Dorner 2100 Series Manual instruction

851-298 Rev. A
Set-up, Operation
& Maintenance Manual
2100, 4100, 6100 Series
Top Mount Drive Package
for Light Load 50 Hz Gearmotors
Table of Contents
Warnings – General Safety 2. . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 6. . . . . . . . .
Required Tools 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 6. . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 6. . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 7. . . . . . . . . . .
Gearmotor Replacement 7. . . . . . . . . . . . . . . . . . . .
Service Parts 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM
851-298 Rev. A 2Dorner Mfg. Corp.
The safety alert symbol, black triangle with white
exclamation, is used to alert you to potential
personal injury hazards.
ÇÇ
Ç
WARNING
ÇÇ
Climbing, sitting, walking or
riding on conveyor will
cause severe injury.
KEEP OFF CONVEYORS.
DANGER
ÇÇ
DANGER
DO NOT OPERATE
CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
ÇÇ
Hazardous voltage will
cause severe injury or
death.
LOCK OUT POWER
BEFORE WIRING.
DANGER
ÇÇ
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
WARNING
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
ÇÇ
ÇÇ
Dorner cannot control the
physical installation and
application of conveyors.
Taking protective measures
is the responsibility of the
user.
When conveyors are used in
conjunction with other equip-
ment or as part of a multiple
conveyor system, CHECK
FOR POTENTIAL PINCH
POINTS and other mechani-
cal hazards before system
start-up.
WARNING
Introduction
IMPORTANT: Some illustrations may show
guards removed. Do NOT operate equipment with-
out guards.
Upon receipt of shipment:
DCompare shipment with packing slip. Contact factory
regarding discrepancies.
DInspect packages for shipping damage. Contact carrier
regarding damage.
DAccessories may be shipped loose. See accessory in-
structions for installation.
Dorner 2100 Series conveyors are covered by the
following patent numbers: 5131529, 5174435, and
corresponding patents and patent applications in other
countries.
Dorner 4100 Series conveyors are covered by patent
number 3923148 and corresponding patents and patent
applications in other countries.
Dorner 6100 Series conveyors are covered by patent
number 5174435 and corresponding patents and patent
applications in other countries.
Dorner’s Limited Warranty applies.
Dorner reserves the right to make changes at any time
without notice or obligation.
Warnings – General Safety

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-298 Rev. A
Refer to Figure 1 for typical components.
A Conveyor
B Mounting Bracket
C Gearmotor
D Belt Tensioner
E Cover
F Timing Belt
G Drive Pulley
H Driven Pulley
Typical Components
Figure 1
CB
E
D
F
H
G
A
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code = CE English
Output Shaft Type = Parallel Shaft
Gearmotor Type = Light Load, Industrial,
Fixed Speed
Mount Style = Top Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
2U T P L WW A –32 32
2 = 2100 Series Conveyor
4 = 4100 Series Conveyor
6 = 6100 Series Conveyor
Drive Pulley (see Table 2)
Driven Pulley (see Table 2)
* See “Ordering and Specifications”Catalog for details.
Table 1: Gearmotor Specifications
Single Phase Three Phase
Output Power 0.022 kw 0.02 kw
Input Voltage 230 Volts A.C. 230/400 Volts A.C.
Input Frequency 50 Hz
Full Load Amperes 0.31 Amperes 0.22/0.13 Amperes
Gearmotor Ratios 8:1 and 28.1:1
Protection Ratings IP44
Product Description

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM
851-298 Rev. A 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Light Load Fixed Speed Parallel Shaft 50 Hz Gearmotors
Gearmotors Belt Drive Driven
Speed Drive
Pulley Driven Pulley
Part Number RPM N-m M/min Pulley Pulley
62Z028PL4(vp)FN 41 2.6 2.1 19 32
62Z028PL4(vp)FN 41 2.6 3.7 32 32
62Z028PL4(vp)FN 41 2.6 6.1 32 19
62Z008PL4(vp)FN 144 0.9 8.5 22 32
62Z008PL4(vp)FN 144 0.9 12.5 32 32
(vp) = voltage and phase
21 = 230 V, 1-phase
23 = 230 V, 3-phase
43 = 400 V, 3-phase
NOTE: 203 through 610 mm wide conveyors with
light load drives should be limited to 2438 mm
length.
NOTE: For belt speed other than those listed, con-
tact factory for details.
Installation
Required Tools
DHex key wrenches:
2.5 mm, 3 mm, 5 mm
DStraight edge
DTorque wrench
Installation Component List
I Top Mount Assembly
J Driven Pulley
K Cover
L M4 Socket Head Screws (4x)
M Timing Belt
N Key
O M6 Socket Head Screws (2x)
Mounting
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Typical components (Figure 2)
Figure 2
K
L
M
I
J
O
N
Specifications

