Dorner SmartFlex 2200 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]
851-829 Rev. A
2200 Series
SmartFlex Conveyors
with Cast Tails
Installation, Maintenance & Parts Manual

Dorner Mfg. Corp. 2 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
Table of Contents
Introduction ......................................................................... 4
Warnings −General Safety ................................................. 5
Product Description ............................................................. 6
Specifications ...................................................................... 7
Modules: .......................................................................... 7
Infeed Module .............................................................. 7
Curve Module............................................................... 7
Intermediate Module .................................................... 7
Incline/Decline Module................................................ 7
Drive Module ............................................................... 7
Top Running Drive Module ......................................... 7
Conveyor Supports: ......................................................... 8
Maximum Distances:.................................................... 8
Specifications: .............................................................. 8
Table 1: Gearmotor Specifications .................................. 8
U.S. Version ................................................................. 8
CE Version ................................................................... 8
SEW Gearmotor Specifications ................................... 9
Heavy Load Gearmotor Specifications ........................ 9
Heavy Load Gearmotor Specifications (continued)..... 9
Table 2: Belt Speed for Standard Load
Fixed Speed 90° Gearmotors...................................... 10
U.S. Version (60 Hz Gearmotors).............................. 10
CE Version (50 Hz Gearmotors)................................ 10
Table 3: Belt Speeds for Standard Load
Variable Speed 90° VFD Gearmotors ........................... 10
U.S. Version (60 Hz Gearmotors).............................. 10
CE Version (50 Hz Gearmotors)................................ 10
Table 4: Belt Speeds for Standard Load
SEW Fixed Speed Gearmotors ...................................... 11
Table 5: Belt Speeds for Standard Load SEW Variable
Speed Gearmotors.......................................................... 11
Table 6: Belt Speed for Heavy Load Fixed Speed 90°
Gearmotors..................................................................... 11
U.S. Version (60 Hz Gearmotors).............................. 11
Table 7: Belt Speed for Heavy Load Variable Speed 90°
VFD Gearmotors............................................................ 11
U.S. Version (60 Hz Gearmotors).............................. 11
Installation ......................................................................... 12
Required Tools............................................................... 12
Recommended Installation Sequence ............................ 12
Module Lengths Longer Than 10 ft (3048 mm) ............ 12
Knuckles ........................................................................ 13
Curves ............................................................................ 13
Tails ............................................................................... 14
Unroll Wear Strips ......................................................... 14
Mounting Brackets......................................................... 15
Install Support Stands .................................................... 15
Belt Installation.............................................................. 15
Weighted Take-Up......................................................... 17
Top Running Drive ........................................................ 18
Install Guiding ............................................................... 19
Standard 1.5" and 3" Guiding..................................... 19
Puck/Pallet Guiding.................................................... 20
Fully Adjustable Guiding ........................................... 21
Install Drive Package ..................................................... 23
Preventive Maintenance and Adjustment .......................... 24
Required Tools ............................................................... 24
Checklist ........................................................................ 24
Lubrication ..................................................................... 24
Maintaining the Conveyor Belt ...................................... 24
Troubleshooting .......................................................... 24
Conveyor Belt Replacement.......................................... 24
Replacing a Section of Belt ........................................ 24
Replacing the Entire Belt............................................ 25
Conveyor Belt Tensioning.............................................. 25
Wear Strip Removal ....................................................... 26
Wear Strip Installation.................................................... 26
Attaching Wear Strip on Straight Frame .................... 26
Attaching Wear Strip on Conveyor Frame ................. 27
Attaching Wear Strip at Wheel Bend ......................... 28
Attaching Wear Strip .................................................. 28
Idler Pulley Assembly .................................................... 30
Drive Spindle Shaft Assembly ....................................... 30
Retaining Guide Replacement........................................ 32
Cantenary Drive End .................................................. 32
Idler End and GTU Drive Tail.................................... 33
Top Running Drive......................................................... 33
Curve Assembly ............................................................. 35
Weighted Take-Up ......................................................... 35
Power Transfer ............................................................... 38
Removal ...................................................................... 38
Installation .................................................................. 41
Roller Transfer ............................................................... 44
Notes .................................................................................. 45
Service Parts....................................................................... 46
Drive Tail ....................................................................... 46
Weighted Take-Up ......................................................... 48
Weighted Take-Up Drive Tail........................................ 50
Idler Tail ......................................................................... 52
Top Running Drive......................................................... 54
Frame Assembly............................................................. 56
Wear Strip Replacement Tool ........................................ 57
65 Width Curve Frame Assembly .................................. 58
105 Width Curve Frame Assembly ................................ 59
150 Width Curve Frame Assembly ................................ 60
65 Width Knuckle Frame Assembly .............................. 61
105 Width Knuckle Frame Assembly ............................ 62
150 Width Knuckle Frame Assembly ............................ 63
04 3" High Sides for Straight Modules .......................... 64
04 3" High Sides for Curve Modules ............................. 65
04 3" High Sides for Incline/Decline Modules .............. 66
05 1.50" High Sides for Straight Modules ..................... 67
05 1.50" High Sides for Curve Modules ........................ 68
05 1.50" High Sides for Incline/Decline Modules ......... 69
13 Fully Adjustable Guiding for Straight Modules........ 70
13 Fully Adjustable Guiding for Curve Modules........... 71
14 Tool-Less Fully Adjustable Guiding
for Straight Modules...................................................... 72
14 Tool-Less Fully Adjustable Guiding
for Curve Modules......................................................... 73
16 Gull Wing Guiding for Straight Modules.................. 74

