Intralox ThermoDrive® Belt Splicing System Instruction Manual

Intralox ThermoDrive® Belt Splicing SystemInstruction Manual

For use with Series 8026 beltsSeries 8050 belts

i SAFETY

i-1

Avoid Injury.

Wear personal protective equipment (PPE)to operate, troubleshoot, or ser-vice this equipment (safety glasses, fin-ger guard, heat-resistant gloves.)

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

Only authorized Intralox service provid-ers should service the Splicing sys-tem.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, con-tact Intralox before proceeding further.

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. Please 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 may encounter during specific operating, trouble-

shooting, or servicing procedures. Please read the corresponding information.

SAFETYi

i SAFETY

i-2

Hazard Severity Panels

DANGER indicates a hazard with a high level of risk. If you do not avoid this hazards, 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 haz-ard 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.

i SAFETY

i-3

Belt Splicing System Hazards

Figure iA: Heat wand and Temperature Control box

Figure iB: Belt cutting and trimming hazards

Figure iC: Clamping fixture

TABLE OF CONTENTS

TOC

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

TABLE OF CONTENTS

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

System Components ........................... 1-1Cutting Template ............................... 1-1Clamping Fixture ............................... 1-1Heat Wand withTemperature Control Box................... 1-1Accessories...................................... 1-1

2 SPLICING SYSTEM COMPONENTSCutting Templateand Accessories.................................. 2-1

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

Heat Wand and TemperatureControl box.......................................... 2-3

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

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

Set Up the Heat Wand.......................... 3-2Enable Power.................................... 3-2Adjust Temperature ControlBox Settings...................................... 3-2

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

4 PREPARE BELT ENDSDifferent Belt Types............................. 4-1

New Prepared-end Belt...................... 4-1New Endless Belt .............................. 4-1Existing Belt ...................................... 4-1

Preparing the Belt................................ 4-1

Inspect Prepared Belt Ends.................. 4-2

5 ALIGN AND SECURE BELT ENDSPrepare the Clamping Fixture............... 5-1

Align the Belt Ends .............................. 5-2

Check Belt Alignment .......................... 5-2

Prepare for Splicing............................. 5-3

6 SPLICE THE BELTPrepare to Splice................................. 6-1

Splice the Ends ................................... 6-1Melt the Ends .................................... 6-1Cool the Belt ..................................... 6-2

7 TRIM THE BELTTrim the Belt ....................................... 7-1

Inspect the Splice ............................... 7-2Good Splice ...................................... 7-2Faulty Splice ..................................... 7-2

8 SHUT DOWN AND PACK UPShut Down.......................................... 8-1

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

9 PREVENTIVE MAINTENANCE

10 TROUBLESHOOT

11SET THE TEMPERATURECONTROL BOXSet Heat Wand TemperatureDisplay (°F or °C) ............................... 11-1

Select Heat WandTemperature Profile............................ 11-1

TABLE OF CONTENTS

1 EQUIPMENT OVERVIEW

1-1

System UseThe Intralox ThermoDrive® Splicing system quickly and reliably splices Intralox Thermo-Drive conveyor belts.

All Splicing systems models operate the same way. Heating time and temperature depend on the material being spliced.

The Splicing system requires only standard electric power for use.

Figure 1A: Splicing system storage case

System Components The Splicing system contains three (3) main components: the Cutting template, the Clamp-ing fixture, and the Heat wand with Tempera-ture Control box. Several accessories are also included with your system.

Cutting TemplateAfter the belt length is finalized to run without tension (contact Intralox for ThermoDrive Con-veyor Design Guidelines), use the Cutting tem-plate and a utility knife (not included) to prepare the belt ends.

Clamping FixtureAlign prepared belts in the Clamping fixture to hold belt ends together for heating. Once heated, remove the Heat wand and close the clamp jaws 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. Several splices can be completed in quick succession and plastic residue removed from the Heat wand Teflon® coating.

AccessoriesThe Splicing system also includes several accessories: a storage case, personal protective equipment (PPE), trim tools, and silicone spac-ers.

