Dorner 6100 Series Manual instruction

851-474 Rev. B

Setup, Operation

& Maintenance Manual

6100 Series Bottom Mount Drive Package

for Heavy Load 905Sanitary Gearmotors

Table of Contents

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

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

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

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

Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Tools 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-phase Motor Starter 7. . . . . . . . . . . . . . . .

Preventive Maintenance & Adjustment 8. . . . . . . . . .

Required Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Belt Replacement 8. . . . . . . . . . . . . . . . . .

Timing Belt Tensioning 9

. . . . . . . . . . . . . . . . . . . . . .

Drive or Driven Pulley Replacement 9. . . . . . . . . .

Gear Reducer Replacement 10. . . . . . . . . . . . . . . . . .

Gear Motor Replacement 12. . . . . . . . . . . . . . . . . . .

Service Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return Policy 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance

851-474 Rev. B 2Dorner Mfg. Corp.

The safety alert symbol, black triangle with

white exclamation, is used to alert you to

potential personal injury hazards.

WARNING

Climbing, sitting, walking

or riding on conveyor will

cause severe injury.

KEEP OFF CONVEYORS.

DANGER

Do NOT OPERATE

CONVEYORS IN AN

EXPLOSIVE ENVIRONMENT.

Exposed moving parts can

cause severe injury.

LOCK OUT POWER before

removing guards or

performing maintenance.

WARNING

Gearmotors may be HOT.

DO NOT TOUCH Gearmotors.

WARNING

Exposed moving parts can

cause severe injury.

REPLACE ALL GUARDS

BEFORE RUNNING

CONVEYOR.

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.

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 fac-

tory regarding discrepancies.

DInspect packages for shipping damage. Contact carri-

er regarding damage.

DAccessories may be shipped loose. See accessory

instructions for installation.

Dorner 6100 Series conveyors are covered by patent

number5174435andcorrespondingpatentsandpatent

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

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance

Dorner Mfg. Corp. 3851-474 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

I Motor Control

Typical Components

Figure 1

Specifications

Gearmotor Mounting Package Models:

Example:

6 WW A1

Language Code = CE English

Output Shaft Type L = Left Hand

R = Right Hand

Drive/Driven Pulleys

(See tables 2, 3 & 4)

–3232

Gearmotor Type = Heavy Load, Sanitary

LU ZB

Mount Style = Bottom Mount

Conveyor Width Reference*

Mount Position = A1, A2, D1 or D2

(see detail to the right)

“–” = Flat Belt (or add cleat type)

D1 D2

* See “Ordering and Specifications”Catalog for details.

Table 1: Gearmotor Specifications

Three-Phase

Output Power 0.19 kW

Input Voltage 230/400 Volts A.C.

Input Frequency 50 Hz

Full Load Amperes 1.2/.7 Amperes

Gearmotor Ratios 5:1, 15:1 and 50:1

Protection Ratings IP55 for Gearmotor and Motor Starter

Product Description

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance

851-474 Rev. B 4Dorner Mfg. Corp.

Table 2: Heavy Load Fixed Speed 905Sanitary 60 Hz Gearmotors

Gearmotors Belt Speed Drive Driven

Part Number RPM N-m ft/min M/min Pulley Pulley

62(c)050(r)Z4(vp)FN 29 50.1 5 1.5 19 32

62(c)050(r)Z4(vp)FN 29 50.1 8 2.4 32 32

62(c)050(r)Z4(vp)FN 29 50.1 12 3.7 48 32

62(c)050(r)Z4(vp)FN 29 50.1 18 5.5 48 22

62(c)015(r)Z4(vp)FN 97 19.9 28 8.5 32 32

62(c)015(r)Z4(vp)FN 97 19.9 41 12.5 48 32

62(c)015(r)Z4(vp)FN 97 19.9 60 18.3 48 22

62(c)005(r)Z4(vp)FN 290 7.2 83 25.3 32 32

62(c)005(r)Z4(vp)FN 290 7.2 124 37.8 48 32

62(c)005(r)Z4(vp)FN 290 7.2 155 47.2 60 32

62(c)005(r)Z4(vp)FN 290 7.2 181 55.2 48 22

62(c)005(r)Z4(vp)FN 290 7.2 226 68.9 60 22

G = CE German 23 = 230 V 3 phase L = Left Hand

U = CE Great Britain 43 = 400V 3 phase R = Right Hand

NOTE: For belt speed other than those listed,

contact factory for details.

