Dorner 1100 Series User manual

For other service manuals visit our website at:
www.dorner.com/service_manuals.asp
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]
851-756 Rev. B
1100 Series Remote Signal
Brushless DC Controller
Operation Manual

Dorner Mfg. Corp. 2 851-756 Rev. B
1100 Series Remote Signal Brushless DC Controller
Table of Contents
Introduction ......................................................................... 2
Warnings - General Safety .................................................. 3
Operations............................................................................ 4
Remote Wired Options .................................................... 4
Input Signals .................................................................... 4
START/STOP Input..................................................... 4
CW/CCW Input............................................................ 4
Setting The Running Speed ............................................. 5
Setting By Internal Potentiometer................................. 5
Speed Control with Internal Potentiometer............... 5
Setting By External Potentiometer ............................... 6
Speed Control with External Potentiometer (customer
supplied).................................................................... 7
Setting By External DC Voltage................................... 8
Return Policy...................................................................... 10
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 1100 series conveyors have patents pending.
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.
IMPORTANT
Some illustrations may show guards
removed. DO NOT operate equipment
without guards.

851-756 Rev. B 3 Dorner Mfg. Corp.
1100 Series Remote Signal Brushless DC Controller
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
DANGER
Hazardous voltage will cause severe injury or
death.
LOCK OUT POWER BEFORE WIRING.
A
WARNING
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
A
WARNING
Exposed moving parts can cause severe
injury.
REPLACE ALL GUARDS BEFORE RUNNING
CONVEYOR.
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.

Dorner Mfg. Corp. 4 851-756 Rev. B
1100 Series Remote Signal Brushless DC Controller
Operations
Remote Wired Options
Refer to Figure 1 for controller components.
Figure 1
Figure 1
Input Signals
START/STOP Input
START is selected when the input is ON, and motor starts
running. The motor accelerates over the time set by the
acceleration/deceleration time potentiometer. STOP is
selected when the input is OFF, and motor stops. The motor
decelerates over the time set by the acceleration/deceleration
time potentiometer.
CW/CCW Input
CW is selected when the input is ON. CCW is selected when
the input is OFF. The drive direction is the same as that of
the motor output shaft when viewed from the motor output
side.
1 Customer Interface Terminal Block
2 DC Driver BLH230
3 Motor Connection Terminal
4 Grounding Screw
5 Customer Interface Cable (Input to Enclosure)
6 Motor Cable Input to Enclosure (Cord Grip
Included Inside)
7Fuse
8 Connector CN2
9 Power Supply
NOTE
For customer supplied wiring:
• Use shielded, multi-conductor cable for input
signal.
• Wires to be AWG26 minimum.
• Shield of multi-conductor cable should be
grounded to sub panel.
1
5
6
2
4
3
7
8
9
A
CAUTION
Do not perform the motor’s starting and
stopping operations by turning the power
supply on and off.
Perform them by inputting START/STOP.
Failure to use START/STOP may cause injury
or damage to the equipment.
NOTE
• The input signals (START/STOP and CW/
CCW) must be ON for at least 10 ms. It may
cause malfunction of the motor.
• Do not operate (switch the ON/OFF status)
of the START/STOP input, CW/CCW input,
and INT.VR/EXT input simultaneously. After
switching a given input, wait at least 10 ms
before switching another input.
NOTE
Depending on the gearhead ratio, the drive
direction of the gear output shaft may be
opposite of that of the motor.

