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Danfoss VLT OneGearDrive Instruction Manual

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MAKING MODERN LIVING POSSIBLE
Instruction Manual
®
VLT
OneGearDrive
www.danfoss.com/drives

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Summary of Contents for Danfoss VLT OneGearDrive

  • Page 1 MAKING MODERN LIVING POSSIBLE Instruction Manual ® OneGearDrive www.danfoss.com/drives...

  • Page 3: Table Of Contents

    3.6 Assembly Kit 3.7 Torque Restraint 3.8 Final Assembly 4 Electrical Installation 4.1 EMC-compliant Installation 4.2 Electrical Connection 4.3 Terminal Box 4.3.1 Connection 4.4 Cage Clamp Connection Diagram ® 4.5 CleanConnect Connection Diagram MG75C422 Danfoss A/S © 08/2014 All rights reserved.
  • Page 4 8.5.1 OneGearDrive Standard 8.5.2 OneGearDrive Standard with Torque Arm in Front Position (optional) 8.5.3 OneGearDrive Hygienic 8.5.4 OneGearDrive Hygienic with Torque Arm in Front Position (optional) 8.6 Options 8.6.1 Torque Arm Set Danfoss A/S © 08/2014 All rights reserved. MG75C422...
  • Page 5 8.6.2.2 Technical Data 8.6.2.3 Dimensions 8.6.2.4 Connections 8.7 Accessories 8.7.1 Accessories for OneGearDrive Standard 8.7.2 Accessories for OneGearDrive Hygienic 9 Appendix 9.1 Glossary 9.2 Abbreviations and Conventions 9.2.1 Abbreviations 9.2.2 Conventions Index MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 6: Introduction

    Ensure that the conditions at the place of work correspond • Recognition of product liability claims. to all the nameplate data. Therefore, read this instruction manual before working on or with the OneGearDrive. ® is a registered trademark. Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 7: Foreseeable Misuse

    Any use not expressly approved by Danfoss constitutes misuse. This also applies to failure to comply with the specified operating conditions and applications. Danfoss assumes no liability of any sort for damage attrib- utable to improper use. 1.5 Approvals 1.6 Disposal...

  • Page 8: Safety

    • • Do not carry out an oil change until the oil has The instruction manual is always available near cooled down sufficiently. the OneGearDrive in complete and readable form. Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 9: Mechanical Installation

    After receiving the delivery, immediately check whether 3.5 Mounting Arrangement the scope of delivery matches the shipping documents. CAUTION Danfoss will not honor claims for defects registered later. HIGH TORQUE AND FORCE Register a complaint immediately: Depending on the reduction ratio, the OneGearDrive develops substantially higher torques and forces than •...

  • Page 10: Mounting Procedure

    [1198] [1086] 55.3 48.2 42.8 38.3 34.8 [1404] [1223] [1084] [973] [883] Table 3.1 Maximum Force 1) X is the distance from the surface of the hollow shaft to the force location. Danfoss A/S © 08/2014 All rights reserved. MG75C422...
  • Page 11 The fixing screw (5) and lock washer (4) are not included in the delivery. The parts are dependent on the length and size of the shaft. For further information, refer to the mounting arrangement (see chapter 3.5 Mounting Arrangement). Shaft Disc d+0.2 edges cut Figure 3.3 Axial Fastening MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 12: Torque Restraint

    (see chapter 8.6.1 Torque Arm Set). Ensure that the torque arm does not create excessive constraining forces, for example, due to the driven shaft running untrue. Excessive backlash can result in excessive shock torques in switching or reversing operations. Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 13: Final Assembly

    Using a flat wrench, turn the screws 180° clockwise. The tightening torque is 4.5 Nm. NOTICE! The OneGearDrive does not require breather vents. Never install breather vents instead of the oil screws. MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 14: Electrical Installation

    The electromagnetic compatibility directive in accordance with IEC/EN 61800-3 is complied with given proper use and installation of the OneGearDrive. This is also true in combination with Danfoss adjustable frequency drives and rectifiers. 4.2 Electrical Connection When connecting the motor, take note of the data on the nameplate, the connection diagram and the relevant safety regulations and rules for the prevention of accidents.

