Dorner 2100 Series User manual

851-255 Rev. D
Set-up, Operation
& Maintenance Manual
2100, 4100, 6100 Series
Top Mount Drive Package
for Standard Load Parallel Shaft 60 Hz Gearmotors
Table of Contents
Warnings – General Safety 2. . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 6. . . . . . . . .
Required Tools 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 7. . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 7. . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 7. . . . . . . . . . .
Gear Motor Replacement 7. . . . . . . . . . . . . . . . . . . .
Service Parts 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors SOMM
851-255 Rev. D 2Dorner Mfg. Corp.
The safety alert symbol, black triangle with white
exclamation, is used to alert you to potential
personal injury hazards.
Ç
Ç
WARNING
Ç
Ç
Climbing, sitting, walking or
riding on conveyor will
cause severe injury.
KEEP OFF CONVEYORS.
DANGER
Ç
DANGER
Do NOT OPERATE
CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Ç
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
WARNING
Ç
Exposed moving parts can
cause severe injury.
REPLACE ALL GUARDS
BEFORE RUNNING
CONVEYOR.
WARNING
Ç
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
equipment or as part of a
multiple conveyor system,
CHECK FOR POTENTIAL
PINCH POINTS and other
mechanical 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 Standard Load Parallel Shaft 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-255 Rev. D
Refer to Figure 1 for typical components.
A Conveyor
B Mounting Bracket
C Gearmotor
D Timing Belt Tensioner
E Cover
F Timing Belt
G Drive Pulley
H Driven Pulley
Typical Components
Figure 1
A
B
C
E
F
H
D
G
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code = U.S. English
Output Shaft Type = Parallel Shaft
Gearmotor Type = Standard Load, Industrial
Mount Style = Top Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
2M T P S WW A–32 32
2 = 2100 Series Conveyor
4 = 4100 Series Conveyor
6 = 6100 Series Conveyor
Belt Type: –= flat belt, A through J = cleated belt
Drive Pulley (see Table 2 & 3)
Driven Pulley (see Table 2 & 3)
* See “Ordering and Specifications”Catalog for details.
Table 1: Gearmotor Specifications
Single Phase Three Phase DC Variable Speed
Output Power 0.17 hp (0.13 kw) 0.25 hp (0.19 kw)
Input Voltage 115 Volts A.C. 230 Volts A.C. 130 Volts D.C.
Input Frequency 60 Hz N/A
Input Current 1.9 Amperes 1.2 Amperes 1.8 Amperes
Motor RPM 1725 2500
Gearmotor Ratios 5:1, 10:1, 20:1, 30:1, 60:1, 80:1
Motor Type Totally enclosed, Fan-cooled Totally enclosed, Non–ventilated
Product Description

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors SOMM
851-255 Rev. D 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Standard Load Fixed Speed 90560 Hz Gearmotors
Gearmotors Belt Speed Drive DrivenDrive
Pulley Driven Pulley
Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
62M180PS411F(n) 10 341 38.5 2 0.6 22 32
62M180PS411F(n) 10 341 38.5 3 0.9 32 32
62M180PS411F(n) 10 341 38.5 4 1.2 48 32
62M060PS4(vp)F(n) 29 270 30.5 5 1.5 19 32
62M060PS4(vp)F(n) 29 270 30.5 8 2.4 32 32
62M060PS4(vp)F(n) 29 270 30.5 12 3.7 48 32
62M030PS4(vp)F(n) 58 135 15.3 16 4.9 32 32
62M020PS411F(n) 86 90 10.2 25 7.6 32 32
62M020PS411F(n) 86 90 10.2 37 11.3 48 32
62M010PS4(vp)F(n) 173 45 5.1 49 14.9 32 32
62M010PS4(vp)F(n) 173 45 5.1 74 22.6 48 28
62M005PS411F(n) 345 25 2.8 99 30.2 32 22
62M005PS411F(n) 345 25 2.8 148 45.1 48 22
62M005PS411F(n) 345 25 2.8 169 51.5 48 28
62M005PS411F(n) 345 25 2.8 197 60.0 44 22
62M005PS411F(n) 345 25 2.8 215 65.5 48 22
62M005PS411F(n) 345 25 2.8 249 75.9 48 19
(vp) = voltage and phase (n) = reversing capability
11 = 115 V, 1-phase N = no reversing switch
23 = 230V, 3-phase R = with reversing switch
(115V, 1 phase only)
Table 3: Belt Speeds for Standard Load Variable Speed 905DC Gearmotors
Gearmotors Belt Speed Drive DrivenDrive
Pulley Driven Pulley
Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
62M180PSD3DEN 14 341 38.5 0.3 –2.7 0.1 –0.8 22 32
62M180PSD3DEN 14 341 38.5 0.5 –4.0 0.1 –1.2 32 32
62M060PSD3DEN 42 270 30.5 0.8 –7.0 0.3 –2.2 19 32
62M060PSD3DEN 42 270 30.5 1.4 –12 0.4 –3.6 32 32
62M030PSD3DEN 83 135 15.3 2.9 –24 0.9 –7.3 32 32
62M020PSD3DEN 125 90 10.2 4.3 –36 1.3 –11 32 32
62M010PSD3DEN 250 72 8.1 9.0 –71 2.6 –22 32 32
62M005PSD3DEN 500 25 2.8 17 –143 5.2 –43 32 32
62M005PSD3DEN 500 25 2.8 26 –214 7.8 –65 48 32
62M005PSD3DEN 500 25 2.8 29 –245 9.0 –75 48 28
NOTE: For belt speed other than those listed,
contact factory for details.
Specifications

