Dorner 2100 Series Manual

851-255 Rev. H
Installation, Maintenance
& Parts Manua
l
2100, 2200, 4100, 6200 and MPB Series
Top Mount Drive Package
for Standard Load Parallel Shaft 60 Hz Gearmotors
Table of Contents
Warnings − General Safety 2. . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearmotors 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Speed Tables 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment NO TAG. . .
Required Tools 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 11. . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 11. . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 11. . . . . . . . . .
Gearmotor Replacement 12. . . . . . . . . . . . . . . . . . .
Service Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2100, 2200, 4100, 6200 Series (All) and MPB
Series (Flat Belt) Top Mount Drive Package 13. .
MPB Series Cleated Belt Top Mount
Drive Package 15. . . . . . . . . . . . . . . . . . . . . . . . . .
4100 Series Adapter Package 16. . . . . . . . . . . . . . . .
Gearmotors 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors
851-255 Rev. H 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 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
Ç
MPB Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE MPB SE-
RIES CONVEYORS.
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 2100 Series conveyors are covered by the
following patent numbers: 5131529, 5174435, and
corresponding patents and patent applications in other
countries.
Dorner 2200 and MPB Series conveyors are covered by
patent number 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 6200 Series conveyors are covered by patent
number 6685009, 5174435, 6109427 and correspond-
ing 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, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors
Dorner Mfg. Corp. 3851-255 Rev. H
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
E
F
H
D
G
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code = U.S. English
Output Shaft Type = Parallel Shaft
Gearmotor Type = Standard Load, Industrial
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 S WW A − 32 32
2 = 2100 Series Conveyor
22 = 2200 & MPB Series Conveyor
4 = 4100 Series Conveyor
6 = 6200 Series Conveyor
2P = MPB Series Conveyor
Belt Type: − = flat belt, A through J = cleated belt
Drive Pulley (see Belt Speed Tables starting on page 4)
Driven Pulley (see Belt Speed Tables starting on page 4)
* See “Ordering and Specifications” Catalog for details.
Table 1: Gearmotor Specifications
Single Phase Three Phase DC Variable Speed
Output Power 0.17 hp (0.13 kw) 0.25 hp (0.19 kw)
Input Voltage 115 Volts A.C. 230 Volts A.C. 130 Volts D.C.
Input Frequency 60 Hz N/A
Input Current 1.9 Amperes 1.2 Amperes 1.8 Amperes
Motor RPM 1725 2500
Gearmotor Ratios 5:1, 10:1, 20:1, 30:1, 60:1, 80:1
Frame Size NEMA 42 CZ
Motor Type Totally enclosed, Fan-cooled Totally enclosed, Non−ventilated
Product Description

