Volta Tools
Contents
1. SpikesAdapter Set for FBW 1300 1301 Cat 81313010 V Trim Knife Narrow Cat 8153108 Utility Knife non standard You must be familiar with the instructions for welding with FBW before continuing with this procedure Insert the Cutting Bar at an angle between the Patterns when the Cutting engraving on the bar and the belt scrap is on the right hand side Push the cutting bar toward the Cutting side and cut the first side with a sharp knife Measure the belt length and mark other end Rotate the cutting bar 180 degree and insert the Cutting Bar as close to the required size Make sure that the scrap and the Cutting engraving on the bar are on your right hand side Add or deduct from the length of the belt according to the position of the pattern The weld is performed at an angle alongside the pattern There will be about 15 mm difference on the final length of the belt according to the cutting line between the patterns Position the adapter on top of the belt with the Welding side facing outward position the belt and the adapter on the FBW www voltabelting com Welding amp Fabrication Tools FBW Flat Butt Welding Insert the cross bar on the first side and repeat the same stages on the other side As the cut is in an angle position the belts ends according to reinforced belt joining instructions page 16 Weld the belt according to the instructi2. e The Sidewall Trolley is designed to facilitate welding of sidewalls on flat belts A pair of wheels and an air nozzle are available for each group of sidewalls Guide Roller Frame For Triac S Cat No 8141506 e The Guide Roller Frame mounts on the barrel of the Leister Triac S providing a frame for welding guides and V belt fabrications on flat belts The Roller Frame requires use of rollers see Guide Roller Frame below for correct operation Roller selection is based on the dimensions of the V belt or guide being used e The Roller is mounted in the frame and the hot air output of the Leister Gun is aimed at the point of contact between the guide V belt and the flat belt Roller 6 mm for Guide Roller Frame Cat No 8141507 Roller 8 M for Guide Roller Frame Cat No 8141502 Roller 10 Z for Guide Roller Frame Cat No 8141501 Roller 13 A for Guide Roller Frame Cat No 8141503 Roller 17 B for Guide Roller Frame Cat No 8141504 Roller 22 C for Guide Roller Frame Cat No 8141505 Flat Roller Nozzle 6 M 8 Z 10 mm Cat No 8121420 Flat Roller Nozzle A 13 mm Cat No 8121421 Flat Roller Nozzle B 17 mm Cat No 8121422 Flat Roller Nozzle C 22 mm Cat No 8121423 Hot Air Gun Handle for Triac S Cat No 8141408 e The Hot Air Gun Handle provides additional grip and stability when using the Triac S This allows the technician to apply addition
3. We aing amp amp or toos The Next Step in Belting a Welding amp Fabrication Tools FBW Flat Butt Welding Table of Contents Page How to use this manual oo cece cece cc cee r tnt ntntnentitititititititititititititititnetenseees 3 Symbols used in this MANUA L nnne 3 identification Data oeeoiieacie niie E es ni ardian SESA 3 Tee OGU TON aei r A E E E A 4 2 Technical Specifications ooo ccescseseseseseseseeeseetevstereresesssvsvsvsvsviveveeeeetetetetess 5 2A FEW LAYO erare irin eanna EEEE EEEE EEEE E EEE EEEE EEEE 6 2 2 The Storage CASO ccc cece cecceeeeeeeeeeesceseeesceeeeeeceeeesesasescissteeseseeeeetestesenttesenseess 7 2 3 The Electrical System oii ceccccccceecscceceescsececenscsececeussececeustsececeuttseceseetteteceustteeeeennteees 7 2 4 Care and Maintenance ooo ccccceccecceccesccsceseveccescscvescesessvesveseessissssvssvsevsensetsssiessseesees 7 2 5 Safety Precautions ooo ccccceccceccsececcecsreccececsececeusrsececersrsecevenstseeesenttseeesenttesesenttreee 8 2 6 Warning Notice for Welding Tools 0 0 0 0 cece ccccnneeeecentseeeeeeseeeeeeesseeesecssseeeseestaeeess 8 3 Welding Instruction ics seccipsiss gate caw secuyechancdeeeesnaceeaviuestcuceeiennbensepasterostaieenselsaerseeneeemte 9 3 1 Preparing the Temperature Controller 000 ccc cece eceteeeeeeteeeeeeteeeeeetteeeesteeeeetieeeeenees 9 3 2 Preparing the Pliers oo cece ccccccessseececscessssescecseesstausceeseestseseeeesesnttatesessesnnaeeeeens 9 Bee
4. Apply double sided tape to the exposed surface of the Adapters and cut away the tape from the SuperDrive tooth grooves Remove the protective paper from the double sided tape on one side and position the belt The difference in working with the SuperDrive belt is that you must position the tooth over the groove before bringing the rest of the belt into contact with the tape Press the belt onto the tape to ensure a firm and consistent contact e Release the Pliers and adjust the Locator Bar so that the belt edge matches one of the scribe marks and re lock the Pliers f Position the other belt end using the scribe mark on the Locator Bar Spacer to align the belt Q Continue the welding process as for a standard flat belt Locking Screws FBW with adapters and Locator Bar Spacer FBW Pliers with adapters and Locator Bar Spacer in place www voltabelting com 17 Welding amp Fabrication Tools FBW Flat Butt Welding 4 3 Welding DualDrive with FBW ano To ensure an accurate and efficient weld of DualDrive belts when splicing with the FBW Welder choose the DD Adapter suitable to your FBW Tool from the table below If you haven t welded this product before weld a section of a trial belt before welding your Volta conveyor belt Required Tools FBW Welding Kit DD Adapter Set for FBW 1300 1301 Cat 81313004 DD Adapter Set for FBW 300 301 Cat 81307253 V Trim Knife Cat 8153105 DD A
5. 3 2 b on Page 5 not remove the protective paper DualDrive DualDrive DualDrive SP DualDrive SP Description FT 1000 FT 1500 FT 1000 FT 1500 8153318 8153319 81626344 81626354 Each Set includes the following items 815331800 815331900 81626345 81626355 815331801 815331901 81626350 81626360 BELTING Technology 10 Notes www voltabelting com With Volta Tools You Can Never Go Wrong e Fast and simple belt installation e Unique and versatile design compact rugged and easy to use e Designed for both shop and field use e Light weight construction e Usually does not require cooling water or air pressure e Convenient design and method of storing and carrying your tools e Welds and fabrications are strong reliable and will last as long as your belt life BELTING Technology EUROPE Tel 31 546 580166 USA Tel 1 973 276 7905 Corporate Headquarters Sales and Manufacturing sales voltabelting com Fax 1 973 276 7908 Fax 31 546 579508 Toll Free 1 877 VOLTAUS a www voltabelting com Volta Belting makes no warranty with respect to any of its products for a particular purpose Copyright 2013 Volta Belting Technology Ltd y See Volta General Terms and Conditions CAT103EN00 Ver E June 2013 if m BELTING Conveying Solutions Technology Welding amp Fa
6. F 428 518 F 428 518 F 428 518 F 428 518 F 428 518 F 220 250 C 220 250 C 220 250 C 220 250 C 220 250 C 220 250 C Al A This equipment is heavy and must be carried by two persons This equipment is heavy and must be carried by a forklift In the USA units are supplied with a 110 VAC North American Standard plug In Europe units are supplied with a 230V German standard plug Users must adapt the plug to the local electrical standards This must be done by a certified electrician and in compliance with local electrical codes and standards www voltabelting com 9 Welding amp Fabrication Tools FBW Flat Butt Welding 2 1 FBW Layout Welder Isolation Pad Control Box Temp Control Main Switch Main Power Output Welder Input Plug Figure 3 FBW Welder and Temperature Controller Crossbar Locator Bar Knob Adjustable Lever Operating Handle Figure 4 FBW Pliers BELTING Technology 2 2 The Storage Case The storage case is meant to protect the tools against dirt and damage during transportation The case is designed to store the entire FBW system Tools and other items that do not belong to the FBW Welding System should not be placed in the storage case Loose unsecured items may move around and damage the Teflon coating of the Welder Do not store chemicals in the FBW storage case
7. Trim off the two pieces of the material that were added to the edges of the belt to facilitate the electrode welding BELTING Technology 3 8 Welding SuperDrive with FT Cut the belt to the required length using the straight edge Apply strips of good quality Double Sided Tape on the Pliers of the Positioner that is included in the kit Trim the unnecessary tape from the grooves Replace the Positioner on the Pliers Position one side of the Remove the Positioner and position the other side of the belt belt on the Pliers using the Positioner as reference and weld the belt according to the welding instructions 3 3 on Page 7 Trim the excess Turn the belt over and trim the flash from the bottom side of the belt with a knife A good weld will be free of cracks and defects Use a finger guard when engaging in various activities that involve the use of sharp objects Handle the knife with care Cut away from your body not toward it www voltabelting com Welding amp Fabrication Tools 3 9 Welding DualDrive and DualDrive SP with FT Cut the belt using the Cutting Bar to the required length Select the appropriate adapter for the belt type to be welded Position the Adapter onto the pliers when the groove of the electrode is facing up Apply Double side Tape on the Adapter surface and trim Weld the belt according to the welding instructions the unnecessary tape from the grooves At this stage do
