How to Replace a PCB Conveyor Belt in SMT Production Line

You play a key role when you replace a PCB Conveyor Belt in your SMT production line. Machine leveling helps keep the conveyor stable, and the right replacement kit ensures smooth operation. Check for gaps at the board interface to prevent defects.

A well-functioning conveyor boosts throughput rate and improves component placement accuracy.
Proper alignment reduces PCB warpage and lowers maintenance needs.
These steps help you maintain efficiency and quality in your SMT process.

Key Takeaways

Gather the right tools and parts before starting. This includes screwdrivers, wrenches, and a compatible replacement belt kit to avoid delays.
Ensure proper machine leveling to prevent conveyor drift and jams. Use a spirit level to confirm the conveyor is flat before replacement.
Conduct thorough pre-replacement checks for safety. Inspect all components for damage and ensure the conveyor is securely anchored.
Clean the conveyor system before installing the new belt. This prevents debris from damaging the new belt and ensures smooth operation.
Regularly check and adjust belt tension after installation. Proper tension prevents slippage and misalignment, keeping the conveyor running efficiently.

Preparation

Tools and Parts

You need the right tools and parts before you start to replace a PCB conveyor belt. Gather everything in advance to avoid delays during the process. Most SMT production lines require basic hand tools and specific replacement kits designed for PCB conveyors.

Screwdrivers help you remove panels and covers.
Wrenches allow you to loosen and tighten bolts.
Clips secure the belt and keep it in place.

Replacement belt kits should match your conveyor’s specifications. Check the kit for compatibility with your machine model. You should also review the PCB size, conveyor speed, and layout. Automation features may affect the type of belt you need.

Tip: Organize your tools and parts on a clean workbench. This helps you work faster and reduces the risk of losing small components.

Machine Leveling

Machine leveling is a critical step before you replace a PCB conveyor belt. A level conveyor keeps the belt running smoothly and prevents problems. If the machine is not level, misalignment can cause the conveyor belt to drift or get stuck. This often leads to jams, which disrupt the movement of PCBs. You may face increased downtime and even damage to the conveyor system or the PCBs themselves.

Check the leveling feet or adjustment screws on your conveyor. Use a spirit level to confirm the surface is flat. Adjust each foot until the bubble sits in the center.

Note: Proper leveling ensures the belt moves evenly and reduces wear over time.

Evaluate your conveyor system based on the size of your PCBs, the speed required for your production, and the overall layout. Automation features may require extra attention to alignment and belt tension. When you prepare carefully, you set yourself up for a successful replacement and smoother SMT production.

Safety

Pre-Replacement Checks

Before you replace a PCB Conveyor Belt, you need to make sure the equipment is safe and stable. Start by inspecting the base plates to confirm they are anchored securely to the foundation. Look at the grout around mounting pads for cracks or signs of shifting. Examine all vertical support members for any deformation, corrosion, or pitting. Use a level or laser tool to check that the conveyor stands plumb and straight.

Inspect cross braces for missing bolts, bending, or rust patches.
Check for torsional distortion when the conveyor is running.
Tighten or replace hardware on stiffeners and braces.
Look at welding seams for cracks or fatigue.
Make sure flexible joints move freely without binding.
Inspect rubber, neoprene, or metal bellows for cracks or wear.
Confirm joint covers and guards are secure and intact.
Examine anchor bolts and sliding plates for proper movement.
Check for settlement, tilting, or misalignment in foundation pads.
Inspect anchor bolts for tension loss or corrosion.
Look at the soil around the foundation for water erosion or cracks.
Confirm vibration isolators or dampers are working well.
Inspect belt covers and side panels for rust, deformation, or detachment.
Tighten or replace fasteners on covers as needed.
Clean under covers to prevent buildup and pests.
Make sure guards meet safety regulations for distance, height, and strength.
Check painted surfaces for bubbling, peeling, or flaking.
Touch up exposed metal with corrosion-resistant paint.
Inspect galvanization or powder coating for damage.
Record coating integrity during scheduled checks.

Tip: Careful inspection before you start helps prevent equipment damage and keeps your team safe.

Safety During Work

You must always follow safety rules while working on the conveyor. Disconnect the power supply before you open any panels or covers. Wear safety gloves and eye protection to guard against sharp edges and debris. Keep your work area clean and free of tools or parts that could cause trips or falls.

