Dorner 2100 Series User manual

851-279 Rev. E
Installation, Maintenance
& Parts Manua
l
2100, 2200, 4100, 6200 and MPB Series
Bottom Mount Drive Package
for Heavy Load 90_Industrial 60 Hz Gearmotors
Table of Contents
Warnings − General Safety 2. . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 12. . . . . . . .
Required Tools 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 12. . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 12. . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 13. . . . . . . . . .
Gear Reducer Replacement 13. . . . . . . . . . . . . . . . .
Service Parts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 2200, 4100, 6200 and MPB Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors
851-279 Rev. E 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
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 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
Ç
MPB Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE MPB SE-
RIES CONVEYORS.
WARNING
Introduction
IMPORTANT: Some illustrations may show guards
removed. Do NOT operate equipment without 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 2200 and MPB Series conveyors are covered by
patent number 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 6200 Series conveyors are covered by patent
numbers: 6685009,5174435,6109427andcorrespond-
ing 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, 2200, 4100, 6200 and MPB Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors
Dorner Mfg. Corp. 3851-279 Rev. E
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
D
E
H
F
G
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code: M = U.S. English
Output Shaft Type : H= 905Industrial
Gearmotor Type: H = Heavy Load, Industrial
Mount Style : B= Bottom Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
2 = 2100 Series Conveyor
22 = 2200 Series Conveyor
4 = 4100 Series Conveyor
6 = 6200 Series Conveyor
2P = MPB Series Conveyor
Drive Pulley (see Table 2 & 3)
Driven Pulley (see Table 2 & 3)
Belt Type ( − = flat belt, A through J = cleated belt )
2M B H H WW A − 32 32
* See “Ordering and Specifications” Catalog for details.
Table 1: Gearmotor Specifications
Single Phase Three Phase DC Variable Speed VFD Variable Speed
Output Power 0.50 hp (0.37 kw)
Input Voltage 115 VAC 208– 230 / 460 VAC 90 VDC 230 VAC
Input Frequency 60 Hz N/A 10 – 60 Hz
Input Current 7.4 Amperes 2.1 – 2/ 1 Amperes 5.0 Amperes 1.6 Amperes
Motor RPM 1725 2500 1725
Gearmotor Ratios 5:1, 10:1, 20:1, 40:1, 60:1
Frame Size NEMA 56C
Motor Type Totally enclosed, Fan-cooled
Product Description

2100, 2200, 4100, 6200 and MPB Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors
851-279 Rev. E 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Heavy Load Fixed Speed 90560 Hz Gearmotors on 2100, 2200
(Gang Drive), 4100 and 6200 Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
6 1.7 32M060HS4(vp)F(n) 60:1 29 270 30.5 22 32
8 2.4 32M060HS4(vp)F(n) 60:1 29 270 30.5 32 32
12 3.7 32M060HS4(vp)F(n) 60:1 29 270 30.5 48 32
12 3.7 32M040HS4(vp)F(n) 40:1 43 247 27.9 32 32
18 5.5 32M040HS4(vp)F(n) 40:1 43 247 27.9 48 32
25 7.6 32M020HS4(vp)F(n) 20:1 86 90 10.2 32 32
37 11.3 32M020HS4(vp)F(n) 20:1 86 90 10.2 48 32
49 14.9 32M010HS4(vp)F(n) 10:1 173 45 5.1 32 32
74 22.6 32M010HS4(vp)F(n) 10:1 173 45 5.1 48 32
99 30.2 32M005HS4(vp)F(n) 5:1 345 25 2.8 32 32
148 45.1 32M005HS4(vp)F(n) 5:1 345 25 2.8 48 32
169 51.5 32M005HS4(vp)F(n) 5:1 345 25 2.8 48 28
197 60.0 32M005HS4(vp)F(n) 5:1 345 25 2.8 44 22
215 65.5 32M005HS4(vp)F(n) 5:1 345 25 2.8 48 22
249 75.9 32M005HS4(vp)F(n) 5:1 345 25 2.8 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 Heavy Load Fixed Speed 90560 Hz Gearmotors on 2200 Series
Conveyors (Excluding Gang Drive)
Belt Speed Gearmotors * Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
6 1.7 32M060HS4(vp)F(n) 60:1 29 270 30.5 19 32
10 3.0 32M060HS4(vp)F(n) 60:1 29 270 30.5 28 28
15 4.6 32M040HS4(vp)F(n) 40:1 43 247 27.9 28 28
16 4.9 32M060HS4(vp)F(n) 60:1 29 270 30.5 44 28
24 7.3 32M040HS4(vp)F(n) 40:1 43 247 27.9 44 28
30 9.1 32M020HS4(vp)F(n) 20:1 86 90 10.2 28 28
48 14.6 32M020HS4(vp)F(n) 20:1 86 90 10.2 44 28
61 18.6 32M010HS4(vp)F(n) 10:1 173 45 5.1 28 28
95 29.0 32M010HS4(vp)F(n) 10:1 173 45 5.1 44 28
104 31.7 32M010HS4(vp)F(n) 10:1 173 45 5.1 48 28
121 36.9 32M005HS4(vp)F(n) 5:1 345 25 2.8 28 28
138 42.1 32M005HS4(vp)F(n) 5:1 345 25 2.8 32 28
176 53.6 32M005HS4(vp)F(n) 5:1 345 25 2.8 32 22
208 63.4 32M005HS4(vp)F(n) 5:1 345 25 2.8 48 28
242 73.8 32M005HS4(vp)F(n) 5:1 345 25 2.8 44 22
264 80.5 32M005HS4(vp)F(n) 5:1 345 25 2.8 48 22
(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)
SpecificationsSpecifications

