Belt Welding Instructions Flat Belt

Belt Welding Instructions
Flat Belt E 20/2 U0/U7 MT s = 2.6 mm Black

Flat Belt TCF-50H s = 2.0 mm White
Flat Belt TC-20E s = 2.0 mm Green/Black
Flat Belt TCF-50HT s = 2.0 mm Green
Tools
Belt Punching Device AF-42
Toolbox with
welding accessories ID No.: 00077210 230VAC
ID No.: 00124351 120VAC
Punching Instructions for Flat Belt with AF-42

(also see Habasit Operating Instructions AF-42)
Preparation
Endless length marking
Screw on the lever of the punching device
The endless length of the belt must be known and marked

min. 230 mm on the belt.
On one side, the belt end must be at least 230 mm

longer than the marking.
Fixing from LEFT

Insert the first belt end into the punching device from
the LEFT and level it with the provided front stop pins.
Align the marking of the endless length with
the left edge of the cutting base.
ATTENTION:
Insert both belt ends with the same side of the belt (upper
or lower side of the belt) facing upwards!
Tighten both clamp bars.
Chapter XII – Annex page 1

Punching
Lock the traversing slide into the first hole.
First punching process:

Push through the toggle lever in one go.
Repeat step by step until the flat belt is completely cut

(the traversing slide always moves forward by
one marking).
Removing
Loosen both clamp bars.
Remove the belts carefully from the punching device.
If the negative piece cannot be pulled from the belt itself,

the edge of the cut must be recut with a sharp knife.
Please note:
If the belts have not yet been introduced into the conveyor, it is recommended that
the negative cast be fixed to the belt itself with thin adhesive tape and that be used
as a pull-in aid and protection!

Fixing from RIGHT

Insert the second belt end into the punching device from
the RIGHT and level it with the provided front stop pins.
Align the marking of the endless length with
the left edge of the cutting base.
ATTENTION:
Punching
See "Punching" in the "Fixing from left" section.
Removing
See "Removing" in the "Fixing from left" section.
Please note:

Punching Instructions for Flat Belt with AF-60

(also see Habasit Operating Instructions AF-60)
Preparation

on the belt.
The belt ends on both sides must be at least 105 mm

Fixing from LEFT

the LEFT with the marking of endless length centred
and level it with the provided rear stop rails.
ATTENTION:

Punching
Move the traversing slide to the initial position and
allow the bolt to snap into grid bore 1.
(2 grid bores must be visible)
Swivel the pivot plate with the cutting die into

the rear position.

Swivel the pivot plate with cutting die into

the front position.
Second punching process:

Push through the toggle lever in one go
Move the traversing slide onward to grid bore 2 and

allow the bolt to snap into it.
the rear position.
Third punching process:

the front position.
Fourth punching process:
Removing

Please note:

Fixing from RIGHT

the RIGHT with the marking of endless length centred
ATTENTION:
Punching
Removing
Please note:

Punching Instructions for Flat Belt with AF-60/US, AF-150/151

(also see Habasit Operating Instructions 3716 AF-60/US, AF-150/151)
Preparation

on the belt.
The belt ends on both sides must be at least 105 mm

Fixing from LEFT

the LEFT with the marking of endless length centred
ATTENTION:
Punching
Lock the traversing slide in place in the marking 1.

Repeat step by step until the travel carriage snaps into

marking 4 (AF-60/US) and/or 5 (AF-150/151).
Fourth punching process:

Removing

Please note:
Fixing from RIGHT

the RIGHT with the marking of endless length centred
ATTENTION:
Punching
Removing
Please note:

Error during punching Cause Measure
The belt ends do not Both belt ends were fixed Fixing according to
fit together and punched from punching instructions
a single side e.g. LEFT
One belt end was placed Punch both belt ends from
with belt upper side at a single belt side
the punching head and (belt upper side or
the other belt end with belt lower side)
the belt lower side to
the punching head
The belt was not aligned Fixing according to

or not attached to punching instructions
rear stop rails
Slide not locked into place Before every punching

process, make sure that
the slide is properly locked
into place
The belt has not been Toggle lever of Punching according to

punched punching device was punching instructions
not pushed through
AF-60/US, AF-150/151 Adjust stop screw to

