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Dorner iDrive 3200 Series, Installation, Maintenance & Parts Manual

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Dorner iDrive 3200 Series Installation, Maintenance & Parts Manual Download Page 12

Dorner Mfg. Corp.

12

851-702 Rev. A

3200 Series iDrive Belt Conveyors

Preventive Maintenance and Adjustment

Required Tools

Standard Tools

• Hex-key wrenches: 

- 2.5 mm, 4 mm, 5 mm

Checklist

• Keep service parts on hand (see “Service Parts” section for

recommendations)

• Keep supply of belt cleaner (part # 625619)
• Clean entire conveyor and knurled pulley while disassem-

bled

• Replace worn or damaged parts

Lubrication

No lubrication is required. Replace bearings if worn.

Maintaining Conveyor Belt

Troubleshooting

Inspect conveyor belt for:
• Surface cuts or wear
• Stalling or slipping
• Damage to V-guide
Surface cuts and wear indicate:
• Sharp or heavy parts impacting belt
• Jammed parts
• Improperly installed bottom wipers (if installed)
• Accumulated dirt in wipers (if installed)
• Foreign material inside the conveyor
• Improperly positioned accessories
• Bolt-on guiding is pinching belt
Stalling or slipping indicates:
• Excessive load on belt
• Conveyor belt or drive timing belt are not properly ten-

sioned

• Worn knurl or impacted dirt on drive pulley
• Intermittent jamming or drive train problems
Damage to V-guide indicates:
• Twisted or damaged conveyor frame
• Dirt impacted on pulleys
• Excessive or improper side loading

Cleaning

Use Dorner Belt Cleaner (part # 625619). Mild soap and 

water may also be used. Do not soak the belt.
For /05 woven polyester and /06 black anti-static belts, use a 

bristled brush to improve cleaning.

Conveyor Belt Replacement

Conveyor Belt Replacement Sequence

• Remove old conveyor belt:
-Conveyor without Stands
-Conveyor with Stands
• Install new conveyor belt
• Tension conveyor belt

NOTE

Visit www.dorner.com for complete list of 
troubleshooting solutions.

IMPORTANT

Do not use belt cleaners that contain alcohol, 
acetone, Methyl Ethyl Ketone (MEK) or other 
harsh chemicals.

A

 WARNING

Exposed moving parts can cause severe 
injury. LOCK OUT POWER before removing 
guards or performing maintenance.

Summary of Contents for iDrive 3200 Series

Page 1: ...anuals 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 851 702 Rev A 3200 Series iDrive Belt Conveyors Installation Maintenance Parts Manual ...

Page 2: ...ithout Stands 14 Belt Installation for Conveyor with Stands 14 Conveyor Belt Tensioning 14 Conveyor Belt Tracking 15 V Guided Belts 15 Non V Guided Belts 15 Pulley Removal 16 A Idler Pulley Removal 16 B Transfer Tail Pulley Removal 17 Pulley Replacement 18 Idler Pulley 18 Transfer Tail Pulley 18 Drive Spindle Removal and Replacement 18 Removal 18 Replacement 20 Motor Removal and Replacement 20 Cir...

Page 3: ...ts Kits logo Warnings General Safety IMPORTANT Some illustrations may show guards removed DO NOT operate equipment without guards A WARNING The 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 ...

Page 4: ...put Shaft Position Conveyor Profile 1 Non V guided Belt conveyor to include mounting brackets 2 V guided Belt conveyor to include mounting brackets 3 Non V guided Belt conveyor not to include mounting brackets 4 V guided Belt conveyor not to include mounting brackets Document Language M English 3 1 0 M WW LLLL A PP BB 0 3 tails 1 1 tails iDrive FD C P S iDrive Control Type iDrive Power Supply iDri...

Page 5: ...ements Belt Travel 9 7 246 mm per revolution of pulley Maximum Belt Speed 171 ft minute 52 m minute Belt Takeup 1 62 41 mm of Belt Takeup on Conveyors Under 12 Length Conveyor Width High Speed Motor Medium Speed Motor Low Speed Motor 6 152mm 46 63 115 8 203mm 43 60 111 10 254mm 37 54 106 12 305mm 34 51 103 14 356mm 30 47 98 16 406mm 25 42 94 18 457mm 16 34 85 20 508mm 14 31 83 22 559mm 10 27 78 24...

