Download - Conveyor Belting Installation and Maintenance

WARNING: Do not pre-tension your ThermoDrive belting. Tensioning this belt can cause damage and will void your warranty.

IntraloxThermoDrive® Belting

Conveyor Belting Installation and Maintenance

DO… • Ensure all transitions, guides, and sprockets are equal to or greater then the minimum bend radius.• Limit the drive sprocket engagement to 180° or less.• Install position limiters in line with each drive sprocket (on flat belting), located on the drive

sprockets at 165° of belt wrap.• Guide the belt with edge rails or containment blocks on both the returnway and carryway• Allow sprockets to float within specified limit. Lateral movement of the sprockets on the

outside edge of the belt should be limited to +/-0.125 in (3 mm). All other sprockets may laterally move +/-0.25 in (6.4 mm).

• Lock all drive sprockets in position. DO NOT… • DO NOT allow ThermoDrive belting to bend tighter than the recommended minimum radius.• DO NOT press limiters tightly against belting; refer to Page 3 for proper clearance.• DO NOT use a snub roller or other device to get more than 180° of wrap.• DO NOT rely on shaft squareness to properly track the belt.• DO NOT use a take-up device to tighten the belt on the conveyor.

DESIGN BASICS: The following are important guidelines detailing what you need to know before beginning an installation of ThermoDrive belting.

DO NOT pre-tension the belt; allow for catenary sag.

DO NOT use take-up adjustment to tighten or track ThermoDrive belting. Take-up shaft should be adjusted so that it is square in the conveyor frame before ThermoDrive belting is installed. No further adjustment is necessary.

DO lock all sprockets.

Maximum allowable lateral movement of the sprockets on the outside edge of the belt should be limited to +/-0.125 in (3 mm). All other sprockets may laterally move +/-0.25 in (6.4 mm).

DO use position limiters.

Position limiters are necessary; they ensure proper, continuous interaction between ThermoDrive belting and drive sprockets without the use of pre-tension.

DO use containment blocks for lateral containment.

11061353361_ENDDRIVE+CALLOUTS_1Flange Roller L

Short Roller RFlange Roller R

11081353361_ENDDRIVE-SPROCKETPOSITIONS_1

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11061353361_ENDDRIVE+CALLOUTS_1Flange Roller L

Short Roller R

A BC

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E F

H

D

H

I

Flange Roller R

BELT SUPPORT:

Carryway: � The center distance between rails does not exceed 6 in (152 mm). � Outside rails are indented 0.5 in (12.7 mm) from edges of belt. � RAILS ARE CHAMFERED OR RADIUSED ON THE ENDS FACING THE DIRECTION OF BELT TRAVEL.

Returnway: � Center distance between continuous support rails does not exceed 12 in (305 mm).

� Outside rails are indented 2 in to 3 in (51 mm to 76 mm) from the belt edge.

� Intermittent supports evenly span the full width of the belt. Rollers can be used as supports on 3 in (76 mm) centers as well.

� Longitudinal spacing between supports does not exceed 72 in (1829 mm).

� Make sure there is at least one span of unsupported belt in the returnway so a catenary sag will result. Catenary Sag is for belt accumulation. Return rails can have a gap in them to provide a section for belt accumulation. These sections need to have a minimum 6 in (152 mm) radius at infeed/outfeed of sag pocket.

� If your belt has flights without a center notch, check for continuous rails supports located along the belt indents with a 0.25 in (6 mm) gap between support rails and flights.

� If your belt has flights with a center notch, check for a continuous rail support along each belt indents and along the center notch allowing for a 0.25 in (6 mm) gap between each rail and adjacent flights.

SPROCKETS: � Sprockets fall within the minimum range specified by the series of Intralox ThermoDrive belting being used. � Outer sprockets are installed at the edges of the belt. � Sprockets are installed on 3 in (76 mm) centers. � Sprockets are locked in place to avoid excessive lateral movement.

