Dorner 2100 Series Instruction manuelle

851-298 Rev. A

Set-up, Operation

& Maintenance Manual

2100, 4100, 6100 Series

Top Mount Drive Package

for Light Load 50 Hz Gearmotors

Table of Contents

Warnings – General Safety 2. . . . . . . . . . . . . . . . . . . .

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Tools 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventative Maintenance & Adjustment 6. . . . . . . . .

Required Tools 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Belt Tensioning 6. . . . . . . . . . . . . . . . . . . . .

Timing Belt Replacement 6. . . . . . . . . . . . . . . . . . .

Drive or Driven Pulley Replacement 7. . . . . . . . . . .

Gearmotor Replacement 7. . . . . . . . . . . . . . . . . . . .

Service Parts 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return Policy 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM

851-298 Rev. A 2Dorner Mfg. Corp.

The safety alert symbol, black triangle with white

exclamation, is used to alert you to potential

personal injury hazards.

ÇÇ

WARNING

ÇÇ

Climbing, sitting, walking or

riding on conveyor will

cause severe injury.

KEEP OFF CONVEYORS.

DANGER

ÇÇ

DANGER

DO NOT OPERATE

CONVEYORS IN AN

EXPLOSIVE ENVIRONMENT.

ÇÇ

Hazardous voltage will

cause severe injury or

death.

LOCK OUT POWER

BEFORE WIRING.

DANGER

ÇÇ

Gearmotors may be HOT.

DO NOT TOUCH Gearmotors.

WARNING

ÇÇ

Exposed moving parts can

cause severe injury.

LOCK OUT POWER before

removing guards or

performing maintenance.

WARNING

ÇÇ

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 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 Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM

Dorner Mfg. Corp. 3851-298 Rev. A

Refer to Figure 1 for typical components.

A Conveyor

B Mounting Bracket

C Gearmotor

D Belt Tensioner

E Cover

F Timing Belt

G Drive Pulley

H Driven Pulley

Typical Components

Figure 1

Specifications

Gearmotor Mounting Package Models:

Example:

Language Code = CE English

Output Shaft Type = Parallel Shaft

Gearmotor Type = Light Load, Industrial,

Fixed Speed

Mount Style = Top Mount

Conveyor Width Reference*

Mount Position = A, B, C or D

(see detail to the right)

2U T P L WW A –32 32

2 = 2100 Series Conveyor

4 = 4100 Series Conveyor

6 = 6100 Series Conveyor

Drive Pulley (see Table 2)

Driven Pulley (see Table 2)

* See “Ordering and Specifications”Catalog for details.

Table 1: Gearmotor Specifications

Single Phase Three Phase

Output Power 0.022 kw 0.02 kw

Input Voltage 230 Volts A.C. 230/400 Volts A.C.

Input Frequency 50 Hz

Full Load Amperes 0.31 Amperes 0.22/0.13 Amperes

Gearmotor Ratios 8:1 and 28.1:1

Protection Ratings IP44

Product Description

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM

851-298 Rev. A 4Dorner Mfg. Corp.

Table 2: Belt Speeds for Light Load Fixed Speed Parallel Shaft 50 Hz Gearmotors

Gearmotors Belt Drive Driven

Speed Drive

Pulley Driven

Pulley

Part Number RPM N-m M/min Pulley Pulley

62Z028PL4(vp)FN 41 2.6 2.1 19 32

62Z028PL4(vp)FN 41 2.6 3.7 32 32

62Z028PL4(vp)FN 41 2.6 6.1 32 19

62Z008PL4(vp)FN 144 0.9 8.5 22 32

62Z008PL4(vp)FN 144 0.9 12.5 32 32

(vp) = voltage and phase

21 = 230 V, 1-phase

23 = 230 V, 3-phase

43 = 400 V, 3-phase

NOTE: 203 through 610 mm wide conveyors with

light load drives should be limited to 2438 mm

length.

NOTE: For belt speed other than those listed, con-

tact factory for details.