851-829 Rev. A 3 Dorner Mfg. Corp.
2200 Series SmartFlex Conveyors with Cast Tails
Table of Contents
16 Gull Wing Guiding for Curve Modules..................... 75
#13 & #14 - Adjustable Guiding and #16 - Gull Wing
Guiding for Incline/Decline Modules............................. 76
#17 & #18 - Puck / Pallet Guiding ................................. 77
Power Transfer ............................................................... 78
Transfer Roller................................................................ 79
Mounting Brackets ......................................................... 80
Motor Mounting Assembly ............................................ 81
Connecting Assembly..................................................... 82
E-Drive and CE Gearmotor Mounting Package............. 83
SEW Gearmotor Mounting Package .............................. 84
Heavy Load Gearmotor Mounting Package ................... 85
90° SEW Gearmotors ..................................................... 86
Standard Load 90° Industrial Gearmotors...................... 86
U.S. Version................................................................ 86
CE Version.................................................................. 87
Heavy Load 90° Industrial Gearmotors.......................... 87
Wear Strip....................................................................... 88
Ordering a Replacement Chain ...................................... 88
Belt Removal Tool ......................................................... 88
Notes .................................................................................. 89
Return Policy...................................................................... 90

Dorner Mfg. Corp. 4 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
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 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 .
Dorner reserves the right to make changes at any time
without notice or obligation.
IMPORTANT
Some illustrations may show guards
removed. DO NOT operate equipment
without guards.

851-829 Rev. A 5 Dorner Mfg. Corp.
2200 Series SmartFlex Conveyors with Cast Tails
Warnings −General Safety
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. 6 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
Product Description
Refer to Figure 1 for typical components.
Figure 1
Figure 1
1 Infeed Module
2CurveModule
3 Incline Module
4 Decline Module
5 Intermediate Module
6 Drive Module
7 Gearmotor
8Stands
3
1
2
4
6
5
8
7