022614RAIL-DETAIL_1

Intralox ThermoDrive® Belting Installation Check List

Plant Name: _____________________________________________

Conveyor/Application Name: _______________________________

TYPICAL COMPONENTS:

A Position Limiter F Drive PlatformB Drive Sprocket G Carryway SupportC Belt Accumulation H Returnway SupportD Containment Block I Idle Sprocket / Support WheelE ThermoDrive Belt or Shoe

12051353361_RETURNWAY-OPTIONS_1

A

B

C

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IMPORTANT:

� Do not install while belt is under tension � Position limiters are installed and properly aligned with drive sprockets � Belt does not, for any reason, wrap the sprocket more than 180˚ � Belt does not, for any reason, bend tighter than the minimum backbend

radius anywhere on the conveyor

022714ENDDRIVE-SPROCKETPOSITIONS_2

11081353361_ENDDRIVE-SPROCKETPOSITIONS_1

POSITION LIMITERS: � Position limiters are installed to maintain a gap of 0.005 in to 0.05 in (0.127 mm to 1.27 mm) between the seated belt and the limiter.

� Limiters are in plane with the drive sprockets.

� Belt does not exceed the rated minimum backbend radius.

� All center drive configurations use a drive sprocket with no fewer than ten teeth.

End Drive: � Position limiter is installed approximately at the 5:30 position for unidirectional “pull” conveyors.

Center Drive: � A minimum of three drive bars are seated on the sprocket.

� If unidirectional, one limiter is installed at the natural infeed (6:00 position) and one at the outfeed (8:30 position) of the belt.

� If bidirectional, two position limiters are installed at the approximate 4:30 and 7:30 positions.

EZ Clean Position Limiter - D-Shaft:

TD8050 D-PROFILE SHAFT

Sprocket PD7 mm Flat Top Nub Top

A B A B

4.0 in (102mm) 3.662 in (93.0mm) .001 in (0.0mm) 3.698 in (93.9mm) .025 in (.6mm)

5.2 in (132mm) 4.270 in (108.5mm) .215 in (5.5mm) 4.306 in (109.4mm) .219 in (5.6mm)


TD8026 D-PROFILE SHAFT

Sprocket PD6 mm Flat Top 5.3 mm Flat Top 4 mm Flat Top Nub Top / Diamond Top

A B A B A B A B

3.2 in (81mm) 3.378 in (85.8mm)

.215 in (5.5mm)

3.356 in (85.2mm)

.200 in (5.1mm)

3.339 in (84.8mm)

.188 in (4.8mm)

3.387 in (86.0mm)

.221 in (5.6mm)

3.9 in (99mm) 3.681 in (93.5mm)

.010 in (.3mm)

3.659 in (92.9mm)

.005 in (.1mm)

3.643 in (92.5mm)

.018 in (.5mm)

3.690 in (93.7mm)

.017 in (.4mm)

6.4 in (163mm) 4.921 in (125.0mm)

.404 in (10.3mm)

4.898 in (124.4mm)

.389 in (9.9mm)

4.881 in (124.0mm)

.378 in (9.6mm)

4.931 in (125.2mm)

.410 in (10.4mm)

Tolerance: +/- .020 in (.5mm)

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165°

End Drivepulling

q 12051353361_CTRDRIVE_UNIDIRECTIONAL-DETAIL_3

Center Drivebidirectional

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Center Driveunidirectional

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53361_LIMITER-GAP-DETAIL_1

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EZ Clean

Install limiter with this face perpendicular to the carryway.

0.005 in to 0.05 in (0.127 mm to 1.27 mm)

1 in Shaft 25mm Shaft

.500in [12.70mm] .492in [12.50mm]

.00001 .000in -.003

.0025.40mm -.008

.0025.00mm -.008

.0000 .984in -.003

A

B

BELT CONTROL & CONTAINMENT: � Provide a suitable location in the returnway to allow the loose belt to accumulate.