Specifications

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance

Dorner Mfg. Corp. 5851-474 Rev. B

Required Tools

DWrenches (for hexagon head fasteners)

8mm, 10mm, 13mm & 14mm

D2.5 mm hex key wrench

DStraight edge

DTorque wrench

Mounting

Exposed moving parts can

cause severe injury.

LOCK OUT POWER before

removing guards or

performing maintenance.

Installation Component List

ABottom Mounting Package Assembly

BM6 x 30 mm, Hexagon Head Screws (4x)

CTiming Belt

DDriven Pulley

EDrive Cover

FMotor Key

GMotor Mounting Screws & Washers (4x)

HDrive Pulley

I Motor

JGear Reducer

KMotor Starter

LM6 x 20mm Hex Head Screws (2x)

MAccessory Mounting Clips

N Key

1.Gather components (Figure 2)

NOTE: 102mm and wider mounting assembly

shown. 51mm and 76mm wide mounting assem-

blies include two spacer (AC of Figure 5) and two

long M6 screws (AD).

Figure 2

2.Remove screws (O of Figure 3) from both sides of

conveyor.

Figure 3

Drive shaft keyway may be

sharp.

HANDLE WITH CARE.

3.Install square key (N of Figure 3) into conveyor

drive shaft.

4a.For 102mm and wider conveyors, loosen (but do not

remove) screws (P of Figure 4). Attach bottom

mount assembly (A) to conveyor with screws (B).

Tighten screws (B) and (P) to 10.4 Nm.

Figure 4

4b.For 51mm to 76mm wide conveyors, loosen (but do

not remove) screws (P of Figure 5). Attach bottom

mount assembly (A) to conveyor with two screws

(B), spacer tubes (AC) and screws (AD). Tighten

screws (B), (AD) and (P) to 10.4 Nm.

Figure 5

AD AC

Installation

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance

851-474 Rev. B 6Dorner Mfg. Corp.

5.Wrap timing belt (C of Figure 6) around driven

pulley (D) and drive pulley (H). Attach driven

pulley (D) to conveyor shaft.

Figure 6

6.Using a straight edge (Q of Figure 7), align driven

pulley (D) with drive pulley (H). Tighten driven

pulley set screws (R).

Figure 7

7.Depending on conveyor belt travel (1 or 2 of

Figure 8), locate timing belt tensioner (S), as

shown. Tension timing belt to obtain 3mm

deflection for 4.3N of force at timing belt

mid-point (T). Tighten tensioner to 51 Nm.

Figure 8

8.Attach cover (E of Figure 9) with screws (U).

Tighten screws to 4 Nm.

Figure 9

Drive shaft keyway may be

sharp.

HANDLE WITH CARE.

9.Install key (F of Figure 10).

Figure 10

IMPORTANT:Be extremely careful when

coupling motor to gear reducer. Avoid

misalignment and forcing the connection causing

possible permanent gear reducer seal damage.

10.Attach gear motor (I of Figure 11) to gear reducer

(J) with screws and washers (G of Figure 10).

Tighten to 41 Nm.

Figure 11

Installation

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance

Dorner Mfg. Corp. 7851-474 Rev. B

11.Attach mounting clips (M of Figure 12) to

conveyor.

Figure 12

12.Attach motor starter (K of Figure 13) to clips with

screws (L). Tighten to 10.4 Nm.

Figure 13

Wiring

Three-phase Motor Starter

Hazardous voltage will

cause severe injury or

death.

LOCKOUT POWER

BEFORE WIRING.

DANGER

NOTE: 230 volt three-phase manual motor

starters must be wired in accordance with

applicable electrical codes.