EQUIPMENT OVERVIEW1

2 SPLICING SYSTEM COMPONENTS

2-1

Cutting Templateand Accessories

Figure 2A: Thermo-Drive Splicing system

Xcelite® trimmer: Sharp nippers with rubber-covered handles used to remove flashing on the belt edge and perform other trimming tasks

gloves: North brand 10XL 51/7145 heavily-insulated gloves worn when handling the Heat wand

Cutting template: 24" or 42" metal plate that provides a hard guide for a standard utility knife when preparing belts for splicing; both templates are designed exclusively for use with Intralox ThermoDrive belts and Splicing sys-tems; use with the finger guard

Hyde® trim tool: Sharp, v-shaped blade used to trim the weld bead from spliced belts; use with the finger guard

Silicone spacers: Rectangular strips of rubber used to align belts of different thicknesses; stored in white, cylindrical can

finger guard: Cut-resistant, Halfarmor™ Hexarmor® Superfabric® finger guard used when handling utility knives or trim tools

Storage case: Sturdy, cushioned, locking case used to hold the Splicing system and any acces-sories

Figure 2B: Storage case

Xcelite®trimmer

gloves

Cutting template

Hyde® trim tool

Silicone spacers(inside)

finger guard

Wear finger guard and use caution when handling knives and trim tools.

SPLICING SYSTEM COMPONENTS2


2-2

Clamping fixture: All-metal, spring-loaded clamp designed to hold prepared belt ends in perfect alignment during heating; provided with a lock toggle, Top clamp bars, four pivot-ing studs, and crank handle

lock toggle: A mechanism designed to hold the clamp jaws open during belt alignment and heating; can be pulled up when the clamp jaws are held fully open; the related stops are held in place by clamp pressure as the clamp is closed

Pivoting stud: Metal stud with thumb knob; designed to hold the Top clamp bar down and secure the belt in place; one pivoting stud and thumb knob is at each end of both clamps

Top clamp bar: Anodized, aluminum pieces with locating bosses to engage the recesses near the pivoting studs; used to hold aligned belt secure; designed with wand rests to hold the wand in position during heating; used to hold aligned belt securely

wand rest: see Top clamp bar

crank handle: Plastic covered, crank-style han-dle which is rotated counter-clockwise to open the clamp and held open by a lock toggle when engaged

NOTEAlways close clamp slowly and purposefully.

Forcing the clamp closed or allowing it to “slam” shut can damage the rack-and-pinion mechanism.

recess: see Top clamp bars

clamp jaws: see Lock toggle, see Top clamp bar

Keep hands and fingers clear of pinch points when closing clamps and securing clamp bars.

Clamping Fixture

Figure 2C: Clamping fixture

pivoting stud recesswand rest

Top clamp barwand restclamp jaws

recesspivoting stud

lock togglepivoting stud

Top clamp bar

wand rest

thumb knobon pivoting stud

crank handle


2-3

Heat wand: Electrically heated, Teflon®-coated heating platen used to melt Intralox Thermo-Drive belt ends for splicing; designed to be connected to the Temperature Control box and used with the Clamping fixture; Teflon® coat-ing allows easy removal of melted plastic resi-due; designed to maintains setpoint temperature for a series of splices; the required voltage shown on the wand must match the required voltage shown on the Temperature Control box

NOTEUse the heat wand in temperatures above 40°F

(5°C) to produce quality splices. Contact Intralox to use of the Splicing system below 40°F (5°C).

gloves: see Cutting Template and Accessories

stand: Rectangular cover designed to hold the Heat wand and allow handle access during use; protects the Teflon®-coated wand surface and surfaces that might be burned by the wand

Wear heat-resistant gloves when han-dling the Heat wand. Heat wand and stand can reach 600°F (315°C).

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

Heat Wand and Temperature Control box

Figure 2D: Heat wand components

gloves

Heat wand

stand

Heat wandconnections

Wand cordTemperature Control box

Power switch

GFI box(with electric cord)


2-4

NOTEConnect the Heat wand to the Temperature Control box BEFORE connecting the Temperature Control

box to an electric outlet.

