Dorner 3100 Series Manual instruction

851-436 Rev. B
Set-up, Operation
& Maintenance Manual
3100 & LPZ Series
Bottom 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 8. . . . . . . . .
Required Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 8. . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 8. . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 9. . . . . . . . . . .
Gear Reducer Replacement 9. . . . . . . . . . . . . . . . . .
Motor Replacement 11. . . . . . . . . . . . . . . . . . . . . . .
Service Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3100 & LPZ Series Bottom Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-436 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
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
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.
Warnings – General Safety

3100 & LPZ Series Bottom Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-436 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
AE
F
G
C
B
H
D
Specifications
Gearmotor Mounting Package Models:
Example:
Language Code = U.S. English
Output Shaft Type = 905
Gearmotor Type: L = Light Load,
S = Standard Load
Mount Style = Bottom Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
DC
B
A
3M B H L WW A–16 16
Belt Type: –= flat belt, A through J = cleated belt
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
Light Load Gearmotor Standard Load Gearmotor
Item Single-
Phase Three Phase DC Variable Speed Single- Phase Three 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 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

3100 & LPZ Series Bottom Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-436 Rev. B 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Fixed Speed 90560 Hz Gearmotors
Light Load Gearmotors Standard 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)FN 29 226 25.5 32M060HS4(vp)FN 29 226 25.5 23 7.0 16 16
32M040HL4(vp)FN 43 237 26.8 32M040HS4(vp)FN 43 247 27.9 34 10.4 16 16
32M040HL4(vp)FN 43 237 26.8 32M040HS4(vp)FN 43 247 27.9 52 15.8 24 16
32M020HL4(vp)FN 86 142 16 32M020HS4(vp)FN 86 248 27.9 69 21.0 16 16
32M020HL4(vp)FN 86 142 16 32M020HS4(vp)FN 86 248 27.9 103 31.4 24 16
32M010HL4(vp)FN 173 78 8.8 32M010HS4(vp)FN 173 156 17.6 137 41.8 16 16
32M010HL4(vp)FN 173 78 8.8 32M010HS4(vp)FN 173 156 17.6 172 52.4 20 16
32M010HL4(vp)FN 173 78 8.8 32M010HS4(vp)FN 173 156 17.6 206 62.8 24 16
N/A N/A N/A N/A 32M005HS4(vp)FN 345 81 9.1 275 83.8 16 16
N/A N/A N/A N/A 32M005HS4(vp)FN 345 81 9.1 343 104.5 20 16
N/A N/A N/A N/A 32M005HS4(vp)FN 345 81 9.1 412 125.6 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 905DC Gearmotors
Light Load Gearmotors Standard 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 4.0 –33 1.2 –10 16 16
32M040HLD3DEN 63 163 18.4 32M040HSD9DEN 63 215 24.3 6.0 –50 1.8 –15 16 16
32M040HLD3DEN 63 163 18.4 32M040HSD9DEN 63 215 24.3 9.0 –75 2.7 –23 24 16
32M020HLD3DEN 125 98 11.1 32M020HSD9DEN 125 196 22.1 12 –100 3.6 –30 16 16
32M020HLD3DEN 125 98 11.1 32M020HSD9DEN 125 196 22.1 18 –150 5.5 –45 24 16
32M010HLD3DEN 250 54 6.1 32M010HSD9DEN 250 108 12.2 24 –200 7.3 –61 16 16
32M010HLD3DEN 250 54 6.1 32M010HSD9DEN 250 108 12.2 30 –250 9.1 –76 20 16
32M010HLD3DEN 250 54 6.1 32M010HSD9DEN 250 108 12.2 36 –300 11 –92 24 16
Table 4: Belt Speeds for Fixed Speed 905VFD Gearmotors
Standard 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 2.3 –22.9 0.7 –7.0 16 16
32M040HS423EN 43 247 27.9 3.4 –34.3 1.0 –10.5 16 16
32M040HS423EN 43 247 27.9 5.1 –51.5 1.6 –15.7 24 16
32M020HS423EN 86 248 27.9 6.9 –68.6 2.1 –20.9 16 16
32M020HS423EN 86 248 27.9 10.3 –103.0 3.1 –31.4 24 16
32M010HS423EN 173 156 17.6 13.7 –137.3 4.2 –41.9 16 16
32M010HS423EN 173 156 17.6 17.2 –171.6 5.2 –52.3 20 16
32M010HS423EN 173 156 17.6 20.6 –205.9 6.3 –62.8 24 16
32M005HS423EN 345 81 9.1 27.5 –274.6 8.4 –83.7 16 16
32M005HS423EN 345 81 9.1 34.3 –343.2 10.5 –104.6 20 16
32M005HS423EN 345 81 9.1 41.2 –411.9 12.6 –125.6 24 16
NOTE: For belt speed other than those listed, con-
tact factory for details.
SpecificationsSpecifications

