Dorner 4100 Series Manual instruction

851-256 Rev. E
Set-up, Operation
& Maintenance Manual
2100, 4100, 6100 Series
Bottom Mount Drive Package
for Standard 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 7. . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Tensioning 7. . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 7. . . . . . . . . . . . . . . . . . .
Drive or Driven Pulley Replacement 8. . . . . . . . . . .
Gear Reducer Replacement 8. . . . . . . . . . . . . . . . . .
Motor Replacement 10. . . . . . . . . . . . . . . . . . . . . . .
Service Parts 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 4100, 6100 Series Bottom Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors SOMM
851-256 Rev. E 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 Standard Load 90°Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 3851-256 Rev. E
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 = Standard 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 Table 2 & 3)
Driven Pulley (see Table 2 & 3)
Belt Type ( –= flat belt, A through J = cleated belt )
2M B H S WW A–32 32
* See “Ordering and Specifications”Catalog for details.
Table 1: Gearmotor Specifications
Single Phase Three Phase DC Variable Speed
Output Power 0.25 hp (0.19 kw)
Input Voltage 115 Volts A.C. 208 to 230/460 Volts A.C. 130 Volts D.C.
Input Frequency 60 Hz N/A
Input Current 5.0 Amperes 1.2 /0.6 Amperes 2.2 Amperes
Motor RPM 1725 2500
Gearmotor Ratios 5:1, 10:1, 20:1, 40:1, 60:1
Frame Size NEMA 42 CZ
Motor Type Totally Enclosed, Fan-cooled
Product Description

2100, 4100, 6100 Series Bottom Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors SOMM
851-256 Rev. E 4Dorner Mfg. Corp.
Table 2: Belt Speeds for Standard Load Fixed Speed 90560 Hz Gearmotors
Gearmotors Belt Speed
Drive
Driven
Belt Speed Drive Driven
Part Number RPM ft/min M/min Pulley Pulley
32M060HL4(vp)FN 29 5 1.5 19 32
32M060HL4(vp)FN 29 8 2.4 32 32
32M040HL4(vp)FN 43 12 3.7 32 32
32M040HL4(vp)FN 43 18 5.5 48 32
32M020HL4(vp)FN 86 25 7.6 32 32
32M020HL4(vp)FN 86 37 11.3 48 32
32M010HL4(vp)FN 173 49 14.9 32 32
32M010HL4(vp)FN 173 74 22.6 48 32
32M005HL4(vp)FN 345 99 30.3 32 32
32M005HL4(vp)FN 345 145 45.1 48 32
32M005HL4(vp)FN 345 169 51.5 48 28
32M005HL4(vp)FN 345 197 60 44 22
32M005HL4(vp)FN 345 215 65 48 22
32M005HL4(vp)FN 345 249 76 48 19
(vp) = voltage and phase
11 = 115 V, 1-phase
23 = 208–230/460 V, 3-phase
Table 3: Belt Speeds for Standard Load Variable Speed 905DC Gearmotors
Gearmotors Belt Speed Drive DrivenDrive Driven
Part Number RPM In–lb N–m ft/min M/min Pulley Pulley
32M060HLD3DEN 42 198 22.4 0.8 – 7.0 0.3 – 2.2 19 32
32M060HLD3DEN 42 198 22.4 1.4 – 12 0.4 – 3.6 32 32
32M040HLD3DEN 63 163 18.4 2.1 – 18 0.7 – 5.4 32 32
32M020HLD3DEN 125 98 11.1 4.3 – 36 1.3 – 11 32 32
32M010HLD3DEN 250 54 6.1 9.0 – 71 2.6 – 22 32 32
32M005HLD3DEN 500 28 3.2 17 – 143 5.2 – 43 32 32
32M005HLD3DEN 500 28 3.2 26 – 214 7.8 – 65 48 32
32M005HLD3DEN 500 28 3.2 29 – 245 9.0 – 75 48 28
NOTE: For belt speed other than those listed, con-
tact factory for details.
Specifications

2100, 4100, 6100 Series Bottom Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 5851-256 Rev. E
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 (2x)
P Timing Belt
NOTE: Gearmotor position on Flat Belt conveyor
shown below left (Figure 2). Gearmotor position on
Cleated Belt conveyor shown below right (Figure 2).
Figure 2
Flate Belt Conveyor Cleated Belt Conveyor
1.Typical components (Figure 3)
Figure 3
O
IMN
K
P
L
J
NOTE: Flat belt mounting package shown above
(Figure 3), cleated belt mounting package similar.
NOTE: Gearmotor may be operated in positions 1,
3 or 4 (Figure 4). Operating in position 4 may require
additional support. Contact factory for details.
Figure 4
1
4
3
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 103
in-lb (12 Nm).
Figure 5
Q
Q
Installation