2100, 2200, 4100, 6200 and MPB Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors
Dorner Mfg. Corp. 5851-279 Rev. E
Table 4: Belt Speeds for Heavy Load Fixed Speed 90560 Hz Gearmotors on MPB Series
Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
13 4.0 32M060HS4(vp)F(n) 60:1 29 270 30.5 22 32
20 6.0 32M060HS4(vp)F(n) 60:1 29 270 30.5 28 28
29 8.9 32M040HS4(vp)F(n) 40:1 43 247 27.9 28 28
44 13.4 32M040HS4(vp)F(n) 40:1 43 247 27.9 48 32
59 17.9 32M020HS4(vp)F(n) 20:1 86 90 10.2 28 28
(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 5: Belt Speeds for Heavy Load Variable Speed 905VFD Gearmotors on 2100, 4100
and 6200 Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Pulley
Pulley
.6−5.6 .2−1.7 32M060HS423EN 60:1 29 226 35.5 22 32
.8−8.2 .3−2.5 32M060HS423EN 60:1 29 226 35.5 32 32
1.2−12 .4−3.8 32M040HS423EN 40:1 43 247 27.9 28 28
2.5−25 .8−7.5 32M020HS423EN 20:1 86 248 27.9 32 32
4.9−49 1.5−15 32M010HS423EN 10:1 173 156 17.6 32 32
9.9−99 3−30 32M005HS423EN 5:1 345 81 9.1 32 32
14−148 4.5−45 32M005HS423EN 5:1 345 81 9.1 48 32
19−197 6−60 32M005HS423EN 5:1 345 58 6.5 44 22
24−249 7.6−76 32M005HS423EN 5:1 345 58 6.5 48 19
* At 60 Hz
Table 6: Belt Speeds for Heavy Load Variable Speed 905VFD Gearmotors on 2200
Series Conveyors (Excluding Gang Drive)
Belt Speed Gearmotors * Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Pulley
Pulley
.6−6 .2−1.8 32M060HS423EN 60:1 29 270 30.5 19 32
1−10 .3−3.1 32M060HS423EN 60:1 29 270 30.5 28 28
1.5−15 .5−4.6 32M040HS423EN 40:1 43 247 27.9 28 28
3−30 .9−9.2 32M020HS423EN 20:1 86 167 18.9 28 28
6−60 1.8−18 32M010HS423EN 10:1 173 115 13 28 28
10−104 3.2−32 32M010HS423EN 10:1 173 115 13 48 28
12−121 3.7−37 32M005HS423EN 5:1 345 58 6.5 28 28
26−264 8.1−81 32M005HS423EN 5:1 345 58 6.5 48 22
* At 60 Hz
SpecificationsSpecificationsSpecifications

