RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW CHAPTER 32 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW Figure 32 1 Front View of RTC Rails Item Description Item Description 1 Rear Outroad Conve.........
RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW CHAPTER 32 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW 19 18 17 16 15 14 13 12 11 10 Figure 32-1 Front View of RTC Rails Item Description Item Description Rear Outroad Conveyor Transport Belt Motor 11 Inroad Conveyor Linear Guide Outroad Board Stop 12 Board at Left Sensor Board Load Servo Motor 13 Rear Inroad Conveyor Transport Belt Motor Front Outroad Conveyor 14 Rear Inroad Conveyor Front Outroad Conveyor Transport Belt Motor 15 Board at Stop Sensor Front Print Station and Board Clamp 16 Moving Rail Stepper Motor Front Inroad Conveyor Transport Belt Motor 17 Rear Print Station and Board Clamp Rail Width Linear Guide (in positions) 18 Outroad Conveyor Linear Guide Front Inroad Conveyor 19 Rear Outroad Conveyor 10 Transport Mechanism Chapter Issue Jul 10 Technical Reference Manual 32.1 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW 12 10 13 14 11 Figure 32-2 Rear View of RTC Rails Item Description Item Description Transport Mechanism Drive Belt Transport Mechanism Linear Guide Pneumatic Rail Width Clamp (in positions) Outroad Vane Rail Lifted Sensor 10 Board Stop Vane Moving Rail Home Sensor 11 Inroad Vane Stepper Motor Moving Rail Leadscrew (in positions) 12 Transport Mechanism Home Vane Transport Mechanism Home Sensor 13 Inroad Vane Board at Right Sensor 14 Inroad Vane Lift Solenoid NOTE Information given in this manual references a machine set up for left to right feed direction For machines designated right to left feed direction, contact DEK Customer Support for assistance Right to left feed machines are not a direct mirror of the left to right machine the following exceptions relate: In the circuit diagram, later in this chapter, Node 11 becomes Node 16 In the circuit diagram, motor wiring designations are mirrored The motors are wired in the single direction mode, that is, left to right or right to left; a machine wired for one direction cannot be wired for the opposite feed direction 32.2 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW The rapid transit conveyor (RTC) is a programmable width conveyor system which sets the rail width and transports boards through the machine using belts and vanes The system can accommodate up to three boards in the machine at one time thereby reducing the machine cycle time The RTC system consists of three sections: • Inroad Conveyor • Print Station • Outroad Conveyor Using belts, Board is transported to the end of the inroad conveyor where the board is stopped by the board stop vane Inroad Conveyor Board NOTE Front rail removed for clarity Board direction Left to Right Board Stop Vane The inroad vane is raised and the vane stepper motor drives the inroad vane to snug the board Board Inroad Vane Vane Stepper Motor Board Stop Vane The transport mechanism moves the vanes placing the board in the centre of the print station Board Print Station Chapter Issue Jul 10 Technical Reference Manual 32.3 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW Board is secured with the board clamps and the board is raised to print height Whilst at print height, the transport mechanism moves the vanes back to the ready position; the inroad vane is driven away from the board stop vane and the inroad vane is lowered Board enters the machine, the inroad vane is raised and the vane stepper motor drives the inroad vane to snug the board Board At the end of the print stroke, the print station is lowered to transport height The transport mechanism moves Board to the centre of the print station and the outroad vane moves Board on to the outroad conveyor Board Board Outroad Vane Outroad Conveyor The printed board is transported out of the machine on the outroad conveyor using belts In the event of the downline machine being busy, Board is stopped at the end of the outroad conveyor by the outroad board stop Board is printed and Board enters the machine and is held at the end of the inroad conveyor 32.4 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW Rail Width The rear print station rail is driven by a CAN Bus servo motor which sets the rail width for the board At transport height, the rear print station is dovetailed to the rear inroad and rear outroad conveyors therefore moving with the print station as the rail width is set During the print cycle, the print station is separated from the inroad and outroad conveyors To prevent the conveyors moving during the print cycle, pneumatic rail width clamps secure the conveyors to the base frame of the RTC rail system Board Clamping The print station can be fitted with one of the following board clamping arrangements: • 380mm Board Clamps • Foil-less Clamps Foil-less clamps are utilized for thin pliable boards where there is a requirement to print close to the board edge The foil-less clamps