., no

t par

alle

l to

driv

e ba

rs)

Rep

eat b

elt e

nd p

repa

ratio

n w

ith a

ttent

ion

to th

e fo

llow

ing.

Cut t

echn

ique

Mak

e se

vera

l ide

ntic

al, s

corin

g cu

ts, N

OT

one

deep

cut

.

Alig

nmen

t pro

blem

• C

lean

any

deb

ris fr

om b

elt e

nds.

• C

lear

deb

ris fr

om g

roov

es in

Dec

k an

d C

ut G

uide

.•

Che

ck d

rive

bar e

ngag

emen

t bef

ore

secu

ring

belt

ends

.Fo

r S81

26 b

elts

, see

S81

26 B

ELT

SPEC

IFIC

S on

pag

e 15

-1.

Bel

t mov

ed d

urin

g cu

t•

Cle

an a

ny d

ebris

from

bel

t end

s.•

Cle

ar d

ebris

from

gro

oves

in D

eck

and

Cut

Gui

de.

• En

gage

driv

e ba

rs in

Cut

Gui

de o

r Gro

oved

Dec

k be

fore

secu

ring.

• Fu

lly se

cure

bel

t to

Cla

mpi

ng F

ixtu

re.

For S

8126

bel

ts, s

ee S

8126

BEL

T SP

ECIF

ICS

on p

age

15-1

.

Belt

end

has

jagg

ed c

ut

Rep

eat b

elt e

nd p

repa

ratio

n w

ith a

ttent

ion

to th

e fo

llow

ing.

Trim

tool

wea

r/dam

age

Insp

ect k

nife

for b

lade

dam

age/

wea

r. R

epai

r or r

epla

ce a

s nee

ded.

Cut t

echn

ique

• B

egin

cut

at b

elt e

dge

(not

on

belt)

.•

Cut

full

wid

th o

f bel

t eac

h tim

e.


10 TROUBLESHOOT

Sym

ptom

& P

ossi

ble

Caus

esAc

tion

to T

ake

Diff

icul

t to

pull

belt

onto

the

Fixt

ure

Belt

tens

ion

too

high

1. E

nsur

e be

lt is

cut

to p

rope

r len

gth.

2. C

lam

p be

lt to

con

veyo

r fra

me

near

Cla

mpi

ng F

ixtu

re to

elim

inat

e pu

ll on

bel

t end

s.3.

Adj

ust c

onve

yor c

ompo

nent

s to

min

imiz

e te

nsio

n.

Driv

e ba

rs s

nagg

ing

on C

lam

ping

Fix

ture

or

C- o

r F-c

lam

ps•

Ang

le c

ardb

oard

from

Cla

mpi

ng F

ixtu

re e

dge

to c

onve

yor f

ram

e to

allo

w th

e be

lt to

slid

e on

to F

ixtu

re.

• A

djus

t cla

mps

as n

eede

d.•

Req

uest

ass

ista

nce

for h

andl

ing

wid

e be

lts.

Belt

end

exte

nds

too

far/

too

little

pas

t Gro

oved

Dec

k ed

ge

Driv

e ba

rs n

ot e

ngag

ed1.

Cle

an d

ebris

from

bel

t end

s.2.

Cle

ar d

ebris

from

gro

oves

in D

eck

and

Cut

Gui

de.

3. E

ngag

e dr

ive

bars

in C

ut G

uide

or G

roov

ed D

eck

befo

re se

curin

g.

Wro

ng C

ut G

uide

use

dR

epea

t bel

t end

pre

para

tion

usin

g th

e bl

ue S

8026

Cut

Gui

de fo

r 26-

mm

pitc

h be

lt or

red

S805

0 C

ut G

uide

for 5

0-m

m p

itch

belt.

Belt

end

edge

s ar

e of

fset

(ho

rizo

ntal

mis

alig

nmen

t)

Ends

diff

eren

t wid

ths

• If

bel

t end

wid

ths a

re w

ithin

1/8

in (3

mm

) of e

ach

othe

r, ce

nter

the

narr

ow b

elt e

nd a

cros

s fr

om th

e w

ide

belt

end.

• If

bel

t end

wid

ths a

re m

ore

than

1/8

in (3

mm

) diff

eren

t fro

m e

ach

othe

r, co

ntac

t Int

ralo

x C

usto

mer

Ser

vice

.

FABR

ICAT

ION

TIP

Slig

ht d

imen

sion

diff

eren

ces,

with

in 1

/16

in (1

.5 m

m) o

n ea

ch e

dge

(or 1

/8 in

(3 m

m) t

otal

bel

t wid

th),

are

acce

ptab

le w

hen

splic

ing

belts

.

Belt

end

top

surf

aces

are

off

set (

vert

ical

mis

alig

nmen

t)

Thum

b kn

obs

not t

ight

ened

eve

nly

Adj

ust t

hum

b kn

obs t

o in

crea

se o

r dec

reas

e C

ut G

uide

pre

ssur

e on

bel

t end

s unt

il be

lt to

p su

r-fa

ces a

re fl

ush.


10 TROUBLESHOOT

Clam

ping

Fix

ture

sec

ured

to u

neve

n su

rface

cau

sing

ver

tical

offs

et o

f Gro

oved

De

cks

If o

ne b

elt e

nd is

low

er th

an th

e ot

her a

cros

s the

full

belt

wid

th, s

him

the

low

er D

eck

with

pa

inte

rs’ t

ape.

See

Mak

e Be

lt Ta

bs o

n pa

ge 1

1-1.