2100, 2200, 4100, 6200 and MPB Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors
851-279 Rev. E 6Dorner Mfg. Corp.
Table 7: Belt Speeds for Heavy Load Variable Speed 905VFD Gearmotors on MPB
Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Pulley
Pulley
1.3−13.4 .4−4.1 32M060HS423EN 60:1 29 270 30.5 22 32
2−19 .9−5.9 32M060HS423EN 60:1 29 270 30.5 28 28
2.9−29 .9−8.9 32M040HS423EN 40:1 43 247 27.9 28 28
5.9−59 1.8−18 32M020HS423EN 20:1 86 167 18.9 28 28
11−117 3.6−36 32M010HS423EN 10:1 173 115 13 28 28
17−175 5.4−54 32M010HS423EN 10:1 173 115 13 48 32
23−234 7.1−71 32M005HS423EN 5:1 345 58 6.5 28 28
* At 60 Hz
Table 8: Belt Speeds for Heavy Load Variable Speed 905DC Gearmotors on 2100, 2200
(Gang Drive), 4100 and 6200 Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
1.0−8.2 .3−2.5 32M060PSD3DEN 60:1 42 270 30.5 22 32
1.4−12 .4−3.6 32M060PSD3DEN 60:1 42 270 30.5 32 32
2.1−18 .7−5.4 32M040PSD3DEN 40:1 63 215 24.3 32 32
4.3−36 1.3−11 32M020PSD3DEN 20:1 125 90 10.2 32 32
9−71 2.6−22 32M010PSD3DEN 10:1 250 72 8.1 32 32
17−143 5.2−43 32M005PSD3DEN 5:1 500 25 2.8 32 32
26−214 7.8−65 32M005PSD3DEN 5:1 500 25 2.8 48 32
29−245 9.0−75 32M005PSD3DEN 5:1 500 25 2.8 48 28
Table 9: Belt Speeds for Heavy Load Variable Speed 905DC Gearmotors on 2200 Series
Conveyors (Excluding Gang Drive)
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
1.8−14 .5−4.5 32M060PSD3DEN 60:1 42 270 30.5 28 28
2.6−22 .8−6.7 32M040PSD3DEN 40:1 63 215 24.3 28 28
2.8−23 .8−7 32M060PSD3DEN 60:1 42 270 30.5 44 28
5.3−44 1.6−13 32M020PSD3DEN 20:1 125 90 10.2 28 28
10−88 3.2−27 32M010PSD3DEN 10:1 250 72 8.1 28 28
17−138 5−42 32M005PSD3DEN 5:1 500 25 2.8 44 28
21−176 6.4−54 32M005PSD3DEN 5:1 500 25 2.8 28 28
33−276 10−84 32M005PSD3DEN 5:1 500 25 2.8 44 28
Specifications

2100, 2200, 4100, 6200 and MPB Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors
Dorner Mfg. Corp. 7851-279 Rev. E
Table 10: Belt Speeds for Heavy Load Variable Speed 905DC Gearmotors on MPB
Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
2.3−19 .7−5.9 32M060PSD3DEN 60:1 42 270 30.5 22 32
3.4−28 1−8.6 32M060PSD3DEN 60:1 42 270 30.5 28 28
5.1−42 1.6−12.9 32M040PSD3DEN 40:1 63 215 24.3 28 28
5.3−44 1.6−13 32M060PSD3DEN 60:1 42 270 30.5 44 28
10−85 3−26 32M020PSD3DEN 20:1 125 90 10.2 28 28
15−127 4.7−39 32M020PSD3DEN 20:1 125 90 10.2 48 32
20−170 6−52 32M010PSD3DEN 10:1 250 72 8.1 28 28
31−255 9−77 32M010PSD3DEN 10:1 250 72 8.1 48 32
* = Cleated and Sidewall Cleated belts opperate at a maximum of 150 Ft/min (45.7 m/min)
NOTE: For belt speed other than those listed, contact
factory for details.
Installation
Required Tools
DHex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm
DTorque wrench
Mounting
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Ç
MPB Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE MPB SE-
RIES CONVEYORS.
WARNING
Installation Component List
I Bottom Mount Assembly
J Drive Pulley
K Cover
L M4 Socket Head Screws (4x)
M Driven Pulley
N Key
O Timing Belt
P M6 Socket Head Screws (2x)
Q M6 Socket−Head Screws & Hard Washers (4x)
R End Support Bracket
S Hex Support Posts (2x)
T Gearhead/Conveyor Support Plate
U Support Plate Spacer
V M6 Socket Head Screws (2x)
W M6 Socket Head Screws (2x)
Specifications

