Drive Belts Tensioning and Calibration (WALLTEQ M-380)

Drive belts tensioning

• Loosen fully the 04 tensioner from both sides X+,X- using (a 24mm wrench key and 24mm socket ratchet),leave the bolts from one side and take them out on the reference side, in order to put the pre-tensioning device

• Look at the plate holding the belts from one side either X+ or X- to see if there will be enough space when tightening to avoid getting in a narrow space with the tensioner square body, if not:

• Using a 6mm Allen key open the plates more to the X- side (close to the square body of the tensioner) if you chose X+ as a reference and vise versa (pay attention to put the lock pieces of belts in place)

• After putting the pre-tensioning device in the reference side tensioners whether X+ or X-,start rotating until the shaft is touching the tensioners body and measure the distance between the plate and the tensioner body ,in our case it was=29 mm from one side and 29.5mm from the other side (it can vary )

• Take out one pre-tensioning device and put the bolt in place and then the other one (if you take off the two pre-tensioners the belt will loosen

• Make sure the distance is always 29mm and 29.5mm with the bolts before going to the next step,(drive belts perfectly pre-tensioned)

• Lift the belt from two points to release the tension

• Using a 24mm ratchet socket key start tensioning the belt from the reference side by adding 17.15mm for both sides for each belt in our case the distance between the plate and the tensioner body was 46.15mm and 46.65mm

• The non reference side the distances between the plate and the tensioner body were 5.16mm and 5.65mm(almost touching the body),the same thing here start tensioning until the distance from the body tensioner for both will equal to: 22.31mm and 22.8 mm

• Lock the 24mm long bolts by their 24mm nuts using a 24mm wrench key

• Drive the bridge back and forth several times (slow speed at first), to see how the movement on the X axe is

Calibration

• By pass the X- side laser sensors (using a short circuit on the second safety module)in order to go under and access the bridge without triggering the safety and lose the precision (brakes release and the bridge lay move a little bit)

• Try to send the bridge to the starting X point of the table #01 which was X=-64mm

• Using a big level, put it against the two guide wagons rails of the Y axe ,and see if the level is matching the fence of the table (do that for three different spots to make sure that the gantries are in parallel)

• It is totally normal that the bridge will not matching the table due to the tensioning, leading to the next step:

• Move the bridge away a little bit towards the X+ let's say X=200mm (access the bridge the same way and put the level the same way and mark the spot above the table sheathing)

• Move the bridge further towards the X+ let's say X=200mm+10000mm ((access the bridge the same way and put the level the same way and mark the spot above the table sheathing)

• Using a reliable metric tape ,measure the distance between the two marks (better to not to start with the O but 100mm instead)

• If the distance measured is 10000mm (which not likely to be the case), do not do the next step

• If the distance measured is let's say 9997mm,(go to soft keys and then service, enter to the left upper box 10000mm and at the left bottom box the 9997mm (do not close the soft key)

• Enter the service and then config and the then go to the f1 document and look for %MC2 and copy the six digits value

• Go back to the soft key and paste the %MC2 value on the upper right box ,and click on calculate

• A new number will show up at the bottom right box copy paste it at f1 file as a replacement of the number you copied paste in the first place

• Right click on the config file and click on update

• Drive the bridge for each table and adjust the X starting point according the the same level against fence procedure until reach a perfect matching (level flush with the metallic bar or fence)

• if the cutting is not straight let's say on table #02 short at the master side and flush at the slave side, increase the value of the encoder by the same discrepancy value in order to make the master even with the slave

• Let's say it was 2mm short at the master side enter X1M at home position and add 02mm so it will be 15502mm( make sure to uncheck the slave encoder and emergency stop pushed to allow you make the change)