Trou

gh g

roov

es c

ause

bel

t end

sag

If th

e be

lt ha

s tro

ugh

groo

ves,

shim

the

Gro

oved

Dec

ks w

ith p

aint

ers’

tape

. See

TRO

UG

H

GRO

OVE

SPE

CIF

ICS

on p

age

14-1

.

S812

6 be

lt ne

eds

shim

min

gFo

r S81

26 b

elt,

see

S812

6 BE

LT S

PEC

IFIC

S on

pag

e 15

-1.

Tabl

e of

Fau

lty S

plic

e Pr

oble

ms

Splic

e ar

ea n

ot s

moo

th a

fter

trim

min

g

Mor

e tri

mm

ing

need

edW

ithin

five

(5)-

10 m

inut

es o

f coo

ling

time,

com

plet

e th

e fo

llow

ing

step

s.•

Trim

aw

ay a

ll w

eld

bead

s and

flas

h us

ing

the

Skiv

er a

nd T

rimm

ers w

ithin

10

min

utes

. •

Feat

her o

ffse

t bel

t edg

es to

geth

er to

elim

inat

e sn

ags.

If b

elt e

nds a

re o

ffse

t mor

e th

an 1

/16

in

(1.5

mm

), re

peat

the

splic

e. If

bel

t wid

ths a

re m

ore

than

1/8

in (3

mm

) diff

eren

t, co

ntac

t In

tralo

x C

usto

mer

Ser

vice

.Se

e TR

IM &

INSP

ECT

THE

BELT

on

page

7-1

.

Trim

tool

wea

r/dam

age

• In

spec

t Ski

ver f

or b

lade

dam

age/

wea

r. R

epai

r or r

epla

ce a

s nee

ded.

• In

spec

t Trim

mer

s for

dam

age/

wea

r. R

epai

r or r

epla

ce a

s nee

ded.

Wel

d be

ad/fl

ash

too

cool

to tr

imA

fter a

bout

10

min

utes

of c

oolin

g, th

e sp

lice

is to

o ha

rd to

trim

pro

perly

. 1.

Cut

the

splic

e co

mpl

etel

y fr

om th

e be

lt an

d re

peat

the

full

splic

ing

proc

edur

e.2.

Do

not a

llow

splic

e to

coo

l mor

e th

an th

ree

(3) m

inut

es b

efor

e be

ginn

ing

to tr

im.

Squa

re s

ilicon

e sp

acer

s no

t use

d w

ith

Ribb

ed V

-Top

bel

t (an

une

ven,

wav

y gr

oove

rem

ains

afte

r ski

ving

)

1. C

ut th

e sp

lice

com

plet

ely

from

the

belt

and

repe

at th

e fu

ll sp

licin

g pr

oced

ure.

2. S

ee R

IBBE

D V

-TO

P™ S

TYLE

SPE

CIF

ICS

on p

age

13-1

.

Belt

ends

or e

dges

are

offs

etSe

e Sp

lice

Offs

et a

t . .

. sym

ptom

bel

ow.


10 TROUBLESHOOT

Sym

ptom

& P

ossi

ble

Caus

esAc

tion

to T

ake

Splic

e bu

rned

or

dam

aged

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Tem

pera

ture

or t

ime

set t

oo h

igh

• A

djus

t set

poin

t to

reco

mm

ende

d te

mpe

ratu

re.

• M

elt b

elt e

nds f

or re

com

men

ded

time.

See

Splic

e th

e Be

lt En

ds o

n pa

ge 6

-2.

Plas

tic re

sidu

e on

Wan

d du

ring

splic

e

Rem

ove

resi

due

befo

re a

nd a

fter e

very

splic

e. S

ee A

llow

Hea

t Wan

d to

Pre

-hea

t on

page

3-5

.

Wan

d Co

rd d

amag

eIf

Con

trol B

ox a

ctua

l tem

pera

ture

dis

play

is m

uch

high

er th

an se

tpoi

nt, c

onta

ct In

tralo

x C

us-

tom

er S

ervi

ce.

Splic

e ha

s un

even

mel

ting/

wel

d be

ad

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Plas

tic re

sidu

e on

Wan

d du

ring

splic

e

Rem

ove

resi

due

befo

re a

nd a

fter e

very

splic

e. S

ee A

llow

Hea

t Wan

d to

Pre

-hea

t on

page

3-5

.

Dirt

or re

sidu

e on

bel

t end

s1.

Cle

an b

elt e

nds w

ith a

food

-saf

e de

terg

ent (

with

out a

mm

onia

or b

leac

h).

2. S

aniti

ze a

nd d

ry e

nds w

ith is

opro

pyl a

lcoh

ol a

nd a

cle

an li

nt-f

ree

rag.

3. A

void

dire

ct h

and

cont

act w

ithin

two

(2) d

rive

bars

of p

repa

red

end.

Cont

act w

ith h

ot H

eat W

and

or S

tand

cau

ses

skin

bur

ns. U

sing

hea

t-res

ista

nt

glov

es a

nd s

leev

es is

reco

mm

ende

d.

Plac

e th

e W

and

Stan

d on

a h

ard,

hea

t-res

ista

nt s

urfa

ce (N

OT a

bel

t) du

ring

pre-

heat

.

Cont

act w

ith h

ot H

eat W

and

or S

tand

cau

ses

skin

bur

ns. U

sing

hea

t-res

ista

nt

glov

es a

nd s

leev

es is

reco

mm

ende

d.

Plac

e th

e W

and

Stan

d on

a h

ard,

hea

t-res

ista

nt s

urfa

ce (N

OT a

bel

t) du

ring

pre-

heat

.


