Dorner 3200 Series User manual

851-532 Rev. B
Installation, Maintenance
& Parts Manual
3200 & LPZ Series
Top Mount Parallel Drive Package for Standard
Load 60 Hz Gearmotors
Table of Contents
Warnings −General Safety 2. . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearmotors 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3200 Belt Speeds 5. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance & Adjustment 8. . . . . . . . . . .
Required Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 8. . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 8. . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 9. . . . . . . . . . .
Motor Replacement 9. . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bottom Mount Drive Package 11. . . . . . . . . . . . . . .
Gearmotors 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3200 & LPZ Series Top Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors IMPM
851-532 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
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 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 without 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 3200 Series conveyors are covered by patent
numbers 5156260, 5156261, 5203447, 5265714 and
patent applications in other countries.
Dorner LPZ Series conveyors are covered by patent
numbers 5156260, 5156261, 5203447, 5265714,
5875883 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.
Dorner has convenient, pre−configured kits of Key
Service Parts for all conveyor products. These time
saving kits are easy to order, designed for fast installa-
tion, and guarantee you will have what you need when
you need it. Key Parts and Kits are marked in the Service
Parts section of this manual with the Performance Parts
Kits logo .
Warnings −General Safety

3200 & LPZ Series Top Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors IMPM
Dorner Mfg. Corp. 3851-532 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
E
F
G
C
B
H
D
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code = U.S. English
Output Shaft Type = Parallel Industrial
Gearmotor Type: S = Standard Load
Mount Style = Top Mount
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
Drive Pulley (see Table 2, 3 & 4)
Driven Pulley (see Table 2, 3 & 4)
Belt Type ( −= flat belt, A through J = cleated belt )
32 M T P S A −16 16
Table 1: Gearmotor Specifications
Single Phase Three Phase DC
Variable Speed
VFD
Variable Speed
Power/
Gear Ratio
hp (kW) hp (kW) hp (kW) hp (kW)
5:1 .08 (.06) .17 (.13) .12 (.09) .17 (.13)
10:1 .17 (.13) .17 (.13) .25 (.19) .17 (.13)
20:1 .33 (.25) .38 (.28) .25 (.19) .38 (.28)
30:1 .33 (.25) .38 (.28) .25 (.19) .38 (.28)
60:1 .33 (.25) .38 (.28) .33 (.25) .38 (.28)
180:1 .33 (.25) .38 (.28) N/A .38 (.28)
Input Voltage 115 VAC 230 VAC 130 VDC 230 VAC
Input Frequency 60 Hz 60 Hz N/A 10 to 60 Hz
Product Description