Page 6: ...ackets and return rollers Refer to Mounting Brackets on page 7 and Return Rollers on page 8 Conveyors Longer Than 13 ft 3962 mm Installation Component List 1 Locate and arrange conveyor sections Figure 5 item 1 by section labels Figure 5 item 2 Figure 5 Figure 5 2 On tension end of the conveyor identified by the pinion locking screw Figure 6 item 1 push in head plate assembly Figure 6 item 2 Loose...

Page 7: ...en conveyor belt refer to Conveyor Belt Tensioning on page 14 6 Install mounting brackets and return rollers Refer to Mounting Brackets on page 7 and Return Roller on page 8 Mounting Brackets 1 Locate brackets Exploded views shown in Figure 11 Figure 12 Figure 11 Figure 11 Figure 12 Figure 12 NOTE For Conveyors longer than 20 ft 6096 mm use the process outlined in the Conveyor Belt Tensioning sect...

Page 8: ...ted Belt and 4 6 51 152 mm Wide Flat Belt Conveyors 1 Locate return rollers Exploded views shown in Figure 14 Figure 15 Figure 14 Figure 14 Figure 15 Figure 15 2 Remove screws Figure 14 item 1 Figure 15 item 1 and clips Item 2 from roller assembly 3 Install roller assemblies Figure 16 item 1 as shown Tighten screws Figure 16 item 2 to 60 in lb 7 Nm Figure 16 Figure 16 8 48 203 1219 mm Wide Flat Be...

Page 9: ...ls with Customer Provided Power Supply 1 Locate the male disconnect plug provided 2 Wire and solder DC power to the two terminals of the provided DC power plug Wire VDC to the short lug Figure 20 item 1 and VDC to the long lug Figure 20 item 2 Figure 20 Figure 20 3 Required power is 36VDC 4 amps minimum 4 See Change Acceleration Deceleration Settings on page 11 for changing factory control setting...

Page 10: ...on when running Make sure the motor is stopped before reversing signal is given BROWN PRE WIRED PRE WIRED CUSTOMER WIRED CONTROL BY CUST BY CUST 13 W 14 LO CONTROLLER BOARD DC POWER TO CONTROLLER MUST BE FUSED AT 5 AMPS V 0 5VDC ANALOG SPEED BLACK BLUE GREEN 36VDC 150W REGULATED RUN REV 5 4 8 F R 6 GND POWER B B FUSE 5A WHT RED CR YELLOW CR VIOLET 12 HI ORANGE CAP with Analog Speed Input BLA BLACK...

Page 11: ...igure 22 Figure 22 3 Locate potentiometers to change See Controller Board layout on page 10 4 Rotate potentiometers Figure 23 item 1 to desired setting Figure 23 Figure 23 5 Reinstall by reversing steps Item Number Description Setting 1 Current Limit 100 2 Gain N A 3 Max Speed 100 4 Min Speed 5 5 Decel 0 10 sec 0 sec 6 Accel 0 10 sec 0 5 sec Item Number Description Position Setting 7 Input Voltage...

Page 12: ...ng is pinching belt Stalling or slipping indicates Excessive load on belt Conveyor belt or drive timing belt are not properly ten sioned Worn knurl or impacted dirt on drive pulley Intermittent jamming or drive train problems Damage to V guide indicates Twisted or damaged conveyor frame Dirt impacted on pulleys Excessive or improper side loading Cleaning Use Dorner Belt Cleaner part 625619 Mild so...

Page 13: ...or belt Belt Removal for Conveyor With Stands 1 Place temporary support stands Figure 26 item 1 at both ends of the conveyor Figure 26 Figure 26 2 Remove mounting brackets Figure 26 item 2 from one side of conveyor Reverse steps 3 4 of Mounting Brackets section on page 7 3 If equipped remove return rollers guiding and accessories from the same side of conveyor 4 On tension end of the conveyor iden...

