Dorner 2100 Series Manual instruction

851-295 Rev. A
Set-up, Operation
& Maintenance Manual
2100, 4100, 6100 Series
Top 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 7. . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 7. . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 7. . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 7. . . . . . . . . . .
Gear Reducer Replacement 8. . . . . . . . . . . . . . . . . .
Motor Replacement 9. . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
851-295 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
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 with-
out 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 Top Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-295 Rev. A
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
Typical Components
Figure 1
H
A
E
C
G
B
D
F
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code = CE English
Output Shaft Type = 905
Gearmotor Type = Standard Load
Mount Style = Top Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
2U T H S WW A–32 32
2 = 2100 Series Conveyor
4 = 4100 Series Conveyor
6 = 6100 Series Conveyor
Belt Type ( –= flat belt, A through J = cleated belt )
Drive Pulley (see Table 2 & 3)
Driven Pulley (see Table 2 & 3)
* 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 Top Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
851-295 Rev. A 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Standard Load Fixed Speed 90550 Hz Gearmotors
Gearmotors Belt Speed Drive DrivenDrive
Pulley Driven Pulley
Part Number RPM N-m M/min Pulley Pulley
62Z060HS4(vp)FN 23 26.4 1.2 19 32
62Z060HS4(vp)FN 23 26.4 2.1 32 32
62Z040HS4(vp)FN 35 28.9 3.0 32 32
62Z040HS4(vp)FN 35 28.9 4.6 48 32
62Z020HS4(vp)FN 70 19.4 6.1 32 32
62Z020HS4(vp)FN 70 19.4 9.1 48 32
62Z010HS4(vp)FN 140 10.7 12.2 32 32
62Z010HS4(vp)FN 140 10.7 18.3 48 32
62Z005HS4(vp)FN 280 5.6 24.4 32 32
62Z005HS4(vp)FN 280 5.6 36.6 48 32
62Z005HS4(vp)FN 280 5.6 45.7 60 32
62Z005HS4(vp)FN 280 5.6 61.6 48 19
62Z005HS4(vp)FN 280 5.6 76.8 60 19
(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 Belt Speed Drive DrivenDrive
Pulley Driven Pulley
Part Number RPM N-m M/min Pulley Pulley
62Z060HS423EN 23 26.4 0.6–1.5 19 32
62Z060HS423EN 23 26.4 1.0–2.6 32 32
62Z040HS423EN 35 28.9 1.5–3.8 32 32
62Z020HS423EN 70 19.4 3.0–7.7 32 32
62Z010HS423EN 140 10.7 6.1–15 32 32
62Z005HS423EN 280 5.6 1.2–30 32 32
62Z005HS423EN 280 5.6 23–57 60 32
62Z005HS423EN 280 5.6 31–78 48 19
NOTE: For belt speed other than those listed, con-
tact factory for details.
Specifications

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-295 Rev. A
Required Tools
DHex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm
DStraight edge
DTorque wrench
Mounting
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Installation Component List
I Top Mount Assembly
J Drive Pulley
K Cover
L M4 Socket Head Screws (4x)
M Driven Pulley
N Key
O M6 Socket Head Screws (2x)
P Timing Belt
1.Typical components (Figure 2)
Figure 2
M N O
P
I
J
K
L
NOTE: Gearmotor may be operated in positions 1,
2 or 3 (Figure 3). Operating in position 2 may require
additional support. Contact factory for details.
Figure 3
1
2
3
2.If required, change gearmotor position by removing
four (4) screws (Q of Figure 4). Rotate gearmotor to
other position and replace screws (Q). Tighten to
12 Nm.
Figure 4
Q
Q
NOTE: 6100 conveyor shown, 2100 & 4100 similar.
3.Locate drive output shaft (R of Figure 5) and remove
two (2) screws (S).
Figure 5
R
S
Installation

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
851-295 Rev. A 6Dorner Mfg. Corp.
4.Attach mount assembly (I of Figure 6) with screws
(O). Tighten screws to 9 Nm.
Figure 6
I
O
ÇÇ
ÇÇ
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
5.Install key (N of Figure 7).
Figure 7
NM
J
P
6.Wrap timing belt (P) around driven pulley (M) and
drive pulley (J). Install driven pulley (M) onto
conveyor shaft.
7.Using a straight edge (T of Figure 8), align driven
pulley (M) with drive pulley (J). Tighten driven
pulley set screws (U).
Figure 8
T
U
M
J
8.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (V of Figure 9) as shown.
Tension timing belt to obtain 3 mm deflection for 456
grams of force at timing belt mid-point (W). Tighten
tensioner screw to 12 Nm.
Figure 9
1
2
W
WV
V
9.Install cover (K of Figure 10) with four (4) screws
(L). Tighten screws to 4 Nm.
Figure 10
K
L
L
Installation