Swivel distance of increase swivel distance
toggle lever too low
The blades of Replace the blades

the punching head are
blunt or damaged

Flat Belt TC-20E s = 2.0 mm Green
Tools
Hot-pressing device PF-61 ID No.: 00077216 230VAC
ID No.: 00129447 120VAC
Cooling tongs CD-61 ID No.: 00077217
Guide rail W=30 ID No.: 00077218
Clamp for guide rail (2x)
Plastic clamps (2x) ID No.: 00161634
Toolbox with
Attention:
The PF-61hot-pressing device may not be used at an ambient temperature below 0°C.
For ambient temperatures < 0°C, use the PF-101hot-pressing device.
Welding Instructions for Flat Belts

(also see Habasit Operating Instructions 3614)
Preparation
The preparation of the connector ends is described
in the punching instructions.
Fixing
(see Habasit Fig. 5a and 6a!)
Insert the connector ends centred into the guide rail.
Push the connections together.
Put on the cover plate and fix it into place with

the clamps.
Push the connections fully together; one belt end will push
the other belt end approx. 3 mm out of the guide rail and
then be pushed back from the other side.

Hot pressing
Plug in and heat the hot-pressing device PF-61.
The luminous diode goes out when the factory-set
)
temperature of 180°C ±2°C is reached.
Heating time approx. 10 min.
Open the hot-pressing device, place it precisely centred

on the guide rail, and close it.
For flat belt E 20/2 U0/U7 MT (black),

TCF-50H (white) and TC-20EF (green/black) additionally
attach 2 plastic clamps to the rim of the housing of
the hot-pressing device (see Habasit, Fig. 12!).
For flat belt TCF-50HT (green) these plastic clamps
must not be used!
Hot pressing time 8 min. for TCF-50HT

s=2.0 mm green
)
Hot pressing time 9 min. for E 20/2 U0/U7 MT
s=2.6 mm black
Hot pressing time 15 min. for TCF-50H
s=2.0 mm white
Hot pressing time 15 min. for TC-20EF
s=2.0 mm green/black
Cooling
After the specified pressing time has elapsed,
the CD-61 cooling tong must be clamped onto
the guide rail immediately.
Open the cooling tongs, place them precisely centred

on the guide rail, and close them.
Cooling time approx. 10 min. for E 20/2 U0/U7 MT

s=2.6 mm black
)
Cooling time approx. 10 min. for TCF-50HT
s=2.0 mm green
Cooling time approx. 10 min. for TCF-50H
s=2.0 mm white
Cooling time approx. 10 min. for TC-20EF

Please note:
The specified cooling time applies to a cooling tongs temperature of approx. 15-25°C!
If the cooling tongs become hot from long use, they can be cooled by being dipped
in cold water.
Removing
Pull the belt out of the guide rail by hand.
)
The cover plate is then separated from the guide rail.
The cover plate must not be dismantled with

a sharp object as this may damage the belt!
The weld is correct if the material interface is slightly melted and the belt has
a constant width of s.
Faulty weld Cause Measure
Material is not melted Temperature <180°C Heat until luminous diode

through due to short heating time goes out
Temperature <180°C Use functional

due to defective hot-pressing device
heater plate
Check the operating
temperature of
the hot-pressing device
once a month
Temperature <180°C Adjust heating regulator

due to low temperature to 180°C according to
setting of heater regulator Habasit's instructions
Hot pressing time was Observe the hot pressing

not observed time according to
the welding instructions

Material is not melted The cooling tongs were Apply the cooling tongs
through not applied according to
The additional Mount the clamps

2 plastic clamps were as specified in the welding
not mounted instructions
(see Habasit, Fig. 12)
Weld is brittle, burnt Temperature >180°C Adjust heating regulator

due to too high temperature to 180°C according to
setting of heating regulator Habasit's instructions
A lot of material has Hot pressing time was Observe the hot pressing
flown out and stuck significantly exceeded time according to
to the guide rail the welding instructions
The belt width varies: The hot-pressing device/ Apply the hot-pressing
on one side > s, cooling tongs were not device/cooling tongs
on the other side < s centred on the guide rail according to the
welding instructions
Large distance between The belt ends were not Follow the instructions
the cutting edges or completely pushed together to fix the connector ends
the weld is not straight in the guide rail
Belts stuck to guide rail Teflon coating damaged Renew teflon coating

