Dorner 6100 Series Manual instruction

851-474 Rev. B
Setup, Operation
& Maintenance Manual
6100 Series Bottom Mount Drive Package
for Heavy Load 905Sanitary Gearmotors
Table of Contents
Warnings – General Safety 2. . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three-phase Motor Starter 7. . . . . . . . . . . . . . . .
Preventive Maintenance & Adjustment 8. . . . . . . . . .
Required Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 8. . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 9
. . . . . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 9. . . . . . . . . .
Gear Reducer Replacement 10. . . . . . . . . . . . . . . . . .
Gear Motor Replacement 12. . . . . . . . . . . . . . . . . . .
Service Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
851-474 Rev. B 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
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
equipment or as part of a
multiple conveyor system,
CHECK FOR POTENTIAL
PINCH POINTS and other
mechanical hazards before
system start-up.
WARNING
Introduction
IMPORTANT: Some illustrations may show
guards removed. Do NOT operate equipment with-
out guards.
Upon receipt of shipment:
DCompare shipment with packing slip. Contact fac-
tory regarding discrepancies.
DInspect packages for shipping damage. Contact carri-
er regarding damage.
DAccessories may be shipped loose. See accessory
instructions for installation.
Dorner 6100 Series conveyors are covered by patent
number5174435andcorrespondingpatentsandpatent
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

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
Dorner Mfg. Corp. 3851-474 Rev. B
Refer to Figure 1 for typical components.
A Conveyor
B Mounting Bracket
C Gearmotor
D Timing Belt Tensioner
E Cover
F Timing Belt
G Drive Pulley
H Driven Pulley
I Motor Control
Typical Components
D
Figure 1
E
H
A
G
I
F
C
B
Specifications
Gearmotor Mounting Package Models:
Example:
6 WW A1
Language Code = CE English
Output Shaft Type L = Left Hand
R = Right Hand
Drive/Driven Pulleys
(See tables 2, 3 & 4)
–3232
Gearmotor Type = Heavy Load, Sanitary
LU ZB
Mount Style = Bottom Mount
Conveyor Width Reference*
Mount Position = A1, A2, D1 or D2
(see detail to the right)
“–” = Flat Belt (or add cleat type)
D1 D2
A2
A1
* See “Ordering and Specifications”Catalog for details.
Table 1: Gearmotor Specifications
Three-Phase
Output Power 0.19 kW
Input Voltage 230/400 Volts A.C.
Input Frequency 50 Hz
Full Load Amperes 1.2/.7 Amperes
Gearmotor Ratios 5:1, 15:1 and 50:1
Protection Ratings IP55 for Gearmotor and Motor Starter
Product Description

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
851-474 Rev. B 4Dorner Mfg. Corp.
Table 2: Heavy Load Fixed Speed 905Sanitary 60 Hz Gearmotors
Gearmotors Belt Speed Drive Driven
Part Number RPM N-m ft/min M/min Pulley Pulley
62(c)050(r)Z4(vp)FN 29 50.1 5 1.5 19 32
62(c)050(r)Z4(vp)FN 29 50.1 8 2.4 32 32
62(c)050(r)Z4(vp)FN 29 50.1 12 3.7 48 32
62(c)050(r)Z4(vp)FN 29 50.1 18 5.5 48 22
62(c)015(r)Z4(vp)FN 97 19.9 28 8.5 32 32
62(c)015(r)Z4(vp)FN 97 19.9 41 12.5 48 32
62(c)015(r)Z4(vp)FN 97 19.9 60 18.3 48 22
62(c)005(r)Z4(vp)FN 290 7.2 83 25.3 32 32
62(c)005(r)Z4(vp)FN 290 7.2 124 37.8 48 32
62(c)005(r)Z4(vp)FN 290 7.2 155 47.2 60 32
62(c)005(r)Z4(vp)FN 290 7.2 181 55.2 48 22
62(c)005(r)Z4(vp)FN 290 7.2 226 68.9 60 22
(c) = Electrical Configuration (vp) = Voltage and Phase (r) = Output Shaft Orientation
G = CE German 23 = 230 V 3 phase L = Left Hand
U = CE Great Britain 43 = 400V 3 phase R = Right Hand
NOTE: For belt speed other than those listed,
contact factory for details.
Specifications

