Intralox ThermoDrive Instruction Manual
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Intralox ThermoDrive Instruction Manual

Belt splicing system v.2.0 for use with td 8026/8126 belts & td 8050 belts
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Intralox ThermoDrive
®
Belt Splicing System v.2.0

Instruction Manual

For use with
TD 8026/8126 belts
TD 8050 belts

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Summary of Contents for Intralox ThermoDrive

  • Page 1: Instruction Manual

    Intralox ThermoDrive ® Belt Splicing System v.2.0 Instruction Manual For use with TD 8026/8126 belts TD 8050 belts...

  • Page 2: Safety Information

    This is a general warning sign. It is used throughout this manual to alert Only authorized Intralox service providers should you to hazards you may encounter service the Splicing System.There are no user-ser- during specific operating, trouble- viceable Splicing System components.

  • Page 3: Safety Symbols

    SAFETY Hazard Severity Panels DANGER indicates a hazard with a high level of risk. If you do not avoid this hazard, it will result in death or serious injury. WARNING indicates a hazard with a medium level of risk. If you do not avoid this hazard, it could result in death or serious injury.

  • Page 4: Heat Wand And Temperature

    SAFETY Belt Splicing System Hazards Figure A: Heat Wand and Temperature Control Box hazards Request assistance when moving or splicing with the 42" Splicing System. Contact with hot Heat Wand or Stand will cause skin burns; use of heat-resistant gloves and sleeves that withstand consistent temperatures up to 500°F is recommended.
  • Page 5 SAFETY Figure B: Clamping Fixture hazards  Belt Splicing System v.2.0...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SAFETY 4 PREPARE BELT ENDS Safety Information ........Belt End Situations ......Imbedded Warnings........ Preparation Overview ......Hazard Severity Panels ......Clean Belt Ends........Safety Symbols ........Cut Belt Ends ........Belt Splicing System Hazards ....Inspect Belt Ends ........

  • Page 7: Table Of Contents

    TABLE OF CONTENTS TROUBLESHOOTING 14 S8126 BELT SPECIFICS S8126 Overview ........ 14-1 10 TROUBLESHOOT Preparing Belt Ends......14-2 Troubleshooting Overview....10-1 Shim the Smooth Edges to Procedures & Inspections ....10-1 Secure Belt Ends......14-2 Faulty Cuts & Splices......10-1 Use Thin Belt Tabs to Secure Belt Ends......

  • Page 8: Table Of Contents

    LIST OF FIGURES LIST OF FIGURES SAFETY Figure 3E: Check voltage requirements ..3- 3 Figure A: Heat Wand and Temperature Figure 3F: Check voltage requirements... 3- 4 Control Box hazards ...........3 Figure 3G: Turn Power on......3- 4 Figure B: Belt cutting and trimming hazards ..3 Figure 3H: Check Control Box display ....
  • Page 9 LIST OF FIGURES 7 TRIM & INSPECT THE BELT Figure 5E: Close the Clamping Fixture .... 5- 3 Figure 7A: Secure the belt......7- 1 Figure 5F: Align right and left belt edges..5- 3 Figure 7B: Separate the weld bead Figure 5G: Secure second belt end ....
  • Page 10 LIST OF FIGURES SPECIAL PROCEDURES 13 TROUGHING GROOVES SPECIFICS Figure 13A: Troughing groove samples..13- 1 11 SPECIAL PROCEDURES Figure 11A: Place the Clamping Fixture on a flat, Figure 13B: Center tape at Grooved stable surface ..........11- 1 Deck edge........... 13- 1 Figure 11B: Make a Belt Tab......
  • Page 11 LIST OF FIGURES Figure 14H: Inspect cut ....... 14- 3 Figure 14I: Place thin Belt Tabs on Grooved Decks ........... 14- 4 Figure 14J: Inspect with square edge... 14- 4 Figure 14K: Inspect touching ends....14- 4 Figure 14L: Clamp belt edges securely ..14- 5 Figure 14M: Maintain control of the Crank Handle ..........