Temperature Control box: Electric device that controls the Heat wand temperature via thermo-couple signals from the wand; the required voltage shown on the wand must match the voltage shown on the Temperature Control box; includes an inline Ground Fault Inter-rupter (GFI) box and internal safety feature that turns off power after two (2) hours of operation

Heat wand connections: See Wand cord

Wand cord: Cable that tranfers 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

Ground Fault Interrupter (GFI) box: Safety device provided inline on the Temperature Control box; generally starts in safe mode (no power, amber light is on); requires investiga-tion or reset when amber light is on

Power switch: Switch that enables power to the Temperature control box AFTER the Wand cord has been connected to the Temperature Control box and the Control box electric cord has been connected to correct power; display appears when power is set to on

Figure 2E: Transformer, provided if needed

transformer: a device used to convert 110V out-let power to 220V when required; provided only if needed; model may vary

Do NOT use the Temperature Control box in or or near wet conditions.

3 SET UP THE SPLICING SYSTEM

3-1

Avoid Injury.

Do NOT use the Temperature Control box in or near wet conditions.


Wear heat-resistant gloves when han-dling Heat wand. Heat wand and stand can reach 600°F (315°C).

Collect Needed Supplies1. Bring Splicing system supplies and personal protective equipment (PPE) to the conveyor.

2. Unload the Temperature Control box, Heat wand, Clamping fixture, and Cutting template in a safe area where belt splicing will occur.

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

4. Collect these helpful shop items:

• tape measure

• writing implement

• utility knife

• timer or watch

• soft, clean, dry, oil-free cloths

• extra blades or sharpener

5. Ensure there is access to required electricity.

6. Ensure the facility temperature is above 40°F (5°C) to produce proper splices. Contact Intralox if splicing in temperatures below 40°F (5°C).

Prepare the Conveyor1. Remove or disable take-ups so the belt can-not be accidentally tensioned later.

2. Remove snub rollers or belt path devices that may cause excess backbends.

3. Replace worn carryway and returnway com-ponents such as sliderbeds, wearstrips, etc.

4. Install new sprockets if installing new belt-ing.

5. String the belt on the conveyor. Be sure you follow the correct pulley wrap configuration avoiding conveyor cross braces, legs, and other catchpoints.

NOTEContact Intralox for the ThermoDrive Conveyor

Design Guidelines to determine proper belt length. Ensure the belt is finalized to run without

tension.

6. Trial-fit and mark the belt for length. Ensure you leave enough catenary sag so the belting NEVER runs under tension.

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

SET UP THE SPLICING SYSTEM3


3-2

Set Up the Heat Wand

Enable Power1. Place the Heat wand in the stand.

2. Connect the round Wand cord plug to the Heat wand by aligning the connector tab. Push and turn to lock in place.

3. Connect the rectangular Wand cord plug to the Temperature Control box. Align the notches and snap the metal clamp in place.

Figure 3A: Wand cord connections and GFI box

4. Plug the Control box cord into an electric outlet.

NOTEIf your standard electric voltage does not match

the required voltage on your Heat wand orTemperature Control box, see Troubleshoot.

5. When the light on the Ground Fault Inter-rupter (GFI) box turns on, press Reset.

6. Set the Control box Power switch to on(—). The display shows the last set temperature.

Adjust Temperature Control Box Settings1. Ensure the temperature displays in your desired unit of measurement. To change the temperature display from Farenheit to Celsius or Celsius to Farenheit, see Set Temperature Control box.

2. Select the correct Temperature profile based on the belt material.

Do NOT use the Temperature Control box in or near wet conditions.

Belt Material Profile

SetpointTemp.°F/°C

Polyurethane profile 1 475° F/246° C

profile 2 500° F/260° C


3-3

3. Ensure the the correct Temperature profile is programmed to run.

Figure 3B: Status on Control box display

4. To change the Temperature profile, see Troubleshoot.

Allow Heat Wand to Pre-heat 1. Allow the Heat wand 10-20 minutes to reach the setpoint.

NOTEAs a safety measure, the Control box automati-

cally powers off after two (2) hours of operation.

2. While the Heat wand is pre-heating, prepare the belt ends. See Prepare Belt Ends.

3. Once the Heat wand reaches its setpoint, wipe off any plastic residue with a clean, dry cloth and return it to the stand.

current profile setpointtemperature number temperature


4 PREPARE BELT ENDS

4-1

Cut Hazard

Wear finger guard and safety glasses when preparing belt ends.

