Gates Mectrol Novitool AERO User manual

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Last Updated: 10-06-15

Welding Guidelines

Novitool® AERO™ Portable Splice Press

Novitool® AERO™ Portable Splice Press Welding Guidelines

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Page 1

Table of Contents

Introduction ................................................................................................................................................... 2

Cautions ......................................................................................................................................................... 3

PC10 and PC20 .............................................................................................................................................. 4

Belt Preparation ................................................................................................................................. 4

Press Assembly.................................................................................................................................. 7

Welder Operation.............................................................................................................................. 11

Welding Parameters ............................................................................................................. 13

CC40 ............................................................................................................................................................. 15

Belt Preparation ............................................................................................................................... 15

Press Assembly................................................................................................................................ 18

Welder Operation.............................................................................................................................. 22

Welding Parameters ............................................................................................................. 23

FC9 and FC12 .............................................................................................................................................. 25

Belt Preparation ............................................................................................................................... 25

Press Assembly................................................................................................................................ 25

Welder Operation.............................................................................................................................. 31

Welding Parameters ............................................................................................................. 32

Troubleshooting .......................................................................................................................................... 35

Contact Information ...................................................................................................................................... 36

Novitool® AERO™ Portable Splice Press Welding Guidelines

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Page 2

Introduction

It is important that the FLEXCO Novitool Aero™Splice Press Safety and Operating manual provided with the

press be followed. The guidelines here are not meant to be a substitute for the FLEXCO handbook but rather

to complement it. Several comments are in order:

The purpose of the heat profile setting recommendations found in this guideline is to ensure a urethane

belt phase transition from solid to liquid during the weld process. The settings to achieve this phase

transition vary due to the individual press, the belt material and the environment. Prior to attempting the

actual weld, it is necessary to confirm that this temperature needed to achieve this phase transition is

met by conducting a test weld. To conduct this test, a thermocouple must be embedded in the belt

material (for toothed belts, the thermocouple should be placed in the silicone pad’s tooth trough). If the

thermocouple doesn’t register the minimum actual belt temperature called out for that pitch, it is likely

that the weld will be compromised. Minimum actual belt temperatures and dwell times can be found

directly below the recommended settings table. If the minimum temperature is not achieved, it will be

necessary to contact Flexco to determine the root cause.

oGates Mectrol can confirm weld integrity through tensile and accelerated life cycle testing. For

tensile testing, submitted samples must be at least 3” wide with 12” of belt length on each side

of the weld. For life testing, samples must be a welded belt 24” wide x 50” long.

Flexco recommends doing a warm up weld prior to performing the actual finished weld, particularly in

cold environments.

Note that a platen press weld causes the welded area to shrink slightly. This shrinkage may cause the

belt edges to lift slightly. Be sure that this edge lift will not affect the belt’s performance in your

application.

Novitool® AERO™ Portable Splice Press Welding Guidelines

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Page 3

Cautions

Overall Safety Rules

To Avoid Severe Personal Injury or Property Damage, Read Carefully and Understand the Following

Safety Precautions.

DANGER

Terminate electrical hazards by removing power cord from wall receptacle or machine base inlet.

WARNING

Terminate pressure related hazards by pressing the red pressure relief button.

CAUTION

Avoid temperature related hazards by handling press components and belt once safely cooled.

Novitool® AERO™ Portable Splice Press Welding Guidelines PC10 and PC20

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Page 4

Belt Preparation –PC10 and PC20

“Split Tooth” Cut Directions

The split tooth technique is recommended for two reasons:

1. The greater the bonded surface area, the greater the weld strength. When compared to base

belt thickness, bonding in the tooth area increases the weld surface area by 240% for the

PC10 and 380% for the PC20

2. Running in an untensioned state, most of the belt flex takes place in the flat area between the

teeth rather than at the tooth itself. The weld should always be located in the area experiencing

the least amount of belt flex.

CAUTION, WEAR PROTECTIVE GLOVES!

1. Determine belt length.

A. Mark both ends of belt, marking must be on the center of the tooth.

Cutting

Fixture

Cutting

Guide

Groove

Belts

Gloves

Utility

Knife

Straight Cut Equipment

To prepare belt ends for a

straight cut the following items

are needed:

Cutting Fixture

Cutting Guide Groove

Utility Knife

Safety Gloves

Belts

Novitool® AERO™ Portable Splice Press Welding Guidelines PC10 and PC20

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Page 5

2. Cut the belt.

A. Insert one end of the belt into the cutting fixture.

(Must have ~ 3 teeth of extra material on the scrap side that will be cut off. This will keep the belt in

place while cutting.)

Ensure that the belt is fully engaged in the cutting guide groove.

B. Place top of the cutting fixture on the top of the belt, apply pressure on it with one hand.

C. Using your other hand, make several straight scoring cuts with the utility knife.

(Do NOT try to cut the belt in one deep cut. It does not work!)

D. You will have two split teeth. Ideally both cut halves would be equal to or slightly larger than half a

tooth. Slightly oversizing creates helpful side pressure when the two halves are forced into the silicone

pad. Welding two cut halves, that together make up less than a full tooth, will cause the belt to thin out

in the tooth area and could compromise the weld due to lack of side pressure pushing the two halves

together.

Straight Cut with Utility Knife

Two Split Teeth

Novitool® AERO™ Portable Splice Press Welding Guidelines PC10 and PC20

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Page 6

3. Clean the prepared ends with alcohol (91% or higher) and a clean rag. Clean top and bottom surfaces at

least 5” to 6” from the joint. A cleaned surface will provide a better, stronger joint.

Clean Prepared Ends

Novitool® AERO™ Portable Splice Press Welding Guidelines PC10 and PC20

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Page 7

Press Assembly –PC10 and PC20

1. Place one end of the belt into the press.

2. Load the other end of the belt into the press from the opposite side.

3. Confirm that the mating surfaces are pressed against each other and that belt edges line up.

Belt in Cutting Guide

Belt Loaded in Opposite Side

Novitool® AERO™ Portable Splice Press Welding Guidelines PC10 and PC20

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Page 8

Tape Positioned Over Belt

4. Fill out the balance of the platen with like-belt material and use a narrow silicone strip (approximately1”

wide and at least 0.015” thinner than the belt itself) at each outside platen end to cap the end of this like-

belt material. Silicone can be substituted to fill out the press but the use of like belt material will reduce the

“hourglass” effect in the weld area caused by shrinkage. Any silicone used on the tooth side must have the

same tooth pattern.

Filler strips along the belt edges serve several purposes

Prevent the belt from flowing out during the welding process

Help minimize shrinkage in the weld area

Balance the top and bottom platen during welding

There can be no gaps or open areas on the platen bed

5. Apply a 1.5” wide strip of blue urethane foil across the top and bottom splice

(Gates Mectrol PN 15260, sold in 50’ lengths).

Filler Strips

Novitool® AERO™ Portable Splice Press Welding Guidelines PC10 and PC20

Novitool® AERO™ Portable Splice Press Welding Guidelines –V6 Page 9

6. Place the clamping bars and tighten clamps.

7. It is recommended that the two belt halves are tack welded together using a soldering gun with a smooth

tip (Weller PN 6160, Weller offers a cordless (battery powered) powered portable soldering iron PN

BP860MP for added convenience). It is also recommended that the tape be tack welded to the belt,

particularly for wider belts where handling the top press beam is more challenging.

8. Place Teflon sheet over the joint area. Be careful to keep it aligned with the welding area.

Add Teflon Sheet

Position Clamping Bars

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