Never bypass safety guards or covers. Use only approved tools and follow your facility’s lockout/tagout procedures. Communicate with your team so everyone knows when maintenance is in progress. If you notice any unusual noises, smells, or movement, stop work and investigate before you continue.

Remember: Safety is not just a step—it is a habit that protects you and your equipment every time you replace a PCB Conveyor Belt.

How to Replace a PCB Conveyor Belt

Power Down and Access

You must always start by making the conveyor safe. Follow these steps to power down and access the belt area:

Turn off the power to the conveyor.
Remove the protective cover.
Loosen the mounting bolts on the motor base. This lets you move the motor back and forth.
Move the motor to make the belt loose enough to remove.

Always ensure that no one stands, rides, walks, touches, or sits on the conveyor belts. Disconnect all energy sources before you begin maintenance. Keep guards on conveyor controls and clear the area of personnel. Only trained staff should handle conveyor controls. Keep loose clothing and hair away from moving parts. Maintain a clean area around the conveyor. Make sure controls are visible and accessible in emergencies. Train your team on control locations and functions. Encourage everyone to report risks.

Remove Old Belt

After you have powered down and accessed the conveyor, you can remove the old belt. Slide the loosened belt off the pulleys and rollers. Take care not to damage any nearby components. If the belt feels stuck, check for any remaining tension or obstructions.

Look for these signs that show you need to replace a PCB conveyor belt:

Cracks, tears, delamination, or excessive wear on the belt edges.
Tracking issues, such as the belt drifting or misaligning.
Material buildup that makes cleaning difficult.
Frequent breakdowns or rising maintenance costs.
Reduced production efficiency or safety concerns.

Dispose of the old belt according to your facility’s guidelines.

Clean and Inspect

Before you install a new belt, clean the conveyor system thoroughly. You can use manual cleaning, clean-in-place (CIP), or clean-out-of-place (COP) methods. Manual cleaning works well for most SMT conveyors. Use a detergent with the right density or dilute it with water. Choose cleaning agents that match the belt material and the type of residue.

Physically wipe down all rollers, pulleys, and surfaces.
Remove any debris or buildup.
Inspect for excessive carryback, which means material sticks to the belt past the discharge point.
Check the head pulley for uneven wear.
Look for impact or entrapment damage on the conveyor.

Automated water and detergent mixing systems can save time and improve cleaning results.

Install New Belt

Now you can install the new belt. Make sure the replacement matches your conveyor’s specifications. Slide the new belt onto the pulleys and rollers. Align it carefully so it sits straight and flat. Reattach any clips or fasteners that secure the belt.

Check that the belt does not twist or overlap. Confirm that the belt fits snugly but is not too tight. If your conveyor uses a specific joining method, follow the manufacturer’s instructions.

Adjust Tension and Alignment

Proper tension and alignment help your conveyor run smoothly. Find the tension adjustment mechanism near the drive motor or pulley. Use a tension gauge to measure the current tension. Adjust the tension to meet the manufacturer’s recommended range for your PCB conveyor.

Identify the tension adjustment mechanism.
Use a tension gauge or indicator, such as TrueView™ 1100 or TriView™, to measure tension.
Adjust the tension to the correct level.
Test the conveyor by running a sample PCB to check movement and alignment.
Monitor and adjust tension as needed.

Tool/Instrument	Description
TrueView™ 1100/TriView™	Tension indicators for measuring conveyor belt tension.
Tension Roll® Transducer	Load cell assembly for measuring tension, customizable in length.
Model C transducers	Load cells for installation at each end of an idler roll.

Regularly check tension and alignment to prevent drift and reduce wear.

Check for Gaps

After you adjust the belt, check for gaps at the board interface. Gaps can cause PCBs to tilt, jam, or misalign. Use a straightedge or feeler gauge to inspect the interface where boards transfer from one section to another. Adjust the conveyor guides or belt position to remove any gaps.

A smooth transition between conveyor sections keeps your SMT line running efficiently. Proper gap checks help you avoid defects and reduce rework.

Test Operation

You must test the conveyor after you replace a PCB conveyor belt. Start by running a sample PCB through the system. Watch for smooth movement and proper alignment. Listen for unusual noises or vibrations.