851-829 Rev. A 7 Dorner Mfg. Corp.
2200 Series SmartFlex Conveyors with Cast Tails
Specifications
Modules:
Infeed Module
Curve Module
Intermediate Module
Incline/Decline Module
Drive Module
Top Running Drive Module
22SF 1 MPP
LLLL
WWW
Profile A Side
Document Language
Module Length
Conveyor Width
I
PP
Profile D Side
BB
Belt Type
SS
Idler Tail Type
Sequence
Number
22SF 2 MPP
AAA
WWW
Profile A Side
Document Language
Angle
Conveyor Width
PP
Profile D Side
BB
Belt Type
SS
Curve Type
Sequence
Number
T
Direction
D
22SF 3 MPP
LLLL
WWW
Profile A Side
Document Language
Module Length
Conveyor Width
I
PP
Profile D Side
BB
Belt Type
SS
Idler Tail Type
Sequence
Number
22SF 4 MPP
AA
WWW
Profile A Side
Document Language
Angle
Conveyor Width
PP
Profile D Side
BB
Belt Type
SS
Knuckle Type
Sequence
Number
U
22SF 5 MPP
LLLL
WWW
Profile A Side
Document Language
Conveyor Length
Conveyor Width
PP
Profile D Side
BB
Belt Type
SS
Drive Tail Type
Sequence
Number
D P T M
Motor Code
Weighted Take-Up Location
Shaft Position
22SF 9 MPP
LLLL
WWW
Profile A Side
Document Language
Conveyor Length
Conveyor Width
PP
Profile D Side
BB
Belt Type
SS
Drive Tail Code
Sequence
Number
N P D M
Motor Code
Drive Module Location
Shaft Position

Dorner Mfg. Corp. 8 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
Specifications
Conveyor Supports:
Maximum Distances:
1 = 36"(914 mm)
2 = 10 ft (3048 mm)*
3 = 36"(914 mm)
* For conveyors longer than 10 ft (3048 mm), install support
at joint.
Note: Additional support required on 180° curve modules.
Figure 2
Figure 2
Specifications:
Table 1: Gearmotor Specifications
U.S. Version
CE Version
3
2
1
Conveyor Widths Reference (WW) 065 085 105 150
Conveyor Belt Width 2.47" (63 mm) 3.27" (83 mm) 4.05" (103 mm) 5.91" (150 mm)
Maximum Load 330 lb (149 kg) 660 lb (299 kg) 660 lb (299 kg) 660 lb (299 kg)
Maximum Belt Speed 250 Ft/min (76 M/min)
Belt Takeup (Standard Weighted Take-up) 8" (203 mm)
Module Length Reference 0167-5000
Module Length 1.67' (509 mm)- 50.00' (15,240 mm)
Total Conveyor Length 99 ft (30,175 mm) maximum
Item Standard Load Gearmotor
Single Phase Three Phase VFD Variable Speed
Output Power 0.5 hp (0.37 kw)
Input Voltage 115 VAC 208 – 230/460 VAC 230 VAC
Input Frequency 60Hz 10 – 60Hz
Input Current 7.4 Amperes 2.1 – 2/1 Amperes 1.6 Amperes
Gearmotor Ratios 5:1, 10:1, 20:1
Frame Size NEMA 56C
Motor Type Totally enclosed, Fan cooled
Item Standard Load Gearmotor
Single Phase Three Phase VFD Variable Speed
Output Power 0.37 kW
Input Voltage 230 VAC 230/400 VAC 230 VAC
Input Frequency 50 Hz 25 to 63 Hz
Input Current 2.6 Amperes 2.1/1.2 Amperes 2.1 Amperes
Gearmotor Ratios 5:1, 10:1, 20:1
Protection Rating IP55
Frame Size IEC 71 B5

