Belt Installation

&
Tensioning Procedure

FENNER (INDIA) LTD.

Important Belt Maintenance Activities:-
Preventive maintenance has the following
important maintenance activities

Safe working environment.

Belt drive should have adequate guard
Periodic belt drive inspection.

Following belt installation procedure

Knowledge about belt and belt types

Proper belt storage

Inspect all belts carefully

Troubleshooting
Effects Of Misalignment

 Misaligned pulleys will accelerate wear of belt sidewalls,

 Shorten both belt and pulleys life.
 Misalignment can also cause belts to roll over in the
pulley or throw the entire load to one side of the belt –
breaking or stretching the tensile cord.
Hence the pulley misalignment should be < 0.5 deg
Pulley Misalignment Should Be Less Than 0.5 deg

CORRECT Parallel Horizontal angular Vertical angular

 Belt Installation & Tensioning procedure
For New Belt
Measure the belt free outside length of the belt (without any tension).
Tension the belt by stretching the belt, in such a way that the belt outside
length increased by 0.4 % to 0.5 % of free outside length. Then after running for few
hours check and re-tension the belt.

For used Belt

• Decrease the center distance until the V-band(s) becomes zero tension.
• Measure the belt outside length .
• Tension the belt by stretching the belt, in such a way that the belt outside
length increased by 0.4 % to 0.5 % of free outside length.
• Recheck pulley alignment.
• Fix the belt guard.
• Turn power back on and restart drive. Look and listen for anything unusual.
• Periodically monitor the tension .
TENSIONING OF BELTS
 The key to long, efficient, trouble-free belt operation is
proper tension. If belts are too loose, the result is
slippage, rapid belt and pulley wear, and loss of
productivity. Conversely, too much tension puts excess
strain on belts, bearings, and shafts, and causes
premature wear of these components.
 Using Pen Tension Gauge
 Note: Never use belt dressing to stop belts from slipping.
 To tension belts, adjust the center distance until the belts
appear fairly tight. When struck with the hand, belts will
bounce back with a springy motion. Run the drive for
about 15 minutes to seat the belts, and apply full load. If
the belts slip or squeal, apply more tension. When the
drive is in motion, slight sag on the slack side is normal.
INSPECTING A DRIVE

 Noise Problem
 Drives which are operating properly make little noise. But there are
following things to be noted.
 Slapping may indicate the belt is striking a guard or some other
obstruction. Usually , it is possible to locate the trouble spot merely by
listening, Then drive stopped, adequate clearance can be provided
 A squeal, or chirp, indicates belts are too loose. Stop the drive and
retention the belt.
 Noise from failed bearings or a loose mechanism in the related
machinery may sound as though emanating from the drive. These noises
should be investigated and corrected.
 Visual Evidence
 Buildup of foreign material inside the guard :
 This can cause excessive wear on belts and pulleys, or even create a “hot
Spot”. Guards should be inspected regularly to prevent this.

 Presence of oil on belts or pulleys :

 Belts will tolerate occasional exposure to oil vapor or slight mist.
However, a buildup of oil will eventually deteriorate the belts or cause
slippage. If excessive oil is present, the source should be eliminated, or
additional protection provided for the drive.

 Excessive vibration :
 This can result from a number of causes such as loose machine mounts,
imbalance in rotating parts, or an intermittent or improperly operating
power source. if the causes cannot be readily determined and corrected, it
is advisable to contact a belt and pulley supplier for technical assistance.
Force / Deflection Method

 1. Measure the span length “L” of your drive (see

illustration at right).
 2. At the center of the span, apply a force
perpendicular to the belt. Measure the force
required to deflect the belt 0.016 mm per
millimeter of span length. For example, for a 100
mm span, the deflection would be 1.6 mm or
approximately 2 mm.
 3. Compare the force required to the
recommended ranges in the tables below. Tighten
or loosen the belt to bring it into the
recommended range.
 4. When you install new belts, tighten them to
“initial tension”
forces shown in the tables. This tension will drop
during the run-in period.
Deflection force required for measuring installation tension in
wedge V-belt drives using’ single or multiple belts