Tools
Hot press PF-101
incl. control unit ID no.: 00201829 230VAC
Compensation plate (2x)
Guide rail W=30 ID No.: 00077218
Clamp for guide rail (2x)
Toolbox with
Attention:
The PF-101hot-pressing device may not be used at an ambient temperature below -30°C.
In the area of freezing applications, the PF-101hot-pressing device should be used with great
care. The cables are not suited for extremely low temperatures; in case of
extreme cold, they become stiff and may break.
Do not store the PF-101hot-pressing device in extremely cold environments or
expose it to extreme cold for longer periods of time.
Please note:
Do not bring the hot-pressing device into the cold environment until the preparation
tasks have been completed. Start the pressing process immediately to prevent
the hot-pressing device from freezing.
If you cannot start the pressing process immediately, set the temperature of the PF-101
hot-pressing device to the minimum value (50°C) and commission the device to prevent
the hot-pressing device from freezing.

Welding Instructions for Flat Belts

(also see Habasit Operating Instructions 36010)
Preparation
The preparation of the connector ends is described
in the punching instructions.
Fixing
(see Habasit Operating Instructions 36010 page 8)
Insert the connector ends centred into the guide rail.
Push the connections together.
Put on the cover plate and fix it into place with

the clamps.
Push the connections fully together; one belt end will push
the other belt end approx. 3 mm out of the guide rail and
then be pushed back from the other side.
Open the hot-pressing device and insert

the first compensation plate (aluminium).
Insert the guide rail into the hot-pressing device with

the belt on the compensation plate.
Place the second compensation plate onto the guide rail,

close the hot-pressing device, and insert the front
clamping screw.
Centre the guide rail with the belt and the compensation
plates in the hot-pressing device before tightening
the clamping screws.
Adjust the applied pressure by tightening the front and

rear clamping screws. The amount of pressure can be
read from the markings of the top indicator (rings on
the pin) or on the side pressure display (bar).
Check the side pressure displays as to whether
the pressure is the same at the front and rear.

Fixing
Applied pressure 1.5 bar (second ring completely visible)
for E 20/2 U0/U7 MT s=2.6 mm black
)
for TCF-50H s=2.0 mm white
for TC-20EF s=2.0 mm green/black
Applied pressure 1.0 bar (first ring completely visible)
for TCF-50HT s=2.0 mm green
Input parameters
Insert the mains plug; the control unit is in standby mode
(red STOP luminous diode at the bottom right).
Call the programming mode with the PROG key,

the yellow display lights up, and values are shown
on the display of the control unit.
The parameters can be selected using the

TEMPERATURE AT TOP, TEMPERATURE AT
BOTTOM, and PRESSING TIME operating keys.
The corresponding yellow display lights up and
the set value is shown on the display of the control unit.
The correct values are set using the UP and DOWN arrow
keys.

Input parameters
Temperature at top 160°C for E20/2 U0/U7 MT

s=2.6 mm black
)
Temperature at top 170°C for TCF-50H
s=2.0 mm white
Temperature at top 170°C for TC-20EF
Temperature at top 170°C for TCF-50HT
s=2.0 mm green
Temperature at bottom 160°C for E20/2 U0/U7 MT

s=2.6 mm black
)
Temperature at bottom 180°C for TCF-50H
s=2.0 mm white
Temperature at bottom 180°C for TC-20EF
Temperature at bottom 180°C for TCF-50HT
s=2.0 mm green
Hot pressing time 1 min. for E 20/2 U0/U7 MT

s=2.6 mm black
)
Hot pressing time 5 min. for TCF-50H
s=2.0 mm white
Hot pressing time 5 min. for TC-20EF
Hot pressing time 3 min. for TCF-50HT
s=2.0 mm green
Once the parameters are set, leave the programming

mode with the PROG key again (the yellow PROG
display extinguishes).
Please note:
The hot pressing time is displayed on the control unit in minutes.
A decimal point must appear at the far right of the display
(see Habasit Operating Instructions 36010).

