Dorner iDrive 3200 Series User manual

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DORNER MFG. CORP. INSIDE THE USA OUTSIDE THE USA
P.O. Box 20 • 975 Cottonwood Ave. TEL: [phone] TEL: [phone]
Hartland, WI 53029-0020 USA FAX: [phone] FAX: [phone]
851-702 Rev. A
3200 Series iDrive
Belt Conveyors
Installation, Maintenance & Parts Manual

Dorner Mfg. Corp. 2 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Table of Contents
Introduction ......................................................................... 3
Warnings −General Safety ................................................. 3
Product Description ............................................................. 4
Specifications ...................................................................... 4
Models: ............................................................................ 4
Flat Belt 3200 Series Conveyor ................................... 4
Cleated Belt 3200 Series Conveyor ............................. 4
Conveyor Supports: ......................................................... 5
Maximum Distances:.................................................... 5
Specifications:.................................................................. 5
iDrive Load Capacity....................................................... 5
Motor Specifications........................................................ 5
Installation ........................................................................... 6
Required Tools................................................................. 6
Recommended Installation Sequence .............................. 6
Conveyors Up to 13 ft (3962 mm)................................... 6
Conveyors Longer Than 13 ft (3962 mm) ....................... 6
Mounting Brackets........................................................... 7
Return Rollers .................................................................. 8
Cleated Belt and 4–6” (51–152 mm) Wide Flat Belt
Conveyors..................................................................... 8
8–48” (203–1219 mm) Wide Flat Belt Conveyors ...... 8
Wiring .............................................................................. 9
Cover Mounted Controls with 115 volt Power Supply 9
Cover Mounted Controls with Customer Provided Power
Supply........................................................................... 9
Customer Wired with Flying Leads ........................... 10
Factory Settings.......................................................... 10
Potentiometers............................................................ 11
Jumpers....................................................................... 11
Change Acceleration / Deceleration Settings............. 11
Preventive Maintenance and Adjustment.......................... 12
Required Tools............................................................... 12
Standard Tools............................................................ 12
Checklist ........................................................................ 12
Lubrication..................................................................... 12
Maintaining Conveyor Belt ........................................... 12
Troubleshooting ......................................................... 12
Cleaning ..................................................................... 12
Conveyor Belt Replacement....................................... 12
Conveyor Belt Replacement Sequence ...................... 12
Belt Removal for Conveyor Without Stands.............. 13
Belt Removal for Conveyor With Stands................... 13
Belt Installation for Conveyor without Stands........... 14
Belt Installation for Conveyor with Stands ................ 14
Conveyor Belt Tensioning ............................................. 14
Conveyor Belt Tracking................................................. 15
V-Guided Belts........................................................... 15
Non V-Guided Belts................................................... 15
Pulley Removal ............................................................. 16
A −Idler Pulley Removal........................................... 16
B −Transfer Tail Pulley Removal ............................. 17
Pulley Replacement ....................................................... 18
Idler Pulley ................................................................. 18
Transfer Tail Pulley.................................................... 18
Drive Spindle Removal and Replacement ..................... 18
Removal ...................................................................... 18
Replacement................................................................ 20
Motor Removal and Replacement.................................. 20
Circuit Board Removal and Replacement ...................... 22
iDrive Motor Tuning ...................................................... 23
Switch Removal and Replacement................................. 24
Notes .................................................................................. 25
Service Parts....................................................................... 26
Drive End Tail Assembly ............................................... 26
Idler End Assembly ........................................................ 28
Transfer Tail Assembly .................................................. 29
Frame Assembly............................................................. 30
Bed Plate and Frame Formulas................................... 30
−04 3” (76mm) Aluminum Side..................................... 31
−05 1.5” (38mm) Aluminum Side.................................. 32
−07 Low to Side Wiper .................................................. 33
−09 Low to High Side .................................................... 34
−10.5” (13mm) Extruded Plastic.................................... 35
−13 Adjustable Guiding ................................................. 36
−14 Tool-Less Adjustable Guiding ................................ 37
0.5” (13mm) Cleated Guiding ........................................ 38
1” (25mm) Cleated Guiding ........................................... 39
2” (51mm) Cleated Guiding ........................................... 40
Flared Side Guiding........................................................ 41
Flat Belt Mounting Brackets .......................................... 42
Cleated Belt Mounting Brackets .................................... 42
Connecting Assembly without Stand Mount.................. 43
Flat Belt Connecting Assembly with Stand Mount........ 43
Cleated Belt Connecting Assembly with Stand Mount.. 44
4” (102mm) to 6” (152mm) Flat Belt Return Roller...... 44
8” (203mm) to 24” (610mm) Flat Belt Return Roller.... 45
Cleated Belt Return Roller ............................................. 45
Conveyor Belt Part Number Configuration.................... 46
Flat Belt Part Number Configuration.......................... 46
Cleated Belt Part Number Configuration.................... 46
Notes .................................................................................. 47
Return Policy...................................................................... 48

851-702 Rev. A 3 Dorner Mfg. Corp.