Page 14: ...r Lift conveyor slightly to avoid pinching belt on temporary support stands Figure 31 Figure 31 4 Re install conveyor mounting brackets Refer Mounting Brackets on page 7 steps 3 through 5 5 Tension belt Refer to Conveyor Belt Tensioning on page 14 6 If equipped re install return rollers and guiding Conveyor Belt Tensioning 1 On tension end of the conveyor identified by the pinion locking screw Fig...

Page 15: ... bulge will be minimal when belt is properly tracked Figure 35 Figure 35 Non V Guided Belts Non V guided belt conveyors are equipped with belt tracking assemblies 1 When adjusting belt tracking always adjust the discharge end of the conveyor first To adjust belt tracking 2 Ensure tensioning racks are extended and touching the idler pulley headplates loosen the pinion locking screw Figure 36 item 1...

Page 16: ...owing the corresponding instructions below A Idler Pulley Removal B Transfer Tail Pulley Removal A Idler Pulley Removal 1 Temporarily support the idler pulley Figure 40 Figure 40 2 On one side of conveyor loosen the two 2 back fastening screws Figure 41 item 1 and remove two 2 front fastening screws Figure 41 item 2 Figure 41 Figure 41 3 Pull back the outer headplate Figure 42 item 1 and remove th...

Page 17: ...gure 44 item 2 from one side of the pulley assembly Figure 44 Figure 44 6 Slide the shaft assembly Figure 45 item 1 out of the pulley Figure 45 item 2 Figure 45 Figure 45 B Transfer Tail Pulley Removal 1 Temporarily support the transfer tail assembly Figure 46 Figure 46 2 On one side of conveyor remove the two 2 back fastening screws Figure 47 item 1 and the two 2 front fastening screws Figure 47 ...

Page 18: ...peat steps 6 through 7 Pulley Replacement Idler Pulley To replace the idler pulley reverse the Idler Pulley Removal procedure on page 16 Transfer Tail Pulley To replace the transfer tail pulley reverse the Transfer Tail Pulley Removal procedure on page 17 Drive Spindle Removal and Replacement Removal 1 Remove belt See Belt Removal for Conveyor Without Stands on page 13 or Belt Removal for Conveyor...

Page 19: ...re 54 item 2 on each side of conveyor 5 Remove two hex head screws Figure 56 item 1 Figure 55 Figure 55 6 Slide drive motor and plate Figure 56 item 1 to loosen tension on timing belt Figure 56 item 2 Figure 56 Figure 56 7 Remove hex head screw Figure 57 item 1 and washer from both sides of the conveyor Figure 57 Figure 57 8 Remove drive spindle assembly Figure 58 item 1 and replace Figure 58 Figu...

Page 20: ...nnect two wiring harness connectors Figure 61 item 1 Figure 61 Figure 61 4 Remove tie strap Figure 61 item 2 from drive motor harness 5 If applicable remove black cap from end Figure 61 item 3 of drive motor NOTE Move drive motor plate Figure 59 item 1 to obtain 1 8 1 4 belt deflection at center of belt Figure 59 item 2 with approximately 3 5 in lb of pressure Tighten two hex head screws Figure 59...

Page 21: ...et screws Figure 64 item 1 holding drive motor gear Figure 64 item 2 onto drive motor shaft Figure 64 Figure 64 9 Remove drive motor gear Figure 65 item 1 from drive motor shaft Figure 65 item 2 Figure 65 Figure 65 10 Remove drive motor from headplate assembly 11 Replace motor 12 Reinstall in reverse order of removal Refer to Drive Spindle Removal and Replacement on page 18 for timing belt tension...

Page 22: ...g harness connectors Figure 67 item 1 from motor connector Figure 67 item 2 and switch wiring connector Figure 67 item 3 Figure 67 Figure 67 4 Remove hex head screw Figure 68 item 1 and loosen hex head screw Figure 68 item 2 Remove circuit board Figure 68 item 3 from conveyor frame Figure 68 Figure 68 5 Replace circuit board 6 Reinstall in reverse order of removal A WARNING Exposed moving parts ca...

