Dorner 3100 Series Manual instruction

851-437 Rev. C
Setup, Operation
& Maintenance Manual
3100 & LPZ Series
Side Mount Drive Package
for Light & Standard 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. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Reducer Replacement 7. . . . . . . . . . . . . . . . . .
Motor Replacement 9. . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-437 Rev. C 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 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 3100 Series conveyors are covered by patent
numbers 5156260, 5156261, 5203447, 5265714 and
applications in other countries.
Dorner LPZ Series conveyors are covered by patent
numbers 5156260, 5156261, 5203447, 5265714,
5875883 and 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

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-437 Rev. C
Refer to Figure 1 for typical components.
A Conveyor
B Mounting Bracket
C Gearmotor
D Coupling
E Coupling Guard
Typical Components
Figure 1
AE
D
B
C
Specifications
Gearmotor Mounting Package Models:
Example: WW A
Language Code = U.S. English
Output Shaft Type = 905Industrial
Gearmotor Type: L = Light Load,
S = Standard Load
H
M LS
Mount Style = Side Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
3
* See “Ordering and Specifications”Catalog for details.
Table 1: Gearmotor Specifications
Light Load Gearmotor Standard Load Gearmotor
Item I Phase III Phase DC
Variable Speed I Phase III Phase VFD Variable Speed DC Variable Speedd
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 25 – 63Hz 60Hz 25 – 63Hz 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

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-437 Rev. C 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Fixed Speed 90560 Hz Gearmotors
Light Load Gearmotors Standard Load Gearmotors Belt Speed
Part Number RPM In-lb N-m Part Number RPM In-lb N-m Ft/min M/min
32M060HL4(vp)FN 29 226 25.5 32M060HS4(vp)FN 29 226 25.5 23 7.0
32M040HL4(vp)FN 43 237 26.8 32M040HS4(vp)FN 43 247 27.9 34 10.4
32M020HL4(vp)FN 86 142 16 32M020HS4(vp)FN 86 248 27.9 69 21.0
32M010HL4(vp)FN 173 78 18.8 32M010HS4(vp)FN 173 156 17.6 137 41.8
N/A N/A N/A N/A 32M005HS4(vp)FN 345 81 9.1 275 83.8
(vp) = voltage and phase
21 = 115 V, 1-phase
23 = 208–230/460 V, 3-phase
Table 3: Belt Speeds for Variable Speed 905DC Gearmotors
Light Load Gearmotors Standard Load Gearmotors Belt Speed
Part Number RPM In-lb N-m Part Number RPM In-lb N-m Ft/min M/min
62Z060HS423EN 42 198 22.4 32M060HSD9DEN 42 198 22.4 4.0 –33 1.2 –10
62Z040HS423EN 63 163 18.4 32M040HSD9DEN 63 215 24.3 6.0 –50 1.8 –15
62Z020HS423EN 125 98 11.1 32M020HSD9DEN 125 196 22.1 12 –100 3.6 –30
62Z010HS423EN 250 54 6.1 32M010HSD9DEN 250 108 12.2 24 –200 7.3 –61
Table 4: Belt Speeds for Variable Speed 905VFD Gearmotors
Standard Load Gearmotors Belt Speed
Part Number RPM In-lb N-m Ft/min M/min
32M060HLD3DEN 29 226 25.5 2.3 –23 0.7 –7.8
32M040HLD3DEN 43 247 27.9 3.4 –34 1.0 –10.5
32M020HLD3DEN 86 248 27.9 6.9 –69 2.1 –21
32M010HLD3DEN 173 156 17.6 13 –137 4.2 –42
32M005HLD3DEN 345 81 9.1 27 –275 8.4 –84
NOTE: For belt speed other than those listed, con-
tact factory for details.
Specifications

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-437 Rev. C
Required Tools
DHex key wrenches:
2.5 mm, 3 mm, 5 mm
DTorque wrench
Mounting
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Installation Component List
F Drive Assembly
G Mounting Screws (6x)
H Key
1.Typical components (Figure 2)
Figure 2
F
G
NOTE: Gearmotor may be operated in positions 1,
2, 3 or 4 (Figure 3).
Figure 3
1
4
3
2
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
2.Locate drive output shaft. Remove screws (I of
Figure 4). Install key (H).
Figure 4
I
H
3.Remove screws (J of Figure 5) and coupling
guard (E).
Figure 5
J
E
Installation

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-437 Rev. C 6Dorner Mfg. Corp.
4.If required, change gearmotor position by removing
screws (K of Figure 6). Rotate gearmotor to other
position (Figure 3) and replace screws (K). Tighten
to 110 in-lb (12 Nm).
Figure 6
K
K
5.Install coupling (D of Figure 7) onto drive output
shaft. Attach drive assembly to conveyor with
mounting screws (G). Install medium length screws
on bottom, long screw upper left, short screws upper
right. Tighten screws to 110 in-lb (12 Nm).
Figure 7
G
D
Ç
Exposed moving parts can
cause severe injury.
KEEP HANDS CLEAR OF
DRIVE WHILE JOGGING
MOTOR.
WARNING
6.Jog motor and rotate coupling to gain access to set
screw (L of Figure 8). Tighten to 33 in-lb (3.7 Nm).
Repeat for second set screw.
Figure 8
L
7.Reinstall coupling guard (E of Figure 9) with screws
(J).
Figure 9
E
J
Installation