  • Page 15: Terminal Box

    OneGearDrive and will invalidate the warranty. Screw-on terminal boxes are supplied with a metric screw thread as standard. M20x1.5 M20x1.5 1x M20x1.5 M20x1.5 Figure 4.2 Terminal Box Screws MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 16: Connection

    ® Refer to the Instruction Manual for VLT ® AutomationDrive FC 302 and VLT Decentral Drive FCD 302 to connect the terminals. Do not connect the OneGearDrive directly to the power supply. Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 17: Cage Clamp Connection Diagram

    KTY sensor 1 Analog input 54 Table 4.2 Connections T1 and T2 1) Only if connected NOTICE! After connection, tighten all four screws on the terminal box cover. The tightening torque is 3 Nm. MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 18: Cleanconnect ® Connection Diagram

    In other cases, it is necessary to protect the gear unit by mechanical means (e.g., slip clutch, sliding hub, etc.). This depends on the maximum permissible limit torque M in continuous running duty specified on the nameplate. Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 19: Commissioning

    The shaft seals must be replaced if any change in shape, color, hardness or sealing effect is detected. MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 20: Maintenance, Diagnostics And Troubleshooting

    6.1.1 Replacing the Brake and Rotor All work must only be carried out by qualified technical personnel on a stationary machine that has been protected against restarting. This also applies to auxiliary circuits. Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 21: Adjusting The Nominal Brake Torque And Replacing The Springs

    Air gap, maximum 0.018 in [0.45 mm] Table 6.2 Nominal Brake Torque Fastening screws Armature plate Magnet Springs Hub for rotor Rotor Friction plate Hollow screws Brake cover and nuts Figure 6.1 Brake and Rotor MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 22: Inspection During Operation

    When changing the oil, inspect and, if necessary, replace Condition of electrical wiring and cables the seals. • Poor heat dispersion If irregularities or problems occur, contact Danfoss Service. It is necessary to flush the OneGearDrive if the oil grade or 6.3 Repair oil type is changed. NOTICE! Flushing the OneGearDrive Drain off the original oil.

  • Page 23: Oil Grade

    Cassida Fluid GL 220 KLÜBER Klübersynth GH 6-220 Klüberoil 4UH1-220N MOBIL Glygoyle HE 220 SHC Cibus 220 Glygoyle 30 SHELL Omala S4 GX 220 – TEXACO – NEVASTANE SL220 Table 6.4 Oil Grades MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 24: Oil Volume

    Table 6.5 Oil Volume in Fluid Ounces Turn the OneGearDrive back into a vertical position. 1) P1 is no longer available in the Danfoss DRIVECAT configurator. Use P2 also for P1 installations. Filling the oil • 32 fl oz = 1 US Quart Fill the OneGearDrive with the appropriate amount of oil through screw hole (1).

  • Page 25: Decommissioning And Disposal

    OneGearDrive. Dismount the OneGearDrive. 7.2 Product Returns Danfoss products can be returned for disposal at no charge. A prerequisite for this is that they are free of deposits, such as oil, grease or other types of contami- nation.

  • Page 26: Motor Datasheet

    This period does not include any extension of the warranty. If disassembly is necessary before start-up, contact Danfoss Service. The instructions contained in this instruction manual must be observed. Danfoss A/S © 08/2014 All rights reserved.

