Dorner 2100 Series Manual instruction

851-279 Rev. D
Set-up, Operation
& Maintenance Manual
2100, 4100, 6100 Series
Bottom Mount Drive Package
for Heavy Load 90_Industrial 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 8. . . . . . . . .
Required Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 8. . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 8. . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 9. . . . . . . . . . .
Gear Reducer Replacement 9. . . . . . . . . . . . . . . . . .
Service Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
851-279 Rev. D 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
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 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 Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-279 Rev. D
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
B
C
D
E
H
F
G
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code = U.S. English
Output Shaft Type = 905Industrial
Gearmotor Type = Heavy Load, Industrial
Mount Style = Bottom Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
2 = 2100 Series Conveyor
4 = 4100 Series Conveyor
6 = 6100 Series Conveyor
Drive Pulley (see Tables 2, 3 & 4)
Driven Pulley (see Tables 2, 3 & 4)
Belt Type ( –= flat belt, A through J = cleated belt )
2M B H H WW A–32 32
* See “Ordering and Specifications”Catalog for details.
Table 1: Gearmotor Specifications
Single Phase Three Phase DC Variable Speed VFD Variable Speed
Output Power 0.50 hp (0.37 kw)
Input Voltage 115 VAC 208– 230 / 460 VAC 90 VDC 230 VAC
Input Frequency 60 Hz N/A 10 – 60 Hz
Input Current 7.4 Amperes 2.1 – 2/ 1 Amperes 5.0 Amperes 1.6 Amperes
Motor RPM 1725 2500 1725
Gearmotor Ratios 5:1, 10:1, 20:1, 40:1, 60:1
Frame Size NEMA 56C
Motor Type Totally enclosed, Fan-cooled
Product Description

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
851-279 Rev. D 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Heavy Load Fixed Speed 90560 Hz Gearmotors
Gearmotors Belt Speed Drive DrivenDrive Driven
Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
32M060HS4(vp)FN 29 226 25.5 5 1.5 19 32
32M060HS4(vp)FN 29 226 25.5 8 2.4 32 32
32M040HS4(vp)FN 43 247 27.9 12 3.7 32 32
32M040HS4(vp)FN 43 247 27.9 18 5.5 48 32
32M020HS4(vp)FN 86 248 27.9 25 7.6 32 32
32M020HS4(vp)FN 86 248 27.9 37 11.3 48 32
32M010HS4(vp)FN 173 156 17.6 49 14.9 32 32
32M010HS4(vp)FN 173 156 17.6 74 22.6 48 32
32M005HS4(vp)FN 345 81 9.1 99 30.3 32 32
32M005HS4(vp)FN 345 81 9.1 145 45.1 48 32
32M005HS4(vp)FN 345 81 9.1 169 51.5 48 28
32M005HS4(vp)FN 345 81 9.1 197 60 44 22
32M005HS4(vp)FN 345 81 9.1 215 65 48 22
32M005HS4(vp)FN 345 81 9.1 249 76 48 19
(vp) = voltage and phase (n) = reversing capability
11 = 115 V, 1-phase N = no reversing switch
23 = 208–230/460 V, 3-phase R = with reversing switch
(115V, 1 phase only)
Table 3: Belt Speeds for Heavy Load Variable Speed 905DC Gearmotors
Gearmotors Belt Speed Drive DrivenDrive Driven
Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
32M060HSD9DEN 42 198 22.4 0.8 –7.0 0.3 –2.2 19 32
32M060HSD9DEN 42 198 22.4 1.4 –12 0.4 –3.6 32 32
32M040HSD9DEN 63 215 24.3 2.1 –18 0.7 –5.4 32 32
32M020HSD9DEN 125 196 22.1 4.3 –36 1.3 –11 32 32
32M010HSD9DEN 250 108 12.2 9.0 –71 2.6 –22 32 32
32M005HSD9DEN 500 56 6.3 17 –143 5.2 –43 32 32
32M005HSD9DEN 500 56 6.3 26 –214 7.8 –65 48 32
32M005HSD9DEN 500 56 6.3 29 –245 9.0 –75 48 28
Table 4: Belt Speeds for Heavy Load Variable Speed 905VFD Gearmotors
Gearmotors Belt Speed Drive DrivenDrive Driven
Part Number RPM In-lb N-m Ft/min M/min Pulley Pulley
32M060HS423EN 29 226 25.5 0.5 –5.0 0.1 –1.5 19 32
32M060HS423EN 29 226 25.5 0.8 –8.2 0.3 –2.5 32 32
32M040HS423EN 43 247 27.9 1.2 –12 0.4 –3.8 32 32
32M020HS423EN 86 248 27.9 2.5 –25 0.8 –7.5 32 32
32M010HS423EN 173 156 17.6 4.9 –49 1.5 –15 32 32
32M005HS423EN 345 81 9.1 9.9 –99 3.0 –30 32 32
32M005HS423EN 345 81 9.1 14 –148 4.5 –45 48 32
32M005HS423EN 345 81 9.1 19 –197 6.0 –60 44 22
32M005HS423EN 345 81 9.1 24 –249 7.6 –76 48 19
NOTE: For belt speed other than those listed,
contact factory for details.
Specifications