851-756 Rev. B 5 Dorner Mfg. Corp.
1100 Series Remote Signal Brushless DC Controller
Operations
Setting The Running Speed
Set the operating speed of the motor using the internal speed
potentiometer, external speed potentiometer or external DC
voltage. The motor speed range is from 100 to 3000 rpm for
the case of the motor alone. Dorner speed ranges are 100 to
2500 rpm for constant motor torque.
Setting By Internal Potentiometer
This potentiometer is used when running speed setting is not
frequently changed.
Adjust the potentiometer using an insulated screwdriver.
Clockwise rotation will increase the set speed. The speed is
set to 0 r/min at time of shipment.
Speed Control with Internal Potentiometer
1. Adjust desired accel/decel at driver (Figure 2, item 1).
Figure 2
Figure 2
Figure 3
Figure 3
2. Connect light blue wire to terminal 2 (COM).
3. Adjust desired speed at driver (Figure 2, item 2).
A
DANGER
Hazardous voltage will cause severe injury or
death.
LOCK OUT POWER BEFORE WIRING.
1 Accel/Decel Time Potentiometer
2 Internal Speed Potentiometer
NOTE
The light blue wire from the controller board is
ordinarily not used if it is taped off. It must be
separated from the harness and connected to
terminal 2 (COM) as shown in (Figure 3).
1
2
12
11
10
9
4
5
6
3
1
2
7
8
BLK
WHT
GRY
YEL
GRN
BLU
BRN
PPL
LT. BLU
RED
ORN
3
1
4
5
6
2
NOT
USED
TERMINAL
BLOCK
INPUTS/OUTPUTS FROM DRIVER
CONNECTOR CN2
START/STOP
CW/CCW
COM

Dorner Mfg. Corp. 6 851-756 Rev. B
1100 Series Remote Signal Brushless DC Controller
Operations
4. Insert multi-conductor cable into cord grip (Figure
4, item 1).
Figure 4
Figure 4
5. Wire START/STOP, COM, and CW/CCW to terminal
(Figure 4, item 2).
6. Install motor cord through interface location (Figure
4, item 3). Refer to Motor Manual 851-748 or 851-749
for details.
Setting By External Potentiometer
This potentiometer is used when the speed is set away from
the driver.
Use a 20 Kohm, 1/4 watt, linear resistance vs angle, external
potentiometer. Clockwise rotation will increase the set
speed.
Figure 5
Figure 5
* Indicates the speed of the motor alone. The speed of the
gear output shaft of a geared type or combination type is
obtained by dividing the motor speed by the gear ratio.
1
2
3

851-756 Rev. B 7 Dorner Mfg. Corp.
1100 Series Remote Signal Brushless DC Controller
Operations
Speed Control with External Potentiometer
(customer supplied)
1. Adjust desired accel/decel at driver (Figure 6, item 1).
Figure 6
Figure 6
Figure 7
Figure 7
2. Insert shielded cable for external potentiometer into
cord grip (Figure 8, item 1). Connect high, med, and
low to 6, 5, and 4 as shown in (Figure 7).
Figure 8
Figure 8
3. Wire START/STOP, COM, and CW/CCW to terminal
(Figure 8, item 2),as shown in (Figure 7).
4. Install motor cord through interface location (Figure
8, item 3). Refer to Motor Manual 851-748 or 851-749
for details.
1 Accel/Decel Time Potentiometer
1
INPUTS/OUTPUTS FROM DRIVER
CONNECTOR CN2
12
11
10
9
4
5
6
3
1
2
7
8
BLK
WHT
GRY
YEL
GRN
BLU
BRN
PPL
LT. BLU
RED
ORN
3
1
4
5
6
2
TERMINAL
BLOCK
NOT
USED
HI
WIPER
LO
20K OHM
1/4 WATT
SPEED
POT
START/STOP
CW/CCW
COM
NOTE
Use a shielded cable for connection with the
external potentiometer. Connection should be
made close to the driver. Connect the shielded
wire to the ground.
1
2
3

