3200 & 5200 Series Bottom Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors

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1 300 & 500 Series Bottom Mount Parallel Drive Package for Standard Load 60 Hz Gearmotors Installation, Maintenance & Parts Manual DORNER MFG. CORP. INSIDE THE USA OUTSIDE THE USA P.O. Box Cottonwood Ave. TEL: TEL: Hartland, WI USA FAX: FAX: Rev. F For other service manuals visit our website at:

2 Table of Contents Introduction... Warnings - General Safety... 3 Product Description... 4 Specifications... 4 Gearmotor Mounting Package Models:... 4 Table : Gearmotor Specifications... 5 Table : RPM/Torque for Fixed Speed Parallel Shaft 60 Hz Gearmotors... 5 Table 3: RPM/Torque for Variable Speed Parallel Shaft VFD Gearmotors... 6 Table 4: RPM/Torque for Variable Speed Parallel Shaft DC Gearmotors... 6 Table 5: RPM/Torque for Brushless DC Gearmotors... 6 Table 6: Pulley Ratio / Timing Belt Number... 7 Table 7: Conveyor Belt Speed Factor... 7 Belt Speed Calculation:... 7 How to Calculate Belt Speed... 7 Installation... 8 Required Tools... 8 Mounting... 8 Introduction IMPORTANT Some illustrations may show guards removed. DO NOT operate equipment without guards. 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 instructions for installation. Preventive Maintenance and Adjustment... 0 Required Tools... 0 Timing Belt Tensioning... 0 Timing Belt Replacement... 0 Drive or Driven Pulley Replacement... Motor Replacement... Single Phase Motor... Three Phase and VFD Motor... DC Variable Speed Motor... Brushless Motor... All Models... Notes... 3 Service Parts... 4 Bottom Mount Parallel Drive Package for Industrial Gearmotors... 4 Pulley Ratio / Timing Belt Combinations... 5 Parallel Shaft Industrial Gearmotors... 6 Notes... 7 Return Policy... 8 Dorner 300 Series conveyors are covered by patent numbers 5,56,60, 5,56,6, 5,03,447, 5,65,74, 6,87,737, 6,90,57, 6,97,509, 6,398,98 and patent applications in other countries. Dorner LPZ Series conveyors are covered by patent numbers 5,56,60, 5,56,6, 5,03,447, 5,65,74, 5,875,883 and patent applications in other countries. Dorner 500 Series conveyors are covered by patent numbers 7,735,638, 7,874,49, 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. Dorner Mfg. Corp Rev. F

3 Warnings - General Safety A WARNING The safety alert symbol, black triangle with white exclamation, is used to alert you to potential personal injury hazards. A WARNING DANGER Climbing, sitting, walking or riding on conveyor will cause severe injury. KEEP OFF CONVEYORS. DANGER DO NOT OPERATE CONVEYORS IN AN EXPLOSIVE ENVIRONMENT. 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. 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 Rev. F 3 Dorner Mfg. Corp.

4 Product Description Refer to (Figure ) for typical components. Conveyor Cover 3 Timing Belt 4 Timing Belt Tensioner 5 Drive Pulley 6 Gearmotor 7 Mounting Bracket 8 Driven Pulley Figure Specifications Gearmotor Mounting Package Models: Example: Figure 3 M B P S A 6 6 Driven Pulley (see Table, 3 & 4) Drive Pulley (see Table, 3 & 4) Belt Type ( = flat belt, A through J = cleated belt ) Mount Position = A, B, C or D (see detail to the right) Gearmotor Type: S = Standard Load B = Brushless DC Output Shaft Type = Parallel Industrial Mount Style = Bottom Mount Language Code = U.S. English Product Series: 3 = 300 Series 5 = 500 Series A D B C Dorner Mfg. Corp Rev. F