3200 Series iDrive Belt Conveyors
Introduction
Upon receipt of shipment:
• Compare shipment with packing slip. Contact factory
regarding discrepancies.
• Inspect packages for shipping damage. Contact carrier
regarding damage.
• Accessories may be shipped loose. See accessory instruc-
tions for installation.
Dorner’s Limited Warranty applies.
Dorner 3200 series conveyors are covered by Patent
Numbers 5,156,260, 6,871,737B2, 6,910,571B1,
6,971,509B2, and corresponding patents and patent
applications in other countries.
Dorner reserves the right to make changes at any time
without notice or obligation.
Dorner has convenient, pre−configured kits of Key Service
Parts for all conveyor products. These time saving kits are
easy to order, designed for fast installation, and guarantee
you will have what you need when you need it. Key Parts
and Kits are marked in the Service Parts section of this
manual with the Performance Parts Kits logo .
Warnings −General Safety
IMPORTANT
Some illustrations may show guards removed.
DO NOT operate equipment without guards.
A
WARNING
The safety alert symbol, black triangle with
white exclamation, is used to alert you to
potential personal injury hazards.
A
DANGER
Climbing, sitting, walking or riding on
conveyor will cause severe injury. KEEP OFF
CONVEYORS.
A
DANGER
DO NOT OPERATE CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
A
WARNING
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
A
WARNING
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.
A
WARNING
Loosening stand height or angle adjustment
screws may cause conveyor sections to drop
down, causing severe injury.
SUPPORT CONVEYOR SECTIONS PRIOR TO
LOOSENING STAND HEIGHT OR ANGLE
ADJUSTMENT SCREWS.

Dorner Mfg. Corp. 4 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Product Description
Refer to figures below for typical components.
Typical Conveyor Components Figure 1:
Figure 1
Figure 1
Typical Controller Components Figure 2:
Figure 2
Figure 2
Specifications
Models:
Flat Belt 3200 Series Conveyor Cleated Belt 3200 Series Conveyor
* See Ordering and Specifications Catalog for details.
1 Conveyor
2 Guiding & Accessories
3 Mounting Brackets
4 Return Rollers
5 Support Stand
6DriveEnd
7 Idler/Tension End
2
1
7
6
5
33
4
1 Speed Control
2 On/Off Switch
3 Direction Switch
4 Power Input Jack
1
2
3
4
Flat Belt 3200 Series Conveyor
Conveyor Width Reference
Conveyor Length Reference
Belt Type*
Output Shaft Position*
Conveyor Profile*
1 = Non-V-guided Belt, conveyor to include mounting brackets
2 = V-guided Belt, conveyor to include mounting brackets
3 = Non-V-guided Belt, conveyor not to include mounting brackets
4 = V-guided Belt, conveyor not to include mounting brackets
Document Language, M = English
3 1 0 M WW LLLL A PP BB
0 = 3” tails
1 = 1” tails
iDrive
FD
-C P S
iDrive Control Type
iDrive Power Supply
iDrive Speed
Cleated Belt 3200 Series Conveyor
Conveyor Width Reference
Conveyor Length Reference
3 1 C M WW LLLL A SSSS
Output Shaft Position*
Cleat Spacing*
Document Language, M = English
Cleat Type*
iDrive
FD
-C P S
iDrive Control Type
iDrive Power Supply
iDrive Speed
1 = Non-V-guided Belt, conveyor to include mounting brackets
2 = V-guided Belt, conveyor to include mounting brackets
3 = Non-V-guided Belt, conveyor not to include mounting brackets
4 = V-guided Belt, conveyor not to include mounting brackets

851-702 Rev. A 5 Dorner Mfg. Corp.