Hot pressing
Start the welding procedure with the START key;
a green display appears.
Cooling
Cooling takes place immediately using the cooling fan.
Please note:
The entire duration of the welding procedure amounts to about 20 minutes.
At the end of the automatic procedure, the green START display and the control unit
enter the standby mode again (red STOP luminous diode at the bottom right).
Removing
Open the front clamping screw and flip it down.
Remove the guide rail with the belt from
the hot-pressing device.
Pull the belt out of the guide rail by hand.

The cover plate is then separated from the guide rail.
Please note:
The cover plate must not be dismantled with a sharp object as this may damage
the belt!

The weld is correct if the material interface is slightly melted and the belt has
a constant width of s.
Material is not melted Temperature set too low Observe the heating
through temperature according to
Hot pressing time was Observe the hot pressing

not observed time according to
Applied pressure was Observe the applied

not maintained pressure according to
Temperature too low due to Use functional

defective heater plate hot-pressing device
Check the operating

temperature of
once a month
The cooling tongs were Apply the cooling tongs

not applied according to the
Weld is brittle, burnt Temperature >180°C Adjust heating regulator

due to too high temperature to 180°C according to
setting of heater regulator Habasit's instructions

A lot of material has Hot pressing time was Observe the hot pressing
flown out and stuck significantly exceeded time according to
to the guide rail the welding instructions
Applied pressure was Observe the applied

exceeded pressure according to
The guide rail was Follow the instructions to

not centred in fixing the guide rail
The belt width varies: The hot-pressing device/ Apply the hot-pressing
on one side > s, cooling tongs were not device/cooling tongs
on the other side < s centred on the guide rail according to the
Large distance between The belt ends were not Follow the instructions
the cutting edges or completely pushed together to fix the connector ends
the weld is not straight in the guide rail
Belts stuck to guide rail Teflon coating damaged Renew teflon coating

Belt Welding Instructions Flat Belt

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Belt Welding Instructions Flat Belt

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Belt Welding Instructions

Flat Belt E 20/2 U0/U7 MT s = 2.6 mm Black

Punching Instructions for Flat Belt with AF-42

Screw on the lever of the punching device

The endless length of the belt must be known and marked

On one side, the belt end must be at least 230 mm

Fixing from LEFT

Tighten both clamp bars.

Chapter XII – Annex page 1

First punching process:

Repeat step by step until the flat belt is completely cut

Remove the belts carefully from the punching device.

If the negative piece cannot be pulled from the belt itself,

Chapter XII – Annex page 2

Fixing from RIGHT

Tighten both clamp bars.

Chapter XII – Annex page 3

Punching Instructions for Flat Belt with AF-60

The endless length of the belt must be known and marked

The belt ends on both sides must be at least 105 mm

Fixing from LEFT

Tighten both clamp bars.

Chapter XII – Annex page 4

Swivel the pivot plate with the cutting die into

First punching process:

Swivel the pivot plate with cutting die into

Second punching process:

Move the traversing slide onward to grid bore 2 and

Third punching process:

Fourth punching process:

Remove the belts carefully from the punching device.

If the negative piece cannot be pulled from the belt itself,

Chapter XII – Annex page 5

Fixing from RIGHT

Tighten both clamp bars.

Chapter XII – Annex page 6

Punching Instructions for Flat Belt with AF-60/US, AF-150/151

The endless length of the belt must be known and marked

The belt ends on both sides must be at least 105 mm

Fixing from LEFT

Tighten both clamp bars.

First punching process:

Repeat step by step until the travel carriage snaps into

Fourth punching process:

Chapter XII – Annex page 7

Remove the belts carefully from the punching device.

If the negative piece cannot be pulled from the belt itself,

Fixing from RIGHT

Chapter XII – Annex page 8

Error during punching Cause Measure

The belt was not aligned Fixing according to

Slide not locked into place Before every punching

The belt has not been Toggle lever of Punching according to

AF-60/US, AF-150/151 Adjust stop screw to

The blades of Replace the blades

Chapter XII – Annex page 9

Cooling tongs CD-61 ID No.: 00077217

Guide rail W=30 ID No.: 00077218

Clamp for guide rail (2x)

Plastic clamps (2x) ID No.: 00161634

Welding Instructions for Flat Belts

Push the connections together.