ENGINEERING MANUAL THERMODRIVE TECHNOLOGY

Transcription

1 ENGINEERING MANUAL THERMODRIVE TECHNOLOGY 2017

2 TABLE OF CONTENTS INTRODUCTION... 5 About Intralox... 5 Intralox Hygienic System... 5 Customer Resources... 6 ThermoDrive Tensionless Belt System... 7 DESIGN GUIDELINES... 9 CONVEYOR DESIGN Design Considerations ThermoDrive Design Prciples ThermoDrive Hygienic Recoendations CONVEYOR FRAME DESIGN Dimensions Framework DRIVE END DESIGN Drive Shaft Drive Sprockets Drive Pulleys Position Limiters Belt Scraper ThermoDrive Tensionless Drive Engagement Unit IDLE END DESIGN Idle Shaft Sprockets, Wheels, and Rollers CARRYWAY DESIGN Support Rail Guideles Straight, Parallel Arrangement Angled Chevron Arrangement Carryway with Flights, Sidewalls, or Flight Notches RETURNWAY DESIGN Belt Accumulation Returnway Support Guideles BELT CONTAINMENT TROUGHED CONVEYORS BELT AND COMPONENT DIMENSION CHANGES PRODUCT LINE BELT SELECTION Visual Overview Belt Selection Considerations BELTS BELT FABRICATION Belt Jog Methods Belt Jog Considerations Belt Features Belt Accessories DRIVE AND IDLE END COMPONENTS Drive End Selection Considerations S8050 Tensionless Drive Engagement Unit

3 TABLE OF CONTENTS Shafts Sprocket Spacers Retaer Rgs Sprockets Position Limiters Support Wheels and Rollers CARRYWAY AND RETURNWAY COMPONENTS Support Rails/Wearstrips Shafts Return Rollers Trough Retrofit Set SPLICING EQUIPMENT BELT MATERIAL PROPERTIES Material Compliance Temperature Factors Belt Chemical Resistance Guide GLOSSARY

4 TABLE OF CONTENTS WARRANTY INFORMATION warrants products of its own manufacture for one year from date of shipment to be free of defects materials or workmanship. Customer s sole remedy is repair or replacement of products found to be defective under normal use or service, except that if repair or replacement prove impracticable, Intralox will refund a proportionate part of the price paid. No other warranty or remedy is expressed or implied unless otherwise provided writg and approved by a representative duly authorized to extend such approval by For product warranty details, refer to the Terms and Conditions statement on your sales voice. Belt Satisfaction Guarantee available at Expedited Service Guarantee available at WARNING Intralox is specifically not responsible for property damage and/or personal jury, direct or direct, or for damages and/or failures caused by improper mache design, application, stallation, operation, abuse and/or misuse of its products. Intralox does not warrant that the design and/or operational function of any mache that corporates and/or tends to corporate Intralox products, conforms to any local, state and/or federal regulations and standards relatg to public safety, worker safety, safety guards, sanitation safety, fire safety or any other safety regulations. All purchasers and users should consult their appropriate local, state and federal safety regulations and standards. Flaable: Intralox products are made of plastic and are flaable. If exposed to open flame or to temperatures above Intralox specifications, these products can burn and may emit dangerous and toxic fumes. Do not expose Intralox conveyor beltg to extreme temperatures or open flame. Prior to stallg, aligng, cleang, lubricatg, or performg matenance on any conveyor belt, sprocket or system, consult the federal, state, and local regulations your area regardg the control of hazardous energy (lockout/tagout). USING THIS MANUAL The recoendations provided the Design Guideles have proven successful for most stallations. Failure to follow the guideles presented this manual can result improper performance of ThermoDrive beltg. For extreme or unique conveyor designs or detailed assistance when considerg ThermoDrive solutions, contact Intralox for assistance. See contact formation on the back cover. PATENTS ThermoDrive technology combes flat, homogeneous, thermoplastic material and the positive drive feature of modular plastic beltg with a unique, patented drive engagement solution. This patented combation creates a one-of-a-kd tensionless belt system. manufactures ThermoDrive products under the followg patents: ; ; ; ; ; ; ; ; Other U.S. and foreign patents pendg. For a current list of patents, visit 3

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6 INTRODUCTION ABOUT INTRALOX With more than 40 years of experience, Intralox contues to lead the way helpg customers achieve their goals by offerg comprehensive conveyance solutions that create significant economic value. Intralox delivers novative, premium technology with a direct busess model and a global, dustry-specific structure. Our dustry-specific teams have an -depth knowledge of customer applications, provide technical support and consultg, and offer 24/7 customer service. Workg with Intralox allows you to experience our uncompromisg coitment to providg solutions and solvg customer challenges. As the pioneer of hygienic conveyance, Intralox delivers results that matter to our customers. We provide reliable, predictable operational performance; dramatic reductions cost; a competitive edge challengg markets; and the highest standard food safety risk management. We contue to go beyond dustry standards with new products, equipment, solutions, and services. Our coitment to novation has led to over 800 patents currently force around the world. When our customers have challenges, we vent smart solutions to meet them. INTRALOX HYGIENIC SYSTEM Contact Intralox to fd out how our complete hygienic system can meet your toughest hygienic challenges. Hygienic belts and components, like our ThermoDrive products, that optimize belt performance usg patented, tensionless technology Research and development through ongog testg by traed dustry experts and global collaboration with customers Consultg, education, and trag available to enhance customer sanitation, quality, engeerg, and operations leadership food safety applications Customer support from award-wng technically traed experts 5

7 INTRODUCTION CUSTOMER RESOURCES For extreme or unique conveyor designs or general assistance when considerg ThermoDrive solutions, contact Intralox for assistance. See contact formation on the back cover. ENGINEERING ASSISTANCE AND DESIGN REVIEW: Intralox can provide engeerg assistance, design reviews, and computer analytics for specific applications. Specific belt and drive calculations, as well as component requirements and suggestions can be provided. CAD DRAWING FILES: AutoCAD.DXF files for ThermoDrive sprockets and limiters are available. The files conta product details that can be used CAD conveyor designs. Visit for files. HYGIENIC CONSULTING AND EDUCATION: Coercial Food Sanitation, an Intralox company, tegrates strategic consultg, expertise, and trag programs to provide durable solutions to food safety and sanitation challenges for food processg plants across the globe. For more formation, visit PRODUCT LITERATURE: Intralox offers additional technical and struction documents for some products listed this manual. Visit or contact Intralox for downloads. COMPANY, PRODUCT, AND APPLICATION INFORMATION: For formation on Intralox, product features, and product applications, visit See for ThermoDrive Installation and Matenance manuals. 6

8 INTRODUCTION THERMODRIVE TENSIONLESS BELT SYSTEM Intralox ThermoDrive technology combes homogeneous thermoplastic material and the positive drive feature of modular plastic beltg with a unique, patented drive engagement solution. This combation creates a one-of-a-kd tensionless belt system that provides exceptional customer value. It elimates the costs and complex adjustments associated with managg a tensioned positive drive or flat belt system. It provides reliable, predictable drive performance and reduces costs with extended belt life, mimal component wear, and improved yield. ThermoDrive technology provides new opportunities hygienic conveyance design. The lightweight, loose conveyor fit makes belts easy to lift and to clean. The open access component and conveyor design possibilities allow cleang place without conveyor adjustment. The homogenous flat belt makes it easy to wipe down for quick product changes and offers fast dryg capabilities. 7

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10 Design Guideles 11

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12 CONVEYOR DESIGN DESIGN CONSIDERATIONS The Intralox ThermoDrive tensionless belt system offers various belt styles, materials, and colors. Once a belt is selected, many fabrications choices like perforations, grooves, flights, and sidewall are available. To make the appropriate selections when designg for a particular application, consider operatg and environmental conditions for the application, like the followg. Conveyance requirements: horizontal, elevatg, clg Overall dimensions of the stalled belt Speed of belt travel Product beg conveyed: weight, shape, size, temperature, moisture content, texture, stickess Processes: heatg, coolg, washg, rsg, drag, dryg, cleang Hygienic and cleang requirements Operatg environment: temperature, humidity, chemical nature, abrasive nature Drive system type Facility or space limitations Information contaed this manual covers the basic conveyor design guideles for the ThermoDrive tensionless belt system sold by Intralox. These general recoendations work for most applications, but contact Intralox for dustry-specific suggestions to ensure success for your application. THERMODRIVE DESIGN PRINCIPLES Never drive ThermoDrive beltg with tension. Never pre-tension ThermoDrive belts. Ensure the belt has extra length and hangs loose the return path. See Catenary Sag on page 37. Install position limiters correctly and rigidly to ensure ThermoDrive tensionless operation. Carefully choose shoe limiters, rollers, or other components to ensure belt engagement at sprockets. Install position limiters on a rigid structure and align them with drive sprockets. Install the ThermoDrive Tensionless Drive Engagement Unit for guaranteed optimal performance. Prevent the belt from bendg tighter than the stated mimum bend radius. Ensure all transitions, rollers, wheels, and sprockets are at or above the mimum bend radius. See Product Le, Belts on page 57. Lock sprockets, rollers, or support wheels place on shafts at the drive and idle ends. NOTE: Retrofit projects may prohibit usg all the ThermoDrive design features required for optimal performance. But, the ThermoDrive design prciples must be followed. Contact Intralox Customer Service for application-specific suggestions. 13

13 CONVEYOR DESIGN D E F G H H D I Typical Components A. Position limiter B. Drive sprocket C. Belt accumulation D. Contament block E. ThermoDrive belt F. Drive bars G. Carryway support H. Returnway support I. Support wheels Figure 1 A B C NOTE: Actual number and type of position limiters (A) can vary from illustration. Desired location of contament block (D) may vary from illustration. See for ThermoDrive Installation and Matenance manuals. THERMODRIVE HYGIENIC RECOMMENDATIONS Implementg the ThermoDrive Design Prciples and other design considerations this document allows optimal ThermoDrive operational performance. Usg the hygienic recoendations provided also improves sanitation and mimizes the hygienic risks herent food conveyance equipment. HYGIENIC DESIGN PRINCIPLES Understand and follow reputable hygienic design prciples, standards, and guideles, as well as regulatory requirements, when designg ThermoDrive conveyor systems for food dustry applications. Coercial Food Sanitation L.L.C., an Intralox company, promotes these design prciples, standards, and guideles durg offered hygienic design classes, and through direct support efforts with food dustry-based clients. Design equipment from compatible and non-toxic materials. Materials must withstand the tended sanitation and production processes, the food product produced, and the processg environment. Design equipment for sanitary operational performance. Design and construct equipment to facilitate matenance and sanitation. Keep structures as simple as possible to provide open access to all areas durg sanitation. Mimize toolg required for spection, matenance, and sanitation protocols. Avoid fasteners when possible, or at mimum, product contact areas or above the exposed product contact surfaces. Prevent cross-contamation by providg self-storage for parts durg disassembly. Ensure related facility equipment systems are hygienically compatible with conveyors. Ensure adequate conveyor clearance from environmental surfaces and other processg equipment. Avoid plated, pated, and coated surfaces when possible. Consider the hygienic design of all enclosures and utilities. 14

14 CONVEYOR DESIGN Design and construct equipment to prevent the gress, survival, and multiplication of microorganisms. Prevent liquid collection by designg components to self-dra. Elimate hollow fabrication when possible, or at mimum, at or above the exposed product contact areas. Elimate niches, butt jots, lap jots, and the use of fasteners when possible. Ensure jots and welds are flush, smooth, and free of pits, cracks, and corrosion challenges. Ensure ternal corners of less than 135 degrees have a mimum (3 ) radius. Avoid designs with sleeved assemblies or press- or shrk-fit designs when possible. NOTE: More hygienic recoendations are provided throughout the Design Guideles. HYGIENIC STANDARDS RESOURCES Refer to the most currently developed sanitary standards and formation from organizations like the followg when implementg ThermoDrive design guideles to meet strict hygienic standards. American Meat Institute (AMI) Grocery Manufacturers Association (GMA) 3-A Sanitary Standards, Inc. European Hygienic Engeerg and Design Group (EHEDG) NSF International Food Safety and Health Sciences Divisions NOTE: Consider consultg the followg standards: EN , NSF 14179, EC 852/2004, and EC 853/