3200 Series iDrive Belt Conveyors
Specifications
Conveyor Supports:
Maximum Distances:
1 = 24” (610 mm) (Drive End)
2 = 12 ft (3658 mm)
3 = 36” (914 mm) (Idler End)
Figure 3
Figure 3
Specifications:
* See Ordering and Specifications Catalog for details.
iDrive Load Capacity (lbs)
Motor Specifications
23
1
Conveyor Width
Reference (WW)
06 08 10 12 14 16 18 20 22 24
Conveyor Belt Width 6”
(152mm)
8”
(203mm)
10”
(254mm)
12”
(305mm)
14”
(356mm)
16”
(406mm)
18”
(457mm)
20”
(508mm)
22”
(559mm)
24”
(609mm)
Maximum Conveyor
Load
See iDrive Load Capacity Chart Below
Conveyor Startup
To r q u e *
13 in-lb
(1.5 Nm)
17 in-lb
(1.9 Nm)
22 in-lb
(2.5 Nm)
25 in-lb
(2.8 Nm)
29 in-lb
(3.3 Nm)
33 in-lb
(3.7 Nm)
41 in-lb
(4.6 Nm)
43 in-lb
(4.9 Nm)
48 in-lb
(5.4 Nm)
50 in-lb
(5.6 Nm)
Conveyor Length
Reference (LLLL)
0300 to 1200 in 0001 increments
Conveyor Length 3 ft (914mm) to 12 ft (3658mm) in 0.12” (0.31mm) increments
Belt Travel 9.7” (246 mm) per revolution of pulley
Maximum Belt Speed* 171 ft/minute (52 m/minute)
Belt Takeup 1.62” (41 mm) of Belt Takeup on Conveyors Under 12’ Length
Conveyor Width High Speed Motor Medium Speed Motor Low Speed Motor
6” (152mm) 46 63 115
8” (203mm) 43 60 111
10” (254mm) 37 54 106
12” (305mm) 34 51 103
14” (356mm) 30 47 98
16” (406mm) 25 42 94
18” (457mm) 16 34 85
20” (508mm) 14 31 83
22” (559mm) 10 27 78
24” (610mm) 8 25 76
NOTE
Maximum conveyor length based on:
• Non-accumulating product
• Product moving towards gearmotor
• Conveyor being mounted horizontal
High Speed Medium Speed Low Speed
Output Power 150 watt 150 watt 150 watt
Motor Voltage 36 volt DC, 4 amp 36 volt DC, 4 amp 36 volt DC, 4 amp
Transformer Voltage 100-240 VAC, 50/60 Hz 100-240 VAC, 50/60 Hz 100-240 VAC, 50/60 Hz
Gearmotor Ratio 15:1 15:1 25:1
Motor Type Brushless DC Brushless DC Brushless DC
Belt Speeds 27-171 Ft./Min., High Speed 21-133 Ft./Min., Medium Speed 15-80 Ft./Min., Low Speed
Duty Cycle Continuous Rated Continuous Rated Continuous Rated
Index Capacity 30 times / Min. 30 times / Min. 30 times / Min.

Dorner Mfg. Corp. 6 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Installation
Figure 4
Figure 4
Required Tools
• Hex-key wrenches:
- 4 mm, 5 mm
• Level
• Torque wrench
Recommended Installation
Sequence
• Install support stands (see accessory instructions)
• Assemble conveyor (if required)
• Attach mounting brackets to conveyor
• Attach conveyor to stands
• Install return rollers on conveyor (optional)
• Mount gearmotor mounting package (see accessory
instructions)
• Attach guides/accessories (see page 26 through 40 of
“Service Parts” section for details)
Conveyors Up to 13 ft (3962 mm)
No assembly is required. Install mounting brackets and
return rollers. Refer to “Mounting Brackets” on page 7 and
“Return Rollers” on page 8.
Conveyors Longer Than 13 ft
(3962 mm)
Installation Component List:
1. Locate and arrange conveyor sections (Figure
5, item 1) by section labels (Figure 5, item 2).
Figure 5
Figure 5
2. On tension end of the conveyor, identified by the pinion
locking screw (Figure 6, item 1), push in head plate
assembly (Figure 6, item 2): Loosen the pinion locking
screw (Figure 6, item 3), adjust the pinion torque screw
(Figure 7, item 1). On both sides of conveyor, loosen
the two tail clamp bolts (Figure 6, item 3), and push
head plate assembly (Figure 6, item 2) inward.