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-298 Rev. A
NOTE: 6100 conveyor shown, 2100 & 4100 similar.
2.Locate drive output shaft (P of Figure 3) and remove
two (2) screws (Q).
Figure 3
Q
P
3.Attach mount assembly (I of Figure 4) with screws
(O). Tighten screws to 9 Nm.
Figure 4
I
O
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
4.Install key (N of Figure 5).
Figure 5
N
R
J
M
5.Wrap timing belt (M) around driven pulley (J) and
drive pulley (R). Install driven pulley (J) onto
conveyor shaft.
6.Using a straight edge (S of Figure 6), align driven
pulley (J) with drive pulley (R). Tighten driven
pulley set screws (T).
Figure 6
S
R
J
T
7.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (U of Figure 7) as shown.
Tension timing belt to obtain 3 mm deflection for 456
grams of force at timing belt mid-point (V). Tighten
tensioner screw to 12 Nm.
V
V
Figure 7
1
2
U
U
8.Install cover (K of Figure 8) with four (4) screws (L).
Tighten to 4 Nm.
Figure 8
L
K
L
Installation

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM
851-298 Rev. A 6Dorner Mfg. Corp.
Required Tools
DHex key wrenches
2.5 mm, 3 mm, 5 mm
DStraight edge
DScrewdriver (for terminal box screws)
DTorque wrench
Timing Belt Tensioning
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Remove four (4) screws (L of Figure 9) and remove
cover (K).
Figure 9
L
K
L
2.Loosen tensioner (U of Figure 10).
Figure 10
U
3.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (U of Figure 11) as shown.
Tension timing belt to obtain 3 mm deflection for 456
grams of force at timing belt mid-point (V). Tighten
tensioner screw to 12 Nm.
Figure 11
1
2
V
V
U
U
4.Install cover (K of Figure 9) with four (4) screws (L).
Tighten screws to 4 Nm.
Timing Belt Replacement
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Remove four (4) screws (L of Figure 9) and remove
cover (K).
2.Loosen tensioner (U of Figure 10).
3.Remove timing belt (M of Figure 12).
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley set screws (T of Figure
12) and remove pulley with belt. For re-installation,
see steps 5 through 8 on page 5.
Figure 12
R
J
M
T
4.Install new timing belt.
5.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (U of Figure 11) as
shown. Tension timing belt to obtain 3 mm
deflection for 456 grams of force at timing belt
mid-point (V). Tighten tensioner screw to 12 Nm.
6.Install cover (K of Figure 9) with four (4) screws (L).
Tighten screws to 4 Nm.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-298 Rev. A
Drive or Driven Pulley Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Complete steps 1 through 3 of “Timing Belt
Replacement”section on page 6.
2.Loosen set screws and remove drive or driven pulley.
NOTE: If drive pulley (R of Figure 13) is replaced,
wrap timing belt around drive pulley and complete
step 3.
Figure 13
R
J
M
T
3.Completesteps5through8of“Installation”section
on page 5.
Gearmotor Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Ç
Hazardous voltage will
cause severe injury or
death.
LOCK OUT POWER
BEFORE WIRING.
DANGER
NOTE: Single phase gearmotor shown, three phase
similar.
1.For single phase motor:
a.Loosen terminal box screws (W of Figure 14) and
remove cover (X).
Figure 14
X
W
b.Record wire colors on terminals U1, W1 and
ground ( )(Figure 15). Loosen terminals U1, W1
and ground and remove wires.
Figure 15
Y
c.Loosen cord grip (Y of Figure 15) and remove
cord.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM
851-298 Rev. A 8Dorner Mfg. Corp.
1.For three phase motor:
a.Loosen terminal box screws (W of Figure 14) and
remove cover (X).
b.Record wire colors on terminals U1, V1, W1 and
ground ( )(Figure 16). Loosen terminals U1, V1,
W1 and ground and remove wires.
Figure 16
Y
c.Loosen cord grip (Y of Figure 16) and remove
cord.
2.Remove four (4) screws (L of Figure 9) and remove
cover (K).
3.Loosen tensioner (U of Figure 10).
4.Remove timing belt (M of Figure 17).
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley set screws (T of Figure
17) and remove pulley with belt (M). For
re-installation, see steps 5 through 8 on page 5.
Figure 17
M
T
5.Loosen two (2) set screws (T of Figure 18). Remove
drive pulley (R).
Figure 18
R
T
ZZ
6.Remove four (4) screws (Z) and detach gearmotor.
7.Mount new gearmotor with four (4) screws (Z).
Tighten to 5 Nm.
8.Replace drive pulley (R of Figure 18) and tighten set
screws (T).
9.Completesteps5through8of“Installation”section
on page 5.
10.Replace wiring:
DFor a single phase motor, reverse step 1 on page 7.
DFor a three phase motor, reverse step 1 on this page.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-298 Rev. A
NOTE: For replacement parts other than those
shown on this page, contact an authorized Dorner
Service Center or the factory.
Item Part No. Part Description
162Z008PL421 Gearmotor, 22 W, 230 Volts, 144 RPM,
50 Hz, 1-Phase, 8:1
62Z028PL423 Gearmotor, 20 W, 230Volts, 41 RPM,
50 Hz, 3-Phase, 28:1
62Z028PL421 Gearmotor, 22 W, 230 Volts, 41 RPM,
50 Hz, 1-Phase. 28:1
62Z008PL423 Gearmotor, 20 W, 230 Volts, 144 RPM,
50 Hz, 3-Phase, 8:1
62Z028PL443 Gearmotor, 20 W, 400 Volts, 41 RPM,
50 Hz, 3-Phase, 28:1
62Z008PL443 Gearmotor, 20 W, 400 Volts, 144 RPM,
50 Hz, 3-Phase, 8:1
2 814-104 Timing Belt, 15mm W x 450mm L
814-105 Timing Belt, 15mm W x 460mm L
814-065 Timing Belt, 15mm W x 475mm L
814-101 Timing Belt, 15mm W x 500mm L
814-064 Timing Belt, 15mm W x 535mm L
3 450365MP Drive Pulley, 19 Tooth
450366MP Drive Pulley, 22 Tooth
450367MP Drive Pulley, 28 Tooth
450368MP Drive Pulley, 32 Tooth
450369MP Drive Pulley, 44 Tooth
4 807-1070 Drive Pulley Woodruff Key
5 450365MP Driven Pulley, 19 Tooth
450366MP Driven Pulley, 22 Tooth
450367MP Driven Pulley, 28 Tooth
450368MP Driven Pulley, 32 Tooth
6 980422M Driven Pulley Key, 4mm x 22mm
Figure 19
5,6
3,4
2
1
Service Parts