1.Loosen cover screws (V of Figure 14) and remove

cover.

Figure 14

NOTE: Line cord must be 0.28¨(7 mm) minimum

to 0.47¨(12 mm) maximum in diameter.

2.Insert line cord through grip (W) and tighten nut.

3.For correct three-phase motor shaft rotation,

connect line phase sequence L1, L2 & L3 to

terminals as shown (Figure 15).

Ground L1 L2 L3

13 5

Figure 15

Controller must be properly grounded. Failure

to properly ground control box may cause injury

to personnel.

NOTE:The motor ground wire is also attached to

left terminal marked (Figure 15).

4.Attach ground wire to lower left terminal marked

(see Figure 15).

5.Replace starter cover and tighten screws (V of

Figure 14).

Installation

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance

851-474 Rev. B 8Dorner Mfg. Corp.

Required Tools

DWrenches (for hexagon head fasteners)

8mm, 10mm, 13mm, 14mm

D2.5 mm hex key wrench

DStraight edge

DTorque wrench

Timing Belt Replacement

Exposed moving parts can

cause severe injury.

LOCK OUT POWER before

removing guards or

performing maintenance.

1.Loosen four (4) screws (U of Figure 16) and

remove cover (E).

Figure 16

2.Loosen tensioner (S of Figure 17).

Figure 17

3.Remove timing belt (C).

NOTE: If timing belt does not slide over pulley

flange, loosen driven pulley set screws (R of

Figure 18) and remove pulley with belt. For

re-installation, see steps 5 and 6 on page 6.

Figure 18

4.Install new timing belt.

5.Depending on conveyor belt travel (1 or 2 of

Figure 19), locate timing belt tensioner (S) as

shown. Tension timing belt to obtain 3mm

deflection for 4.3N of force at timing belt

mid-point (T). Tighten tensioner to 51 Nm.

Figure 19

NOTE: Do not over-tighten screws (U of Figure

16).

6.Attach cover (E of Figure 16) and tighten four (4)

screws (U) to 4 Nm.

Preventive Maintenance & Adjustment

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance

Dorner Mfg. Corp. 9851-474 Rev. B

Timing Belt Tensioning

Exposed moving parts can

cause severe injury.

LOCK OUT POWER before

removing guards or

performing maintenance.

WARNING

1.Remove four (4) screws (U of Figure 20) and

remove cover (E).

Figure 20

2.Loosen tensioner (S of Figure 21).

Figure 21

3.Depending on direction of conveyor belt travel (1

or 2 of Figure 22), position belt tensioner (S) as

shown. Tension belt to obtain 3mm deflection for

456 grams of force at belt mid-point (T). Tighten

tensioner screw to 12Nm.

Figure 22

4.Attach cover (E of Figure 23) with four (4) screws

(U). Tighten to 4Nm.

Figure 23

Drive or Driven Pulley Replacement

ÇÇ

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 set screws and remove drive or driven

pulley.

NOTE: If drive pulley (H of Figure 21) is replaced,

wrap timing belt around drive pulley and complete

step 3.

3.Complete steps 5 through 8 of “Installation”

section on page 6.

Preventive Maintenance and Adjustment

6100 Series Bottom Mount Drive Package for Heavy Load 90°Sanitary Gearmotors Setup, Operation & Maintenance

851-474 Rev. B 10 Dorner Mfg. Corp.

Gear Reducer Replacement

Exposed moving parts can

cause severe injury.

LOCK OUT POWER before

removing guards or

performing maintenance.

WARNING

1.Remove four (4) screws (U of Figure 24) and

remove cover (E).

Figure 24

2.Loosen tensioner (S of Figure 25).

Figure 25

3.Loosen drive pulley set screws (X of Figure 26).

Remove drive pulley (H) and timing belt (C).

Figure 26

4.Remove screws and washers (G of Figure 27).

Detach motor (I) from gear reducer (J).

Figure 27

5.Remove four (4) gear reducer mounting screws (Z

of Figure 28). Remove gear reducer.

Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

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