are assisted with the use of a vacuum box beneath the product board Rear Board Clamp Board Front Board Clamp Board Clamps Rear Foil-less Clamp Board Front Foil-less Clamp Foil-less Clamps Figure 32-3 Board Clamping Arrangements Chapter Issue Jul 10 Technical Reference Manual 32.5 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW Board Specifications The RTC system can accommodate the following board specifications: • Minimum Board Size - 50mm (length) by 40mm (width) • Maximum Board Size - 375mm (length) by 254mm (width) • Board Thickness - 0.4mm to 5.0mm • Maximum Board Weight - 0.5kg • Under Board Clearance - 25mm NOTE Dedicated or Grid-Lok tooling must be used for boards greater than 295mm in length DEK recommends that the board length exceeds the board width when transporting boards through the RTC system Under Board Components When printing on a board with components on the underside, sufficient gap from the front and rear edges of the board must be component free to allow for transport belts and vanes Rear Edge 5mm Front Edge 6mm Plan View on Board 32.6 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW Board Cut-Outs The board length dimension programmed into the software sets the distance between the inroad vane and the board stop vane Board Length Inroad Vane Board Stop Vane 1.5mm (nominal) 2.5mm (nominal) Plan View on Board The distance between the two vanes might be different to the board length in the following circumstances: • The board has cut-outs that coincide with the vanes • The board is not square or rectangular • The board has rounded or chamfered corners If the board length is present where the vanes contact the board, as in the graphic above, the remainder of this section may be ignored The board length dimension programmed into the software must be the overall length of the board Any cut-outs that coincide with the board stop vane or the inroad vane must be compensated for using the Leading Edge Cut Out or Trailing Edge Cut Out parameters The Leading Edge Cut Out parameter compensates for any difference between the right hand side of the board and the point that the board stop vane contacts the board, if different The parameter is adjustable from 0.0mm to 50.0mm in 0.1mm increments Board Length Leading Edge Leading Edge Cut Out Plan View on Board Chapter Issue Jul 10 Technical Reference Manual 32.7 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW The Trailing Edge Cut Out parameter compensates for any difference between the left hand side of the board and the point that the inroad vane contacts the board, if different The parameter is adjustable from 0.0mm to half the board length in 0.1mm increments Board Length Trailing Edge Trailing Edge Cut Out Plan View on Board To prevent the board turning and jamming in the rails, ensure that the remaining front and rear edges of the board (board length minus cut outs) are 50mm or greater Chamfered or Rounded Corners If either the inroad or board stop vanes contact with a chamfered or rounded corner, this must be treated as a cut out 4.0mm (nominal) 4.0mm (nominal) Trailing Edge Cut Out Trailing Edge Cut Out Plan View on Board Boards with chamfered or rounded corners may jam in the rails if the vanes contact directly with the chamfering or rounding, pushing the board towards the rear rail 32.8 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW RTC Rising Table The RTC system uses the standard rising table mechanism but incorporates a smaller manual tooling plate and different home vane The manual tooling plate measures 295mm from left to right and the maximum board length is 375mm Therefore, any boards greater than 295mm in length must be supported using dedicated or Grid-Lok tooling Board Tooling Manual Tooling Plate The tooling locating dowel holes on the rising table are located in a different position to the standard rising table For more information refer to the Vacuum Box Tooling section of the Board Support Tooling Module The rising table home vane on the RTC machine ensures that the home position is 10mm higher than a standard machine The rails on the RTC machine are 5mm lower than a standard machine (measured from the screen), that combined with the rising table home position means that the maximum under board clearance is reduced by 15mm to 27mm (25mm available in software to allow for adequate clearance) NOTE For tooling options see the board support tooling chapter Chapter Issue Jul 10 Technical Reference Manual 32.9 32.10 USB NOTE The breaks in the CAN Bus chain reflect that additional I/O Nodes may be fitted, refer to Machine Control chapter for the complete CAN Bus chain I/O Node 11 becomes I/O Node 16 when the machine is configured for Right to Left feed Motors 8M17 thru 8M21 are wired opposite to the wiring shown when the machine is configured for Right to Left Feed Motherboard Machine PC Technical Reference Manual Dual Stepper X3 NextMove Interface Card X4 NextMove ES (I/O Node 1) X5 Machine Control Enclosure CAN Bus M36PL22 M36PL17 M36PL11 DIG OUT