8. Te Boie Rae E E Ea a ETER EARE 2 SA WNO Me BEI ae ae ee apia neem eee eee eee ee ceo aes eet ne eee eee 10 3 5 Trimming and Checking the Weld ooo icccceccccccecccccceccscccecescecevesseeesessesettseseetttsseetttseeeens 10 3 6 Instructions for Splicing Reinforced Flat Belts 10 3 7 Instructions for Welding Narrow Belts 2 000 ooo cccceeccceesceesesseecensrsesensreveventseesentreesens 10 3 8 Instructions for Welding H Material Belts 0000000 ccc cece cc cccceceeeeneeetteeetnsteeeenneaes 10 4 Welding Positive Drive Volta Products iariociomnpivsnaritvasdncntinns dannabsoasuamdenvainverustiendplawarntinen 15 4 1 Instructions for Welding SuperDrive H M Material Belts with FBW 721 or FBW 1061 15 16 4 2 Instructions for Welding SuperDrive H M Material Belts with FBW H M Adapter 17 4 3 Welding DualDrive with Adapter and FBW ooo cceceeeeeecceeeeennteteeeeeenes 18 19 4 4 Welding DualDrive SP DD SP and DD SP La lerene 20 21 4 5 Welding Volta Hinge Lace with FBW ea E E EEEn 22 23 5 Welding Special Volta Products oii ce ceccccceceveseseveseeeeeeveesvevevevevevevevevee 24 5 1 Welding MiniCleat with Adapter and FBW 24 5 2 Welding Spikes with UE asec cin iy tetrsrivamasecartehevtecytadbialenntynoia seins Hemienalvanbanaiedtemieunicnennes 25 26 5 3 Welding Cresent top CT with FBV ccccccceccccecececcevesccectseeevetsteeetstseeenteee 26 27 0 General TIDS eee ee een E ene etre een ee eer ere ee er 2
9. VAC Trimmer Makita Model 3703 220 VAC 1 Set Trimmer Wrenches for securing cutting bits 1 x 16 Flat Cutting Bit 1 V4 x V2 50 Cutting Bit 1 Case for FT 1000 1500 The 4 hole bit Alignment Gauge Cat 8153320 is to be used together with 1 4 x 2 50 Cutting Bit Cat 8153337 Equipment not Supplied with the Kit Vacuum cleaner Leister Hot Air Gun and Nozzles BELTING Technology 2 Capabilities The FT 1000 and FT 1500 are designed to provide electrode welding capabilities for all Volta flat belts including SuperDrive DualDrive and DualDrive SP The FT pliers have cutouts in the base designed for the SuperDrive and adapters for DualDrive and DualDrive SP The belt is mounted on the Pliers one time and all other operations from belt end preparation through trimming the weld on the top of the belts are done without removing the belt from the Pliers These changes simplify the electrode welding of flat belts Belt Width Welding Capabilities 2 1 up to 1000 mm up to 1500 mm The FT 1000 and FT 1500 Electrode Welding Kit is designed for use by presonnel who have been trained in Electrode Welding of Volta flat belts These instructions are not a substitute for training and experience Safety Precautions A N m Always disconnect the Trimmer from electricity before replacing the bits Failure to do so can cause both mechanical damage and personal injury Turn the Trimmer on only when
10. allow you to get the feel for the pressure required while welding and closing the Pliers after welding If you still have problems please contact Volta for aditional technical advice BELTING Technology 4 Welding Positive Drive Volta Products 4 1 Instructions for Welding SuperDrive H M Material Belts Using FBW 301 FBW 721 FBW 1061 or FBW 1301 It is Essential to carry out several welding trails to become familiar with welding the Positive Drive conveyor belts 1 The cutting bar is marked with positioning arrows as per photo 2 a Use the Cutting Bar to cut the belt between the teeth to EA ensure a 90 cut and the correct pitch Push the cutting bar away from you and then against the right side until the single tooth stencil fits exactly in line with the tooth giving you a perfect 90 position for marking your line Draw a line and then check that the line is parallel to the teeth Photo s 2 amp 3 When cutting the belt this line will help us to make sure that the cut is square b Reposition the cutting bar make a clean cut using a sharp knife When cutting the SD we will have 2 ends one usable and one unusable photo 4 5 6 this is due to the fact that we did not cut in the middle of the pitch V Tip Use double sided tape on the bottom side of the cutting bar to prevent slippage while cutting www voltabelting com 15 S o Welding amp Fabrication Tools FBW Flat Butt Welding B M
11. consistent and gentle pressure until the Stoppers do not allow you to continue Immediately open the Pliers Weld the belt according to the welding instructions in the FBW Manual Check the weld for any cracks or bubbles if needed cut the belt and rejoin it you will lose about 80mm from the belt length Check the pitch pitch larger than normal is not acceptable however welding results with pitch up to 2mm shorter is acceptable BELTING Technology 4 2 Instructions for welding SuperDrive H M Material Belts Using FBW H M Adapter For owners of the FBW 720 FBW 1060 and FBW 1300 Volta has prepared an Adapter kit for welding SuperDrive H and M material belts The kit includes For FBW 300 301 For FBW 720 721 For FBW 1060 1061 FBW 1300 1301 Cat 8162567 Cat 81625901 Cat 81625907 Cat 81626192 Cat 81307252 Cat 81307242 Cat 81310602 Cat 81313001 Cat 81625902 Cat 81625903 Cat 81625905 Cat 81625906 Fig 1 Fig 2 Fig 3 Cutting Bar SuperDrive H M FBW Adapter Bar SuperDrive H M Locator Bar Spacer SuperDrive H M Welding Instructions a Use the Cutting Bar to cut the belt between the teeth To b ensure a 90 cut Repeat stages 1a 1d on page 15 16 Position the Locator Bar Spacer and the Adapters on the Pliers Base Raise the two hinged Locking Screws to a vertical position and close and lock the Pliers see figure below
12. tape Inadequate or uneven pressure on the Crossbars Make sure the Crossbars have been properly tightened Refer to Welding Instructions Bubbles in the joint Welder Temperature is too high Ensure that the Temperature Controller has been properly setup Insufficient pressure when closing the Pliers after removing the Welder or too slow an action Perform a number of trial welds to improve closing pressure and or speed Bad or inadequate joint on H material belts Pressing too hard when closing the Pliers after welding Too slow an operation when closing the Pliers after welding Reduce pressure when closing the Pliers Refer to Page 14 Instructions for Welding H Material Repeat the procedure to increase speed Refer to Page 14 Instructions for Welding H Material www voltabelting com Welding amp Fabrication Tools FBW Flat Butt Welding 8 FBW Controller and Welder Electrical Diagram SW FUSE L N Gg FBW Welder and Temperature Controller Electrical Schematic BELTING Technology 9 Calibrating the FBW Welder Controller Temperature Controller Model JCS Pe PE ME Fi FE i ma dih E Eii ei ee D Ba ir Beg oe O an i ad LU aot ty Kaim Pier Before calibrating the welder make sure it is not plugged in and that the tip is at Room Temperature General Perform steps 1 amp 2 before connecting the Welder t
13. using the Hot Air Gun amp Teflon coated pressure wheel to create smooth surface Welding at a high temperature may result in some bubbles forming on the top surface These are acceptable and will not affect the joint strength however any longitudinal cracks will probably evolve into a breakage at a later stage BELTING Technology 3 7 Trimming the Excess from the Weld a Release the four Quick Release Nuts and remove the belt clamps b Remount the belt clamps with the angle facing out Do not tighten the quick release nuts 22 Belt Clamp angles facing out C Prepare the Trimmer for trimming the excess material Mount the flat cutting bit in the Trimmer see 4 page 4 The belt should be allowed to cool approximately five minutes before trimming off the excess material The time required to prepare the Trimmer for use will be sufficient for this cooling period When performing the following steps remember to follow all the Safety Precautions page 5 The procedure for preparing the Trimmer for use is identical page 8 with the following exceptions Mount the flat cutting bit onto the Trimmer refer to 4 in page 4 Set the bit alignment gauge flat on the table with the flat surface face up three holes face down Place the Trimmer in the alignment base Ease the Trimmer into position so that the bit is flush with the flat surface Tighten the Trimmer base clamp The Trimmer operates at high speed Hol
14. 6 mm Cat No 8121410 V Guide Nozzle Z M 10 8 Cat No 8121411 V Guide Nozzle 13 A Cat No 8121412 V Guide Nozzle 17 B Cat No 8121413 V Guide Nozzle 22 C Cat No 8121414 e The nozzles attach to the Leister Triac S for welding V cleats or guides on flat belts Nozzle selelction is based on the profile being welded We recommend using the Hot Air Gun Handle for Triac S Flat Belt Welding Tools D BELTING Technology gt The FBW System is a light weight easy to use tool for butt welding flat belts in both the shop and field The FBW requires only electrical power for correct and efficient operation FBW Flat Butt Welding System Model Maximum Weld FBW 301 110V 300 mm 12 Cat No 8160708 FBW 301 230V 300 mm 12 Cat No 8160709 FBW 721 110V 720 mm 29 Cat No 81607210 FBW 721 230V 720 mm 29 Cat No 81607200 FBW 1061 110V 1060 mm 42 Cat No 81610610 FBW 1061 230V 1060 mm 42 Cat No 81610600 FBW 1301 110V 1300 mm 51 Cat No 81613000 FBW 1301 230V 1300 mm 51 Cat No 81613010 FBW 1700 230V 1700 mm 67 Cat No 8161701 FBW 2100 230V 2100 mm 83 Cat No 8162100 FBW PD Flat Butt Welding System for Positive Drive Belts 1 Non standard item contact your local Volta Belting distributor for availability 2 Includes a built in adapter for spl
15. 7 7 Troubleshooting Guide 2 eiennenn 27 8 FBW Controller and Welder Electrical Diagram 0 0 0 0 0 0 00 occ cece 28 9 Calibrating the FBW Welder Controller o oo cececcccccescssceeseseseeeevsveeee 29 30 VM SSS E E N EE E EAE EE A E 31 32 BELTING Technology Thank you for buying the Volta FBW Welding Kit If you have any questions about the use of this tool please contact our Technical Service Department at email sales voltabelting com or visit our website www voltabelting com How to Use this Manual This manual has been designed to provide the operator with all the necessary information on how to use the above tool correctly Warnings in the manual should be carefully followed for your personal safety Be sure you carefully read the instructions in this manual before using the tool This will ensure use in compliance with safety standards symbols Used in the Manual This symbol is used for important Notes amp Tips A This symbol is used to warn you of actions that are dangerous for the operator Read the associated warnings and instructions carefully Identification Data The identification plate is on the front of the clamp You should include the model and serial number in all inquiries to Volta Belting about this tool Q VOLTA FBW 301 S No PL 067 09 7 Identification Plate Example Important the identification plate should never be removed The data on the plate should not be modified www vol