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
Dorner Mfg. Corp. 5851-474 Rev. B
Required Tools
DWrenches (for hexagon head fasteners)
8mm, 10mm, 13mm & 14mm
D2.5 mm hex key wrench
DStraight edge
DTorque wrench
Mounting
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Installation Component List
ABottom Mounting Package Assembly
BM6 x 30 mm, Hexagon Head Screws (4x)
CTiming Belt
DDriven Pulley
EDrive Cover
FMotor Key
GMotor Mounting Screws & Washers (4x)
HDrive Pulley
I Motor
JGear Reducer
KMotor Starter
LM6 x 20mm Hex Head Screws (2x)
MAccessory Mounting Clips
N Key
1.Gather components (Figure 2)
NOTE: 102mm and wider mounting assembly
shown. 51mm and 76mm wide mounting assem-
blies include two spacer (AC of Figure 5) and two
long M6 screws (AD).
Figure 2
A
BD
I
C
E
H
J
G
F
K
N
M
L
2.Remove screws (O of Figure 3) from both sides of
conveyor.
Figure 3
O
N
O
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
3.Install square key (N of Figure 3) into conveyor
drive shaft.
4a.For 102mm and wider conveyors, loosen (but do not
remove) screws (P of Figure 4). Attach bottom
mount assembly (A) to conveyor with screws (B).
Tighten screws (B) and (P) to 10.4 Nm.
Figure 4
A
P
B
B
4b.For 51mm to 76mm wide conveyors, loosen (but do
not remove) screws (P of Figure 5). Attach bottom
mount assembly (A) to conveyor with two screws
(B), spacer tubes (AC) and screws (AD). Tighten
screws (B), (AD) and (P) to 10.4 Nm.
Figure 5
A
PB
AD AC
Installation

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
851-474 Rev. B 6Dorner Mfg. Corp.
5.Wrap timing belt (C of Figure 6) around driven
pulley (D) and drive pulley (H). Attach driven
pulley (D) to conveyor shaft.
Figure 6
D
C
H
6.Using a straight edge (Q of Figure 7), align driven
pulley (D) with drive pulley (H). Tighten driven
pulley set screws (R).
Figure 7
Q
D
R
H
7.Depending on conveyor belt travel (1 or 2 of
Figure 8), locate timing belt tensioner (S), as
shown. Tension timing belt to obtain 3mm
deflection for 4.3N of force at timing belt
mid-point (T). Tighten tensioner to 51 Nm.
Figure 8
12
T
TS
8.Attach cover (E of Figure 9) with screws (U).
Tighten screws to 4 Nm.
Figure 9
E
U
U
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
9.Install key (F of Figure 10).
Figure 10
F
G
IMPORTANT:Be extremely careful when
coupling motor to gear reducer. Avoid
misalignment and forcing the connection causing
possible permanent gear reducer seal damage.
10.Attach gear motor (I of Figure 11) to gear reducer
(J) with screws and washers (G of Figure 10).
Tighten to 41 Nm.
Figure 11
JI
G
Installation

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
Dorner Mfg. Corp. 7851-474 Rev. B
11.Attach mounting clips (M of Figure 12) to
conveyor.
Figure 12
M
12.Attach motor starter (K of Figure 13) to clips with
screws (L). Tighten to 10.4 Nm.
Figure 13
K
L
L
Wiring
Three-phase Motor Starter
Ç
Hazardous voltage will
cause severe injury or
death.
LOCKOUT POWER
BEFORE WIRING.
DANGER
NOTE: 230 volt three-phase manual motor
starters must be wired in accordance with
applicable electrical codes.
1.Loosen cover screws (V of Figure 14) and remove
cover.
Figure 14
W
V
V
NOTE: Line cord must be 0.28¨(7 mm) minimum
to 0.47¨(12 mm) maximum in diameter.
2.Insert line cord through grip (W) and tighten nut.
3.For correct three-phase motor shaft rotation,
connect line phase sequence L1, L2 & L3 to
terminals as shown (Figure 15).
Ground L1 L2 L3
13 5
Figure 15
Controller must be properly grounded. Failure
to properly ground control box may cause injury
to personnel.
Ç
Ç
NOTE:The motor ground wire is also attached to
left terminal marked (Figure 15).
4.Attach ground wire to lower left terminal marked
(see Figure 15).
5.Replace starter cover and tighten screws (V of
Figure 14).
Installation