2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors
851-255 Rev. H 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Standard Load Fixed Speed Parallel Shaft 60 Hz Gearmotors on
2100, 2200 Gang Drive, 4100 and 6200 Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
2 0.6 62M180PS4(vp)F(n) 180:1 10 341 38.5 22 32
3 0.9 62M180PS4(vp)F(n) 180:1 10 341 38.5 32 32
4 1.2 62M180PS4(vp)F(n) 180:1 10 341 38.5 48 32
6 1.7 62M060PS4(vp)F(n) 60:1 29 270 30.5 22 32
8 2.4 62M060PS4(vp)F(n) 60:1 29 270 30.5 32 32
12 3.7 62M060PS4(vp)F(n) 60:1 29 270 30.5 48 32
16 4.9 62M030PS4(vp)F(n) 30:1 58 135 15.3 32 32
25 7.6 62M020PS4(vp)F(n) 20:1 86 90 10.2 32 32
37 11.3 62M020PS4(vp)F(n) 20:1 86 90 10.2 48 32
49 14.9 62M010PS4(vp)F(n) 10:1 173 45 5.1 32 32
74 22.6 62M010PS4(vp)F(n) 10:1 173 45 5.1 48 32
99 30.2 62M005PS4(vp)F(n) 5:1 345 25 2.8 32 32
148 45.1 62M005PS4(vp)F(n) 5:1 345 25 2.8 48 32
169 51.5 62M005PS4(vp)F(n) 5:1 345 25 2.8 48 28
197 60.0 62M005PS4(vp)F(n) 5:1 345 25 2.8 44 22
215 65.5 62M005PS4(vp)F(n) 5:1 345 25 2.8 48 22
249 75.9 62M005PS4(vp)F(n) 5:1 345 25 2.8 48 19
(vp) = voltage and phase (n) = reversing capability
11 = 115 V, 1-phase N = no reversing switch
23 = 230V, 3-phase R = with reversing switch
(115V, 1 phase only)
Table 3: Belt Speeds for Standard Load Fixed Speed Parallel Shaft 60 Hz Gearmotors on
2200 Series Conveyors (Excluding Gang Drive)
Belt Speed Gearmotors * Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
3 0.9 62M180PS4(vp)F(n) 180:1 10 341 38.5 28 28
5 1.5 62M180PS4(vp)F(n) 180:1 10 341 38.5 44 22
6 1.7 62M060PS4(vp)F(n) 60:1 29 270 30.5 19 32
10 3.0 62M060PS4(vp)F(n) 60:1 29 270 30.5 28 28
16 4.9 62M060PS4(vp)F(n) 60:1 29 270 30.5 44 28
30 9.1 62M020PS4(vp)F(n) 20:1 86 90 10.2 28 28
48 14.6 62M020PS4(vp)F(n) 20:1 86 90 10.2 44 28
61 18.6 62M010PS4(vp)F(n) 10:1 173 45 5.1 28 28
95 29.0 62M010PS4(vp)F(n) 10:1 173 45 5.1 44 28
104 31.7 62M010PS4(vp)F(n) 10:1 173 45 5.1 48 28
121 36.9 62M005PS4(vp)F(n) 5:1 345 25 2.8 28 28
138 42.1 62M005PS4(vp)F(n) 5:1 345 25 2.8 32 28
176 53.6 62M005PS4(vp)F(n) 5:1 345 25 2.8 32 22
208 63.4 62M005PS4(vp)F(n) 5:1 345 25 2.8 48 28
242 73.8 62M005PS4(vp)F(n) 5:1 345 25 2.8 44 22
264 80.5 62M005PS4(vp)F(n) 5:1 345 25 2.8 48 22
(vp) = voltage and phase (n) = reversing capability
11 = 115 V, 1-phase N = no reversing switch
23 = 230V, 3-phase R = with reversing switch
(115V, 1 phase only)
SpecificationsSpecifications

2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors
Dorner Mfg. Corp. 5851-255 Rev. H
Table 4: Belt Speeds for Standard Load Fixed Speed Parallel Shaft 60 Hz Gearmotors on
MPD Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
4.5 1.4 62M180PS4(vp)F(n) 180:1 10 341 38.5 22 32
6 1.7 62M060PS4(vp)F(n) 60:1 29 270 30.5 19 32
6.5 2 62M180PS4(vp)F(n) 180:1 10 341 38.5 28 28
13 4.0 62M060PS4(vp)F(n) 60:1 29 270 30.5 22 32
20 6.0 62M060PS4(vp)F(n) 60:1 29 270 30.5 28 28
39 11.9 62M030PS4(vp)F(n) 30:1 58 135 15.3 28 28
59 17.9 62M020PS4(vp)F(n) 20:1 86 90 10.2 28 28
(vp) = voltage and phase (n) = reversing capability
11 = 115 V, 1-phase N = no reversing switch
23 = 230V, 3-phase R = with reversing switch
(115V, 1 phase only)
Table 5: Belt Speeds for Standard Load Variable Speed Parallel Shaft VFD Gearmotors
on 2100, 4100 and 6200 Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Pulley
Pulley
.6−5.6 .2−1.7 62M060PS423EN 60:1 29 270 30.5 22 32
.8−8.2 .3−2.5 62M060PS423EN 60:1 29 270 30.5 32 32
2.5−25 .8−7.5 62M020PS423EN 20:1 86 167 18.9 32 32
4.9−49 1.5−15 62M010PS423EN 10:1 173 115 13 32 32
9.9−99 3−30 62M005PS423EN 5:1 345 58 6.5 32 32
14−148 4.5−45 62M005PS423EN 5:1 345 58 6.5 48 32
19−197 6−60 62M005PS423EN 5:1 345 58 6.5 44 22
24−249 7.6−76 62M005PS423EN 5:1 345 58 6.5 48 19
* At 60 Hz
Table 6: Belt Speeds for Standard Load Variable Speed Parallel Shaft VFD Gearmotors
on 2200 Series Conveyors (Excluding Gang Drive)
Belt Speed Gearmotors * Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Pulley
Pulley
.6−6 .2−1.8 62M060PS423EN 60:1 29 270 30.5 19 32
1−10 .3−3.1 62M060PS423EN 60:1 29 270 30.5 28 28
3−30 .9−9.2 62M020PS423EN 20:1 86 167 18.9 28 28
6−60 1.8−18 62M010PS423EN 10:1 173 115 13 28 28
10−104 3.2−32 62M010PS423EN 10:1 173 115 13 48 28
12−121 3.7−37 62M005PS423EN 5:1 345 58 6.5 28 28
26−264 8.1−81 62M005PS423EN 5:1 345 58 6.5 48 22
* At 60 Hz
SpecificationsSpecificationsSpecifications

