Dorner 2100 Series Manual instruction

851-296 Rev. A
Set-up, Operation
& Maintenance Manual
2100, 4100, 6100 Series
Side Mount Drive Package
for Standard Load 50 Hz Gearmotors
Table of Contents
Warnings – General Safety 2. . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For 2100 & 4100 Flat Belt Conveyors 5. . . . . . . .
For 6100 Conveyors &
2100 Cleated Belt Conveyors 6. . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 7. . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Reducer Replacement 7. . . . . . . . . . . . . . . . . .
Motor Replacement 8. . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 4100, 6100 Series Side Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
851-296 Rev. A 2Dorner Mfg. Corp.
The safety alert symbol, black triangle with white
exclamation, is used to alert you to potential
personal injury hazards.
ÇÇ
Ç
WARNING
ÇÇ
Climbing, sitting, walking or
riding on conveyor will
cause severe injury.
KEEP OFF CONVEYORS.
DANGER
ÇÇ
DANGER
Do NOT OPERATE
CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
ÇÇ
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
WARNING
ÇÇ
Exposed moving parts can
cause severe injury.
REPLACE ALL GUARDS
BEFORE RUNNING
CONVEYOR.
WARNING
ÇÇ
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
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 4100 Series conveyors are covered by patent
number 3923148 and corresponding patents and patent
applications in other countries.
Dorner 6100 Series conveyors are covered by patent
number 5174435 and corresponding patents and patent
applications in other countries.
Dorner’s Limited Warranty applies.
Dorner reserves the right to make changes at any time
without notice or obligation.
Warnings – General Safety

2100, 4100, 6100 Series Side Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-296 Rev. A
Refer to Figure 1 for typical components.
A Conveyor
B Mounting Bracket
C Gearmotor
D Coupling
E Inspection Plug
Typical Components
Figure 1
A
E
D
B
C
Specifications
Gearmotor Mounting Package Models:
Example:
WW A
Language Code = CE English
Output Shaft Type = 905Industrial
Gearmotor Type = Standard Load, Industrial
H
U SS
Mount Style = Side Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
2 = 2100 Series Conveyor
4 = 4100 Series Conveyor
6 = 6100 Series Conveyor
6
* See “Ordering and Specifications”Catalog for details.
Table 1: Gearmotor Specifications
Single Phase Three Phase VFD Variable Speed
Output Power 0.18 kw
Input Voltage 230 Volts A.C. 230/400 Volts A.C. 230 Volts A.C.
Input Frequency 50 Hz 25 to 63 Hz
Input Current 1.6 Amperes 1.4/0.8 Amperes 1.4 Amperes
Gearmotor Ratios 5:1, 10:1, 20:1, 40:1, 60:1
Protection Rating IP55
Frame Size IEC 63 B5
Product Description

2100, 4100, 6100 Series Side Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
851-296 Rev. A 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Standard Load Fixed Speed 90550 Hz Gearmotors
Gearmotors Belt Speed
M/min
Part Number RPM N-m M/min
62Z060HS4(vp)FN 23 26.4 2.1
62Z040HS4(vp)FN 35 28.9 3.0
62Z020HS4(vp)FN 70 19.4 6.1
62Z010HS4(vp)FN 140 10.7 12.2
62Z005HS4(vp)FN 280 5.6 24.4
(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 90550 Hz Gearmotors
Gearmotors
RPM Belt Speed
M/min
Part Number @ 50Hz N-m M/min
62Z060HS423EN 23 26.4 1.0 to 2.6
62Z040HS423EN 35 28.9 1.5 to 3.8
62Z020HS423EN 70 19.4 3.0 to 7.7
62Z010HS423EN 140 10.7 6.1 to 15.0
62Z005HS423EN 280 5.6 12.2 to 30
NOTE: For belt speed other than those listed, contact
factory for details.
Specifications

2100, 4100, 6100 Series Side Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-296 Rev. A
Required Tools
DHex key wrenches:
3 mm & 5 mm
DLarge flat–blade screwdriver
DTorque wrench
Mounting
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Installation Component List
F Drive Assembly
G M6 Socket Head Screws (2x)
H Hex Shaft (2100 & 4100 flat belt conveyor only)
I Socket Head Screws M6 x 90 mm (4x)
J Screws
K Inspection Plugs (2x)
L Set Screws (2x)
M Access Hole
N Key (2100 cleated belt or 6100 conveyors only)
1.Typical components (Figure 2)
Figure 2
FH
G
NOTE: Gearmotor may be operated in positions 1, 2,
3 or 4 (Figure 3).
Figure 3
1
4
3
2
2.If required, change gearmotor position by removing
four (4) screws (I of Figure 4). Rotate gearmotor to
other position (Figure 3) and replace screws (I).
Tighten to 12 Nm.
Figure 4
I
I
For 2100 & 4100 Flat Belt Conveyors
IMPORTANT: On 95 mm and wider conveyors, the hex
broach is offset from center towards the drive side for
hex shaft engagement.
3a.Locate drive mounting position and remove two (2)
screws (J of Figure 5).
Figure 5
J
Installation