DIG OUT M36PL18 N12PL4 N12SK3 N11PL4 N11SK3 N2SK3 N2SK2 Motor 2BMotor 2B+ Motor 2AMotor 2A+ DIG IN 11 DIG IN 10 DIG IN DIG IN 8PL22 +V Dir Enable 0V +V Dir Enable 0V To I/O Node * See Notes 2,3 CAN Bus Speed Controller BGE 3004 Speed Controller BGE 3004 8PL10 8PL12 8PL147 Speed Controller BGE 3004 Right R-L Speed Controller BGE 3004 Right L-R Left L-R Left R-L I/O Node 12 Rail Width Stepper Motor M M N2PL4 * I/O Node 11 Transport Mechanism Servo Motor Main Machine I/O Node 8SK135 8SK133 8SK132 8SK134 8PL03 8PL04 N12PL01 + Sig 0V + Sig 0V + Sig 0V + Sig 0V + Sig 0V M M M M M Vane Stepper Motor (8M19) Outroad Board Sensor (8SE7) Inroad Board Sensor (8SE8) Rail Lift Sensor (8SE5) Board At Stop Sensor (8SE32) Front Outroad Belt Drive (8M21) Rear Outroad Belt Drive (8M18) Rear Inroad Belt Drive (8M17) Front Inroad Belt Drive (8M20) Moving Rail Home (8SE6) Transport Mechanism Home (8SE31) Inroad Vane Lift Solenoid (16SOL03) DIG OUT 15 + Sig 0V Outroad Board Stop Solenoid (16SOL22) DIG OUT 12 N11PL01 Rail Width Clamp Solenoid (16SOL14) Board Clamp Solenoid (16SOL10) DIG OUT 10 DIG OUT RAPID TRANSIT CONVEYOR (RTC) MODULE ELECTRICAL SCHEMATIC ELECTRICAL SCHEMATIC Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS Rail to Table Height The rail to table height is factory set and must not be adjusted Board Clamp Setting WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP Raise the rising table to vision height Toggle the board clamps to On Using a 0.6mm feeler gauge, check that the gap between the board clamp and the board support plate on both ends of the front print station rail Board Clamp Board Support Plate Feeler Gauge View on Inside of Print Station Rail Using a 0.6mm feeler gauge, check that the gap between the board clamp and the board support plate on both ends of the rear print station rail If no adjustment is required, go to Step 10 To adjust the board clamp setting, loosen the two board clamp adjustment screws using a flat bladed screwdriver Board Clamp Adjustment Screw Board Clamp Adjustment Screw Plan View of Print Station Rail Using feeler gauges, move the board clamp to achieve the 0.6mm gap between the board clamp and the board support plate on both ends of the print station rail Tighten the two board clamp adjustment screws 32.16 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS Recheck the gap at both ends of the print station rail 10 Remove the feeler gauges 11 Toggle the board clamps to Off 12 Home the rising table Home Position Rail Width Check WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP Ensure the board clamps are fitted and the Board Clamp Setting procedure has been carried out In Diagnostics select Rapid Transit Conveyor module Select Home Rapid Transit Conveyor Inroad Vane Motor Select Home Rapid Transit Conveyor Board Transport Motor Select Home Rail Width Select Adjust and set board width to 250mm Select Exit Select Drive Rail to Board Width Select Run Diagnost 10 Open the front printhead cover/shutter 11 Place a vernier gauge just below the board clamp foil in the centre of the board clamps and check that the vernier reads between 250.25mm ±0.10mm Rear Board Clamp 250.25mm ±0.10mm Front Board Clamp Plan View of Board Clamps 12 If the rail width is correct, go to Step 22 13 Close the front printhead cover/shutter and press the System button when Chapter Issue Jul 10 Technical Reference Manual 32.17 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS prompted 14 Select Set Rail Board Width Calibration 15 Select Run Diagnost to open the Rail Width Offset window 16 Use Incr or Decr to set the offset required to achieve the dimension in Step 11 NOTE Increasing the offset increases the dimension between the rear rail and the home position therefore, decreasing the width between the front and rear rails Home Position RAIL WIDTH OFFSET 0.00 mm +/- 3.00mm Rail Width Plan View on Print Station of RTC Rails 17 Select Move 18 Open the front printhead cover/shutter and recheck the measurement 19 If the rail width is incorrect, close the front printhead cover/shutter, press the System button and repeat Steps 16 to 18 20 If the rail width is correct, close the front printhead cover/shutter, press the System button and select Set 21 Select Yes to save the information Inroad/Outroad Conveyors Conveyor Height Setting The inroad and outroad conveyors must be the same height as the print station for smooth transition of the board through the length of the rail system Use the following procedure to check and adjust the height: To move the vanes clear of the front print station rails, set the board length to maximum and home the rapid transit conveyor board loader Place the Board Clamp Setting Plate (140403) half on the print station and half on the inroad conveyor Viewing from the left side of the machine, ensure that the board clamp setting plate is in contact with the transport belts on the front and rear inroad conveyors 32.18 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS If adjustment is required on the front inroad