Page 23: ...IN CCW Figure 69 item 2 to top speed within 3 Ft Min See Speed Chart below 3 Turn speed pot Figure 70 item 7 all the way down Fully CCW 4 Adjust MIN Figure 69 item 4 to low speed within 3 Ft Min See Speed Chart above 5 Verify proper low and high speeds are achieved by turning speed pot Figure 70 item 7 CCW to the lowest setting and the CW to the highest setting 1 CUR LIM 100 4 00 position 2 GAIN 1...

Page 24: ...ect wiring harness connector Figure 73 item 1 from circuit board wiring connector Figure 73 item 2 Figure 73 Figure 73 4 Remove tie strap Figure 73 item 3 holding wiring harness to conveyor frame 5 Remove two hex head screws Figure 74 item 1 and switch assembly Figure 74 item 2 from conveyor frame Figure 74 Figure 74 6 Replace switch assembly 7 Reinstall in reverse order of removal A WARNING Expos...

Page 25: ...851 702 Rev A 25 Dorner Mfg Corp 3200 Series iDrive Belt Conveyors Notes ...

Page 26: ...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 16 26 21 11 21 19 12 5 2 9 14 4 14 12 22 1 21 17 23 13 3 6 8 7 20 19 18 10 15 19 22 25 24 20 28 29 27 ...

Page 27: ... 350092 Tail Plate Non Drive Side for 6 and 8 wide Conveyors 350093 Tail Plate Non Drive Side for 8 and 10 wide and wider Conveyors 12 350095 Tracking Block 13 350096 Motor Mounting Plate 14 350097 Inner Tail Plate 15 350098 Slide Bar 16 350103 Control Assembly 17 605280P Washer 0 361 x 0 750 x 0 120 18 920406M Socket Head Screw M4 0 70 x 6mm 19 920408M Socket Head Screw M4 0 70 x 8mm 20 920892M L...

Page 28: ... Spindle Wand Assembly includes items 8 and 11 5 301196 Hex Tension Tracking Shaft 6 3202WW Tail Articulation Bar 7 3289WW 3 Idler Pulley 8 605280P Hard Washer 9 807 1151 Tracking Shaft Retaining Ring 10 807 1152 Hex Head Cap Screw M6 x 20mm 11 915 235 Stub Shaft Retaining Ring 12 920893M Low Head Socket Screw M8 x 16mm 13 32T3 WW Idler Spindle Kit includes items 4 and 7 14 32TT3 WW Tail Assembly ...

Page 29: ...301354 Inner Transfer Tail Support Plate 8 3202WW Tail Articulation Bar 9 3217WW 1 Idler Tail Axle Shaft 10 3219WW Support Bar 11 3237WW Transfer Tail Roller 12 807 1136 Washer 13 807 1151 Retaining Ring 14 807 1152 Hex Head Cap Screw M6 x 20mm 15 910 203 3 8 Hex Nut 16 915 319 Retaining Ring 17 920408M Hex Head Cap Screw M4 x 8mm 18 920893M Low Head Socket Screw M8 x 16mm 19 32T1 WW 1 Idler Spind...

Page 30: ...il 10 3229WW Pinion 11 See Bed Plate Rail chart Bed Plate Rail WW Conveyor width reference 06 24 in 02 increments LLLLL Frame Length see Bed Plate Frame Formulas Item 11 Bed Plate Rail Width Part Number 2 54mm 300888 LLLLL 4 102mm 300889 LLLLL 6 152mm 300890 LLLLL LLLLL Bed Plate Length see Bed Plate Frame Formulas Width Bed Plate Configuration 6 4 8 6 10 2 4 2 12 2 6 2 14 4 4 4 16 4 6 4 18 6 4 6 ...

Page 31: ... LLLLL Conveyor Length XXXX X 12 Tail Factor of Sections of Conveyor Tail Factor 00000 for center drive with transfer tail both ends 00100 for end drive with one transfer tail 00200 for end drive and center drives with standard tails 00325 for All Cleated Conveyors Conveyor Length XXXX 0100 1200 of Conveyor Sections XXXX Conveyor Length XX XX ft 17 4 End Drive Conveyor with Standard Tails Conveyor...