Different Belt Types

New Prepared-end BeltUsually you do not need to trim new belts with with prepared ends. If a new belt is too long (contact Intralox for ThermoDrive Conveyor Design Guidelines), cut away the excess belt-ing, then prepare both ends using the instruc-tions here.

New Endless BeltIf ordered correctly, you do not need to shorten a new belt. If a new, endless belt is too long, cut away the excess belting, then prepare both ends using the instructions here.

Existing BeltCut away the damaged or excess length of the belt. Prepare both belt ends using the instruc-tions here.

NOTEIf the minimum sag requirement cannot be met when you cut away the damaged section and

splice the ends, splice a new belt sectioninto the existing belt. Contact Intralox to order

replacement belt sections.

Preparing the BeltOnce a length of belt is confirmed to run with-out tension (contact Intralox for Intralox Ther-moDrive Conveyor Design Guidelines), prepare the belt ends using the instructions below.

1. Place the belt with the drive bars face up on a clean, solid, stable cutting surface that will not slide or move.

2. Place the cutting template on the belt so the hard guide edge faces the end of the belt to be removed.

Figure 4A: Place cutting template on belt

hard belt end to guide edge be removed

drive template groove with bar engaged drive bar

PREPARE BELT ENDS4

4 PREPARE BELT ENDS

4-2

3. Ensure the drive bars fully engage the tem-plate grooves.

NOTEWhen preparing Series 8050 belt, the template

back rests against a drive bar.When preparing Series 8026 belt, the template

back rests between drive bars.

4. Hold the template down firmly and pushed forward toward the end of the belt being removed.

5. Hold a utility knife blade vertical to and against the template guide edge at one side of the belt.

Figure 4B: Use the Cutting template as a guide

6. Use the Cutting template guide edge to make several scoring cuts (rather than one deep cut) across the width of the belt.

Inspect Prepared Belt Ends1. Ensure the prepared belt ends are square (perpendicular to the belt top surface), straight, clean, and parallel to the drive bar.

2. Clean the belt ends using denatured alcohol. Cleaning agents (like window cleaner) contam-inate the splice.

3. Allow the alcohol to evaporate completely before splicing.


5 ALIGN AND SECURE BELT ENDS

5-1

Avoid Injury.

Keep hand and fingers clear of pinch points when closing clamps and secur-ing Top clamp bars.

Keep hands clear of Heat wand and stand while clamping. Heat wand and stand can reach 600°F (315°C).

Prepare the Clamping Fixture1. Ensure the following:

• the belt is strung on the conveyor

• the belt is following the proper belt path

• the belt ends are on the carryway

2. Place the Clamping fixture on the conveyor frame, but under the belt ends.

3. Remove the Top clamp bars and set them aside.

4. Ensure the Clamping fixture grooves are clear of debris. Debris build-up prevents the clamp from closing fully.

5. Rotate the crank handle counter-clockwise to open the Clamping fixture, and manually lift the lock toggle up into position between the clamp jaws.

Figure 5A: Rotate handle

Figure 5B: Lift lock toggle

6. Hold the crank handle allowing the clamp jaws to close gently on the lock toggle.

NOTEDo not use force to close the clamp.

The jaws close by spring pressure only.Forcing the clamp to close damages

the rack-and-pinion mechanism.

Keep hand and fingers clear of pinch points when closing clamps and securing Top clamp bars.

ALIGN AND SECURE BELT ENDS5


5-2

Align the Belt Ends1. Place the belt ends on the center of the Clamping fixture with the drive bars engaging the grooves. The Clamping fixture accommo-dates ThermoDrive 8026 or 8050 series belts.

2. Adjust both belt ends so they overhang the clamp jaw edge about 2 mm.

3. If one belt is slightly wider than the other, center the narrow belt across from the wider belt.

Figure 5C: Place the belts on the Clamping fixture

4. Ensure the top surface of belt ends share the same horizontal plane. If necessary, use a sili-cone spacer pad between the clamp fixture and the bottom of the belt when splicing thinner belt styles (6.0 mm, 5.3 mm, 4.0 mm) to Nub Top belt styles.

