For other service manuals visit our website at: www.dorner.com/service_manuals.asp DORNER MFG. CORP. INSIDE THE USA OUTSIDE THE USA P.O. Box 20 • 975 Cottonwood Ave. TEL: 1-800-397-8664 TEL: 262-367-7600 Hartland, WI 53029-0020 USA FAX: 1-800-369-2440 FAX: 262-367-5827 851-255 Rev. K 2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors Installation, Maintenance & Parts Manual
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2100, 2200, 4100, 6200 & MPB Series Top Mount Drive
Pack. for Standard Load Parallel Shaft 60 Hz
Gearmotors Installation, Maintenance & Parts Manual
For other service manuals visit our website at:www.dorner.com/service_manuals.asp
DORNER MFG. CORP. INSIDE THE USA OUTSIDE THE USAP.O. Box 20 • 975 Cottonwood Ave. TEL: 1-800-397-8664 TEL: 262-367-7600Hartland, WI 53029-0020 USA FAX: 1-800-369-2440 FAX: 262-367-5827
851-255 Rev. K
Table of ContentsIntroduction ......................................................................... 2Warnings − General Safety ................................................. 3Product Description ............................................................. 4Specifications ...................................................................... 4Installation ........................................................................... 9
Preventive Maintenance and Adjustment.......................... 11Required Tools............................................................... 11Timing Belt Tensioning ................................................. 11Timing Belt Replacement .............................................. 12
Drive or Driven Pulley Replacement ............................. 12Gearmotor Replacement................................................. 12
Service Parts....................................................................... 142100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package ............................................ 144100 Series Adapter Package ........................................ 15Gearmotors .................................................................... 15
Upon receipt of shipment:• Compare shipment with packing slip. Contact factory
regarding discrepancies.• Inspect packages for shipping damage. Contact carrier
regarding damage.• Accessories may be shipped loose. See accessory instruc-
tions 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 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.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 installation, 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 .
NOTESome illustrations may show guards removed. DO NOT operate equipment without guards.
Dorner Mfg. Corp. 2 851-255 Rev. K
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
Warnings − General Safety
A WARNINGThe safety alert symbol, black triangle with white exclamation, is used to alert you to potential personal injury hazards.
A DANGER
Climbing, sitting, walking or riding on conveyor will cause severe injury. KEEP OFF CONVEYORS.
A DANGER
Do NOT OPERATE CONVEYORS IN AN EXPLOSIVE ENVIRONMENT.
A WARNING
Exposed moving parts can cause severe injury.LOCK OUT POWER before removing guards or performing maintenance.
A WARNING
Gearmotors may be HOT.DO NOT TOUCH Gearmotors.
A WARNING
Exposed moving parts can cause severe injury.REPLACE ALL GUARDS BEFORE RUNNING CONVEYOR.
A WARNING
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.
A WARNING
MPB Series Conveyors are not reversible. Reversing creates pinch points which can cause severe injury.DO NOT REVERSE MPB SERIES CONVEYORS.
851-255 Rev. K 3 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
Product Description
Refer to Figure 1 for typical components. Figure 1
NOTEFor belt speed other than those listed, contact factory for details.
Dorner Mfg. Corp. 8 851-255 Rev. K
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
Installation
Required Tools• Hex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm• Torque wrench
Mounting
1. Typical components (Figure 2)
Installation Component List:
Figure 2
Figure 2
2. For your reference, the following figures show gearmotor mounting configurations for various conveyor series.
Figure 3
2200 Series
Figure 3 Figure 4
6200 Series
Figure 4 Figure 5
4100 Series
Figure 5
A WARNING
Exposed moving parts can cause severe injury.LOCK OUT POWER before removing guards or performing maintenance.
A WARNING
MPB Series Conveyors are not reversible. Reversing creates pinch points which can cause severe injury.DO NOT REVERSE MPB SERIES CONVEYORS.
A WARNING
For MPB Series and Cleated Belt Conveyors Gearmotors must be mounted as shown in Figure 7.Failure to do so creates pinch points which can cause severe injury.