Dorner Mfg. Corp. 8 851-756 Rev. B
1100 Series Remote Signal Brushless DC Controller
Operations
Setting By External DC Voltage
External DC voltage is used when the speed is set by D/A
output from an external control device such as a
programmable controller.
For external DC voltage, use DC power supply (0 to 5 VDC,
1 mA or more) where the primary and secondary sides are
provided with reinforced insulation.
Figure 9
Figure 9
* Indicates the speed of the motor alone. The speed of the
gear output shaft of a geared type or combination type is
obtained by dividing the motor speed by the gear ratio.
Figure 10
Figure 10
1. Adjust desired accel/decel at driver (Figure 11, item 1).
Figure 11
Figure 11
NOTE
• The external DC power supply voltage must
not exceed 5 VDC. Otherwise, the driver
may be damaged.
• When connecting the external DC power
supply, sufficient care must be taken not to
mistake power polarity. Connection with
incorrect polarity may damage the driver.
• Use a shielded cable for connection with the
external DC power supply. Connection
should be made close to the driver. Connect
the shielded wire to the ground.
12
11
10
9
4
5
6
3
1
2
7
8
BLK
WHT
GRY
YEL
GRN
BLU
BRN
PPL
LT. BLU
RED
ORN
3
1
4
5
6
2
NOT
USED
TERMINAL
BLOCK
INPUTS/OUTPUTS FROM DRIVER
CONNECTOR CN2
VRL
VRM
+
-
EXTERNAL DC POWER
SUPPLY
0 TO 5 VDC
1 mA OR MORE
START/STOP
CW/CCW
COM
1

851-756 Rev. B 9 Dorner Mfg. Corp.
1100 Series Remote Signal Brushless DC Controller
Operations
2. Insert multi-conductor cable into cord grip (Figure
12, item 1).
Figure 12
Figure 12
3. Wire START/STOP, COM, and CW/CCW to terminal
(Figure 12, item 2).
4. Wire DC control speed signal negative to location 4 and
positive to location 5 as shown in (Figure 10).
5. Install motor cord through interface location (Figure
12, item 3). Refer to Motor Manual 851-748 or 851-749
for details.
1
2
3

851-756 Rev. B Printed in U.S.A.
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. 2013
DORNER MFG. CORP.
975 Cottonwood Ave., PO Box 20
Hartland, WI 53029-0020 USA
TEL [phone] (USA)
FAX [phone] (USA)
Internet: www.dorner.com
Outside the USA:
TEL [phone]
FAX [phone]
Return Policy
Returns must have prior written factory authorization or they will not be accepted. Items that are returned to Dorner without
authorization will not be credited nor returned to the original sender. 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. Dorner part number(s) of 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 (if available, part serial number).
A representative will discuss action to be taken on the returned items and provide a Returned Goods Authorization (RMA)
number for reference. RMA will automatically close 30 days after being issued. To get credit, items must be new and
undamaged. There will be a return charge on all items returned for credit, where Dorner was not at fault. It is the customer’s
responsibility to prevent damage during return shipping. Damaged or modified items will not be accepted. The customer is
responsible for return freight.
Returns will not be accepted after 60 days from original invoice date. The return charge covers inspection, cleaning,
disassembly, disposal and reissuing of components 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. Contact Dorner for the name of your local representative. Our Customer
Service Team will gladly help with your questions on Dorner products.
For a copy of Dorner's Warranty, contact factory, distributor, service center or visit our website at www.dorner.com.
For replacement parts, contact an authorized Dorner Service Center or the factory.
Product Type
Standard Products Engineeredto
order parts
Product Line Conveyors Gearmotors
& Mounting
Packages
Support
Stands Accessories SpareParts (non-belt) SpareBelts - Standard
Flat Fabric
Spare Belts -
Cleated &
Specialty
Fabric
Spare Belts -
Plastic Chain All equipment
and parts
1100
30% return fee for all products except:
50% return fee for conveyors with modular belt,
cleated belt or specialty belts non-returnable case-by-case
2200
2200 Modular Belt
2200 Precision Move
2300
2300 Modular Belt
3200
3200 LPZ
3200 Precision Move
4100
5200
5300
6200
Controls
7200 / 7300 50% return fee for all products
7350
non-returnable
7360
7400
7600