5. Place the Top clamp bars on the Clamping fixture so the wand rests face each other.

6. Slightly and equally tighten all stud nuts so even pressure is applied across the belt width. The Top clamp bars hold the belt in place.

NOTEThe lock toggle holds the Clamping fixture open

while you position the belt ends.

Check Belt Alignment1. Push the crank handle down to open the clamp jaws slightly. The lock toggle falls back to the release position.

2. Holding the crank handle, allow the clamp jaws to close gently until the belt edges touch lightly.

NOTEDo not allow the fixture to push the belt ends.

The belt edges may become misaligned.

Figure 5D: Check belt alignment


wand rests


5-3

3. Holding the handle in place, ensure the belt ends meet the following requirements:

• Belt ends are straight, square, and parallel to each other with less than 1/32" gap at any point along the touching belt ends.

• Belt edges are flush. If one belt is slightly wider than the other, center the narrow belt across from the wider belt.

• Top belt surfaces are flush.

4. When belts are correctly aligned, fully tighten the stud nuts. Ensure pressure is evenly applied across the belt width.

Figure 5E: Tighten stud nuts

Prepare for Splicing1. After tightening stud nuts, ensure belt ends still meet the belt alignment requirements.

2. Rotate the crank handle counter-clockwise to open the Clamping fixture, and manually flip the lock toggle up into position between the two clamp jaws.

3. Splice the belt. See Splice the Belt for instructions.

6 SPLICE THE BELT

6-1

Avoid Injury.

Keep hand and fingers clear of pinch points when closing clamps and secur-ing Top clamp bars.


Prepare to Splice1. Ensure the Splicing system is set up accord-ing to instructions (see Set Up the Splicing Sys-tem).

2. Ensure the Belt is correctly aligned accord-ing to instructions (see Align and Secure Belt Ends).

3. Ensure the Clamping fixture is locked open (see Align and Secure Belt Ends).

NOTEThe splicing procedure requires two operators.

One person should control the Clamp fixture while the other controls the Heat wand.

Splice the Ends

NOTEThe wand face temperature varies above and

below the setpoint. Do NOT begin splicing until the display shows the

temperature has peaked, cooled slightly,and begun to rise again.

1. When the Heat wand temperature rises to the setpoint, hold the crank handle down to open the clamp jaws slightly. The lock toggle should fall down automatically. If not, push it down with the Heat wand during insertion.

2. Remove the Heat wand from the stand.

Figure 6A: Remove Heat wand from the stand

Melt the Ends1. Insert the Heat wand between clamp jaws. Rest the Heat wand shoulders on top of the wand rests and center the wand in the Clamping fixture.

SPLICE THE BELT6

6 SPLICE THE BELT

6-2

Figure 6B: Heat wand in Clamping fixture

2. Holding the crank handle, allow the clamp jaws to close gently on the Heat wand. The clamp jaws rest on internal stops to ensure accurate belt pitch after splicing.

3. During heating, ensure the belt ends on both sides of the Heat wand fully contact the wand face, and are melting evenly. If not, stop and re-trim both belt ends square and straight.

NOTEAs the belt ends melt, the internal stops come to

rest on the wand face. The handle may move slightly as the belt ends melt.

4. After 30 seconds, push the crank handle down and remove the Heat wand.

Cool the Belt1. Allow the Clamping fixture to close gently pushing the heated ends of the belt together before they begin to cool.

2. Wipe the melted plastic residue from the Heat wand with a clean, dry cloth before return-ing the Heat wand to the stand.

Figure 6C: Wipe residue from the Heat wand

3. After two (2) minutes of cooling (in normal room temperature conditions), remove the Top clamp bars.

4. Ensure a small, even bead of molten belt material is on the top, bottom, and sides of the splice.

NOTEAn irregular, uneven, or missing bead indicates a

faulty splice. See Troubleshoot.

5. Remove the weld bead from the belt. See Trim the Belt.



7 TRIM THE BELT

7-1

Cut/Puncture Hazard


Trim the Belt

NOTERemove the bead formed during the splicing

process before the spliceis completely cooled.

1. With the belt on the Clamping fixture and top clamp bars removed, use the Hyde® tool to carefully trim the weld bead from the top of the belt.