  • Page 12: Equipment Overview System Use

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

  • Page 13: Accessories

    1 EQUIPMENT OVERVIEW Accessories The following accessories come with the above components: a storage case, Silicone Spacers, Teflon tape, Pitch Gauge, trim tools, a stop- watch, and Belt Tabs. NOTE For details about components and voltage requirements, see SPLICING SYSTEM COM- PONENTS on page 2-1.

  • Page 14: Splicing System Components Accessories

    (Flexco™ rough-top Skiver or similar) stopwatch: Digital timing device with large dis- Belt Tabs: Small pieces of ThermoDrive belt play used on Grooved Deck ends to ensure even utility knife: Self-retracting safety knife with a clamping pressure across the belt during splic- 1 3/4"...

  • Page 15: Clamping Fixture

    The 8026/8050 Top Clamp/Cut Guide set does not provide correct pitch with metal lacing. Contact ture frame on the right and left of the Grooved Intralox with questions about metal lacing. Decks designed to smooth belt movement onto the decks...

  • Page 16: Figure 2D: Top Clamp/Cut Guide Set

    Clamping Fixture Grooved Decks; designed Locating Pins: Fixed metal posts that corre- only for use with ThermoDrive belts and Splic- spond to the Cut Guide locating holes; designed ing Systems to properly align Cut Guides on the Grooved...

  • Page 17: Heat Wand And Temperature Control Box

    Figure 2E: Heat Wand components Heat Wand: Electrically operated, heating Stand: Metal guard designed to hold the Heat platen used to melt Intralox ThermoDrive belt Wand upright, allow handle access during use, ends for splicing; designed to be connected to and prevent accidental contact with the Wand;...
  • Page 18 2 SPLICING SYSTEM COMPONENTS Temperature Control Box: Electric device that controls the Heat Wand temperature via thermocouple signals to and from the Wand; includes an Electric Cord with three-pronged plug Always use ground fault protection/ residual current protection when operating in damp or wet conditions. Electric Cord: Cord connected from the Temperature Control Box provided with a three-prong plug for use in a grounded outlet...

  • Page 19: Standard Procedures

    STANDARD PROCEDURES...

  • Page 20: Set Up The Splicing System

    Prepare the Conveyor Do NOT submerge equipment or expose it to direct spray. See the ThermoDrive® Belting Conveyor Belt- ing Installation and Maintenance at the Always use ground fault protection/ Intralox website or contact Intralox for com- residual current protection when plete assembly and disassembly instructions.

  • Page 21: Prepare Clamping Fixture

    3 SET UP THE SPLICING SYSTEM • Place clamps ahead of the Clamping Fix- Prepare Clamping Fixture ture on an inclined conveyor to prevent sliding. Request assistance when moving or splicing with the 42" Splicing System. Secure Clamping Fixture to Conveyor 1.

  • Page 22: Prepare The Heat Wand

    3 SET UP THE SPLICING SYSTEM 2. Insert the tethered retaining pin into the hole Prepare the Heat Wand on the shaft to secure the Handle in place. FABRICATION TIP Make Power Connections Ensure the tether and fastener face outward. 1.

  • Page 23: Adjust Temperature Setpoint

    3 SET UP THE SPLICING SYSTEM Do NOT submerge equipment or Adjust Temperature Setpoint expose it to direct spray. 1. Choose the setpoint based on belt material. Always use ground fault protection/ residual current protection when Belt Material Setpoint operating in damp or wet conditions. Temp.°F/°C 4.

  • Page 24: Allow Heat Wand To Pre-Heat

    3 SET UP THE SPLICING SYSTEM 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. Contact with hot Heat Wand or Stand will cause skin burns. Using heat- resistant gloves and sleeves is recom- mended.

  • Page 25: Prepare Belt Ends

    Existing Belt: Cut away the damaged or excess belting, then prepare belt ends using instruc- tions here. Cut Hazard NOTE Wear safety glasses and use caution Contact Intralox to order replacement belt sections when preparing belt ends. for splicing as needed. Belt End Situations Preparation Overview NOTE...

  • Page 26: Clean Belt Ends

    4 PREPARE BELT ENDS Clean Belt Ends Cut Belt Ends 1. If used belt has not been severed into belt Prepare each belt end to be spliced on the ends, clean the belt area—top, bottom, and Clamping Fixture with drive bars face up or edges—where the belt will be severed.

