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How do I Splice a Belt? |
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Splicing is a skill like any other. It can be learned through training, and it improves with practice. Another major factor in faster, easier splicing is having the right tools for the job (see list at left).
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Read more...
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How do I make splice clips? |
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Tools Needed: To make splice clips, you will need the following tools: Two sets of pliers One set of cutters. Types of Splicing Clips: This process can be completed for the following types of splicing clips: One-Space Three-space Double loop ends.
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Read more...
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How to Identify your Flat-Flex® Belt |
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To identify a Flat-Flex belt, you will need to determine the following:
- Count the number of wire strands in a 12 inch length of belting. This will determine the exact pitch (or distance from each woven strand of wire to the next) in terms of wire strands per foot of belt.
- Measure the wire diameter with a wire gauge.
- Measure the overall width of the belt in inches from outside edge to outside edge.
- Count of the number of rectangular openings (called spaces) across the width of the belt.
- Check to see if the belt has single loop edges or double loop edges. (Note: double loop edges are only available on certain meshes with .035" diameter wire or .050" diameter wire.)
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Read more...
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Inspection and Installation Check List |
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Yes
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No
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Before You Begin Splicing
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1. Power to conveyor is disconnected |
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2. Wearing safety glassess |
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3. Correct replacement belt selected |
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4. Correct tools on hand |
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5. All tensioning mechanisms released |
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6. Belt threaded onto conveyor right (smooth) side up |
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7. Loop edges curve back away from direction of belt travel |
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8. Belt edges tied together with wire, twine, plastic wire tie |
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Read more...
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Trouble Shooting Guide |
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Problem
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Possible Cause(s)
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Solution(s)
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Splice clips breaking
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• European style sprocket arrangement used (sprockets in even spaces)
• Belt improperly spliced
• Clips and/or strands not straightened after splicing
• Sprockets not properly installed/aligned
• Uneven tension
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• Adjust to American style arrangement (sprockets in odd spaces)
• Reinstall following splicing instructions
• Straighten clips/strands with pliers
• Check sprocket alignment and adjust if needed
• Adjust tension so it is equal on both sides of frame
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Read more...
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Sanitation Procedures for Food Processors |
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Flat-Flex® belts constructed of Type 302 stainless steel have been approved by the USDA/FDA for direct contact with food. In addition, the USDA has published regulations for the proper cleaning and sanitizing of wire belts to eliminate the dangers of contamination from bacterial and other potentally harmful substances.
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Read more...
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12 Potential Causes of Downtime Related to Conveyor Belting |
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By their very nature, all conveyor belts have a finite life, including metal belts. Conveyor belts can be compared to a tire on an automobile. A tire has X number of revolutions on the road surface before its life is over, and a conveyor belt will travel around the conveyor circuit X number of times before its life is over. While its difficult to predict exact belt life, the main types of failure are known as Yield, wear, and fatigue failure. Every conveyor belt will experience one or a combination of these failure modes. There is no way to prevent a conveyor belt from failing once its average life cycle is “used-up”. However, it is a fact that most conveyor belts do not wear out, or “use-up” their life. Most belts, if they actually do fail during use in a production environment, fail because of factors not related to strength, belt life, or robustness of the belt. They fail, usually for one or more of the reasons outlined below. These failures result in critical downtime… which equates to lost opportunity, lost production, and lost profits. We have listed 12 of the most common issues that have been found to be the culprit in conveyor and / or belting breakdown situations. They are listed in reverse order with number 12 being the least common, and number 1 being the most common.
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Read more...
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Splicing a Flat-Flex® Single Loop Edge |
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Splicing a Flat-Flex® Single Loop Edge
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| 1. Begin Splicing In The Center |
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Diagram A (click image to enlarge)
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Diagram B (click image to enlarge)
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Move the two ends of the belt to be spliced to the discharge end of the conveyor unit.
• Confirm that the edge loops are curving back away from the direction of belt travel as shown in Diagram A. If not, check to be sure that the belt is not threaded backwards on the conveyor.
• Lay the strand down between the two belt edges and check to see that the edge loops are going in the same direction as the belt's edge loops. (The strand must also be "right side up" for it to lay flat. You will know immediately if you have installed the splice strand "wrong side up" and will have to start over.)