  • Page 27: General Specifications And Environmental Conditions

    7.28 11.30 4.80 7.20 2.91 5.79 3.09 7.24 3.54 0.14 M10x20 deep 4.53 Figure 8.2 OneGearDrive Standard 3.64 1.48 1.48 1.31 +0.007 0.05 0.05 2.89 2.89 7.28 Figure 8.3 Steel/Stainless Steel 30 MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 28: Onegeardrive Standard With Torque Arm In Front Position (Optional)

    Figure 8.5 Steel/Stainless Steel 40 8.5.2 OneGearDrive Standard with Torque Arm in Front Position (optional) 3.64 11.30 4.80 1.38 3.09 2.91 5.79 7.28 0.24 0.04 4.84 Figure 8.6 Torque Arm in Front Position Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 29: Onegeardrive Hygienic

    Figure 8.7 OneGearDrive Hygienic 3.64 1.48 1.48 1.31 +0.007 0.05 0.05 2.89 2.89 7.28 Figure 8.8 Stainless Steel 30 3.64 1.48 1.48 1.51 +0.007 0.06 0.06 2.89 2.89 7.28 Figure 8.9 Stainless Steel 35 MG75C422 Danfoss A/S © 08/2014 All rights reserved.

  • Page 30: Onegeardrive Hygienic With Torque Arm In Front Position (Optional)

    Never turn the CleanConnect plug from the delivered position and do not use it to lift the OneGearDrive. If the plug is rotated, the cables could be damaged, causing a short circuit. Contact Danfoss Service if the plug is not fastened tightly.

  • Page 31: Options

    Only use the original Danfoss or comparable mounting set to mount the OneGearDrive to the conveyor. The mounting equipment used must ensure the same degree of flexibility as the original Danfoss mounting set. The torque arm cannot be screwed directly on to the conveyor frame.

  • Page 32: Mechanical Brake

    Maximum brake torque Table 8.3 Technical Data: Mechanical Brake Option 8.6.2.3 Dimensions Figure 8.15 shows the dimensions of the OneGearDrive with the mechanical brake option. 21.50 Figure 8.15 Dimensions: OneGearDrive with Mechanical Brake Option Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 33: Connections

    The connection and use of the mechanical brake has been tested and released with VLT AutomationDrive FC 302 and ® Decentral Drive FCD 302. Any other adjustable frequency drive may require a different connection. Contact Danfoss Service for further information. ®...

  • Page 34: Accessories

    Ordering number Motor connector without cable 178H1613 Motor connector with 5 m cable 178H1630 Motor connector with 10 m cable 178H1631 Torque arm, stainless steel 178H5006 Table 8.6 Accessories for OneGearDrive Hygienic Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 35: Appendix

    Wire retention method without using special tools in the terminal box. Maximum ambient temperature specified. CleanConnect Terminal box EHEDG-certified connection from Danfoss with a stainless Connection cage for the OneGearDrive Standard. steel connector. Torque arm set Accessory for the OneGearDrive that includes a torque arm Canadian test and certification mark.

  • Page 36: Conventions

    • Bulleted lists indicate other information and description of figures. • Italicized text indicates: Cross-reference Link Footnote Parameter name, parameter group name or parameter option • All dimension drawings are in inches. Danfoss A/S © 08/2014 All rights reserved. MG75C422...

  • Page 37: Index

    Mounting arrangement................ 7 Standard....................25 Standard with torque arm in front position......26 Mounting set for torque arm............29 Disclaimer....................4 Dismounting..................23 Disposal instructions................5 Nameplate....................24 Due diligence................... 6 Faults......................20 MG75C422 Danfoss A/S © 08/2014 All rights reserved.
  • Page 38 Spare parts....................22 Speed (rated)..................24 Springs (brake)..................19 Start-up Measures before commissioning..........17 Stator......................24 Storage Conditions..................24 Measures after storage..............24 Measures during storage.............. 24 Support....................... 5 Surface damage..................7 Danfoss A/S © 08/2014 All rights reserved. MG75C422...
  • Page 39 Index Instruction Manual MG75C422 Danfoss A/S © 08/2014 All rights reserved.
  • Page 40 Danfoss shall not be responsible for any errors in catalogs, brochures or other printed material. Danfoss reserves the right to alter its products at any time without notice, provided that alterations to products already on order shall not require material changes in specifications previously agreed upon by Danfoss and the Purchaser. All trademarks in this material are property of the respective companies.

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