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1. Securely fasten welder to mounting surface.
2. If this is a new welder, proceed to step 4.
3. Examine the light green coated surface of the heating element for scratches. A scratched and damaged coated surface can affect weld results; heating element may need replaced.
4. On the front of the control box is an on/offswitch, indicator light and fuse holder. On the left side of the control box is a power supply line and thermocouple. Plug the power supply line and thermocouple into the left side of the control box. On the right side of the control box is the main power cord that is plugged into an 110/120v (or 220/240v, as specified when ordered) electrical power source.
5. On top of the control box is the temperature control dial. Set the control dial at 440°F for all reinforced polyurethane belts including the red LCF Can Cable belt or 500°F for light blue, light green and natural Can Cable belts. Turn the power switch to the on position. The large red indicator light will stay on. On the temperature control dial, an indicator light will come on and remain on while element is heating. Warning: Do not start welding until this light goes out the first time. This indicator light will then fluctuate on and off as the heating element maintains the correct welding temperature. Note: If light green coated surface contains polyurethane residue, use a clean, dry cloth to remove it. Warning: Do not use any object to scrape polyurethane from surface.
6. Turn large wing nut several turns counter-clockwise until it stops. Pull back on red knob on front (sliding) die. Push down on black knob on top of welder and pull brass pin out to release coated heating element. Swing heating element away from die area.
7. Remove the black star-shaped thumbnuts from the welder. Select and position the correct vee or round dies in the welder. Insert a black star-shapedthumbnut into each die and finger-tighten as in Figure 1. When welding V-belt, the split die fits into the front (sliding) section of the welder.
8. Using the cutting shears provided, cut each end of round belt at a 15°angle, or V-belt straight as in Figure 2.
9. For round belt, continue to step 9a; uncogged V-belt, continue to step 9b; cogged V-belt, to step 9c.
1. Slide end of the round belt into the rear die until it overhangs approximately 1/16" and angle on belt is parallel with angle on die. Clamp the belt into position by lightly tightening the knurled thumbnut finger tight. On the front (sliding) die, the flat side of the holding clamp must face up. If not, turn knurled thumbnut counter-clockwise and remove. Push holding clamp from base and rotate clamp 180° until flat side is up. Reassemble knurled thumbnut. Slide end of belt into front die and position exactly same as rear die. Lightly finger-tighten knurled thumbnut. See Figure 3. Caution: Make sure belt does not contain any twist.
2. Slide end of the uncogged V-belt into the rear die until it overhangs approximately 1/16", but not more than 1/8". Clamp belt into position by lightly tightening the knurled thumbnut finger tight. On the front (sliding) die the flat side of theholding clamp must face up. If not, turn knurled thumbnut counter-clockwise and remove. Push holding clamp from base and rotate clamp 180° until the flat side is up. Reassemble knurled thumbnut. Slide end of V-belt into front die and position exactly the same as the rear die. Lightly finger-tighten knurledthumbnut. See Figure 4. Caution: Make sure belt does not contain any twist.
3. Slide end of the cogged V-belt into the rear die until one cog overhangs. Clamp belt into position by lightly tightening the knurled thumbnut finger tight. On the front (sliding) die, the flat side of the holding clamp must face down. If not, turn knurled thumbnut counter-clockwise and remove. Push holding clamp from base and rotate clamp 180° till flat side is down. Reassemble knurled thumbnut. Slide end of cogged V-belt into front die and position exactly the same as the rear die. Lightly finger-tighten thumbnut. See Figure 5. Note: Lip on holding clamp must be engaged in notch on V-belt. Caution: Make sure belt does not contain any twist.
10. Swing coated heating element into position above and between dies. Pull out on brass pin, push down and hold black knob (on top of welder) and release brass pin. This locks heating element into position.
11. Turn large wing nut clockwise, moving it forward until both overlapping surfaces contact the coated heating element. Continue turning large wing nut as belt ends melt and material is squeezed out of weld area. Continue turning large wing nut until it stops. Warning: do not over tighten. See Figure 6.
12. After a maximum of 20 seconds (less for smaller profiles), turn large wing nut counter-clockwise 3-4 full turns. Pull back on red knob till front (sliding) die stops. Push down on black knob on top of welder; on back of welder, slightly push on the two guide rods to move coated heating element. Pull brass pin out and release coated heating element. Swing heating element away from die area. Immediately push red knob forward and quickly spin large wing nut clockwise until stop is reached. Important: This sequence must be done very quickly. See Figure 7.
13. While weld is cooling, use a clean, dry cloth to wipe excess polyurethane material from coated heating element. It is important that heating element be cleaned between every weld.
14. After a minimum of one minute, turn large wing nut counter-clockwise several turns. Loosen both knurled thumbnuts several turns and pull back on red knob on front (sliding) die. Remove belt from welder, Figure 8, and using special flash cutters trim weld flash from belt, Figure 9. Note: The flash cutters have been designed specifically for trimming polyurethane and are not to be used for cutting metal, wire, etc. Warning: Allow the belt to cure for a minimum of ½ hour prior to installing, tensioning or putting strain on the belt weld.