851-829 Rev. A 9 Dorner Mfg. Corp.
2200 Series SmartFlex Conveyors with Cast Tails
Specifications
SEW Gearmotor Specifications
Heavy Load Gearmotor Specifications
Heavy Load Gearmotor Specifications (continued)
Item SEW Gearmotor
Three Phase VFD Variable Speed
Output Power 0.5 Hp (0.37 kW) 0.75 Hp (0.56 kW) 1 Hp (0.75 kW) 0.5 Hp (0.37 kW) 0.75 Hp (0.56 kW) 1 Hp (0.75 kW)
Input Voltage 230/460 230/460
Input
Frequency 60 Hz 10 to 60 Hz
Input Current 1.84/0.92
Amperes 2.50/1.25 Amperes 2.90/1.44 Amperes 1.84/0.92 Amperes 2.50/1.25 Amperes 2.90/1.44 Amperes
RPM 47 134 264 8 to 47 22 to 134 44 to 264
Ratio 37.7:1 13.4:1 6.8:1 37.7:1 13.4:1 6.8:1
Motor Frame IEC71 IEC71 IEC80 IEC71 IEC71 IEC80
Motor Type IP54 Totally Enclosed Fan Cooled IP54 Totally Enclosed Fan Cooled
Item Heavy Load Gearmotor
Single Phase Three Phase
Output Power 0.5 Hp (0.37 kW) 0.5 Hp (0.37 kW) 1 Hp (0.75 kW) 1.5 Hp (1.11 kW) 2.0 Hp (1.49 kW)
Input Voltage 115 VAC 208-230/460 VAC
Input Frequency 60 Hz
Input Current 8.0 Amperes 2.0/1.0 Amperes 3.4/1.7 Amperes 5.0/2.5 Amperes 6.2/3.1 Amperes
Gearmotor
Ratios 60:1, 80:1, 100:1 60:1, 80:1, 100:1 40:1, 50:1 25:1, 30:1 15:1, 20:1
Frame Size NEMA 56 C NEMA 56 C NEMA 56 C NEMA 145TC C NEMA 145TC C
Motor Type Totally Enclosed Fan Cooled
Item Heavy Load Gearmotor
VFD Variable Speed
Output Power 0.5 Hp (0.37 kW) 1 Hp (0.75 kW) 1.5 Hp (1.11 kW) 2.0 Hp (1.49 kW)
Input Voltage 230/460 VAC
Input Frequency 15 to 60 Hz
Input Current 1.6/0.8 Amperes 3.2/1.6 Amperes 4.2/2.1 Amperes 5.0/2.5 Amperes
Gearmotor
Ratios 60:1, 80:1, 100:1 40:1, 50:1 25:1, 30:1 15:1, 20:1
Frame Size NEMA 56 C NEMA 56 C NEMA 145TC C NEMA 145TC C
Motor Type Totally Enclosed Fan Cooled

Dorner Mfg. Corp. 10 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
Specifications
Table 2: Belt Speed for Standard Load Fixed Speed 90° Gearmotors
U.S. Version (60 Hz Gearmotors)
(vp) = voltage and phase
11 = 115 V, 1-phase
23 = 208 – 230/460 V, 3-phase
CE Version (50 Hz Gearmotors)
(vp) = voltage and phase
21 = 230 V, 1-phase
23 = 230 V, 3-phase
43 = 400 V, 3-phase
Table 3: Belt Speeds for Standard Load Variable Speed 90° VFD Gearmotors
U.S. Version (60 Hz Gearmotors)
CE Version (50 Hz Gearmotors)
Part Number RPM In-lb N-m Belt Speed 65 mm 85 mm 105 mm & 150mm
Ft/min M/min Ft/min M/min Ft/min M/min
32M060ES4(vp)FN 29 226 25.5 39 12 38 12 41 12
32M040ES4(vp)FN 43 247 27.9 57 17 57 17 60 18
32M020ES4(vp)FN 86 248 27.9 115 35 113 35 120 37
Part Number RPM N-m Belt Speed 65 mm 85 mm 105 mm & 150 mm
Ft/min M/min Ft/min M/min Ft/min M/min
62Z060ES4(vp)FN 23 26.8 31 9.3 30 9.2 32 9.8
62Z040ES4(vp)FN 35 29.4 47 14 46 14 49 15
32Z020ES4(vp)FN 70 29.9 93 28 92 28 98 30
32Z010ES4(vp)FN 140 21.5 187 57 185 56 196 60
Part Number RPM In-lb N-m Belt Speed 65 mm 85 mm 105 mm & 150mm
Ft/min M/min Ft/min M/min Ft/min M/min
32M060ES423EN 29 226 25.5 9.7 - 39 2.9 - 12 9.6 - 38 2.9 - 12 10 - 41 3.1 - 12
32M040ES423EN 43 247 27.9 14 - 57 4.4 - 17 14 - 57 4.3 - 17 15 - 60 4.6 - 18
32M020ES423EN 86 248 27.9 29 - 115 8.7 - 35 28 - 113 8.6 - 35 30 - 120 9.2 - 37
32M010ES423EN 173 156 17.6 58 - 231 18 - 70 57 - 228 17 - 70 60 - 242 18 - 74
Part Number RPM N-m Belt Speed 65 mm 85 mm 105 mm & 150mm
Ft/min M/min Ft/min M/min Ft/min M/min
62Z060ES423EN 23 26.8 7.7 - 31 2.3 - 9.3 7.6 - 30 2.3 - 9.2 8 - 32 2.4 - 9.8
62Z040ES423EN 35 29.4 12 - 47 3.6 - 14 12 - 46 3.5 - 14 12 - 49 3.7 - 15
32Z020ES423EN 70 29.9 23 - 93 7.1 - 28 23 - 92 7 - 28 24 - 98 7.5 - 30
32Z010ES423EN 140 21.5 47 - 187 14 - 57 46 - 185 14 - 56 49 - 196 15 - 60