Figure 7A: Trim the belt top

2. Gently remove the spliced belt from the Clamping fixture and turn the belt over onto a flat surface.

3. Use the Hyde® tool to trim the weld bead from the bottom of the belt.

Figure 7B: Trim the belt bottom

4. Use the utility knife to trim the flash from both edges of the belt.

Figure 7C: Trim flash from belt edges

5. If the belt ends were a slightly different width, use a utility knife to smooth the belt edges together and eliminate catch points.

TRIM THE BELT7

7 TRIM THE BELT

7-2

Inspect the SpliceAfter five (5) to ten (10) minutes of cooling, bend the splice and inspect for cracks, bubbles, or pits.

Good SpliceIf the splice is free of cracks, bubbles, and pits, the belt can be placed back into production.

Faulty Splice1. If cracks or imperfections are present, cut out the bad splice entirely using the Cutting tem-plate on the adjacent drive bars.

NOTENever separate a belt at a faulty splice.

Always use newly prepared belt ends when splicing to ensure proper pitch.

2. Before splicing again, see Troubleshoot and follow manual instructions carefully to ensure success with the next splice.

8 SHUT DOWN AND PACK UP

8-1

Avoid Injury.

Wear heat-resistant gloves when han-dling the Heat wand. Heat wand and stand can reach 600° F (315° C).


Shut Down 1. Turn Temperature Control box Power to off and unplug it from the electric outlet.

2. Disconnect the Wand cord from the Temper-ature Control box and Heat wand.

3. Clean the Clamping fixture with a clean, dry cloth and close clamp jaws.

4. Let the Heat wand and stand cool completely (usually 15-20 minutes) in a safe place.

Pack the Storage Case1. Place the Heat wand stand in the front stor-age compartment.

2. Place the Heat wand inside the stand.

3. Place the Clamping fixture in the back stor-age compartment.

4. Wrap the Wand cord without kinking and place it in the heat wand compartment.

Figure 8A: Pack Heat wand, Clamping fixture, and Wand cord

5. Wrap the Temperature Control box cord and place the Control box and cord in the left stor-age compartment.

6. Place the Cutting template, personal protec-tion equipment (PPE), trim tools, silicone spac-ers, and any other accessories in the accessory tray.

Figure 8B: Accessory tray with Cutting template and accessories

7. Place the accessory tray on top of the Clamp-ing fixture.

8. Close and latch the storage case.

9. Store the case for future use.

latchesstorage case lid

Heat wand, stand, and Wand cord

Clamping fixture

TemperatureControl box

SHUT DOWN AND PACK UP8

9 PREVENTIVE MAINTENANCE

9-1

Avoid injury.



Keep hands and fingers clear of pinch points when closing clamp and secur-ing Top clamp bars.

PREVENTIVE MAINTENANCE9

Perform the following procedures quarterly to ensure the Splicing system is in good working order when you need it most. Contact Intralox about faulty or missing critical components. Gloves and trim tools can be replaced locally.

Tech. Initials

Maintenance Procedure to Perform

Mon

thly

Quar

terly

Bian

nual

ly

Annu

ally

Ensure components described in Overview and Components are in the Splicing system storage case. x

Ensure the Instruction manual and Quick Reference sheet are in thestorage case. x

Ensure safety labels are adhered per photographs in this manual. See Safety. Contact Intralox or Clarion Safety for replacement labels. x

Set up the Splicing system and inspect for the following:

• Ensure the Clamping fixture opens easily and smoothly.

• 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.

• Ensure the Heat wand warms up when powered on.

x

Ensure the transformer (if supplied) is in working order. xSecure any misaligned or loose components, etc. xClean the display with minimal lens cleaning solution and a soft cloth. xUse a clean, dry cloth to remove dust or belt debris from each Splicing system component. x

10 TROUBLESHOOT

10-1

Avoid injury.

Wear heat-resistant gloves when han-dling Heat wand. Heat wand and stand can reach 600°F (315°C).

Keep hands and fingers clear of pinch points when closing clamp or securing Top clamp bars.