16. Fabrication Tools FBW Flat Butt Welding 3 7 Instructions for Welding Narrow Belts The FBW models 301 721 and 1061 can be used to weld narrow belts from 150 mm by using double sided tape and without assembling the Crossbars Observe the following rules a Use good quality tape and make sure it is thoroughly adhered to the Pliers b When welding reinforced belts work upside down with the fabric facing upwards C If the belt still moves while welding raise the welding temperature by 15 C to 20 C to allow an easier melting of the material and reduce the pressure required When you finish return the Temperature Controller to 220 C 3 8 Instructions for Welding H Material Belts The procedures for welding M and H family materials are basically the same However when welding H family belts it is necessary to be extra careful The following are specific areas to watch out for a When welding H material belts and especially belts 4 mm thick or more in ambient conditions of low temperature and high humidity it is necessary to warm the belt ends before welding b With the belt ends secured in the Pliers use a Leister Hot Air Gun to direct hot air over the belts ends for approximately 2 minutes C Without delay continue with the standard welding procedures described above d Ifyou do not havea Leister Hot Air Gun you can place the Welder in the Pliers over the Pliers supports Close the Pliers without bringing the belt ends in
17. In fj J F f I E Pas i i Now you must turn the cutting bar 180 and cut the second end of the belt so the scrap unusable piece will not be part of the belt Both egdes of the belt must be cut so that The end result is that both ends of the belt will have a both the final ends are usable 1 2 pitch 2 to 3mm combined pitch of SuperDrive tooth pitch 3 4mm When welding the belt those 3 4mm will melt and the final pitch should be the exact pitch needed A pitch of Minus 1 to 2mm is acceptable Place double sided tape on both sections of the Pliers base Position the locator bar as per normal operation of 3mm 5mm Cut the tape away from the teeth grooves in the base belt and then slide it until one of the positioning lines is in the center of the groove photo 8 Remove the protective paper from the double sided tape on one side and position the belt The difference in working with the SuperDrive belt is that you must position the teeth over the groove before bringing the rest of the belt into contact with the tape To make this easier mark the center of the tooth on the top side of the belt and aline it against the central positioning line Press the belt against the locator bar and onto the tape to ensure a firm consistant contact Photo 8 Position the second belt end against the locator bar and fix the belt with the cross bar Photo 9 Position the FBW Welder in place Apply
18. Sleeve Mounting Tool is designed to mount Volta Sleeves SLV on rollers The tool uses air pressure to form a cushion between the roller and the sleeve during sleeve installation e The tool consists of a base sleeve adapter and push rod The base is standard and used with all adapter sizes The adapter and push rod are suited to specific sleeve diameters and must be ordered based on the spesific sleeve size being used For information on adapter and push rod catalog numbers contact your local Volta Belting distributor VaR Flash Trimming Tool 110V Cat No 8140030 VaR Flash Trimming Tool 230V Cat No 8140031 e When producing large quantities of round belt rings use our Flash Trimming Tool to trim the flash after welding This jig provides adjustments for different belt diameters and a heated blade for smoothly trimming the flash from the belt The finished weld presents a physically smooth and visually clean joint e This tool is suitable to use with round profiles from 3mm to 12mm e Available only in selected markets www voltabelting com 11 With Volta Tools You Can Never Go Wrong e Fast and simple belt installation e Unique and versatile design compact rugged and easy to use e Designed for both shop and field use e Light weight construction e Usually does not require cooling water or air pressure e Convenient design and method of storing and carrying your tools e Welds an
19. The groove after milling www voltabelting com Q Welding amp Fabrication Tools 3 6 Welding the Belt The process of electrode welding is the same for all Volta flat belts Follow standard Volta procedures The electrode must always be of the same material as the belt being Belt Thickness 7 mm Electrode 9 mm Electrode welded Use M material electrodes on M material belts and H material electrodes on H material belts Tips for successful joining of M type material belts 1 Check that the router bit height is set to the position where it almost touches the bottom of the groove as low as possible without actually touching 2 Make a clean groove Repeat the grinding a few times and use a knife to clean any remaining material 3 Preheat both the belt and the electrode 4 Use a relatively high welding temperature with the new type LEISTER hot air gun 1600W setup at mark 8 8 5 and with the old type 1400W set on mark 8 5 9 5 Weld relatively slowly while applying moderate downward pressure continuously use Leister top handle to assist in pressing down Cat No 8141408 6 While welding make sure that the electrode runs freely into the nozzle and is not stretched by being pulled Use a second person to feed the electrode loosely if needed Check the weld to make sure that there are no longitudinal cracks on either side 8 If needed make some cosmetics finishes to the top surface
20. Tool Kit 110V Cat No 8160716 VaR Tool Kit 230V Cat No 8160715 Welding Tools The kit includes F 51 Pliers WU Welder 110 or 230 V D 11 Driller Belt Snippers e The VaR Tool Kit is a plastic case with foam insert to hold a set of VaR welding tools This provides a convenient method of storing and carrying your VaR The F 51 Pliers make this kit the most versatile on the market with the capability of welding V and round belts from 2 mm up to 32mm Mini VaR Tool Kit 110V Cat No 8160718 Mini VaR Tool Kit 230V Cat No 8160719 e The Mini VaR Tool Kit combines all the tools necessary to weld small belt sections Welds round belts up to 8 mm 5 6 and V belts up to 13mm The kit includes Tool case Mini pliers Mini welder and stand Mini snippers and trimmer Handles for the pliers are optional For availability contact your local Volta Belting distributor VaR Easy Overlap Welding Kit 110V Cat No 8140016 VaR Easy Overlap Welding Kit 230V Cat No 8140019 e The VaR Easy Overlap Welding Kit provides easy Multi Grip and Double V The kit includes Easy Overlap Pliers dies not shown Welder and Stand D 11 Driller Utility Knife Double Sided Tape accurate and strong connections for Volta reinforced belts Dies are available to adapt the Pliers to receive most V and Round sizes Ridge Top Super Grip The kit do
21. Use this Manual This manual has been designed to provide the operator with all the necessary information on how to use the above tool correctly Warnings in the manual should be carefully followed for your personal safety Be sure you carefully read the instructions in this manual before using the tool This will ensure use in compliance with safety standards Symbols Used in the Manual This symbol is used for important Notes amp Tips A This symbol is used to warn you of actions that are dangerous for the operator Read the associated warnings and instructions carefully Identification Data The identification plate is on the front of the clamp You should include the model and serial number in all inquiries to Volta Belting about this tool VOLTA FT 1500 S No PL 049 11 y Identification Plate Example A Important the identification plate should never be removed The data on the plate should not be modified www voltabelting com 9 Welding amp Fabrication Tools 1 Introduction Flat Belt Electrode Welder Make sure that your cutting bit corresponds with the correct bit alignment gauge FT Welding Kit Includes Description 110 VAC FT 1000 1500 DOIE 1 Base 2 Belt Clamps 4 Quick Release Nuts 1 Electrode Clamp 1 Positioner SD Cutting Bar Trimmer Adaptor Alas 220 VAC Bit Alignment Gauge 1 Trimmer Makita Model 3707 FC 110
22. al Data Catalog for details FT Flat Electrode Welding System Model FT 1000 Welding System 110V Cat No 8153415 FT 1000 Welding System 230V Cat No 8153416 FT 1500 Welding System 110V Cat No 8153420 FT 1500 Welding System 230V Cat No 8153421 e The FT Welding System includes a build in adapter for splicing SuperDrive belt DD Adapter for FT 1000 Cat No 8153318 DD Adapter for FT 1500 Cat No 8153319 e The DualDrive adapter is also available as separate unit DDSP Adapter for FT 1000 Cat No 81626344 DDSP Adapter for FT 1500 Cat No 81626354 e The DualDrive SP adapter is also available as separate unit Pliers for Narrow Flat Belt Welding Pliers P 100 Cat No 8130300 Pliers P 200 Cat No 8130310 P 100 Adapter D E Cat No 8130302 e The P 100 and P 200 are the latest additions to the line of narrow flat belt welding tools The P 100 is designed to butt weld belts of up to 100 mm in width The P 200 is designed to butt weld belts of up to 200 mm in width When welding at an angle the maximum belt width is reduced BELTING Technology Miscellanous Tools Leister Knife Cat No 8153100 e The Leister knife is designed to a provide clean and accurate trimming and also for cutting conveyor belt splices Sleeve Mounting Jig Base Cat No 8151660 Sleeve Mounting Adapter Set e The