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16 CONVEYOR FRAME DESIGN DIMENSIONS Certa dimensions are required on all conveyors usg ThermoDrive beltg. Design the conveyor frame dimensions based on the chosen ThermoDrive belt series and sprocket size. See Conveyor Frame Dimension Guideles on page 17 to determe the required dimensions. See ThermoDrive Hygienic Recoendations on page 14. B A C A. Distance between the sprocket shaft centerle and the top of the carryway. B. Distance between the sprocket shaft centerle and the begng of the carryway. C. Distance between the top of the carryway and the top of the returnway. Figure 2 S8026 Conveyor Frame Dimension Guideles S8026 Sprocket Description Pitch Diameter Outer Diameter No. of A B C teeth S8050 Conveyor Frame Dimension Guideles S8050 Sprocket Description Pitch Diameter Outer Diameter No. of A B C teeth

17 CONVEYOR FRAME DESIGN FRAMEWORK ThermoDrive tensionless belt systems require a conveyor framework appropriate for a loosely fitted belt. The design should clude open spaces and mimal jots for appropriate sanitation and matenance based on the application. Ensure the frame design allows for belt liftg and cleang at the conveyor or endless belt removal for easy conveyor cleang. Ensure the conveyor frame allows for belt stallation and future repairs. For example, ensure enough area above the carryway for belt splicg. Or, provide a cantilevered or break-away support design the conveyor for endless belt stallation. Framework Component Data Components Recoended Material Surface Fish Conveyor framework the product contact area 316 or 304 staless steel Not to exceed Ra32 micro-ches (Ra0.8 ) Conveyor framework structural members and guards outside the product contact area 304 staless steel Not to exceed Ra125 micro-ches (Ra3.2 ) HYGIENIC RECOMMENDATIONS Review Hygienic Design Prciples before followg these recoendations. See Hygienic Design Prciples on page 14 General Framework Keep frame construction as simple as possible. Use chemically resistant materials. Use solid round or angled profiles when possible. Use square profiles only when placed at an angle so water dras fully. Elimate hollow tube and non-hermetically sealed standoffs when possible at least at or above the exposed product contact areas. Fully seal hollow fabrication with contuous welds to prevent terior contamation if needed. Avoid tappg or drillg hollow frame components. Fully weld connections with a mimum (3 ) radius. Elimate exposed threads, niches, butt jots, and lap jots. Grd flush all product contact surface welds. Polish all external surfaces to the needed Ra usg hand polishg techniques, bead blastg, or electro-polishg. Passivate (pickle) the surface when required to meet requirements. Install simple belt liftg and idle shaft removal mechanisms for easy access to all frame parts under the belt and side the frame for cleang, sanitation, and spection. Periodically spect the conveyor frame for wear marks, pittg, and crackg. Frame Supports Mimize support leg quantity and raise conveyor cross members where possible. Design a mimum 18 (457 ) clearance between the floor and a direct product contact surface. For example, the product contact side of belt while returng under the conveyor and all guide rollers that contact that side of the belt. Design a mimum 12 (305 ) clearance between the floor and the bottom of lower conveyor framework. 18

18 CONVEYOR FRAME DESIGN Design leg connections without niches, butt jots, or lap jots and use high-quality welds. Design threaded leg adjustments one of two ways. Use only ternal threaded leg adjustments that can be fully hermetically sealed, but do not penetrate the primary hollow tube support. Use external leg adjustments with full external and cleanable surfaces. Design portable conveyors with standoffs fully welded between legs (just above casters) and top plates. Slope the top plate ( ) for draage. Consider the followg designs for stallg conveyor feet or pads to the floor. Design equipment leg and foot mounts on elevated masonry piers with sealant under feet. If boltg feet directly to the floor, choose flat foot pads without concave voids. Use mimal fasteners, a compatible sealant, and frequent deep cleang. Design solid staless steel legs without feet to be stalled with a solid masonry floor with properly rated masonry grout (not appropriate with floor coatgs on masonry or some tile applications). 19

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20 DRIVE END DESIGN ThermoDrive beltg can be driven several ways. By shafts, sprockets, and patented position limiters By motorized pulleys with Intralox-approved drive geometry and position limiters By the patented Tensionless Drive Engagement Unit Dependg on the process and product, certa methods can provide a more hygienic solution. DRIVE SHAFT Square shafts provide maximum efficiency drivg the belt. Square shafts allow the positive transmission of torque to the sprockets without keys and keyways. They also allow lateral movement of sprockets to accoodate the herent differences thermal expansion or contraction between plastics and metals. For customized Intralox square shaft options, see Product Le, Drive and Idle End Components on page 77. Choose square shafts made of 303, 304, 316, or 17-4 PH staless steel. Fasten shafts to the conveyor frame level and square with the belt path. Further adjustment is not required. Choose the standard 1.5 (40 ) shaft to ensure enough rigidity to mimize deflection most applications. Reta all drive sprockets on the shaft. When usg retaer rgs, ensure shaft corners are grooved. For retaer rgs and sprocket spacers, see Product Le, Drive and Idle End Components on page 77. Use heavy-duty split retaer rgs as needed. B C A E D F A. Shaft B. Bearg journal C. Square section (distance between beargs) D. Drive end journal E. Retaer rg groove F. Keyway for driver hub (not required on idle shaft) Figure 3 21

21 DRIVE END DESIGN DRIVE SPROCKETS Choose sprockets based on ThermoDrive belt pitch and hygienic requirements. Design the drive system with the followg stallation requirements md. I nstall sprockets with a (13-38 ) dent from the belt edge to the sprocket tooth outside edge. Keep dent as narrow as possible. F or flighted belts, mata a maximum 0.5 (13 ) dent from the belt edge and a large belt flight dent to achieve the required clearances. F or ThermoLace belts, mata a mimum 1 (25 ) dent from the belt edge to prevent catchg ThermoLace edges. Figure 4 Install sprockets so lateral movement is limited to +/ (3.2 ) CVY-15_v3 P osition sprockets as syetrically as possible with a maximum 3 (76 ) centerle spacg. Consider sprocket spacers place of retaer rgs between sprockets. P revent the belt from bowg more than 0.08 (2 ) between sprockets durg operation by addg sprockets. Figure 5 C onsider usg stacked sprockets heavily-loaded applications or when precise scrapg CVY-37_v1 is critical (Figure 6). Figure 6 HYGIENIC RECOMMENDATIONS U se ThermoDrive EZ Clean sprockets designed for self-drag and spray-through CVY-36_v1 sanitation. This style is especially well-suited for clean place systems. Use Intralox sprocket spacers for a more hygienic spaced sprocket solution. Ensure clean place systems are designed so spray fully covers the sprockets. 22

22 DRIVE END DESIGN DRIVE PULLEYS Choose motorized pulleys considerg the followg guideles. Contact the Intralox Customer Service for approved pulley manufacturers and pulley evaluation suggestions. Choose a rigid full-width drive meetg ThermoDrive specifications with non-pliable teeth. Ensure the pulley surface has good wear resistance characteristics and exhibits a coefficient of friction (COF) of 0.35 or less agast beltg. For example, the structure can be made of acetal, ultra high molecular weight polyethylene res (UHMW-PE), 304 or 316 staless steel, or covered a hard polyurethane shell. A polyurethane shell of adequate hardness wears quickly and shortens the life of the motorized pulley. HYGIENIC RECOMMENDATIONS Use full width, contuous drive geometry to mimize jots and crevices. Ensure pulley surface materials are approved for product contact by regulatory agencies. Ensure the drive assembly has mimal exposed fasteners and uses a food-grade lubricant. Set shaft ends slots for easy unit disassembly or removal for cleang. POSITION LIMITERS Patented ThermoDrive tensionless operation requires the use of position limiters the form of curved shoes, circular rollers, scrapers, or other novative designs. Position limiters ensure proper, contuous engagement between ThermoDrive belts and drive sprockets without usg tension. For design and dimension specifics about Intralox shoe-style position limiters and available rollers, see Product Le, Drive and Idle End Components on page 77. Contact Intralox Customer Service for application-specific suggestions. POSITION LIMITER CHOICES For ideal end drive design, use concave, shoe-style position limiters that span a mimum of three S8026 drive bars (Figure 7) or two S8050 drive bars (Figure 8). Only use rollers or scrapers as limiters certa applications. Use rollers as limiters only for abrasive or lightly-loaded, end drive applications. Mount roller limiters on a shaft supported by ball beargs. Use rollers for center drive applications. See Position Limiter Position by Drive Type on page 26. Use scrapers as limiters only very lightly-loaded applications. See Belt Scraper on page 28. Ensure limiter belt contact surface material is UHMW-PE; never use a limiter with an acetal contact surface. POSITION LIMITER ALIGNMENT AND SPACING Ensure limiter mountg structures are rigid enough to handle about 40% of the belt load. For example, prevent the mountg beam or crossbar from deflectg more than 0.05 (1.25 ) under a uniformly distributed load of 40% of the calculated belt pull. Align limiters with drive sprockets so they can support the seated belt (Figure 12). 23

23 DRIVE END DESIGN Place shoe-style limiters with a ( ) spacg between the seated belt and the limiter (Figures 7 and 8, A). Limiters too far from the belt cause belt engagement issues. Ensure limiters do not exert pressure through the belt and onto the sprockets. Limiters pchg the belt agast the drive sprocket can cause termittent drive disruption or noisy drive operation. A A Figure 7 Figure 8 Set roller limiters with a maximum 0.02 (0.5 ) spacg between the seated belt and the roller (Figure 9). Keep a sprocket tooth beneath the belt when settg the roller limiter (Figure 9). If the gap between sprocket teeth is under the roller durg stallation, the roller can be stalled too close to the sprocket. This can cause belt pchg at startup and belt damage (Figure 10). Figure 9 Figure 10 Plan to make periodic spections for secure limiter mountg and limiter wear. Adjust position limiters as needed. 24

24 DRIVE END DESIGN BELTS WITHOUT ACCESSORIES P lace the limiter support structure laterally across the belt width and parallel to the drive shaft (Figure 11). or spaced or stacked sprockets, align limiters with sprockets with a maximum 3 (76 ) F centerle spacg (Figures 11 and 12). Figure 11 Figure 12 BELTS WITH ACCESSORIES CVY-15_v3 Align a limiter with each outermost drive sprocket (Figures 12 and 13). E nsure a (3.2 ) clearance between the belt edge and contament components. Ensure a 0.25 (6.4 ) clearance between flight or sidewall edges and limiter edges. Figure CVY-21_v3 25

25 DRIVE END DESIGN POSITION LIMITER POSITION BY DRIVE TYPE END DRIVE Ideal end drive design allows the belt to pull at the full load ratg with a belt wrap of degrees. Use the followg recoendations for position limiter types and locations end drive designs. Use shoe or roller limiters lightly-loaded applications. Use shoe limiters heavily-loaded applications. Place limiters degrees from the top of the sprocket (Figure 14, 0 degrees) the direction of travel to ensure ideal belt wrap for uni-directional applications (Figure 14). If the position limiter cannot be placed at degrees, place it degrees from the top (Figure 15). Ensure the belt wrap does not exceed 180 degrees (Figure 15) Figure 14 0 A B A. Mimum belt wrap B. Maximum belt wrap 120 Figure

26 DRIVE END DESIGN CENTER DRIVE For center drive designs, use the followg recoendations for sprocket and position limiter types and locations. Figure 16 Use a center drive sprocket with a mimum of 10 teeth (Figure 16). Use roller limiters for center drive applications (Figure 16). Use full-width roller limiters for most belts. For flighted or sidewall belts, align roller limiters with the outermost sprockets. Also, align a sprocket and limiter at the flight notch if possible. Ensure a clearance of 0.25 (6.4 ) between roller limiters and flight or sidewall edges. Use roller limiters to achieve a 90-degree belt wrap (Figure 17). This also provides a compact drive system. Ensure roller limiter diameters meet or exceed the belt mimum backbend diameter. For a bi-directional drive, place roller limiters at the 135-degree and 225-degree positions from top center (Figure 17) Figure

27 DRIVE END DESIGN For a uni-directional drive with the drive near the discharge end, place one roller limiter where the belt should first contact the sprockets. Then, place a second roller limiter about 90 degrees from the first (Figure 18). 90 Figure 18 For a belt with flights, contact Intralox Customer Service for application-specific suggestions. HYGIENIC RECOMMENDATIONS Design position limiter mountg without niches, butt jots, lap jots, and fasteners when possible. Ensure component materials are approved for product contact by regulatory agencies. Consider usg the ThermoDrive Tensionless Drive Engagement Unit for optimal hygienic and operational performance. BELT SCRAPER Include a scraper with ThermoDrive belt conveyor applications to remove product residue automatically durg operation. For effective cleang operation, use the followg guideles. NOTE: Worn or deflectg scrapers reduce operational performance. This can reduce product yield, limiter effectiveness, and scrapg efficiency. SCRAPER DESIGN CONSIDERATIONS To optimize scraper performance, consider temperature variations, product to convey, scraper deflection, scraper wear, and other criteria durg design. Use solid UHMW-PE scrapers most applications. Only use soft, polyurethane-tipped scrapers consistently wet or greasy applications. Scrapers can wear prematurely or deteriorate agast extended lengths of dry belt. Ensure the scraper tip is designed to rema straight and conform to the belt surface. Consider mimizg sprocket spacg, usg stacked sprockets, or usg full-width pulley with a scraper to prevent belt deflection between sprockets. This can improve scrapg and sanitation especially heavily-loaded applications. Ensure the scraper and mountg fixture are rigid enough to prevent deflectg more than 0.01 (0.3 ) from the belt center durg operation. Design the scraper to be mounted at an angle for maximum cleang performance (Figure 19). Do not mount the scraper vertically. 28