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-255 Rev. D
Required Tools
DHex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm
DStraight edge
DTorque wrench
Mounting
Ç
Exposed moving parts can cause
severe injury.
LOCK OUT POWER before
removing guards or performing
maintenance.
WARNING
Installation Component List
I Top Mount Assembly
J Drive Pulley
K Cover
L M4 Socket Head Screws (4x)
M Driven Pulley
N Key
O M6 Socket Head Screws (2x)
P Timing Belt
1.Typical components (Figure 2)
Figure 2
J
K
L
M
O
PN
I
NOTE: 6100 conveyor shown, 2100 & 4100 similar.
2.Locate drive output shaft (R of Figure 3) and remove
two (2) screws (S).
Figure 3
R
S
3.Attach mount assembly (I of Figure 4) with screws
(O). Tighten to 80 in-lb (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
M
N
J
P
5.Wrap timing belt (P) around driven pulley (M) and
drive pulley (J). Install driven pulley (M) onto
conveyor shaft.
InstallationInstallation

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors SOMM
851-255 Rev. D 6Dorner Mfg. Corp.
6.Using a straight edge (T of Figure 6), align driven
pulley (M) with drive pulley (J). Tighten driven
pulley set screws (U).
Figure 6
T
UM
J
7.Depending on direction of conveyor belt travel (1 or 2
of Figure 7), position belt tensioner (V) as shown.
Tension belt to obtain 0.125¨(3 mm) deflection for 1.0
lb (456 grams) of force at belt mid-point (W). Tighten
tensioner screw to 103 in-lb (12 Nm).
Figure 7
1
W
W
2
V
8.Install cover (K of Figure 8) with four (4) screws (L).
Tighten to 35 in-lb (4 Nm).
Figure 8
K
L
L
Preventive Maintenance and Adjustment
Required Tools
DHex key wrenches
–2 mm, 2.5 mm, 3 mm & 5 mm
DAdjustable wrench (for hexagon head screws)
DStraight edge
DTorque wrench
Timing Belt Tensioning
Ç
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 8) and remove
cover (K).
2.Loosen tensioner (V of Figure 9).
Figure 9
V
Installation