23. al pressure to the material in order to ensure maximum contact between the materials being welded www voltabelting com 7 Welding amp Fabrication Tools Flat Belt Fabrication Tools Leister Triac S 110V 1600W Cat No 8111403 Leister Triac S 230V 1600W Cat No 8111404 Nozzle Pencil Tip 5 mm Cat No 8120005 e The Leister Triac S features an adjustable temperature control This allows the Triac S to be used to weld different belt materials The Triac S comes equipped with a pencil nozzle for focus work Nozzles can be used to adapt the Triac S to weld V guides and electrodes Nozzle 5 mm Round Cat No 8121405 e For special fabrications Nozzle 7 9 mm Inverted Electrode Cat No 8121409 e For welding 7 or 9 mm electrodes upside down on flat belts as low profile cleats Nozzle 7 mm Electrode Cat No 8121406 e For electrode welding 1 5 to 2 5 mm thick flat belts Nozzle 9 mm Electrode Cat No 8121408 e For electrode welding 3 to 5 mm thick flat belts Non standard item Contact your Volta distributor for availability Hot Air Gun Electron 110V 2700 W Cat No 8111401 Hot Air Gun Electron 230V 3400 W Cat No 8111402 e The Leister Hot Air Gun Electron is used for welding sidewalls and other coating materials to flat belts The Hot Air Gun Electron mounts in the Sidewall Trolley Frame V Guide Nozzle
24. atures are equivalent the Auto Tuning process has ended 6 Proceed to the next step TEMPERATURE CORRECTION Temperature Correction Off Set This step provides compensation for the cable and circuit differences between the Welder and the Controller and must be performed when either the Welder or Controller has been replaced The correct performance of this step and therefore of the FBW Welder requires an accurate temperature measuring device with a quick read probe These units are available at most industrial supply outlets This step is to be done immediately after completing step 4 from Auto Tuning section The off set can be done only if you have a thermometer in order to compare the data against the temperature shown in the Temperature Controller Measure and record the temperature on the surface of the Welder 2 Note the difference in temperature between the upper display of the Temperature Controller and the temperature measured on the welder Record this number and whether the welder temperature is higher or lower than the Temperature Controller Temperature 3 Press MODE and hold both for 3 seconds until L oc E appears in the upper display on the lower display appears 4 non blinking lights 4 Press MODE several times until the symbol appears in the upper display This symbol will remain throughout the remainder of step 5 The number that appears in the lower display represents the compensation value of th
25. brication Tools The Next Step in Belting Welding amp Fabrication Tools 9 Volta Belting Technology has been manufacturing conveyor belting for over 40 years The knowledge gained in those years of experience has gone into the design and assembly of every Volta belting tool We have worked with belting houses in the shops and in the field to see how our tools would be used We also checked the conditions experienced by conveyor belt ing technicians on site gt What we learned in the field has gone into the design of a full and very versatile line of belting tools Whether you buy our tools separately or in kits the result is always the same Volta tools have a light weight design so that each tool is compact rugged and easy to use Our tools will always provide you with long and reliable service We design and manufacture custom made tools to specification for your special belting requirements Our state of the art tools and accessories make welding and fabricating your Volta belts an effortless amp professional experience Mini Pliers R 8 F 51 Pliers for special products Easy Overlap Welding Tool VaR Tools BELTING Technology Pliers F 51 Cat No 8130201 e This versatile tool is ideal for welding a wide range of V and round belts V belts from 8mm to 32mm Round belts with diameters from 2 mm 744 to 20 mm Flat belts with widths up to 50 mm 2 e T
26. chemical fumes and possible spills may damage the wiring and internal components of the Controller 2 3 The Electrical System All metal parts of the FBW Welding System are grounded Ensure that the electrical plug is connected to a power source with an earth ground The thermo couple wires must not be disconnected as this will cause uncontrolled heating and damage the Welder Electrical Shock Hazard Never remove the ground from the power cord or internal wiring 2 4 Care and Maintenance Keep the system dry and clean Occasionally apply a light coating of oil to sliding metal parts The quality of the finished weld is affected by the condition of the Welder To obtain the highest quality results from your Welder always wipe the Welder s flat surfaces with a clean cotton cloth to remove material and dirt immediately after welding When welding is completed return the tools to their storage box There is no need to wait for the Welder to fully cool down The partitions inside the box will ensure that the system does not move during transportation and guarantee the tool s long lasting functioning is high extra care must be taken to avoid burns It is recommended that you wear The Welder must be cleaned while hot Because the temperature of the welder protective gloves www voltabelting com Q Welding amp Fabrication Tools FBW Flat Butt Welding A A 2 5 Safety Precautions Volta Belting accepts no liability fo
27. d fabrications are strong reliable and will last as long as your belt life IN BELTING Technology Corporate Headquarters Sales and Manufacturing sales voltabelting com USA Tel 1 973 276 7905 Fax 1 973 276 7908 Toll Free 1 877 VOLTAUS EUROPE Tel 31 546 580166 Fax 31 546 579508 www voltabelting com Volta Belting makes no warranty with respect to any of its products for a particular purpose Copyright 2010 Volta Belting Technology Ltd See Volta General Terms and Conditions CAT103ENO00 Ver D August 2012 soa Design amp Engineering Solutions Thermo Regulated Easy Overlap Welding Tool Special Features e Welder heat is precisely thermo regulated with the cutting edge technology PID Controller e The Welding Wand has a much higher electric flow capacity e The Welder Tip is 90mm long creating a greatly extended overlap area at the join e Strong durable case protects and holds all parts of the kit together in convenient set Kit Contents 1 Case 2 Welder and Welder Control box 3 Clamp 4 Manual drill D 11 5 Knife 6 Double sided adhesive tape In addition specific size dies Should be orderd seperatly Special Benefits e Constant welding temperature enables successful joins in differing environmental conditions e Welder Temperature is controlled in extreme cold conditions of up to 30 C 22 F e Extended 90mm overlap area results in a much
28. d it firmly to prevent it form jumping out of control when it is turned on www voltabelting com 11 Welding amp Fabrication Tools Check the height of the cutting bit on a different piece of belt before starting this procedure d Set the Trimmer base between the two belt clamps Note that the Trimmer base has a groove across one dimension A This groove must be aligned with the belt joint so that the excess material flash passes under the groove Turn the vacuum cleaner on Plug in the Trimmer and after ensuring that the area is ready turn the Trimmer on The Trimmer should be positioned to start trimming on the piece of belt added to the edge of the base belt After trimming the belt ends in one direction reverse the direction of movement and slowly return to your starting position If it is necessary perform the trimming operation a second time You must thoroughly clean the area between the belt clamps first Turn the Trimmer off and unplug it Make some cosmetic finishes using the Hot Air Gun melt the top surface and quickly apply pressure using a teflon coated roller e Remove the Quick Release Nuts and the Belt Clamps Carefully pull the belt to release it from the double sided tape Flip the belt over and place it upside down on a smooth flat surface you can use the plier base Using a sharp knife such as a Leister Knife or the angle V Knife trim the excess material from the bottom of the joint
29. dapter DDSP Adapter Stopper for the DD DDSP Control box Instructions Manual e NINI e e ea MM ilM FBW Welding Instructions Manual FBW Case see picture at the top of the page 2 Technical Specifications Table 1 FBW Welder System Specifications FBW 300 301 110 230V FBW 720 721 110 230V FBW 1060 1061 110 230V FBW 1300 1301 110 230 VAC FBW 1700 110 230 VAC BELTING Technology FBW 2100 110 230 VAC Single phase Single phase Single phase Single phase Single phase Single phase 400 W 800 W 1100 W 1300 W 1700 W 2000 W 3 7 amps 7 3 amps 10 amps 12 amps N A N A 1 8 amps 3 6 amps 5 amps 5 9 amps 7 4 amps 8 7 amps slow blow slow blow slow blow slow blow slow blow slow blow 10 amp 10 amps 15 amps 15 amps N A N A 10 amp 10 amps 10 amps 10 amps 10 amps 15 amps yes yes yes yes N A N A yes yes yes yes yes yes 13 6 35 16 48 22 82 37 106 48 121 55 22 10 70 32 92 42 181 82 225 102 255 116 24 300 28 720 41 7 1060 51 1300 66 9 1700 82 5 2100 6 150 15 7 400 24 4 620 33 845 45 7 1160 56 1420 0 06 0 2 0 06 0 2 0 06 0 2 0 06 0 2 0 06 0 2 0 06 0 2 1 5 5 1 5 5 1 5 5 1 5 5 1 5 5 1 5 5 15 15 15 15 15 15 428 518