Installation

Required Tools

DHex key wrenches:

2.5 mm, 3 mm, 5 mm

DStraight edge

DTorque wrench

Installation Component List

I Top Mount Assembly

J Driven Pulley

K Cover

L M4 Socket Head Screws (4x)

M Timing Belt

N Key

O M6 Socket Head Screws (2x)

Mounting

ÇÇ

Exposed moving parts can

cause severe injury.

LOCK OUT POWER before

removing guards or

performing maintenance.

WARNING

1.Typical components (Figure 2)

Figure 2

Specifications

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM

Dorner Mfg. Corp. 5851-298 Rev. A

NOTE: 6100 conveyor shown, 2100 & 4100 similar.

2.Locate drive output shaft (P of Figure 3) and remove

two (2) screws (Q).

Figure 3

3.Attach mount assembly (I of Figure 4) with screws

(O). Tighten screws to 9 Nm.

Figure 4

Drive shaft keyway may be

sharp.

HANDLE WITH CARE.

WARNING

4.Install key (N of Figure 5).

Figure 5

5.Wrap timing belt (M) around driven pulley (J) and

drive pulley (R). Install driven pulley (J) onto

conveyor shaft.

6.Using a straight edge (S of Figure 6), align driven

pulley (J) with drive pulley (R). Tighten driven

pulley set screws (T).

Figure 6

7.Depending on conveyor belt travel (direction 1 or 2),

locate timing belt tensioner (U of Figure 7) as shown.

Tension timing belt to obtain 3 mm deflection for 456

grams of force at timing belt mid-point (V). Tighten

tensioner screw to 12 Nm.

Figure 7

8.Install cover (K of Figure 8) with four (4) screws (L).

Tighten to 4 Nm.

Figure 8

Installation

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM

851-298 Rev. A 6Dorner Mfg. Corp.

Required Tools

DHex key wrenches

2.5 mm, 3 mm, 5 mm

DStraight edge

DScrewdriver (for terminal box screws)

DTorque wrench

Timing Belt Tensioning

ÇÇ

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 9) and remove

cover (K).

Figure 9

2.Loosen tensioner (U of Figure 10).

Figure 10

3.Depending on conveyor belt travel (direction 1 or 2),

locate timing belt tensioner (U of Figure 11) as shown.

Tension timing belt to obtain 3 mm deflection for 456

grams of force at timing belt mid-point (V). Tighten

tensioner screw to 12 Nm.

Figure 11

4.Install cover (K of Figure 9) with four (4) screws (L).

Tighten screws to 4 Nm.

Timing Belt Replacement

ÇÇ

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 9) and remove

cover (K).

2.Loosen tensioner (U of Figure 10).

3.Remove timing belt (M of Figure 12).

NOTE: If timing belt does not slide over pulley

flange, loosen driven pulley set screws (T of Figure

12) and remove pulley with belt. For re-installation,

see steps 5 through 8 on page 5.

Figure 12

4.Install new timing belt.

5.Depending on conveyor belt travel (direction 1 or 2),

locate timing belt tensioner (U of Figure 11) as

shown. Tension timing belt to obtain 3 mm

deflection for 456 grams of force at timing belt

mid-point (V). Tighten tensioner screw to 12 Nm.

6.Install cover (K of Figure 9) with four (4) screws (L).

Tighten screws to 4 Nm.

Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM

Dorner Mfg. Corp. 7851-298 Rev. A

Drive or Driven Pulley Replacement

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 6.

2.Loosen set screws and remove drive or driven pulley.

NOTE: If drive pulley (R of Figure 13) is replaced,

wrap timing belt around drive pulley and complete

step 3.

Figure 13

3.Completesteps5through8of“Installation”section

on page 5.

Gearmotor Replacement

Exposed moving parts can

cause severe injury.

LOCK OUT POWER before

removing guards or

performing maintenance.

WARNING

Hazardous voltage will

cause severe injury or

death.

LOCK OUT POWER

BEFORE WIRING.

DANGER

NOTE: Single phase gearmotor shown, three phase

similar.

1.For single phase motor:

a.Loosen terminal box screws (W of Figure 14) and

remove cover (X).