Figure 6
Figure 6
NOTE
Conveyor MUST be mounted straight, flat and
level within confines of conveyor. Use a level
(Figure 4, item 1) for setup.
1
1 Conveyor frame
2 Section Label
2
2
1
1
32

851-702 Rev. A 7 Dorner Mfg. Corp.
3200 Series iDrive Belt Conveyors
Installation
Figure 7
Figure 7
3. Roll out conveyor belt and place conveyor frame
sections (Figure 8, item 1) into belt loop.
Figure 8
Figure 8
4. Join conveyor sections and install connector brackets
(Figure 9, item 1) or connector/mount brackets (Figure
9, item 2) and screws (Figure 9, item 3) on both sides
as indicated. Tighten screws to 60 in-lb (7 Nm).
Figure 9
Figure 9
Figure 10
Figure 10
5. Tighten conveyor belt, refer to “Conveyor Belt
Tensioning” on page 14.
6. Install mounting brackets and return rollers. Refer to
“Mounting Brackets” on page 7 and “Return Roller” on
page 8.
Mounting Brackets
1. Locate brackets. Exploded views shown in Figure 11 &
Figure 12.
Figure 11
Figure 11
Figure 12
Figure 12
NOTE
For Conveyors longer than 20 ft (6096 mm)
use the process outlined in the “Conveyor
Belt Tensioning” section on page 14. Extend
the Drive End Tail Assembly to the zero mark
of the tension indicator (Figure 10, item 1)
before proceeding to step 5. The zero mark
for the tension indicator is when the indicator
begins to turn black.
1
11
3
1
2
1
1
5
4
3
2
1
5
4
3
2

Dorner Mfg. Corp. 8 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Installation
2. Remove screws (Figure 11, item 1 & 2) or (Figure
12, item 1 & 2), washers (Item 3), nuts (Item 4) and T-
bars (Item 5) from brackets.
3. Insert T-bars (Figure 11, item 5) or (Figure 12, item 5)
into conveyor side slots (Figure 13, item 1). Fasten
brackets (Figure 13, item 2) to conveyor with mounting
screws (Figure 13, item 3).
Figure 13
Figure 13
4. Fasten brackets to support stand with mounting screws
(Figure 13, item 4), washers (Figure 13, item 5) and
nuts (Figure 13, item 6).
5. Tighten screws (Figure 13, item 3 & 4) to 60 in-lb (7
Nm).
Return Rollers
Cleated Belt and 4–6” (51–152 mm) Wide
Flat Belt Conveyors
1. Locate return rollers. Exploded views shown in Figure
14 & Figure 15.
Figure 14
Figure 14
Figure 15
Figure 15
2. Remove screws (Figure 14, item 1) & (Figure
15, item 1) and clips (Item 2) from roller assembly.
3. Install roller assemblies (Figure 16, item 1) as shown.
Tighten screws (Figure 16, item 2) to 60 in-lb (7 Nm).
Figure 16
Figure 16
8–48” (203–1219 mm) Wide Flat Belt
Conveyors
1. Locate return rollers. Exploded view shown in Figure
17.
Figure 17
Figure 17
2. Remove screws (Figure 17, item 1) and clips (Figure
17, item 2) from roller assembly.
3. Install roller assembly as shown (Figure 18, item 1).
Tighten screws (Figure 18, item 2) to 60 in-lb (7 Nm).
Figure 18
Figure 18
NOTE
Mounting brackets for flat belt conveyors
shown.
1
3
2
54 6
12
21
12
2
1
1
2
2
2
2
1
1
2
1

851-702 Rev. A 9 Dorner Mfg. Corp.
3200 Series iDrive Belt Conveyors
Installation
Wiring
The 3200 series iDrive is available in 3 models:
• Cover Mounted Controls with 115 volt Power Supply
• Cover Mounted Controls with Customer Provided Power
Supply
• Customer Wired with Flying Leads
Cover Mounted Controls with 115 volt
Power Supply
1. No wiring is required. Attach quick disconnect end of
power supply to power jack (Figure 19, item 1).
Figure 19
Figure 19
2. See “Change Acceleration / Deceleration Settings” on
page 11 for changing factory control settings.