conveyor, loosen the two print station lift bracket locking screws on the front inroad conveyor Locking Nut Locking Screws Adjusting screw Print Station Lift Bracket View on Front of RTC Rail System Using an 8mm spanner, loosen the locking nut Adjust the adjusting screw until the board clamp setting plate is sitting evenly on the print station board support plate and the transport belts of the front inroad conveyor Tighten the two print station lift bracket locking screws on the front inroad conveyor Using two 10mm spanners, hold the adjusting screw whilst tightening the locking nut Recheck the level 10 If adjustment is required on the rear inroad conveyor, move the board clamp setting plate fully on to the inroad conveyor 11 Manually lift the rear print station rail Chapter Issue Jul 10 Technical Reference Manual 32.19 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS 12 Loosen the two print station lift bracket locking screws on the rear inroad conveyor Locking Screws Print Station Lift Bracket Locking Nut Adjusting Screw View on Rear of Rear RTC Rail 13 Lower the rear print station rail 14 Using an 8mm spanner, loosen the locking nut 15 Move the board clamp setting plate back to its original position 16 Adjust the adjusting screw until the board clamp setting plate is sitting evenly on the print station board support plate and the transport belts of the rear inroad conveyor 17 Move the board clamp setting plate fully on to the inroad conveyor 18 Manually lift the rear print station rail 19 Tighten the two print station lift bracket locking screws on the rear inroad conveyor 20 Lower the rear print station rail 21 Using two 8mm spanners, hold the adjusting screw whilst tightening the locking nut 22 Move the board clamp setting plate back to its original position and recheck the level 23 Remove the board clamp setting plate from the rail system 24 Move the rapid transit conveyor board loader to the ready position 25 Place the board clamp setting plate half on the print station and half on the outroad conveyor 26 Viewing from the right side of the machine, ensure that the board clamp setting plate is in contact with the transport belts on the outroad conveyor 27 If adjustment is required, repeat Steps to 23 on the outroad conveyors 32.20 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS Front Conveyor Alignment The front inroad conveyor must be perfectly aligned to the print station rail as the vanes travel the whole length of the rail system Use the following procedure to check and adjust the alignment: To move the vanes clear of the front print station rails, set the board length to maximum and home the rapid transit conveyor board loader Using a metre straight edge rule above the transport belt on the inroad conveyor and above the board support plate on the print station rail, check that the inroad conveyor and print station are aligned If adjustment is required, loosen the two front inroad conveyor securing screws Front Inroad Conveyor Securing Screws View on Front Inroad Conveyor Place a 5mm Allen key between the conveyor and the print station to maintain the correct gap Adjust the conveyor to achieve alignment with the print station rail Tighten the securing screws, remove the Allen key and recheck the alignment Move the rapid transit conveyor board loader to the ready position Using a metre straight edge rule above the transport belt on the outroad conveyor and above the board support plate on the print station rail, check that the outroad conveyor and print station are aligned If adjustment is required, loosen the two front outroad conveyor securing screws 10 Place a 5mm Allen key between the conveyor and the print station to maintain the correct gap 11 Adjust the conveyor to achieve alignment with the print station rail 12 Tighten the securing screws, remove the Allen key and recheck the alignment Chapter Issue Jul 10 Technical Reference Manual 32.21 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS Rear Conveyor Alignment The rear inroad and outroad conveyors taper slightly away from the print station Use the following procedure to check and adjust the alignment: Using a vernier above the board support plate, measure the rail width on the print station (Dimension A) Board Guide Securing Screws C B A Measure the rail width on the inroad conveyor close to the print station (Dimension B) Dimension B must be between Dimension A and A plus 0.05mm NOTE Ensure that the measurement is taken from the flat and not the chamfered end Measure the rail width on the inroad conveyor close to the end of the inroad conveyor (Dimension C) Dimension C must be between Dimension B plus 0.10mm and B plus 0.20mm NOTE Ensure that the measurement is taken from the flat and not the chamfered end If adjustment is required, loosen the board guide securing screws and adjust the board guide to achieve the measurements above Tighten the board guide securing screws Repeat Steps to for the outroad conveyor Rail Lifted Sensor 32.22 There is no adjustment on the