  • Page 27: Engagement/Alignment

    4 PREPARE BELT ENDS 3. Engage the drive bars in the Grooved Decks, 5. Place each Pivoting Stud in a Cut Guide if drive bars face down. Align the drive bars recess and finger-tighten the thumb knobs to with the grooves on the Grooved Deck, if belt hold the belt end securely.

  • Page 28: Inspect Belt Ends

    4 PREPARE BELT ENDS 6. Hold the utility knife blade on the stainless Inspect Belt Ends cut surface of the Grooved Deck before the belt and vertically against the Cut Guide Edge. Ensure the prepared belt end cuts meet these requirements.

  • Page 29: Align And Secure Belt Ends

    5 ALIGN AND SECURE BELT ENDS ALIGN AND SECURE BELT ENDS Align Belt Ends FABRICATION TIP Avoid Injury. These instructions provide the Keep hands and fingers clear of Frame most common cutting procedures. edge when opening the Clamping If you are aligning S8126 belt ends, a belt with Fixture.

  • Page 30: Lightly Secure Belt Ends

    5 ALIGN AND SECURE BELT ENDS 3. Hold the belt end in place and align the Lightly Secure Belt Ends Locating Pins and holes to lower a Cut Guide onto the Grooved Deck and belt end. 1. Center a belt end on the closest Grooved 4.

  • Page 31: Check Alignment & Tightly Secure Belt Ends

    If belt widths are more than 1/8" (3.2 mm) different, contact Intralox. 3. When belt edges are aligned, evenly finger- tighten the thumb knobs on each Cut Guide.

  • Page 32: Inspect Tension

    5 ALIGN AND SECURE BELT ENDS 5. Open the Clamping Fixture. Inspect Alignment FABRICATION TIP With the prepared belt ends touching lightly, Once belt ends aligned and secured, do not confirm belt ends meet requirements below and allow the Clamping Fixture to close prepared end requirements.

  • Page 33: Alignment

    5 ALIGN AND SECURE BELT ENDS  Belt end top surfaces are flush within 1/ 64" (0.5 mm). This is most easily assessed by sliding the Skiver tip across the belt ends to ‘feel’ for an uneven surface. Figure 5J: Inspect belt surface vertical alignment FAIL: If belt ends do NOT meet these require- ments, troubleshoot until requirements are met.

  • Page 34: Splice The Belt

    6 SPLICE THE BELT SPLICE THE BELT NOTE Release Stand latches before trying to remove the Heat Wand. Avoid Injury. Keep hands and fingers clear of Frame 2. Once the temperature setpoint is reached, edge when opening the Clamping hold the Heat Wand handle(s) and wipe plastic fixture.

  • Page 35: Splice The Belt Ends

    6 SPLICE THE BELT 4. Choose the correct melting time based on Splice the Belt Ends belt material. Belt Material Setpoint Melt Cool FABRICATION TIP Temp. time time These instructions provide the most common Polyurethane splicing procedures. If the belt is S8126, see 450°...

  • Page 36: Figure 6D: Wand Rest At One End

    6 SPLICE THE BELT 2. With the Clamping Fixture fully open, set the 5. When the melt time is reached, quickly open Heat Wand on both Wand Rests. the Grooved Decks fully and remove the Heat Wand. Figure 6D: Wand Rest at one end 3.

  • Page 37: Allow The Belt To Cool

    6 SPLICE THE BELT 2. Return the Heat Wand to the Stand. Latch in Allow the Belt to Cool place. 3. After two (2) minutes of cooling (in normal Contact with hot Heat Wand or Stand room temperature conditions), remove the Cut will cause skin burns;...

  • Page 38: Trim & Inspect The Belt

    7 TRIM & INSPECT THE BELT TRIM & INSPECT THE BELT 3. Move the rounded blade on the Skiver from side to side at the belt edge to separate the weld bead from the belt top surface. Cut/Puncture Hazard Wear safety glasses and use caution when handling knives and trim tools.