10 TROUBLESHOOT

Ends

wav

y, d

iago

nal,

or n

ot s

quar

e•

Insp

ect k

nife

for b

lade

dam

age/

wea

r. R

epai

r or r

epla

ce a

s nee

ded.

• C

lean

deb

ris fr

om b

elt s

urfa

ces.

• C

lear

deb

ris fr

om g

roov

es in

Dec

k an

d C

ut G

uide

.•

Che

ck d

rive

bar e

ngag

emen

t bef

ore

secu

ring

belt

ends

.•

Fully

secu

re b

elt i

n C

lam

ping

Fix

ture

. Fo

r S81

26 b

elt,

see

S812

6 BE

LT S

PEC

IFIC

S on

pag

e 15

-1.

• H

old

blad

e ve

rtica

lly a

gain

st C

ut G

uide

Edg

e fo

r ent

ire c

ut.

• M

ake

seve

ral i

dent

ical

, sco

ring

cuts

, NO

T on

e de

ep c

ut.

Ends

mov

ed/n

ot s

ecur

e•

Cle

an d

ebris

from

bel

t sur

face

s.•

Cle

ar d

ebris

from

gro

oves

in D

eck

and

Cut

Gui

de.

• C

heck

driv

e ba

r eng

agem

ent b

efor

e se

curin

g be

lt en

ds.

• Fu

lly se

cure

bel

t in

Cla

mpi

ng F

ixtu

re.

For N

ub T

op b

elt s

urfa

ces,

see

NU

B TO

P ST

YLE

SPEC

IFIC

S on

pag

e 12

-1.

For S

8126

bel

t, se

e S8

126

BELT

SPE

CIF

ICS

on p

age

15-1

.

Clam

ping

Fix

ture

sla

mm

ed s

hut f

or

cool

ing

Mai

ntai

n co

ntro

l of t

he C

rank

Han

dle

whe

n cl

osin

g th

e C

lam

ping

Fix

ture

for s

plic

e co

olin

g.

Allo

win

g G

roov

ed D

ecks

to sl

am c

lose

d ca

uses

mol

ten

spla

sh a

nd p

ossi

ble

mis

alig

nmen

t.

Splic

e ha

s lit

tle/n

o m

eltin

g (e

.g.,

no w

eld

bead

)

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Wro

ng C

ut G

uide

use

dR

epea

t bel

t end

pre

para

tion

usin

g th

e bl

ue S

8026

Cut

Gui

de fo

r 26-

mm

pitc

h be

lt or

red

S805

0 C

ut G

uide

for 5

0-m

m p

itch

belt.

Tem

pera

ture

or t

ime

set i

ncor

rect

ly•

Adj

ust s

etpo

int t

o re

com

men

ded

tem

pera

ture

. •

Mel

t bel

t end

s for

reco

mm

ende

d tim

e.Se

e Sp

lice

the

Belt

Ends

on

page

6-2

.

Heat

Wan

d no

t pre

-hea

ted

Allo

w H

eat W

and

10–2

0 m

inut

es to

reac

h se

tpoi

nt a

nd st

abili

ze b

efor

e sp

licin

g.

Splic

e ha

s litt

le/n

o m

eltin

g (e

.g.,

no w

eld

bead

) con

tinue

d on

nex

t pag

e


10 TROUBLESHOOT

Sym

ptom

& P

ossi

ble

Caus

esAc

tion

to T

ake

Splic

e ha

s litt

le/n

o m

eltin

g (e

.g.,

no w

eld

bead

) con

tinue

d fr

om p

revi

ous p

age

Faci

lity

too

cold

High

airf

low

in a

rea

1. In

crea

se fa

cilit

y te

mpe

ratu

re in

splic

ing

area

if p

ossi

ble

(abo

ve 4

0ºF/

4ºC

pre

ferr

ed).

2. R

educ

e ai

r flo

w m

echa

nica

lly if

pos

sibl

e.3.

Shi

eld

splic

ing

area

from

air

flow

with

car

dboa

rd o

r sim

ilar.

4. H

old

the

Hea

t Wan

d in

a c

ontro

lled

loca

tion

outs

ide

of th

e St

and

until

it st

abili

zes a

t set

poin

t be

fore

splic

ing.

5. C

onta

ct In

tralo

x C

usto

mer

Ser

vice

for s

ugge

stio

ns.

Ends

mov

ed/n

ot s

ecur

e•

Cle

an d

ebris

from

bel

t sur

face

s.•

Cle

ar d

ebris

from

gro

oves

in D

eck

and

Cut

Gui

de.

• C

heck

driv

e ba

r eng

agem

ent b

efor

e se

curin

g be

lt en

ds.

• Fu

lly se

cure

bel

t in

Cla

mpi

ng F

ixtu

re.

For N

ub T

op b

elt s

urfa

ces,

see

NU

B TO

P ST

YLE

SPEC

IFIC

S on

pag

e 12

-1.

For R

ibbe

d V

-Top

bel

ts, s

ee R

IBBE

D V

-TO

P™ S

TYLE

SPE

CIF

ICS

on p

age

13-1

.Fo

r S81

26 b

elt,

see

S812

6 BE

LT S

PEC

IFIC

S on

pag

e 15

-1.

Equi

pmen

t dam

age

Rev

iew

pos

sibl

e eq

uipm

ent p

robl

ems.

See

Tabl

e of

Equ

ipm

ent/F

acili

ty P

robl

ems o

n pa

ge 1

0-2.

