Dorner 2100 Series Manual instruction

851-292 Rev. B
Setup, Operation
& Maintenance Manual
2100 & 6100 Series
Center Mount Drive Package
for Standard & Heavy Load 60 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 8. . . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 8. . . . . . . . . . . .
Gear Reducer Replacement 8. . . . . . . . . . . . . . . . . . .
Motor Replacement 10. . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100 & 6100 Series Center Mount Drive Package for Standard & Heavy Load 60Hz Gearmotors SOMM
851-292 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
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 without
guards.
Upon receipt of shipment:
DCompare shipment with packing slip. Contact factory
regarding discrepancies.
DInspect packages for shipping damage. Contact carrier re-
garding 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 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 & 6100 Series Center Mount Drive Package for Standard & Heavy Load 60Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-292 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
Typical Components
Figure 1
A
G
C
B
H
D
E
F
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code = US English
Output Shaft Type = 905
Gearmotor Type: S = Standard Load, H = Heavy Load
Mount Style: 1 = Type 1, Veritical Mount;
2 = Type 2, Bottom Mount
Conveyor Width Reference*
Mount Position = A or D
(see detail to the right)
D
A
2M 1 H S WW A 32 32
2 = 2100 Series Conveyor
6 = 6100 Series Conveyor
Drive Pulley (see Tables 2, 3 & 4)
Driven Pulley (see Tables 2, 3 & 4)
* See “Ordering and Specifications”Catalog for details.
Table 1: Gearmotor Specifications
Standard Load Gearmotor Heavy Load Gearmotor
Item Single-
Phase Three Phase DC Variable Speed Single- Phase Three Phase VFD Variable Speed DC Variable Speed
Output Power 0.25 hp (0.19 kw) 0.5 hp (0.37 kw)
Input Voltage 115VAC 208 – 230/460
VAC 130VDC 115VAC 208 – 230/460 VAC 230 VAC 90VDC
Input Frequency 60Hz N/A 60Hz 10 – 60Hz N/A
Input Current
(Amperes) 5.0 1.2/0.6 2.2 7.4 2.1 – 2/1 1.6 5.0
Gearmotor Ratios 5:1, 10:1, 20:1, 40:1, 60:1 5:1, 10:1, 20:1, 40:1, 60:1
Frame Size NEMA 42CZ NEMA 56C
Motor Type Totally enclosed, Fan cooled Totally enclosed, Fan cooled
Product Description