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-255 Rev. D
3.Depending on direction of conveyor belt travel (1 or
2 of Figure 7), position belt tensioner (V) as shown.
Tension belt to obtain 0.125¨(3 mm) deflection for 1.0
lb (456 grams) of force at belt mid-point (W). Tighten
tensioner screw to 103 in-lb (12 Nm).
4.Install cover (K of Figure 8) with four (4) screws (L).
Tighten to 35 in-lb (4 Nm).
Timing Belt Replacement
Ç
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 8) and remove
cover (K).
2.Loosen tensioner (V of Figure 9).
3.Remove timing belt (P of Figure 10).
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley set screws (U of Figure
10) and remove pulley with belt (P). For
re-installation, see steps 5 and 6 beginnng on
page 5.
Figure 10
U
P
4.Install new timing belt.
5.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (V of Figure 7) as
shown. Tension timing belt to obtain 0.125¨(3 mm)
deflection for 1.0 lb (456 grams) of force at timing belt
mid-point (W). Tighten tensioner screw to 103 in-lb
(12 Nm).
6.Install cover (K of Figure 8) with four (4) screws (L).
Tighten to 35 in-lb (4 Nm).
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 this page.
2.Loosen set screws and remove drive or driven pulley.
NOTE: If drive pulley (J of Figure 13) is replaced,
wrap timing belt around drive pulley and complete
step 3.
3.Completesteps5through8of“Installation”section
beginning on page 5.
Gear Motor Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Ç
Ç
Hazardous voltage will
cause severe injury or
death.
LOCKOUT POWER BEFORE
before wiring.
DANGER
1.For single phase motor, unplug power cord from
outlet.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors SOMM
851-255 Rev. D 8Dorner Mfg. Corp.
2.For three phase motor:
a. Loosen terminal box screws (X of Figure 11) and
remove cover (Y).
Figure 11
Y
X
b. Record incoming wire colors connecting to red,
black and blue leads. Loosen wire nuts and remove
incoming wires.
c. Loosen cord grip and remove cord.
3.For DC variable speed motor, unplug motor cord at
disconnect (Z of Figure 12).
Figure 12
Z
4.Remove four (4) screws (L of Figure 8) and remove
cover (K).
5.Loosen tensioner (V of Figure 9).
6.Loosen drive pulley set screws (AA of Figure 13).
Remove drive pulley (J) and timing belt (P).
Figure 13
AA J
P
7.Remove four (4) gear motor mounting screws (Q of
Figure 14). Remove gearmotor.
Figure 14
Q
Q
8.Remove four (4) adapter plate screws (AB of Figure
15). Remove adapter plate.
Figure 15
AB
AB
9.Install new gearmotor to adapter plate and mounting
bracket. Tighten screws (Q of Figure 14) to 103 in-lb
(12 Nm).
NOTE: Drive pulley (J of Figure 13) is removed.
Wrap timing belt around drive pulley and complete
step 10.
10.Completesteps5through8of“Installation”section
beginning on page 5.
11.Replace wiring:
DFor a single phase motor, reverse step 1 on page 7.
DFor a three phase motor, reverse step 2, on this page.
DFor a DC variable speed motor, reverse step 3 on this
page.
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-255 Rev. D
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
1 62M180PS411FN Motor, 0.08hp (0.06Kw), 10 RPM,
115VAC, 60Hz, 1-Phase
62M180PS411FR Motor, 0.08hp (0.06Kw), 10 RPM,
115VAC, 60Hz, 1-Phase with revers-
ing switch
62M060PS411FN Motor, 0.17hp (0.13Kw), 29 RPM,
115VAC, 60Hz, 1-Phase
62M060PS411FR Motor, 0.17hp (0.13Kw), 29 RPM,
115VAC, 60Hz, 1-Phase with revers-
ing switch
62M060PS423FN Motor, 0.25hp (0.19Kw), 29 RPM,
230VAC, 60Hz, 3-Phase
62M030PS411FN Motor, 0.17hp (0.13Kw), 58 RPM,
115VAC, 60Hz, 1-Phase
62M030PS411FR Motor, 0.17hp (0.13Kw), 58 RPM,
115VAC, 60Hz, 1-Phase with revers-
ing switch
62M030PS423FN Motor, 0.25hp (0.19Kw), 58 RPM,
230VAC, 60Hz, 3-Phase
62M020PS411FN Motor, 0.17hp (0.13Kw), 86 RPM,
230VAC, 60Hz, 1-Phase
62M020PS411FR Motor, 0.17hp (0.13Kw), 86 RPM,
115VAC, 60Hz, 1-Phase with revers-
ing switch
62M010PS411FN Motor, 0.17hp (0.13Kw), 173 RPM,
115VAC, 60Hz, 1-Phase
62M010PS411FR Motor, 0.17hp (0.13Kw), 173 RPM,
115VAC, 60Hz, 1-Phase with revers-
ing switch
62M010PS423FN Motor, 0.25hp (0.19Kw), 173 RPM,
230VAC, 60Hz, 3-Phase
62M005PS411FN Motor, 0.17hp (0.13Kw), 345 RPM,
230VAC, 60Hz, 1-Phase
62M005PS411FR Motor, 0.17hp (0.13Kw), 345 RPM,
115VAC, 60Hz, 1-Phase with revers-
ing switch
62M180PSD3DEN Motor, 0.12hp (0.09Kw), 14 RPM,
130VDC
62M060PSD3DEN Motor, 0.25hp (0.19Kw), 42 RPM,
130VDC
62M030PSD3DEN Motor, 0.25hp (0.19Kw), 83 RPM,
130VDC
62M020PSD3DEN Motor, 0.25hp (0.19Kw), 125 RPM,
130VDC
62M010PSD3DEN Motor, 0.25hp (0.19Kw), 250 RPM,
130VDC
62M005PSD3DEN Motor, 0.25hp (0.19Kw), 500 RPM,
130VDC
Figure 16
7
1
5
4
2
3
6
Item Part No. Part Description
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
814-108 Timing Belt, 15mm W x 520mm L
814-064 Timing Belt, 15mm W x 535mm L
814-099 Timing Belt, 15mm W x 565mm L
3 802-046 Tensioner Bearing
4 450365MP Driven Pulley, 19Tooth, 12mm bore
450366MP Driven Pulley, 22Tooth, 12mm bore
450367MP Driven Pulley, 28Tooth, 12mm bore
450368MP Driven Pulley, 32Tooth, 12mm bore
5 980422M Square Key, 4 mm x 22 mm
6 450365MP Drive Pulley, 19Tooth, 0.75”bore
450366MP Drive Pulley, 22Tooth, 0.75”bore
450367MP Drive Pulley, 28Tooth, 0.75”bore
450368MP Drive Pulley, 32Tooth, 0.75”bore
450369MP Drive Pulley, 44Tooth, 0.75”bore
450370MP Drive Pulley, 48Tooth, 0.75”bore
450371MP Drive Pulley, 60Tooth, 0.75”bore
7 912–078 Key, Square, 0.188”x 0.75”L
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 at
www.dorner.com
851-255 Rev. D Printed in U.S.A. 300
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.
For replacement parts, contact an authorized
Dorner Service Center or the factory.
Return Policy