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-279 Rev. D
Required Tools
DHex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm
DStraight edge
DTorque wrench
Mounting
Ç
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Installation Component List
I Bottom Mount Assembly
J Drive Pulley
K Cover
L M4 Socket Head Screws (4x)
M Driven Pulley
N Key
O Timing Belt
P M6 Socket Head Screws (2x)
Q M6 Socket–Head Screws & Washers (4x)
R End Support Bracket
S Hex Support Posts (2x)
T Conveyor/Gearhead Support Plate
U Support Plate Spacer
V M6 Socket Head Screws (2x)
W M6 Socket Head Screws (2x)
1.Typical components (Figure 2)
Figure 2
O
I
M
P
J
K
L
N
Q
R
TU
W
S
V
Q
NOTE: 2100 and 6100 2”& 3”(44mm & 70mm) and
4100 1”through 6”(25mm –52mm) conveyors do
not include parts R through W of Figure 2.
NOTE: Gearmotor may be operated in positions
1 & 3 (Figure 3).
Figure 3
13
2.If required, change gearmotor position by removing
four (4) screws (X of Figure 4) from bottom mount
assembly and two (2) screws (Y of Figure 5) from gear
reducer support. Rotate gearmotor to other position and
replace screws. Tighten to 103 in-lb (12 Nm).
Figure 4
X
X
Figure 5
Y
Installation

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
851-279 Rev. D 6Dorner Mfg. Corp.
NOTE: 6100 conveyor shown, 2100 & 4100 similar.
3.Locate drive output shaft (Z of Figure 6) and remove
two (2) screws (AA).
Figure 6
AA
Z
For 2100 and 6100 2”&3”and 4100
1”through 6”wide conveyors
4a. Attach mounting assembly (I of Figure 7) with
screws (P). Tighten to 80 in-lb (9 Nm). Proceed to
step 8.
Figure 7
I
P
For 2100 and 6100 4”-and-wider and 4100
8”-and-wider conveyors
4b.4On side opposite drive output shaft, remove original
factory–installed screws (AB of Figure 8).
Figure 8
AB
5b.5Attach mounting assembly (I of Figure 7) with
screws (O). Tighten to 80 in-lb (9 Nm).
6b.6Install hex support posts (S of Figure 9). Tighten
posts to 80 in-lb (9 Nm).
Figure 9
S
7b.7Install spacer (U of Figure 10) and support plate
(T) with screws (V). Install support bracket (R)
with screws (W). Tighten screws (V & W) to 80
in-lb (9 Nm). Proceed to step 8.
Figure 10
U
R
T
V
W
Installation

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-279 Rev. D
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
8.Install key (N of Figure 11).
Figure 11
N
O
J
M
9.Wrap timing belt (O) around driven pulley (M) and
drive pulley (J). Install driven pulley (M) onto
conveyor shaft.
10.Using a straight edge (AC of Figure 12), align driven
pulley (M) with drive pulley (J). Tighten driven
pulley set screws (AD).
Figure 12
AD
M
AC
J
11.Depending on direction of conveyor belt travel (1 or 2
of Figure 13), position belt tensioner (AE) as shown.
Tension belt to obtain 0.125¨(3 mm) deflection for 1.0
lb (456 grams) of force at belt mid-point (AF). Tighten
tensioner screw to 103 in-lb (12 Nm).
1
AF
AF
Figure 13
2
AE
12.Install cover (K of Figure 14) with four (4) screws
(L). Tighten to 35 in-lb (4 Nm).
Figure 14
K
L
13.Mount assembly to support structure with four (4)
screws (Q of Figure 15). Tighten to 80 in-lb (9 Nm).
Figure 15
Q
Installation