5 Table : Gearmotor Specifications Specifications * Controller Inputs Table : RPM/Torque for Fixed Speed Parallel Shaft 60 Hz Gearmotors (vp) = voltage and phase = 5 V, -phase 3 = 08 30/460 V, 3-phase Single Phase Three Phase DC Variable Speed VFD Variable Speed Brushless DC Power/ Gear Ratio hp (kw) hp (kw) hp (kw) hp (kw) hp (kw) 5: 0.08 (0.06) 0.7 (0.3) 0. (0.09) 0.7 (0.3) - 0: 0.7 (0.3) 0.7 (0.3) 0.5 (0.9) 0.7 (0.3) 0.5 (0.9) 0: 0.33 (0.5) 0.38 (0.8) 0.5 (0.9) 0.38 (0.8) 0.5 (0.9) 30: 0.33 (0.5) 0.38 (0.8) 0.5 (0.9) 0.38 (0.8) - 50: (Brushless Only) N/A N/A N/A N/A 0.5 (0.9) 60: 0.33 (0.5) 0.38 (0.8) 0.33 (0.5) 0.38 (0.8) - 80: 0.33 (0.5) 0.38 (0.8) N/A 0.38 (0.8) - Input Voltage 5 VAC 30 VAC 30 VDC 30 VAC *5/30 VAC Input Frequency 60 Hz 60 Hz N/A 0 to 60 Hz 60 Hz Input Current/ Gear FLA FLA FLA FLA N/A Ratio 5: N/A 0: N/A 0: N/A 30: N/A 60: N/A 80: 4.9 N/A.9 N/A Motor RPM Power/Ratio Totally Enclosed Fan Cooled Totally Enclosed Non Ventilated Standard Load Gearmotors Part Number RPM In-lb N-m 6M80PS4vpFn M060PS4vpFn M030PS4vpFn M00PS4vpFn M00PS4vpFn M005PS4vpFn Totally Enclosed Fan Cooled Totally Enclosed Non-Ventilated Rev. F 5 Dorner Mfg. Corp.

6 Specifications Table 3: RPM/Torque for Variable Speed Parallel Shaft VFD Gearmotors Standard Load Gearmotors Part Number RPM In-lb N-m 6M80PS43EN M060PS43EN M030PS43EN M00PS43EN M00PS43EN M005PS43EN Table 4: RPM/Torque for Variable Speed Parallel Shaft DC Gearmotors Standard Load Gearmotors Part Number RPM In-lb N-m 6M80PSD3DEN M060PSD3DEN M030PSD3DEN M00PSD3DEN M00PSD3DEN Table 5: RPM/Torque for Brushless DC Gearmotors Gearmotors Part Number Gear Ratio RPM In-lb N-m 6M050PSBDDEN 50: M00PSBDDEN 0: M00PSBDDEN 0: NOTE For belt speed other than those listed, contact factory for details. Dorner Mfg. Corp Rev. F

7 Specifications Table 6: Pulley Ratio / Timing Belt Number Motor (Drive) Pulley Teeth Conveyor (Driven) Pulley Teeth Pulley Ratio Flat Belt Timing Belt Cleated Belt N/A N/A N/A Figure Driven Pulley Drive Pulley Figure Table 7: Conveyor Belt Speed Factor Series Ft/revolution M/revolution / Belt Speed Calculation: How to Calculate Belt Speed. Determine gearmotor RPM from tables -5.. Determine the pulley kit ratio. Count the number of teeth on the drive and driven pulleys following figure. Using table 6, look up pulley ratio based on pulley combinations. 3. Determine conveyor speed factor using table 7. Based on your conveyor type, select the appropriate factor. 4. Calculate belt speed: Example: Belt Speed = Gearmotor RPM (tables -5) x Pulley Kit Ratio (table 6) x Conveyor Speed Factor (table 7) 300 Series parallel shaft DC variable speed 0: gearmotor with 4 tooth sprocket on gearmotor (Drive) and 6 tooth sprocket on the conveyor output shaft (Driven). Gearmotor = 6M00PSD3DEN = 5-5 RPM Pulley Kit = 4 t mtr. - 6 t conv. =.50 Speed Factor = 300 Series = ft/min per RPM Minimum Belt Speed = 5 x.50 x = 8 Ft/min Maximum Belt Speed = 5 x.50 x = 5 Ft/min Rev. F 7 Dorner Mfg. Corp.

8 Installation Required Tools Hex key wrenches: mm,.5 mm, 3 mm, 5 mm Straight edge Torque wrench Mounting. Locate drive output shaft (Figure 4, item ). Remove two () M8 screws (Figure 4, item ) and four (4) M6 screws (Figure 4, item 3) and discard. Figure 4 A WARNING 3 3 Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance. Installation Component List: Figure 4 3. Attach bottom mount drive assembly (Figure 5, item ) with two () M8 screws (Figure 5, item ) and four (4) M6 screws (Figure 5, item 3). Tighten M6 screws to 46 in-lbs (6.5 N-m) and M8 screws to 88 in-lbs (3.5 N-m). Figure 5 Bottom Mount Drive Assembly Tensioner 3 Driven Pulley 4 Timing Belt 5 M8 Socket Head Screws (x) 6 M6 Socket Head Screws (4x) 7 Key 8 Drive Pulley 9 Cover Screws 0 Cover 3. Typical components (Figure 3). Figure 3 3 Figure 5 A WARNING Drive shaft keyway may be sharp. HANDLE WITH CARE. Figure 3 NOTE Cleated belt mounting package shown, flat belt mounting package similar. Dorner Mfg. Corp Rev. F

