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Contents

1 Safety 3

1.1 Safety Warnings 3

1.2 Safety Information for the Operation of Geared Motors 3

1.2.1 General 3

1.2.2 Personnel 3

1.2.3 Intended Use Taking into Account the Relevant Technical Regulations 4

1.2.4 Transportation, Storage 4

1.2.5 Mounting Arrangement, Assembly 4

1.2.6 Connection 4

1.2.7 Commissioning 5

1.2.8 Operation 5

1.2.9 Spring-loaded Brakes 5

1.2.10 Maintenance 5

1.2.11 Operating Instructions 5

1.2.12 Faults 5

1.2.13 Electromagnetic Compatibility 5

1.2.14 Warranty and Liability 5

2 Geared Motors with Permanent Magnet Motors 6

2.1 Geared Motors Degree of Protection 6

2.2 Surface Damage 6

2.3 Rating Plate 6

2.4 Mounting Arrangement 7

2.5 Proposal Assembly Kit 7

2.6 Torque Restraint 8

2.7 Electrical Connection 8

2.8 Terminal Box 9

2.9 Connection Diagram Cage Clamp 10

2.10 Connection Diagram Three-phase Gear Motors 11

2.11 Connection Diagram Signal Plug 12

2.12 Overload Protection 13

2.13 Lubricant Changes 13

2.14 Lubricant Grade 13

2.15 Lubricant Volume 14

2.16 Changing the oil 15

2.17 Bearing Lubrication for Geared Motors 15

2.18 Disposal 15

3 Storage and Commissioning of Geared Motors with Permanent Mag-net Motors 16

Contents VLT OneGearDrive Operating Instructions

MG75C202 - VLT® is a registered Danfoss trademark 1

3.1 Storage of Geared Motors with Permanent Magnet Motors 16

3.2 Geared Motor Condition and Storage Space 16

3.3 Measures During the Storage Period 16

3.4 Measures before Commissioning 16

3.4.1.1 Motor Component 16

3.4.1.2 Gear Unit Component 16

4 Dimensions 17

4.1 VLT OneGearDrive Standard 17

4.2 VLT OneGearDrive Standard with Torque Arm in Front Position (optional) 18

4.3 VLT OneGearDrive Hygienic 19

4.4 VLT OneGearDrive Hygienic with Torque Arm in Front Position (optional) 20

5 Motor Datasheet 21

5.1 Permanent Magnet Three-phase Synchronous Motor 21

5.2 Resolver Data 21

6 Options 22

6.1 Torque Arm Set 22

6.2 Mechanical Brake 24

6.2.1 Overview 24

6.2.2 Technical Data 24

6.2.3 Dimensions 24

6.2.4 Connection 25

6.2.5 Maintenance 26

6.2.5.1 Illustration 26

6.2.5.2 Readjusting the Air Gap 26

6.2.5.3 Replacing the Rotor 26

6.2.5.4 Adjusting the Nominal Braking Torque and Replacing the Springs 26

Index 27

Contents VLT OneGearDrive Operating Instructions

2 MG75C202 - VLT® is a registered Danfoss trademark

1 Safety

1.1 Safety Warnings

SymbolsThe following symbols are used in this manual.

WARNINGIndicates a potentially hazardous situation which, if notavoided, could result in death or serious injury.

CAUTIONIndicates a potentially hazardous situation which, if notavoided, may result in minor or moderate injury. It mayalso be used to alert against unsafe practices.

CAUTIONIndicates a situation that may result in equipment orproperty-damage-only accidents.

NOTEIndicates highlighted information that should be regardedwith attention to avoid mistakes or operate equipment atless than optimal performance.

Approvals

Table 1.1

1.2 Safety Information for the Operation ofGeared Motors

1.2.1 General

This safety information applies in addition to the relevantproduct-specific operating instructions and for safetyreasons must be taken into particular consideration inevery case. This safety information is intended to protectpersons and objects from injury and hazards which canarise from improper use, incorrect operation, inadequatemaintenance or other incorrect handling of electric driveunits in industrial installations. Low-voltage machines haverotating parts and may have parts that are live, even whenthe machine is at rest, and surfaces that may become hotin operation. Warning signs and information signs on themachine are to be observed without exception. Detailsmay be found in our detailed operating instructions. They

are provided with the machine when it is supplied and canbe requested separately as required by stating the motormodel.