• BEND the strand from each side enough to INSERT the ends into the two spaces next to the center space (Spaces B and D in Diagram A)
• INSERT the strand ends into the center space of the opposite edge (Space 3 in Diagram B)
• Pull the ends of the strand through until the center space "locks" in place (You should be pulling the strands toward you)
• Use pliers or the Wire Belt Wire Straightening Tool to STRAIGHTEN the wire in the center space (Once the center is connected, you may remove the ties holding the belt edges together) |
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| 2. Weave Strand To One Side |
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Diagram C (click image to enlarge)
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Diagram D (click image to enlarge)
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• BEND one end of the wire up and INSERT it around the Z-bend in the next space on the edge of the wire closest to you (Space 5 on Diagram C). Always try to avoid bending the wire at the Z-bend!
• BEND the wire toward the center and INSERT around the Z-bend next to the center space (Space D on Diagram D)
• Pull the strand wire through the mesh and STRAIGHTEN it with your pliers
• Repeat these three moves until you reach the side edge of the belt
• Using your pliers, connect the strand's edge loop to the belt's edge loop (on the far edge)
• Connect the edge loop on the near edge of the belt to the strand's edge loop
• STRAIGHTEN the strand with your pliers |
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| 3. Weave Strand To The Other Side |
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Diagram E (click image to enlarge)
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Diagram F (click image to enlarge)
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Diagram G (click image to enlarge)
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• Repeat the steps in #3, going in the opposite direction, weaving to the other side edge of the belt (Diagrams C through G)
• If you are installing a new belt, you are finished splicing |
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| 4. Check Drive Shaft Sprocket Alignment |
• There should be a 3/16" clearance between all sprockets (and/or blanks) and the Z-bends next to them
• Check alignment of sprocket teeth with a straight edge (only necessary if the sprockets are not keyed to the Drive Shaft) |
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| 5. Check Entire Belt Circuit |
• Z-bends should NOT come in contact with ANY conveyor component (including end rolls, wear strips, transfer support rails or nose bars, etc.)
• Adjust as needed |
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| 6. Adjust Tension |
• Flat-Flex® is a low tension belt. Use minimal tension… only enough so that drive sprockets properly engage the belt
• Run conveyor and check to be sure it runs smoothly
• Note: Too much tension will cause premature belt failure! |
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Splicing a Flat-Flex® Double Loop Edge |
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Splicing a Flat-Flex® Double Loop Edge
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Diagram A
• At the last space before the Double Loop Edge, gently bend the splicing strand in the center of the last space.
• Insert the end of the splicing strand into the double loop edge (small space) on the near side. You will need to rotate the wire to feed the DLE through the space.
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Diagram B
• Insert needle nose pliers from underneath, grab the center of DLE on strand and pull up into space.
• Straighten initial bend
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Diagram C
• Flex the belt by pushing down in center of last row of spaces
• Rotate splicing strand so you can push the end up from underneath the last space on far edge.
• Hook DLE over last large space Z-bend.
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Diagram D
• Connect the splice strand edge hook to the near side loop edge using pliers.
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Diagram E
• Connect the far side loop edge by hooking it into the splice strand using pliers.
• Connect the opposite edge of the belt in the same manner… only in mirror image.
• Straighten any bends in wire strands.
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REMINDER:
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You may need to rotate splicing strand to thread it around the Z-bends. However, try to avoid bending any strand at the Z-bend itself. You may bend the strand in the center of the large space or may flex the belt by pushing down in the center of the last row of spaces to create enough "slack" to weave the DLE into place.
Double Loop Edges are only available in wire diameters up to .050 inches. |
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Installing Splice Clips |
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Installing Splice Clips
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Splice clips come in two varieties: single space and 3-space clips. The 3-space clip is obviously stronger because its center space is woven into the belt as in the full strand splice method. These two types of clips should be used together, whenever possible to create a stronger splice and to help minimize the spacing gaps in the belt. (For example, a 7-space belt could be spliced using two 3-space clips... whereas, a 9-space belt would use 1 single and two 3-space clips. See How Many Clips.)
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IMPORTANT NOTE:
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| Two different end loops from adjacent clips cannot be attached to the same Z-bend. Only one splice clip end loop per Z-bend is allowed. |
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IMPORTANT NOTE:
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| If a belt has damage in more than one place on account of fatigue, do not try to repair it. Install a new belt. Also, never save old belts to use for repairs because they have already been weakened from use. Purchase several extra feet of new belt to use exclusively for repairs. |
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How Many Clips?