9 4. Install key (Figure 6, item ). Figure 6 3 Installation 8. Depending on conveyor belt travel (direction A or B), locate timing belt tensioner (Figure 9, item ) as shown. Tension timing belt to obtain /8 (3 mm) deflection for 6 lb (3 Kg) of force at timing belt midpoint (Figure 9, item ). Tighten tensioner screw to 0 in-lb ( Nm). Figure 9 A B 4 Figure 6 5. Wrap timing belt (Figure 6, item ) around driven pulley (Figure 6, item 3) and drive pulley (Figure 6, item 4). Install driven pulley onto conveyor shaft. 6. Using a straight edge (Figure 7, item ), align driven pulley (Figure 7, item ) with drive pulley (Figure 7, item 3). Figure 9 9. Install cover (Figure 0, item ) with four (4) screws (Figure 0, item ). Tighten screws to 35 in-lb (4 Nm). Figure 0 Figure 7 3 Figure 0 Figure 7 7. Tighten driven pulley taper-lock screws (Figure 8, item ). Figure 8 Figure Rev. F 9 Dorner Mfg. Corp.

10 Preventive Maintenance and Adjustment Required Tools Hex key wrenches: mm,.5 mm, 3 mm, 5 mm Adjustable wrench (for hexagon head screws) Straight edge Torque wrench Timing Belt Tensioning. Remove four (4) screws (Figure 0, item ) and remove cover (Figure 0, item ).. Loosen tensioner (Figure, item ). Figure A WARNING Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance. Timing Belt Replacement A WARNING Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance.. Remove four (4) screws (Figure 0, item ) and remove cover (Figure 0, item ).. Loosen tensioner (Figure, item ). 3. Remove timing belt (Figure, item ). NOTE If timing belt does not slide over pulley flange, loosen driven pulley taper-lock screws (Figure 8, item ) & (Figure, item ) and remove pulley with belt (Figure, item ). For re-installation, see steps 5 thru 7 on page 9. Figure Figure 3. Depending on conveyor belt travel (direction A or B), locate timing belt tensioner (Figure 9, item ) as shown. Tension timing belt to obtain /8 (3 mm) deflection for 6 lb (3 Kg) of force at timing belt midpoint (Figure 9, item ). Tighten tensioner screw to 0 in-lb ( Nm). 4. Install cover (Figure 0, item ) with four (4) screws (Figure 0, item ). Tighten screws to 35 in-lb (4 Nm). Figure 4. Install new timing belt. 5. Depending on conveyor belt travel (direction A or B), locate timing belt tensioner (Figure 9, item ) as shown. Tension timing belt to obtain /8 (3 mm) deflection for 6 lb (3 Kg) of force at timing belt midpoint (Figure 9, item ). Tighten tensioner screw to 0 in-lb ( Nm). 6. Install cover (Figure 0, item ) with four (4) screws (Figure 0, item ). Tighten screws to 35 in-lb (4 Nm). Dorner Mfg. Corp Rev. F

11 Preventive Maintenance and Adjustment Drive or Driven Pulley Replacement A WARNING DANGER Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance.. Complete steps through 3 of Timing Belt Replacement section on page 0.. Remove taper-lock screws (Figure 3, item ). Insert one () of taper lock screws in remaining hole (Figure 3, item ). Tighten screw until pulley is loose. Remove pulley and taper hub assembly. Single Phase Motor. For single phase motor, unplug power cord from outlet. Three Phase and VFD Motor. Loosen terminal box screws (Figure 4, item ) and remove cover (Figure 4, item ). Figure 4 Hazardous voltage will cause severe injury or death. LOCK OUT POWER BEFORE WIRING. Figure 3 Figure 3 NOTE If drive pulley (Figure 6, item 4) is replaced, wrap timing belt around drive pulley and complete step Complete steps 5 through 9 of Installation section beginning on page 9. Motor Replacement A WARNING Figure 4. Record incoming wire colors on red, black and blue leads. Loosen wire nuts and remove incoming wires. 3. Loosen cord grip and remove cord. DC Variable Speed Motor. For DC variable speed motor, unplug motor cord at disconnect (Figure 5, item ). Figure 5 Figure 5 Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance Rev. F Dorner Mfg. Corp.