851-829 Rev. A 11 Dorner Mfg. Corp.
2200 Series SmartFlex Conveyors with Cast Tails
Specifications
Table 4: Belt Speeds for Standard Load SEW Fixed Speed Gearmotors
Table 5: Belt Speeds for Standard Load SEW Variable Speed Gearmotors
Table 6: Belt Speed for Heavy Load Fixed Speed 90° Gearmotors
U.S. Version (60 Hz Gearmotors)
Table 7: Belt Speed for Heavy Load Variable Speed 90° VFD Gearmotors
U.S. Version (60 Hz Gearmotors)
Part Number RPM In-lb N-m Belt Speed 65 mm 85 mm 105 mm & 150 mm
Ft/min M/min Ft/min M/min Ft/min M/min
32M038WS423EN 47 548 61.9 63 19 62 19 66 20
32M013WS423EN 134 327 37.0 179 54 177 54 187 57
Part Number RPM In-lb N-m Belt Speed 65 mm 85 mm 105 mm & 150 mm
Ft/min M/min Ft/min M/min Ft/min M/min
32M038WS423EN 47 548 61.9 16 - 63 4.8 - 19 15 - 62 4.7 - 19 16 - 66 5 - 20
32M013WS423EN 134 327 37.0 45 - 179 14 - 54 44 - 177 13 - 54 47 - 187 14 - 57
Part Number RPM In-lb N-m Belt Speed 65 mm 85 mm 105 mm & 150 mm
Ft/min M/min Ft/min M/min Ft/min M/min
32M100EH4(vp)FN 17 913 103 23 6.9 22 6.8 24 7.2
32M080EH4(vp)FN 22 833 94 29 8.9 29 8.8 31 9.4
32M060EH4(vp)FN 29 680 76 39 12 38 12 41 12
32M050EH423FN 35 1206 136 47 14 46 14 49 15
32M040EH423FN 43 1023 115 57 17 57 17 60 18
32M030EH423FN 58 1217 137 77 24 76 23 81 25
32M025EH423FN 70 1069 121 93 28 92 28 98 30
32M020EH423FN 86 1184 134 115 35 113 35 120 37
32M015EH423FN 115 910 103 153 47 152 46 161 49
Part Number RPM In-lb N-m Belt Speed 65 mm 85 mm 105 mm & 150 mm
Ft/min M/min Ft/min M/min Ft/min M/min
32M100HH423EN 17 913 103 5.7 - 23 1.7 - 6.9 5.6 - 22 1.7 - 6.8 5.9 - 24 1.8 - 7.2
32M080HH423EN 22 833 94 7.3 - 29 2.2 - 8.9 7.3 - 29 2.2 - 8.8 7.7 - 31 2.3 - 9.4
32M060HH423EN 29 680 76 9.7 - 39 2.9 - 12 9.6 - 38 2.9 - 12 10 - 41 3.1 - 12
32M050HH423EN 35 1206 136 12 - 47 3.6 - 14 12 - 46 3.5 - 14 12 - 49 3.7 - 15
32M040HH423EN 43 1023 115 14 - 57 4.4 - 17 14 - 57 4.3 - 17 15 - 60 4.6 - 18
32M030HH423EN 58 1217 137 19 - 77 5.9 - 24 19 - 76 5.8 - 23 20 - 81 6.2 - 25
32M025HH423EN 70 1069 121 23 - 93 7.1 - 28 23 - 92 7 - 28 24 - 98 7.5 - 30
32M020HH423EN 86 1184 134 29 - 115 8.7 - 35 28 - 113 8.6 - 35 30 - 120 9.2 - 37
32M015HH423EN 115 910 103 38 - 153 12 - 47 38 - 152 12 - 46 40 - 161 12 - 49
32M010HH423EN 173 636 72 58 - 231 18 - 70 57 - 228 17 - 70 60 - 242 18 - 74