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
JK
L
M
O
P
N
I
Gearmotoris mountedto HeadPlate
Gearmotor
is mounted to
Drive Spacer
Gearmotoris mountedto DriveAdapterPlate
851-255 Rev. K 9 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
Installation
Figure 6
2100 Series
Figure 6 Figure 7
MPB Series
Figure 7
3. Locate drive output shaft (Figure 8, item Q) and remove two (2) screws (R).
Figure 8
Figure 8
4. Attach mount assembly (Figure 9, item I) with screws (O). Tighten screws to 80 in-lb (9 N−m).
Figure 9
Figure 9
5. Install key (Figure 10, item N). Figure 10
Figure 10
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 (Figure 9, item S). Place the cam bearing and spacer (Figure 11, item S) 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).
NOTE6200 Series conveyor shown, other Series similar.
Gearmotor
is mounted
to HeadPlate
Gearmotoris mountedto HeadPlate
Q
R
A WARNING
Drive shaft keyway may be sharp.HANDLE WITH CARE.
I
O
M
N
P
Q
Dorner Mfg. Corp. 10 851-255 Rev. K
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
Preventive Maintenance and Adjustment
Figure 11
Figure 11
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
Figure 12
9. Install cover (Figure 13, item K) with four screws (L). Tighten to 35 in-lb (4 N−m).
Figure 13
Figure 13
Preventive Maintenance and Adjustment
Required Tools• Hex key wrenches − 2 mm, 2.5 mm, 3 mm & 5 mm
• Adjustable wrench (for hexagon head screws)• Torque wrench
Timing Belt Tensioning
1. Remove four screws (Figure 13, item L) and remove cover (K).
3. 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).
S
M
1
V
V
2
U
K
L
L
A WARNING
Exposed moving parts can cause severe injury.LOCK OUT POWER before removing guards or performing maintenance.
U
851-255 Rev. K 11 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
Preventive Maintenance and Adjustment
4. Install cover (Figure 13, item K) with four screws (L).
Tighten to 35 in-lb (4 N−m).
Timing Belt Replacement
1. Remove four screws (Figure 13, item L) and remove cover (K).
4. Install new timing belt.5. Depending on conveyor belt travel (direction 1 or 2),
locate timing belt tensioner (Figure 12, item U) 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 (V). Tighten tensioner screw to 103 in-lb (12 N−m).
6. Install cover (Figure 13, item K) with four screws (L). Tighten to 35 in-lb (4 N−m).
Drive or Driven Pulley Replacement
1. Complete steps 1 through 3 of “Timing Belt Replacement” section on page 12.
2. Loosen set screws and remove drive or driven pulley.
3. Complete steps 6 through 9 of “Installation” section beginning on page 10.
Gearmotor Replacement
1. For single phase motor, unplug power cord from outlet.2. For three phase motor:
a. Loosen terminal box screws (Figure 16, item W) and remove cover (X).
A WARNING
Exposed moving parts can cause severe injury.LOCK OUT POWER before removing guards or performing maintenance.
NOTEIf timing belt does not slide over pulley flange, loosen two driven pulley set screws (Figure 15, item T) and remove pulley with belt (P). For re-installation, see steps 6 and 7 on page 10.
T
P
A WARNING
Exposed moving parts can cause severe injury.LOCK OUT POWER before removing guards or performing maintenance.
NOTEIf drive pulley (Figure 18, item J) was replaced, wrap timing belt around drive pulley and complete step 3.
A WARNING
Exposed moving parts can cause severe injury.LOCK OUT POWER before removing guards or performing maintenance.
A DANGER
Hazardous voltage will cause severe injury or death.LOCKOUT POWER BEFORE before wiring.
Dorner Mfg. Corp. 12 851-255 Rev. K
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
Preventive Maintenance and Adjustment
Figure 16
Figure 16
b. Record incoming wire colors connecting to red, black and blue leads. Loosen wire nuts and remove incoming wires.
c. Loosen cord grip and remove cord.3. For DC variable speed motor, unplug motor cord at
disconnect (Figure 17, item Y). Figure 17
Figure 17
4. Remove four screws (Figure 13, item L) and remove cover (K).
9. Install new gearmotor to adapter plate with screws (Figure 20, item AB). Tighten screws to 103 in-lb (12 N−m).
10. Install gearmotor/adapter plate assembly on mounting bracket with screws (Figure 19, item AA). Tighten screws to 103 in-lb (12 N−m).