12 Preventive Maintenance and Adjustment Brushless Motor. Twist covers (Figure 6, item ) apart. Figure 9 Figure 6 Figure 6. Remove outer cord cover (Figure 7, item ) from inner cord cover (Figure 7, item ). Figure 7 All Models Figure 9. Remove the drive pulley see steps and of Drive or Driven Pulley Replacement section on page.. Remove four (4) screws (Figure 0, item ). Detach motor (Figure 0, item ) from the mounting plate (Figure 0, item 3). Retain motor output shaft key (Figure 0, item 4). Figure 0 3 Figure 7 3. Open inner cord cover (Figure 8, item ). Figure 8 4 Figure 8 4. Unplug motor cord connectors (Figure 9, item ) and signal cable connectors (Figure 9, item ). Figure 0 3. Install new motor using the four (4) mounting screws (Figure 0, item ). 4. Re-install the drive pulley reverse step of Drive or Driven Pulley Replacement section on page. 5. Complete steps 5 through 9 of Installation section beginning on page Replace wiring: For a single phase motor, reverse step in Single Phase Motor on page. For a three phase motor, reverse steps -3, in Three Phase and VFD Motor on page. For a DC variable speed motor, reverse step on DC Variable Speed Motor on page. For a brushless motor, reverse steps - on Brushless Motor on page. Dorner Mfg. Corp Rev. F

13 Notes Rev. F 3 Dorner Mfg. Corp.

14 Service Parts NOTE For 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. Bottom Mount Parallel Drive Package for Industrial Gearmotors Item Part Number Description Drive Cover Drive Cover (Flat Belt) Drive Tensioner Slide Mounting Plate 3054 Mounting Plate (Flat Belt) Tensioner Bearing Assembly Driven Pulley, 4 Tooth, Taper Lock TL Driven Pulley, 6 Tooth, Taper Lock TL08 Item Part Number Description Drive Pulley, 4 Tooth, Taper Lock TL Drive Pulley, 6 Tooth, Taper Lock TL Drive Pulley, 8 Tooth, Taper Lock TL Drive Pulley, 0 Tooth, Taper Lock TL Drive Pulley, Tooth, Taper Lock TL Drive Pulley, 4 Tooth, Taper Lock TL Taper Lock Bushing, 0 MM, TL Taper Lock Bushing, 0.75", TL Taper Lock Bushing, 0.75", TL Taper Lock Bushing, 0.75", TL60 Dorner Mfg. Corp Rev. F

15 Service Parts Item Part Number Description Timing Belt,.0 W x.0 L Timing Belt,.0 W x.0 L Timing Belt,.0 W x 3.0 L 84-5 Timing Belt,.0 W x 5.5 L Timing Belt,.0 W x 7.0 L Timing Belt,.0 W x 8.0 L Timing Belt,.0 W x 30.0 L Cap Head Screw, /4-8 x 0.75" Item Part Number Description Flat Washer 90483M Flange Socket Head Screw, M4 x 6 mm 90608M Socket Head Screw, M6 x 8 mm 3 906M Socket Head Screw, M6 x mm M Socket Head Screw, M8 x 35 mm M Socket Head Screw, M6 x 45 mm M Square Key M Hex Jam Nut, M6 Pulley Ratio / Timing Belt Combinations Motor (Drive) Pulley Teeth Conveyor (Driven) Pulley Teeth Pulley Ratio Flat Belt Timing Belt Cleated Belt N/A N/A N/A Figure Driven Pulley Drive Pulley Figure Rev. F 5 Dorner Mfg. Corp.