Dorner Mfg. Corp. 12 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
Installation
Required Tools
•3/32"hex wrench
• 3 mm hex wrench
• 4 mm hex wrench
• 5 mm hex wrench
• 6 mm hex wrench
• 8 mm hex wrench
• 10 mm wrench
• 13 mm wrench
• 16 mm wrench
• Belt Removal Tool #203480
Recommended Installation
Sequence
• Locate and arrange sections by section labels:
• Assemble conveyor (Module lengths longer than 10 ft.
(3000 mm)
• Install knuckles
• Install curves
• Install tails
• Unroll wear strips
• Install mounting bracket
• Install support stands
• Install belt
• Install weighted take-up
• Install guiding
• Install drive package
- Motor mounting package
- Gearmotor
Typical Connecting Components (Figure 3)
Figure 3
Figure 3
Module Lengths Longer Than 10 ft
(3048 mm)
1. Locate and arrange conveyor sections by section labels
(Figure 4, item 1).
Figure 4
Figure 4
2. Join both conveyor sections, and tighten two set screws
(Figure 4, item 2) on both sides. Tighten all set screws
1/4 turn past contact with frame.
1ClampPlate
2 Conveyor frames
3 Set Screw, M8 - 1.25 x 10 mm
2
2
3
1
1
1
2

851-829 Rev. A 13 Dorner Mfg. Corp.
2200 Series SmartFlex Conveyors with Cast Tails
Installation
Knuckles
Figure 5
Figure 5
1. Join knuckle conveyor frame section (Figure 6, item 1),
and conveyor frame (Figure 6, item 2) and secure with
two set screws (Figure 6, item 3) on both sides. Tighten
all set screws 1/4 turn past contact with frame.
Figure 6
Figure 6
Curves
Typical Curve Connecting Components (Figure 7)
Figure 7
Figure 7
1. Remove two screws (Figure 8, item 1) and guard
(Figure 8, item 2) from curve assembly.
Figure 8
Figure 8
2. Install curve assembly (Figure 9, item 1) clamp plates
(Figure 9, item 2) into one conveyor section (Figure
9, item 3) by lining up clamp plate with slot in conveyor
frame.
Figure 9
Figure 9
NOTE
Be sure all frame sections (Figure 5, item 1)
are properly supported during knuckle
assembly.
1
1
32
1
1ClampPlate
2 Conveyor Frames
3 Curve Assembly
4 Set Screw, M8 - 1.25 x 10 mm
1
3
4
2
1
12
3
2
1

Dorner Mfg. Corp. 14 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
Installation
3. Secure with two set screws (Figure 10, item 1). Tighten
all set screws 1/4 turn past contact with frame.
Figure 10
Figure 10
4. Install outer curve frame assembly (Figure 11, item 1)
clamp plate (Figure 11, item 2) into conveyor frame
section (Figure 11, item 3) by lining up clamp plate
with slot in conveyor frame.
Figure 11
Figure 11
5. Install opposite end of conveyor onto curve assembly,
repeating procedure. Tighten all set screws 1/4 turn past
contact with frame.
6. Install guard with (Figure 12, item 1) two screws
(Figure 12, item 2).
Figure 12
Figure 12
Tails
1. Install tail assembly (Figure 13, item 1) clamp plate
into conveyor frame section (Figure 9, item 2) by lining
up clamp plate with slot in conveyor frame.
Figure 13
Figure 13
2. Secure with two set screws (Figure 13, item 3). Tighten
all set screws 1/4 turn past contact with frame.
Unroll Wear Strips
1. Unroll wear strip (Figure 14, item 1).
Figure 14
Figure 14
2. Guide wear strip into channel (Figure 14, item 2) on
conveyor frame.
1
3
1
2
2
21
NOTE
Top and bottom wear strips are shipped
pinned/attached at various places on
conveyor.
1
3
2
1
2

