Dorner 2100 Series User manual

851-253 Rev. E
Installation, Maintenance
& Parts Manual
2100, 2200, 4100, 6100, MPB Series
Side Mount Drive Package
for Standard Load 90°Industrial 60 Hz Gearmotors
Table of Contents
Warnings −General Safety 2. . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearmotors 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2200 Belt Speeds 4. . . . . . . . . . . . . . . . . . . . . . . . . .
2100, 4100 & 6100 Belt Speeds 4. . . . . . . . . . . . . .
MPB Belt Speeds 5. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For 4100 and 2100 Flat Belt Conveyors 7. . . . . .
For 6100, 2200, MPB and 2100 Cleated Belt
Conveyors 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 9. . . . . . . . .
Required Tools 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Reducer Replacement 9. . . . . . . . . . . . . . . . . .
Motor Replacement 10. . . . . . . . . . . . . . . . . . . . . . .
Service Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Mount Drive Package for 90_60 Hz Motors 12
4100 Adapter Components 13. . . . . . . . . . . . . . . . .
Gearmotors 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 2200, 4100, 6100, MPB Series Side Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors
851-253 Rev. E 2Dorner Mfg. Corp.
The safety alert symbol, black triangle with white
exclamation, is used to alert you to potential
personal injury hazards.
Ç
Ç
WARNING
Ç
Climbing, sitting, walking or
riding on conveyor will
cause severe injury.
KEEP OFF CONVEYORS.
DANGER
Ç
DANGER
Do NOT OPERATE
CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Ç
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
WARNING
Ç
Exposed moving parts can
cause severe injury.
REPLACE ALL GUARDS
BEFORE RUNNING
CONVEYOR.
WARNING
Ç
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
Ç
MPB Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE MPB SE-
RIES CONVEYORS.
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 2200, 6100 & 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.
Warnings −General Safety

2100, 2200, 4100, 6100, MPB Series Side Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors
Dorner Mfg. Corp. 3851-253 Rev. E
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:
6WW A
Language Code = U.S. English
Output Shaft Type = 905Industrial
Gearmotor Type = Standard Load, Industrial
HM SS
Mount Style = Side Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
* See “Ordering and Specifications” Catalog for details.
2 = 2100 Series Conveyor
22 = 2200 Series Series Conveyors
4 = 4100 Series Conveyor
6 = 6100 Series Conveyor
2P = MPB Series Conveyor
Table 1: Gearmotor Specifications
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
Product Description

2100, 2200, 4100, 6100, MPB Series Side Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors
851-253 Rev. E 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Standard Load Fixed Speed 90560 Hz Gearmotors on 2200
Series Conveyors
Gearmotors Belt Speed
Part Number
RPM
In lb
Nm
Ft/min
M/min
Part Number RPM In-lb N-m Ft/min M/min
32M060HL4(vp)F(n) 29 226 25.5 10.0 3.0
32M040HL4(vp)F(n) 43 237 26.8 15.0 4.6
32M020HL4(vp)F(n) 86 142 16 30.0 9.1
32M010HL4(vp)F(n) 173 78 8.8 61.0 18.6
32M005HL4(vp)F(n) 345 41 4.6 121.0* 36.9*
(vp) = voltage and phase (n) = Reversing Capability
11 = 115 V, 1-phase N = No Reversing Capability
23 = 208 – 230/460 V, 3-phase R = With Reversing Capability
* = Nosebar transfers operate at maximum 77Ft/min (23.5M/min) belt speed
Table 3: Belt Speeds for Standard Load Variable Speed 905DC Gearmotors on 2200
Series Conveyors
Gearmotors Belt Speed
Max
Part Number
Max
RPM In-lb N-m Ft/min M/min
32M060HLD3DEN 42 198 22.4 1.8 – 14.0 0.5 – 4.5
32M040HLD3DEN 63 163 18.4 2.6 – 22.0 0.8 – 6.7
32M020HLD3DEN 125 98 11.1 5.3 – 44.0 1.6 – 13.0
32M010HLD3DEN 250 54 6.1 10.0 – 88.0* 3.2 – 27.0*
32M005HLD3DEN 500 28 3.2 21.0 – 176.0* 6.4 – 54.0*
* = Nosebar transfers operate at maximum 77Ft/min (23.5M/min) belt speed
Table 4: Belt Speeds for Standard Load Fixed Speed 90560 Hz Gearmotors on 2100,
4100 & 6100 Series Conveyors
Gearmotors Belt Speed
Part Number
RPM
In lb
Nm
Ft/min
M/min
Part Number RPM In-lb N-m Ft/min M/min
32M060HL4(vp)F(n) 29 226 25.5 8.0 2.4
32M040HL4(vp)F(n) 43 237 26.8 12.0 3.7
32M020HL4(vp)F(n) 86 142 16 25.0 7.6
32M010HL4(vp)F(n) 173 78 8.8 49.0 14.9
32M005HL4(vp)F(n) 345 41 4.6 99.0 30.2
(vp) = voltage and phase (n) = Reversing Capability
11 = 115 V, 1-phase N = No Reversing Capability
23 = 208 – 230/460 V, 3-phase R = With Reversing Capability
Table 5: Belt Speeds for Standard Load Variable Speed 905DC Gearmotors on 2100,
4100 & 6100 Series Conveyors
Gearmotors Belt Speed
Max
Part Number
Max
RPM In-lb N-m Ft/min M/min
32M060HLD3DEN 42 198 22.4 1.4 – 12 0.4 – 3.6
32M040HLD3DEN 63 163 18.4 2.1 – 18 0.7 – 5.4
32M020HLD3DEN 125 98 11.1 4.3 – 36 1.3 – 11
32M010HLD3DEN 250 54 6.1 9.0 – 71 2.6 – 22
32M005HLD3DEN 500 28 3.2 17 – 143 5.2 – 43
SpecificationsSpecifications