Splic

e ha

s fa

ulty

dri

ve b

ar p

itch

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Wro

ng C

ut G

uide

use

dR

epea

t bel

t end

pre

para

tion

usin

g th

e bl

ue S

8026

Cut

Gui

de fo

r 26-

mm

pitc

h be

lt or

red

S805

0 C

ut G

uide

for 5

0-m

m p

itch

belt.

Cut a

lignm

ent t

echn

ique

Splic

e al

ignm

ent t

echn

ique

• C

lean

deb

ris fr

om b

elt e

nds.

• C

lear

deb

ris fr

om g

roov

es in

Dec

k an

d C

ut G

uide

.•

Che

ck d

rive

bar e

ngag

emen

t bef

ore

secu

ring

belt

ends

. Fo

r S81

26 b

elts

, see

S81

26 B

ELT

SPEC

IFIC

S on

pag

e 15

-1.

• En

sure

pro

per p

roce

dure

is b

eing

use

d fo

r the

serie

s, st

yle,

and

type

bel

t bei

ng a

ligne

d.Fo

r Nub

Top

bel

t sur

face

s, se

e N

UB

TOP

STYL

E SP

ECIF

ICS

on p

age

12-1

.

Splic

e te

chni

que

Ensu

re p

rope

r pro

cedu

re is

bei

ng u

sed

for t

he se

ries,

styl

e, a

nd ty

pe b

elt b

eing

alig

ned.

See

SP

LIC

E TH

E BE

LT o

n pa

ge 6

-1.


10 TROUBLESHOOT

Belt

tens

ion

too

high

1. C

lam

p be

lt to

con

veyo

r fra

me

near

Cla

mpi

ng F

ixtu

re to

elim

inat

e pu

ll on

bel

t end

s.2.

Adj

ust c

onve

yor c

ompo

nent

s to

min

imiz

e te

nsio

n.

Clam

ping

Fix

ture

not

pro

perly

clo

sing

• C

lear

any

deb

ris b

etw

een

Gro

oved

Dec

ks.

• C

lam

ping

Fix

ture

dam

aged

. See

Tab

le o

f Equ

ipm

ent/F

acili

ty P

robl

ems o

n pa

ge 1

0-2.

Splic

e br

eaks

whe

n be

nt

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Wro

ng C

ut G

uide

use

dR

epea

t bel

t end

pre

para

tion

usin

g th

e bl

ue S

8026

Cut

Gui

de fo

r 26-

mm

pitc

h be

lt or

red

S805

0 C

ut G

uide

for 5

0-m

m p

itch

belt.

Tem

pera

ture

or t

ime

set i

ncor

rect

ly•

Adj

ust s

etpo

int t

o re

com

men

ded

tem

pera

ture

. •

Mel

t bel

t end

s for

reco

mm

ende

d tim

e.Se

e Sp

lice

the

Belt

Ends

on

page

6-2

.

Belt

splic

e no

t coo

l eno

ugh

• M

ove

splic

ed b

elt a

s gen

tly a

s pos

sibl

e as

it c

ools

.•

Do

not b

end

splic

e fo

r ins

pect

ion

until

the

belt

has c

oole

d at

leas

t fiv

e (5

) min

utes

at n

orm

al

room

tem

pera

ture

.

Clam

ping

Fix

ture

sla

mm

ed s

hut f

or

cool

ing

Mai

ntai

n co

ntro

l of t

he C

rank

Han

dle

whe

n cl

osin

g th

e C

lam

ping

Fix

ture

for s

plic

e co

olin

g.

Allo

win

g G

roov

ed D

ecks

to sl

am c

lose

d ca

uses

mol

ten

spla

sh a

nd p

ossi

ble

mis

alig

nmen

t.

Splic

e ha

s vi

sibl

e bu

bble

s or

pits

Som

e pi

tting

is e

xpec

ted

in u

sed

belt

ends

, but

mus

t be

min

imal

. Lar

ge p

its o

r con

secu

tive

smal

l pits

indi

cate

a fa

ulty

splic

e. C

ut th

e fa

ulty

sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Tem

pera

ture

or t

ime

too

high

• A

djus

t set

poin

t to

reco

mm

ende

d te

mpe

ratu

re.

• M

elt b

elt e

nds f

or re

com

men

ded

time.

See

Splic

e th

e Be

lt En

ds o

n pa

ge 6

-2.

Splic

e ha

s visi

ble

bubb

les o

r pits

con

tinue

d on

nex

t pag

e


10 TROUBLESHOOT

Sym

ptom

& P

ossi

ble

Caus

esAc

tion

to T

ake

Splic

e ha

s visi

ble

bubb

les o

r pits

con

tinue

d fr

om p

revi

ous p

age

Dirt

or re

sidu

e on

bel

t end

s1.

Cle

an b

elt e

nds w

ith a

food

-saf

e de

terg

ent (

with

out a

mm

onia

or b

leac

h).

2. S

aniti

ze a

nd d

ry e

nds w

ith is

opro

pyl a

lcoh

ol a

nd a

cle

an li

nt-f

ree

rag.

3. A

void

dire

ct h

and

cont

act w

ithin

two

(2) d

rive

bars

of p

repa

red

end.

Plas

tic re

sidu

e on

Wan

d du

ring

splic

e

Rem

ove

resi

due

befo

re a

nd a

fter e

very

splic

e. S

ee A

llow

Hea

t Wan

d to

Pre

-hea

t on

page

3-5

.

Clam

ping

Fix

ture

sla

mm

ed s

hut f

or

cool

ing

Mai

ntai

n co

ntro

l of t

he C

rank

Han

dle

whe

n cl

osin

g th

e C

lam

ping

Fix

ture

for s

plic

e co

olin

g.