2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors
851-255 Rev. H 6Dorner Mfg. Corp.
Table 7: Belt Speeds for Standard Load Variable Speed Parallel Shaft VFD Gearmotors
on MPD Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM*
In-lb*
N-m*
Pulley
Pulley
1.3−13.4 .4−4.1 62M060PS423EN 60:1 29 270 30.5 22 32
2−19 .9−5.9 62M060PS423EN 60:1 29 270 30.5 28 28
5.9−59 1.8−18 62M020PS423EN 20:1 86 167 18.9 28 28
11−117 3.6−36 62M010PS423EN 10:1 173 115 13 28 28
17−175 5.4−54 62M010PS423EN 10:1 173 115 13 48 32
23−234 7.1−71 62M005PS423EN 5:1 345 58 6.5 28 28
* At 60 Hz
Table 8: Belt Speeds for Standard Load Variable Speed Parallel Shaft DC Gearmotors on
2100, 4100 and 6200 Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
.3−2.7 .1−.8 62M180PSD3DEN 180:1 14 341 38.5 22 32
.5−4 .1−1.2 62M180PSD3DEN 180:1 14 341 38.5 32 32
1.0−8.2 .3−2.5 62M060PSD3DEN 60:1 42 270 30.5 22 32
1.4−12 .4−3.6 62M060PSD3DEN 60:1 42 270 30.5 32 32
2.9−24 .9−7.3 62M030PSD3DEN 30:1 83 135 15.3 32 32
4.3−36 1.3−11 62M020PSD3DEN 20:1 125 90 10.2 32 32
9−71 2.6−22 62M010PSD3DEN 10:1 250 72 8.1 32 32
17−143 5.2−43 62M005PSD3DEN 5:1 500 25 2.8 32 32
26−214 7.8−65 62M005PSD3DEN 5:1 500 25 2.8 48 32
29−245 9.0−75 62M005PSD3DEN 5:1 500 25 2.8 48 28
Table 9: Belt Speeds for Standard Load Variable Speed Parallel Shaft DC Gearmotors on
2200 Series Conveyors (Excluding Gang Drive)
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
.4−3.4 .1−1.0 62M180PSD3DEN 180:1 14 341 38.5 22 32
.6−5 .2−1.5 62M180PSD3DEN 180:1 14 341 38.5 28 28
1.8−14 .5−4.5 62M060PSD3DEN 60:1 42 270 30.5 28 28
2.8−23 .8−7 62M060PSD3DEN 60:1 42 270 30.5 44 28
3.5−29 1.1−9 62M030PSD3DEN 30:1 83 135 15.3 28 28
5.3−44 1.6−13 62M020PSD3DEN 20:1 125 90 10.2 28 28
10−88 3.2−27 62M010PSD3DEN 10:1 250 72 8.1 28 28
17−138 5−42 62M005PSD3DEN 5:1 500 25 2.8 44 28
21−176 6.4−54 62M005PSD3DEN 5:1 500 25 2.8 28 28
33−276 10−84 62M005PSD3DEN 5:1 500 25 2.8 44 28
Specifications