2100, 2200, 4100, 6100, MPB Series Side Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors
Dorner Mfg. Corp. 5851-253 Rev. E
Table 6: Belt Speeds for Standard Load Fixed Speed 90560 Hz Gearmotors on MPB
Series Conveyors
Gearmotors Belt Speed
Part Number
RPM
In lb
Nm
Ft/min
M/min
Part Number RPM In-lb N-m Ft/min M/min
32M060HL4(vp)F(n) 29 226 25.5 20 6.0
32M040HL4(vp)F(n) 43 237 26.8 29 8.9
32M020HL4(vp)F(n) 86 142 16 59 17.9
(vp) = voltage and phase (n) = Reversing Capability
11 = 115 V, 1-phase N = No Reversing Capability
23 = 208 – 230/460 V, 3-phase R = With Reversing Capability
Table 7: Belt Speeds for Standard Load Variable Speed 905DC Gearmotors on MPB
Series Conveyors
Gearmotors Belt Speed
Max
Part Number
Max
RPM In-lb N-m Ft/min M/min
32M060HLD3DEN 42 198 22.4 3.4−28 1.0−8.6
32M040HLD3DEN 63 163 18.4 5.1−42 1.6−12.9
32M020HLD3DEN 125 98 11.1 10−85 3−26
32M010HLD3DEN 250 54 6.1 20−170* 6−52*
* = Cleated and Sidewall Cleated belts opperate at a maximum of 150 ft/min (45.7 m/min)
NOTE: For belt speed other than those listed, contact
factory for details.
Specifications

2100, 2200, 4100, 6100, MPB Series Side Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors
851-253 Rev. E 6Dorner Mfg. Corp.
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
Ç
MPB Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE MPB SE-
RIES CONVEYORS.
WARNING
Installation Component List
F Drive Assembly
G M6 Socket Head Screws (2x)
H Hex Shaft (2100 & 4100 Flat Belt Conveyor Only)
1.Typical components (Figure 2)
Figure 2
F
G
H
NOTE: Flat belt mounting package shown above (Fig-
ure 2), cleated belt mounting package similar.
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 100 in-lb (12 N−m).
Figure 4
I
I
InstallationInstallation

2100, 2200, 4100, 6100, MPB Series Side Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors
Dorner Mfg. Corp. 7851-253 Rev. E
For 4100 and 2100 Flat Belt Conveyors
IMPORTANT: On 4 inch (95 mm) and wider conveyors,
the hex broach is offset from center towards the drive
side for hex shaft engagement.
3a The figures below show gearmotor mounting for
4100 and 2100 series conveyors.
Figure 5 −4100 Series
Gearmotor
and Drive
Plate are
mounted to
Spacer Plate
Figure 6 −2100 Series
Gearmotor
and Drive
Plate are
mounted to
Spacer Plate
4a.Locate drive mounting position and remove two (2)
screws (J of Figure 7).
Figure 7
J
5a.Remove inspection plugs (K of Figure 8).
Figure 8
K
H
M
L
6a.Insert hex shaft (H of Figure 10) into coupling.
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 9).
Figure 9
L
7a.Jog motor and rotate coupling to align set screw (L
of Figure 8) with access hole (M). Tighten to 32 in-lb
(3.7 N−m). Repeat for second set screw.
Ç
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER AFTER
JOGGING MOTOR.
WARNING
8a.Replace inspection plugs (K of Figure 10). 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 N−m).
Figure 10
G
K
H
Installation