Allo

win

g G

roov

ed D

ecks

to sl

am c

lose

d ca

uses

mol

ten

spla

sh a

nd p

ossi

ble

mis

alig

nmen

t.

Clam

ping

Fix

ture

not

pro

perly

clo

sing

• C

lear

any

deb

ris b

etw

een

Gro

oved

Dec

ks.

• C

lam

ping

Fix

ture

dam

aged

. See

Tab

le o

f Equ

ipm

ent/F

acili

ty P

robl

ems o

n pa

ge 1

0-2.

Belt

tens

ion

too

high

1. C

lam

p be

lt to

con

veyo

r fra

me

near

Cla

mpi

ng F

ixtu

re to

elim

inat

e pu

ll on

bel

t end

s.2.

Adj

ust c

onve

yor c

ompo

nent

s to

min

imiz

e te

nsio

n.

Splic

e ha

s vi

sibl

e cr

acks

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Wro

ng C

ut G

uide

use

dR

epea

t bel

t end

pre

para

tion

usin

g th

e bl

ue S

8026

Cut

Gui

de fo

r 26-

mm

pitc

h be

lt or

red

S805

0 C

ut G

uide

for 5

0-m

m p

itch

belt.

Cut t

echn

ique

or a

lignm

ent p

robl

em•

Mak

e se

vera

l ide

ntic

al, s

corin

g cu

ts, N

OT

one

deep

cut

.•

Hol

d bl

ade

verti

cally

aga

inst

Cut

Gui

de E

dge

for e

ntire

cut

. •

Enga

ge d

rive

bars

in C

ut G

uide

or G

roov

ed D

eck

befo

re se

curin

g.•

Fully

secu

re b

elt t

o C

lam

ping

Fix

ture

.Fo

r S81

26 b

elts

, see

S81

26 B

ELT

SPEC

IFIC

S on

pag

e 15

-1.

Cont

act w

ith h

ot H

eat W

and

or S

tand

cau

ses

skin

bur

ns. U

sing

hea

t-res

ista

nt

glov

es a

nd s

leev

es is

reco

mm

ende

d.

Plac

e th

e W

and

Stan

d on

a h

ard,

hea

t-res

ista

nt s

urfa

ce (N

OT a

bel

t) du

ring

pre-

heat

.


10 TROUBLESHOOT

Equi

pmen

t dam

age

• In

spec

t kni

fe fo

r bla

de d

amag

e/w

ear.

Rep

air o

r rep

lace

as n

eede

d.•

Che

ck C

ut G

uide

Edg

e fo

r cur

ves o

r wav

es. C

onta

ct In

tralo

x C

usto

mer

Ser

vice

for m

ore

info

rmat

ion.

Clam

ping

Fix

ture

not

pro

perly

clo

sing

• C

lear

any

deb

ris b

etw

een

Gro

oved

Dec

ks.

• C

lam

ping

Fix

ture

dam

aged

. See

Tab

le o

f Equ

ipm

ent/F

acili

ty P

robl

ems o

n pa

ge 1

0-2.

Belt

not l

ying

flat

on

Carr

yway

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Cut t

echn

ique

• C

lean

bel

t end

s with

a fo

od-s

afe

dete

rgen

t (w

ithou

t am

mon

ia o

r ble

ach)

.•

Cle

ar d

ebris

from

gro

oves

in D

eck

and

Cut

Gui

de.

• C

heck

driv

e ba

r eng

agem

ent b

efor

e se

curin

g be

lt en

ds.

For S

8126

bel

ts, s

ee S

8126

BEL

T SP

ECIF

ICS

on p

age

15-1

.•

Mak

e se

vera

l ide

ntic

al, s

corin

g cu

ts, N

OT

one

deep

cut

.

Poor

alig

nmen

t•

Cle

an d

ebris

from

bel

t sur

face

s.•

Cle

ar d

ebris

from

gro

oves

in D

eck

and

Cut

Gui

de.

• C

heck

driv

e ba

r eng

agem

ent b

efor

e se

curin

g be

lt en

ds.

• Fu

lly se

cure

bel

t in

Cla

mpi

ng F

ixtu

re.

For N

ub T

op b

elt s

urfa

ces,

see

NU

B TO

P ST

YLE

SPEC

IFIC

S on

pag

e 12

-1.

For S

8126

bel

t, se

e S8

126

BELT

SPE

CIF

ICS

on p

age

15-1

.

Belt

tens

ion

too

high

1. C

lam

p be

lt to

con

veyo

r fra

me

near

Cla

mpi

ng F

ixtu

re to

elim

inat

e pu

ll on

bel

t end

s.2.

Adj

ust c

onve

yor c

ompo

nent

s to

min

imiz

e te

nsio

n.


10 TROUBLESHOOT

Sym

ptom

& P

ossi

ble

Caus

esAc

tion

to T

ake

Splic

e of

fset

at e

dges

(ho

rizo

ntal

mis

alig

nmen

t)

Belt

ends

not

pro

perly

alig

ned

Belt

ends

diff

eren

t wid

ths

FABR

ICAT

ION

TIP

Slig

ht d

imen

sion

diff

eren

ces,

with

in 1

/16

in (1

.5 m

m) o

n ea

ch e

dge

(or 1

/8 in

(3 m

m) t

otal

bel

t wid

th),

are

acce

ptab

le w

hen

splic

ing

belts

.