30. dapter Set for FBW 720 721 Cat 81307244 Stoppers 2 units Cat 81626340 DD Adapter Set for FBW 1060 1061 Cat 81310604 Utility Knife non standard You must be familiar with the instructions for welding with FBW before continuing with this procedure To keep the correct pitch place the stopper on the welder Loosen the screws of the Stoppers and place them in the groove on the end sides of the Welder Tightly secure the screws the tooth towards the cutting side cut the first end of the belt along the Cutting side Turn the cutting bar 180 and cut the second end of the belt A N Do not assemble disassemble stoppers when welder is hot For the FBW 721 and FBW 1061 Apply about 10cm of double sided tape on the center plier base this will hold the adaptors in place BELTING Technology a ms a Teg z a Be im P S r a Kaki i ee aye a Ei Ja oe Se EA RE Position the Adapters onto the Pliers with the Cutting sides Position the crossbar without tightening the knobs Close the facing outwards Position both sides of the belt on the Pliers plier and push the two ends together this will align the two The belts teeth should face down and interlock with ends of the belt with the adaptors Now tighten the FBW the grooves of the adapters Crossbars 7 Th l i Ay 8 1 E i i 1 i Zz Position the FBW Welder in plac
31. dentical to the belt being welded at both outer edges of the belt and across the groove in the Pliers base These pieces must be as wide as the Trimmer base to provide a smooth surface to start the trimming and cleaning procedures The positioning of these pieces purpose is to start and finish the weld outside the belt area Position four small pieces of belt material near the four studs on the Pliers base These pieces will ensure that both clamps will maintain an even pressure across the belt s width All pieces must be the same material and thickness as the actual belt being welded b Position the two belt clamps over the belt with the angled edge facing one another C Position the electrode clamp on the end of the Pliers base opposite to you Secure the belt and electrode clamps in position using the Quick Release Nuts The nuts sould only be hand tightend It is not necessary to overtighten the quick release nuts 9 Belt Clamp angles facing in www voltabelting com D Welding amp Fabrication Tools 3 4 Preparing the Trimmer for Beveling the Belt Edges a Mount the 50 Cutting Bit see 5 page 4 in the Trimmer using the two wrenches supplied with the Trimmer Ensure that the Trimmer is not connected to power before proceeding with these steps D Set the Trimmer in the Trimmer base Do not tighten the base handle at this point C Set the bit alignment gauge flat on the table with the four holes facing up Place the Trim
32. e Apply consistent and Trim and check the weld A good weld will be free of cracks gentle pressure until the Stoppers do not allow you to and defect Pitch tolerance should be 0 8 mm 0 8 mm continue Immediately open the Pliers Weld the belt according to the welding instructions in the FBW Manual www voltabelting com Welding amp Fabrication Tools FBW Flat Butt Welding To ensure an accurate and efficient weld of DualDrive SP belts use FBW DualDrive SP Adapter Kit If you haven t welded this product before weld a section of a trial belt before welding your Volta conveyor belt For welding DD SP Lace follow the same instructions as seen on pages 22 23 Required Tools FBW Welding Kit DDSP Adapter Set for FBW 1300 1301 Cat 81626335 DDSP Adapter Set for FBW 300 301 Cat 81626315 V Trim Knife Narrow Cat 8153108 DDSP Adapter Set for FBW 720 721 Cat 81626325 Stoppers 2 units Cat 81626340 DDSP Adapter Set for FBW 1060 1061 Cat 81626330 Utility Knife non standard You must be familiar with the instructions for welding with FBW before continuing with this procedure To keep the correct pitch place the stopper on the welder Heat up the Welder Choose the DualDrive SP Adapter that Loosen the screws of the Stoppers and place them in the fits to the Pliers see Required Tools above Cut the two ends groove on the end sides of the Welder Tightly secure t
33. e Lace This hinge lace is suitable for belt thicknesses of 2 5 to 4mm When working with lace it is important that you work according to the following instructions If you haven t welded this product before weld a section of a trial belt before welding your Volta conveyor belt You must be familiar with the welding instruction in the FBW Manual before continuing with this procedure Position one side of the belt on the Pliers according to the welding instructions in the FBW Manual Remember to use double sided tape for this task Cut the belt to the required length taking into consideration the lace Join the lace and cut to the belt s width Aa Pal Weld the belt to the lace according to the welding instructions for FBW The thicker the belt the longer the melt should be to match the thickness of your belt Position the lace as you did the belt Make sure the lace sides interlock and the flat side faces down The lace should be symmetrically aligned to the belt BELTING Technology Heat a Round Chisel with the Leister Hot Air Gun and trim the Repeat from Step 3 to weld the other end of the belt excess from the top of the belt or apply some soap water for easier trimming You may use a V Knife or a Lesiter Knife to trim the excess from the bottom of the belt Make sure the lace and the belt are symmetrically aligned Trim the lace approximately 5 mm from each side Insert a hinge pin i
34. e previous Welder 5 Using ak or enter the new compensation factor into the Temperature Controller If the welder temperature was higher than the Controller temperature add ah the value recorded in step 2 to the compensation value If the Welder temperature was lower than the Controller Temperature subtract the value from step 2 from the compensation value Example Temperature Controller upper display shows a temperature of 220 C Welder temperature is measured as being 230 C Lower Display of the Temperature Controller displays Correction Factor 4 Use the and reduce the lower display value by 10 The new compensation value will be 6 4 10 6 6 Press MODE to return to the original display 7 Allow 5 minutes for the welder to stabilize and measure the temperature again 8 If the temperature is 5 C 9 F or less the Controller and the Welder is ready for use if not repeat temperature correction step 3 7 9 If you finished working turn the Main Power switch to OFF BELTING Technology 10 Notes www voltabelting com 31 With Volta Tools You Can Never Go Wrong e Fast and simple belt installation e Unique and versatile design compact rugged and easy to use e Designed for both shop and field use e Light weight construction e Usually does not require cooling wat
35. eable blade Cat No 81533010 Stanley Blade 1992 Cat No 1160030 e The Cutter if designed to provide a clean and accurate cut on all VaR and narrow flat belts It can cut all belts up to 32mm Mini Welder 110 V 40 W Cat No 8111110 Mini Welder 230 V 40 W Cat No 8111220 e The Mini Welder is used for welding V and Round belts Round profiles of up to 8 mm diameter and trapezoid of up to 13mm e The Mini Welder is available as a separate unit and also as part of the Mini VaR Tool Kit Welding Width Welder Universal WU 1 Welder Universal WU 2 50 mm 2 Cat No 8111203 Cat No 8111204 Welder W 141 110V Welder W 142 230V 100 mm 4 Cat No 81113044 Cat No 81113045 Welder W 241 110V Welder W 242 230V 200 mm 8 Cat No 81113046 Cat No 81113047 supplied with 110 VAC plug supplied with German 230 VAC plug e These welders are designed for both shop and field use The blade length of each welder is designed for use with specific Volta pliers Refer to the Pliers section of this catalog to determine the correct welder for use with your pliers These welders are designed to be used with our pliers e These welders are available as a separate unit The WU Welder is available as a separate unit and also as part of the VaR Tool Kit VaR Tools Kits BELTING Technology VaR
36. er or air pressure e Convenient design and method of storing and carrying your tools e Welds and fabrications are strong reliable and will last as long as your belt life 4A Ea Lola BELTING Technology USA Tel 1 973 276 7905 EUROPE Tel 31 546 580166 Corporate Headquarters Sales and Manufacturing sales voltabelting com Fax 1 973 276 7908 Fax 31 546 579508 Toll Free 1 877 VOLTAUS www voltabelting com Z Volta Belting makes no warranty with respect to any of its products for a particular purpose Copyright 2013 Volta Belting Technology Ltd 4 See Volta General Terms and Conditions CAT600ENO0 Ver H November 2013 i mn Welding amp Fabrication Tools BELTING FT Flat Electrode Welding Technology The Next Step in Belting se Welding amp Fabrication Tools Table of Contents Page How to use this manual oo ccc ce ccs ents eetetestittsseseitetensesisissieetetetenseststeeeee 3 Symbols used in this manual nnne nn 3 DR NON en E E E E ES 3 1s WMO MODY sereen eos sek n aaa ee see ic EERE A ES 4 2 Capabilities ccccecceceescecesevsesvsvececevevesevsvsceseveverssvivesevteresvevivesveverereevieetess 5 3 Welding Instruction 2 cece cece ee te tees eeceeseeesteteeseesetsesesesieisisssetsnsesisisistesineeees 6 3 1 Vacuum Cleaner Adapter 000 00c cece eect e ect ce eens eeeteecetseeeteeeetseseteeeetseeetteeenseeeen 6 3 2 Preparing the BU rccerccers sep cscrcsecsi
37. es not include dies Order specific dies based on the belts size you intend to weld www voltabelting com 6 Welding amp Fabrication Tools Flat Belt Welding and Fabrication Tools gt High quality reliability as well as maximum flexibility are only some of the benefits you will receive when using our Flat Belt Welding and Fabrication Tools Flat conveyor belts range in widths from less than 50 mm 2 up to 2 meters 80 and more We manufacture a variety of tools capable of welding a broad range of belts both in the shop and the field Flat Butt Welder Welding narrow flat belts with Pliers P 200 9 The welding process is completely reliable when using Volta Tools because of its unique and versatile design Our tools are durable and rugged and do not require cooling water or air pressure We designed our tools for ease of handling and use Most units can be transported and operated by one technician and if the welding belts are over 1 5 m 60 in width they require only two people for handling Electrode welding of cleats FT Electrode welder BELTING Technology Flat Belt Fabrication Tools Sidewall Trolley Set SWT 100 Cat No 814151800 Including the following 5 items 1 Trolley Frame Cat No 814151802 2 Nozzle 40 mm Cat No 814151804 3 Nozzle 70 mm Cat No 814151806 4 Sidewall Wheel Set 20 40 mm Cat No 814151808 5 Sidewall Wheel Set 50 100 mm Cat No 814151810