2100 & 6100 Series Center Mount Drive Package for Standard & Heavy Load 60Hz Gearmotors SOMM
851-292 Rev. B 4Dorner Mfg. Corp.
Table 1: Belt Speeds for Standard & Heavy Load Fixed Speed 90560 Hz Gearmotors
Standard Load Gearmotors Heavy Load Gearmotors Belt Speed Drive DrivenDrive Driven
Part Number RPM In-lb N-m Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
32M060HL4(vp)F(n) 29 226 25.5 32M060HS4(vp)F(n) 29 226 25.5 6 1.8 19 32
32M060HL4(vp)F(n) 29 226 25.5 32M060HS4(vp)F(n) 29 226 25.5 10 3.0 32 32
32M040HL4(vp)F(n) 43 237 26.8 32M040HS4(vp)F(n) 43 247 27.9 15 4.6 32 32
32M040HL4(vp)F(n) 43 237 26.8 32M040HS4(vp)F(n) 43 247 27.9 23 7.0 48 32
32M020HL4(vp)F(n) 86 142 16 32M020HS4(vp)F(n) 86 248 27.9 30 9.1 32 32
32M020HL4(vp)F(n) 86 142 16 32M020HS4(vp)F(n) 86 248 27.9 45 13.7 48 32
32M010HL4(vp)F(n) 173 78 8.8 32M010HS4(vp)F(n) 173 156 17.6 61 18.6 32 32
32M010HL4(vp)F(n) 173 78 8.8 32M010HS4(vp)F(n) 173 156 17.6 91 27.7 48 32
32M005HL4(vp)F(n) 345 41 4.6 32M005HS4(vp)F(n) 345 81 9.1 121 36.9 32 32
32M005HL4(vp)F(n) 345 41 4.6 32M005HS4(vp)F(n) 345 81 9.1 154 46.9 28 22
32M005HL4(vp)F(n) 345 41 4.6 32M005HS4(vp)F(n) 345 81 9.1 181 55.2 48 28
32M005HL4(vp)F(n) 345 41 4.6 32M005HS4(vp)F(n) 345 81 9.1 208 63.4 48 28
32M005HL4(vp)F(n) 435 41 4.6 32M005HS4(vp)F(n) 345 81 9.1 264 80.5 48 22
(vp) = voltage and phase
11 = 115 V, 1-phase
23 = 208 –230/460 V, 3-phase
Table 2: Belt Speeds for Standard & Heavy Load Variable Speed 905DC Gearmotors
Standard Load Gearmotors Heavy Load Gearmotors Belt Speed Drive DrivenDrive Driven
Part Number RPM In-lb N-m Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
32M060HLD3DEN 42 198 22.4 32M060HSD9DEN 42 198 22.4 1.0 –9 0.3 –2.6 19 32
32M060HLD3DEN 42 198 22.4 32M060HSD9DEN 42 198 22.4 1.8 –15 0.5 –4.5 32 32
32M040HLD3DEN 63 163 18.4 32M040HSD9DEN 63 215 24.3 2.6 –22 0.8 –6.7 32 32
32M020HLD3DEN 125 98 11.1 32M020HSD9DEN 125 196 22.1 5.3 –44 1.6 –13 32 32
32M010HLD3DEN 250 54 6.1 32M010HSD9DEN 250 108 12.2 10 –88 3.2 –27 32 28
32M010HLD3DEN 250 54 6.1 32M010HSD9DEN 250 108 12.2 18 –150 5.5 –46 48 32
32M005HLD3DEN 500 28 3.2 32M005HSD9DEN 500 56 6.3 21 –176 6.4 –54 32 16
32M005HLD3DEN 500 28 3.2 32M005HSD9DEN 500 56 6.3 27 –224 7.3 –61 28 22
32M005HLD3DEN 500 28 3.2 32M005HSD9DEN 500 56 6.3 31 –255 9.3 –78 32 22
Table 3: Belt Speeds for Heavy Load Variable Speed 905VFD Gearmotors
Heavy Load Gearmotors Belt Speed Drive DrivenDrive Driven
Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
32M060HS423EN 29 226 25.5 0.7 –6 0.2 –1.8 19 32
32M060HS423EN 29 226 25.5 1.2 –10 0.4 –3.1 32 32
32M040HS423EN 43 247 27.9 1.8 –15 0.6 –4.6 32 32
32M020HS423EN 86 248 27.9 3.6 –30 1.1 –9.2 32 32
32M010HS423EN 173 156 17.6 7 –61 2.2 –18 32 32
32M010HS423EN 173 156 17.6 12 –104 3.8 –32 48 28
32M005HS423EN 345 81 9.1 14 –121 4.4 –37 32 32
32M005HS423EN 345 81 9.1 23 –190 7 –58 44 28
32M005HS423EN 345 81 9.1 29 –242 9 –74 44 22
NOTE: For belt speed other than those listed, con-
tact factory for details.
SpecificationsSpecifications

2100 & 6100 Series Center Mount Drive Package for Standard & Heavy Load 60Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-292 Rev. B
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
NOTE: Type 1 mounting package shown below left
(Figure 2.) Type 2 mounting package shown below
right (Figure 2.)
Figure 2
Type 1 Type 2
NOTE: For Type 1 mounting package, the gearmo-
tor may be operated in positions 1 or 4 (Figure 3).
Figure 3
1
4
1.Gather installation components (Figure 4)
Figure 4
L
I
O
M
K
P
J
N
Installation Component List
I Mount Assembly
J Drive Pulley
K Cover
L M4 Socket Head Screws (4x)
M Driven Pulley
N Key
O M6 Socket Head Screws (3x)
P Timing Belt
NOTE: Type 1 mounting package shown (Figure 4),
Type 2 mounting package similar.
2.If required, change gearmotor position by removing
four (4) screws (Q of Figure 5). Rotate gearmotor to
other position and replace screws (Q). Tighten to
103 in-lb (12 Nm).
Figure 5
Q
Q
Installation

2100 & 6100 Series Center Mount Drive Package for Standard & Heavy Load 60Hz Gearmotors SOMM
851-292 Rev. B 6Dorner Mfg. Corp.
3.Locate drive output shaft (S of Figure 6) and remove
two (2) screws (R).
Figure 6
R
S
4.Attach mount assembly (I of Figure 7) with mount-
ing screws (O). Install long screws on bottom.
Tighten screws to 80in-lb (9 Nm.).
Figure 7
I
OO
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
5.Install key (N of Figure 8).
Figure 8
N
M
P
J
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 9), align driven
pulley (M) with drive pulley (J). Tighten driven
pulley set screws (U).
Figure 9
M
T
J
U
Installation