� Coefficient of thermal expansion should be considered for the application.

� Conveyor side rails, frames, containment blocks, or flanged rollers can be utilized to contain lateral belt movement.

� Recommended clearance between the belt guide and the edge of the belt is 0.25 in (6.4 mm) per side (consult Intralox Technical Support Group).

� The flange height of a return roller should be .75 in (19 mm).

� Chamfer both sides of containment block-leading and trailing ends. Minimum length of containment block should be 6 in (150 mm).

� When containment blocks are used, spacing should fall into the range of 6-8 ft (1.8-2.4 m). Applications where side loading is present need longer containment blocks.

� Full-length containment rails are preferred at areas where side loading or diverting product occur.

TRANSITIONS: � A UHMW shoe with a radius greater than the rated backbend of the belt typically 18 in (457 mm) radius, is used on the conveying side.

� The radius in the upper transition could be 18 in (457 mm) or larger depending on the size of the application.

� Hold-down shoes are a continuous arc through the transition and include 2 in (51 mm) infeeds and outfeeds.

� Infeeds are flush to belt surface and chamfered back to the conveyor edge.

� Recommended thickness of hold-down shoes is 1.25 in (32 mm).

� If your belt has flights with a center notch, check for a UHMW PE hold down shoe located in the center of the notch allowing for a 0.25 in (6 mm) gap between the shoe and adjacent flights.

� Support sprockets, if used, are equal to or larger than the rated minimum sprocket diameter for the belt.

CONVEYOR FRAME: � The framework of the conveyor does not impede or otherwise obstruct the belts path of travel.

11061353361_CONTAINMENT BLOCK DETAIL_1

.25” (6 mm) minimum chamfer

.031” (.8 mm) minimum radius

EZ CLEAN POSITION LIMITER - UNIVERSAL:

TD8050 UNIVERSAL MOUNT

Sprocket PD7 mm Flat Top Nub Top

C D C D




TD8026 UNIVERSAL MOUNT

Sprocket PD6 mm Flat Top 5.3 mm Flat Top 4 mm Flat Top Nub Top / Diamond Top

C D C D C D C D

3.2 in (81mm) 4.188 in (106.4mm)

.804 in (20.4mm)

4.166 in (105.8mm)

.819 in (20.8mm)

4.149 in (105.4mm)

.831 in (21.1mm)

4.197 in (106.6mm)

.798 in (20.3mm)

3.9 in (99mm) 4.491 in (114.1mm)

.990 in (25.1mm)

4.469 in (113.5mm)

.995 in (25.3mm)

4.453 in (113.1mm)

.982 in (24.9mm)

4.500 in (114.3mm)

.983 in (25.0mm)

6.4 in (163mm) 5.731 in (145.6mm)

.596 in (15.1mm)

5.708 in (145.0mm)

.611 in (15.5mm)

5.691 in (144.6mm)

.622 in (15.8mm)

5.741 in (145.8mm)

.590 in (15.0mm)

Tolerance: +/- .020 in (.5mm)

.625in [15.88mm]

0

0

.500

in [1

2.70

mm

]

1.50

0in

[38.

10m

m]

C

D

.75 in (19 mm)

.25 in (6 mm) minimum chamfer

.031 in (.8 mm) minimum radius

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Intralox ThermoDrive® Sprocket Installation Guide

Use the timing marks (notches along the gullet, as shown below) to properly align the sprockets along the sprocket shaft.

11081353361_SPLIT-SPROCKET-ASSY_1

EZ Clean Sprocket

EZ Installed Split Sprocket

• 1 in (25.5 mm) nominal hub width• Assembled with a single bolt • Can be installed on the shaft without the removal of snap rings or lock collars

INSTALLATION INSTRUCTIONS:Use all appropriate safety gear and procedures during installation. Step 1. Find a suitable location on the conveyor frame where the limiter bracket may be bolted or welded. Bolted brackets will allow disassembly as required by sanitation. Welded ones cannot be disassembled.