38. he F 51 Pliers is used with our welders to produce clean and exceptionally strong welds e The F 51 Pliers are available as a separate unit and also as part of the VaR Tool Kit Mini Pliers R 8 Cat No 8130202 Handles for Mini Pliers R 8 Cat No 8130208 e For accurate welding of small belt profiles use Volta Mini Pliers R 8 e The Mini Pliers R 8 is a very versatile tool You may weld round belts with a maximum diameter of 8 mm 5 6 and V belts up to section A e The Mini Pliers R 8 may be used with or without optional handles The handles are easily mounted and are convenient and easy to use e The Mini Pliers R 8 are available as a separate unit and also as part of the Mini VaR Tool Kit Driller D 11 Set Includes Driller and three bits Il Ill Cat No 8151600 Drill Bit Cat No 8151601 Drill Bit Il Cat No 8151602 Drill Bit Ill Cat No 8151603 e The Driller is used for removing the reinforcing cord from the ends of reinforced VaR belts before welding The Driller is supplied with three standard bits e The technical data sheets for reinforced belts include a column indicating which bit to use for each belt dimension e The Driller is available as a separate unit and also as part of the VaR Tool Kit and EZ Overlap Kit www voltabelting com 9 Welding amp Fabrication Tools VaR Tools Belt cutter with replac
39. he screws of the belt along the side marked Cutting Ensure that the cut is accurate and straight A N Do not assemble disassemble stoppers when welder is hot O O S Foes riTTsi aa ii i pe j EP 4 ipa A i d N l i 9454900 EURUD PUVA i TE DED DEI Apply strips of good quality Double Sided Tape on the Adapters on the grooved surfaces from the narrow side inwards Trim the unnecessary tape from the grooves BELTING Technology Position the FBW Welder in place Apply consistent and gentle pressure until the Stoppers do not allow you to continue Immediately open the Pliers Weld the belt according to the Position the Adapters onto the Pliers with the narrow sides facing welding instructions in the FBW Manual inwards Position both sides of the belt on the Pliers The belts teeth should face down and interlock with the grooves of the adaptors tighten the FBW Crossbars a 4 as 2i i ee cae i j a aa A ane am i os ata a a E ni E Fi ro E a et a p Trim the excess from both sides of the belt Apply soap water Trim and check the weld A good weld will be free of cracks and defects Pitch tolerance should be 0 8 mm 0 8 mm for easier trimming www voltabelting com 21 Welding amp Fabrication Tools FBW Flat Butt Welding 4 5 Welding Volta Hinge Lace with FBW There are occasions when it may be necessary to splice the flat belt using Volta Hing
40. he two pressure on Crossbars Uneven pressure will allow the belt to shift during welding and too much pressure will cause the Crossbars to bend Note If the belt is narrow in comparison to the tool add belt pieces to each side of the belt to fill the gap This will prevent bending of the crossbar ends of the belt Open the Pliers and remove the Locator Bar Leave the Pliers open The system is now ready for welding BELTING Technology Clean the belt and Welder With the Welder cable away from the operator place the pre heated Welder between the two edges of the belt Position the Welder over the Pliers guide bars Using the Operating Handle bring the two belt ends into contact with the Welder Apply very gentle pressure and observe the melting of the material along both sides of the Welder Do not hold the Welder during the welding process The Welder should be free to move with the belt When the material is evenly melted along the length of both sides of the Welder move the Operating Handle to open the Pliers Quickly remove the Welder and close the Pliers This operation should be performed quickly but without too much force With the belt ends pressed together lock the Adjusting Lever The weld requires approximately 5 minutes to cool The time required for cooling depends on the thickness of the belt and the ambient temperature When removing the Welder pull it straight up in a quick movemen
41. icing the SuperDrive belt Note Special adapters for Crescent Top Spikes and MiniCleat are also available Model Maximum Weld FBW 301 PD 110V 300 mm 12 Cat No 81613100 Cat No 81613105 FBW 301 PD 230V FBW 721 PD 110V 720 mm 29 Cat No 81613110 FBW 721 PD 230V 300 mm 12 720 mm 29 Cat No 81613115 FBW 1061 PD 110V 1060 mm 42 Cat No 81613120 Cat No 81613125 FBW 1061 PD 230V FBW 1301 PD 110V Cat No 81613130 FBW 1301 PD 230V 1060 mm 42 1300 mm 51 1300 mm 51 Cat No 81613135 e The Positive Drive welding system includes built in adapter and Stoppers for splicing the SuperDrive DualDrive and DualDrive SP belts e The DualDrive amp DualDrive SP adapter is also available as separate unit www voltabelting com Welding amp Fabrication Tools Flat Belt Welding Tools The FT Welding System includes a built in adapter for splicing SuperDrive The FT Welding System is a light weight easy to use tool for electrode welding flat belts in both the shop and field The FT Welding System uses a router to cut the bevel on the belt edges and to trim the weld after welding The weld is carried out by using a Leister Hot Air Gun and Volta electrodes Electrode sizes are selected based on the thickness of the belt being welded Refer to the our Technic
42. it is in position on the pliers Never apply power when the bits are exposed When operating the Trimmer always wear protective glasses Before operating the Trimmer read the Safety Instructions included with the Trimmer The Trimmer Bits are precision tools and as such must be handled with care Dropping a bit will damage the cutting edge making the bit dull This reduces the effectiveness of the tool and the quality of the work The Trimmer must be laid on it side when not in use This is to prevent damage of the bits www voltabelting com Q Welding amp Fabrication Tools 3 Welding Instructions 3 1 Vacuum Cleaner Adapter The FT 1000 and FT 1500 are designed to operate with a vacuum cleaner attached to the Trimmer mount The Trimmer base has a vacuum hose connector already attached The vacuum cleaner will draw off the trimmings leaving a clean work surface By removing the loose trimmings the vacuum permits a smoother and cleaner trimming operation Both the FT 1000 and FT 1500 may be used and are compatible with the requirements for cleanliness in food processing facilities a If your vacuum hose does not match correctly you will need to provide an adapter One possibility is to make an insert of cardboard or other flat flexible material Fig 3 D Position the insert in the Trimmer mount and mount the vacuum hose on the insert C An alternative is to purchase a Universal Adapter You can cut the adapter to ma
43. lt Locator Bar has notes for different belt thicknesses One side is marked for 1 5 to 2 5 mm belts and the opposite side for 3 to 5 mm belts BELTING Technology Apply strips of good quality double sided tape on the upper surfaces of the Pliers jaws Ensure that you have the correct side facing up Move the Operating Handle to close the Pliers jaws and lock in place using the Locking Lever By pulling the lever up you can adjust the handle position www voltabelting com Q Welding amp Fabrication Tools FBW Flat Butt Welding Cut the two ends of the belt at 90 Ensure that the cut is Remove the protective paper from one piece of the accurate and straight doublesided tape and place one end of the belt against the Clean the belt ends with denatured alcohol The belt Locator Bar in line with a reference mark Press the belt onto ends must be free of dirt and grease in order to ensure the tape to ensure good adhesion There should be no gaps between the belt edge and the Locator Bar Gaps will produce a consistent high quality weld an inconsistent weld and lead to early failure of the weld Repeat this procedure for the opposite belt end Make sure Set the Crossbars in place and swing the Locking Bolt into you align the edge of the belt with the reference mark on position Finger tighten the nuts Be careful to apply even the Locator Bar to ensure a straight edge between t
44. mer on the alignment gauge with the bit positioned over the hole marked with the belt thickness required Lower the Trimmer into position so that the bit is sitting all the way down in the hole Tighten the Trimmer base clamp attached after mounting the bits and aligning the Trimmer in the Trimmer base to The Trimmer base is shown without the vacuum attachment The vacuum can be facilitate this step BELTING Technology 3 5 Bevel the Belt Ends Set the Trimmer Mount between the two belt clamps Before turning it on conduct a visual check to make sure that the router bit does not touch the aluminum base Turn on the vacuum cleaner Plug in the Trimmer and after ensuring that the area is ready and the bit is not touching the base turn the Trimmer on The Trimmer operates at high speed Hold it firmly to prevent it from jumping out of control when it is turned on The Trimmer should be positioned to start trimming in the piece of belt added at the edge of the base belt To ensure a clean trim the Trimmer should be pushed forward at a slow pace After trimming the belt ends in one direction reverse the direction of movement and slowly return to your starting position It is not necessary to remove burs from the edge of the trimmed belt These small pieces will melt during the welding process If there are loose pieces on the belt you can clear them away before proceeding Turn the Trimmer off and unplug it