2100, 4100, 6100 Series Side Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
851-296 Rev. A 6Dorner Mfg. Corp.
4a.Remove inspection plugs (K of Figure 6).
Figure 6
KM
L
H
5a.Insert hex shaft (H) into coupling.
ÇÇ
Exposed moving parts can
cause severe injury.
KEEP HANDS CLEAR OF
DRIVE WHILE JOGGING
MOTOR.
WARNING
NOTE: Coupling has two (2) set screws (L of Figure 7).
Figure 7
L
6a.Jog motor and rotate coupling to align set screw (L
of Figure 6) with access hole (M). Tighten to 3.7 Nm.
Repeat for second set screw.
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER AFTER
JOGGING MOTOR.
WARNING
7a.Replace inspection plugs (K of Figure 8). Insert hex
shaft (H) into drive pulley hex bushing and slide
drive against conveyor. Install two (2) screws (G).
Tighten to 80 in-lb (9 Nm).
Figure 8
H
G
K
For 6100 Conveyors & 2100 Cleated Belt Conveyors
ÇÇ
ÇÇ
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
NOTE: 6100 conveyor shown, 2100 cleated belt con-
veyor similar.
3b.Locate drive output shaft. Remove two screws (J of
Figure 9). Install key (N).
Figure 9
J
N
4b.Remove inspection plugs (K of Figure 10).
Figure 10
G
F
K
5b.Slide coupling over drive output shaft and install
drive assembly (F).
ÇÇ
Exposed moving parts can
cause severe injury.
KEEP HANDS CLEAR OF
DRIVE WHILE JOGGING
MOTOR.
WARNING
NOTE: Coupling has two (2) set screws (L of Figure 7).
Installation

2100, 4100, 6100 Series Side Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-296 Rev. A
6b.Jog motor and rotate coupling to align set screw (L
of Figure 11) with access hole (M). Tighten to 3.7
Nm. Repeat for second set screw.
Figure 11
L
M
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER AFTER
JOGGING MOTOR.
WARNING
7b.Replace inspection plugs. (K of Figure 10)
Preventive Maintenance and Adjustment
Required Tools
DHex key wrenches:
2.5 mm, 3 mm, 5 mm
DLarge flatblade screwdriver
DAdjustable wrench (for hexagon head screws)
DTorque wrench
Gear Reducer Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Remove inspection plug(s) (K of Figure 10).
Ç
Exposed moving parts can
cause severe injury.
KEEP HANDS CLEAR OF
DRIVE WHILE JOGGING
MOTOR.
WARNING
NOTE: Coupling has two (2) set screws (L of Figure 7).
2.Jog motor and rotate coupling to align set screw (L
of Figure 11) with access hole (M). Loosen set screw.
Repeat for second set screw.
3.Remove two (2) screws (G of Figure 10). Remove
drive assembly (F).
4.Remove four (4) screws (I of Figure 12) and remove
mounting bracket & guard (O).
Figure 12
I
I
O
5.Loosen two (2) set screws (L of Figure 13) and
detach coupling (P).
Figure 13
P
L
6.Remove four screws (Q of Figure 14). Detach motor
with adapter flange (R) from gear reducer (S). Retain
motor output shaft key (T).
Installation