Step 2. Center the shoe over the outside sprocket. Use a shim / feeler gauge to make sure that a gap of 0.005 in to 0.05 in (0.127 mm to 1.27 mm) is maintained between the seated belt and the limiter.

Step 3. Slide and rotate the mounting bracket as necessary to find a suitable location on the conveyor frame where the bracket can be fastened in place (bolted or welded).

Step 4. Mark the location, remove the shaft, and attach the bracket.

Step 5. Slide the shaft through the collar until the shoe is centered on the outside sprocket.

Step 6. Tighten the collar to hold the shaft and shoe in the proper location.

Step 7. Repeat steps 1-6 on the other side of the conveyor.

Step 8. Visually inspect the belt’s path of travel to make sure that a gap of not less than 0.25 in (6 mm) exists between the edge of each flight and the limiter shoe. Where necessary, fasten containment blocks to limit the belt’s lateral movement to +/- 0.25 in (6 mm). Make sure lateral belt movement is contained at the edge of the belt so the flights can never come in contact with the limiter shoe.

Flighted Belt Position Limiter Kit

ASSEMBLY:

ITEM NO. QTY. DESCRIPTION

1 1 PLATE

2 1 SNAP RING

3 1 SHOE

4 1 SHOE

5 1 SHOE

6 1 SHOE

7 1 SHAFT

The kit includes a left and a right assembly, both of which are required for (the drive end of) one conveyor. Each kit consists of two UHMW shoes.

0.005 in to 0.05 in (0.127 mm to 1.27 mm)

11081353361_LIMITER-GAP-DETAIL_1

A

EZ Clean

INSERTING THE RODThe Intralox ThermoLace Joining Method for ThermoDrive belting has a headless rod retention system and allows rod insertion from the top of the belt.

1. Lace the belting together ensuring proper alignment.

2. Flex the rod retention feature upward using your thumb while inserting the rod into the lace with your other hand.

3. Insert the rod into the lace.

4. Continue to push the rod into the lace until it goes no further.

5. Proper rod retention is achieved by flexing the retention feature downward, so that it blocks the rod.

REMOVING THE ROD

1. To remove the rod, flex the rod retention feature upward exposing the installed plastic rod. Using a spare plastic rod or similar, dull object, push against the installed rod until it begins to push against the opposite flush edge.

2. Flex the opposite flush edge upward and continue pushing the rod through the lace until the rod is exposed.

3. Using pliers or your hands, grab the exposed rod and pull to remove the plastic rod from the lace. Remove any other tools used and separate the belt.

Intralox ThermoLace™ Joining Method for ThermoDrive belting

Sanitary Design Principles of Intralox ThermoDrive Belting

Intralox ThermoDrive belting is designed to completely eliminate the belt areas that are traditionally difficult to clean. The absence of hinges and pins on the surface of the belt, along with radiused interior corners throughout, combine to facilitate a conveyor belt that can be easily cleaned to a microscopic level with minimal water and chemical use.

The smooth, continuous conveying surface of Intralox ThermoDrive belting eliminates the niches where bacteria can build up, thereby inhibiting the growth of biofilm.

The tensionless drive aspects of Intralox ThermoDrive belting, combined with the belt’s light weight, allow sanitation crews the option to lift and clean Intralox ThermoDrive belting while it is on the conveyor. Belt soaking is not required.

Intralox ThermoDrive® Series 8050 and 8026 belts are NSF certified/ANSI 3A certified, and FDA compliant

CLEANING INTRALOX THERMODRIVE® BELTINGThe following procedures have proven effective for most sanitation programs. Some of the variables may need to be adjusted depending on the concentration of soil levels, as well as current sanitation protocols. Contact Intralox Customer Service for detailed belt cleaning guidelines.