Cover Mounted Controls with Customer
Provided Power Supply
1. Locate the male disconnect plug provided.
2. Wire and solder DC power to the two terminals of the
provided DC power plug. Wire +VDC to the short lug
(Figure 20, item 1) and -VDC to the long lug (Figure
20, item 2).
Figure 20
Figure 20
3. Required power is 36VDC, 4 amps minimum.
4. See “Change Acceleration / Deceleration Settings” on
page 11 for changing factory control settings.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
1
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
2
1

Dorner Mfg. Corp. 10 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Installation
Customer Wired with Flying Leads 1. Locate lead wires (Figure 21, item 1) extending from
conveyor side rail. Determine wiring diagrams based on
diagrams above.
Figure 21
Figure 21
2. Shielding wiring is recommended.
3. See “Change Acceleration / Deceleration Settings” on
page 11 for changing factory control settings.
Factory Settings
Controller Board:
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
NOTE
1. Start Stop Application: Maximum start stop
cycles are 20 per minute.
2. Reversing Applications: Do not reverse the
motor direction when running. Make sure the
motor is stopped before reversing signal is
given.
BROWN
PRE-WIRED
PRE-WIRED
CUSTOMER-WIRED CONTROL
BY CUST.
BY CUST.
13 W
14 LO
CONTROLLER BOARD
*DC POWER TO CONTROLLER MUST BE FUSED AT 5 AMPS
V+-
0-5VDC
ANALOG SPEED
BLACK
BLUE
GREEN
36VDC/150W
REGULATED
RUN
REV
5
4
-
+
8 F/R
6 GND
POWER*
(-)
(+) B
B
FUSE
5A WHT
RED
CR
YELLOW
CR
VIOLET
12 HI
ORANGE
CAP
with Analog Speed Input
BLA
BLA
CK
CK
BLUE
BLUE
GREEN
GREEN
YELLO
YELLO
W
ORANGE
ORANGE
BR
BR
OWN
WN
36VDC/150W
REGULATED
PRE-WIRED
PRE-WIRED
PRE-WIRED
PRE-WIRED
CUSTOMER-WIRED CONTROL
BY CUST.
BY CUST.
RUN
REV
5
4
-
+
8 F/R
6 GND
13 W
12 HI
14 LO
CONTROLLER BOARD
POWER*
WER*
(-)
(+) B
B
FUSE
FUSE
5A WH
WH
T
CR
VIOLE
VIOLE
T
RED
RED
CR
*DC POWER
WER
TO CONTROLLER MUST BE FUSED AT 5 AMPS
POT
SPEED
10 K OHM
10 K OHM
1 WATT
with Speed Potentiometer
1
MINMAX
DECELACCEL
GAINCUR
3
2
1
P5
3
2
1
P2
1
2
3
P3
1 2 3 4
9
8
7
5
6

851-702 Rev. A 11 Dorner Mfg. Corp.
3200 Series iDrive Belt Conveyors
Installation
Potentiometers
Jumpers
NOTE: Refer to Dart Controls Instruction Manual for 700B Control Series for further details.
Change Acceleration / Deceleration
Settings
1. Remove belt. (See “Belt Removal for Conveyor Without
Stands” on page 13 or “Belt Removal for Conveyor
With Stands” on page 13.)
2. Remove control board mounting screws (Figure
22, item 1) from bottom of plate.
Figure 22
Figure 22
3. Locate potentiometers to change. See Controller Board
layout on page 10.
4. Rotate potentiometers (Figure 23, item 1) to desired
setting.
Figure 23
Figure 23
5. Reinstall by reversing steps.
Item Number Description Setting
1 Current Limit % 100%
2 Gain % N/A
3 Max. Speed % 100%
4 Min. Speed % 5%
5 Decel. (0-10 sec.) 0 sec.
6 Accel. (0-10 sec.) 0.5 sec.
Item Number Description Position Setting
7 Input Voltage (P3) P3-2 & 3 (36) 24/36 VDC
8 Sensor Spacing (P2) P2-1 & 2 (120) 120 deg.
9 Potentiometer Function (P5) P5-2 & 3 (U) Unidirectional
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
1
1

Dorner Mfg. Corp. 12 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Preventive Maintenance and Adjustment
Required Tools
Standard Tools
• Hex-key wrenches:
- 2.5 mm, 4 mm, 5 mm
Checklist
• Keep service parts on hand (see “Service Parts” section for
recommendations)
• Keep supply of belt cleaner (part # 625619)
• Clean entire conveyor and knurled pulley while disassem-
bled
• Replace worn or damaged parts
Lubrication
No lubrication is required. Replace bearings if worn.