Page 32: ...h Formulas LLLLL Conveyor Length XXXX X 12 Tail Factor of Sections of Conveyor Tail Factor 00000 for center drive with transfer tail both ends 00100 for end drive with one transfer tail 00200 for end drive and center drives with standard tails 00325 for All Cleated Conveyors Conveyor Length XXXX 0100 1200 of Conveyor Sections XXXX Conveyor Length XX XX ft 17 4 End Drive Conveyor with Standard Tail...

Page 33: ... Head Screw M6 x 20mm LLLLL Conveyor Length XXXX X 12 Tail Factor of Sections of Conveyor Tail Factor 00000 for center drive with transfer tail both ends 00100 for end drive with one transfer tail 00200 for end drive and center drives with standard tails 00325 for All Cleated Conveyors Conveyor Length XXXX 0100 1200 of Conveyor Sections XXXX Conveyor Length XX XX ft 17 4 End Drive Conveyor with St...

Page 34: ...LLLLL Conveyor Length XXXX X 12 Tail Factor of Sections of Conveyor Tail Factor 00000 for center drive with transfer tail both ends 00100 for end drive with one transfer tail 00200 for end drive and center drives with standard tails 00325 for All Cleated Conveyors Conveyor Length XXXX 0100 1200 of Conveyor Sections XXXX Conveyor Length XX XX ft 17 4 End Drive Conveyor with Standard Tails Conveyor ...

Page 35: ...Screw M6 x 20mm LLLLL Conveyor Length XXXX X 12 Tail Factor of Sections of Conveyor Tail Factor 00000 for center drive with transfer tail both ends 00100 for end drive with one transfer tail 00200 for end drive and center drives with standard tails 00325 for All Cleated Conveyors Conveyor Length XXXX 0100 1200 of Conveyor Sections XXXX Conveyor Length XX XX ft 17 4 End Drive Conveyor with Standard...

Page 36: ...m 202989 Aluminum Profile Guide 8 2438mm 202990 Aluminum Profile Guide 9 2743mm 202991 Aluminum Profile Guide 10 3048mm 202992 Aluminum Profile Guide 11 3353mm 202993 Aluminum Profile Guide 12 3658mm 202994 Aluminum Profile Guide 13 3962mm 2 200830M Drop In Tee Bar 3 202004 Mounting Bracket 4 202027M Guide Mounting Shaft Vertical 5 202028M Guide Mounting Shaft Horizontal 6 674175MP Square Nut 7 80...

Page 37: ... Drop In Tee Bar 4 202004M Mounting Bracket 5 202027M Vertical Mounting Guide Shaft 6 202028M Horizontal Mounting Guide Shaft 7 674175MP Square Nut M6 1 00 8 920612M Socket Head Screw M6 1 00 x 12 mm 9 920616M Socket Head Screw M6 1 00 x 16 mm 10 460063 LLLLL Aluminum Profile Guide 11 614068P LLLLL Extruded Guide LLLLL Length in inches with 2 decimal places Length Example Length 95 25 LLLLL 09525 ...

Page 38: ...m LLLLL Conveyor Length XXXX X 12 Tail Factor of Sections of Conveyor Tail Factor 00000 for center drive with transfer tail both ends 00100 for end drive with one transfer tail 00200 for end drive and center drives with standard tails 00325 for All Cleated Conveyors Conveyor Length XXXX 0100 1200 of Conveyor Sections XXXX Conveyor Length XX XX ft 17 4 End Drive Conveyor with Standard Tails Conveyo...

Page 39: ...LL Right Hand 381737 LLLLL 3 or More Left Hand 381736 LLLLL Middle Sections 381700 LLLLL Right Hand 381737 LLLLL LLLLL Conveyor Length XXXX X 12 Tail Factor of Sections of Conveyor Tail Factor 00000 for center drive with transfer tail both ends 00100 for end drive with one transfer tail 00200 for end drive and center drives with standard tails 00325 for All Cleated Conveyors Conveyor Length XXXX 0...