Steps Activity

1. Perform dry pickup.Pick up and dispose of any food products that may have accumulated on or around the equipment to be cleaned.

2. Rinse the entire frame. *

a. Rinse top of belt, including the curve around the sprockets, starting at the idle end and working toward the discharge end.

b. Rinse sprockets and shafts.c. Lift belt and rinse the carryway and as much of the inside of the belt as possible.

The belt surface facing up should be completely rinsed.

3. Apply detergent; let stand no longer than 20 minutes.

Apply detergent with belt running until all surfaces inside and out are covered to the degree recommended by your chemical supplier.

4. Repeat step 2. Outside of belt must be cleaned last to avoid recontamination.

5. Sanitize. Rinse sanitizer if required by law or company policy.

*Recommended water temperature 120˚ – 140˚F (49˚ – 60˚C)

INSPECTING THE BELT AFTER SANITATIONUse all appropriate safety gear & procedures during inspections.

1. Make sure that high concentrations of chemical residue are rinsed off of the belt.

2. If limiters are removed for sanitation purposes, make sure they are properly repositioned.

3. Sprockets must be properly spaced along drive shaft and aligned with the limiters.

4. Carryway and returnway rails should be seated so that the joints do not interfere with the drive bars.

5. Make sure that the belt is seated between the containment blocks prior to start-up.

6. Make sure that the belt is not tensioned (tight) for any reason.

7. Look for unusual wear patterns on the belt. This could indicate a mechanical obstacle in the belt’s circuit.

TROUBLESHOOTING

Problem Possible Cause Solution

Failed splice

Weld bead was not skived off from the bottom of the belt

Skive off all weld beads because they add additional strain on the seam when in contact with the sprockets as the belt revolves around them.

Improper welding temperature (see Splicing System Instruction Manual)

Make sure belts are welded at the recommended temperature and time intervals.

Belt is running under tension Remove tensioning devices and run the belt loose.

Belts are impacted without proper carryway support Place full sliderbed support at the point of impact.

Belt is backflexing or “hammocking” over segmented rollers Replace segmented roller with a full width roller.

Belt not running straight

Belt is running under tension Remove tensioning device and run the belt loose.

Belt is insufficiently containedAdd containment blocks at any point of side loading and just before the belt enters the tail section of the conveyor.

Conveyor frame and/or components are not level or square

Adjust conveyor frame. Check shaft alignment after any adjustment in frame.

Sprockets are not aligned correctly on shaft

Check sprocket alignment by laying straight edge parallel to the shaft at the base of any tooth on the sprocket to make sure that all sprockets are in the same position across the belt.

Return rollers are not level or square to conveyor frame

Inspect and correct any return roller that is not level or square with conveyor frame.

Belt not engaging with drive sprockets

Position limiters are not installed, or are installed with too large of a gap

Install limiters in the correct position, maintaining the proper gap between the seated belt and the limiter (see limiter install guide).


Sprockets are not aligned correctly on shaft

Check sprocket alignment by referencing the alignment nub located inside one gullet of the molded sprockets, or by laying straight edge parallel to the shaft at the base of any tooth in the sprocket to make sure that all sprockets are in the same position across the belt.

Excessive belt wear

Uneven joints in the carryway

Make sure that all joints are even. It is recommended to ramp the leading edge of all joints. Or “Bricklay” wearstrip to avoid a common junction across the width for the drive bar to fall into.


Belt is too wide for the conveyor dimensionsReplace with a belt that has been trimmed to the correct dimensions (typically 0.25 in (6 mm) trimmed from each side of the belt).

Binding of belt in conveyor frame

Check conveyor frame to ensure it is level and square. Add containment blocks where necessary. Other Considerations1. Frame / Sidewall warpage2. Containment block too close together3. Belt too wide

Belts are impacted without proper carryway support Place full sliderbed support at the point of impact.

Sprockets move laterally to center

or edge of belt

Retainer rings are not properly utilized or are missing Replace missing rings and/or add rings as necessary.