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-437 Rev. C
Required Tools
DHex key wrenches:
2.5 mm, 3 mm, 5 mm
DAdjustable wrench (for hexagon head screws)
DTorque wrench
Gear Reducer Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
NOTE: The gear reducer and output shaft are
permanently fixed with LoctiteRAdhesive. Both
components must be replaced. See “Service Parts”
Section for part numbers.
1.Remove screws (J of Figure 9) and coupling
guard (E).
Ç
Exposed moving parts can
cause severe injury.
KEEP HANDS CLEAR OF
DRIVE WHILE JOGGING
MOTOR.
WARNING
2.Jog motor and rotate coupling to gain acess to set
screw (L of Figure 8). Loosen set screw. Repeat for
second set screw.
3.Remove mounting screws (G of Figure 7) and
remove drive assembly.
4.Remove two (2) set screws (L of Figure 10) and
remove coupling (D).
Figure 10
L
D
5.Remove three (3) screws (K of Figure 11) and
remove mounting bracket (B).
Figure 11
B
K
K
Preventive Maintenance and Adjustment

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-437 Rev. C 8Dorner Mfg. Corp.
6.Remove four screws (M of Figure 12). Detach motor
(N) from gear reducer (O). Retain motor output shaft
key (P).
Figure 12
N
OP
Q
M
R
S
7.Remove two (2) screws (Q) and detach output shaft
cover (R).
8.Remove gear reducer output shaft key (S).
9.Apply LoctiteR680 Adhesive (W of Figure 13) to
new shaft.
Figure 13
W
10.Insert the new shaft with adhesive (U Figure 14) and
key (V) into new gear reducer. Tighten set screws to
33 in-lb (3.7 Nm).
Figure 14
TU
V
NOTE: Allow LoctiteRAdhesive to cure for one (1)
hour prior to starting conveyor.
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 (P of Figure 12) in keyway, slide motor (N)
and gear reducer (O) together. Install screws (M) and
tighten.
12.Attach mounting bracket (B of Figure 11) to gearmo-
tor with screws (K). Tighten screws to 110 in-lb
(12 Nm).
13.Attach coupling (D of Figure 10) to gear reducer
shaft. Tighten two (2) set screws (L) to 33 in-lb (3.7
Nm).
14.Completesteps2through7of“Installation”section
beginning on page 5.
Preventive Maintenance and Adjustment

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-437 Rev. C
Motor Replacement
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, unplug power cord from
outlet
2.For three phase and VFD variable speed motor:
a.Loosen terminal box screws (X of Figure 15) and
remove cover (Y).
Figure 15
X
Y
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 (Z of Figure 16).
Figure 16
Z
4.Remove four (4) screws (AA of Figure 17). Detach
motor (AB) from gear reducer (AC). Retain motor
output shaft key (AD).
Figure 17
AC
AD
AB
AA
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 (AD of Figure 18) in keyway, slide motor
(AB) and gear reducer together. Install screws (AA)
and tighten.
Figure 18
AD
AA
AB
6.Replace wiring:
DFor a single phase motor, reverse step 1 on this page.
DFor a three phase or 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 AdjustmentPreventive Maintenance and Adjustment

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-437 Rev. C 10 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
1 826-328 Motor, 0.25hp (0.19Kw), 115/230 Volts,
60 Hz, 1-Phase
826-337 Motor, 0.25hp (0.19Kw), 115/230 Volts,
60 Hz, 1-Phase with Reversing
826-330 Motor, 0.25hp (0.19Kw),
208–230/460 Volts, 60 Hz, 3-Phase
826-332 Motor, 0.25hp (0.19Kw), 130 VDC
826–017 Motor, 0.5hp (0.37Kw), 115/230 Volts,
60Hz, 1–Phase
826–025 Motor, 0.5hp (0.37Kw)
208–230/460 Volts, 60Hz, 3 Phase
826–333 Motor, 0.5hp (0.37Kw), 90VDC
826–249 Motor, 0.5hp (0.37Kw), 230 Volts,
3 Phase Inverter Duty
2 32M005HL Gear Reducer, 5:1, NEMA 42CZ
32M010HL Gear Reducer, 10:1, NEMA 42CZ
32M020HL Gear Reducer, 20:1, NEMA 42CZ
32M040HL Gear Reducer, 40:1, NEMA 42CZ
32M060HL Gear Reducer, 60:1, NEMA 42CZ
32M005HS Gear Reducer, 5:1, NEMA 56C
32M010HS Gear Reducer, 10:1, NEMA 56C
32M020HS Gear Reducer, 20, NEMA 56C
32M040HS Gear Reducer, 40, NEMA 56C
32M060HS Gear Reducer, 60, NEMA 56C
3 807-584 Coupling
4 300599 Gear Reducer Shaft
5 912–084 Key, Square, 0.188”x 1.5”L
6 980018M Key, Square, 6mm x 18mm L (2x)
Figure 19
2
4
1
53
6
Service Parts

3100 & LPZ Series Side Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 11 851-437 Rev. C
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
851-437 Rev. C Printed in U.S.A. 300
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-Ring2
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