2100, 2200, 4100, 6200 and MPB Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors
851-279 Rev. E 8Dorner Mfg. Corp.
1.Typical components (Figure 2)
Figure 2
O
I
M
P
J
K
L
N
Q
R
TU
W
S
V
Q
NOTE: 2100, 2200, MPB and 6200 2” & 3” (51mm &
76mm) and 4100 1” through 6” (25mm – 152mm)
conveyors do not include parts R through W of
Figure 2.
NOTE: Gearmotor may be operated in positions 1 & 3
(Figure 3).
Figure 3
13
2.If required, change gearmotor position by removing
four screws (X of Figure 4) from bottom mount
assembly and two screws (Y of Figure 5) from gear
reducer support. Rotate gearmotor to other position and
install screws. Tighten screws to 103 in-lb (12 Nm).
Figure 4
X
X
Figure 5
Y
Installation

2100, 2200, 4100, 6200 and MPB Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors
Dorner Mfg. Corp. 9851-279 Rev. E
3.For your reference, the following figures show the
attachment area of complete mounting packages for
the various conveyor series.
Figure 6 − 2200 Series
Figure 7 − 6200 Series
Figure 8 − 4100 Series
Figure 9 − 2100 Series
Figure 10 − MPB Series
Gearmotor bottom
mount assembly is
mounted to Head
Plate
Gearmotor bottom
mount assembly is
mounted to Drive
Spacer
Gearmotor bottom
mount assembly is
mounted to Drive
Adapter Plate
Gearmotor bottom
mount assembly is
mounted to Head
Plate
Gearmotor bottom
mount assembly is
mounted to Head
Plate
NOTE: 6200 conveyor shown, other Series similar.
4.Locate drive output shaft (Z of Figure 11) and
remove two screws (AA).
Figure 11
AA
Z
For 2100, 2200 and 6200 − 2” & 3” (51mm & 76mm)
wide conveyors and 4100 − 1” through 6”
(25mm – 152mm) wide conveyors:
5.Attach bottom mount assembly (I of Figure 12) with
screws (P). Tighten to 80 in-lb (9 Nm). Proceed to step
10.
Figure 12
I
P
AD
For 2100, 2200, 6200 and MPB − 4” (102mm) and
wider conveyors and 4100 − 8” (203mm) and
wider conveyors:
6.On side opposite drive output shaft, remove two
screws (AB of Figure 13).
Figure 13
AB
Installation

2100, 2200, 4100, 6200 and MPB Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors
851-279 Rev. E 10 Dorner Mfg. Corp.
NOTE: Refer to Figures 6 through 10 while doing step
7.
7.Attach bottom mount assembly (I of Figure 12) with
two screws (P). Tighten to 80 in-lb (9 Nm).
8.Install hex support posts (S of Figure 14). Tighten
posts to 80 in-lb (9 Nm).
Figure 14
S
9.Install spacer (U of Figure 15) (2100 & 6200 Only)
and gearhead/conveyor support plate (T) with
screws (V). Install end support bracket (R) with
screws (W). Tighten screws (V & W) to 80 in-lb (9
Nm).
Figure 15
U
R
T
V
W
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
10.Install key (N of Figure 16).
Figure 16
N
O
J
M
11.Wrap timing belt (O) around driven pulley (M) and
drive pulley (J). Install driven pulley (M) onto
conveyor shaft.
12.Remove cam bearing and spacer (AD of Figure 12).
Place cam bearing and spacer (AD of Figure 17) next
to driven pulley (M). Ensure flanges of driven pulley
are aligned with cam bearing. Tighten driven pulley
set screws (AA). This will allow for proper belt
alignment while conveyor is in use. Install cam
bearing and spacer (AD).
Figure 17
AA
AD
M
Installation