Dorner 2100 Series Manual instruction

851-261 Rev. E
Set-up, Operation
& Maintenance Manual
2100, 4100, 6100 Series
Top Mount Drive Package
for Light Load 60 Hz Gearmotors
Table of Contents
Warnings – General Safety 2. . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 6. . . . . . . . .
Required Tools 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 6. . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 6. . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 7. . . . . . . . . . .
Gearmotor Replacement 7. . . . . . . . . . . . . . . . . . . .
Service Parts 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 60 Hz Gearmotors SOMM
851-261 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
Hazardous voltage will
cause severe injury or
death.
LOCK OUT POWER
BEFORE WIRING.
DANGER
Ç
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
WARNING
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Ç
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
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 Light Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-261 Rev. E
Refer to Figure 1 for typical components.
A Conveyor
B Mounting Bracket
C Gearmotor
D Belt Tensioner
E Cover
F Timing Belt
G Drive Pulley
H Driven Pulley
Typical Components
Figure 1
CB
E
D
F
H
G
A
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code = U.S. English
Output Shaft Type = Parallel Shaft
Gearmotor Type: L = Fixed Speed,
V = Variable Speed
Mount Style = Top Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
2M T P L 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 Tables 2 & 3)
Driven Pulley (see Tables 2 & 3)
* See “Ordering and Specifications”Catalog for details.
Table 1: Gearmotor Specifications
Single Phase DC Variable Speed
Output Power 0.03 hp (0.025 kw) 0.06 hp (0.04 kw)
Input Voltage 115 Volts A.C. 130 Volts D.C.
Input Frequency 60 Hz N/A
Full Load Amperes 0.49 Amperes 0.48 Amperes
Gearmotor Ratios 15:1 and 36:1 18:1 and 60:1
Product Description

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 60 Hz Gearmotors SOMM
851-261 Rev. E 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Light Load Fixed Speed Parallel Shaft 60 Hz Gearmotors
Gearmotors Belt Speed Drive Driven
Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
62M036PL411FN 42 36 4.1 7 2.1 19 32
62M036PL411FN 42 36 4.1 12 3.7 32 32
62M036PL411FN 42 36 4.1 17 5.2 32 22
62M036PL411FN 42 36 4.1 24 7.3 44 22
62M015PL411FN 100 15 1.7 29 8.8 32 32
62M015PL411FN 100 15 1.7 41 12.5 32 22
Table 3: Belt Speeds for Light Load Variable Speed Parallel Shaft DC Gearmotors
Gearmotors Belt Speed Drive Driven
Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
62M060PLD3DEN 42 65 7.4 0.8 – 7 0.3 – 2.2 19 32
62M060PLD3DEN 42 65 7.4 1.4 – 12 0.4 – 3.6 32 32
62M018PLD3DEN 139 21 2.4 4.8 – 40 1.5 – 12 32 32
62M018PLD3DEN 139 21 2.4 7–58 2.1 – 18 32 32
NOTE: 8–24 in (203 –610 mm) wide conveyors
with light load drives should be limited to 96 in
(2438 mm) length.
NOTE: For belt speed other than those listed, con-
tact factory for details.
Installation
Required Tools
DHex key wrenches:
2.5 mm, 3 mm, 5 mm
DStraight edge
DTorque wrench
Installation Component List
I Top Mount Assembly
J Driven Pulley
K Cover
L M4 Socket Head Screws (4x)
M Timing Belt
N Key
O M6 Socket Head Screws (2x)
Mounting
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
1.Typical components (Figure 2)
Figure 2
K
L
M
I
J
O
N
NOTE: 6100 conveyor shown, 2100 & 4100 similar.
2.Locate drive output shaft (P of Figure 3) and remove
two (2) screws (Q).
SpecificationsSpecifications

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-261 Rev. E
Figure 3
Q
P
3.Attach mount assembly (I of Figure 4) with screws
(O). Tighten screws to 80 in-lb (9 Nm).
Figure 4
I
O
Ç
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
4.Install key (N of Figure 5).
Figure 5
N
R
J
M
5.Wrap timing belt (M) around driven pulley (J) and
drive pulley (R). Install driven pulley (J) onto
conveyor shaft.
6.Using a straight edge (S of Figure 6), align driven
pulley (J) with drive pulley (R). Tighten driven
pulley set screws (T).
Figure 6
S
R
J
T
7.Depending on direction of conveyor belt travel (1 or 2
of Figure 7), position timing belt tensioner (U) as
shown. Tension timing belt to obtain 1/8”(3 mm)
deflection for 1 lb (456 grams) of force at timing belt
mid-point (V). Tighten tensioner screw to 106 in-lb
(12 Nm).
V
V
Figure 7
1
2
U
U
8.Install cover (K of Figure 8) with four (4) screws (L).
Tighten to 35 in-lb (4 Nm).
Figure 8
L
K
L
Installation