11. Complete steps 6 through 9 of “Installation” section beginning on page 10.
12. Replace wiring:
• For a single phase motor, reverse step 1 on page 12.• For a three phase motor, reverse step 2, on page 12.• For a DC variable speed motor, reverse step 3 on page 13.
X
W
Y
J
P
NOTEIf drive pulley (Figure 18, item J) was removed, wrap timing belt around drive pulley and complete step 11.
AA
AA
AB
AB
851-255 Rev. K 13 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
Service Parts
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package
NOTEFor replacement parts other than those shown in this section, contact an authorized Dorner Service Center or the factory. Key Service Parts and Kits are identified by the Performance Parts Kits logo . Dorner recommends keeping these parts on hand.
1
2
3
21
22
12
11
19
7
18
20
6
10164
17
15
5
9
14
8
Item Part Number Description
1 202390M Nut, Cam Follower
2 450027M Adaptor Plate Assembly (6200 Only)
3 450029M Adaptor Plate Assembly
4 450375M Cover Mounting Bracket
5 450376M Drive Guard
6 450443M Grove Mounting Plate
7 450445 Spacer
8 802−046 Bearing
9 807−226 Snap−out Plastic Plug
10 807−952 Groove Pin (6200 Only)
11 902−157 Sock Cap Head Screw 1/4−28 x .75”
12 903−161 Flat Cap Head Screw 1/4−28 x .75”
13 912−084 Square Key .188” x 1.50” ???
14 920406M Socket Head Screw M4 x 6mm
15 920410M Socket Head Screw M4 x 10mm
16 920625M Socket Head Screw M6 x 25mm
920616M Socket Head Screw M6 x 16mm (4100 Only)
17 920695M Socket Low Head Screw M6 x 20mm
18 920845M Socket Head Screw M8 x 45mm
19 980422M Square Key 4mm x 22mm
912−053 Square Key .125” x .75” (4100 Series − 1” (25mm) Wide Conveyor Only)
20 814-104 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
814-112 Timing Belt, 15mm W x 495mm L
814-101 Timing Belt, 15mm W x 500mm L
814-108 Timing Belt, 15mm W x 520mm L
814-064 Timing Belt, 15mm W x 535mm L
814-099 Timing Belt, 15mm W x 565mm L
21 450365MP Driven Pulley, 19Tooth, 12mm bore
450366MP Driven Pulley, 22Tooth, 12mm bore
450367MP Driven Pulley, 28Tooth, 12mm bore
450368MP Driven Pulley, 32Tooth, 12mm bore
22 450434 Drive Pulley, 22Tooth, 0.75” bore
450435 Drive Pulley, 28Tooth, 0.75” bore
450436 Drive Pulley, 32Tooth, 0.75” bore
450437 Drive Pulley, 44Tooth, 0.75” bore
450438 Drive Pulley, 48Tooth, 0.75” bore
450439 Drive Pulley, 60Tooth, 0.75” bore
Item Part Number Description
Dorner Mfg. Corp. 14 851-255 Rev. K
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
2100, 2200, 4100, 6200 & MPB Series Top Mount Drive Pack. for Standard Load Parallel Shaft 60 Hz Gearmotors
Return Policy
Returns must have prior written factory authorization or they will not be accepted. Items that are returned to Dorner without authorization will not be credited nor returned to the original sender. 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. Dorner part number(s) of 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 for reference.
There will be a return charge on all new undamaged items returned for credit where Dorner was not at fault. Dorner is not responsible for return freight on such items.
Conveyors and conveyor accessoriesStandard catalog conveyors 30%MPB Series, cleated and specialty belt conveyors 50%7400 & 7600 Series conveyors non-returnable itemsEngineered special products case by caseDrives and accessories 30%Sanitary stand supports non-returnable items
PartsStandard stock parts 30%MPB, cleated and specialty belts non-returnable items
Returns will not be accepted after 60 days from original invoice date.
The return charge covers inspection, cleaning, disassembly, disposal and reissuing of components 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. Contact Dorner for the name of your local representative. Our Technical Sales, Catalog Sales and Service Teams will gladly help with your questions on Dorner products.
For a copy of Dorner's Warranty, contact factory, distributor, service center or visit our website at www.dorner.com.
For replacement parts, contact an authorized Dorner Service Center or the factory.