Small pulley diameter Condition 2

range Deflection of 0.01 mm per
mm Condition 1 millimeter of span length if span
Deflection of 0.02 mm per millimeter of span length length exceeds 500 mm
if span length is 500 mm or less Required deflection force F at
Required deflection force F at centre of span for centre of span for belt speed of
Cross-section
belt speed of
symbol

0 m/s to 10 m/s to 20 m/s to 0 m/s to 10 m/s to 10 m/s to

10 m/s 20 m/s 30 m/s 10 m/s 20 m/s 30 m/s
N N N N N N

Wedge belts
67 to 95 16 to 24 13 to 20 10 to 18 ' 8 to 12 6.5 to 10 5.5 to 9
95 and above
SPZ
24 to 34 20 to 32 18 to 28 12 to 17 10 to 16 9 to 14

100 to 140 28 to 40 24 to 34 19 to 28 14 to 20 12 to 17 9.5 to 14

SPA
140 and above 40 to 62 34 to 52 28 to 44 20 to 31 17 to 26 14 to 22

160 to 265 50 to 72 40 to 64 36 to 54 25 to 36 20 to 32 18 to 27
SPB
265 and above 72 to 92 64 to 82 54 to 74 36 to 46 32 to 41 27 to 37

224 to 355 92 to 132 76 to 116 64 to 104 46 to 66 38 to 58 32 to 52

SPC
355 and above 132 to 170 116 to 152 104 to 140 66 to 85 58 to 76 52 to 70

56 to 95 20 to 30 16 to 25 13 to 23 10 to 15 8 to 13 7 to 11
SPZX
95 and above 30 to 43 35 to 40 23 to 35 15 to 21 13 to 20 11 to 18

80 to 140 35 to 50 30 to 43 24 to 35 18 to 25 15 to 21 12 to 18
SPAX
Deflection force required for measuring installation tension in classical V-
belt drives using’ single or multiple belts
V-belts

Z 56 to 100 8 to 12 7 to 9.5 6 to 7.5 4 to 6 3.5 to 5 3 to 4

1 00 and above 12 to 17 10 to 14 9 to 12 6 to 8.5 " 5.5 to 7 4.5 to 6

80 to 140 16 to 24 13 to 19 10 to 16 8 to 12 6.5 to 9.5 5.5 to 8

A
140 and above 24 to 35 19 to 28 16 to 24 12 to 18 9.5 to 14 8 to 12

125 to 200 32 to 48 26 to 38 20 to 32 16 to 24 13 to 19 10 to 16
B
200 and above 48 to 70 38 to 58 32 to 48 24 to 35 19 to 29 16 to 24

200 to 400 62 to 92 52 to 76 40 to 62 31 to 46 26 to 38 20 to 31
C
400 and above 92 to 140 72 to 116 62 to 92 46 to 70 38 tc 58 31 to 46

355 to 600 124 to 180 164 to 152 84 to 124 62 to 90 52 to 76 42 to 62

D
600 and above 180 to 268 152 to 230 124 to 180 90 to 134 76 to 115 62 to 90

40 to 100 10 to 15 9 to 12 7.5 to 9.4 5 to 7.5 4.4 to 6 3.7 to 5

ZX 100 and above 15 to 21 12 to 18 11 to 15 7.5 to 11 7 to 9 6 to 7.5

63 to 140 20 to 30 16 to 24 13 to 20 10 to 15 8 to 12 7 to 10
AX
1 40 and above 30 to 44 24 to 35 20 to 30 13 to 19 12 to 18 10 to 15

90 to 200 40 to 60 33 to 48 25 to 40 20 to 30 16 to 24 13 to 20
BX
200 and above 60 to 88 48 to 73 40 to 60 30 to 44 24 to 36 20 to 30

140 to 400 78 to 115 65 to 95 50 to 78 39 to 58 33 to 48 25 to 39

CX
400 and above 115 to 175 95 to 145 78 to 115 58 to 88 48 to 73 39 to 58
 Belt Troubleshooting Guide
PROBLEM PROBABLE CAUSE ACTION TO PERFORM
Short Belt Life

Tensile members damaged through Replace all belts with new match free set,
improper installation. properly installed.

