Dorner 2100 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]
851-257 Rev. J
2100, 2200, 4100, 6200, MPB
Series Top Mount Drive
Package for Standard Load
90° Industrial 60 Hz
Gearmotors
Installation, Maintenance & Parts Manual

Dorner Mfg. Corp. 2 851-257 Rev. J
2100, 2200, 4100, 6200, MPB Series Top MountDrive Package for Standard Load 90° Industrial 60 Hz Gearmotors
Table of Contents
Introduction ......................................................................... 2
Warnings −General Safety ................................................. 3
Product Description............................................................. 4
Specifications ...................................................................... 4
Installation........................................................................... 8
Required Tools................................................................. 8
Mounting ......................................................................... 8
Preventive Maintenance and Adjustment.......................... 12
Required Tools............................................................... 12
Timing Belt Tensioning ................................................ 12
Timing Belt Replacement ............................................. 12
Drive or Driven Pulley Replacement............................. 13
Gear Reducer Replacement............................................ 13
Motor Replacement........................................................ 14
Service Parts....................................................................... 16
2100, 2200, 4100, 6200 Series and MPB Series
Flat Belt Conveyors Top Mount Drive Package
for Standard Load 90° Industrial Gearmotors................ 16
MPB Series Cleated Belt Conveyor Bottom
Mount Drive Package for Standard Load 90°
Industrial Gearmotors .................................................... 17
4100 Mounting Package................................................. 18
Gearmotors .................................................................... 18
Notes .................................................................................. 19
Return Policy...................................................................... 20
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 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 2200, 6200 & MPB 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.
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.

851-257 Rev. J 3 Dorner Mfg. Corp.
2100, 2200, 4100, 6200, MPB Series Top MountDrive Package for Standard Load 90° Industrial 60 Hz Gearmotors
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
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.
A
WARNING
MPB Series Conveyors are not reversible.
Reversing creates pinch points which can
cause severe injury.
DO NOT REVERSE MPB SERIES
CONVEYORS.

Dorner Mfg. Corp. 4 851-257 Rev. J
2100, 2200, 4100, 6200, MPB Series Top MountDrive Package for Standard Load 90° Industrial 60 Hz Gearmotors
Product Description
Refer to Figure 1 for typical components. Figure 1
Figure 1
Specifications
Gearmotor Mounting Package Models:
Example: * See Ordering and Specifications Catalog for details.
Table 1: Gearmotor Specifications
AConveyor
B Mounting Bracket
C Gearmotor
D Timing Belt Tensioner
ECover
F Timing Belt
GDrivePulley
H Driven Pulley
A
B
C
D
E
F
G
H
Language Code = U.S. English
Output Shaft Type = 90°Industrial
Gearmotor Type = Standard Load, Industrial
Mount Style = Top Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
22 M T H SWW A −32 32
2 = 2100 SeriesConveyor
22 = 2200 & MPB SeriesConveyor
4 = 4100 SeriesConveyor
6 = 6200 SeriesConveyor
2P = MPB SeriesConveyor
Belt Type: − = flat belt, A through J = cleate
d
Drive Pulley (see Table 2 & 3)
Driven Pulley (see Table 2 & 3)
DC
B
A
Single Phase Three Phase DC Variable Speed
Output Power 0.25 hp (0.19 kw)
Input Voltage 115 Volts A.C. 208 to 230/460 Volts A.C. 130 Volts D.C.
Input Frequency 60 Hz N/A
Input Current 5.0 Amperes 1.2 /0.6 Amperes 2.2 Amperes
Motor RPM 1725 2500
Gearmotor Ratios 5:1, 10:1, 20:1, 40:1, 60:1
Frame Size NEMA 42 CZ
Motor Type Totally Enclosed, Fan-cooled