Figure 14

b.Record wire colors on terminals U1, W1 and

ground ( )(Figure 15). Loosen terminals U1, W1

and ground and remove wires.

Figure 15

c.Loosen cord grip (Y of Figure 15) and remove

cord.

Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM

851-298 Rev. A 8Dorner Mfg. Corp.

1.For three phase motor:

a.Loosen terminal box screws (W of Figure 14) and

remove cover (X).

b.Record wire colors on terminals U1, V1, W1 and

ground ( )(Figure 16). Loosen terminals U1, V1,

W1 and ground and remove wires.

Figure 16

c.Loosen cord grip (Y of Figure 16) and remove

cord.

2.Remove four (4) screws (L of Figure 9) and remove

cover (K).

3.Loosen tensioner (U of Figure 10).

4.Remove timing belt (M of Figure 17).

NOTE: If timing belt does not slide over pulley

flange, loosen driven pulley set screws (T of Figure

17) and remove pulley with belt (M). For

re-installation, see steps 5 through 8 on page 5.

Figure 17

5.Loosen two (2) set screws (T of Figure 18). Remove

drive pulley (R).

Figure 18

6.Remove four (4) screws (Z) and detach gearmotor.

7.Mount new gearmotor with four (4) screws (Z).

Tighten to 5 Nm.

8.Replace drive pulley (R of Figure 18) and tighten set

screws (T).

9.Completesteps5through8of“Installation”section

on page 5.

10.Replace wiring:

DFor a single phase motor, reverse step 1 on page 7.

DFor a three phase motor, reverse step 1 on this page.

Preventive Maintenance and Adjustment

2100, 4100, 6100 Series Top Mount Drive Package for Light Load 50 Hz Gearmotors SOMM

Dorner Mfg. Corp. 9851-298 Rev. A

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

162Z008PL421 Gearmotor, 22 W, 230 Volts, 144 RPM,

50 Hz, 1-Phase, 8:1

62Z028PL423 Gearmotor, 20 W, 230Volts, 41 RPM,

50 Hz, 3-Phase, 28:1

62Z028PL421 Gearmotor, 22 W, 230 Volts, 41 RPM,

50 Hz, 1-Phase. 28:1

62Z008PL423 Gearmotor, 20 W, 230 Volts, 144 RPM,

50 Hz, 3-Phase, 8:1

62Z028PL443 Gearmotor, 20 W, 400 Volts, 41 RPM,

50 Hz, 3-Phase, 28:1

62Z008PL443 Gearmotor, 20 W, 400 Volts, 144 RPM,

50 Hz, 3-Phase, 8:1

2 814-104 Timing Belt, 15mm W x 450mm L

814-105 Timing Belt, 15mm W x 460mm L

814-065 Timing Belt, 15mm W x 475mm L

814-101 Timing Belt, 15mm W x 500mm L

814-064 Timing Belt, 15mm W x 535mm L

3 450365MP Drive Pulley, 19 Tooth

450366MP Drive Pulley, 22 Tooth

450367MP Drive Pulley, 28 Tooth

450368MP Drive Pulley, 32 Tooth

450369MP Drive Pulley, 44 Tooth

4 807-1070 Drive Pulley Woodruff Key

5 450365MP Driven Pulley, 19 Tooth

450366MP Driven Pulley, 22 Tooth

450367MP Driven Pulley, 28 Tooth

450368MP Driven Pulley, 32 Tooth

6 980422M Driven Pulley Key, 4mm x 22mm

Figure 19

5,6

3,4

Service Parts

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 @

www.dorner.com

851-298 Rev. A Printed in U.S.A. 400

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

DORNER

Arnold-Sommerfeld-Ring2

D-52499 Baesweiler

USA

TEL 1-800-397-8664 (USA)

FAX 1-800-369-2440 (USA)

Germany

TEL (02401) 80 52 90

FAX (02401) 80 52 93

Internet: www.dorner.com

Outside the USA:

TEL 1-262-367-7600, FAX 1-262-367-5827

DORNER MFG. CORP.

Return Policy

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