• If

bel

t edg

e of

fset

is g

reat

er th

an 1

/16

in (1

.5 m

m),

the

splic

e is

faul

ty. C

ut th

e fa

ulty

splic

e fr

om th

e be

lt an

d re

peat

the

splic

ing

proc

edur

es w

ith c

aref

ul a

ttent

ion

to a

lignm

ent.

• If

bel

t edg

e of

fset

is 1

/16

in (1

.5 m

m) o

r les

s, tri

m o

ff sn

ags a

nd u

se tr

im to

ols t

o sm

ooth

bel

t ed

ges b

efor

e th

e sp

lice

fully

coo

ls.

• If

bel

t end

wid

ths m

easu

re m

ore

than

1/8

in (3

mm

) diff

eren

t fro

m e

ach

othe

r, co

ntac

t In

tralo

x C

usto

mer

Ser

vice

.

Splic

e of

fset

at t

op s

urfa

ces

(ver

tical

mis

alig

nmen

t)

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Belt

top

surfa

ces

not p

rope

rly a

ligne

d •

Adj

ust t

hum

b kn

obs t

o in

crea

se o

r dec

reas

e C

ut G

uide

pre

ssur

e on

bel

t end

s unt

il be

lt to

p su

rfac

es a

re fl

ush.

• If

one

bel

t end

is lo

wer

than

the

othe

r acr

oss t

he fu

ll be

lt w

idth

, shi

m th

e lo

wer

Dec

k w

ith

pain

ters

’ tap

e. S

ee M

ake

Belt

Tabs

on

page

11-

1.•

If th

e be

lt ha

s driv

e ba

rs re

mov

al (o

r tro

ugh

groo

ves)

, shi

m th

e G

roov

ed D

ecks

with

pai

nter

s’

tape

. See

TRO

UG

H G

ROO

VE S

PEC

IFIC

S on

pag

e 14

-1.

• Fo

r S81

26 b

elt,

see

S812

6 BE

LT S

PEC

IFIC

S on

pag

e 15

-1.

Squa

re s

ilicon

e sp

acer

s no

t use

d w

ith

Ribb

ed V

-Top

bel

t end

sSe

e RI

BBED

V-T

OP™

STY

LE S

PEC

IFIC

S on

pag

e 13

-1.

Equi

pmen

t dam

age

Cut

Gui

des a

re b

ent.

Con

tact

Intra

lox.

This

dam

age

may

be

caus

ed b

y ov

er-ti

ghte

ning

thum

b kn

obs c

ausi

ng th

e C

ut G

uide

s to

bow

or

war

p.


10 TROUBLESHOOT

Tabl

e of

Bel

t Fai

lure

sSp

lice

Tear

s in

Pro

duct

ion

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Splic

e w

as n

ot in

spec

ted

befo

re ru

nnin

gSe

e TR

IM &

INSP

ECT

THE

BELT

on

page

7-1

.

Wel

d be

ad/fl

ash

snag

ging

on

conv

eyor

fra

me

1. C

heck

trim

tool

s for

dam

age

or w

ear.

2. S

kive

bot

h to

p an

d bo

ttom

wel

d be

ads.

3. B

e su

re to

smoo

th sn

ags o

r off

sets

from

bel

t edg

es.

Too

muc

h be

lt re

mov

ed d

urin

g tri

mm

ing

Skiv

e ra

ised

wel

d be

ad fr

om th

e fla

t bel

t sur

face

s; d

o no

t cre

ate

a ch

anne

l at t

he sp

lice.

Wro

ng C

ut G

uide

use

dR

epea

t bel

t end

pre

para

tion

usin

g th

e bl

ue S

8026

Cut

Gui

de fo

r 26-

mm

pitc

h be

lt or

red

S805

0 C

ut G

uide

for 5

0-m

m p

itch

belt.

Tem

pera

ture

or t

ime

set i

ncor

rect

ly•

Adj

ust s

etpo

int t

o re

com

men

ded

tem

pera

ture

. •

Mel

t bel

t end

s for

reco

mm

ende

d tim

e.Se

e Sp

lice

the

Belt

Ends

on

page

6-2

.

Belt

not e

ngag

ing

spro

cket

s

Cut

the

faul

ty sp

lice

from

the

belt

and

repe

at th

e sp

licin

g pr

oced

ures

with

car

eful

atte

ntio

n to

the

follo

win

g ite

ms.

Driv

e ba

r pitc

h fa

ulty

Insp

ect d

rive

bar p

itch

at sp

lice

with

Pitc

h G

auge

. If p

itch

does

not

mee

t ins

pect

ion,

repe

at

splic

ing

proc

edur

e w

ith sp

ecia

l atte

ntio

n to

the

follo

win

g:•

Cle

an d

ebris

from

bel

t end

s.•

Cle

ar d

ebris

from

gro

oves

in D

eck

and

Cut

Gui

de.

• En

gage

driv

e ba

rs in

Cut

Gui

de o

r Gro

oved

Dec

k be

fore

secu

ring.

• U

se th

e bl

ue S

8026

Cut

Gui

de fo

r 26-

mm

pitc

h be

lt or

red

S805

0 C

ut G

uide

for 5

0-m

m p

itch

belt.

Belt

not e

ngag

ing

spro

cket

s con

tinue

d on

nex

t pag

e


10 TROUBLESHOOT

Sym

ptom

& P

ossi

ble

Caus

esAc

tion

to T

ake

Belt

not e

ngag

ing

spro

cket

s con

tinue

d fr

om p

revi

ous p

age

Spro

cket

s ar

e m

isal

igne

d on

sha

ftSe

e Th

erm

oDri

ve®

Bel

ting

Con

veyo

r Bel

ting

Inst

alla

tion

and

Mai

nten

ance

at t

he In

tralo

x w

ebsi

te.