28 DRIVE END DESIGN Keep a sprocket tooth beneath the scraper when mountg, as with rollers (Figure 9 and 10), to prevent belt pchg at startup. Pchg can cause belt damage and creased scraper wear. With ThermoLace beltg, use a scraper 2 (51 m) shorter than the belt width to prevent catchg ThermoLace edges. Ideal ThermoLace scraper width: Scraper Width=BW-2 (51 ) Figure 19 HYGIENIC RECOMMENDATIONS Use scraper materials approved for product contact by regulatory agencies. Use scraper material compatible with coon cleang chemicals for the application. Design self-adjustg scraper systems with mimal fasteners the food stream and easy removal and replacement without tools durg sanitation. Elimate any niches or collection pots that can harbor bacteria. SCRAPER ACTING AS A LIMITER CONSIDERATIONS Use scrapers as limiters only very lightly-loaded applications. If the scraper is designed to act as a limiter, mount the scraper place and mimize scraper deflection. See Position Limiter Alignment and Spacg on page 23. Plan to make regular adjustments as the scraper wears durg use. Design the scraper tip to contact the belt degrees from the top of the sprocket (Figure 14, 0 degrees) the direction of travel. If the position limiter cannot be placed there, place it degrees from the top (Figure 19). 29

29 DRIVE END DESIGN THERMODRIVE TENSIONLESS DRIVE ENGAGEMENT UNIT Consider cludg the ThermoDrive Tensionless Drive Engagement Unit conveyor designs. This patented, pre-assembled drive engagement solution precisely places position limiters to guarantee optimal ThermoDrive belt performance new and retrofit designs. The optional scraper assembly is ideally designed for effective scrapg a compact design. Tool-free assembly and disassembly of engagement components provides creased cleang efficiency and sanitation. D E Typical Components A. Bearg assembly B. Frame C. Sprockets D. Bearg E. Drive shaft F. Handle G. Smart bar H. Scraper mount (optional) I. Position limiter J. Scraper assembly (optional) C B A J Figure 20 F G H I TDEU-35_v2b Rev Choose sprockets with a square shaft. Choose stacked sprockets (Figure 21) for heavily-loaded applications. Choose spaced sprockets (Figure 22) for lightly-loaded applications. Figure TDEU-40_v1 Figure 22 Use only compatible style sprockets with the engagement unit TDEU-41_v1 Use the self-adjustg scraper assembly with Flat Top belts. For more choices, see Product Le, Drive and Idle End Components on page 77. Contact Intralox for the most up-to-date offergs of the engagement unit. HYGIENIC RECOMMENDATIONS U se a scraper assembly for contuous belt residue removal to reduce cleang frequency. 30

30 IDLE END DESIGN ThermoDrive tensionless belt systems can have one or more idle ends dependg on the drive location. Adjustable idle shafts are often used ThermoDrive stallations to allow cremental shaft movement for controllg the amount and position of loose belt the returnway. Ability to move the shaft can simplify belt stallation, sanitation, and repair, but should not be used to pre-tension the beltg. When designg an adjustable idle shaft, ensure the followg. Only plan to adjust the idle shaft position for mor belt path position adjustments. Most applications require less than 6 (152 ) of adjustability. Elimate all belt tension for proper operation and effective cleang and sanitation. IDLE SHAFT Choose between round and square shafts made of 303, 304, or 316 staless steel for idle ends. Use dynamic components when possible to reduce friction the system. Either mount idle components on a rotatg, square shaft or mount rotatg components on a fixed, round shaft. Use a square shaft with ball bearg supports for heavily-loaded applications. Fasten shafts to the conveyor frame level and square with the belt path. Further adjustment is not required. Plan to use retaer rgs or sprocket spacers with spaced idle components. See Product Le, Drive and Idle End Components on page 77. SPROCKETS, WHEELS, AND ROLLERS Contact Intralox Customer Service for application-specific suggestions. CONVEYOR INFEED FOR END OR CENTER DRIVES Mount rollers or wheels to a square or keyed shaft with ball beargs heavily-loaded applications. Only use compatible components together. Mount 1 (25 ) or wider rollers or wheels with a maximum 6 (152 ) centerle spacg. Mount components with a maximum 1.5 (38 ) dent from the belt edge to the component outside edge. Ensure the component diameter meets or exceeds the mimum acceptable sprocket diameter. If small transitions are required, consider these options. Lock sprockets (rather than rollers) on a rotatg shaft to mimize vibration. Use thner belt material. Place support rails or similar at the returnway iediately before the pulley (Figure 23) to control belt position. Use UHMW-PE materials when possible. Figure 23 31

31 IDLE END DESIGN CONVEYOR OUTFEED FOR CENTER DRIVES Mount 1 (25 ) or wider sprockets with a maximum 3 (76 ) centerle spacg for lightly-loaded applications. Install sprockets with a (13-38 ) dent from the belt edge to the sprocket tooth outside edge. For heavy loads, consider stacked sprockets or a full-width idle roller. Mount sprockets to a square or keyed shaft with ball bearg supports that accoodate the expected shaft load. Journal bearg designs can be suitable some applications. Contact Intralox Customer Service for application-specific suggestions. Use UHMW-PE materials when possible. HYGIENIC RECOMMENDATIONS Ensure component materials are approved for product contact by regulatory agencies. Elimate ball beargs at the idle section on an end drive or unidirectional center drive conveyor (allowed because of tensionless design). Choose one of the followg idle end designs A full-width, UHMW-PE idle roller UHMW-PE wheels rotatg on a fixed, round 316 staless steel shaft UHMW-PE wheels fixed on a rotatg, square 316 staless steel shaft with UHMW-PE journal beargs Use Intralox sprocket spacers for the most hygienic spaced sprocket or wheel solution. Design the adjustable idle section to be mounted with mimal fasteners, threaded rods, and tools. For example, clude equally spaced slots for idle shaft mountg to ensure easy disassembly or removal durg cleang and sanitation. Ensure clean place systems are designed so idle shaft components receive full spray coverage. 32

32 CARRYWAY DESIGN ThermoDrive belts can be supported by carryways of various materials and arrangements. Design carryways as a contuous runng surface with low friction to reduce belt wear and consider the followg guideles. Consider thermal expansion and contraction of materials when assessg components, dimensions, and locations. See Belt and Component Dimension Changes on page 47. Calculate a full range of mimum and maximum belt lengths and widths with consideration of belt dimension changes when designg carryways. See Belt and Component Dimension Changes on page 47. Consider belt contament options before designg the carryway. SUPPORT RAIL GUIDELINES The most coon carryway support components the field for ThermoDrive beltg are UHMW-PE support rails or wearstrips. See Product Le, Carryway and Returnway Components on page 93. Use rails with a smooth surface fish not exceedg Ra125 micro-ches (Ra3.2 microns). Ensure cut ends and edges are smoothed before use. Avoid fasteners or keep fasteners out of the belt path by counterskg or similar. Consider thermal expansion and contraction of material when assessg rail lengths and fastener locations. See Belt and Component Dimension Changes on page 47. Never use acetal or high-density polyethylene (HDPE) support rails. Avoid use of UHMW-PE products facility temperatures above 160 F (71 C). NOTE: For retrofits, 300 Series, flat staless steel bars can be used for belt support certa lightly-loaded and low-speed applications. Do not use round supports. Contact Intralox Customer Service for application-specific suggestions. STRAIGHT, PARALLEL ARRANGEMENT Support rails or wearstrips are most coonly stalled a pattern of straight, parallel lengths for carryway support usg these guideles (Figure 24). A B A. Belt travel B. Gap for thermal expansion C. Jot stagger of the rail C Figure 24 33

33 CARRYWAY DESIGN Use flat rails with a mimum 1 (25 ) width. Design outermost rails a maximum 0.5 (13 ) from the belt edges. Design rails with a maximum 6.0 (152 ) centerle distance between rails. Chamfer all rail jots, cut edges, and sharp corners to elimate catch pots and allow smooth belt transitions. Chamfer feed and outfeed ends to prevent drive bar catch pots, vibration, and component damage. Consider thermal expansion and contraction of UHMW-PE wearstrips at operatg temperatures to ensure a proper gap between ends. Stagger rail jots to mimize drive bar catch pots. Consider usg a solid UHMW-PE carryway bed at feed or loadg areas to address product impact. Contact Intralox Customer Service for heavily-loaded application-specific suggestions. ANGLED CHEVRON ARRANGEMENT Support rails and wearstrips can be stalled a chevron pattern for certa applications and retrofit projects usg these guideles (Figure 25). Placg rails this overlappg V pattern fully supports the width of the belt as it moves along the carryway. The angled surfaces can also help remove gritty or abrasive material from the belt bottom. Figure 25 D C B A. Belt travel B. Rail angle from centerle: degrees C. Rail maximum centerle spacg: 5.2 (132 ) D. Spacg between rails: mimum 0.4 (10 ) Use flat rails with a mimum 1.25 (32 ) width and stall the modified flat rails a chevron pattern. Set a maximum 5.2 (132 ) centerle spacg between rails (Figure 25, C). Mata a mimum 0.4 (10 ) spacg between rails at the chevron center to reduce debris buildup (Figure 25, D). Chamfer all rail jots, cut edges, and sharp corners to elimate catch pots and allow smooth belt transitions. Chamfer feed and outfeed rail ends to prevent drive bar catch pots, vibration, and component damage. Consider usg an angled (L-shaped) UHMW-PE contament rail at belt edges to assist with contament. Ensure a mimum 0.75 (19 ) vertical surface. Contact Intralox Customer Service for heavily-loaded application-specific suggestions. 34

34 CARRYWAY DESIGN CARRYWAY WITH FLIGHTS, SIDEWALLS, OR FLIGHT NOTCHES For flighted or sidewall belts, consider these additional carryway design guideles. Order belts with a mimum 1.25 (33 ) flight or sidewall dent. Order center notches on belts with flights wider than 24 (610 ). This enables smooth belt transitions. Plan to use position limiters at flight notches on the drive end. Align the sprocket, notch, and limiter. Do not use hold down shoes or similar for belt contament purposes. Ensure a mimum 0.25 (6.4 ) clearance between components and flight or sidewall outside edges. Ensure a mimum (3.2 ) clearance between components and flight or sidewall edges. Use belt support, like UHMW-PE hold down components, at all transitions. For flighted or sidewall belts a Z-Conveyor (like an Incle-to-Packagg application), contact Intralox Customer Service. HYGIENIC RECOMMENDATIONS Use only solid profile support rails. Elimate niches, butt jots, lap jots, and the use of fasteners when possible. Ensure component materials are approved for product contact by regulatory agencies. Design carryways for easy, tool-free disassembly and reassembly durg sanitation. Consider a syetrical design to prevent errors durg reassembly. For example, consider creatg grooves wearstrips for stallation on round supports (Figure 26). Plan for component thermal expansion and contraction when designg grooves. Figure 26 Conceptual illustration 35

35

36 RETURNWAY DESIGN The returnway of a tensionless conveyor with patented ThermoDrive technology is very important to the overall design. The belt is designed to be stalled and naturally operate with loose beltg. A properly designed returnway with proper belt stallation allows tensionless operation, enables belt liftg and access for sanitation, and controls the natural belt accumulation for belt length changes. Design the returnway usg the followg guideles. Consider thermal expansion and contraction of material when assessg rail lengths and fasteners. See Belt and Component Dimension Changes on page 47. Calculate a full range of mimum and maximum belt lengths and widths before designg belt support, contament, and accumulation. See Belt and Component Dimension Changes on page 47. BELT ACCUMULATION CATENARY SAG Loose belt the returnway hangs and assumes the shape of a curve called catenary. Curve dimensions are based on the distance between supports, the length of hangg belt, and the belt weight. Consider the amount of loose belt stored the returnway to prevent belt contact with obstacles like drip pans, frame supports, fasteners, and wirg. Use returnway support components to control the locations, lengths, and depths of sags. BELT ACCUMULATION Loose belt naturally accumulates the largest unsupported area the returnway iediately followg the drive sprockets (Figure 27) or at the lowest section of cled conveyors. Figure 27 To change the belt accumulation location, design a long unsupported space a different area on the returnway. Consider the optimal belt accumulation location when designg the returnway. Prevent contact between belt and obstacles like drip pans, frame supports, fasteners, and wirg. 37