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
851-279 Rev. D 8Dorner Mfg. Corp.
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 14) and remove
cover (K).
2.Loosen tensioner (AE of Figure 16).
Figure 16
AE
O
3.Depending on direction of conveyor belt travel (1 or
2 of Figure 13), position belt tensioner (AE) as
shown. Tension belt to obtain 0.125¨(3 mm) deflection
for 1.0 lb (456 grams) of force at belt mid-point (AF).
Tighten tensioner screw to 103 in-lb (12 Nm).
4.Install cover (K of Figure 14) with four (4) screws
(L). Tighten to 35 in-lb (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 14) and remove
cover (K).
2.Loosen tensioner (AE of Figure 16).
3.Remove timing belt (O of Figure 17).
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley set screws (AG of Figure
17) and remove pulley with belt (O). For
re-installation, see steps 9 and 10 on page 7.
Figure 17
AG
O
4.Install new timing belt.
5.Depending on direction of conveyor belt travel (1 or
2 of Figure 13), position belt tensioner (AE) as
shown. Tension belt to obtain 0.125¨(3 mm) deflection
for 1.0 lb (456 grams) of force at belt mid-point (AF).
Tighten tensioner screw to 103 in-lb (12 Nm).
6.Install cover (K of Figure 14) with four (4) screws
(L). Tighten to 35 in-lb (4 Nm).
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-279 Rev. D
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 8.
2.Loosen set screws and remove drive or driven pulley.
NOTE: If drive pulley (J of Figure 18) is replaced,
wrap timing belt around drive pulley and complete
step 3.
3.Complete steps 9 through 12 of “Installation”
section on page 7.
Gear Reducer 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 14) and remove
cover (K).
2.Loosen tensioner (AE of Figure 16).
3.Loosen drive pulley set screws (AG of Figure 18).
Remove drive pulley (J) and timing belt (O).
Figure 18
O
J
AG
4.Remove screws (V & W of Figure 19) and remove
support bracket (R), support plate (T) and
spacer (U).
Figure 19
U
R
T
V
W
5.Remove hex support posts (S of Figure 20).
Figure 20
S
6.Remove two (2) bracket screws (AH of Figure 21)
and remove bracket (AI).
Figure 21
AI
AH
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
851-279 Rev. D 10 Dorner Mfg. Corp.
7.Remove four (4) gear reducer mounting screws (AJ
of Figure 22). Remove gearmotor.
Figure 22
AJ
8.Remove four screws (AK of Figure 23). Detach
motor (AL) from gear reducer (AM). Retain motor
output shaft key (AN).
Figure 23
AL
AM
AP
AO
AK
AK
AQ
AN
9.Remove two (2) screws (AO) and detach output
shaft cover (AP).
10.Remove gear reducer output shaft key (AQ).
11.Loosen six (6) set screws (AR of Figure 24). Remove
drive shaft (AS) and key (AT).
Figure 24
AR AS
AT
12.Apply grease (AU of Figure 25) to shaft.
Figure 25
AU
13.Replace the original shaft components into new gear
reducer (see Figure 24). Tighten set screws (AR) 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.
14.With key (AN of Figure 23) in keyway, slide motor
(AL) and gear reducer (AM) together. Install screws
(AK) and tighten.
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 11 851-279 Rev. D
15.Reverse steps 4 through 7 beginning on page 9.
NOTE: Drive pulley (J of Figure 18) is removed.
Wrap timing belt around drive pulley and complete
step 16.
16.Complete steps 9 through 13 of “Installation”
section on page 7.
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.
LOCKOUT POWER BEFORE
before wiring.
DANGER
1.For single phase motor, unplug power cord from
outlet.
2.For three phase and VFD variable speed motor:
a. Loosen terminal box screws (AV of Figure 26) and
remove cover (AW).
Figure 26
AV
AW
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 (AX of Figure 27).
Figure 27
AX
4.Remove four screws (AK of Figure 28). Detach
motor (AL) from gear reducer (AM). Retain motor
output shaft key (AN).
Figure 28
AL
AK
AM
AN
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 (AN of Figure 29) in keyway, slide motor
and gear reducer together. Install screws (AK) and
tighten.
Figure 29
AN
AK
6.Replace wiring:
DFor a single phase motor, reverse step 1 on this page.
DFor a three phase and VFD variable speed motor, re-
verse step 2, on this page.
DFor a DC variable speed motor, reverse step 3 on this
page.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
851-279 Rev. D 12 Dorner Mfg. Corp.
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
1 826-017 Motor, 0.5 hp (0.37 Kw) 115/230 Volts,
60 Hz, 1-Phase
826-025 Motor, 0.5 hp (0.37 Kw)
208–230/460 Volts, 60 Hz, 3-Phase
826-333 Motor, 0.5 hp (0.37 Kw) 90 Volts DC
826-249 Motor, 0.5 hp (0.37 Kw) 230V, 10–60Hz,
Inverter Duty, 3 Phase
2 32M005HS Gear Reducer, 5:1, 56C
32M010HS Gear Reducer, 10:1, 56C
32M020HS Gear Reducer, 20:1, 56C
32M040HS Gear Reducer, 40:1, 56C
32M060HS Gear Reducer, 60:1, 56C
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
4 802-046 Tensioner Bearing
5 450365MP Driven Pulley, 19Tooth
450366MP Driven Pulley, 22Tooth
450367MP Driven Pulley, 28Tooth
450368MP Driven Pulley, 32Tooth
6 980422M Square Key, 4 mm x 22 mm (2x)
7 450365MP Drive Pulley, 19Tooth
450366MP Drive Pulley, 22Tooth
450367MP Drive Pulley, 28Tooth
450368MP Drive Pulley, 32Tooth
450369MP Drive Pulley, 44Tooth
450370MP Drive Pulley, 48Tooth
450371MP Drive Pulley, 60Tooth
8 450444M Gear Reducer Shaft
9 912–084 Key, Square, 0.188”x 1.5”L
Figure 30
6
8
9
1
7
5
3
2
1
4
Service Parts

2100, 4100, 6100 Series Bottom Mount Drive Package for Heavy Load 90_Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 13 851-279 Rev. D
Notes

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
851-279 Rev. D Printed in U.S.A.
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.
For replacement parts, contact an authorized
Dorner Service Center or the factory.
Return Policy