851-829 Rev. A 15 Dorner Mfg. Corp.
2200 Series SmartFlex Conveyors with Cast Tails
Installation
Mounting Brackets
1. Locate brackets. Exploded views shown in Figure 15.
Figure 15
Figure 15
2. Remove nuts (Figure 15, item 1),washers (Figure
15, item 2), and screws (Figure 15, item 3) from
brackets (Figure 15, item 4).
3. Insert bracket with studs (Figure 15, item 5) with head
parallel to slot into conveyor side slots.
4. Fasten brackets (Figure 16, item 1) to conveyor with
nuts (Figure 16, item 2) on studs. Turn nuts clockwise
to rotate studs in side slots.
Figure 16
Figure 16
5. Tighten nuts (Figure 16, item 2).
Install Support Stands
1. Fasten brackets (Figure 17, item 1) to support stand
(Figure 17, item 2) with mounting screws, washers, and
nuts (Figure 17, item 3).
Figure 17
Figure 17
Belt Installation
Typical Belt Components (Figure 18).
Figure 18
Figure 18
1. Position the belt on the conveyor frame.
NOTE
Be certain that stud slot (Figure 16, item 3) is
close to vertical when finished tightening nut.
5
4
3
1
2
1
2
3
3
NOTE
For detailed assembly instructions, please
see your appropriate support stand manual.
1 Chain Belt
2 Belt Rod
3
2
1
2
1

Dorner Mfg. Corp. 16 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
Installation
2. Install the belt with direction arrow (Figure 19, item 1)
pointing in direction of belt travel (Figure 19, item 2).
Install belt from under tail end (Figure 19, item 3) and
onto cogs (Figure 19, item 4) of shaft.
Figure 19
Figure 19
3. Continue wrapping belt (Figure 20, item 1) on top of
idler tail retaining guide (Figure 20, item 2), continuing
to turn shaft (Figure 20, item 3) to guide belt around
cogs (Figure 20, item 4) of shaft.
Figure 20
Figure 20
4. Insert the belt rod:
Standard Tail
• Install belt around drive end of conveyor and bring the
ends of the belt (Figure 22, item 1) together.
• Insert rod (Figure 22, item 2).
• Use punch and hammer or belt removal tool #203480 to
press pin just below flush with side of belt. Stop when pin
detent is felt.
Figure 21
Figure 21
Figure 22
Figure 22
3
1
2
4
1
1
2
4
3
NOTE
Before inserting belt rod to connect belt ends,
be certain that the slack on belt is showing in
slotted area (Figure 21, item 1) on conveyor
drive end.
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2

851-829 Rev. A 17 Dorner Mfg. Corp.
2200 Series SmartFlex Conveyors with Cast Tails
Installation
Weight ed Take U p Tail
• Install belt around drive end of conveyor and bring the
ends (Figure 23, item 1) of the belt together.
• Belt should only have enough slack to allow the idler
assembly to be installed.
• Insert rod (Figure 23, item 2).
• Use punch and hammer or belt removal tool #203480 to
press pin just below flush with side of belt. Stop when pin
detent is felt.
Figure 23
Figure 23
Weighted Take-Up
1. Install idler pulley assembly (Figure 24, item 1) onto
belt (Figure 24, item 2).
Figure 24
Figure 24
2. Make sure teeth on pulley and guard are facing mating
teeth on take up box assembly.
3. Raise weighted take up box assembly, with plate
(Figure 25, item 1) on idler pulley assembly on outside
of outer plate (Figure 25, item 2) weighted take up
assembly.
Figure 25
Figure 25
4. Raise weighted take up assembly (Figure 26, item 1)
with notch (Figure 26, item 2) in assembly mating with
stud (Figure 26, item 3) on conveyor frame.
Figure 26
Figure 26
5. Install and tighten two hex head screws (Figure
27, item 1) on each side to secure assembly to frame.
Figure 27
Figure 27
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11

