Help Center
How do I Splice a Belt? E-mail
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).
Read more... [How do I Splice a Belt?]
 
How do I make splice clips? E-mail

How do I make splice clips?

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Making your own splice clips

To make your own belt splicing clips you will need the following tools: 2 sets of pliers and 1 pair of wire cutters.

Next follow steps 1-5 below to make the following types of belt splicing clips: One-space clips, Three-space clips, Double loop ends clips.

 

how_to_splice_1.jpg
how_to_splice_2.jpg
how_to_splice_3.jpg
how_to_splice_4.jpg how_to_splice_5.jpg
 
How to Identify your Flat-Flex® Belt E-mail

How to Identify your Flat-Flex® Belt

pdf Download PDF File

     Go to the Form Request to Identify a Belt

how_to_identify.jpg

SPECIFICATION

REF.

VALUE

WIDTH A  
STRANDS PER FOOT B  
PITCH C  
WIRE DIAMETER D  
EDGE TYPE (SLE, CC, DLE) E  
SINGLE LOOP EDGE WIDTH F  

SPECIFICATION

REF.

VALUE

DOUBLE LOOP EDGE WIDTH (IF APPLICABLE) G  
NUMBER OF SPACES H  
FIRST SPACE WIDTH I  
CENTER SPACE WIDTH(S) J  
MATERIAL(SS, MUSIC, OTHER) -  


Step 1

Measure the overall width of the belt in inches from outside edge to outside edge.

Step 2

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.

Step 3

Measure the wire diameter with calipers or a wire gauge.

Step 4

Check to see if the belt has single loop edges, c-cure edges, or double loop edges. Measure the loop edge width.

Step 5

Count of the number of rectangular openings (called spaces) across the width of the belt.

Step 6

Determine if all spaces are of equal width. Occasionally, end spaces will be of different width than middle spaces.

Step 7

Determine belt material. Most common materials are stainless steel and music wire. Music wire has a strong magnetic attraction. Stainless steel has only a slight magnetic attraction. Use a magnet to distinguish.

 
Inspection and Installation Check List E-mail

Inspection and Installation Check List

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Yes
No
Before You Begin Splicing
    1. Power to conveyor is disconnected
    2. Wearing safety glassess
    3. Correct replacement belt selected
    4. Correct tools on hand
    5. All tensioning mechanisms released
    6. Belt threaded onto conveyor right (smooth) side up
    7. Loop edges curve back away from direction of belt travel
    8. Belt edges tied together with wire, twine, plastic wire tie
     
Yes
No
After Splicing/Installation Completed
    9. Check drive sprocket alignment for 1/8" to 3/16" clearance with Z-bends
    10. Check sprocket teeth alignment (Not needed if shaft "keyed"
    11. Check position of wear strips and adjust if making contact with Z-bends (belt joints)
    12. Check belt tracking in grooved end rolls and transfer rollers
    13. Retighten/adjust tension
    14. Test tracking by running belt without product; adjust belt
    15. Check for proper disposal of old wire and all wire pieces
    16. Tools returned to proper storage location
     
Yes
No
Conveyor Safety Check
    17. Are operating insttructions clearly listed and posted?
    18. Are safeety guards adequate to prevent accident and injury?
    19. Are limit switches and alarms working?
    20. Personnel know location of emergency stop/control switches?
     
Yes
No
Routine maintenance Inspection/Evaluation
    21. Check belt surface for bent or broken wire strands; straighten or repair immediately
    22. Check splice clips (if used) for wear/damage
    23. Check all conveyor components for excessive wear (drive sprockets, blanks, wear strips, etc.); replace if needed
    24. Check sprocket alignment for 1/8" to 3/16" clearance
    25. Check sprocket teeth alignment (Not needed if shaft "keyed")
    26. Check position of wear strips and adjust if making contact with Z-bends (belt joints)
    27. Check belt tracking in grooved end rolls and transfer rollers
    28. Check tension; adjust tension mechanisms as necessary
    29. Check levelness of conveyor frame
    30. Test tracking by running belt slowly without product

 

 