37 RETURNWAY DESIGN B A Figure 28 Consider the distance required between returnway components to accoodate belt accumulation. Ensure the belt accumulation area length is a mimum of 30 (762 ) and a maximum of 6 ft (1.8 m) most applications (Figure 28, A). Determe the approximate catenary sag vertical clearance needed when designg the returnway. See Catenary Sag Clearance Reference a on page 38. Catenary Sag Clearance Reference a Length of Unsupported Area (Figure 28, A) Typical Vertical Clearance b, c (Figure 28, B) ft cm Up to 2 ft ft ft ft ft a. For horizontal returnways; contact Intralox Customer Service for other returnway styles b. For belts without vertical accessories; for belts with flights or sidewalls, add the height of the tallest accessory to the dicated clearance dimension c. The typical total clearance allows for a range of possible belt sags when the belt is the correct length for optimal operation; the actual clearance needed may be less based on the application Expect the sag depth to vary durg conveyor operation based on belt speed, temperature changes, and load changes. NOTE: To verify tensionless belt operation, stop the conveyor and shift the belt sideways at the feed idle end. The belt should move without effort. Contact Intralox Customer Service for application-specific suggestions. 38

38 RETURNWAY DESIGN RETURNWAY SUPPORT GUIDELINES A conveyor returnway can clude various framework styles with components like contuous rails, termittent wear shoes, and rollers (Figure 29). ThermoDrive tensionless belt systems can use a combation of contuous and termittent support. Dependg on the conveyor, multiple belt accumulation areas can be required to store the belt properly. Sag might not distribute evenly all unsupported areas. See Belt Accumulation on page 37. Returnway support can be dynamic, like rollers, or static, like shoes or rails, dependg on the application. A A. Contuous rail B. Wear shoe C. Roller B C Figure 29 CONTINUOUS RAILS Design support rails with a maximum 12 (305 ) lateral centerle distance between rails. Design outer rails 2-3 (51-76 ) side the belt edge for most belts. See Returnway with Flights or Sidewalls on page 40. Include a mimum of one unsupported area between contuous rail ends to accoodate loose belt. Figure 30 39

39 RETURNWAY DESIGN INTERMITTENT SUPPORT (WEAR SHOES AND ROLLERS) Mount belt support components that span the full belt width when possible. Design supports with a maximum 72 (1829 ) distance along the conveyor length for most applications (Figure 31, A). For example, design a support every 36 (914 ) along the returnway with one ( ) unsupported area for belt accumulation. A Figure 31 Prevent belt damage by ensurg all belt bends are equal or larger than the mimum backbend diameter. See Product Le, Belts on page 57. Consider usg flanged rollers or shoes to provide support and conta the belt. See Belt Contament on page 43. HYGIENIC RECOMMENDATIONS Use UHMW-PE returnway components approved for product contact by regulatory agencies. Use solid UHMW-PE rollers without ball beargs for returnway support when possible. These mimize belt and component contact and the number of components. Use UHMW-PE support wheels for wide belt applications unsuitable for full-width idle rollers. Elimate niches, butt jots, lap jots, and the use of fasteners when possible. Mount components with mimal fasteners for easy, tool-free disassembly and reassembly durg sanitation. RETURNWAY WITH FLIGHTS OR SIDEWALLS For flighted or sidewall belts, consider these additional returnway design guideles. B A Figure 32 Figure 33 Use contuous support rails at belt edges for returnway support (Figure 32). Chamfer support rail feed and outfeed ends to elimate catch pots (Figure 32). Order belts with a mimum 1.25 (33 ) flight or sidewall dent (Figure 33, B). Design outer support rails or other components with a mimum 0.25 (6.4 ) clearance from flights or sidewall (Figure 33, A) CVY-07_v3 40

40 RETURNWAY DESIGN Do not allow flights or sidewalls to contact returnway rails or components. Do not use rails for belt contament purposes. For flighted or sidewall belts used a Z-Conveyor (like an Incle-to-Packagg application), contact Intralox Customer Service. RETURNWAY WITH FLIGHTS, SIDEWALLS, OR FLIGHT NOTCHES B Figure 34 A For wide flighted or sidewall belts, consider these additional returnway design guideles. Order center notches on flights wider than 24 (610 ). This enables a smooth transition of the belt on the returnway. Plan to use position limiters at flight notches on the drive end. Align the sprocket, notch, and limiter. Order belts with a mimum 1.25 (32 ) flight or sidewall dent (Figure 34, B). Design rails or other components with a mimum 0.25 (6.4 ) clearance from flight or sidewall outside edges (Figure 34, A). Design components at notches as needed with a mimum 0.25 (6.4 ) clearance between the rail and flight edges (Figure 34, C). Use belt support, like UHMW-PE hold down components, at all transitions. C 41

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42 BELT CONTAINMENT ThermoDrive belt contament is achieved along belt edges. Full-width belt drive bars on the belt bottom surface provide the lateral rigidity to conta the belt. Only conveyor contament rails, blocks, or flanged rollers are needed along path edges. NOTE: In retrofit applications, conveyor frames can be used to conta the belt some applications. Consider addg UHMW-PE components to framework to mimize belt wear. Contact Intralox Customer Service for application-specific suggestions. A Figure 35 Consider thermal expansion and contraction of material when assessg component dimensions and locations. See Belt and Component Dimension Changes on page 47. Calculate a full range of mimum and maximum belt dimensions based on facility and operatg temperatures and belt load. Use the largest belt dimensions to design a mimum (3.2 ) clearance between contament components and the belt edge on each side of the belt (Figure 35, A). C A. Required clearance B. Belt width C. Carryway support rails D. Contament components Use components made of UHMW-PE with a smooth surface fish not exceedg Ra125 micro-ches (Ra3.2 microns) to mimize belt friction. Never use components made of acetal or HDPE. Mount belt contament blocks or flanged rollers near the idle shaft (Figure 31). Then, add more contament components along the conveyor length a maximum 8 ft (2.4 m) distance apart. A B D A When usg flanged rollers, ensure a mimum 0.75 (19 ) flange height at belt edges (Figure 36, A). Ensure side flanged edges are chamfered to mimize wear. See Product Le, Carryway and Returnway Components on page 93. Figure 36 43

43 BELT CONTAINMENT Use long contament blocks or full-length or angled (L-shaped) contament rails for applications with side loadg or product divertg. Design contament blocks and rails with the followg specifications to mimize belt wear and friction. Figure 37 A B A mimum 6 (150 ) length A mimum 0.25 (6.4 ) chamfer on feed and outfeed ends (Figure 37, A) A mimum (0.8 ) corner radius to avoid belt edge damage (Figure 37, B) A mimum 0.5 (13 ) vertical height above belt edges Countersk all fasteners below contament component surfaces to prevent belt contact with fasteners (Figure 37). Design vertical contament surfaces to be parallel to the carryway and perpendicular to the belt edge (Figure 37). HYGIENIC RECOMMENDATIONS: Elimate niches, butt jots, lap jots, and the use of fasteners when possible. Mount components for easy, tool-free disassembly and reassembly durg sanitation. For example, tegrate contament to carryway guide rails, mount components on frame slots, or design them to fit on round bars the frame. Design all concave cuts with a mimum (3 ) ternal radius. Ensure component materials are approved for product contact by regulatory agencies. 44

44 TROUGHED CONVEYORS Unlike tensioned flat beltg or rigid modular beltg, ThermoDrive belts can be easily troughed for product control without sacrificg the benefits of the patented tensionless, sprocket-driven operation. There are several possible configurations. Contact Intralox Customer Service with troughed conveyor designs. Design troughed conveyors usg design guideles provided this manual and corporate the followg trough-specific guideles. Use UHMW-PE contament rails or blocks for lateral belt contament (Figure 38). See Belt Contament on page 43. Figure 38 Ensure the carryway transition distance is 1.5 times the belt width before the belt engages the drive or idle pulleys. Adequate transition distance (Figure 39) mimizes stra on belt edges and reduces belt friction. Figure 39 45

45 TROUGHED CONVEYORS CONTINUOUS CARRYWAY FOR BELTS WITH NO TROUGH GROOVE Mimum belt width and trough radius: numbers are terdependent; contact Intralox Customer Service Figure 40 Wearstrip spacg: 3-6 ( ) centers Maximum contament block spacg: 6-8 ft ( m) Mimum transition length: 1.5 x belt width V-SHAPED CARRYWAY FOR BELTS WITH ONE TROUGH GROOVE Mimum belt width: 10 (254 ) Figure 41 Standard groove width: 1.75 (44.5 ) Base belt thickness at groove: 2 Maximum angle from horizontal: 30 degrees Maximum contament block spacg: 6-8 ft ( m) Mimum transition length: 1.5 x belt width Available with notched flights For formation on S8126 troughed conveyor belt, see Product Le, S8126 Flat Top E (6.0 ) on page 68. Contact Intralox Customer Service for S8126 conveyor design and stallation specifics. For formation on ThermoDrive Trough Retofit Set, see Product Le, Trough Retrofit Set on page 95. U-SHAPED CARRYWAY FOR BELTS WITH TWO TROUGH GROOVES Standard groove width: 1.75 (44.5 ) Figure 42 Base belt thickness at groove: 2 Mimum groove center distance: 10 (254 ) Mimum section length: 4 (102 ) Maximum angle from horizontal: 60 degrees Maximum contament block spacg: 6-8 ft ( m) Mimum transition length: 1.5 x belt width Available with notched flights For trough groove and drive bar removal specifics, see Product Le, Belt Features on page

46 BELT AND COMPONENT DIMENSION CHANGES Changes load and temperature expand and contract belts and components durg operation. Ensure the correct itial belt and component dimensions when orderg. Consider the belt and component dimension changes (length and width) when designg the belt path. Cold temperatures can cause over-tensiong and excessive shaft load. Hot temperatures can cause belt storage or contact issues. BELT DIMENSION VARIATION CONSIDERATIONS Ensure contament components are designed with adequate clearance from the belt. Ensure adequate returnway supports are provided to accoodate the weight, depth, and location of belt accumulation durg expansion. Calculate the belt weight based on dimensions usg Belt Data. See Product Le, Belts on page 57. Ensure returnway obstacles like drip pans, frame supports, fasteners, and wirg do not contact the belt at maximum and mimum sizes. Ensure belt accumulation or obstacles do not apply tension to the belt. COMPONENT DIMENSION VARIATION CONSIDERATIONS Ensure holes are slotted to allow for component movement relation to fasteners. Leave adequate gaps between component jots. Consider that belts and components change simultaneously. TOTAL BELT DIMENSION CALCULATION Use the steps here to determe the total belt length for your conveyor. Contact Intralox Customer Service for calculation help. 1. Calculate the belt needed between each unsupported area the returnway. Unsupported returnway belt length formula: (2.66 S²) / D = X Where: X = belt length at chosen sag, () S = desired sag depth, () D = distance between chosen supports, () 2. Add all Unsupported returnway belt lengths (X) the returnway to calculate the Returnway belt needed (X 2 ). 3. Use the Returnway belt needed (X 2 ) to calculate the Total belt length recoended for stallation. Total belt length formula: CL + (2AC) + X 2 = TBL Where: TBL = Total belt length, () CL = Conveyor length from sprocket center to sprocket center, () AC = Belt wrap at end drive sprocket or rollers, () X 2 = Returnway belt needed, () 4. Contact Intralox Customer Service for suggested extra belt length for splicg and repair. 5. Consider all temperature changes durg the full operatg cycle (downtime, production, sanitation) to calculate mimum and maximum belt dimensions. See Thermal Expansion and Contraction Calculations on page