16 Service Parts Parallel Shaft Industrial Gearmotors Item Part Number Description 6M80PS4FN Motor, 0.08hp (0.06Kw), 5 Volts, 60 Hz, -Phase 6M80PS4FR Motor, 0.08hp (0.06Kw), 5 Volts, 60 Hz, -Phase with Reversing 6M80PS43FN Motor, 0.7hp (0.3Kw), 08 30/460 Volts, 60 Hz, 3-Phase 6M060PS4FN Motor, 0.7hp (0.3Kw), 5 Volts, 60 Hz, -Phase 6M060PS4FR Motor, 0.7hp (0.3Kw), 5 Volts, 60 Hz, -Phase with Reversing 6M060PS43FN Motor, 0.7hp (0.3Kw), 08 30/460 Volts, 60 Hz, 3-Phase 3M030PS4FN Motor, 0.33hp (0.5Kw), 5 Volts, 60 Hz, -Phase 3M030PS4FR Motor, 0.33hp (0.5Kw), 5 Volts, 60 Hz, -Phase with Reversing 6M030PS43FN Motor, 0.38hp (0.8Kw), 08 30/460 Volts, 60 Hz, 3-Phase 3M00PS4FN Motor, 0.33hp (0.5Kw), 5 Volts, 60 Hz, -Phase 3M00PS4FR Motor, 0.33hp (0.5Kw), 5 Volts, 60 Hz, -Phase with Reversing 6M00PS43FN Motor, 0.38hp (0.8Kw), 08 30/460 Volts, 60 Hz, 3-Phase 3M00PS4FN Motor, 0.33hp (0.5Kw), 5 Volts, 60 Hz, -Phase 3M00PS4FR Motor, 0.33hp (0.5Kw), 5 Volts, 60 Hz, -Phase with Reversing 6M00PS43FN Motor, 0.38hp (0.8Kw), 08 30/460 Volts, 60 Hz, 3-Phase 3M005PS4FN Motor, 0.33hp (0.5Kw), 5 Volts, 60 Hz, -Phase 3M005PS4FR Motor, 0.33hp (0.5Kw), 5 Volts, 60 Hz, -Phase with Reversing 6M005PS43FN Motor, 0.38hp (0.8Kw), 08 30/460 Volts, 60 Hz, 3-Phase 6M80PSD3DEN Motor, 0. hp (0.09 Kw), 30 Volts DC Item Part Number Description 6M060PSD3DEN Motor, 0.5 hp (0.9 Kw), 30 Volts DC 6M030PSD3DEN Motor, 0.5 hp (0.9 Kw), 30 Volts DC 6M00PSD3DEN Motor, 0.5 hp (0.9 Kw), 30 Volts DC 6M00PSD3DEN Motor, 0.33 hp (0.5 Kw), 30 Volts DC 6M80PS43EN Motor, 0.7 hp (0.3 Kw), 30 Volts, 60 Hz, 3 Phase VFD 6M060PS43EN Motor, 0.7 hp (0.3 Kw), 30 Volts, 60 Hz, 3 Phase VFD 6M030PS43EN Motor, 0.38 hp (0.8 Kw), 30 Volts, 60 Hz, 3 Phase VFD 6M00PS43EN Motor, 0.38 hp (0.8 Kw), 30 Volts, 60 Hz, 3 Phase VFD 6M00PS43EN Motor, 0.38 hp (0.8 Kw), 30 Volts, 60 Hz, 3 Phase VFD 6M005PS43EN Motor, 0.38 hp (0.8Kw), 30 Volts, 60 Hz, 3-Phase VFD 6M050PSBDDEN Motor, 0.5hp (0.9Kw), 60 RPM, Brushless DC 6M00PSBDDEN Motor, 0.5hp (0.9Kw), 50 RPM, Brushless DC 6M00PSBDDEN Motor, 0.5hp (0.9Kw), 300 RPM, Brushless DC Key, Square, 0.88 x 0.75 L Dorner Mfg. Corp Rev. F

17 Notes Rev. F 7 Dorner Mfg. Corp.

18 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:. Name and address of customer.. 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 (if available, part serial number). A representative will discuss action to be taken on the returned items and provide a Returned Goods Authorization (RMA) number for reference. RMA will automatically close 30 days after being issued. To get credit, items must be new and undamaged. There will be a return charge on all items returned for credit, where Dorner was not at fault. It is the customer s responsibility to prevent damage during return shipping. Damaged or modified items will not be accepted. The customer is responsible for return freight. Conveyors and conveyor accessories Standard catalog conveyors 30% MPB, 700, 7300 Series, cleated and specialty belt 50% AquaGard & AquaPruf Series conveyors non-returnable items Engineered to order products case by case Drives and accessories 30% Sanitary stand supports non-returnable items Parts Standard stock parts 30% Plastic chain, 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 Customer Service Team 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 For replacement parts, contact an authorized Dorner Service Center or the factory. Dorner Mfg. Corp. reserves the right to change or discontinue products without notice. All products and services are covered in accordance with our standard warranty. All rights reserved. Dorner Mfg. Corp. 0 DORNER MFG. CORP. 975 Cottonwood Ave., PO Box 0 Hartland, WI USA TEL (USA) FAX (USA) Internet: Outside the USA: TEL FAX Rev. F Printed in U.S.A.

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