  • Page 39: Trim Second Weld Bead

    7 TRIM & INSPECT THE BELT Trim Second Weld Bead Trim Belt Edges 1. Hold the Trimmers vertically against the belt FABRICATION TIP edge and cut away any flash on either side. The most common procedure for removing the second weld bead is provided here. For an alternate procedure, see SPECIAL PROCEDURES on page 11-1.

  • Page 40: Inspect The Belt

    7 TRIM & INSPECT THE BELT 3. Create a smooth belt edge without snags Ensure these requirements are met before run- along the splice. Be sure not to puncture or ning the belt. score the belt.  The belt top and bottom are smooth and flat at the splice.
  • Page 41 7 TRIM & INSPECT THE BELT  When the belt is bent at the splice, the splice has NO visible cracks or bubbles, and no more than two (2) small pits. To inspect the splice, pull the belt edges together so the belt bends at the splice (as though it was around a 4"...

  • Page 42: Shut Down, Cool, & Pack Up

    8 SHUT DOWN, COOL, & PACK UP SHUT DOWN, COOL, & PACK UP 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- Avoid Injury. nents and seal them in the plastic bag with the Crank Handle.

  • Page 43: Figure 8B: Secure The Twist Latches

    8 SHUT DOWN, COOL, & PACK UP • Put the coiled cords in the empty compart- ment next to the Temperature Control Box. NOTE Storing Temperature Control Box with Heat Wand cord attached can damage components. • Put the Clamping Fixture in the long com- partment near the hinges.

  • Page 44: Troubleshooting

    TROUBLESHOOTING...

  • Page 45: Troubleshoot

    This manual provides all procedures and but remember the requirements below. instructions a facility maintenance technician needs to splice ThermoDrive belt ends together. Included here are troubleshooting tables with Repeat Cuts information about possible problems and sug- •...

  • Page 46: Table Of Equipment/Facility Problems

    Symptom & Possible Causes Action to Take Voltage/Plug Mismatch Error in ordering or shipping Contact Intralox Customer Service or Technical Support to correct err Temperature Control Box Display is blank or shows S.Err Connection problem 1. Ensure equipment and facility voltages match.
  • Page 47 Mechanical problem 1. Remove visible debris from spring assemblies. 2. Apply gear lubricant to the moving parts at springs and linear bearin 3. Contact Intralox Technical Support about bearing replacements or r Grooved Decks, or bearing shafts. NOTE Do not disassemble the Clamping Fixture assembly. All components a through Clamping Fixture openings.

  • Page 48: Table Of Preparing And Aligning Belt Ends Problems

    Belt Tabs lost or discarded • Make additional Belt Tabs from available belt material. See Make B • Contact Intralox Customer Service to order Belt Tabs. Table of Preparing and Aligning Belt Ends Problems Belt end not square (i.e., not perpendicular to belt top surface) Repeat belt end preparation with attention to the following.
  • Page 49 Trim tool wear/damage Inspect knife for blade damage/wear. Repair/replace as needed. Cut Guide wear Check Cut Guide Edge for curves or waves. Contact Intralox Technica damage. Belt end diagonal (i.e., not parallel to drive bars) Repeat belt end preparation with attention to the following.
  • Page 50 Symptom & Possible Causes Action to Take Difficult to pull belt onto the Fixture Belt tension too high 1. Ensure belt is cut to proper length. 2. Clamp belt to conveyor frame near Clamping Fixture to eliminate p 3. Adjust conveyor components to minimize tension. Drive bars snagging on Clamping Fixture •...