2100, 4100, 6100 Series Bottom Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors SOMM
851-256 Rev. E 6Dorner Mfg. Corp.
NOTE: 6100 conveyor shown, 2100 & 4100 similar.
3.Locate drive output shaft (R of Figure 6) and remove
two (2) screws (S).
Figure 6
S
R
4.Attach mounting assembly (I of Figure 7) with
screws (O). Tighten to 80 in-lb (9 Nm).
Figure 7
I
O
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
5.Install key (N of Figure 8).
Figure 8
N
P
J
M
6.Wrap timing belt (P) around driven pulley (M) and
drive pulley (J). Install driven pulley (M) onto
conveyor shaft.
7.Using a straight edge (T of Figure 9), align driven
pulley (M) with drive pulley (J). Tighten driven
pulley set screws (U).
Figure 9
U
M
T
J
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 0.125¨(3 mm) deflection
for 1.0 lb (456 grams) of force at timing belt mid-point
(W). Tighten tensioner screw to 103 in-lb (12 Nm).
1
W
W
Figure 10
2
V
9.Install cover (K of Figure 11) with four (4) screws
(L). Tighten to 35 in-lb (4 Nm).
Figure 11
K
L
L
Installation

2100, 4100, 6100 Series Bottom Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 7851-256 Rev. E
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 11) and remove
cover (K).
2.Loosen tensioner (V of Figure 12).
Figure 12
V
P
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 0.125¨(3 mm)
deflection for 1.0 lb (456 grams) of force at timing belt
mid-point (W). Tighten tensioner screw to 103 in-lb
(12 Nm).
4.Install cover (K of Figure 11) 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 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 set screws (U of Figure
13) and remove pulley with belt (P). For
re-installation, see steps 6 and 7 on page 6.
Figure 13
U
P
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 0.125¨(3 mm)
deflection for 1.0 lb (456 grams) of force at timing belt
mid-point (W). Tighten tensioner screw to 103 in-lb
(12 Nm).
6.Install cover (K of Figure 11) 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 Standard Load 90°Industrial 60 Hz Gearmotors SOMM
851-256 Rev. E 8Dorner Mfg. Corp.
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 7.
2.Loosen set 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
on page 6.
Gear Reducer 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.Loosen drive pulley set screws (X of Figure 14).
Remove drive pulley (J) and timing belt (P).
Figure 14
P
J
X
4.Remove four (4) gear reducer mounting screws (Q
of Figure 15). Remove gearmotor.
Figure 15
Q
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
AD
AC
Y
Y
AE
AB
6.Remove two (2) screws (AC) and detach output
shaft cover (AD).
7.Remove gear reducer output shaft key (AE).
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Bottom Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors SOMM
Dorner Mfg. Corp. 9851-256 Rev. E
8.Loosen six (6) set screws (AF of Figure 17). Remove
drive shaft (AG) and key (AH).
bw7110016a
Figure 17
AF AG
AH
9.Apply grease (AI of Figure 18) to shaft.
Figure 18
AI
10.Replace the original shaft components into new gear
reducer (see Figure 17). Tighten set screws (AF) 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.
11.With key (J 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
Flate Belt Conveyor Cleated Belt Conveyor
12.Install gearmotor to mounting bracket and tighten
screws (Q of Figure 15) to 103 in-lb (12 Nm).
NOTE: Drive pulley (J of Figure 14) is removed.
Wrap timing belt around drive pulley and complete
step 13.
13.Completesteps6through9of“Installation”section
on page 6.
Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Bottom Mount Drive Package for Standard Load 90°Industrial 60 Hz Gearmotors SOMM
851-256 Rev. E 10 Dorner Mfg. Corp.
Motor Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Ç
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 motor:
a. Loosen terminal box screws (AJ of Figure 20) and
remove cover (AK).
Figure 20
AJ
AK
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 (AL of Figure 21).
Figure 21
AL
4.Remove four screws (Y of Figure 22). Detach motor
(Z) from gear reducer (AA). Retain motor output
shaft key (AB).
Figure 22
Z
Y
AA
AB
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 (AB of Figure 23) in keyway, slide motor
and gear reducer together. Install screws (Y) and
tighten.
Figure 23
AB
Y
6.Replace wiring:
DFor a single phase motor, reverse step 1 on this page.
DFor a three phase motor, reverse step 2, on this page.
DFor a DC variable speed motor, reverse step 3 on this
page.
Preventive Maintenance and Adjustment