Perform these tests to confirm proper operation:

Test Type	Description
Solder Paste Inspection (SPI)	Checks solder paste quality on the PCB.
X-ray Inspection	Inspects hidden solder joints, especially under BGAs.
Automated Optical Inspection	Checks solder joints and component placement.
Manual Visual Inspection	Inspects the PCB for defects missed by machines.
Flying Probe Testing	Checks individual components and connections.
In-Circuit Testing (ICT)	Test the electrical connections of components.
Functional Testing	Simulates real-world conditions to confirm PCB performance.

If your SMT line handles high volumes, adjustable speed control can help. Adjustable speed lets you optimize transport based on PCB size and complexity. This feature ensures efficient movement and precise placement throughout the assembly line.

Feature	Benefit
Adjustable Speed Control	Optimizes transport for different PCB types and production needs.
Enhanced Efficiency	Ensures precise and efficient movement in high-volume lines.

When you replace a PCB conveyor belt with care and attention to detail, you keep your SMT production line running at its best.

Troubleshooting and Maintenance

Common Mistakes

You may encounter several common mistakes when you replace a PCB Conveyor Belt. Many technicians forget to check the belt tension after installation. Incorrect tension can cause slippage or misalignment. Some people skip cleaning the conveyor before installing the new belt. Dirt and debris can damage the new belt quickly. Others ignore the importance of machine leveling, which leads to uneven wear and tracking problems. You should also avoid using the wrong replacement kit, as this can cause compatibility issues and frequent breakdowns.

Tip: Always follow the manufacturer’s instructions and double-check each step to avoid these mistakes.

Troubleshooting Tips

If your new conveyor belt does not operate correctly, you can use a systematic approach to find the problem. The table below lists common symptoms, possible causes, and corrective actions:

Symptom	Possible Cause	Corrective Action
The conveyor does not start.	The circuit breaker is tripped.	Check for a short circuit in the motor or cable.
	No power from the I/O PCB to the motor.	Verify the voltage at the I/O PCB and the motor.
	Blown fuses (I/O-version R and earlier).	Check the fuses on the I/O PCB.
	The conveyor motor capacitor is defective.	Inspect the motor capacitor for damage.
	The conveyor belt is damaged.	Inspect conveyor belt and repair or replace.
	The conveyor belt tension is incorrect.	Adjust the belt tension.

You can solve most issues by checking these areas first. If the problem continues, contact your equipment supplier for further support.

Maintenance Advice

You can extend the lifespan of your conveyor belt with good maintenance habits. Follow these steps for the best results:

Clean the conveyor belt regularly to prevent slippage and wear.
Adjust the belt tension properly to avoid misalignment.
Inspect the system often to catch problems early.
Repair any damage right away to reduce downtime.
Lubricate moving parts to lower friction and wear.
Choose the correct conveyor belt for your machine to minimize future issues.

Regular maintenance helps you avoid costly repairs and keeps your SMT line running smoothly.

You can keep your SMT production line running smoothly when you follow each step to replace a PCB Conveyor Belt. Gather the right tools, check machine leveling, and inspect safety features before you start.

Clean and inspect the conveyor system.
Adjust tension and alignment.
Test the belt with a sample PCB.

Regular maintenance and careful preparation help you avoid problems and improve performance. Always use the correct replacement kit for the best results.

FAQ

How often should you replace a PCB conveyor belt?

You should inspect your conveyor belt every three to six months. Replace it if you see cracks, fraying, or slipping. Regular checks help you avoid sudden breakdowns and keep your SMT line running smoothly.

What tools do you need for belt replacement?

You need screwdrivers, wrenches, and a tension gauge. Some conveyor models may require special clips or fasteners. Always check your machine’s manual for a complete list.

Why does machine leveling matter before replacing the belt?

Machine leveling keeps the conveyor stable. A level machine helps the belt track straight and reduces wear. You prevent jams and misalignment by checking the level before you start.

How do you know if the belt tension is correct?

Use a tension gauge or follow your manufacturer’s guidelines. The belt should move smoothly without slipping or making noise. If you see drifting or hear squeaks, adjust the tension.

Can you use any replacement belt for your SMT conveyor?

No, you must use a belt that matches your conveyor’s specifications. Using the wrong belt can cause tracking problems and damage your equipment. Always check the part number and size before you install a new belt.