 
Trouble Shooting Guide E-mail

Trouble Shooting Guide

pdf Download PDF File
Problem Possible Cause(s) Solution(s)
Splice clips breaking • 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
• 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
Belt surges • Belt not supported on frame
• Load too high
• Uneven product loading
• Wrong type of wear strips
• Install supports on return path
• Change to heavier mesh belt
• Correct loading method
• Change to different type / material / design / wear strip
Excessive wear strip wear • Abrasive cleaner used
• Load too high
* Not enough wear strips
• Wrong type of wear strips
• Install spray wash on belt to reduce grit build up
• Change to heavier mesh belt
• Install more wear strips
• Change to different type / material / design / wear strip
Damage to flights • Product jamming on loader
• Flights getting caught on frame support
• Flights rubbing on return path
• Check hopper/chute in-feed sides and correct jamming
• Check for obstructions on frame and correct
• Allow sufficient clearance with frame; indent flights
Belt edges curling up • High temperature
• Too much tension
• Belt joints unsupported
• Load too high
• Use crowned belts (a specialty belt); Call Technical Support at 800-922-2637 or 603-644-2500 for information and pricing
• Adjust tension take-up
• Adjust sprockets/blanks/rollers to within 3/16" of Z-bends
• Change to heavier mesh belt
Belt not tracking properly • Sprocket teeth misaligned
• Conveyor frame not square
• Support rolls not squarely aligned
• Drive shaft not aligned
• Uneven product loading
• Belt improperly spliced
• Belt is "wrong side up"
• Check alignment and adjust
• Realign conveyor frame
• Realign support rolls
• Realgn following alignment instructions
• Correct loading method
• Reinstall following splicing instructions
• Reinstall belt with smooth side up
Belt runs to one side • Sprocket teeth misaligned
• Conveyor frame not square
• Support rolls not squarely aligned
• Transfer roll not functioning properly
• Drive shaft not aligned
• Uneven product loading
• Uneven tension
• Belt improperly spliced
• Check alignment and adjust
• Realign conveyor frame
• Realign support rolls
• Change to grooved end roll
• Realign following alignment instructions
• Correct loading method
• Adjust tension so it's equal on both sides of frame
• Reinstall following splicing instructions
Belt wears edges • Not enough clearance
• Conveyor frame not square
• Shafts not locked down
• Sprocket teeth misaligned
• Belt expansion from high temperature
• Adjust clearance between belt edge and on side rail
• Realign conveyor frame
• Use collars on outside of bearings to prevent lateral shifing
• Check alignment and adjust
• Adjust clearance between belt edge and side rail to allow for heat expansion
Belt slips on sprockets • Insufficient tension
• Sprockets not properly installed/aligned
• Worn sprockets
* Drive sprockets too small
• Insufficient belt wrap
• Adjust tension take-up
• Check sprocket alignment; adjust if needed
• Replace sprocket
• Replace with larger diameter sprockets from Wire Belt, or increase wrap
• Increase wrap around drive sprockets up to between 120º to 180º
Belt blackening • Frozen/stuck roller
• Too much tension
• Load too high
• Improper/inadequate cleaning
• Free roller; reduce or eliminate steel-to-steel contact
• Adjust tension take-up
• Change to heavier mesh belt
• Install continuous spray cleaning device on conveyor
Excessive belt wear or poor belt life • Contact with other equipment
• Support rolls not rotating
• Too much tension
• Uneven tension
• End roll/reverse bend too small
• Wrong type of wear strip
• Abrasive cleaner used
• Load too high
• Speed too high
• Belt improperly spliced
• Frame not level
• Eliminate contact
• Check bearing and replace if needed
• Adjust tension take-up
• Adjust tension so it is equal on both sides of frame
• Check chart pg. 4 for min. diameter
• Change to a different type/material/design/wear strip
• Install spray wash on belt to reduce grit build up
• Change to a heavier mesh belt
• Reduce running speed
• Reinstall following splicing instructions
• Correct affected area
Excessive sprocket wear • Too much tension
• Abrasive cleaner used
• Sprocket teeth misaligned
• Not enough drive sprockets
• Sprockets not properly installed/aligned
• Load too high
• Belt speeds too high
• Shaft(s) bent
• Adjust tension take-up
• Install spray wash on belt to reduce grit build-up
• Check alignment and adjust
• Add more sprockets
• Check sprocket alignment and adjust if needed
• Change to heavier mesh belt
• Reduce speed
• Check shafts and replace if needed
Belt jumps on sprockets • Worn sprockets
• Wrong size sprockets
• Belt is "wrong side up"
• Product build-up between belt and sprockets
• Too much tension
• Replace using Wire Belt sprockets
• Replace with correct S.P.F. (strands per foot) and sprocket dimensions
• Reinstall belt with smooth side up
• Install wiper on return belt to prevent product getting trapped; install side guards on frame
• Adjust tension take-up
Read more... [Trouble Shooting Guide]
 
Sanitation Procedures for Food Processors E-mail
Flat-Flex® belts constructed of Type 302 stainless steel have been approved by the USDA/FDA for direct contact with food. In addition,  both the USDA and FDA have published recommendations for the proper cleaning and sanitizing of, equipment such as conveyor belts, utensils, containers, and even general processing environments, to help prevent and/or eliminate the dangers of contamination from bacterial and other potentially harmful substances.
Read more... [Sanitation Procedures for Food Processors]
 
12 Potential Causes of Downtime Related to Conveyor Belting E-mail
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.
Read more... [12 Potential Causes of Downtime Related to Conveyor Belting]
 
How To Splice Compact Grid™ E-mail

Compact Grid

Compact Grid SplicingSplicing

Wire Belt has custom designed the Compact Grid™ Splicing Tool Kit to make splicing as simple and easy as possible. Each Tool Kit includes two CG-Splice Levers, and one set of CG-Splice Pliers. These tools are especially designed to help align and crimp the belt into place. The CG-Splice Pliers are designed to provide a perfectly shaped crimp, making the splice joint complete without damaging surrounding wire strands, or over-crimping the splice strand.