2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors
Dorner Mfg. Corp. 7851-255 Rev. H
Table 10: Belt Speeds for Standard Load Variable Speed Parallel Shaft DC Gearmotors
on MPB Series Conveyors
Belt Speed Gearmotors Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Drive
Pulley
Driven
Pulley
Ft/min
M/min
Part Number
Gear Ratio
RPM
In-lb
N-m
Pulley
Pulley
1.1−9 .3−2.9 62M180PSD3DEN 180:1 14 341 38.5 28 28
2.3−19 .7−5.9 62M060PSD3DEN 60:1 42 270 30.5 22 32
3.4−28 1−8.6 62M060PSD3DEN 60:1 42 270 30.5 28 28
5.3−44 1.6−13 62M060PSD3DEN 60:1 42 270 30.5 44 28
6.8−57 2.1−17 62M030PSD3DEN 30:1 83 135 15.3 28 28
10−85 3−26 62M020PSD3DEN 20:1 125 90 10.2 28 28
15−127 4.7−39 62M020PSD3DEN 20:1 125 90 10.2 48 32
20−170 6−52 62M010PSD3DEN 10:1 250 72 8.1 28 28
31−255 9−77 62M010PSD3DEN 10:1 250 72 8.1 48 32
* = Cleated and Sidewall Cleated belts opperate at a maximum of 150 Ft/min (45.7 m/min)
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
DTorque wrench
Mounting
Ç
Exposed moving parts can cause
severe injury.
LOCK OUT POWER before
removing guards or performing
maintenance.
WARNING
Ç
MPB Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE MPB SE-
RIES CONVEYORS.
WARNING
Ç
For MPB Series and Cleated
Belt Conveyors Gearmotors
must be mounted as shown
in Figure 3.
Failure to do so creates
pinch points which can
cause severe injury.
WARNING
Specifications

2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors
851-255 Rev. H 8Dorner Mfg. Corp.
1.Typical components (Figure 2)
Installation Component List
I Top Mount Assembly
J Drive Pulley
K Cover
L M4 Socket Head Screws (4x)
M Driven Pulley
N Key
O M6 Socket Head Screws (2x)
P Timing Belt
Figure 2
J
K
L
M
O
P
N
I
2.For your reference, the following figures show
gearmotor mounting configurations for various
conveyor series.
F
igure 3 − 2200 Series
F
igure 4 − 6200 Series
Gearmotor
is mounted
to Head
Plate
Gearmotor
is mounted to
Drive Spacer
F
igure 5 − 4100 Series
F
igure 6 − 2100 Series
F
igure 7 − MPB Series
Gearmotor
is mounted
to Drive
Adapter
Plate
Gearmotor
is mounted
to Head
Plate
Gearmotor
is mounted
to Head
Plate
NOTE: 6200 Series conveyor shown, other Series si-
milar.
3.Locate drive output shaft (Q of Figure 8) and remove
two (2) screws (R).
Figure 8
Q
R
Installation

2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors
Dorner Mfg. Corp. 9851-255 Rev. H
4.Attach mount assembly (I of Figure 9) with screws
(O). Tighten screws to 80 in-lb (9 N−m).
Figure 9
I
O
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
5.Install key (N of Figure 10).
Figure 10
M
N
J
P
Q
6.Wrap timing belt (P) around driven pulley (M) and
drive pulley (J). Install driven pulley onto conveyor
shaft (Q).
7.Remove cam bearing and spacer (S of Figure 9).
Place the cam bearing and spacer (S of Figure 11)
next to the driven pulley (M). Ensure the flanges of
the driven pulley are aligned with the cam bearing.
Tighten driven pulley set screws (T). This will allow
for proper belt alignment while conveyor is in use.
Install cam bearing and spacer (S).
Figure 11
T
S
M
8.Depending on direction of conveyor belt travel (1 or 2
of Figure 12), position belt tensioner (U) as shown.
Tension belt to obtain 0.125¨ (3 mm) deflection for 1.0
lb (456 grams) of force at belt mid-point (V). Tighten
tensioner screw to 103 in-lb (12 N−m).
Figure 12
1
V
V
2
U
Installation

2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Standard Load Parallel Shaft 60 Hz Gearmotors
851-255 Rev. H 10 Dorner Mfg. Corp.
9.Install cover (K of Figure 13) with four screws (L).
Tighten to 35 in-lb (4 N−m).
Figure 13
K
L
L
Installation