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 60 Hz Gearmotors SOMM
851-261 Rev. E 6Dorner Mfg. Corp.
Required Tools
DHex key wrenches:
2.5 mm, 3 mm, 5 mm
DStraight edge
DScrewdriver (for terminal box screws)
DTorque wrench
Timing Belt Tensioning
Ç
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 9) and remove
cover (K).
Figure 9
L
K
L
2.Loosen tensioner (U of Figure 10).
Figure 10
U
3.Depending on direction of conveyor belt travel (1 or 2
of Figure 11), position timing belt tensioner (U) as
shown. Tension timing belt to obtain 1/8”(3 mm)
deflection for 1 lb (456) grams of force at timing belt
mid-point (V). Tighten tensioner screw to 106 in-lb
(12 Nm).
Figure 11
1
2
V
V
U
U
4.Install cover (K of Figure 9) with four (4) screws (L).
Tighten screws to 35 in-lb (4 Nm).
Timing Belt Replacement
Ç
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 9) and remove
cover (K).
2.Loosen tensioner (U of Figure 10).
3.Remove timing belt (M of Figure 12).
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley set screws (T of Figure
12) and remove pulley with belt. For re-installation,
see steps 5 through 8 on page 5.
Figure 12
R
J
M
T
4.Install new timing belt.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-261 Rev. E
5.Depending on direction of conveyor belt travel (1 or
2 of Figure 11), position timing belt tensioner (U) as
shown. Tension timing belt to obtain 1/8”(3 mm)
deflection for 1 lb (456 grams) of force at timing belt
mid-point (V). Tighten tensioner screw to 106 in-lb
(12 Nm).
6.Install cover (K of Figure 9) with four (4) screws (L).
Tighten screws to 35 in-lb (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 page 6.
2.Loosen set screws and remove drive or driven pulley.
NOTE: If drive pulley (R of Figure 13) is replaced,
wrap timing belt around drive pulley and complete
step 3.
Figure 13
R
J
M
T
3.Completesteps5through8of“Installation”section
on page 5.
Gearmotor 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.
LOCK OUT POWER
BEFORE WIRING.
DANGER
1.For single phase motor, unplug power cord from
outlet.
2.For DC variable speed motor, unplug motor cord at
disconnect (W of Figure 14).
Figure 14
W
3.Remove four (4) screws (L of Figure 9) and remove
cover (K).
4.Loosen tensioner (U of Figure 10).
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 60 Hz Gearmotors SOMM
851-261 Rev. E 8Dorner Mfg. Corp.
5.Remove timing belt (M of Figure 15).
Figure 15
M
T
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley set screws (T of Figure
15) and remove pulley with belt (M). For
re-installation, see steps 5 through 8 on page 5.
6.Loosen two (2) set screws (T of Figure 16). Remove
drive pulley (R).
Figure 16
R
T
7.Remove four (4) screws (X) and detach gearmotor.
Figure 17
X
8.Mount new gearmotor with four (4) screws (X).
Tighten to 45 in-lb (5 Nm).
9.Replace drive pulley (R of Figure 16) and tighten set
screws (T).
10.Completesteps5through8of“Installation”section
on page 5.
11.Replace wiring:
DFor a single phase motor, reverse step 1 on page 7.
DFor DC variable speed motor, reverse step 2 on
page 7.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-261 Rev. E
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
162M036PL411FN Gearmotor, 0.03 hp, 115 Volts,
42 RPM, 60 Hz, 1-Phase, 36:1
62M015PL411FN Gearmotor, 0.03 hp, 115 Volts,
100 RPM, 60 Hz, 1-Phase, 15:1
62M060PLD3DEN Gearmotor, 0.06 hp, 130 Volts,
42 RPM, DC, 60:1
62M018PLD3DEN Gearmotor, 0.06 hp, 130 Volts,
139 RPM, DC, 18:1
2 814-107 Timing Belt, 15mm W x 360mm L 2814-103 Timing Belt, 15mm W x 385mm L
814-100 Timing Belt, 15mm W x 400mm L
814-096 Timing Belt, 15mm W x 425mm L
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
814-101 Timing Belt, 15mm W x 500mm L
814-064 Timing Belt, 15mm W x 535mm L
3 450383MP Drive Pulley, 19 Tooth, 10mm Bore
3450384MP Drive Pulley, 22 Tooth, 10mm Bore
450385MP Drive Pulley, 28 Tooth, 10mm Bore
450386MP Drive Pulley, 32 Tooth, 10mm Bore
450387MP Drive Pulley, 44 Tooth, 10mm Bore
450365P Drive Pulley, 19 Tooth, 0.5”Bore
450366P Drive Pulley, 22 Tooth, 0.5”Bore
450367P Drive Pulley, 28 Tooth, 0.5”Bore
450368P Drive Pulley, 32 Tooth, 0.5”Bore
450369P Drive Pulley, 44 Tooth, 0.5”Bore
4 980422M Key, 4mm x 22mm, 10mm Bore 4912–052 Key, 1/8”x 5/8”, 1/2”Bore
5 450365MP Driven Pulley, 19 Tooth
5450366MP Driven Pulley, 22 Tooth
450367MP Driven Pulley, 28 Tooth
450368MP Driven Pulley, 32 Tooth
6 980422M Key, 4mm x 22mm
Figure 18
1
2
3 4
5 6
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 at
www.dorner.com
851-261 Rev. E Printed in U.S.A. 400
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