Step 1
Once the belt has been passed through the conveyor circuit and properly located on the drive and idler components, the leading belt-end hooks
(Strand A) will align with the trailing belt-end loops (Strand B)… as shown in this photo.


Step 2
Insert the leading belt-end hooks
(Strand A) into the trailing belt-end loops (Strand B) as shown.


Step 3
Once the hooks and loops are joined together, the belt should be slightly tensioned before the final steps in the splicing operation are performed. Be careful not to over-tension the belt at this point, because a little slack will be required for the next step.

Step 4
Insert the CG-Splice Levers into the belt hooks and loops as shown here. Apply a slight amount of pressure to the lever to form a tented position. Hook the end of the lever into the next strand to lock the tented strand in place. (As shown below in Step 4 A–D).

Compact Grid offers many advantages over competitive belts
Step 1
Compact Grid offers many advantages over competitive belts
Step 2
Compact Grid offers many advantages over competitive belts
Step 3
 
Compact Grid offers many advantages over competitive belts
Compact Grid offers many advantages over competitive belts
Compact Grid offers many advantages over competitive belts
Compact Grid offers many advantages over competitive belts

Step 4

Step 5
With the CG-Splice Levers in place, and the belt in a slightly “tented” position, the CG-Splice Pliers can be used to crimp down the leading belt hooks (As shown below figure A). The CG-Splice pliers are designed to fit within the mesh of the belt, which enables the strand to be crimped to the proper depth. To correctly crimp your belt into position, start the crimping process 5 spaces in from the edge of the belt (As shown below figure B). Crimp moving outward towards the edge of the belt. Repeat this process on the opposite side of the belt. Now that you have the outer edges locked, you may crimp the remaining center spaces to complete the splice.

Compact Grid offers many advantages over competitive belts
Compact Grid offers many advantages over competitive belts
 
Splicing a Flat-Flex® Single Loop Edge E-mail

Splicing a Flat-Flex® Single Loop Edge

pdf Download PDF File

Splicing Wire Belt

Splicing Wire Belt
Step 1 – Begin Splicing In The Center

  • 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)

Splicing Wire Belt

Splicing Wire Belt

Step 2 – Weave Strand To One Side

  • 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

Splicing Wire Belt

Splicing Wire Belt

Splicing Wire Belt

Step 3 – Weave Strand To The Other Side

  • 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

Step 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)

STEP 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

STEP 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!
 
Splicing a Flat-Flex® Double Loop Edge E-mail

Splicing a Flat-Flex® Double Loop Edge

pdf Download PDF File

dle_instruction_a.jpg

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.

dle_instruction_b.jpg

DIAGRAM B

  • Insert needle nose pliers from underneath, grab the
    center of DLE on strand and pull up into space.
  • Straighten initial bend

dle_instruction_c.jpg

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.

dle_instruction_d.jpg

DIAGRAM D

  • Connect the splice strand edge hook to the near side loop edge using pliers.

dle_instruction_e.jpg

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.
 
Installing Splice Clips E-mail

Installing Splice Clips

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IMPORTANT NOTE:
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.
IMPORTANT NOTE:
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.

Splice clips come in two varieties: 1-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... where as, a 9-space belt would use 1 single and two 3-space clips. See drawings below.) Refer to the chart on the reverse side for how many clips you should use for your belt.

 

5_space.jpg


7_space.jpg


9_space.jpg

How Many Clips?
# of Belt Spaces Single Clips Single +
3-Space Clips
3 2 0 + 1
5 3 1 + 1
7 4 0 + 2
9 5 1 + 2
11 6 0 + 3
13 7 1 + 3
15 8 0 + 4
17 9 1 + 4
19 10 0 + 5
21 11 1 + 5
23 12 0 + 6
25 13 1 + 6
27 14 0 + 7
29 15 1 + 7
31 16 0 + 8
33 17 1 + 8
35 18 0 + 9
37 19 1 + 9
39 20 0 + 10

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.

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

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.

4. INSTALL SPLICE CLIP ON THE OPPOSITE EDGE

  • Install the same type of splice clip on the opposite edge in the same way.

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).

6. RE-TIGHTEN THE TENSION

 

 
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