Page 40: ...1936 LLLLL Right Hand 381937 LLLLL 3 or More Left Hand 381936 LLLLL Middle Sections 381900 LLLLL Right Hand 381937 LLLLL LLLLL Conveyor Length XXXX X 12 Tail Factor of Sections of Conveyor Tail Factor 00000 for center drive with transfer tail both ends 00100 for end drive with one transfer tail 00200 for end drive and center drives with standard tails 00325 for All Cleated Conveyors Conveyor Lengt...

Page 41: ...de 3 914mm 202214 Side Flare Mounting Guide 4 1219mm 202215 Side Flare Mounting Guide 5 1524mm 202216 Side Flare Mounting Guide 6 1829mm 3 202522M Flared Guide 45 2 610mm 202523M Flared Guide 45 3 914mm 202524M Flared Guide 45 4 1219mm 202525M Flared Guide 45 5 1524mm 202526M Flared Guide 45 6 1829mm 4 639971 Drop In Tee Bar 5 910506M Button Head Screw M5 x 6mm 6 911 512 Washer 7 920694M Cap Low H...

Page 42: ...ee Bar 3 605279P Washer 4 807 920 Square Nut M6 5mm x 10mm 5 920620M Socket Head Screw M6 x 20mm 6 920692M Socket Head Screw M6 x 12mm Item Part Number Description 1 4 6 2 3 5 Item Part Number Description 1 240836 Cleated Mounting Assembly 2 300150M Drop In Tee Bar 3 605279P Washer 4 807 920 Square Nut M6 5mm x 10mm 5 920620M Socket Head Screw M6 x 20mm 6 920692M Socket Head Screw M6 x 12mm Item P...

Page 43: ...escription 1 240858 Frame Bar Connector 2 240859 Intermediate Clamp Plate 3 920692M Socket Head Screw M6 x 12mm Item Part Number Description 6 5 4 3 2 1 Item Part Number Description 1 240858 Frame Connector Bar 2 240837 Stand Mount Joint 3 605279P Washer 4 807 920 Square Nut M6 5mm x 10mm 5 920620M Socket Head Screw M6 x 20mm 6 920692M Socket Head Screw M6 x 12mm Item Part Number Description ...

Page 44: ...et Assembly 3 605279P Washer 4 807 920 Square Nut M6 5mm x 10mm 5 920620M Socket Head Screw M6 x 20mm 6 920692M Socket Head Screw M6 x 12mm Item Part Number Description 2 5 4 3 1 7 6 Item Part Number Description 1 240825 Return Roller Guard Short 2 240827 Return Roller Clip 3 802 027 Bearing 4 913 100 Dowel Pin 5 920693M Socket Low Head Screw M6 x 16mm 6 240840 Roller Assembly Includes Items 1 3 a...

Page 45: ...827 Return Roller Clip 3 2409WW Return Roller Guard 4 2410WW Return Roller Rod 5 920693M Socket Head Screw M6 x 16mm 6 3249WW Flat Belt Return Roller Assembly WW Conveyor width reference 08 24 in 02 increments Item Part Number Description 5 2 4 1 3 7 6 Item Part Number Description 1 240825 Return Roller Guard Short 2 240828 Cleated Return Roller Clip 3 802 027 Bearing 4 913 100 Dowel Pin 5 920693M...

Page 46: ...er as indicated below Add V for V guided belts Cleated Belt Part Number Configuration Refer to Dorner patent plate Figure 76 From the model number determine cleated belt T width WW length LLLL cleat type C and cleat spacing SSSS Use data to configure belt part number as indicated below Add V for V guided belt Flat Belt Conveyor Model Number 3 T WW LLLL SBV Cleated Belt Conveyor Model Number 3 T WW...

Page 47: ...851 702 Rev A 47 Dorner Mfg Corp 3200 Series iDrive Belt Conveyors Notes ...

Page 48: ...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 7200 7300 Series clea...

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