Belt

tens

ion

too

high

See

Ther

moD

rive

® B

eltin

g C

onve

yor B

eltin

g In

stal

latio

n an

d M

aint

enan

ce a

t the

Intra

lox

web

site

.


SPECIAL PROCEDURES

SPEC

IAL

PROC

EDUR

ES

11 SPECIAL PROCEDURES

S11
PECIAL PROCEDURES
Avoid Injury.


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


Set Up at the ReturnwayWhen 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.

NOTEReturnway splicing can require extra assistance.

1. Place the Clamping Fixture on a sturdy, flat, 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. Ensure there is adequate space above and around the Clamping Fixture for Heat Wand movement.

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

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

NOTEAll 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 in (13 mm) pieces. At least four (4) are used for each splice.




11-2

Shim for Belt Top Surface (Vertical) AlignmentIf the Cut Guide thumb knobs have been adjusted, but one belt top surface is higher than the other, shim with painters’ tape.

FABRICATION TIPIf top surface alignment is intermittent, see

TROUGH GROOVES SPECIFICS on page 14-1. If splicing S8126, see S8126 BELT SPECIF-

ICS on page 15-1.

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.

Figure 11C: Apply tape at Deck edge

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 11E: Replace the belt end

NOTETape layers can be added and removed in areas as

needed until belt top surfaces are aligned.

Grooved Deck edge (under tape)

first groove




Trim the Second Weld Bead— Alternative TechniqueIf working alone or with low clearance, con-sider 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.

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.

Inspect the Clamping FixtureEnsure the Clamping Fixture meets the follow-ing 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 clock-wise, then locks closed at the “click.”

Ensure the pads on each end of the Clamping Fixture touch. Middle Clamp-ing Fixture pads do not have to touch.

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



11-4

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


12 NUB TOP STYLE SPECIFICS

N12
UB TOP STYLE SPECIFICS
Avoid Injury.




Nub Top OverviewNubs 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 flat Silicone Spacers.

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

Remove NubsUse the Skiver to remove all nubs within 0.5 in (12 mm) of each belt end.

Figure 12B: Remove nubs from splicing area

Prepare Flat Silicone Spacers for UseCut four (4) 0.5 in (12 mm) lengths of flat Sili-cone Spacer and ensure the remaining two strips fit between the Grooved Deck Locating Pins.

Figure 12C: Flat spacers for 42 in Clamping Fixture

FABRICATION TIPIf the belt is machined with trough grooves, see TROUGH GROOVE SPECIFICS on page 14-1.


12 NUB TOP STYLE SPECIFICS

12-2

Use Flat Silicone SpacersPosition flat 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 spacer strip

FABRICATION TIPPlace 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 flat spacer with Deck edge

belt end extends past Deck edge


13 RIBBED V-TOP™ STYLE SPECIFICS

R13
IBBED V-TOP™ STYLE SPECIFICS
Avoid Injury.




Ribbed V-Top OverviewRaised Vs and ribs can hinder secure belt end clamping and make belt trimming difficult.

Figure 13A: Ribbed V-Top samples

When splicing belts with a Ribbed V-Top sur-face style, include these steps in the procedure for best results.

• Before aligning belt ends, remove the top surface profile at belt ends with the Belt End Router Set to allow proper trimming after splicing.

• Before aligning belt ends, prepare the square Silicone Spacers.

• When aligning belt ends, use square Sili-cone Spacers to clamp belt ends securely.

Remove Top Surface ProfileUse the Belt End Router Set to remove the ribs and raised Vs within 0.5 in (12 mm) of each belt end.

Figure 13B: Milling the Belt Ends

See the ThermoDrive Belt End Router Set User Manual for instructions.

Prepare SquareSilicone Spacers for UseCut four (4) 1.5 in (38 mm) lengths of square Silicone Spacer for the belt tabs. Ensure the remaining two strips fit between the Grooved Deck Locating Pins.

Figure 13C: Square Spacers for 24 in ClampingFixture


13 RIBBED V-TOP™ STYLE SPECIFICS

13-2

FABRICATION TIPIf the belt is machined with trough grooves, see TROUGH GROOVE SPECIFICS on page 14-1.

Use Square Silicone Spacers1. Align the milled Ribbed V-Top belt ends on the Clamping Fixture.

2. Follow instructions in ALIGN AND SECURE BELT ENDS on page 5-1 except for the follow-ing steps.

a. Use the 8050 Flat Top belt tabs.

b. Place a 1.5 in (33 mm) square spacer on top of each belt tab at the grooved deck edge.

Figure 13D: Align Ribbed V-Top belt end

FABRICATION TIPPlace Spacer strips on Belt Tabs, if used.

3. Once belt ends are aligned and secured, insert the square Silicone Spacers between the smooth belt end and the Cut Guides (or Grooved Decks, if drive bars face up).

Figure 13E: Insert square Silicone Spacers

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

Figure 13F: Align square Silicone Spacer flush with Deck edge

belt end extends past Deck edge


14 TROUGH GROOVE SPECIFICS

T14
ROUGH GROOVE SPECIFICS
Avoid Injury.




Trough Groove OverviewA trough groove or deep drive bar removal can cause a slight sag in the belt top surface that can affect splicing quality.

Figure 14A: Trough groove samples

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

FABRICATION TIPSplice on the carryway with drive bars face

down for best results.

Shim the Grooved Deck

FABRICATION TIPIf belt top surfaces are not flush (vertically misaligned) where trough 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 painters’ tape about the same length as the belt width.