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
851-474 Rev. B 8Dorner Mfg. Corp.
Required Tools
DWrenches (for hexagon head fasteners)
8mm, 10mm, 13mm, 14mm
D2.5 mm hex key wrench
DStraight edge
DTorque wrench
Timing Belt Replacement
Ç
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
1.Loosen four (4) screws (U of Figure 16) and
remove cover (E).
Figure 16
U
E
U
2.Loosen tensioner (S of Figure 17).
Figure 17
C
S
3.Remove timing belt (C).
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley set screws (R of
Figure 18) and remove pulley with belt. For
re-installation, see steps 5 and 6 on page 6.
Figure 18
D
R
4.Install new timing belt.
5.Depending on conveyor belt travel (1 or 2 of
Figure 19), locate timing belt tensioner (S) as
shown. Tension timing belt to obtain 3mm
deflection for 4.3N of force at timing belt
mid-point (T). Tighten tensioner to 51 Nm.
Figure 19
12
T
TS
NOTE: Do not over-tighten screws (U of Figure
16).
6.Attach cover (E of Figure 16) and tighten four (4)
screws (U) to 4 Nm.
Preventive Maintenance & Adjustment

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
Dorner Mfg. Corp. 9851-474 Rev. B
Timing Belt Tensioning
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Remove four (4) screws (U of Figure 20) and
remove cover (E).
Figure 20
U
E
U
2.Loosen tensioner (S of Figure 21).
Figure 21
C
S
H
3.Depending on direction of conveyor belt travel (1
or 2 of Figure 22), position belt tensioner (S) as
shown. Tension belt to obtain 3mm deflection for
456 grams of force at belt mid-point (T). Tighten
tensioner screw to 12Nm.
Figure 22
12
T
TS
4.Attach cover (E of Figure 23) with four (4) screws
(U). Tighten to 4Nm.
Figure 23
U
E
U
Drive or Driven Pulley Replacement
ÇÇ
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Complete steps 1 through 3 of “Timing Belt
Replacement”section on page 8.
2.Loosen set screws and remove drive or driven
pulley.
NOTE: If drive pulley (H of Figure 21) is replaced,
wrap timing belt around drive pulley and complete
step 3.
3.Complete steps 5 through 8 of “Installation”
section on page 6.
Preventive Maintenance and Adjustment

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
851-474 Rev. B 10 Dorner Mfg. Corp.
Gear Reducer Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Remove four (4) screws (U of Figure 24) and
remove cover (E).
Figure 24
U
E
U
2.Loosen tensioner (S of Figure 25).
Figure 25
C
S
H
3.Loosen drive pulley set screws (X of Figure 26).
Remove drive pulley (H) and timing belt (C).
Figure 26
X
H
C
4.Remove screws and washers (G of Figure 27).
Detach motor (I) from gear reducer (J).
G
G
Figure 27
J
I
5.Remove four (4) gear reducer mounting screws (Z
of Figure 28). Remove gear reducer.
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
Dorner Mfg. Corp. 11 851-474 Rev. B
Figure 28
J
ZZ
6.Attach new gear reducer to bottom mount with
screws (Z).
IMPORTANT: Be extremely careful when
coupling motor to gear reducer. Avoid
misalignment and forcing the connection causing
possible permanent gear reducer seal damage.
7.With key (F of Figure 29) in keyway, slide motor
(I) and gear reducer (J) together. Install screws (G)
and tighten.
Figure 29
I
J
G
G
F
8.Wrap timing belt (C of Figure 30) around drive
pulley (H) and driven pulley (D). Attach drive
pulley (H) to gear reducer shaft.
Figure 30
C
H
D
9.Using a straight edge (Q of Figure 7), align drive
pulley (H) with driven pulley (D). Tighten drive
pulley set screws (X).
Figure 31
Q
D
X
H
10.Depending on conveyor belt travel (1 or 2 of
Figure 32), locate timing belt tensioner (S), as
shown. Tension timing belt to obtain 3mm
deflection for 4.3N of force at timing belt
mid-point (T). Tighten tensioner to 51Nm.
Figure 32
12
T
TS
Preventive Maintenance and Adjustment