Maintaining Conveyor Belt
Troubleshooting
Inspect conveyor belt for:
• Surface cuts or wear
• Stalling or slipping
• Damage to V-guide
Surface cuts and wear indicate:
• Sharp or heavy parts impacting belt
• Jammed parts
• Improperly installed bottom wipers (if installed)
• Accumulated dirt in wipers (if installed)
• Foreign material inside the conveyor
• Improperly positioned accessories
• Bolt-on guiding is pinching belt
Stalling or slipping indicates:
• Excessive load on belt
• Conveyor belt or drive timing belt are not properly ten-
sioned
• Worn knurl or impacted dirt on drive pulley
• Intermittent jamming or drive train problems
Damage to V-guide indicates:
• Twisted or damaged conveyor frame
• Dirt impacted on pulleys
• Excessive or improper side loading
Cleaning
Use Dorner Belt Cleaner (part # 625619). Mild soap and
water may also be used. Do not soak the belt.
For /05 woven polyester and /06 black anti-static belts, use a
bristled brush to improve cleaning.
Conveyor Belt Replacement
Conveyor Belt Replacement Sequence
• Remove old conveyor belt:
-Conveyor without Stands
-Conveyor with Stands
• Install new conveyor belt
• Tension conveyor belt
NOTE
Visit www.dorner.com for complete list of
troubleshooting solutions.
IMPORTANT
Do not use belt cleaners that contain alcohol,
acetone, Methyl Ethyl Ketone (MEK) or other
harsh chemicals.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.

851-702 Rev. A 13 Dorner Mfg. Corp.
3200 Series iDrive Belt Conveyors
Preventive Maintenance and Adjustment
Belt Removal for Conveyor Without Stands
1. If equipped, remove return rollers and guiding and
accessories from one side of conveyor.
2. On tension end of the conveyor, identified by the pinion
locking screw (Figure 24, item 1), push in head plate
assembly (Figure 24, item 2): Loosen the pinion
locking screw (Figure 24, item 1), adjust the pinion
torque screw (Figure 25, item 1). On both sides of
conveyor, loosen the two tail clamp bolts (Figure
24, item 3), and push head plate assembly (Figure
24, item 2) inward.
Figure 24
Figure 24
Figure 25
Figure 25
3. Remove conveyor belt.
Belt Removal for Conveyor With Stands
1. Place temporary support stands (Figure 26, item 1) at
both ends of the conveyor.
Figure 26
Figure 26
2. Remove mounting brackets (Figure 26, item 2) from
one side of conveyor. (Reverse steps 3 & 4 of
“Mounting Brackets” section on page 7).
3. If equipped, remove return rollers, guiding and
accessories from the same side of conveyor.
4. On tension end of the conveyor, identified by the pinion
locking screw (Figure 27, item 1), push in head plate
assembly (Figure 27, item 2): Loosen the pinion
locking screw (Figure 27, item 1), adjust the pinion
torque screw (Figure 28, item 1). On both sides of
conveyor, loosen the two tail clamp bolts (Figure
27, item 3), and push head plate assembly (Figure
27, item 1) inward.
Figure 27
Figure 27
Figure 28
Figure 28
5. Remove belt (Figure 29, item 1) from conveyor.
Figure 29
Figure 29
1
3
2
1
2
12
1
3
2
1
1
1

Dorner Mfg. Corp. 14 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Preventive Maintenance and Adjustment
Belt Installation for Conveyor without
Stands
1. Orient belt so splice leading fingers (Figure 30, item 1)
point in the direction of belt travel as identified by the
conveyor directional label (Figure 30, item 2).
Figure 30
Figure 30
2. Slide belt onto the conveyor frame assembly.
3. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 14.
4. If equipped, install wipers, return rollers and guiding
Belt Installation for Conveyor with Stands
1. Ensure temporary support stands (Figure 31, item 1)
are placed at both ends of the conveyor.