2100, 4100, 6100 Series Side Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
851-296 Rev. A 8Dorner Mfg. Corp.
Figure 14
R
ST
U
Q
V
W
7.Remove two (2) screws (U) and detach output shaft
cover (V).
8.Remove gear reducer output shaft key (W).
9.Loosen six (6) set screws (X of Figure 15). Remove
drive shaft (Y) and key (Z).
Figure 15
XY
Z
10.Apply grease (AA of Figure 16) to shaft.
Figure 16
AA
11.Replace the original shaft (Y Figure 15) and key (Z)
into new gear reducer. Tighten set screws to 3 Nm.
IMPORTANT:Be extremely careful when coupling
motor to gear reducer. Avoid misalignment and
forcing the connection causing possible permanent
gear reducer seal damage.
12.With key (T of Figure 14) in keyway, slide motor
with adapter flange (R) and gear reducer (S)
together. Install screws (Q) and tighten.
13.Attach coupling (P of Figure 13) to gear reducer
shaft. Tighten two (2) set screws (L) to 3.7 Nm.
14.Attach mounting bracket & tube (O of Figure 12) to
gearmotor. Tighten screws (I) to 12 Nm.
15.Complete installation steps:
DSee “2100 Flat Belt Conveyors”section on page 5.
DSee “6100 and 2100 Cleated Belt Conveyors”sec-
tion on page 6.
Motor Replacement
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
ÇÇ
Hazardous voltage will
cause severe injury or
death.
LOCK OUT POWER
BEFORE WIRING.
DANGER
1.For single phase motor:
a.Loosen terminal box screws (AB of Figure 17) and
remove cover (AC).
Figure 17
AB
AC
b.Record wire colors on terminals 2, 6 and ground
()(Figure 18). Loosen terminals 2, 6 and ground
and remove wires.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Side Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-296 Rev. A
321657 12119
Figure 18
AD
c.Loosen cord grip (AD of Figure 18) and remove
cord.
2.For three phase and VFD variable speed motor:
a.Loosen terminal box screws (AB of Figure 17) and
remove cover (AC).
b.Record wire colors on terminals U1, V1, W1 &
PE (Figure 19). Loosen terminals U1, V1, W1 &
PE and remove wires.
Figure 19
AD
c.Loosen cord grip (AD of Figure 19) and remove
cord.
3.Remove four (4) screws (P of Figure 20). Detach
motor with adapter flange (R) from gear reduc-
er (S). Retain motor output shaft key (T).
Figure 20
P
R
T
S
4.Remove four (4) screws and nuts (AE of Figure 21).
Remove adapter flange (AF).
Figure 21
AF
AE
5.Install adapter flange (AF) on new motor. Install
screws and nuts (AE) and tighten.
IMPORTANT:Be extremely careful when coupling
motor to gear reducer. Avoid misalignment and
forcing the connection causing possible permanent
gear reducer seal damage.
6.With key (T of Figure 22) in keyway, slide motor
with adapter flange (R) and gear reducer together.
Install screws (P) and tighten.
Figure 22
TP
R
7.Replace wiring:
DFor a single phase motor, reverse step 1 on page 8.
DFor a three phase or VFD variable speed motor, re-
verse step 2 on this page.
Preventive Maintenance and Adjustment

NOTE: For replacement parts other than those
shown on this page, contact an authorized Dorner
Service Center or the factory.
Item Part No. Part Description
1 826-281 Motor, 0.19 Kw 230 Volts, 1400 RPM
50 Hz, 1-Phase
826-284 Motor, 0.19 Kw 230/400 Volts, 1400 RPM
50 Hz, 3-Phase
2 62Z005HS Gear Reducer, 5:1, 63B5
62Z010HS Gear Reducer, 10:1, 63B5
62Z020HS Gear Reducer, 20:1, 63B5
62Z040HS Gear Reducer, 40:1, 63B5
62Z060HS Gear Reducer, 60:1, 63B5
3 807-995 Coupling
4 450444M Gear Reducer Shaft
5 912–084 Key, Square, 0.188” x 1.5” L
6 980416M Key, Square, 4mm x 16mm L Figure 23
2
4
6
1
5
3
Service Parts
No returns will be accepted without prior written factory authorization. When calling for authorization, please
have the following information ready for the Dorner Factory representative or your local distributor:
1. Name and address of customer.
2. Item(s) being returned.
3. Reason for return.
4. Customer’s original order number used when ordering the item(s).
5. Dorner or distributor invoice number.
A representative will discuss action to be taken on the Returned items and provide a Returned Goods
Authorization Number to reference.
There will be a 15% restocking charge on all new items returned for credit where Dorner was not at fault. These
will not be accepted after 60 days from original invoice date. The restocking charge covers inspection, cleaning,
disassembly, and reissuing to inventory.
If a replacement is needed prior to evaluation of returned item, a purchase order must be issued. Credit
(if any) is issued only after return and evaluation is complete.
Dorner has representatives throughout the world. Feel free to contact Dorner for the name of your local representative.
Our technical sales and service staff will gladly help with your questions on Dorner products.
For a copy of Dorner’s Limited Warranty, contact factory, distributor, service center or visit our website @
www.dorner.com
851-296 Rev. A Printed in U.S.A. 300
975 Cottonwood Ave. PO Box 20
Hartland, WI 53029-0020 USA
Dorner Mfg. Corp. reserves the right to change or
discontinue products without notice. All products and
services are covered in accordance with our standard
warranty. All rights reserved. Dorner Mfg. Corp. 2000
DORNER
Arnold-Sommerfeld-Ring 2
D-52499 Baesweiler
USA
TEL [phone] (USA)
FAX [phone] (USA)
Germany
TEL [phone]
FAX [phone]
Internet: www.dorner.com
Outside the USA:
TEL [phone], FAX [phone]
DORNER MFG. CORP.
Return Policy