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
851-474 Rev. B 12 Dorner Mfg. Corp.
11.Attach cover (E of Figure 33) with screws (U).
Tighten screws to 4Nm.
Figure 33
U
E
U
Motor Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Ç
Ç
Hazardous voltage will
cause severe injury or
death.
LOCKOUT POWER
BEFORE before wiring.
DANGER
1.Loosen terminal box screws (AA of Figure 34) and
remove cover (AB).
Figure 34
AB
AA
AA
2.Record incoming wire colors. Loosen wire nuts
and remove wires.
3.Loosen cord grip and remove cord.
4.Remove screws and washers (G of Figure 35).
Detach motor (I) from gear reducer (J). Retain
motor output shaft key (F).
Figure 35
I
G
J
G
F
IMPORTANT: Be extremely careful when
coupling motor to gear reducer. Avoid
misalignment and forcing the connection causing
possible permanent gear reducer seal damage.
5.With key (F of Figure 36) in keyway, slide new
gear motor and gear reducer (J) together. Install
screws and washers (G) and tighten.
Figure 36
J
G
G
F
6.To replace wiring, reverse steps 1, 2 and 3 on this
page.
Preventive Maintenance and Adjustment

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance
Dorner Mfg. Corp. 13 851-474 Rev. B
NOTE: For replacement parts other than those
shown on this page, contact an authorized Dorner
Service Center or the factory.
Item Part Number Part Description
1 826-342 Motor,0.19Kw 230/400 Volts, 50 Hz,
3-Phase
2 820–262 Gear Reducer, 5:1, 71B5 RH
820–263 Gear Reducer, 5:1, 71B5 LH
820–264 Gear Reducer, 15:1, 71B5 RH
820–265 Gear Reducer, 15:1, 71B5 LH
820–266 Gear Reducer, 50:1, 71B5 RH
820–267 Gear Reducer, 50:1, 71B5 LH
3 814-104 Timing Belt, 15mm W x 450mm L
814-105 Timing Belt, 15mm W x 460mm L
814-065 Timing Belt, 15mm W x 475mm L
814-112 Timing Belt, 15mm W x 495mm L
814-101 Timing Belt, 15mm W x 500mm L
814-108 Timing Belt, 15mm W x 520mm L
814-064 Timing Belt, 15mm W x 535mm L
814-099 Timing Belt, 15mm W x 565mm L
4 802-123 Tensioner Bearing (2x Required)
5 450365MP Driven Pulley, 19 Tooth, 12mm bore
450366MP Driven Pulley, 22 Tooth, 12mm bore
450367MP Driven Pulley, 28 Tooth, 12mm bore
450368MP Driven Pulley, 32 Tooth, 12mm bore
6 980422M Square Key, 4 mm x 22 mm
7 450397 Drive Pulley, 19 Tooth, .62” bore
450398 Drive Pulley, 22 Tooth, .62” bore
450399 Drive Pulley, 28 Tooth, .62” bore
450400 Drive Pulley, 32 Tooth, .62” bore
450430 Drive Pulley, 44 Tooth, .62” bore
450431 Drive Pulley, 48 Tooth, .62” bore
450432 Drive Pulley, 60 Tooth, .62” bore
8 683526 Key, Square, 0.188” x .62” L,
Stainless Steel
Figure 37
6
8
7
5
3
2
1
4
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
851-474 Rev. B Printed in U.S.A. 200
580 Industrial Drive, 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.
For replacement parts, contact an authorized
Dorner Service Center or the factory.
Return Policy