851-257 Rev. J 5 Dorner Mfg. Corp.
2100, 2200, 4100, 6200, MPB Series Top MountDrive Package for Standard Load 90° Industrial 60 Hz Gearmotors
Specifications
Table 2: Belt Speeds for Standard Load Fixed Speed 90° 60 Hz Gearmotors
on 2200 Series Conveyors
(vp) = voltage and phase
11 = 115 V, 1-phase
23 = 208−230/460 V, 3-phase
(n) = Reversing Capability
N = No Reversing switch
R = With reversing switch
* = Nosebar transfers operate at maximum 77 Ft/min (23.5
M/min) belt speed
Table 3: Belt Speeds for Standard Load Variable Speed 90° DC Gearmotors
on 2200 Series Conveyors
* = Nosebar transfers operate at maximum 77 Ft/min (23.5 M/min) belt speed
NOTE
For belt speed other than those listed in
Tables 2
− 7, contact factory for details.
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number RPM In-lb N-m Ft/min M/min
32M060HL4(vp)F(n) 29 226 25.5 6 1.8 19 32
32M060HL4(vp)F(n) 29 226 25.5 10 3.0 28 28
32M060HL4(vp)F(n) 29 226 25.5 16 4.9 44 28
32M040HL4(vp)F(n) 43 237 26.8 15 4.6 28 28
32M040HL4(vp)F(n) 43 237 26.8 24 7.3 44 28
32M020HL4(vp)F(n) 86 142 16.0 30 9.1 28 28
32M020HL4(vp)F(n) 86 142 16.0 48 14.6 44 28
32M010HL4(vp)F(n) 173 78 8.8 61 18.6 28 28
32M010HL4(vp)F(n) 173 78 8.8 95*29.0*44 28
32M010HL4(vp)F(n) 173 78 8.8 104*31.7*48 28
32M005HL4(vp)F(n) 345 41 4.6 121*36.9*28 28
32M005HL4(vp)F(n) 345 41 4.6 138*42.1*32 28
32M005HL4(vp)F(n) 345 41 4.6 176*53.6*32 22
32M005HL4(vp)F(n) 345 41 4.6 208*63.4*48 28
32M005HL4(vp)F(n) 345 41 4.6 242*73.8*44 22
32M005HL4(vp)F(n) 345 41 4.6 264*80.5*48 22
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number RPM In-lb N-m Ft/min M/min
32M060HLD3DEN 42 198 22.4 1.8 – 14.0 0.5 – 4.6 28 28
32M060HLD3DEN 42 198 22.4 2.8 – 23.0 0.8 – 7.0 44 28
32M040HLD3DEN 63 163 18.4 2.6 – 22.0 0.8 – 6.7 28 28
32M020HLD3DEN 125 98 11.1 5.3 – 44.0 1.6 – 13.0*28 28
32M010HLD3DEN 250 54 6.1 10.0 – 88.0*3.2 – 27.0*28 28
32M010HLD3DEN 250 54 6.1 17.0 – 138.0*5.0 – 42.0*44 28
32M005HLD3DEN 500 28 3.2 21.0 – 176.0*6.4 – 54.0*28 28
32M005HLD3DEN 500 28 3.2 33.0 – 276.0*10.0 – 84.0*44 28

Dorner Mfg. Corp. 6 851-257 Rev. J
2100, 2200, 4100, 6200, MPB Series Top MountDrive Package for Standard Load 90° Industrial 60 Hz Gearmotors
Specifications
Table 4: Belt Speeds for Standard Load Fixed Speed 90° 60 Hz Gearmotors
on 2100 4100 & 6200 Series Conveyors
(vp) = voltage and phase
11 = 115 V, 1-phase
23 = 208−230/460 V, 3-phase
(n) = Reversing Capability
N = No Reversing switch
R = With reversing switch
Table 5: Belt Speeds for Standard Load Variable Speed 90° DC Gearmotors
on 2100 4100 & 6200 Series Conveyors
Table 6: Belt Speeds for Standard Load Fixed Speed 90° 60 Hz Gearmotors
on MPB Series Conveyors
(vp) = voltage and phase
11 = 115 V, 1-phase
23 = 208−230/460 V, 3-phase
(n) = Reversing Capability
N = No Reversing switch
R = With reversing switch
Gearmotors Belt Speed Drive Pulley Driven Pulley
Part Number RPM Ft/min M/min
32M060HL4(vp)F(n) 29 6 1.8 19 32
32M060HL4(vp)F(n) 29 10 3.0 28 28
32M060HL4(vp)F(n) 29 16 4.9 44 28
32M040HL4(vp)F(n) 43 15 4.6 28 28
32M040HL4(vp)F(n) 43 24 7.3 44 28
32M020HL4(vp)F(n) 86 30 9.1 28 28
32M020HL4(vp)F(n) 86 48 14.6 44 28
32M010HL4(vp)F(n) 173 61 18.6 28 28
32M010HL4(vp)F(n) 173 95*29.0*44 28
32M010HL4(vp)F(n) 173 104*31.7*48 28
32M005HL4(vp)F(n) 345 121*36.9*28 28
32M005HL4(vp)F(n) 345 138*42.1*32 28
32M005HL4(vp)F(n) 345 176*53.6*32 22
32M005HL4(vp)F(n) 345 208*63.4*48 28
32M005HL4(vp)F(n) 345 242*73.8*44 22
32M005HL4(vp)F(n) 345 264*80.5*48 22
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number RPM In-lb N-m Ft/min M/min
32M060HLD3DEN 42 198 22.4 1.8 – 14.0 0.5 – 4.6 28 28
32M060HLD3DEN 42 198 22.4 2.8 – 23.0 0.8 – 7.0 44 28
32M040HLD3DEN 63 163 18.4 2.6 – 22.0 0.8 – 6.7 28 28
32M020HLD3DEN 125 98 11.1 5.3 – 44.0 1.6 – 13.0*28 28
32M010HLD3DEN 250 54 6.1 10.0 – 88.0*3.2 – 27.0*28 28
32M010HLD3DEN 250 54 6.1 17.0 – 138.0*5.0 – 42.0*44 28
32M005HLD3DEN 500 28 3.2 21.0 – 176.0*6.4 – 54.0*28 28
32M005HLD3DEN 500 28 3.2 33.0 – 276.0*10.0 – 84.0*44 28
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number RPM In-lb N-m Ft/min M/min
32M060HL4(vp)FN 29 226 25.5 25.5 4.1 22 32
32M060HL4(vp)FN 29 226 25.5 25.5 6.0 28 28
32M040HL4(vp)FN 43 237 26.8 26.8 8.9 28 28
32M040HL4(vp)FN 43 237 26.8 26.8 13.4 48 32
32M020HL4(vp)FN 86 142 16.0 16.0 17.9 28 28