rail lifted sensor or the vane Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS Board Ultra-sonic Sensors Positional Adjustment There are three board sensors: • Board at Left Sensor • Board at Stop Sensor • Board at Right Sensor The board sensors are adjustable in the X and Y directions to compensate for any holes or cut-outs on the product board that coincide with the sensor when the board is in the stopped position With the board in the stopped position over the sensor, if the sensor is not seeing the board due to a hole or cut-out, use the following procedure to adjust the sensor: Power down the machine In the X direction; using a 2.5mm Allen key, loosen the two bolts that secure the sensor to the bracket Sensor Bracket Board at Right Sensor Board at Left Sensor Board at Stop Sensor View on Front of RTC System Move the sensor to the required position Tighten the two bolts that secure the sensor to the bracket In the Y direction; using a 2.5mm Allen key, loosen the two bolts that secure the sensor bracket to the rails Move the sensor to the required position Tighten the two bolts that secure the sensor bracket to the rails Power up the machine and check for correct operation of the sensor Chapter Issue Jul 10 Technical Reference Manual 32.23 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS Sensitivity Adjustment The sensitivity setting of the sensors is critical as it is important that the sensor is only activated by the board and not machine parts To achieve an optimum setting carry out the following procedure: Press the yellow Set button on the sensor for approximately two seconds The green LED comes On LED Se Set Button t Sensor (also at outroad conveyor) Board View on Inroad Conveyor of RTC System Place a board on the rails above the belts Press the yellow Set button again The green LED comes on again Remove the board from the rails and confirm that the green LED is Off Place the board on the belts and above the sensor The green LED should be On Remove the board and place it back on top of the rail as in step The green LED should be Off This confirms that the sensor is correctly set NOTE If the sensor fails to set correctly it may need to be reset Disconnect the power from the sensor by unscrewing the plug at the back Reconnect the plug and press Set for approximately ten seconds; the LED flashes rapidly The sensor is now reset and the procedure above can be followed to set the sensitivity 32.24 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES Board Clamp Replacement WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP Remove the two board clamp securing screws using a flat bladed screwdriver Board Clamp Securing Screws Plan View of Print Station Rail Lift the board clamp off the rail Fit the new board clamp to the print station rail Pushing the board clamp towards the other rail, refit the screws removed in Step NOTE The Board Clamp Setting procedure is not required after board clamp replacement Board Clamp Foil Replacement WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP Remove the two board clamp securing screws using a flat bladed screwdriver Board Clamp Securing Screws Plan View of Print Station Rail Lift the board clamp off the rail and turn upside down on a solid surface Using a 2mm Allen key, remove the cap head screws that secure the foil to the board clamp Fit the new foil with the screws removed in Step Chapter Issue Jul 10 Technical Reference Manual 32.25 RAPID TRANSIT CONVEYOR (RTC) MODULE REPLACEMENT PROCEDURES Fit the board clamp to the print station rail Pushing the board clamp towards the other rail, refit the screws removed in Step NOTE The Board Clamp Setting procedure is not required after board clamp replacement Rear Rail Drive Belt At the rear of the rising table, slacken the adjustable idler pulley using two 8mm spanners (one either side of the drive mechanism support plate) Moving Rail Stepper Motor Pulley Drive Mechanism Support Plate Right Hand Drive Shaft Pulley Left Hand Drive Shaft Pulley Adjustable Idler Pulley Slide the adjustable idler pulley to slacken the drive belt Remove the drive belt and discard NOTE If the drive belt has snapped, the left and right drive shafts may be out of synchronization with each other Turn the left and right hand drive shaft pulleys (together) fully counter-clockwise Fit the replacement drive belt without moving the right or left hand drive shaft pulley Using a suitable cable tie, engage a forcemeter with the adjustable idler pulley Apply a horizontal force of 6kg Maintaining this force, tighten the adjustable idler pulley securing nut Using a tension meter on the bottom of the drive belt, check the tension is between 40Hz - 45Hz Adjust the drive belt tension as necessary to achieve the reading in Step In Diagnostics select Rapid Transit Conveyor module 10 Select Cycle Rail Width to even out the tension in the belt NOTE Ensure there is no tooling on the table 11 Stop after one complete cycle and repeat Steps 7-8 12 Select Home Rail Width 32.26 