47 BELT AND COMPONENT DIMENSION CHANGES THERMAL EXPANSION AND CONTRACTION CALCULATIONS Always consider thermal expansion and contraction when choosg conveyor component materials, purchasg belt, and makg design choices. Dimension changes depend on product material, temperature changes durg operation, and overall dimensions. Use the followg formation to calculate mimum and maximum belt or component dimension changes durg the full operatg cycle (downtime, production, sanitation). CALCULATE FACILITY TEMPERATURE CHANGE Use the followg formula to calculate overall facility temperature change. Facility temperature change formula: T 2 T 1 = T 3 Where: T 3 = temperature change, F ( C) T 2 = application temperature, F ( C) T 1 = 72 (22), Intralox belt production temperature F ( C) CALCULATE MATERIAL DIMENSION CHANGES Use the followg formula to calculate the dimension change of belts, support rails, wearstrip, or other plastic contament components. Dimension change formula: D x T 3 x CTE = Δ Where: Δ = dimension change, imperial (metric) D = itial dimension (length or width) on leavg Intralox, imperial (metric) T 3 = temperature change, F ( C) CTE = Coefficient of Thermal Expansion Coefficients of Lear Thermal Expansion (CTE) Material Imperial Dimension (µ/- F) Metric Dimension (µm/m- C) Polyurethane HTL Cold Use UHMW-PE For example, calculate the change length of a 100 ft (30 m) long ThermoDrive 8050 polyurethane belt operatg with an average belt temperature of 45 F (7 C). Calculations Imperial Metric Temperature change (T 3 = T 2 -T 1 ) 45 F 72 F = -27 F 7 C-22 C = -15 C Initial belt length (D) 100 ft = m Length change (Δ=D x T 3 x CTE) 1200 x -27 F x 83 (µ/- F) = µ = m x -15 C x 150 (µm/m- C) = µm = BELT ELONGATION UNDER LOAD All belts temporarily stra (stretch) with load applied. The extent of change depends on belt material, load, and overall belt length. 48

48 Product Le 49

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50 BELT SELECTION VISUAL OVERVIEW Belts Series 8026 Flat Top Polyurethane (5.3 ) Series 8026 Flat Top Polyurethane (6.0 ) Series 8026 Embedded Diamond Top Polyurethane (6.3 ) Series 8026 Nub Top Polyurethane (7.4 ) Series 8026 Flat Top Cold Use (6.0 ) Series 8050 Flat Top Polyurethane (7.0 ) Series 8050 Embedded Diamond Top Polyurethane (7.5 ) Series 8050 Nub Top Polyurethane (8.0 ) Series 8050 Flat Top Cold Use (7.0 ) Series 8050 Flat Top High Temperature Heavy Load (HTL) (7.0 ) Belt Jog Methods Series 8050 Flat Top XT (7.0 ) Series 8126 Flat Top Polyurethane (6.0 ) Prepared ends Endless ThermoLace Metal Lace 51

51 BELT SELECTION Belt Fabrications Perforations Trough Grooves Drive Bar Removal 90 degree flights 75 degree flights Scoop flights Short top scoop flights Flight Gussets Sidewalls BELT SELECTION CONSIDERATIONS To select the right ThermoDrive belt, consider all of the options. 1. Choose a basic belt. Each belt description dicates several characteristics. For example, S8050 Flat Top (7.0 ) Polyurethane dicates the followg belt characteristics. The belt material is polyurethane. The belt style (surface texture) is Flat Top. The belt series is 8050, which has 50 drive pitch (distance between each drive bar). The belt thickness is 7.0. Thickness is determed by the drive pitch, material, and surface texture. 2. Based on the belt description, choose other specifics. Not all belts have the same options. Available belt jog methods Available belt features like trough grooves, drive bar removal, or perforations Available accessories like flights, sidewalls, and gussets 3. Review the followg belt selection considerations, then specific belt product formation to choose wisely for your application. Contact Intralox Customer Service for application-specific suggestions. 52

52 BELT SELECTION CHOOSE MATERIAL ThermoDrive belts and accessories are available standard polyurethane and special application materials. Polyurethane most coonly used material; available blue or white Can be used contuous temperature ranges from 20 F (-7 C) to 140 F (60 C) Dependg on belt series, style, and thickness, offers belt strengths from 175 lb/ft (260 kg/m) to 420 lb/ft (625 kg/m) Cold Use (CU) employed for ambient to very cold temperatures; provides peak performance colder environments Can be used applications with temperature ranges from 75 F (24 C) to -30 F (-34 C) Dependg on belt series and thickness, offers a belt strength of 150 lb/ft (223 kg/m) to 225 lb/ft (335 kg/m) High Temperature Heavy Load (HTL) employed for high temperatures and/or heavy loads Can be used applications with temperature ranges from 60 F (-15 C) to 210 F (100 C) Offers belt strengths up to 1056 lb/ft (1572 kg/m) XT employed for extreme temperatures high or low Can be used applications with temperature ranges from -4 F (-20 C) to 170 F (77 C) Offers belt strengths up to 800 lb/ft (1190 kg/m) CHOOSE BELT STYLE (SURFACE TEXTURE) ThermoDrive belts and accessories are available standard Flat Top surfaces and special application surfaces. Flat Top (FT) an engeered matte surface fish optimized for efficient product release and cleanability Embedded Diamond Top (EDT) a cleanable embedded diamond surface texture with superior product release characteristics Nub Top (NT) a raised top profile that provides grip characteristics with some products and release characteristics with other products; contact Intralox Customer Service for application-specific formation 53

53 BELT SELECTION CHOOSE BELT SERIES ThermoDrive belts are available with 26 or 50 nomal drive pitch. A shorter pitch reduces sprocket diameter and the space required for product transfers. A longer pitch correlates with larger transfers and sprocket diameters, thicker belts, and creased belt pull. Series 8026 and 8126 belts 26 drive pitch; often used for lightly-loaded applications and products requirg short transfer distances Series 8050 belts 50 drive pitch; often used for moderate to heavily-loaded applications where bigger transfer distances are acceptable CHOOSE BELT JOINING METHOD ThermoDrive belt ends can be joed by various methods: splicg, ThermoLace, or metal lacg. Overall belt strength is affected by the strength of jog method chosen. See Belt Jog Methods on page 69. CHOOSE BELT FEATURES AND ACCESSORIES FOR FABRICATION Special belt features are available for unique applications. Perforations belt hole pattern employed most often for hygienic dewaterg applications Trough grooves drive bar removal along the belt length that completely removes drive bar and (1 ) of the belt cover; employed to enable a deep trough for severe trough applications; not required for all trough conveyors Drive bar removal drive bar removal along the belt length that leaves about (0.13 ) of drive bar and full cover thickness Various accessories are available on certa belts. Flights vertical accessory hygienically joed across the belt width available various types, heights, thicknesses, and styles (surface textures); contributes to reliable conveyance on cle or elevator applications Flight gussets angled flight support joed to the belt to crease flight rigidity; often used heavily-loaded applications Synchronized Sidewalls vertical accessory hygienically joed along belt length available various thicknesses, heights, and styles (surface textures); employed for effective product contament 54

54 BELT SELECTION Belts, Features, and Accessories Availability Reference Material Polyurethane Cold Use HTL XT Color Blue White Blue Natural Blue Style FT EDT NT FT EDT NT FT EDT NT FT EDT NT FT EDT NT Series BTF BTF 6.0 BTF BTF BTF 6.3 BTF 7.4 BTF Series BPTFS BPTFS BTFS BT BT 7.5 BTFS 8.0 BTF Series B FT Flat Top; EDT Embedded Diamond Top; NT Nub Top B Belt available designated series, thickness, material, color, and style P Perforations available; T Trough grooves available; F Flights available; S Sidewalls available For details, see Belt Features on page 71. See Belt Accessories on page

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56 BELTS Pitch S8026 Flat Top E (5.3 ) Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (6T) Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, ThermoLace, metal lace blue, white Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Engeered matte surface is optimized for efficient product release and cleanability. Available with flights. See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (1.8 ) 1.00 NOM. (26 ) (5.3 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Polyurethane to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use over 100 F (38 C), contact Intralox Customer Service for actual belt strength. 57

57 BELTS Pitch S8026 Flat Top E (6.0 ) Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, ThermoLace, metal lace blue, white Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Engeered matte surface is optimized for efficient product release and cleanability. Available with flights. See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (2.5 ) 1.00 NOM. (26 ) (6 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Polyurethane to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use over 100 F (38 C), contact Intralox Customer Service for actual belt strength. 58

58 BELTS S8026 Embedded Diamond Top E (6.3 ) Pitch Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, ThermoLace, metal lace blue, white Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Includes a proven Embedded Diamond Top profile to provide superior release characteristics applications where product release requirements exceed Flat Top characteristics Available with flights. ThermoLace is Flat Top on each side of hge rod. See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (2.7 ) 1.00 NOM. (26 ) (6.3 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Polyurethane to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use over 100 F (38 C), contact Intralox Customer Service for actual belt strength. 59

59 BELTS Pitch S8026 Nub Top E (7.4 ) Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, ThermoLace, metal lace blue Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Provides excellent product grip for moderate cle conveyance; offers superior release of certa products. Available with flights. ThermoLace is Flat Top on each side of hge rod. See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details..055 (1.4 ).138 (3.51 ) 1.00 (26 ).291 (7.4 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Polyurethane to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use over 100 F (38 C), contact Intralox Customer Service for actual belt strength. 60

60 BELTS S8026 Flat Top Cold Use E (6.0 ) Pitch Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter See Product Notes See Product Notes Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, metal lace blue Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Engeered matte surface is optimized for efficient product release and cleanability. For use ambient to very cold conditions; designed for peak performance colder environments. Available with flights. Mimum backbend and sprocket diameter varies with temperature: 3 (76 ) diameter at 20 to 75 F (-6.7 to 24 C) 4 (102 ) diameter at 0 to 20 F (-17.8 to -6.7 C) 5 (127 ) diameter at -30 to 0 F (34.4 to C See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (2.5 ) 1.00 NOM. (26 ) (6 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Cold Use to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use under 30 F (-1 C), contact Intralox Customer Service for actual belt strength. 61

61 BELTS Pitch S8050 Flat Top E (7.0 ) Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, ThermoLace, metal lace blue, white Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Engeered matte surface is optimized for efficient product release and cleanability. Available with flights and Synchronized Sidewalls. See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (3 ) 1.96 NOM. (50 ) (7 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Polyurethane to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use over 100 F (38 C), contact Intralox Customer Service for actual belt strength. 62

62 BELTS S8050 Embedded Diamond Top E (7.5 ) Pitch Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, ThermoLace, metal lace blue Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Includes a proven Embedded Diamond Top profile to provide superior release characteristics applications where product release requirements exceed Flat Top characteristics. Available with flights and Synchronized Sidewalls. ThermoLace is Flat Top on each side of hge rod. See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (3.5 ) 1.96 NOM. (50 ) (7.5 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Polyurethane to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use over 100 F (38 C), contact Intralox Customer Service for actual belt strength. 63

63 BELTS Pitch S8050 Nub Top E (8.0 ) Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, ThermoLace, metal lace blue Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Provides excellent product grip for moderate cle conveyance; offers superior release of certa products. Available with flights. ThermoLace is Flat Top on each side of hge rod. See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (1.09 ) (2.92 ) 1.96 NOM. (50 ) (8.0 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Polyurethane to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use over 100 F (38 C), contact Intralox Customer Service for actual belt strength. 64

64 BELTS S8050 Flat Top Cold Use E (7.0 ) Pitch Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) See Product Notes See Product Notes Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, metal lace blue Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Engeered matte surface is optimized for efficient product release and cleanability. For use ambient to very cold conditions; designed for peak performance colder environments. Available with flights. Mimum backbend and sprocket diameter varies with temperature: 4 (102 ) diameter at 20 to 75 F (-6.7 to 24 C) 5 (127 ) diameter at 0 to 20 F (-17.8 to -6.7 C) 6 (152 ) diameter at -30 to 0 F (34.4 to C See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (3 ) 1.96 NOM. (50 ) (7 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Cold Use to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use under 30 F (-1 C), contact Intralox Customer Service for actual belt strength. 65

65 BELTS S8050 Flat Top High Temperature Heavy Load (HTL) E (7.0 ) Pitch Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, metal lace natural Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Designed specifically for high temperatures and/or heavy loads. For contuous use below 60 F (15 C) contact Intralox Customer Service for required mimum sprocket diameter. See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (3 ) 1.96 NOM. (50 ) (7 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) b W Belt Weight lb/ft kg/m F C lb/ft² kg/m² HTL to to a. With sprockets spaced on 3 (76 ) centers; Use stacked sprockets for applications with loads greater than 50% of belt strength. For contuous use over 170 F (77 C), contact Intralox Customer Service for actual belt strength. b. In some applications, contuous use temperatures can exceed 210 F (100 C). 66

66 BELTS Pitch S8050 Flat Top XT (7.0 ) Overall Thickness Mimum Width 1 25 Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) Open Area (seamless surface) 0% Available Jog Methods Available Colors Product Notes prepared ends, endless, metal lace blue Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Designed specifically for extreme temperatures high or low See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (3 ) 1.96 NOM. (50 ) (7 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² XT to to a. With sprockets spaced on 3 (76 ) centers; Use stacked sprockets for applications with loads greater than 60% of belt strength. For contuous use over 100 F (38 C), contact Intralox Customer Service for actual belt strength. 67