3200 & LPZ Series Top Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors IMPM
851-532 Rev. B 4Dorner Mfg. Corp.
Table 1: Gearmotor Specifications Continued
Single Phase Three Phase DC
Variable Speed
VFD
Variable Speed
Input Current/
Gear Ratio
FLA FLA FLA FLA
5:1 1.2 1.0 1.0 1.0
10:1 1.9 1.0 1.8 1.0
20:1 4 1.9 1.8 1.9
30:1 4 1.9 1.8 1.9
60:1 4 1.9 2.3 1.9
180:1 4 1.9 N/A 1.9
Motor RPM 1725 1725 2500 1725
Power/Ratio Totally Enclosed Fan Cooled Totally Enclosed
Non−Ventilated
Totally Enclosed
Fan Cooled
Table 2: Belt Speeds for Fixed Speed Parallel Shaft 60 Hz Gearmotors
Standard Load Gearmotors Belt Speed Drive Driven
Part Number
RPM
In-lb
N-m
Ft/min
M/min
Drive
Pulle
y
Driven
Pulle
y
P
art
N
um
b
er
RPM
I
n-
lb
N
-m
F
t
/
m
i
n
M/
m
i
n
Pulley
Pulley
62M180PS4vpFn 10 226 7.6 2.3 16 16
62M180PS4vpFn 10 226 11.4 3.5 24 16
62M060PS4vpFn 29 237 22.9 7.0 16 16
32M030PS4vpFn 58 142 45.8 14.0 16 16
32M020PS4vpFn 86 78 68.6 20.9 16 16
32M020PS4vpFn 86 78 103.0 31.4 24 16
32M010PS4vpFn 173 41 137.3 41.9 16 16
32M010PS4vpFn 173 41 171.6 52.3 20 16
32M010PS4vpFn 173 41 205.9 62.8 24 16
32M005PS4vpFn 345 41 274.6 83.7 16 16
32M005PS4vpFn 345 41 343.2 104.6 20 16
32M005PS4vpFn 345 41 411.9 125.6 24 16
(vp) = voltage and phase
11 = 115 V, 1-phase
23 = 208 – 230/460 V, 3-phase
Table 3: Belt Speeds for Variable Speed Parallel Shaft VFD Gearmotors
Standard Load Gearmotors Belt Speed Drive Driven
Part Number
RPM
In-lb
N-m
Ft/min
M/min
Drive
Pulle
y
Driven
Pulle
y
P
art
N
um
b
er
RPM
I
n-
lb
N
-m
F
t
/
m
i
n
M/
m
i
n
Pulley
Pulley
62M180PS4vpFn 10 226 1.3−7.6 0.4−2.3 16 16
62M060PS4vpFn 29 237 3.8−22.9 1.2−7.0 16 16
32M030PS4vpFn 58 142 7.6−45.8 2.3−14.0 16 16
32M020PS4vpFn 86 78 11.5−68.6 3.5−20.9 16 16
32M020PS4vpFn 86 78 17.2−103.
05.2−31.4 24 16
32M010PS4vpFn 173 41 22.9−137.
37.0−41.9 16 16
32M010PS4vpFn 173 41 34.4−205.
910.5−62.8 24 16
32M005PS4vpFn 345 41 45.9−274.
614.0−83.7 16 16
Specifications

3200 & LPZ Series Top Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors IMPM
Dorner Mfg. Corp. 5851-532 Rev. B
32M005PS4vpFn 345 41 57.3−343.
2
17.5−104.
620 16
32M005PS4vpFn 345 41 68.8−411.
9
21.0−125.
624 16
Table 4: Belt Speeds for Variable Speed Parallel Shaft DC Gearmotors
Standard Load Gearmotors Belt Speed Drive Driven
Part Number
RPM
In-lb
N-m
Ft/min
M/min
Drive
Pulley
Driven
Pulley
P
art
N
um
b
er
RPM
I
n-
lb
N
-m
F
t
/
m
i
n
M/
m
i
n
Pulley
Pulley
62M180PSD3DEN 14 226 1.3−11.1 0.4−3.4 16 16
62M180PSD3DEN 14 226 2.0−16.6 0.6−5.1 24 16
62M060PSD3DEN 42 237 4.0−33.2 1.2−10.1 16 16
62M030PSD3DEN 83 142 8.0−66.3 2.4−20.2 16 16
62M020PSD3DEN 125 78 11.9−99.5 3.6−30.3 16 16
62M020PSD3DEN 125 78 17.9−149.2 5.5−45.5 24 16
62M010PSD3DEN 250 41 23.9−199.0 7.3−60.7 16 16
62M010PSD3DEN 250 41 29.8−248.7 9.1−75.8 20 16
62M010PSD3DEN 250 41 35.8−298.5 10.9−91.0 24 16
NOTE: For belt speed other than those listed, contact
factory for details.
Installation
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
E Cover
F Timing Belt
G Drive Pulley
H Driven Pulley
I Top Mount Drive Assembly
J Cover Screws
K Key
L M6 Socket Head Screws (4x)
M M8 Socket Head Screws (2x)
N Tensioner
Specifications