Flight wear or damage

Flights contacting obstructions on conveyor frame, returnway, or adjacent equipment

Eliminate obstructions to the flight travel. Check the conveyor frame to ensure it is level and square. Correct any conditions causing belt to rub or bind. Inspect for proper belt containment. Flights should never be used to contain lateral belt movement. Check for proper belt containment and clearance at the position limiter.

High impact in infeed area

Reduce or eliminate impact on belt by adding an “impact plate” above belt to absorb initial shock. Mount plate at an angle that will direct impacting piece gently onto the belt. Other solutions include using short flights, adding full sliderbed support at the point of impact, and chamfering the flight edges.

Improper flight support on returnway

Flighted belts should be supported on each side of belt (on the “indent”) and as needed across the belt width. It is recommended that flighted belts should be supported with continuos rails on the belt indents. A center support may be required depending on the width of the belt and size of the application. Consult Intralox Customer Service for more information.

ThermoDrive Preventative Maintenance Checklist1. Low Tension Inspection M Ensure belt setup (including catenary sag) is

low tension—NOT tensioned or pretensioned.

M Confirm that belt can be moved laterally on the drive/idle shaft.

M Confirm that belt has one or more areas for returnway accumulation (due to load or temperature).

2. Field/Factory Splices Inspection M Look for cracks, voids, or signs of failure.

M Confirm that belt edges at splice are flush.

M Confirm that splice beads have been removed from edge and surface (top and bottom).

3. Surface and Belt Edge Wear Inspection M Inspect surface for deformation, cracks,

scratches, or grooves.

M Inspect belt edge for shavings, blue dust, or cracks.

M Inspect surface and edge for belt discoloration.

M If wear patterns are identified: Inspect the conveyor for catch points, sharp edges, etc.

4. Drive Bar Inspection M Inspect drive bar for wear.

5. Drive Sprocket and Idle Support Wheel Inspection

M Inspect tooth profile and bore for wear.

M Ensure that all sprockets and support wheels are locked down and are maintaining recommended spacing.

6. Position Limiters Inspection M Ensure that all limiters are in line with

sprockets.

M Inspect limiters for proper clearance–limiters should touch, but not pinch, the belt.

M Inspect limiters for wear or embedded foreign objects.

M Ensure that limiter fasteners do not come into contact with moving belt or accessories.

7. Flight Inspection M Inspect flight base for cracks (across width and

indent edge).

M Inspect flight tips for surface wear.

M Inspect vertical flight sides for surface wear.

M If wear patterns are identified: Inspect the conveyor for catch points, sharp edges, etc.

8. Wearstrip Inspection (Carryway and Returnway)

M Inspect wearstrips for wear patterns or embedded foreign objects.

M Ensure that all wearstrips are still on the conveyor and are properly secure.

M Ensure that all mounting hardware is countersunk.

9. Containment Block Inspection M Inspect containment blocks for unusual wear

patterns or blue dust.

M Ensure that all mounting hardware is countersunk.

M Ensure that the containment is properly secure and in place.

M Inspect containment for proper clearance.

10. Product Containment Rail Inspection M Ensure that flights are not dragging against

rails.

M Ensure that there is proper clearance above the belt surface so that the belt is not being pinched.

11. Snag Point Inspection M Look for any noticeable snags or catch points

throughout the entire system.

NOTE: Run conveyor at production temperatures to ensure smooth belt operation. Refer to steps 1-11 if you identify vibration, clicking, or sprocket disengagement. For specific design criteria, please reference the Intralox ThermoDrive Technical Manual.

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

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

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1800-128742

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

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

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+800-4687-25690800-894392

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

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© 2013 Intralox, L.L.C. This document contains confidential and proprietary information of Intralox, L.L.C. It may not be copied or disclosed to third parties without the written authorization of Intralox. This document, whether in printed or electronic form, remains the property of Intralox and must be returned at our request.