67 BELTS Pitch Overall Thickness Mimum Width Maximum Width Mimum Backbend Diameter Mimum Sprocket Diameter (10T) Open Area (seamless surface) 0% Available Jog Methods prepared ends, endless Available Colors blue Product Notes S8126 Flat Top E (6.0 ) Contact Intralox for precise belt measurements and stock status before designg equipment or orderg a belt. Engeered matte surface is optimized for efficient product release and cleanability. Designed for retrofittg certa high tension trough conveyors applications to tensionless ThermoDrive solutions; contact Intralox Customer Service for details. For use with S8126-specific drive and idle components. Drive bar width is 2.4 (62 ). See Belt Selection Considerations on page 52 for help selectg a belt. See Material Compliance on page 101 for compliance details (2.5 ) 1.00 NOM. (26 ) (6 ) Belt Data Belt Material BS Belt Strength a Temperature Range (contuous) W Belt Weight lb/ft kg/m F C lb/ft² kg/m² Polyurethane to to a. With sprockets spaced on 3 (76 ) centers; Consider usg stacked sprockets for optimal operational performance heavily-loaded applications; For contuous use over 100 F (38 C), contact Intralox Customer Service for actual belt strength. 68

68 BELT FABRICATION BELT JOINING METHODS Belt ends are fabricated with the chosen belt jog method. Endless belts: Order endless belts to be stalled without field splicg. Prepared ends: Order prepared ends for length adjustments and field splicg at stallation. ThermoLace ends: Order ThermoLace ends for easy belt disassembly durg cleang; often used with the Synchronized Sidewall mechanical fastener kit. Metal lace ends: Order metal lace ends for easy belt disassembly durg cleang; often used with the Synchronized Sidewall mechanical fastener kit. BELT JOINING CONSIDERATIONS Consider the followg when choosg a belt jog method. Spliced belt jots offer the most hygienic solutions. Belt splicg can be performed by Intralox technicians the field if needed. ThermoDrive splicers can be purchased and used by customers with mimal trag. The Synchronized Sidewall mechanical fastener kit can be used with any belt jog method. Sidewall mechanical fastener kits are designed for use on belts with metal lacg or ThermoLace jog, but can be used on any belt with Synchronized Sidewall. Endless Belt Jog Strength Ratg Same as belt material Mimum Belt Width 1 (25 ) Maximum Belt Width 72 (1829 ) Width Increments 1/32 (0.79 ) Flush Edge Design Spliced Compatible Belts All Repairs require belt splicg; see Splicg Equipment on page 97 All prepared end and endless belts clude at least one 6 (152 ) space between flights for splicg. Belt Prepared Ends for Splicg Strength Ratg Same as belt material Mimum Belt Width 1 (25 ) Maximum Belt Width 72 (1829 ) Width Increments 1/32 (0.79 ) Flush Edge Design Spliced Compatible Belts All Repairs require belt splicg; see Splicg Equipment on page 97 All prepared end and endless belts clude at least one 6 (152 ) space between flights for splicg. 69

69 BELT FABRICATION Strength Ratg Mimum Belt Width Maximum Belt Width Width Increments Rod Diameter Rod Material Flush Edge Design Compatible Belts S8026 ThermoLace Jog 200 lb/ft (298 kg/m) 4 (102 ) 72 (1829 ) 0.5 (13 ) (2.5 ) Blue acetal Included rod retention S8026 polyurethane Belt on either side of a ThermoLace jot is Flat Top for 3 (75 ) when joed to other belt top surfaces or perforated belts. ThermoLace jots wider than 42 (1067 ) are bricklayed. S8026 ThermoLace is a patented jog method. Strength Ratg Mimum Belt Width Maximum Belt Width Width Increments Rod Diameter Rod Material Flush Edge Design Compatible Belts S8050 ThermoLace Jog 275 lb/ft (409 kg/m) pricebook (102 ) 72 (1829 ) 0.5 (13 ) (3.6 ) Blue acetal Solid lk rod retention S8050 polyurethane Belt on either side of a ThermoLace jot is Flat Top for 6 (150 ) when joed to other belt top surfaces or perforated belts. ThermoLace jots wider than 42 (1067 ) are bricklayed. Strength Ratg Mimum Belt Width Maximum Belt Width Width Increments Rod Diameter Rod Material Edge Design Compatible Belts Metal Lace Jog 300 lb/ft 6 (152 ) 72 (1829 ) 1.0 (25 ) 0.08 (2 ) Brown nylon-coated staless steel unheaded hge rod Retag washer Clips are Flexco Ready Set Staple #62 Staless products. Contact Intralox Customer Service for spare washers, rods, or metal lace clips. All 70

70 BELT FABRICATION Available for sidewall sizes Synchronized Sidewall Mechanical Fastener Kit Kit contents Kit cludes components for two sidewall splices 1.25 Brad Pot drill bit metal plates screws lock nuts One kit needed for each belt splice. BELT FEATURES Special belt features are available for unique applications. Belt perforations are employed for hygienic dewaterg applications with 8050 belts. Belt trough grooves are employed for some trough conveyor applications. Drive bar removal is employed for various applications. Contact Intralox Customer Service for application-specific suggestions. Mimum Belt Width Maximum Belt Width Perforation Styles Compatible Material Belt Perforations 2 (51 ) 66 (1676 ) 0.25 (6 ) holes 20% open space Polyurethane Contact Intralox Customer Service for available non-uniform coverage options (for example, rows of perforations). Available with all jog methods Not available with 6 (152 ) of S8050 ThermoLace jots Mimum Belt Width Maximum Belt Width Mached Groove Width Compatible Material 10 (254 ) 72 (1829 ) 1.75 (44.5 ) Trough Groove Polyurethane, Cold Use, HTL, XT Contact Intralox Customer Service for application-specific suggestions. Completely removes drive bars plus (1 ) of the belt cover Not available with metal lace jog Not available with 3 (76 ) of S8026 ThermoLace jots or 6 (152 ) of S8050 ThermoLace jots Do not mount drive sprockets at trough grooves. 71

71 BELT FABRICATION Mimum Belt Width Maximum Belt Width Mached Groove Width Compatible Material Drive Bar Removal 10 (254 ) 72 (1829 ) Varies Polyurethane, Cold Use, HTL, XT Contact Intralox Customer Service for application-specific suggestions. Leaves about (0.127 ) of drive bar and full cover thickness Not available with 3 (76 ) of S8026 ThermoLace jots or 6 (152 ) of S8050 ThermoLace jots Only mount drive sprockets at drive bars. Customized by application BELT ACCESSORIES Accessory thickness 3 Available Flight and Sidewall Materials and Styles Polyurethane Cold Use HTL XT Blue White Blue Natural Blue Smooth ED Smooth ED Smooth ED Smooth Smooth 90 degree flight degree flight Scoop flight Short top scoop flight Sidewall Smooth Smooth style (surface texture); ED Embedded Diamond style (surface texture) 72

72 BELT FABRICATION FLIGHT SELECTION CONSIDERATIONS Consider the followg when selectg flights for belts. Flight and belt material must match; Flight and belt styles can differ. Maximum flight length is 36 (914 ). Flight notches are available; standard notches are 2 (51 ). Consider cludg notches for flights greater than 24 (610 ) wide. Mimum recoended flight dent from belt edge is 1.25 (32 ). Contact Intralox Customer Service for flight gusset formation. All prepared end and endless belts clude at least one 6 (152 ) space between flights for splicg. Available Flight Heights Available Thicknesses 0.12 (3 ) 0.16 (4 ) 0.20 (7 ) 90 Degree Flight Data Available Materials Polyurethane (all); Cold Use (4 and 7 blue) Flights can be cut down to any height required for a particular application (mimum of 0.25 [7 ]). Smooth blue flights available all sizes, styles, and materials Smooth white flights available only 0.16 (4 ) and 0.20 (7 ) thick polyurethane material Dual-sided embedded diamond flights available only 0.16 (4 ) and 0.20 (7 ) thick, blue polyurethane material Cold Use flights available only 0.16 (4 ) and 0.20 (7 ) thick, smooth, blue material Mimum flight spacg on S8026 belt is 2.0 (51 ). Mimum flight spacg on S8050 belt is 1.9 (49 ). Available Flight Heights Available Thicknesses 0.16 (4 ) 0.20 (7 ) 75 Degree Flight Data Available Materials Polyurethane Flights can be cut down to any height required for a particular application (mimum of 3.0 [75 ]). Smooth surface flights available blue and white Dual-sided embedded diamond flights available only blue Mimum flight spacg on S8026 belt is 3.0 (76 ). Mimum flight spacg on S8050 belt is 3.9 (49 ). 73

73 BELT FABRICATION Available Flight Heights Available Thicknesses 0.16 (4 ) 0.20 (7 ) Smooth surface flights available blue and white Dual-sided embedded diamond flights available only blue Scoop angle is degrees. Mimum flight spacg on S8026 belt is 3.0 (76 ). Mimum flight spacg on S8050 belt is 3.9 (49 ). Available Flight Heights Available Thicknesses 0.16 (4 ) 0.20 (7 ) Smooth surface flights available blue and white Dual-sided embedded diamond flights available only blue Short top scoop angle is degrees. Mimum flight spacg on S8026 belt is 3.0 (76 ). Mimum flight spacg on S8050 belt is 3.9 (49 ). Scoop Flight Data Available Materials Polyurethane Short Top Scoop Flight Data Available Materials Polyurethane FLIGHT GUSSETS CONSIDERATIONS Consider the followg when selectg flight gussets. Flight gussets are used to crease flight rigidity and are employed heavily-loaded applications. Contact Intralox Customer Service for application-specific formation. Flight Gusset Data Available Gusset Height/Width Available Thicknesses Available Materials Height and width based on flight height 0.20 (7 ) Polyurethane Available only on S8050 belts Available only for flights 7.0 (178 ) or wider Flight gusset quantity and spacg based on flight width 74

74 BELT FABRICATION SIDEWALL SELECTION CONSIDERATIONS Consider the followg when selectg sidewalls. Sidewall material must match belt and flight material. Sidewall is smooth on both sides unless otherwise dicated. Mimum recoended sidewall dent is 1.25 (32 ). Maximum belt width is 42 (1067 ) with a 1.25 (32 ) dent. 25 sidewall pitch is created with 1.5 thick material and creates a (24.59 ) footprt. 50 sidewall pitch is created with 2 thick material and creates a (44.45 ) footprt. Mimum gap to flight is 0.2 (5 ± 2 ). Sidewall Pitch Available Sidewall Heights S8050 Synchronized Sidewalls Data M. Recoended Sprocket PD Available Materials Polyurethane Polyurethane Cold Use Polyurethane Cold Use Polyurethane Cold Use Polyurethane Cold Use Polyurethane Cold Use Polyurethane sidewall available blue and white Sgle-sided embedded diamond sidewall available only blue polyurethane; embedded diamond surface faces product Cold Use sidewall available only blue 75

75

76 DRIVE AND IDLE END COMPONENTS DRIVE END SELECTION CONSIDERATIONS B A C Choose between usg a pre-engeered drive solution like the patented Tensionless Drive Engagement Unit or designg a drive end solution from dividual drive end components. Use belt pitch and other conveyor design dimensions to make drive end component decisions. See Design Guideles, Conveyor Frame Design, Dimensions on page 17. Contact Intralox Customer Service for more formation. S8050 TENSIONLESS DRIVE ENGAGEMENT UNIT The ThermoDrive Tensionless Drive Engagement Unit is a patented, pre-engeered belt drive subassembly that optimizes operational performance. The unit is adaptable to any end drive conveyor design and bolts directly to the conveyor frame with a standard or custom pattern. Available for new or existg conveyors Mimizes harborage Simplifies the sanitation process Delivers precise and consistent scrapg performance Component Specifications Frame: Three-sided, 316L staless steel construction with smart bar bushgs Drive Shaft: Choice of 304, 316, or 17-4 PH staless steel shafts; choice of stacked or spaced 6.5 (165 ) 10T acetal sprockets; and heavy-duty split retaer rgs Smart bar assembly: Staless steel smart bar with patented tool-free position limiters with UHMW-PE belt-contact surfaces; bolted or with handles Self-adjustg scraper: Optional, 316L staless steel assembly with removable UHMW-PE scraper and acetal mounts that attach to the smart bar Belt compatibility: S8050 Flat Top Polyurethane, Cold Use, High Temperature Heavy Load, or XT belt Endless or prepared end belts from ( ) wide; with or without flights Not compatible with sidewalls Belt pull allowance: Contact Intralox Customer Service for more formation. Spares: Replacement sprockets, position limiters, scrapers, and handles available for dividual purchase Contact Intralox Customer Service for application-specific suggestions and new component variations before placg an order. 77