45. ngraving on the bar are on your right hand side To carry out this step please stand on the opposite side of the belt Add or deduct from the length of the belt according to the position of the pattern BELTING Technology Weld the belt according to the instructions as described in the FBW Intruction Manual Page 13 When welding belts made of L material be careful and use less pressure during the melting process and tightening after melting After cooling the belt trim the weld with a wood chisel when the flat side is facing the belt Use liquid soap to improve the cut if required Turn the belt and trim the bottom weld as usual Check the weld and perform cosmetic finish if necessary A good weld will be free of cracks and defects Remains of the pattern after cutting will disappear during the final trimming of the weld 6 General Tips Before splicing H family FELW 1 6 FELW 2 FRL 2 or belts with adapters it is strongly recommended that you spend a few minutes practicing before welding the actual belt 7 Troubleshooting Guide Symptom Unstable temperature reading Possible cause Thermocouple Suggested solution Contact a qualified technician Welder overheating Thermocouple Contact a qualified technician Irregularity in the excess Belt not cut properly Re cut and re weld Belt moves during welding Low quality double sided tape Use a high quality double sided
46. nto the slit and check its symmetry and adequacy Belt with Volta Hinge Lace www voltabelting com Welding amp Fabrication Tools FBW Flat Butt Welding 5 1 Welding MiniCleat with Adapter and FBW Required Tools FBW Welding Kit MC Adapter Set for FBW 1300 130 Cat 81313007 MC Adapter Set for FBW 300 301 Cat 81307251 V Trim Knife Cat 8153105 MC Adapter Set for FBW 720 721 Cat 81307240 Utility Knife MC Adapter Set for FBW 1060 1061 Cat 81310600 eroanda You must be familiar with the instructions for welding with FBW before continuing with this procedure E jA a T F tag T wd To ensure correct position on the pliers and right pitch of the Position both sides of the belt on the Pliers with the belts pattern place the adapter on the belt and cut the two ends of patten facing up Position the Adapters onto the Belt Align the belt along the Cutting side of the Adapter the belt patten to the Adapter grooves Position and then tighten the FBW Crossbars Weld the belt Trim and check the weld A good weld will be free of cracks according to the FBW Instructions Manual and defects BELTING Technology 5 2 Welding Volta Spikes with FBW Required Tools FBW Welding Kit SpikesAdapter Set for FBW 300 301 Cat 813072533 SpikesAdapter Set for FBW 720 721 Cat 81307247 SpikesAdapter Set for FBW 1060 1061 Cat 81310607
47. o the Temperature Controller Steps 3 and 4 must be done when a different Welder is connected to the Temperature Controller When pressing MODE press La first Temperature Scale Selection Select Fahrenheit or Celsius temperature scales 1 Turn the Main Power switch to ON and wait for the display to stabilize upper display is 4 blinking lines lower display is a temperature value about 2 3 seconds 2 While holding both L amp _ and F press MODE for 3 seconds until 4 ri L appears in the upper display PV The lower display SV will show the Thermocouple Type and temp scale 3 Using and F select the desired temperature scale y EF Centigrade coy El Fahrenheit F J for Thermo Cuple Type C amp F for temperature scale There are approximately 20 options to scroll through 4 Press MODE several times to return to the original display see step in temperature scale selection Maximum Temperature Setting This step sets the Welder s maximum allowable temperature 1 Press L _ MODE and hold both for 3 seconds until L oc E appears in upper display Lower display will be four non blinking lights Press the MODE button once The symbol 4 H will appear in the upper display Press ak or L _ to set the maximum allowable temperature 270 C 518 F Press the MODE button once The symbol L L will appear in the upper display Press La o
48. ons as described in the FBW Users Manual 5 3 Welding Cresent top CT with FBW p F ee ee m Pr E a 2 oe a E a a a a E After the belt is cooled down trim the weld with the V shape knife Use liquid soap to improve the cut if required Turn the belt and position it on top of the cutting bar in a way that the spikes are inserted to the grooves this will allow you an easy trim of the underside Check the weld and perform cosmetic finish if necessary A good weld will be free of cracks and defects The weld is performed at an angle alongside the crescent pattern There will be a 20 mm difference on the final length of the belt according to the cutting line between the patterns Required Tools FBW Welding Kit CT Cutting Bar Cat 81626365 Wood Chisel 6 mm 4 You must be familiar with the instructions for welding with FBW before continuing with this procedure B ce ig T a in a k i i o Meese NNN N Place the belt with the pattern facing to the left as shown in the picture Insert the Cutting Bar at an angle between the patterns when the Cutting engraving on the bar and the belt scrap is on the right hand side Cut the belt with a sharp knife If the belt is wider than the adapter cut the belt in two steps Go to the other side of the belt and insert the Cutting Bar as close to the required size Make sure that the scrap and the Cutting e
49. r L _ to set the minimum allowable temperature 0 C 0 oF factory settings Press MODE several times to return to the original display see step in temperature scale selection Turn the Main Power switch to OFF Connect Welder and turn main switch on CON OW WN A W WN Welder Working Temperature Select the Welder operating temperature 1 Press MODE until the symbol 4 appears in the upper display 2 Press on __ or _ _ to select the desired temperature 220 C 428 F 3 Press MODE several times to return to the original display see step 1 www voltabelting com Welding amp Fabrication Tools FBW Flat Butt Welding Auto Tuning This step calibrates the Temperature Controller to a new Welder 1 Connect the Welder to the Controller and turn the Main Power switch ON A N The Welder must be cold when beginning this procedure 2 While holding the L press MODE several times until 5 r appears red in the upper display on the lower display appears 4 non blinking lights 3 Press La until the symbol 5 r appears green in the lower display 4 Press MODE to start the Auto Tuning cycle A A LED at the bottom right corner of the display marked AT will blink indicating that the device is in the AUTO TUNING mode Do NOT press any buttons while the unit is AUTO TUNING This process takes approximately 20 minutes 5 When the AT light stops blinking and the temper
50. r use of this tool in a manner other than that specified in this manual Volta Belting accepts no responsibility for unauthorized modifications performed on this tool This User Manual and the warnings contained herein must be read carefully and kept clearly visible in the vicinity of the FBW Welding Tool Failure to pay attention to these warnings can lead to accidents injuries or damage to health 2 6 Warning Notice for Welding Tools 1 Always use the original storage box to keep the welding tool when not in use Always store tools in a dry and secure environment 2 Select and use the most appropriate welding tool for your application The selection is based on material dimensions 3 Use the welding tool only at its rated voltage See Table 1 FBW Welder System Specifications 4 Ensure that the unit is connected to an earth grounded power source Failure to comply with this requirement can cause electrical shock 5 Do not use the welding tool in a damp or wet environment 6 Do not carry the welder by its power cord or use it for unsuitable purposes Protect the cord from heat and sharp objects 8 Do not pull on the power cord to remove the plug from its socket 9 Always work in a well ventilated area when welding Some materials can generate toxic fumes when verheated 10 Always weld on a non combustible surface and be aware of surrounding materials Heat may cause fire or damage other materials 11 Ensure that the s
51. s from weld excess from weld Separate the belt from the Pliers and turn it over placing Check the splice quality by bending the belt in both the trimmed surface on the Pliers Trim the excess from directions Check the quality of the splice across the width of the bottom of the belt the belt and on both sides A good weld will be free of cracks and defects In case of a bad splice repeat the above steps this will cause the loss of about 5 mm of the belt s length Use a finger guard when engaging in various activities that involve the use of sharp objects Handle the knife with care Cut away from your body not toward it BELTING Technology 3 6 Instructions for Splicing Reinforced Flat Belts Reinforced belts must be spliced in an angle 15 45 a Prepare the Control Box and Pliers d Align the sharp upper edge of the belt with a reference b Cut both ends of the belt to the desired angle mark on the Belt Locator Bar and press the belt onto the doublesided tape 1 mm offset C Position the second belt end on the opposite Pliers base Ensure that there is an offset of 1 mm This offset will compensate for the material melted during welding and ensure a smooth Straight edge f Mount the Crossbars on the Pliers Perfom weld as per g After trimming the weld check that the belt edge is welding instructions aligned A small disalignment may be trimmed www voltabelting com 13 Welding amp