Dorner Mfg. Corp. 18 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
Installation
Top Running Drive
1. Install top running drive assembly (Figure 28, item 1)
clamp plates into conveyor frame sections (Figure
28, item 2) by lining up clamp plates with slots in
conveyor frame.
Figure 28
Figure 28
2. Secure with four set screws (Figure 28, item 3) on both
sides of conveyor. Tighten all set screws 1/4 turn past
contact with frame.
3. Install belt with the direction arrow pointing in the
direction of belt travel.
4. Install belt around conveyor ends and bring the ends of
the belt (Figure 29, item 1) together.
Figure 29
Figure 29
5. Insert the belt rod. Use a punch and hammer or belt
removal tool #203480 (Figure 29, item 2) to press pin
just below flush with side of belt. Stop when pin detent
is felt.
6. Install drive motor mounting plate (Figure 30, item 1)
using four hex head cap screws (Figure 30, item 2).
Figure 30
Figure 30
7. Install belt hold down tabs (Figure 31, item 1) to drive
assembly (Figure 31, item 2) using four socket head
screws (Figure 31, item 3).
Figure 31
Figure 31
8. Repeat on opposite side.
9. Install belt hold down wheel (Figure 32, item 1) and
tighten set screw (Figure 32, item 2).
Figure 32
Figure 32
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851-829 Rev. A 19 Dorner Mfg. Corp.
2200 Series SmartFlex Conveyors with Cast Tails
Installation
10. Install drive package (Figure 33, item 1) to drive motor
mounting bracket (Figure 33, item 2) using four socket
head screws (Figure 33, item 3).
Figure 33
Figure 33
Install Guiding
All guiding must be located and installed by the end user.
Standard 1.5" and 3" Guiding
1. Install stud (Figure 34, item 1) onto retaining clip
(Figure 34, item 2) with nut (Figure 34, item 3).
Figure 34
Figure 34
2. Install stud (Figure 34, item 1) into side rail channel
(Figure 34, item 4).The end clips should be no greater
than 12" from end of the conveyor.
3. Fasten retaining clip (Figure 35, item 1) to conveyor
with nut (Figure 35, item 2) on stud.
Figure 35
Figure 35
4. Tighten nuts (Figure 35, item 2).
5. Install guide (Figure 36, item 1) and retaining clip
(Figure 36, item 2) to conveyor side rail with socket
head screw (Figure 36, item 3).
Figure 36
Figure 36
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3
2
2
4
1
3
NOTE
Be certain that slot (Figure 35, item 3) is
close to vertical when finished tightening nut.
2
1
3
1
23

Dorner Mfg. Corp. 20 851-829 Rev. A
2200 Series SmartFlex Conveyors with Cast Tails
Installation
Puck/Pallet Guiding
1. Install clip assembly (Figure 37, item 1) into side rail
channel (Figure 37, item 2). The end clips should be no
greater than 12"from the end of the conveyor.
Figure 37
Figure 37
2. Fasten clip (Figure 37, item 1) to conveyor with nut
(Figure 37, item 3) on stud.
3. Tighten nuts (Figure 38, item 1).
Figure 38
Figure 38
4. Attach wear strip (Figure 39, item 1) to guiding
(Figure 39, item 2).
Figure 39
Figure 39
5. Attach guiding (Figure 40, item 1) to clip (Figure
40, item 2) and tighten screw (Figure 40, item 3).
Figure 40
Figure 40
NOTE
Make sure that the studs (Figure 37, item 4)
rotate inside the channel and engage with the
conveyor.
NOTE
Be certain that slot (Figure 38, item 2) is
close to vertical when finished tightening nut.
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3
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4
1
3
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42
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