77 DRIVE AND IDLE END COMPONENTS SHAFTS Select round or square shafts as needed for drive, idle, and returnway component stallation. Intralox offers customized square shafts. Round shafts not available from Intralox. SQUARE SHAFT CONSIDERATIONS Use only staless steel shafts with ThermoDrive belt systems. ThermoDrive sprockets only available with 1.5, 40, 2.5, and 65 bore sizes Retaer rg grooves not required with sprocket spacers, heavy-duty split retaer rgs, or self-set retaer rgs Contact Intralox Customer Service for a Shaft Specification Form or help with orderg. CUSTOM SHAFT MACHINING Once ordered to customer specifications, the shaft stock is cut to length and the raw shaft is precision straightened. The bearg journals are turned, and needed retaer rg grooves, keyways, and chamfers are cut. A thorough quality spection is performed before shippg. Notify Intralox Customer Service when orderg if the gearbox is hollow. Square Size Shafts Available from Intralox USA Tolerances Staless Steel (303/304) Staless Steel (316) / / / / Contact Intralox Customer Service for larger diameters or shafts longer than 12 ft (3.6 m). Square Size Shafts Available from Intralox Europe Tolerances Staless Steel (303/304) Staless Steel (316) / N/A / N/A Contact Intralox Customer Service for larger diameters or shafts longer than 3 m (9.8 ft). DIMENSIONS REQUIRED: A - LENGTH, overall B - LENGTH, bearg-end journal C - LENGTH, square section D - LENGTH, drive-end journal and keyway dimensions E - DIAMETER, bearg journal F - DIAMETER, drive-end journal G - WIDTH, retaer rg groove H - WIDTH, sprocket hub I - DIAMETER, rg groove J - LENGTH of keyway TOLERANCES (Unless otherwise specified) OVERALL LENGTH... < 48. ± (< 1200 ± 0.8 )... < 48. ± (< 1200 ± 0.8 ) JOURNAL DIAM / (Øh7 vlgs. NEN-ISO 286-2) KEYWAY WIDTHS / (+ 0.05/ ) SURFACE FINISHES JOURNAL microches (1.6 micrometers) OTHER MACHINED SURFACES microches (3.25 micrometers) Unless otherwise specified USA keyways are for parallel square keys (ANSI B , R1973). Metric keyways are for flat, laid keys with round ends (DIN 6885-A) Shaft Retaer Rg Groove and Chamfer Dimensions Shaft Size Groove Diameter Width Chamfer ± / ± ± / ± ± / ± ± / ±

78 DRIVE AND IDLE END COMPONENTS SPROCKET SPACERS SELECTION CONSIDERATIONS Choose sprocket spacers stead of retaer rgs between sprockets hygiene-sensitive applications with spaced sprockets. Consider stacked sprockets heavily-loaded applications. Contact Intralox Customer Service for recoendations. Available x-ray detectable or metal detectable materials Appropriate for 3 (76 ) centerle sprocket and support wheel spacg Requires at least one retaer rg at each shaft end *See Sprocket Spacer Quantity Reference a,b on page 80 charts for example configurations. *Quantity Reference charts are for reference only. Contact Intralox Customer Service for quantity and stallation formation when usg sprocket spacers with these components: mached sprockets; flighted or sidewall belts; ThermoLace or metal lace jog methods; scrapers. Sprocket Spacer Width Sprocket Spacer Width X-Ray Detectable Sprocket Spacer Data Available Bore Sizes U.S. Sizes Metric Sizes Round Square Round Square Sprocket Spacer Width Sprocket Spacer Width Detectable Sprocket Spacer Data Available Bore Sizes U.S. Sizes Metric Sizes Round Square Round Square

79 DRIVE AND IDLE END COMPONENTS Mimum Belt Width M. Number of Sprockets S8026 Sprocket Spacer Quantity Reference a,b Drive Shaft Number of 2.0 Spacers Number of 1.5 Spacers Number of Support Wheels Idle Shaft d Number of 2.0 Spacers c a. Contact Intralox Customer Service for quantity and stallation formation when usg sprocket spacers with these components: mached sprockets; flighted or sidewall belts; ThermoLace or metal lace jog methods; scrapers. b. Install the most narrow spacers toward the shaft center. Use one heavy-duty split retaer rg outside of each outermost drive sprocket or support wheel. c. For belt widths ( ), stack sprockets between heavy-duty split retaer rgs. d. Idle end quantities are based on support wheels stalled with 3 (75 ) centerle spacg. Mimum Belt Width M. Number of Sprockets S8050 Sprocket Spacer Quantity Reference a,b Drive Shaft Number of 1.0 Spacers Number of 1.5 Spacers Number of Support Wheels Idle Shaft d Number of 2.0 Spacers c a. Contact Intralox Customer Service for quantity and stallation formation when usg sprocket spacers with these components: mached sprockets; flighted or sidewall belts; ThermoLace or metal lace jog methods; scrapers. b. Install the most narrow spacers toward the shaft center. Use one heavy-duty split retaer rg outside of each outermost drive sprocket or support wheel. c. For belt widths ( ), stack sprockets between heavy-duty split retaer rgs. d. Idle end quantities are based on support wheels stalled with 3 (75 ) centerle spacg 80

80 DRIVE AND IDLE END COMPONENTS RETAINER RINGS STAINLESS STEEL RETAINER RINGS 2. Rg groove diameter Staless steel retaer rgs are available to fit square shafts. The followg ANSI Type 3AMI rgs, conformg to MIL SPEC R-2124B are available for ThermoDrive applications. Shaft Sizes Groove Width Groove Diameter INTRALOX USA INTRALOX EUROPE STAINLESS STEEL SELF-SET RETAINER RING A - Custom set screw fully serted, head first, from this side Self-set retaer rgs are available to fit 1.5, 2.5, 40, 65, and other square shafts. Retaer rgs are made from non corrosive 316 staless steel. No mached grooves are needed on the shaft, but the shaft must have chamfered edges. These retaer rgs are USDA accepted and patented. The rgs snap to place on the square shaft even with shaft stalled. They are fixed position with a unique set screw that does not fall out durg operation. Self-set retaer rgs are not recoended applications where high lateral forces are expected. STAINLESS STEEL HEAVY-DUTY SPLIT RETAINER RING Heavy-duty split retaer rgs are available to fit 1.5, 2.5, 40, and 60 square shafts. The retaer rgs are made from 304 staless steel. These retaer rgs do not require the shaft to be chamfered, and can be stalled with the shaft place. For use applications with high lateral loads on the sprockets. 81

81 DRIVE AND IDLE END COMPONENTS SPROCKETS S8026 AND S8050 SPROCKETS SPROCKET SELECTION CONSIDERATIONS Select a sprocket series compatible with the belt series. Select a sprocket size compatible with the belt mimum sprocket diameter. For belts with Synchronized Sidewall, choose sprocket size based on see S8050 Synchronized Sidewalls Data on page 75. Contact Intralox Customer Service for lead times before orderg. Choose an EZ Clean style for hygienic applications. S8026 & S8050 Sprocket Quantity Reference S8026 S8050 Mimum Belt Width a Mimum Number of Mimum Belt Width a Mimum Number of Sprockets Per Shaft b Sprockets Per Shaft b c d a. Use the Mimum Belt Width smaller than your belt width to determe the mimum number of sprockets needed. Belts are available (0.79 ) crements. b. More sprockets are required for heavily-loaded applications. All sprockets must be locked place. Allow a maximum +/ (3.0 ) of lateral movement. c. For S8026 belt widths ( ), stack sprockets between heavy-duty split retaer rgs. d. For S8050 belt widths ( ), stack sprockets between heavy-duty split retaer rgs. 82

82 DRIVE AND IDLE END COMPONENTS Sprocket Spacg as a Function of Belt Strength Used MAXIMUM SPROCKET SPACING, MAXIMUM SPROCKET SPACING, PERCENT OF ALLOWABLE BELT STRENGTH USED, % Based on maximum centerle sprocket spacg Applies to all ThermoDrive series and styles For applications with belt pull over 50% of the rated belt pull, contact Intralox Customer Service. No. of Teeth Pitch Dia. Pitch Dia. Outer Dia. S8026 EZ Clean Molded Acetal Sprocket Data a Outer Dia. Hub Width Hub Width Available Bore Sizes U.S. Sizes Metric Sizes Round Square Round Square 6 b a. Contact Intralox Customer Service for lead times before orderg. b. Not compatible with ThermoLace No. of Teeth Pitch Dia. Pitch Dia. Outer Dia. S8026 EZ Clean Mached Acetal Sprocket Data a Outer Dia. Hub Width Hub Width Available Bore Sizes U.S. Sizes Metric Sizes Round Square Round 8 b Square a. Contact Intralox Customer Service for lead times before orderg. b. Not compatible with ThermoLace 83

83 DRIVE AND IDLE END COMPONENTS No. of Teeth Pitch Dia. Pitch Dia. Outer Dia. S8050 EZ Clean Molded Acetal Sprocket Data a Outer Dia. Hub Width Hub Width Available Bore Sizes U.S. Sizes Round Square Metric Sizes Round Square a. Contact Intralox Customer Service for lead times before orderg. No. of Teeth Pitch Dia. Pitch Dia. Outer Dia. S8050 EZ Clean Mached Acetal Sprocket Data a Outer Dia. Hub Width Hub Width Round Available Bore Sizes U.S. Sizes Square Metric Sizes Round Square b a. Contact Intralox Customer Service for lead times before orderg. b. Not compatible with ThermoLace No. of Teeth Pitch Dia. Pitch Dia. Outer Dia. Outer Dia. S8050 Split Sprocket Data abc Available Bore Sizes U.S. Sizes Metric Sizes Hub Width Hub Width Round Square Round Square a. Contact Intralox Customer Service for lead times before orderg. b. Available mached natural acetal or abrasion resistant natural nylon c. Sprockets have a preferred drivg direction; check body side arrows. 84

84 DRIVE AND IDLE END COMPONENTS S8126 SPROCKETS AND DRIVE END Belt Width () 2.5 (65 ) Wide Flanged Support Roller (Quantity) S8126 Drive End Component Quantity Reference Data 2.5 (65 ) Wide Support Roller (Quantity) 1 (25 ) Wide Support Roller (Quantity) 6 (152 ) Wide Tail Roller (Quantity) SS Split Lockg Collars (Quantity) Component Spacg Edge to Edge Mimum Total Belt Edge Clearance Mimum Length of Square Portion of Shaft No. of Teeth Pitch Dia. Pitch Dia. Outer Dia. Outer Dia. S8126 Mached Acetal Sprocket Data a Hub Width Hub Width Available Bore Sizes U.S. Sizes Round Square Metric Sizes Round Square 12 b a. Contact Intralox Customer Service for lead times before orderg. b. Not compatible with ThermoLace For other drive end components referenced, see S8126 Idle End on page

85 DRIVE AND IDLE END COMPONENTS POSITION LIMITERS Intralox provides various wear shoe-style position limiters for stallation at the conveyor drive end. EZ Clean Universal position limiters employed most often on flat and flighted belts EZ Clean D-shaft position limiters only for flat belts with light loads Available only UHMW-PE Pitch Dia. Pitch Dia EZ Clean Position Limiter (D-shaft mount) Data Dimensions (H x W x D) x 2.31 x x 59 x x 2.82 x x 72 x x 3.04 x x 77 x x 3.29 x x 84 x x 3.15 x x 80 x [12.70].492 [12.50] 1 Shaft 25 Shaft A B Sprocket PD 3.2 (81 ) 3.9 (99 ) 6.4 (163 ) S8026 Position Limiter (D-shaft Mount) Installation Dimensions 5.3 Flat Top 6 Flat Top 6.3 EDT 7.4 NT A B A B A B A B (85.2 ) (92.9 ) (124.4 ) (5.1 ) (0.1 ) (9.9 ) (85.8 ) (93.5 ) (125.0 ) (5.5 ) (0.3 ) (10.3 ) (86.1 ) (93.8 ) (125.3 ) (5.7 ) (0.4 ) (10.5 ) (87.0 ) (94.7 ) (126.2 ) (6.3 ) (0.7 ) (11.1 ) 86