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 14B: Center tape at Grooved Deck edge

Grooved Deck edge (under tape)

first groove


14 TROUGH GROOVE SPECIFICS

14-2

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

Figure 14C: Trim tape width

Use the drive bar removal or trough grooves at the belt end as a guide to trim and remove tape from the areas with drive bars.

Figure 14D: Trim tape length

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

Figure 14E: Finish belt end alignment



15 S8126 BELT SPECIFICS

S15
8126 BELT SPECIFICS
Avoid Injury.




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

It is important to know the standard TD Splic-ing 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.

Figure 15A: S8126 Samples

FABRICATION TIPUse a 24 in 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 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 pro-cedure.

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



15-2

Preparing Belt Ends

Shim the Smooth Edges toSecure Belt Ends

FABRICATION TIPTape shims must raise the smooth belt edges so the Cut Guide can secure them, but not so much

that the belt drive bars cannot 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 in (6–7 mm) from where the prepared 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 15B: 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.

Use Thin Belt Tabs toSecure Belt EndsUse these guidelines to place one (1) Belt Tab correctly 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 15C: Choose Belt Tabs thinner than belt

• Ensure the Belt Tab drive bars engage the grooves.

Figure 15D: Place Belt Tabs on Grooved Decks

6 mm TD 8126 FT belt

5.3 mm Belt Tab



Repeatedly Inspect Alignment before CuttingTo align the belt ends on Grooved Decks for cutting or splicing, use the following guide-lines.

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 15E: Inspect with square edge

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

Figure 15F: Clamp belt edges securely

Add the Second Cut Guide to Secure Belt for CuttingWith the belt end properly aligned and tightly secured, place the 8050 Cut Guide on the sec-ond locked Grooved Deck. Hold the Cut Guide against the Belt Tabs and hand-tighten the thumb knobs.

Figure 15G: Secure the second Cut Guide in place

Inspect Cuts for SquarenessWhen the cuts are complete, inspect each pre-pared end for straight, square cuts. Hold it against the straight Cut Guide and use a square to check for 90° corners.

Figure 15H: Inspect cut

90°



15-4

Align & Secure Belt Ends

FABRICATION TIPFor best results, use a 24 in Splicing System and align belts with drive bars face down.

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

Remove any Belt TensionTo minimize pull on the belt ends, ensure ade-quate 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 15-2.

Figure 15I: Place thin Belt Tabs on Grooved Decks

Repeatedly Inspect AlignmentCheck 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 15J: Inspect with square edge

Control Crank Handle During AlignmentGently open and close the Clamping Fixture to inspect belt end alignment. Do not allow belt ends to touch.

Figure 15K: Inspect touching ends

FABRICATION TIPNormal clamping force can cause belt end

misalignment.Maintain control of Crank Handle at all times.

90°



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

Figure 15L: Clamp belt edges securely

FABRICATION TIPCheck for secure clamping by tugging gently

on the belt edges just before splicing.

If the belt moves when pulled, consider adding another tape layer to the tape shims. Do not add so much that belt drive bars cannot engage the

Grooved Decks.

Splice the Belt EndsBecause 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 Handlefor 25 Seconds of MeltingTurn 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.

Figure 15M: Maintain control of the Crank Handle

Close Decks Gently for CoolingWhen removing the Heat Wand, control the Crank Handle to close the Clamping Fixture completely, but gently.

FABRICATION TIPNormal clamping force can cause belt end

misalignment. Maintain control of Crank Handle at all times.



15-6

Trim & Inspect the BeltTo 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 in (1.6 mm) and are perpendicular to the belt edge.

Figure 15N: Inspect drive bar alignment

NOTERemove tape shims before running the belt.


PREVENTIVE MAINTENANCE

PREV

ENTI

VE M

AINT

ENAN

CE

16 PERFORM PREVENTIVE MAINTENANCE

P16
ERFORM PREVENTIVE MAINTENANCE
Avoid injury.

Contact with hot Heat Wand or Stand causes skin burns; using heat-resistant

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.
Tech. Initials

Maintenance Procedure to Perform

Mon

thly

Quar

terly

Bian

nual

ly

Annu

ally

Ensure all components are in the Splicing System storage case. For a com-ponent list and replacement part details, see the ThermoDrive Technology Engineering Manual or see SPLICING SYSTEM COMPONENTS on page 2-1.

x

Ensure the Instruction Manual is in the storage case. xEnsure safety labels are adhered per photographs in this manual. See Belt Splicing System Hazards on page i-3. Contact Intralox or Clarion Safety for replacement labels if needed.

x

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.

• Ensure the Heat Wand pre-heats when powered on.

x

Secure any misaligned or loose components, etc. xClean the Temperature Control Box display with minimal lens cleaning solution and a soft cloth. x

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


Country- and industry-specific toll-free phone numbers, and information on Intralox’s global locations, available at www.intralox.com.

Intralox, L.L.C. USA, New Orleans, LA, +504-733-0463, Toll Free: 1-800-535-8848Intralox, L.L.C. Europe, Amsterdam, The Netherlands, +31-(0)20-540 36 00, Toll Free: 0800-4687-2569 Intralox Shanghai LTD., Shanghai, China, Toll Free: 400-842-3469Equipment R&D and Test Center, Savage, Maryland, USAGlobal Assembly Center Locations: Japan • United Kingdom • Australia • Brazil • India

© 09/2018 Intralox, L.L.C. 5006184_ENGLISH

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Intralox ThermoDrive Belt Splicing System v. 2.0 User Manual