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE REPLACEMENT PROCEDURES 13 Perform the Rear Rail Parallelism check (Adjustments and Settings section of this chapter refers) to ensure no teeth were jumped during the belt change Inroad/Outroad Transport Belts The rear inroad and outroad transport belts are 3mm in diameter The front inroad and outroad transport belts are 2mm in diameter Ensure the correct diameter transport belts are used when replacement is required Transport Mechanism Drive Belt Use the following procedure to replace the transport mechanism drive belt: In Diagnostics select Rapid Transit Conveyor module Home the vane stepper motor Home the transport mechanism Power down the machine Using a 2mm Allen key, remove the four screws that secure the board stop vane to the bearing block and remove the vane Remove the two screws that secure the front outroad conveyor to the transport mechanism and remove the conveyor Disconnect the vane stepper motor connection Belt Clamp Securing Screws Drag Chain Securing Screw Holes Belt Clamp Vane Stepper Motor Connection Transport Mechanism Pulley Securing Nut Plan View on RTC System Using a flat bladed screwdriver, remove the two screws that secure the drag chain to the belt clamp Manually move the transport mechanism to align the three belt clamp securing screws with the cut-out in the extrusion 10 Using a 10mm spanner, release the belt tension by loosening the transport mechanism pulley securing nut on the inroad side of the transport mechanism Chapter Issue Jul 10 Technical Reference Manual 32.27 RAPID TRANSIT CONVEYOR (RTC) MODULE REPLACEMENT PROCEDURES 11 Using a 3mm Allen key, remove the three screws that secure the belt clamp to the bearing block and remove the belt clamp 12 Remove the drive belt from the transport mechanism 13 Fit the new drive belt terminating both ends at the top of the bearing block 14 When placing the belt in place on the bearing block, ensure that any slack is taken up without applying any tension to the belt 15 Refit the belt clamp 16 Refit the drag chain to the belt clamp 17 Connect the vane stepper motor 18 Refit the board stop vane 19 Refit the front outroad conveyor 20 Using a piece of wire between the pulley and the transport mechanism extrusion, engage a forcemeter on the transport mechanism pulley on the inroad side of the transport mechanism Apply a horizontal force of 24kg 21 Maintaining this force, tighten the securing nut 22 Carry out the front conveyor alignment for the outroad conveyor, Front Conveyor Alignment - Adjustments and Settings section of this chapter refers 32.28 Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE CALIBRATIONS CALIBRATIONS Conveyor Transport Belt Speed WARNING LETHAL VOLTAGE DANGEROUS VOLTAGES EXIST IN THIS EQUIPMENT ENSURE ALL ELECTRONIC COVERS AND MAIN MACHINE COVERS ARE FITTED BEFORE OPERATING THIS EQUIPMENT The inroad and outroad conveyor transport belts are driven independently by four variable speed motors Inevitably one motor drives faster than the other motor It is necessary to calibrate these motors so they drive at the same speed Each belt motor speed is controlled by a separate speed controller module situated on the right hand RTC rail support beam The belt speed is measured using a tachometer on the transport belt pulley and adjusted using the potentiometer on the speed controller module Calibration Procedure In Diagnostics, select Rapid Transit Conveyor Select Toggle Inroad Belts to start the belts on the inroad conveyor Select Toggle Outroad Belts to start the belts on the outroad conveyor Chapter Issue Jul 10 Technical Reference Manual 32.29 RAPID TRANSIT CONVEYOR (RTC) MODULE CALIBRATIONS Using a tachometer fitted with the surface speed test wheel, positioned on the input or output pulley, measure the speed of all four transport belts and check that the speed is 44 - 46 metres/min If adjustment is required, using the labels attached to the cables connecting to the motor speed controllers, identify which motor speed controller is associated with the transport belt that needs to be adjusted Adjust the appropriate motor speed using the potentiometer situated beneath the white plastic cover on the motor speed controller module Select Toggle Inroad Belts to stop the belts on the inroad conveyor Select Toggle Outroad Belts to stop the belts on the outroad conveyor Select Exit to leave diagnostics 32.30 Technical Reference Manual Chapter Issue Jul 10 ... has been carried out In Diagnostics select Rapid Transit Conveyor module Select Home Rapid Transit Conveyor Inroad Vane Motor Select Home Rapid Transit Conveyor Board Transport Motor Select Home... Solenoid (16SOL10) DIG OUT 10 DIG OUT RAPID TRANSIT CONVEYOR (RTC) MODULE ELECTRICAL SCHEMATIC ELECTRICAL SCHEMATIC Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE ADJUSTMENTS AND SETTINGS... Technical Reference Manual Chapter Issue Jul 10 RAPID TRANSIT CONVEYOR (RTC) MODULE OVERVIEW The rapid transit conveyor (RTC) is a programmable width conveyor system which sets the rail width and