No returns will be accepted without prior written factory authorization. When calling for authorization, please
have the following information ready for the Dorner Factory representative or your local distributor:
1. Name and address of customer.
2. Item(s) being returned.
3. Reason for return.
4. Customer’s original order number used when ordering the item(s).
5. Dorner or distributor invoice number.
A representative will discuss action to be taken on the Returned items and provide a Returned Goods
Authorization Number to reference.
There will be a 15% restocking charge on all new items returned for credit where Dorner was not at fault. These
will not be accepted after 60 days from original invoice date. The restocking charge covers inspection, cleaning,
disassembly, and reissuing to inventory.
If a replacement is needed prior to evaluation of returned item, a purchase order must be issued. Credit
(if any) is issued only after return and evaluation is complete.
Dorner has representatives throughout the world. Feel free to contact Dorner for the name of your local
representative. Our technical sales and service staff will gladly help with your questions on Dorner products.
For a copy of Dorner’s Limited Warranty, contact factory, distributor, service center or visit our website @
www.dorner.com
851-298 Rev. A Printed in U.S.A. 400
975 Cottonwood Ave. PO Box 20
Hartland, WI 53029-0020 USA
Dorner Mfg. Corp. reserves the right to change or
discontinue products without notice. All products and
services are covered in accordance with our standard
warranty. All rights reserved. Dorner Mfg. Corp. 2000
DORNER
Arnold-Sommerfeld-Ring2
D-52499 Baesweiler
USA
TEL [phone] (USA)
FAX [phone] (USA)
Germany
TEL [phone]
FAX [phone]
Internet: www.dorner.com
Outside the USA:
TEL [phone], FAX [phone]
DORNER MFG. CORP.
Return Policy