1.2.2 Personnel

All necessary work on electric drive units, in particular alsoplanning work, transport, assembly, installation, commis-sioning, maintenance, repair, may only be performed byadequately qualified personnel (e.g. electrical engineers asspecified in draft EN 50 110-1/DIN VDE 0105), who havethe operating instructions provided and other productdocumentation available during any corresponding workand who are obliged to abide by the instructionscontained therein. This work must be monitored by aspecialist supervisor. Qualified personnel are persons whoare authorised due to training, experience and instructionas well as their knowledge of relevant standards, rules,accident prevention regulations and operating conditions.The person responsible for the safety of the installationmust perform the activities required in each case and beable to recognise and avoid potential hazards.Knowledge of first-aid measures and of the availablelifesaving equipment is also required.Non-qualified personnel are forbidden to work on thegeared motors.

Safety VLT OneGearDrive Operating Instructions


1 1

1.2.3 Intended Use Taking into Account theRelevant Technical Regulations

These machines are intended for commercial installations,unless otherwise expressly agreed. They comply with thestandards of the series EN 60034/DIN VDE 0530. Use in apotentially explosive atmosphere is forbidden, if notexpressly intended for this purpose (refer to additionalinformation). If in a special case - use in non-commercialinstallations - increased safety precautions are required(e.g. protection against access by children’s fingers), theseconditions must be ensured when setting up the instal-lation. The machines are designed for ambienttemperatures between -20 ˚C to +40 ˚C as well as forinstallation heights up to 1000m above sea level. Anydeviations found on the rating plate must be taken intoconsideration. Ensure that the conditions at the place ofwork correspond to all the rating plate data.

CAUTIONLow-voltage machines are components for installation inmachines in the sense of the Machinery Directive2006/42/EC. It is forbidden to use the machine untilconformity of the final product with this directive isestablished (refer to EN 60204-01).

1.2.4 Transportation, Storage

When the electric drive units are being transported, theeye bolts - where provided in the design - must be firmlytightened down their bearing surface. They may be usedonly for transporting the drive unit and not for lifting boththe drive unit and the driven machine. Report any damagediscovered after delivery to the haulage companyimmediately. Commissioning may have to be suspended.If drive units are to be stored, ensure a dry, dust free andlow vibration (veff < 0,2 mm/s) environment (damagesustained during storage). The life of the lubricants andseals is reduced with longer storage times.There is a risk of fracture at very low temperatures (underapproximately -20 ˚C). If the transport eye bolts arereplaced, use drop forged eye bolts as specified in DIN580.

1.2.5 Mounting Arrangement, Assembly

Fasten the drive unit by its flange. Attach the gear unitswith hollow shafts on to the driven shaft using the meansprovided.

CAUTIONCaution! Depending on the reduction ratio, geared motorsdevelop substantially higher torques and forces than high-speed motors of similar power.

Mounts, substructure and torque restraint must be ratedfor the high forces anticipated during operation andsecured sufficiently against loosening. Cover the outputshaft(s) and any second motor shaft extension present, aswell as the transmission elements mounted on it(couplings, chain wheels etc.), so that they cannot betouched.

1.2.6 Connection

All work can only be carried out by qualified technicalpersonnel on a stationary machine, which has beenprotected against re-starting. This applies also to auxiliarycircuits. Remove any transportation blocks before start-up.