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# of Spaces
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Single
Clips
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Single +
3-Space Clips
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3
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2
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0 + 1
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5
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3
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1 + 1
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7
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4
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0 + 2
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9
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5
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1 + 2
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11
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6
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0 + 3
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13
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7
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1 + 3
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15
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8
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0 + 4
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17
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9
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1 + 4
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19
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10
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0 + 5
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21
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11
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1 + 5
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23
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12
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0 + 6
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25
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13
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1 + 6
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27
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14
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0 + 7
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29
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15
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1 + 7
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31
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16
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0 + 8
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33
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17
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1 + 8
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35
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18
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0 + 9
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37
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19
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1 + 9
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39
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20
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0 + 10
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41
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21
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1 + 10
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43
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22
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0 + 11
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45
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23
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1 + 11
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47
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24
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0 + 12
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49
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25
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1 + 12
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| 1. Before You Begin Splicing |
• Plan out the number, type and placement of splice clips by laying them out in position across the belt.
• Make certain that no two end loops on the clip hook around the same Z-bend and that all end loops point away from the direction of belt travel. |
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| 2. Begin installation with the center space |
• Insert the appropriate type of splice clip into the center space on the edge of the belt
• If installing a single clip, use needle nose pliers to grip the splice clip, and hook the two ends around the Z-bends on either side of the center space
-OR-
• If using a 3-space clip, bend the clip in the center and insert the ends into the two spaces next to the center space.
• Then insert the ends into the center space of the opposite edge and pull through until the center "locks" into place.
• Use the needle nose pliers to grip the end loop, bend the wire up and hook it around the Z-bend on the opposite edge of the belt. Repeat for other end loop.
• Straighten the wire with pliers |
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| 3. Install the next splice clip on an outside edge |
If a single clip is used:
• Remove the ties holding the edges together
• Insert the splice clip through the near edge
• Connect the edge loop to the splice clip
• Grip the splice clip with your pliers and hook the end around the adjacent edge loop and the first Z-bend on the far edge
-OR-
If a 3-space clip is used:
• Remove the ties holding the edges together
• Bend and insert the splice clip around the second space in from the belt edge, then insert the ends into the opposite edge of the belt. Pull through until center locks in place.
• Using pliers, connect the outside edge loop to the splice clip. Then grip the end of the clip and hook it around the adjacent edge loop. Hook the opposite end to its adjacent Z-bend.
• Straighten wire with pliers or Wire Belt's Wire Straightening tool. |
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| 4. Install splice clip on the opposite edge |
| • Install the same type of splice clip on the opposite edge in the same way. |
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| 5. Install the remaining splice clips |
| • Install the remaining splice clips, as appropriate, across the belt. There should be the exact same number and type of splice clips on either side of the center clip (the first clip you installed). |
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| 6. Re-tighten the tension. |
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Splicing Flat-Flex XT Belts |
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Splicing Flat-Flex XT Belts
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The use of one- and three-space splice clips are recommended for installing Flat-Flex® XT belts. Consult the chart below for the recommended number and combinations of one- and three-space clips to use for the number of spaces across the width of various Flat-Flex® XT belts. These numbers may be different than for classic Flat-Flex.
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24 x .072 XT
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Belt Width
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# XT Spaces*
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# of Clips
3-Space + 1-Space Clips
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42 x .062 XT
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Belt Width
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# XT Spaces*
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# of Clips
3-Space + 1-Space Clips
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11.94 to 14.50
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5
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2 + 1
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14.56 to 17.00
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6
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3 + 0
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17.19 to 19.75
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7
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3 + 1
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19.81 to 22.25
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8
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4 + 0
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22.44 to 25.00
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9
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4 + 1
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25.05 to 27.50
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10
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5 + 0
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27.69 to 30.25
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11
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5 + 1
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30.31 to 32.75
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12
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6 + 0
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32.94 to 35.50
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13
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6 + 1
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35.56 to 38.00
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14
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7 + 0
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38.19 to 40.75
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15
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7 + 1
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40.81 to 43.48
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16
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8 + 0
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10.06 to 12.88
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4
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2 + 0
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12.94 to 15.75
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5
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2 + 1
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15.81 to 18.50
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6
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3 + 0
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18.56 to 21.38
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7
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3 + 1
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21.44 to 24.25
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8
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4 + 0
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24.31 to 27.13
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9
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4 + 1
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27.19 to 30.00
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10
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5 + 0
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30.06 to 32.88
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11
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5 + 1
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32.94 to 35.75
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12
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6 + 0
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35.81 to 38.63
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13
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6 + 1
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38.69 to 40.50
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14
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7 + 0
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40.56 to 42.00
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15
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7 + 1
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*Also the required number of sprockets needed. Use one sprocket for every XT (narrow) space.
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IMPORTANT NOTE:
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| If you prefer to use single space clips exclusively, you use the same number of clips as XT spaces - placing the clips only in the XT spaces. |
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