3200 & LPZ Series Top Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors IMPM
851-532 Rev. B 6Dorner Mfg. Corp.
1.Typical components (Figure 2)
Figure 2
L
H
E
F
G
K
M
I
J
N
NOTE: Cleated belt mounting package shown, flat belt
mounting package similar.
2.Locate drive output shaft (Q of Figure 3). Remove
two (2) M8 screws (P) and four (4) M6 screws (O)
and discard.
Figure 3
Q
P
O
O
3.Attach top mount drive assembly (B of Figure 4)
with two (2) M8 screws (M) and four (4) M6 screws
(L). Tighten M6 screws (L) to 146 in−lbs (16.5 N−m)
and M8 screws (M) to 288 in−lbs (32.5 N−m).
Figure 4
B
M
L
Ç
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
4.Install key (K of Figure 5).
Figure 5
K
H
F
G
5.Wrap timing belt (F) around driven pulley (H) and
drive pulley (G). Install driven pulley (H) onto
conveyor shaft.
6.Using a straight edge (R of Figure 6), align driven
pulley (H) with drive pulley (G). Tighten driven
pulley taper-lock screws (S of Figure 7).
Installation

3200 & LPZ Series Top Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors IMPM
Dorner Mfg. Corp. 7851-532 Rev. B
Figure 6
H
R
G
Figure 7
S
7.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (N of Figure 8) as shown.
Tension timing belt to obtain 1/8” (3 mm) deflection
for 6 lb (3 Kg) of force at timing belt mid-point (T).
Tighten tensioner screw to 110 in-lb (12 Nm).
1
2
T
Figure 8
T
N
8.Install cover (E of Figure 9) with four (4) screws (J).
Tighten screws to 35 in-lb (4 Nm).
Figure 9
E
J
J

3200 & LPZ Series Top Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors IMPM
851-532 Rev. B 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 (J of Figure 9) and remove
cover (E).
2.Loosen tensioner (N of Figure 10).
Figure 10
N
3.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (N of Figure 8) as
shown. Tension timing belt to obtain 1/8” (3 mm)
deflection for 6 lb (3 Kg) of force at timing belt
mid-point (T). Tighten tensioner screw to 110 in-lb
(12 Nm).
4.Install cover (E of Figure 9) with four (4) screws (J).
Tighten screws 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 (J of Figure 9) and remove
cover (E).
2.Loosen tensioner (N of Figure 10).
3.Remove timing belt (F of Figure 11).
NOTE: If timing belt does not slide over pulley
flange, loosen driven pulley taper-lock screws (S of
Figure 7 & 11) and remove pulley with belt (F). For
re-installation, see steps 5 and 6 on page 6.
Figure 11
F
S
4.Install new timing belt.
5.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (N of Figure 8) as
shown. Tension timing belt to obtain 1/8” (3 mm)
deflection for 6 lb (3 Kg) of force at timing belt
mid-point (T). Tighten tensioner screw to 110 in-lb
(12 Nm).
6.Install cover (E of Figure 9) with four (4) screws (J).
Tighten screws to 35 in-lb (4 Nm).
Preventive Maintenance and Adjustment

3200 & LPZ Series Top Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors IMPM
Dorner Mfg. Corp. 9851-532 Rev. B
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.Remove taper-lock screws (S of Figure 12). Insert one
(1) of taper lock screws (S of Figure 12) in remaing
hole (U). Tighten screw (S) until pulley is loose.
Remove pulley and taper hub assembly.
Figure 12
S
U
NOTE: If drive pulley (G of Figure 5) is replaced,
wrap timing belt around drive pulley and complete
step 3.
3.Complete steps5 through8 of “Installation” section
beginning on page 6.
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 (V of Figure 13) and
remove cover (W).
Figure 13
W
V
b.Record incoming wire colors on red, black and
blue leads. Loosen wire nuts and remove incoming
wires.
c.Loosen cord grip and remove cord.
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

3200 & LPZ Series Top Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors IMPM
851-532 Rev. B 10 Dorner Mfg. Corp.
3.For DC variable speed motor, unplug motor cord at
disconnect (X of Figure 14).
Figure 14
X
4.Remove the drive pulley see steps 1 and 2 of “Drive
or Driven Pulley Replacement” section on page 9.
5.Remove four (4) screws (J of Figure 15). Detach
motor (C) from the mounting plate (B). Retain motor
output shaft key (K).
Figure 15
C
B
K
J
6.Install new motor using the four (4) mounting
screws (J of Figure 15).
7.Re−install the drive pulley reverse step 2 of “Drive
or Driven Pulley Replacement” section on page 9.
8.Complete steps5 through8 of “Installation” section
beginning on page 6.
9.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 Adjustment