Relatively rapid failure, no Under designed drive. Redesign.

visible reason.
Worn pulley grooves (Check with
Replace pulleys.
groove gauge).

Remove source of oil or grease. Clean

Sidewalls soft and sticky. Low belts and grooves with cloth moistened
adhesion between cover plies. Oil or grease on belts or pulleys. with non-flammable, non-toxic
Cross section swollen. degreasing agent or commercial
detergent and water.

Bottom & Sides Burned

Sidewalls dry and hard. Low Belt slipping under starting or Replace
Sides and bottom of cover
belt burned Remove belt andoftighten
source drive untildrive
heat. Ventilate
adhesion between plies. High temperature.
stalling load. slipping
in betterstops.
way.
Bottom of belt cracked.
Worn Pulleys. Replace pulleys.
 Belt Troubleshooting Guide
PROBLEM PROBABLE CAUSE ACTION TO PERFORM
Belt Turnover
Belt turns over and runs
that way or it may turn Excess Lateral belt whip. Use FENNER Band-Flex belt.
over and come off.
Foreign Material in Remove material - shield
grooves. drive.

Misaligned pulleys. Realign the drive.

Worn pulley grooves.

(Check with groove Replace pulley.
gauge).

Tensile member broken

Replace with match free set,
through improper
properly installed.
installation.
Belt troubleshooting example
Belt Slips, burnt (Spin Burn) Appearance
• Worn or Damaged pulley
•Wrong Belt Cross-Section or Type
•Excessive Oil or Grease
•Excessive Moisture
•Overload Drive-Under belting
•Insufficient Wrap on Small Pulley

Damaged Cogs-Reasons
Excessive Heat
•Pulley Too Small
•Backside Idler
•Pulley Misaligned
•Improper or Prolonged Storage

Cracked Belt -Reasons

Belt slippage.
Excessive heat.
 FENNER POWERBAND BANDED V-BELTS
• High impact strength and load carrying power provides longer life.
Mainly used in industrial drive which requires matched set belts, the band provides
extra power to these belts.
• Chloroprene rubber compounds provides oil and heat resistance.
• Specially-treated extra togh cover withstands slip and shear forces at peak loads
without generating excessive heat. It also fends off penetration by foreign materials.
• This belt is suitable for drives with heavy vibration.

“e” DIMENSION THICKNESS

SECTION
mm mm

JA 15.88 10.0
JB 19.00 13.0
JC 25.40 17.0
JSPZ 12.00 10.0
JSPA 15.00 10.5
JSPB 19.00 15.6
JSPC 25.5 22.6
J3V 10.3 10.0
J5V 17.5 15.0
J8V 28.57 25.0
 DO’S
•Check for correct pulley groove using profile gauge and proper positioning
of the belts.
•Shorten the centre distance of the drive until the belts can be put on pulleys
without forcing.
•Check drive alignment periodically and avoid uneven side wear of belts.
•Check pulley grooves for rust, dust and dirt periodically.
•Check belt tension frequently during first 24-48 hours of run-in
operation.(avoid over or under tension for proper power transmission)
•If it is necessary to change any belt in the drive, replace all belts with new
matched set to avoid uneven tension distribution by replacing.
•Proper ventilation for the drive should be provided to prevent high
temperature leading to bottom cracking, deterioration of rubber compound
and adhesion).
•Always keep FENNER spare belts to avoid last minute rush and settling for
inferior brands.
 DON’T’S
•Never fit vee belts with levers. This action will damage the belt before it is
used.
•Never put less number of belts in your drive then it required.
•Never keep slack sides haphazardly on top or below.
•Avoid uneven and excessive tension in belt.
•Never use belt dressing. (This will pull the jacket off the belt in a very short
time).and don’t expose to direct sunlight.
•Never use idlers on back of a belt.
•Do not keep belt on floor or keep in a heavily bent or pied condition.
•Do not mix and use different makes in one drive.
•Avoid hot bearings and belt noise.(This is caused through worn grooves,
wrong bearings and belt slippage).
•Do not keep any source of heat close to belt drives