3100 & LPZ Series Bottom Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-436 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
Installation Component List
I Bottom Mount Assembly
J Drive Pulley
K Cover
L M4 Socket Head Screws (4x)
M Driven Pulley
N Key
O M6 Socket Head Screws (6x)
P Timing Belt
1.Typical components (Figure 2)
Figure 2
L
I
O
M
K
P
J
N
NOTE: Flat belt mounting package shown, cleated
belt mounting package similar.
NOTE: Gearmotor position on Flat Belt conveyor
shown below left, Figure 3. Gearmotor position on
Cleated Belt conveyor shown below right, Figure 3.
Figure 3
Flat Belt Conveyor Cleated Belt Conveyor
Figure 4
1
4
3
NOTE: Gearmotor may be operated in positions 1,
3 or 4 (Figure 4).
Installation

3100 & LPZ Series Bottom Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-436 Rev. B 6Dorner Mfg. Corp.
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
110 in-lb (12 Nm).
Figure 5
Q
Q
3.Locate drive output shaft (R of Figure 6) and remove
screws (S).
Figure 6
R
S
4.Attach mount assembly (I of Figure 7) with screws
(O). Install medium length screws on bottom, long
screw upper left, short screws upper right. Tighten
screws to 110 in-lb (9 Nm).
Figure 7
I
O
O
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
5.Install key (N of Figure 8).
Figure 8
NM
P
J
6.Wrap timing belt (P) around driven pulley (M) and
drive pulley (J). Install driven pulley (M) onto
conveyor shaft.
Installation

3100 & LPZ Series Bottom Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-436 Rev. B
7.Using a straight edge (T of Figure 9), align driven
pulley (M) with drive pulley (J). Tighten driven
pulley taper-lock screws (U).
Figure 9
M
T
J
U
8.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (V of Figure 10) as shown.
Tension timing belt to obtain 1/8”(3 mm) deflection
for 6 lb (3 Kg) of force at timing belt mid-point (W).
Tighten tensioner screw to 110 in-lb (12 Nm).
12
W
Figure 10
W
V
9.Install cover (K of Figure 11) with four (4) screws
(L). Tighten screws to 35 in-lb (4 Nm).
Figure 11
K
L
L
Installation

3100 & LPZ Series Bottom Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-436 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
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 on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (V of Figure 10) as
shown. Tension timing belt to obtain 1/8”(3 mm)
deflection for 6 lb (3 Kg) of force at timing belt
mid-point (W). Tighten tensioner screw to 110in-lb
(12 Nm).
4.Install cover (K of Figure 11) with four (4) screws
(L). 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 (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 taper-lock screws (U of
Figure 13) and remove pulley with belt (P). For
re-installation, see steps 6 and 7 on beginning on
page 6.
Figure 13
P
U
4.Install new timing belt.
5.Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (V of Figure 10) as
shown. Tension timing belt to obtain 1/8”(3 mm)
deflection for 6 lb (3 Kg) of force at timing belt
mid-point (W). Tighten tensioner screw to 110in-lb
(12 Nm).
6.Install cover (K of Figure 11) with four (4) screws
(L). Tighten screws to 35 in-lb (4 Nm).
Preventive Maintenance and Adjustment

3100 & LPZ Series Bottom Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-436 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.Loosen taper-lock 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
beginning on page 6.
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 four (4) screws (L of Figure 11) and remove
cover (K).
2.Loosen tensioner (V of Figure 12).
3.Loosen drive pulley taper-lock screws (X of Figure
14). Remove drive pulley (J) and timing belt (P).
Figure 14
X
J
P
4.Remove four (4) gear reducer mounting screws (Q
of Figure 15). Remove gearmotor.
Figure 15
Q
Preventive Maintenance and Adjustment

3100 & LPZ Series Bottom Mount Drive Package for Light & Standard Load 60 Hz Gearmotors SOMM
851-436 Rev. B 10 Dorner Mfg. Corp.
5.Remove four screws (Y of Figure 16). Detach motor
(Z) from gear reducer (AA). Retain motor output
shaft key (AB).
Figure 16
Z
AA
AC
AD
AB
AE
Y
6.Remove two (2) screws (AC) and detach output
shaft cover (AD).
7.Remove gear reducer output shaft key (AE).
8.Apply LoctiteR680 Adhesive (AI of Figure 17) to
new shaft.
Figure 17
AI
9.Insert the new shaft with adhesive (AG of Figure 18)
and key (AH) into new gear reducer. Tighten set
screws (AF) to 35 in-lb (4 Nm).
Figure 18
AF AG
AH
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.
10.With key (AB of Figure 16) in keyway, slide motor
(Z) and gear reducer (AA) together. Install screws
(Y) and tighten.
NOTE: Gearmotor position on Flat Belt conveyor
shown below left, Figure 19. Gearmotor position on
Cleated Belt conveyor shown below right, Figure 19.
Figure 19
Flat Belt Conveyor Cleated Belt Conveyor
11.Install gearmotor to mounting bracket and tighten
screws (Q of Figure 15) to 110in-lb (12 Nm).
Preventive Maintenance and Adjustment