851-257 Rev. J 7 Dorner Mfg. Corp.
2100, 2200, 4100, 6200, MPB Series Top MountDrive Package for Standard Load 90° Industrial 60 Hz Gearmotors
Specifications
Table 7: Belt Speeds for Standard Load Variable Speed 90° DC Gearmotors
on MPB Series Conveyors
* = Cleated and Sidewall Cleated belts operate at a maximum of 150 ft/min (45.7 m/min)
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number RPM In-lb N-m Ft/min M/min
32M060HLD3DEN 42 198 22.4 2.3−19 0.7−5.9 22 32
32M060HLD3DEN 42 198 22.4 3.4−28 1−8.6 22 32
32M060HLD3DEN 42 198 22.4 5.3−44 1.6−13 44 28
32M040HLD3DEN 63 163 18.4 5.1−42 1.6−12.9 28 28
32M020HLD3DEN 125 98 11.1 10−85 3−26 28 28
32M020HLD3DEN 125 98 11.1 15−127 4.7−39 48 32
32M010HLD3DEN 250 54 6.1 20−170*6−52*28 28
32M010HLD3DEN 250 54 6.1 31−255*9−77*48 32

Dorner Mfg. Corp. 8 851-257 Rev. J
2100, 2200, 4100, 6200, MPB Series Top MountDrive Package for Standard Load 90° Industrial 60 Hz Gearmotors
Installation
Required Tools
• Hex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm
• Straight edge
• Torque wrench
Mounting
Figure 2
Figure 2
Figure 3
Figure 3
Installation Component List:
1. Typical gearmotor components (Figure 4)
Figure 4
Figure 4
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
A
WARNING
MPB Series Conveyors are not reversible.
Reversing creates pinch points which can
cause severe injury.
DO NOT REVERSE MPB SERIES
CONVEYORS.
A
WARNING
Gearmotors must be mounted as shown in
Figure 2 and Figure 3.
Failure to do so creates pinch points which
can cause severe injury.
NOTE
Gearmotor position on Flat Belt conveyors
shown in Figure 2. Gearmotor position on
Cleated Belt and MPB Series conveyors
shown in Figure 3.
I Top Mount Assembly
JDrivePulley
KCover
L M4 Socket Head Screws (4x)
M Driven Pulley
NKey
O M6 Socket Head Screws (2x)
P Timing Belt
Flat Belt Conveyor
Cleated Belt Conveyor MPB SeriesConveyor
I
J
K
P
O
N
M
L

851-257 Rev. J 9 Dorner Mfg. Corp.
2100, 2200, 4100, 6200, MPB Series Top MountDrive Package for Standard Load 90° Industrial 60 Hz Gearmotors
Installation
2. For your reference, the following figures show
gearmotor mounting configurations for various
conveyor series.
Figure 5
2200 Series
Figure 5
Figure 6
6200 Series
Figure 6
Figure 7
4100 Series
Figure 7
Figure 8
2100 Series
Figure 8
Figure 9
MPB Series
Figure 9
Figure 10
Figure 10
NOTE
Flat belt mounting package shown above
(Figure 4), cleated belt mounting package
similar.
Gearmotor
is mounted
to Head
Plate
Gearmotor
is mounted to
Drive Spacer
Gearmotor
is mounted
to Drive
Adapter
Plate
NOTE
Gearmotor may be operated in positions 1, 2
or 3 (Figure 10). Dependent on conveyor belt
speed and gearmotor type, position 2 may
require a vibration dampening bracket. Order
7018WW for 2200 and MPB conveyors or
7019WW for 2100 and 6200 conveyors. (WW
= conveyor width). 4100 conveyors do not
require brackets.
Gearmotor
is mounted
to Head
Plate
Gearmotor
is mounted
to Head
Plate
1
2
3

Dorner Mfg. Corp. 10 851-257 Rev. J
2100, 2200, 4100, 6200, MPB Series Top MountDrive Package for Standard Load 90° Industrial 60 Hz Gearmotors
Installation
3. If required, change gearmotor position by removing four
(4) screws (Figure 11, item Q). Rotate gearmotor to
other position and replace screws (Q). Tighten to 103 in-
lb (12 N−m).
Figure 11
Figure 11
4. Locate drive output shaft (Figure 12, item R) and
remove two (2) screws (S).
Figure 12
Figure 12
5. Attach mount assembly (Figure 13, item I) with screws
(O). Tighten to 80 in-lb (9 N−m).
Figure 13
Figure 13
6. Install key (Figure 14, item N).
NOTE
6200 conveyor shown, 2100, 2200, 4100 &
MPB similar.
Q
Q
R
S
A
WARNING
Drive shaft keyway may be sharp.
HANDLE WITH CARE.
T
O
I