2100 & 6100 Series Center Mount Drive Package for Standard & Heavy Load 60Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-292 Rev. B
8.Depending on direction of conveyor belt travel ( 1 or 2
of Figure 10), position belt tensioner (V) as shown.
Tension belt to obtain .125”( 3 mm) deflection for
1.0 lb (456 grams) of force at belt mid-point (W).
Tighten tensioner screw to 103 in-lb (12 Nm).
21
Figure 10
V
W
W
9.Install cover (K of Figure 11) with four (4) screws
(L). Tighten screws to35 in-lb (4 Nm).
Figure 11
K
L
L
Preventive Maintenance and Adjustment
Required Tools
DHex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm
DAdjustable wrench (for hexagon head screws)
DStraight edge
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 11) and remove
cover (K).
2.Loosen tensioner (V of Figure 12).
Figure 12
V
3.Depending direction of conveyor belt travel (1 or 2
of Figure 10), position belt tensioner (V) as shown.
Tension belt to obtain .125”( 3 mm) deflection for
1.0 lb (456 grams) of force at belt mid-point (W).
Tighten tensioner screw to 103 in-lb (12 Nm).
4.Install cover (K of Figure 11) with four (4) screws
(L). Tighten screws to 35 in-lb (4 Nm).
Installation

2100 & 6100 Series Center Mount Drive Package for Standard & Heavy Load 60Hz Gearmotors SOMM
851-292 Rev. B 8Dorner Mfg. Corp.
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 11) and remove
cover (K).
2.Loosen tensioner (V of Figure 12).
3.Remove timing belt (P of Figure 13).
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley set screws (U of Figure
13) and remove pulley with belt (P). For
re-installation, see steps 6 and 7 on page 6.
Figure 13
P
U
4.Install new timing belt.
5.Depending direction of conveyor belt travel (1 or 2
of Figure 10), position belt tensioner (V) as shown.
Tension belt to obtain .125”( 3 mm) deflection for
1.0 lb (456 grams) of force at belt mid-point (W).
Tighten tensioner screw to 103 in-lb (12 Nm).
6.Install cover (K of Figure 11) 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 Replace-
ment”section on page 8.
2.Loosen set screws and remove drive or driven pulley.
NOTE: If drive pulley (J of Figure 14) is replaced,
wrap timing belt around drive pulley and complete
step 3.
3.Completesteps6through9of “Installation”section
on page 6.
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 (L of Figure 11) and remove
cover (K).
2.Loosen tensioner (V of Figure 12).
3.Loosen drive pulley set screws (X of Figure 14).
Remove drive pulley (J) and timing belt (P).
Figure 14
X
J
P
Preventive Maintenance and Adjustment

2100 & 6100 Series Center Mount Drive Package for Standard & Heavy Load 60Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-292 Rev. B
4.Remove four (4) gear reducer mounting screws (Q of
Figure 15). Remove gearmotor.
Figure 15
Q
Q
5.Remove four screws (Y of Figure 16). Detach motor
(Z) from gear reducer (AA). Retain motor output
shaft key (AB).
Z
AA
AC
AD
AB
AE
Y
Figure 16
6.Remove two (2) screws (AC) and detach output shaft
cover (AD).
7.Loosen six (6) set screws (AF of Figure 17). Remove
drive shaft (AG) and key (AH).
8.Remove gear reducer output shaft key (AE).
Figure 17
AF AG
AH
9.Apply grease (AI of Figure 18) to shaft.
Figure 18
AI
10.Replace the original shaft (AG of Figure 17) and key
(AH) into new gear reducer. Tighten set screws (AF)
to 26 in-lb (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 16) in keyway, slide motor
(Z) and gear reducer (AA) together. Install screws
(Y) and tighten.
12.Install gearmotor to mounting bracket and tighten
screws (Q of Figure 15) to 103 in-lb (12 Nm).
NOTE: Drive pulley (J of Figure 14) is removed.
Wrap timing belt around drive pulley and complete
step 13.
13.Completesteps6through9of “Installation”section
on page 6.
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

2100 & 6100 Series Center Mount Drive Package for Standard & Heavy Load 60Hz Gearmotors SOMM
851-292 Rev. B 10 Dorner Mfg. Corp.
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.
LOCK OUT POWER
BEFORE WIRING.
DANGER
1.For single phase motor, unplug power cord from
outlet.
2.For three phase motor:
a.Loosen terminal box screws (AJ of Figure 19) and
remove cover (AK).
Figure 19
AJ
AK
b.Record wire colors on terminals 1, 2 and 3.
Loosen wire nuts and remove wires 1, 2 and 3.
c.Loosen cord grip and remove cord.
3.For DC variable speed motor, unplug motor cord at
disconnect (AL of Figure 20).
Figure 20
AL
4.Remove four screws (Y of Figure 21). Detach motor
(Z) from gear reducer (AA). Retain motor output
shaft key (AB).
Figure 21
Z
Y
AA
AB
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 (AB of Figure 22) in keyway, slide motor
and gear reducer together. Install screws (Y) and
tighten.
Figure 22
AB
Y
6.Replace wiring:
DFor a single phase motor, reverse step 1 on this page.
DFor a three phase motor, reverse step 2, on this page.
DFor a DC variable speed motor, reverse step 3 on this
page.
Preventive Maintenance and Adjustment