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

If your Splicing system components are dam-aged or part of your splicing process is unsuc-cessful, follow these steps:

1. Find the description of your problem under the Symptom column.

2. Perform each action listed to the right of that problem until the equipment is operating prop-erly again.

3. If you cannot eliminate the problem, contact Intralox.

NOTEThere are no user-servicable components in the Splicing system. Attempts to cut, drill, or other-

wise modify any electrical or mechanical compo-nents will void your warranty.

Symptom Cause/Action to Take

Set Up Splicing system

Facility standard voltage does not match Splicing system required voltage.

Contact Intralox.

Prepare Belt Ends

Belt cuts are faulty. The cutting blade is dull or damaged.Replace the utility blade or knife.

The Cutting template was not held firmly or the blade was not positioned correctly.

Repeat the cut. See Prepare Belt Ends.The Cutting template edge guide is worn.

Contact Intralox.

TROUBLESHOOT 10

10 TROUBLESHOOT

10-2

Align and Secure the Belt

The Clamping fixture does not operate smoothly and easily.

The Clamping fixture needs cleaning.Apply light oil or WD-40 to the springs and linear bearings.

A spring in the Clamping fixture is misaligned.Contact Intralox.

The Clamping fixture jaws do not open parallel or do not open completely.

The internal rack-and-pinion system skipped a tooth. This is usually caused by forcing the clamp jaws shut or allowing the clamp jaws to “slam” shut.

Contact Intralox.

Splice the Belt

Splice is faulty.

Insufficient or no melting

The Temperature Control box is receiving no power or inconsistent power.

If the Temperature Control box display does not appear, ensure the following:

• connections to the power source are secure• connections from the Temperature Control box

to the Heat wand are secure• the GFI box is reset (amber light should be off)• Control box Power is set to on (—)

The temperature profile is set incorrectly. See Set the Temperature Control Box to set the cor-rect profile.

The Heat wand is not finished warming up.Wait at least 20 minutes for the Heat wand to warm up.

The Heat wand and Temperature Control box are incompatible. Ensure the Heat wand and Temperature Control box are labeled with the same voltage.

The environment is too cold. 1. Only use the Splicing system in environments warmer than 40°F.2. Contact Intralox for specific guidelines for splic-ing in low temperatures.

The Heat wand cord is damaged or kinked.1. Inspect the Heat wand cord for damage or kinks. 2. Contact Intralox.


10 TROUBLESHOOT

10-3

Splice is faulty.

Uneven melting

Plastic residue is on the Heat wand face.When the Heat wand reaches the setpoint tempera-ture, wipe off any belt residue with a clean, dry cloth and return it to the stand.

The ends were not correctly prepared.• Ensure prepared belt ends are clean, straight,

and parallel to the drive bar. See Prepare Belt Ends.

• Ensure prepared belt ends are correctly aligned and properly secured in the Clamping fixture. See Align and Secure Belts.

Splice is faulty.

Plastic is burned or damaged.

Temperature Control box display shows an unusually high temperature.

The temperature profile is set incorrectly.See Set the Temperature Control Box.

The Heat wand and Temperature Control box are incompatible. Ensure that the Heat wand and Temperature Con-trol box are labeled with the same voltage.

The Wand cord is damaged, kinked, or not contacting the aluminum spacer.

NOTEContinued use with damaged components can damage

the Heat wand and belt material.

1. Inspect the Wand cord for damage or kinks. 2. Contact Intralox.

Plastic residue is on the Heat wand.

Plastic residue was not removed after the last splice.1. When the Heat wand reaches the setpoint tem-perature, wipe off any belt residue with a soft, clean, dry cloth.2. Return the Heat wand to the stand. 3. Ensure residue is removed properly after each splice.

The Teflon coating is worn and in need of replacement.Contact Intralox.

The drive bar pitch is incorrect.

The belts were not correctly prepared. Cut out the splice and prepare the belt ends again. See Prepare Belts Ends.


Trim the Belt

The weld bead or other flash is visible at the splice.

The belt is not trimmed. See Trim the Belt.

An incorrect or damaged trim tool was used.1. Ensure trim tools are sharp and in good working order.2. See Trim the Belt.


11 SET THE TEMPERATURE CONTROL BOX

11-1

Avoid Injury.

Contact with hot Heat wand or stand will cause skin burns. Wear heat-resis-tant gloves when handling wand/stand.