  • Page 51: Table Of Faulty Splice Problems

    • Feather offset belt edges together to eliminate snags. If belt ends are (1.5 mm), repeat the splice. If belt widths are more than 1/8" (3 mm Intralox Technical Support. See TRIM & INSPECT THE BELT on page 7-1. Trim tool wear/damage •...
  • Page 52 Symptom & Possible Causes Action to Take Splice burned or damaged Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items. Temperature or time set too high • Adjust setpoint to recommended temperature. •...
  • Page 53 Ends wavy, diagonal, or not square • Inspect knife for blade damage/wear. Repair/replace as needed. • Clean debris from belt surfaces. • Clear debris from grooves in Deck and Cut Guide. • Check drive bar engagement before securing belt ends. •...
  • Page 54 3. Shield splicing area from air flow with cardboard or similar. 4. Hold the Heat Wand in a controlled location outside of the Stand unt before splicing. 5. Contact Intralox Technical Support for suggestions. Ends moved/not secure • Clean debris from belt surfaces.
  • Page 55 Belt tension too high 1. Clamp belt to conveyor frame near Clamping Fixture to eliminate p 2. Adjust conveyor components to minimize tension. Clamping Fixture not properly closing • Clear any debris between Grooved Decks. • Clamping Fixture damaged. See Table of Equipment/Facility Proble Splice breaks when bent Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.
  • Page 56 Symptom & Possible Causes Action to Take Splice has visible bubbles or pits continued from previous page Dirt or residue on belt ends 1. Clean belt ends with a food-safe detergent (without ammonia or ble 2. Sanitize and dry ends with isopropyl alcohol and a clean lint-free ra 3.
  • Page 57 Equipment damage • Inspect knife for blade damage/wear. Repair/replace as needed. • Check Cut Guide Edge for curves or waves. Contact Intralox Techni ment damage. Clamping Fixture not properly closing • Clear any debris between Grooved Decks. • Clamping Fixture damaged. See Table of Equipment/Facility Proble Belt not lying flat on Carryway Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items.
  • Page 58 • If the belt has troughing grooves, shim the Grooved Decks with Pain TROUGHING GROOVES SPECIFICS on page 13-1. • For S8126 belt, see S8126 BELT SPECIFICS on page 14-1. Equipment damage Cut Guides are bent. Contact Intralox. This is often caused by over-tightening thumb knobs causing the Cut G...

  • Page 59: Table Of Belt Failures

    Table of Belt Failures Splice Tears in Production Cut the faulty splice from the belt and repeat the splicing procedures with careful attention to the following items. Splice was not inspected before running See TRIM & INSPECT THE BELT on page 7-1. Weld bead/flash snagging on conveyor 1.
  • Page 60 Symptom & Possible Causes Action to Take Belt not engaging sprockets continued on next page Sprockets are misaligned on shaft See ThermoDrive® Belting Conveyor Belting Installation and Mainten website. Belt tension too high See ThermoDrive® Belting Conveyor Belting Installation and Mainten website.

  • Page 61: Special Procedures

    SPECIAL PROCEDURES...

  • Page 62: Special Procedures

    11 SPECIAL PROCEDURES SPECIAL PROCEDURES 3. Ensure there is adequate space above and around the Clamping Fixture for Heat Wand movement. Avoid Injury. Make Belt Tabs Keep hands and fingers clear of Frame edge when opening the Clamping If Belt Tabs are lost or missing, use scrap belt, a Fixture.

  • Page 63: Shim For Belt Top Surface (Vertical) Alignment

    11 SPECIAL PROCEDURES Wear safety glasses and use caution Shim for Belt Top Surface when handling knives and trim tools. (Vertical) Alignment 3. Use the utility knife to trim the tape at the If the Cut Guide thumb knobs have been Deck edge.

  • Page 64: Trim The Second Weld Bead-Alternative Technique

    11 SPECIAL PROCEDURES Trim the Second Weld Bead— Inspect the Clamping Fixture Alternative Technique Ensure the Clamping Fixture meets the follow- ing requirements before aligning belt ends. If working alone or with low clearance, con- sider this alternative technique for removing ...
  • Page 65 11 SPECIAL PROCEDURES If the Clamping Fixture does not meet these requirements, see TROUBLESHOOT on page 10-1.  11-4 Belt Splicing System v.2.0...

  • Page 66: Nub Top Style Specifics

    12 NUB TOP STYLE SPECIFICS NUB TOP STYLE SPECIFICS Remove Nubs Use the Skiver to remove all nubs within 0.5" Avoid Injury. (12 mm) of each belt end. Keep hands and fingers clear of Frame edge when opening the Clamping Fixture.