2100, 2200, 4100, 6100, MPB Series Side Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors
851-253 Rev. E 8Dorner Mfg. Corp.
For 6100, 2200, MPB and 2100 Cleated Belt
Conveyors
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
3b The figures below show gearmotor mounting for
6100, 2200 and MPB series conveyors.
Figure 11 −6100 Series
Gearmotor
and Drive
Plate are
mounted to
Spacer Plate
Figure 12 −2200 Series
Gearmotor
and Drive
Plate are
mounted to
Head Plate
Figure 13 −MPB Series
Gearmotor
and Drive
Plate are
mounted to
Head Plate
NOTE: 6100 conveyor shown, 2200 and MPB cleated
belt conveyors similar.
4b.Locate drive output shaft. Remove two screws (J of
Figure 14). Install key (N).
Figure 14
N
J
5b.Remove inspection plugs (K of Figure 15).
Figure 15
F
K
G
6b.Slide coupling over drive output shaft and install
drive assembly (F of Figure 15) with screws (G).
Tighten to 80 in-lb (9 N−m).
Ç
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 9).
7b.Jog motor and rotate coupling to align set screw (L
of Figure 16) with access hole (M). Tighten to 32
in-lb (3.7 N−m). Repeat for second set screw.
Figure 16
L
M
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER AFTER
JOGGING MOTOR.
WARNING
8b.Replace inspection plugs. (K of Figure 15).
Installation

2100, 2200, 4100, 6100, MPB Series Side Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors
Dorner Mfg. Corp. 9851-253 Rev. E
Required Tools
DHex key wrenches:
2.5 mm, 3 mm, 5 mm
DLarge flat-blade screwdriver
DAdjustable wrench (for hexagon head screws)
DExternal snap ring pliers
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 plugs (K of Figure 15).
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 9).
2.Jog motor and rotate coupling to align set screw (L
of Figure 16) with access hole (M). Loosen set
screw. Repeat for second set screw.
3.Remove two (2) screws (G of Figure 15). Remove
drive assembly (F).
4.Remove four (4) screws (I of Figure 17) and remove
mounting bracket & tube (O).
Figure 17
I
I
O
5.Loosen two (2) set screws (L of Figure 18) and
detach coupling (P) from gear reducer.
Figure 18
L
P
6.Remove four screws (Q of Figure 19). Detach motor
(R) from gear reducer (S). Retain shaft key (T).
Figure 19
Q
R
T
W
Q
S
V
U
7.Remove two (2) screws (U) and detach output shaft
cover (V).
8.Remove gear reducer output shaft key (W).
Preventive Maintenance and Adjustment

2100, 2200, 4100, 6100, MPB Series Side Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors
851-253 Rev. E 10 Dorner Mfg. Corp.
9.Loosen six (6) set screws (X of Figure 20). Remove
drive shaft (Y) and key (Z).
Figure 20
XY
Z
10.Apply grease (AA of Figure 21) to shaft.
Figure 21
AA
11.Replace the original shaft components into new gear
reducer (see Figure 20).
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 19) in keyway, slide motor (R)
and gear reducer (S) together. Install screws (Q) and
tighten.
13.Attach coupling (P of Figure 18) to gear reducer shaft.
Tighten two set screws (L) to 32 in-lb (4.7 N−m).
14.Attach mounting bracket & tube (O of Figure 17) to
gearmotor. Tighten screws (I) to 103 in-lb (12 N−m).
15.Complete installation steps:
DSee “4100 and 2100 Flat Belt Conveyors” section on
page 7.
DSee “6100 2200, MPB and 2100 Cleated Belt Con-
veyors” section on page 8.
Motor Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Ç
Hazardous voltage will
cause severe injury or
death.
LOCKOUT POWER BEFORE
before wiring.
DANGER
1.For single phase motor, unplug power cord from
outlet.
2.For three phase motor:
a. Loosen terminal box screws (AB of Figure 22) and
remove cover (AC).
Figure 22
AB
AC
b. Record wire colors connecting to wires 1, 2 and 3.
Loosen wire nuts and remove wires 1, 2 and 3.
c. Loosen cord grip and remove cord.
Preventive Maintenance and Adjustment