Your Splicing system using one of three WAT-LOW temperature controllers at the control box:

• WATLOW 935A

• WATLOW EZ-ZONE®

• WATLOW SD_T

Instructions for setting each controller are in this section.

Use the chart below to choose the correct set-point or profile for your splice.

Set the 935ATemperature Controller

Figure 11A: Watlow Series 935A controller

Temperature Display (°F or °C)Temperature units must be configured by the factory.

Select Heat WandTemperature Setpoint1. Choose the setpoint temperature based on the belt material.

2. At the Control box, press and hold SET.

3. Press ▲ or ▼ to scroll to the desired set point.

4. Release SET to complete the change.

5. A four-digit time appears (for example, 02:00) indicating the length of time before the controller powers off automatically.

6. After several seconds, the status screen returns to show the current temperature.

Belt Material Profile

SetpointTemp.°F/°C

Polyurethane profile 1 475° F/246° C

Polyester profile 2 500° F/260° C

SET THE TEMPERATURE CONTROL BOX 11


11-2

Set the WATLOW EZ-ZONE® Temperature Controller

Figure 11B: Control box display with status screen

Temperature Display (°F or °C)At the Control box display, hold both ▲and ▼ for six (6) seconds until SEt appears.1. Press ▲ until 9LbL appears.

2. Press Advance (green button) until C-F appears.

3. Press ▲ to choose F or C.

4. Press ∞ until the current temperature status display appears.

Select Heat WandTemperature Profile1. Choose the correct temperature profile based on the belt material.

2. At the Control box display, press Advance (green button) one or more times until P.AC 1 appears.

3. Press ▲ until End appears.

Figure 11C: Change the profile

4. Press Advance until P.St 1 appears.

5. Press ▲ to select profile 1 or 2.

Figure 11D: Profile number is in red

6. Press Advance one or more times until P.AC 1 appears.

7. Press ▲ until ProF appears.

8. Press ∞ several times to return to the status screen and show the current temperature.


11-3

WATLOW SD_TTemperature Controller

Figure 11E: WATLOW SD_T controller

Temperature Display (°F or °C)1. At the Control box display, hold both ▲and ▼ for four (4) seconds until SET appears.

2. Press ▲ or ▼ until C-F appears on display.

3. Press and hold SET.

4. Press ▲ or ▼ to choose F or C.

5. Release SET.

6. Press ∞ several times to return to the status display and show the current temperature.

Select Heat WandTemperature Profile1. Choose the correct profile based on the belt material.

2. At the Control box display, press and hold SET to view the currently programmed setpoint.

3. Press ▲ or ▼ to change the setpoint value.

4. Release SET to complete the change.

5. The controller starts using the new setpoint after three (3) seconds. Or, you can press the ∞ key two(2) times to use the new value immedi-ately.

6. The status screen returns to show the current temperature.

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

INTRALOX, L.L.C. JAPANTokyo, Japan0120-779-040

INTRALOX BRASIL LTdA.São Paulo, Brazil0800-771-4325

INTRALOX AuSTRALIA PTy. LTd.Victoria, Australia

1800-128742

INTRALOX, L.L.C. EuROPEAmsterdam, The Netherlands

+800-4687-2569+31-(0)20-540 36 00

INTRALOX, L.L.C. uSANew Orleans, LA1-800-535-8848+504-733-0463

INTRALOX LTd.Birmingham, United Kingdom

+800-4687-25690800-894392

INTRALOX SHANGHAI LTd.Shanghai, China

Northern: 10800-711-0100Southern: 10800-110-0100

A subsidiary of Laitram, L.L.C., Intralox is a registered trademark of Laitram, L.L.C. All rights reserved world-wide. [ἀ ermoDrive is a registered trademark of ἀ ermoDrive, LLC.]

Notice: ἀ e information contained in this manual is provided only as an aid and service to our customers. In-tralox, L.L.C. does not warrant the accuracy or applicability of such information and, Intralox, L.L.C. is specifi-cally not responsible for property damages and/or personal injury, direct or indirect, for damages and/or fail-ures caused by improper operation, abuse and/or misuse of its products, whether or not based on information contained herein.

Intralox ThermoDrive® Belt Splicing System Instruction Manual

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