2. Orient belt so splice leading fingers (Figure 30, item 1)
point in the direction of belt travel as identified by the
conveyor directional label (Figure 30, item 2).
3. Install belt (Figure 31, item 2) on conveyor. Lift
conveyor slightly to avoid pinching belt on temporary
support stands.
Figure 31
Figure 31
4. Re-install conveyor mounting brackets. Refer
“Mounting Brackets” on page 7, steps 3 through 5.
5. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 14.
6. If equipped, re-install return rollers and guiding.
Conveyor Belt Tensioning
1. On tension end of the conveyor, identified by the pinion
locking screw (Figure 32, item 1), loosen the two tail
clamp bolts (Figure 32, item 2), on both sides of
conveyor.
Figure 32
Figure 32
2. With 5mm hex wrench, hold pinion torque screw
(Figure 33, item 1). Loosen the pinion locking screw
(Figure 32, item 1) and turn the pinion torque screw
(Figure 33, item 1) to extend head plate assembly
(Figure 32, item 3).
Figure 33
Figure 33
1
2
2
2
1
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
NOTE
For conveyors longer than 20 ft (6096 mm)
the belt tensioning procedure outlined below
may be preformed on both the Drive and Idler
Ends of the conveyor.
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851-702 Rev. A 15 Dorner Mfg. Corp.
3200 Series iDrive Belt Conveyors
Preventive Maintenance and Adjustment
3. Extend head plate assembly until proper tension in the
belt is achieved. If proper tensioning can not be obtained
before the belt life indicator is all black (Figure
34, item 1) the belt must be replaced.
Figure 34
Figure 34
4. After adjusting proper tensioning, tighten the pinion
locking screw (Figure 32, item 1) to 69 in−lbs (7.8 N−
m), and tighten tail clamp bolts (Figure 32, item 2) on
both sides of conveyor to 146 in-lb (16.5 N−m).
5. If belt tracking is necessary, refer to “Conveyor Belt
Tracking” on page 15.
Conveyor Belt Tracking
V-Guided Belts
V-guides on belts help maintain proper belt tracking. Track
as needed to reduce belt bulge from center of belt (Figure
35). See steps below in “Non V-guided Belts” procedure for
adjusting for any belt bulging. Belt bulge will be minimal
when belt is properly tracked.
Figure 35
Figure 35
Non V-Guided Belts
Non V-guided belt conveyors are equipped with belt tracking
assemblies.
1. When adjusting belt tracking, always adjust the
discharge end of the conveyor first. To adjust belt
tracking:
2. Ensure tensioning racks are extended and touching the
idler pulley headplates: loosen the pinion locking screw
(Figure 36, item 1) and rotate the pinion torque screw
(Figure 33, item 1) clockwise until contact with the
head plate is made, then tighten the pinion locking
screw (Figure 36, item 1) to 69 in−lbs (7.8 N−m)
3. On the side of conveyor to be adjusted, loosen two (2)
tail clamp screws (Figure 36, item 2).
Figure 36
Figure 36
4. With the conveyor running, use wrench (Figure
37, item 1) to rotate the tracking screw (Figure
38, item 1) in small increments until the belt tracks in
the center of the conveyor.
Figure 37
Figure 37
NOTE
On pinion gear, do not exceed a torque of 100
in-lb (11.3 N
− m). Over tensioning the
conveyor belt could cause excessive pulley
bearing load and early failure.
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Dorner Mfg. Corp. 16 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Preventive Maintenance and Adjustment
Figure 38
Figure 38
5. Re-tighten the head plate fastening screws (Figure
39, item 1) with a 5 mm hex-key wrench to 146 in-lb
(16.5 Nm).
Figure 39
Figure 39
Pulley Removal
Remove conveyor belt to access pulley(s). See “Conveyor
Belt Replacement” on page 12. Remove the desired pulley
following the corresponding instructions below:
•A−Idler Pulley Removal
•B−Transfer Tail Pulley Removal
A −Idler Pulley Removal
1. Temporarily support the idler pulley.
Figure 40
Figure 40
2. On one side of conveyor, loosen the two (2) back
fastening screws (Figure 41, item 1) and remove two
(2) front fastening screws (Figure 41, item 2).
Figure 41
Figure 41
3. Pull back the outer headplate (Figure 42, item 1) and
remove the inner spacer (Figure 42, item 2).
Figure 42
Figure 42
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
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851-702 Rev. A 17 Dorner Mfg. Corp.