  • Page 67: Use Silicone Spacers

    12 NUB TOP STYLE SPECIFICS Use Silicone Spacers Position Silicone Spacer strips between belt nubs and the Cut Guides (or Grooved Decks, if drive bars face up) during alignment. Figure 12D: Place Cut Guide on Silicone Spacer FABRICATION TIP Place Spacer strips on Belt Tabs, if used. Ensure Spacer strips do not extend past Grooved Deck edges.

  • Page 68: Troughing Grooves Specifics

    13 TROUGHING GROOVES SPECIFICS TROUGHING GROOVES SPECIFICS Shim the Grooved Deck Avoid Injury. FABRICATION TIP Keep hands and fingers clear of Frame If belt top surfaces are not flush (vertically edge when opening the Clamping misaligned) where troughing grooves meet, shim the Grooved Deck with Painters’...

  • Page 69: Trim The Tape

    13 TROUGHING GROOVES SPECIFICS Make Adjustments: Adjust tape length, place- Trim the Tape ment, and layers as needed during alignment to ensure belt top surfaces align. Trim the tape along the deck edge to prevent tape contact with Heat Wand during Splicing. Figure 13E: Finish belt end alignment Figure 13C: Trim tape width ...

  • Page 70: S8126 Belt Specifics

    14 S8126 BELT SPECIFICS S8126 BELT SPECIFICS FABRICATION TIP Use a 24" Splicing System and splice with drive bars face down for best results. Avoid Injury. Keep hands and fingers clear of Frame Prepare the Belt Ends: When preparing S8126 edge when opening the Clamping belt ends, include these steps in the procedure.

  • Page 71: Preparing Belt Ends

    14 S8126 BELT SPECIFICS Preparing Belt Ends Use Thin Belt Tabs to Secure Belt Ends Shim the Smooth Edges to Use these guidelines to correctly place one (1) Secure Belt Ends Belt Tab between each Pivoting Stud and Locating Pin before lightly securing belt ends. FABRICATION TIP •...

  • Page 72: Repeatedly Inspect Alignment Before Cutting

    14 S8126 BELT SPECIFICS Repeatedly Inspect Alignment Add the Second Cut Guide to before Cutting Secure Belt for Cutting To align the belt ends on Grooved Decks for With the belt end properly aligned and tightly cutting or splicing, use the following guide- secured, place the 8050 Cut Guide on the sec- lines.

  • Page 73: Align & Secure Belt Ends

    14 S8126 BELT SPECIFICS Align & Secure Belt Ends Repeatedly Inspect Alignment Check Parallel Alignment: Ensure the belt ends FABRICATION TIP are visibly parallel to the Grooved Deck when For best results, use a 24" Splicing System and first placing belts, aligning belt ends, and just align belts with drive bars face down.

  • Page 74: Hold The Cut Guides When Fully Tightening Thumb Knobs

    14 S8126 BELT SPECIFICS Splice the Belt Ends Hold the Cut Guides when Fully Tightening Thumb Knobs Because S8126 belting is difficult to clamp Hold the Cut Guides against the Belt Tabs, securely, even normal clamping force can shift while finger-tightening the thumb knobs evenly the belt ends during splicing.

  • Page 75: Trim & Inspect The Belt

    14 S8126 BELT SPECIFICS Trim & Inspect the Belt To trim and inspect S8126 belt splices, add these steps to the procedure. • Use special care when inspecting drive bar pitch. • Use a square edge to ensure drive bar ends are aligned within 1/16"...
  • Page 76 PREVENTIVE MAINTENANCE...

  • Page 77: 15 Perform Preventive Maintenance

    Ensure the Instruction Manual is in the storage case. Ensure safety labels are adhered per photographs in this manual. See Belt Splicing System Hazards on page -3. Contact Intralox or Clarion Safety for replacement labels if needed. Set up the Splicing System and inspect for the following: •...
  • Page 78 Intralox Shanghai LTD. , Shanghai, China, North Toll Free: 10800-711-0100, South Toll Free: 10800-110-0100 Global Assembly Center Locations: Japan • United Kingdom • Australia • Brazil • India Country- and industry-specific free phone numbers available at intralox.com © 2016 Intralox, L.L.C. 5002187_ENGLISH...

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