52. stronger join e The normal strength of the belt is achieved eliminating any weak spot at the join e A higher work load can be conveyed e Suitable for round profiles of up to 12 5mm diameter Additional Accessories for Cold Atmosphere Adaptor Plate for Vertical Welding Incubator Hood neutralizes the welder from varying environmental influences that could cause the welding tip to cool down Volta Belting Technology Ltd www voltabelting com sales voltabelting com March 2011 Version A Design amp Engineering Solutions Thermo Regulated Easy Overlap Welding Tool Special Features e Welder heat is precisely thermo regulated with the cutting edge technology PID Controller e The Welding Wand has a much higher electric flow capacity e The Welder Tip is 90mm long creating a greatly extended overlap area at the join e Strong durable case protects and holds all parts of the kit together in convenient set Kit Contents 1 Case 2 Welder and Welder Control box 3 Clamp 4 Manual drill D 11 5 Knife 6 Double sided adhesive tape In addition specific size dies Should be orderd seperatly Special Benefits e Constant welding temperature enables successful joins in differing environmental conditions e Welder Temperature is controlled in extreme cold conditions of up to 30 C 22 F e Extended 90mm overlap area results in a much stronger join e The normal strength of the bel
53. t This will prevent the welder from pulling melted material off of the belt ends The cooling process can be sped up by directing compressed air along the weld 3 5 mm Amount of excess when belt ends are properly melted www voltabelting com 11 Welding amp Fabrication Tools FBW Flat Butt Welding Clean the Welder using a clean dry lint free soft Cotton When the belt is cooled leave the Pliers closed and remove cloth while the Welder is hot Leaving material on the the two Crossbars Welder will damage the Welders surface and reduce the efficiency of the Welder and the quality of the welds Welded belt with excess The following factors must be kept in mind when welding e The amount of pressure required to secure the ends of the belt depends on the thickness and type of material being welded e During welding air bubbles are formed in the melted ends The bubbles should be pressed out during the operation e Iftoo much pressure is applied during welding the heat will penetrate only a very narrow section along the edge of the belt When the Pliers are closed this small amount of melted material will be pushed out To ensure a quality weld the heat must penetrate a wide section of the belt Using a Leister Knife or other appropriate tool trim the excess from the top of the belt Using Leister Knife to trim Using V trimmer to trim Using Utility knife to trim excess from weld exces
54. t is achieved eliminating any weak spot at the join e A higher work load can be conveyed e Suitable for round profiles of up to 12 5mm diameter Additional Accessories for Cold Atmosphere Adaptor Plate for Vertical Welding Incubator Hood neutralizes the welder from varying environmental influences that could cause the welding tip to cool down Volta Belting Technology Ltd www voltabelting com sales voltabelting com March 2011 Version A
55. tabelting com 9 Welding amp Fabrication Tools FBW Flat Butt Welding 1 Introduction The FBW Welding Kit is designed to splice Volta flat conveyor belts of up to 2100 mm 83 wide FBW Welding Kit gt The FBW Welding Kit is available in a variety of sizes and voltage power ratings The model number indicates the width of belt that may be welded on a 90 joint For example the Model 300 301 welds a 300 mm 12 wide belt and the model 1300 1301 welds a belt that is 1300 mm 51 wide Description FBW Welding Kit Components Standart kit Case for FBW Pliers second line in both charts Welding Accessories Welder Control Box SD Cutting Bar Locator Bar V Trim knife Control box Instructions Manual ee FBW Welding Instructions Manual FBW Case see picture at the top of the page 9 Models 300 301 720 721 1060 1061 and 1300 1301 may be operated by one person The FBW 1700 and 2100 require two operators for correct and safe operation because of the length and weight of the Welder The FBW Welding Kit is supplied in a storage case to store the system components Store only the FBW Welding components in this box to avoid damage of the items Description FBW Welding Kit Components Positive Drive Set PD Case for FBW Pliers second line in both charts Welding Accessories Welder Control Box SD Cutting Bar Locator Bar V Trim knife DD A
56. tch the vacuum and hose diameters you require Fig 2 d The final step is to tape the joint This provides a solid connection and also maintains the vacuum Fig 4 3 2 Preparing the Belt a Cut the belt to the required length using a straight edge ruler Repeat the square process for the second belt end Mount two strips of double sided tape on the Pliers base The strips are mounted on either side of the central groove At this stage do not remove the backing BELTING Technology D Mount the Positioner see Welding Kit page 4 on one side of the Pliers base so that the straight edge of the Positioner corresponds with the center of the groove in the Pliers base C Remove the protective paper from the exposed doublesided tape Position the end of the belt against the Positioner edge and press down on the tape Ensure that the edge of the belt is flush against the Positioner edge Press the belt end firmly onto the Pliers base This will ensure good adhesion with the tape Remove the belt Positioner and the protective paper from the second piece of double sided tape Position the free end of the belt end against the mounted belt Ensure that the edge of the belt is flush against the opposite belt edge Press the belt end firmly onto the Pliers base This will ensure good adhesion with the tape 3 3 Preparation for Securing the Belt Ends a Position two pieces of flat belt material which is i
57. to contact with the Welder at least for a minute The heat from the Welder will warm the belt ends before you begin to weld e When you bring the belt ends in contact with the Welder press gently until the two ends have an even melt along the entire length of both sides of the Welder At this point stop pressing and maintain this position for approximately 20 seconds This allows the heat from the Welder to penetrate farther into the H material providing a sufficiently large softened area to ensure a good weld Open the Pliers quickly and with a snap which will prevent material from sticking to the Welder Release pressure remove the Welder continue with the standard welding procedures described above f Using the Operating Handle quickly close the pliers because the H material cools down quickly When working with H material belts especially those that are 4 mm or thicker apply extra pressure when closing the belt This is needed to force any air bubbles out of the joint However remember that applying too much pressure will reduce the quality of the weld by forcing all of the melted material out of the area of the joint and leaving only cold material Q The splice must be left to cool for at least 10 minutes after welding Checking the splice by bending it too soon will weaken or break the splice h Because of the care needed to ensure a quality weld it is important to perform several trial welds before welding a belt This will
58. urface of the welding bar is clean and in good condition 12 Hold the Welder by the handles only The Welder surface can be very hot and will cause burns 13 If the unit requires repair return it to Volta Belting or to your local Volta distributor 3 1 Preparing the Temperature Controller Connect the Welder to the Controller and then connect the main power to the power supply Turn the Power Switch to ON and allow 15 minutes for the Welder to warm up and the temperature to stabilize The Welder is supplied after factory adjustment and should not be altered unless there is a problem The Temperature Controller should be adjusted to 220 C 428 F for all belt types If you need to readjust the temperature please refer to Page 31 3 2 Preparing the Pliers e Operating Handle Knobs 4 each Position the Pliers with the Operating Handle closest to you Loosen the 4 knobs securing the Crossbars The two knobs closest to the Operating Handle are hinged and can be swung out and down to remove the Crossbars Remove the Crossbars and set them aside FBW models 1300 1301 1700 amp 2100 are equipped with magnetic crossbars To remove these crossbars slide or roll them off the Pliers Belt Locator Bar Position the Locator Bar between the jaws of the Pliers Place the Locator Bar in the center of the Pliers and over the Pliers Shafts The belt locator has reference marks for belt alignment Each side of the Be
59. veraxeveerresceurerenisneancerceeeonpivennararreumniaeniemmeneaseeoen 6 7 3 3 Preparation for Securing the Belt BiG ciatesnscrcesccaorsesacun asusacsasnvnicmnsnndomrsaintadarsedeammaatanseawon 7 3 4 Preparing the Trimmer for Beveling the Belt Edges seeseensnseereessseresrssrrennnnnnenn 8 3 5 Bevel the Belt NS sessed ss accsrin ieee coat ensesdiebeaviaken ttina tineti nett AEAEE ch abeienaiedstanipondestencetdnipabanacerns 9 3 6 Welding the OGM ess aicnedenscersaeransinecestieunenaioudnenstadnpoadertdesanteainnsapiepietsbegsneaddaketdesdiuereaddyentadininsinnss 10 3 7 Trimming the excess from the Weld cei cteirccteiersiaannnarcumi ie eealiass 11 12 3 8 Welding SuperDrive a cco ee ee ees 13 3 8 Welding DualDrive and DualDrive SP with FT 0 eerie rrneetrneeneneeens 14 A NOG ea eT neve nn ese ven Seen ne eee eT E 15 FT Flat Electrode Welding System Model FT 1000 Welding System 110V Cat No 8153415 FT 1000 Welding System 230V Cat No 8153416 FT 1500 Welding System 110V Cat No 8153420 FT 1500 Welding System 230V Cat No 8153421 e The FT Welding System includes a build in adapter for splicing SuperDrive belt BELTING Technology gt Thank you for buying the Volta FT Welding Kit If you have any questions about the use of this tool please contact our Technical Service Department at email sales voltabelting com or visit our website www voltabelting com How to
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