3200 Series iDrive Belt Conveyors
Preventive Maintenance and Adjustment
4. Slide the idler pulley assembly (Figure 43, item 1) out
of the headplate on the opposite side.
Figure 43
Figure 43
5. Remove the pulley shaft assembly: remove the clip ring
(Figure 44, item 1) and washer (Figure 44, item 2)
from one side of the pulley assembly.
Figure 44
Figure 44
6. Slide the shaft assembly (Figure 45, item 1) out of the
pulley (Figure 45, item 2).
Figure 45
Figure 45
B −Transfer Tail Pulley Removal
1. Temporarily support the transfer tail assembly.
Figure 46
Figure 46
2. On one side of conveyor, remove the two (2) back
fastening screws (Figure 47, item 1), and the two (2)
front fastening screws (Figure 47, item 2).
Figure 47
Figure 47
3. Remove the inner spacer (Figure 48, item 1).
Figure 48
Figure 48
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Dorner Mfg. Corp. 18 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Preventive Maintenance and Adjustment
4. Slide the transfer tail pulley assembly (Figure
49, item 1) out of the headplate on the opposite side.
Figure 49
Figure 49
5. Remove hex nuts (Figure 50, item 1).
Figure 50
Figure 50
6. Remove support plates (Figure 51, item 1) and washers
(Figure 51, item 2).
Figure 51
Figure 51
7. Remove pulleys (Figure 52, item 1) and additional
washers (Figure 52, item 2).
Figure 52
Figure 52
8. To remove additional pulleys, repeat steps 6 through 7.
Pulley Replacement
Idler Pulley
To replace the idler pulley, reverse the “Idler Pulley
Removal” procedure on page 16.
Transfer Tail Pulley
To replace the transfer tail pulley, reverse the “Transfer Tail
Pulley Removal” procedure on page 17.
Drive Spindle Removal and
Replacement
Removal
1. Remove belt. (See “Belt Removal for Conveyor Without
Stands” on page 13 or “Belt Removal for Conveyor
With Stands” on page 13.)
2. Remove wear plate (Figure 53, item 1) by removing
plate fastening screws (Figure 53, item 2) on each side
and end of conveyor
Figure 53
Figure 53
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A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
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851-702 Rev. A 19 Dorner Mfg. Corp.
3200 Series iDrive Belt Conveyors
Preventive Maintenance and Adjustment
3. Disconnect two wiring harness connectors (Figure
54, item 1).
Figure 54
Figure 54
4. Loosen four hex head screws (Figure 54, item 2) on
each side of conveyor.
5. Remove two hex head screws (Figure 56, item 1).
Figure 55
Figure 55
6. Slide drive motor and plate (Figure 56, item 1) to
loosen tension on timing belt (Figure 56, item 2).
Figure 56
Figure 56
7. Remove hex head screw (Figure 57, item 1) and washer
from both sides of the conveyor.
Figure 57
Figure 57
8. Remove drive spindle assembly (Figure 58, item 1) and
replace.
Figure 58
Figure 58
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Dorner Mfg. Corp. 20 851-702 Rev. A
3200 Series iDrive Belt Conveyors
Preventive Maintenance and Adjustment
Replacement
Install in reverse order of removal.
Figure 59
Figure 59
Motor Removal and Replacement
1. Remove belt. (See “Belt Removal for Conveyor Without
Stands” on page 13 or “Belt Removal for Conveyor
With Stands” on page 13.)
2. Remove wear plate (Figure 60, item 1) by removing
plate fastening screws (Figure 60, item 2) on each side
and end of conveyor
Figure 60
Figure 60
3. Disconnect two wiring harness connectors (Figure
61, item 1).
Figure 61
Figure 61
4. Remove tie strap (Figure 61, item 2) from drive motor
harness.
5. If applicable, remove black cap from end (Figure
61, item 3) of drive motor.
NOTE
Move drive motor plate (Figure 59, item 1) to
obtain 1/8 - 1/4” belt deflection at center of
belt (Figure 59, item 2) with approximately 3-
5 in-lb of pressure. Tighten two hex head
screws (Figure 59, item 3) to 15 in-lb (1.6
Nm) to secure position.
A
CAUTION
Over tightening of timing belt will result in
reduced gearmotor and timing belt life.
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2
1
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
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