86 0 DRIVE AND IDLE END COMPONENTS Sprocket PD 4.0 (102 ) 5.2 (132 ) 6.5 (165 ) S8050 Position Limiter (D-shaft Mount) Installation Dimensions 7 Flat Top 7.5 EDT 8.0 NT A B A B A B (93.0 ) (108.5 ) (124.0 ) (0.0 ) (5.5 ) (10.0 ) (93.6 ) (109.1 ) (124.4 ) (0.4 ) (5.6 ) (10.3 ) (94.1 ) (109.6 ) (124.9 ) (0.8 ) (5.6 ) (10.5 ) Pitch Dia. Pitch Dia EZ Clean Position Limiter (universal mount) Data Dimensions (H x W x D) x 2.31 x x 59 x x 2.82 x x 72 x x 3.04 x x 77 x x 3.29 x x 84 x [15.88] [12.70] [38.10] C D Sprocket PD 3.2 (81 ) 3.9 (99 ) 6.4 (163 ) S8026 Position Limiter (Universal Mount) Installation Dimensions 5.3 Flat Top 6.0 Flat Top 6.3 EDT 7.4 NT C D C D C D C D (105.8 ) (113.5 ) (145.0 ) (20.8 ) (25.3 ) (15.5 ) (106.4 ) (114.1 ) (145.6 ) (20.4 ) (25.1 ) (15.1 ) (106.7 ) (114.4 ) (145.9 ) (20.2 ) (25.0 ) (14.9 ) (107.6 ) (115.3 ) (146.8 ) (19.6 ) (24.7 ) (14.3 ) 87

87 DRIVE AND IDLE END COMPONENTS Sprocket PD 4.0 (102 ) 5.2 (132 ) 6.5 (165 ) S8050 Position Limiter (Universal Mount) Installation Dimensions 7.0 Flat Top 7.5 EDT 8.0 NT C D C D C D (113.6 ) (129.0 ) (144.6 ) (25.4 ) (19.9 ) (15.4 ) (113.8 ) (129.2 ) (144.8 ) (25.3 ) (19.9 ) (15.3 ) (114.7 ) (130.1 ) (145.5 ) (24.7 ) (19.8 ) (14.9 ) Pitch Dia. Pitch Dia Position Limiter Block Data Dimensions (H x W x D) x 2.5 x 1 80 x 60 x x 3 x 1 95 x 75 x x 3.25 x x 80 x x 3.5 x x 90 x x 4.2 x x 106 x 25 Pitch Dia. Pitch Dia. Flighted Belt Position Limiter Kit Data Dimensions (H x W x D) a x 3 x 1 38 x 76 x x 2 x 1 50 x 50 x x 2 x 1 63 x 50 x x 2 x 1 75 x 50 x 25 a. Dimensions do not clude mountg plate. 88

88 DRIVE AND IDLE END COMPONENTS SUPPORT WHEELS AND ROLLERS S8026 AND S8050 IDLE END Support wheels and rollers are compatible with S8026 and S8050 belts unless otherwise dicated. Wheel Dia. Support wheels are designed for use on square shafts. When usg round shafts, use return rollers. Support wheel and roller diameters must meet the mimum sprocket diameter required for the belt. Choose flanged rollers only for shaft outside ends when belt contament is required. Wheel Dia. Hub Width Hub Width Support Wheel Data ab Available Bore Sizes U.S. Sizes Metric Sizes Round Square Round Square 3.9 c a. Contact Intralox Customer Service for lead times before orderg. b. Designed to work with correspondg diameter sprockets; material is UHMW-PE. c. See Return Roller Dataab on page 89 and Flanged Return Roller Dataabc on page 89 for round shafts. Roller Dia. Roller Dia. Hub Width Hub Width Return Roller Data ab Available Bore Sizes U.S. Sizes Round a. Contact Intralox Customer Service for lead times before orderg. b. Material is UHMW-PE. Square Metric Sizes Round Square Roller Dia. Roller Dia. Hub Width Hub Width Flanged Return Roller Data abc Round Available Bore Sizes U.S. Sizes Square Metric Sizes Round a. Contact Intralox Customer Service for lead times before orderg. b. Material is UHMW-PE; flange is 0.75 (19 ) above roller diameter. Square 89

89 DRIVE AND IDLE END COMPONENTS S8126 IDLE END Belt Width 2.5 (65 ) Wide Flanged Support Roller (Quantity) S8126 Idle End Component Quantity Reference Data 2.5 (65 ) Wide Support Roller (Quantity) 1 (25 ) Wide Support Roller (Quantity) 6 (152 ) Wide Tail Roller (Quantity) SS Split Lockg Collars (Quantity) Component Spacg Edge to Edge Mimum Total Belt Edge Clearance Mimum Length of Square Portion of Shaft Roller Dia. Roller Dia. Hub Width Hub Width S8126 Acetal Support Wheel Data a Available Bore Sizes U.S. Sizes Round Square Metric Sizes Round Square a. Contact Intralox Customer Service for lead times. 90

90 DRIVE AND IDLE END COMPONENTS S8126 Acetal Flange Roller Data a Roller Dia. Roller Dia. Hub Width Hub Width Available Bore Sizes U.S. Sizes Round Square Metric Sizes Round Square a. Contact Intralox Customer Service for lead times. S8126 Acetal Tail Roller Data a Available Bore Sizes Roller Dia. Roller Dia. Hub Width Hub Width U.S. Sizes Round Square Metric Sizes Round Square a. Contact Intralox Customer Service for lead times. 91

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92 CARRYWAY AND RETURNWAY COMPONENTS SUPPORT RAILS/WEARSTRIPS STANDARD FLAT WEARSTRIPS Standard flat wearstrips are available UHMW-PE measurg 0.25 (6 ) thick x 1.25 (32 ) wide x 120 (3 m). UHMW-PE wearstrips are FDA and USDA compliant for direct food contact. NOTE: Recoended for stallation with S8126 beltg. SPECIALTY WEARSTRIPS Intralox offers various clip-on wearstrips cludg the followg. For new applications, use flat wearstrips with wide surface area for carryways and returnways. Use clip-on wearstrips only for lightly-loaded retrofit applications or to prove concepts. It is not recoended for normal production operation. Contact Intralox Customer Service for application-specific formation. A B 120 (3.0 m) Guide Rail Snap-On UHMW Wearstrips (B6XX27IXXWMV-00) 120 (3.0 m) Barbed Clip-On UHMW Wearstrips (B6XX23IXXWMV-00) 93

93 CARRYWAY AND RETURNWAY COMPONENTS STAINLESS STEEL-BACKED UHMW-PE WEARSTRIP COMPONENTS For new applications, use flat wearstrips with a wide surface area for carryways and returnways. Only use staless steel-backed UHMW-PE wearstrips for light load, retrofit applications or to prove concepts. Staless steel-backed UHMW-PE wearstrips can create a rigid belt carryway surface on any frame with cross members. Staless steel-backed UHMW-PE wearstrips should be mounted to cross members with a self-tighteng staless steel clamp with nut (self-tighteng staless steel clamp with nut sold separately). Wearstrips can be stalled parallel, chevron, or other configurations. Ensure stallation design allows for thermal expansion and contraction. Chamfer or bend down the leadg edges of any wearstrip. Recoended for temperatures up to 160 F (71 C) NOTE: Recoended for Trough Retrofit Set stallations. T 120 (3.05 m) Staless Steel Back UHMW Wearstrip (B6XX42IXXWMV-00) Self-tighteng Staless Steel Wearstrip clamp with nut 5/16-18 UNC (C9AX1XXXXXXX-01) 6 (152 ) Staless Steel Connector for Staless Steel Back Wearstrip (C4BXXXXXXXMT-00) SHAFTS Select round or square shafts as needed for carryway and returnway component stallation. Intralox offers customized square shafts. See Square Shaft Considerations on page 78. Round shafts not available from Intralox. RETURN ROLLERS See Support Wheels and Rollers on page

94 CARRYWAY AND RETURNWAY COMPONENTS TROUGH RETROFIT SET The new troughg conveyor retrofit set lets customers upgrade flat belt legacy equipment to high-performance ThermoDrive components. Designed for transverse angle style conveyors Custom brackets fit most angled support rods Customers can use existg frame and possibly idle and returnway components Most coonly employed for dough conveyg Component Specifications Trough retrofit brackets: Customized staless steel, laser-cut brackets fit support rods 6.0 (152 ) to 21.5 (546 ) long 0.5 (12.7 ) to 1.75 (44.4 ) diameter Retrofit bracket contament blocks: White UHMW-PE contament blocks Press-fit onto the bracket Provide 6 (152 ) of contact with syetrical chamfers Recoended for use with these wearstrips, clamps, and connectors T-shaped staless backed virg UHMW (PE1000) 120 (31.75 cm) x 1.25 ( cm) Self-tighteng wearstrip clamps with upgraded fasteners 6 (152 ) staless steel wearstrip connectors to add rigidity and elimate catch pots Trough conveyors must meet specifications defed the ThermoDrive Trough Retrofit Set Audit. Installation Instructions at Contact Intralox Customer Service for applicationspecific formation. Patent pendg bracket design B D C A A. Bracket B. Contament block C. Self-tighteng wearstrip clamps D. 6 staless steel wearstrip connector 95

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96 SPLICING EQUIPMENT THERMODRIVE SPLICING SYSTEM V. 2 This patented belt splicg solution provides tools to prepare belt ends, then quickly and reliably splice them the field. The splicer is compatible with all Intralox ThermoDrive conveyor belt series and styles up to 42 (1067 ) wide. Splicg System v. 2 Electric Complete Clampg Fixture Max. M./Max. Power Set belt width Temp Range Supply Weight Dimensions Weight F C V lb kg lb kg v/ v v/ v L x 11.5 W x 4.5 H 857 L x 292 W x 114 H L x W x 4.75 H 1314 L x 333 W x 121 H Compatible with S8026, S8050, and S8126 belts up to 42 (1220 ) wide ThermoDrive Splicg System v. 2 cludes these components. Clampg fixture Cuttg template Heat wand and stand Control box and cord User manual Small Tool Accessory pack with trim tools Storage case The splicer is an all-metal fixture that safely controls the position of the belt ends as the heat wand is used to melt and jo belt ends for splicg. The splicer cludes top clamps/cut guides, grooved decks for belt end alignment, and a crank handle. The sturdy storage case neatly houses all components and cludes casters and a handle to transport the unit for belt stallation and repair. Compliance: CE, PSE-circle, CB Scheme Certification DE Warranty: one year 97

97 SPLICING EQUIPMENT THERMODRIVE STREAMLINE SPLICING SET This patented belt splicg solution provides tools to prepare belt ends, then quickly and reliably splice them the field. The splicer is compatible with all Intralox ThermoDrive conveyor belt series and styles up to 72 (1829 ) wide. Splicg System v. 2 Electric Complete Clampg Fixture Max. M./Max. Power Set belt width Temp Range Supply Weight Dimensions Weight F C V lb kg lb kg v/ v ThermoDrive Streamle Splicg Set cludes these components. Integrated wand splicer Control box and cord Hand-held Belt Preparation Tool User manual Small tool accessory pack with trim tools Storage case L x 18.5 W x 6.5 H (extended) 857 L x 292 W x 114 H The Integrated Wand Splicer is an all-metal fixture that safely and precisely controls the position of the belt and the movement of the heatg element durg splicg. This simplifies the process and ensures an accurate result. The Integrated Wand Splicer cludes top clamps, S8026/S8050 deck serts, a crank handle, and a self-contaed heatg element. The rugged storage case neatly houses all components and cludes large casters and handles to transport the unit for belt stallation and repair. Compliance: CE, PSE-circle Warranty: one year 98

98 SPLICING EQUIPMENT THERMODRIVE STREAMLINE HAND-HELD BELT PREPARATION TOOL This patent-pendg, stand-alone, manual cuttg device uses a concealed cuttg blade and grooved guide plates to quickly and accurately prepare belt ends for splicg. The cuttg blade is replaceable and guide plates are terchangeable to accoodate different belt series. Hand-held Belt Preparation Tool Dimensions Weight lb kg 5 L x 5 W x 7 H 127 L x 127 L x 178 H Provided with every Streamle Splicg Set Available as a separate purchase for use with Splicg System v.2 or similar Not compatible with S8126 belt or drive bar removal over 3 (72 ) wide SPLICING EQUIPMENT SPARE COMPONENTS Contact Intralox Customer Service to purchase replacement components for any ThermoDrive Splicg equipment. Available components clude, but are not limited to, the followg: Temperature control boxes Wand cords Carryg handles Crank handles Heat wands Silicone Spacer kits Teflon tape Pitch gauge Plug adaptor Top clamps Skivg tool Belt preparation tool handle Belt preparation tool grooved guide Belt preparation tool hook blade 99