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-295 Rev. A
Required Tools
DHex key wrenches
–2 mm, 2.5 mm, 3 mm & 5 mm
DAdjustable wrench (for hexagon head screws)
DStraight edge
DExternal snap ring pliers
DTorque wrench
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 (L of Figure 10) and remove
cover (K).
2.Loosen tensioner (V of Figure 11).
Figure 11
V
3.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (V of Figure 9) as shown.
Tension timing belt to obtain 3 mm deflection for
456 grams of force at timing belt mid-point (W).
Tighten tensioner screw to 12 Nm.
4.Install cover (K of Figure 10) with four (4) screws
(L). Tighten screws to 4 Nm.
Timing Belt Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Remove four (4) screws (L of Figure 10) and remove
cover (K).
2.Loosen tensioner (V of Figure 11).
3.Remove timing belt (P of Figure 12).
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley set screws (U of Figure
12) and remove pulley with belt (P). For
re-installation, see steps 6 and 7 on page 6.
Figure 12
U
P
4.Install new timing belt.
5.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (V of Figure 9) as shown.
Tension timing belt to obtain 3 mm deflection for
456 grams of force at timing belt mid-point (W).
Tighten tensioner screw to 12 Nm.
6.Install cover (K of Figure 10) with four (4) screws
(L). Tighten screws to 4 Nm.
Drive or Driven Pulley Replacement
Ç
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 this page.
2.Loosen set screws and remove drive or driven pulley.
NOTE: If drive pulley (J of Figure 13) is replaced,
wrap timing belt around drive pulley and complete
step 3.
3.Completesteps6through9of“Installation”section
on page 6.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
851-295 Rev. A 8Dorner Mfg. Corp.
Gear Reducer Replacement
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Remove four (4) screws (L of Figure 10) and remove
cover (K).
2.Loosen tensioner (V of Figure 11).
3.Loosen drive pulley set screws (X of Figure 13).
Remove drive pulley (J) and timing belt (P).
Figure 13
XJ
P
4.Remove four (4) gear reducer mounting screws (Q
of Figure 14). Remove gearmotor.
Figure 14
Q
5.Remove four screws (Y of Figure 15). Detach motor
with adapter flange (Z) from gear reducer (AA).
Retain motor output shaft key (AB).
Figure 15
AC
AD Y
Z
AE
AB
AA
6.Remove two (2) screws (AC) and detach output shaft
cover (AD).
7.Remove gear reducer output shaft key (AE).
8.Loosen six (6) set screws (AF of Figure 16). Remove
drive shaft (AG) and key (AH).
Figure 16
AF AG
AH
9.Apply grease (AI of Figure 17) to shaft.
Figure 17
AI
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-295 Rev. A
10.Replace the original shaft (AG of Figure 16) and key
(AH) into new gear reducer. Tighten set screws (AF)
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.
11.With key (AB of Figure 15) in keyway, slide motor
with adapter flange (Z) and gear reducer (AA)
together. Install screws (Y) and tighten.
12.Install gearmotor to mounting bracket and tighten
screws (Q of Figure 14) to 12 Nm.
NOTE: Drive pulley (J of Figure 13) is removed.
Wrap timing belt around drive pulley and complete
step 13.
13.Completesteps6through9of“Installation”section
on page 6.
Motor Replacement
Ç
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.
LOCK OUT POWER
BEFORE WIRING.
DANGER
1.For single phase motor:
a.Loosen terminal box screws (AJ of Figure 18) and
remove cover (AK).
Figure 18
AJ
AK
b.Record wire colors on terminals 2, 6 and ground
()(Figure 19). Loosen terminals 2, 6 and ground
and remove wires.
321657 12119
Figure 19
AL
c.Loosen cord grip (AL of Figure 19) and remove
cord.
2.For three phase and VFD variable speed motor:
a.Loosen terminal box screws (AJ of Figure 18) and
remove cover (AK).
b.Record wire colors on terminals U1, V1, W1 & PE
(Figure 20). Loosen terminals U1, V1, W1 & PE
and remove wires.
Figure 20
AL
c.Loosen cord grip (AL of Figure 20) and remove
cord.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Standard Load 50 Hz Gearmotors SOMM
851-295 Rev. A 10 Dorner Mfg. Corp.
3.Remove four (4) screws (Y of Figure 21). Detach
motor (Z) with adapter flange from gear reducer
(AA). Retain motor output shaft key (AB).
Figure 21
AA
ZY
AB
4.Remove four (4) screws and nuts (AM of Figure 22).
Remove adapter flange (AN).
Figure 22
AN
AM
5.Install adapter flange (AN) on new motor. Install
screws and nuts (AM) 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 (AB of Figure 23) in keyway, slide motor
with adapter flange (Z) and gear reducer together.
Install screws (Y) and tighten.
Figure 23
ZAB Y
7.Replace wiring:
DFor a single phase motor, reverse step 1 on page 9.
DFor a three phase or VFD variable speed motor, re-
verse step 2 on page 9.
Preventive Maintenance and Adjustment