Check to ensure safe isolation from the supply!The terminal box may only be opened once it has beenensured that the power is switched off. The information onvoltage and frequency on the rating plate mustcorrespond with the mains voltage under observance ofthe terminal circuit. Exceeding the tolerances as in EN60034 / DIN VDE 0530, i.e. voltages ±5 %, frequency ±2 %,cam form, symmetry, increases heating and reduces servicelife.Observe any accompanying connection diagrams, partic-ularly for special equipment (e.g. thermistor protectionetc.). The type and cross-section of the main conductors, aswell the protective conductors and any potential equali-zation which may become necessary, must correspond tothe general and local installation regulations. Withswitching duty, take the starting current into account.Protect the drive unit against overload and in dangeroussituations against automatic restarting due to inadvertentstarting.Lock the terminal box again to protect against contactwith live components.



11

1.2.7 Commissioning

Before commissioning, remove the protective films.Disconnect the mechanical connection to the drivenmachine as far as possible and examine the direction ofrotation in the no-load state. Remove feather keys orsecure them in such a way that they cannot be ejected.Ensure that the current draw in the loaded condition doesnot exceed the rated current indicated on the rating platefor any length of time. Observe the drive unit after firstcommissioning for at least one hour for any unusual heator noise.

1.2.8 Operation

CAUTIONDanger of burnsThe surface of the VLT OneGearDrive can reach temper-atures of over 60 ˚C during operation.

• Do not touch the VLT OneGearDrive until it hascooled down.

With certain layouts (e.g. unventilated machines), relativelyhigh temperatures can occur on the motor frame, whichare, however, within the limits specified in the standard. Ifthese drive units are located in a place where they aresubject to intensive contact, measures must be taken bythe installer or operator to provide protective shielding.

1.2.9 Spring-loaded Brakes

Spring-loaded brakes are safety brakes, which continue towork in the event of power failure or usual wear. If amanual release bracket is provided, remove it duringoperation. Since other components could also fail, takesuitable safety precautions to avoid any injury to personsor damage to objects cause by un-braked operation.

1.2.10 Maintenance

In order to prevent breakdown, danger and damage,examine the drive units at regular intervals depending onthe operating conditions. Observe the lubrication intervalsfor bearings and gear units specified in the respectiveoperating instructions. Replace worn or damaged partsusing original spare parts or standard parts.

1.2.11 Operating Instructions

For reasons of clarity, the operating instructions and safetyinformation do not contain all information relating to allgeared motors types and cannot take into account everyconceivable case of installation, operation or maintenance.The information is essentially limited to that which is

required for qualified personnel in normal workingsituations. Any unclear points can be clarified bycontacting Danfoss.

1.2.12 Faults

Changes in relation to normal operation, such as highertemperatures, vibrations, noises etc. tend to indicate thatthe function is impaired. To avoid faults which could leaddirectly or indirectly to injury to persons or damage toproperty, inform the maintenance staff responsible. If inany doubt, switch the geared motors off immediately.

1.2.13 Electromagnetic Compatibility

The operation of the low-voltage machine in its intendedapplication must meet the protection requirements of theEMC (electromagnetic compatibility) Directive 2004/108/EC.Correct installation (e.g. screened cables) is the responsi-bility of the system’s installers. Precise information can betaken from the operation instructions. For systems withfrequency inverters and rectifiers, the manufacturer’selectromagnetic compatibility information must also betaken into consideration. The electromagnetic compatibilitydirective in accordance with EN 61000-6-2 and EN61000-6-4 is complied with given proper use and instal-lation of the geared motors. This is also true incombination with Danfoss frequency inverters andrectifiers. The additional information provided in theoperation instructions must be taken into considerationwhen using the motors in residential, commercial andtrade sectors, as well as in small businesses in accordancewith EN 61000-6-1 and EN 61000-6-3.

1.2.14 Warranty and Liability

The warranty obligations of Danfoss arise out of therelevant supply contract, which is neither expanded norrestricted by this safety information or other instructions.

NOTEThis safety information must be kept in a safe place, whereit is available to all persons working with the VLTOneGearDrive.



1 1

2 Geared Motors with Permanent Magnet Motors

2.1 Geared Motors Degree of Protection

The VLT OneGearDrive range complies with EN 60529 andIEC 34-5/529. The drives are totally enclosed and dust-tightas well as hose proof.

The VLT OneGearDrive-Basic is supplied as standard inIP67.

The VLT OneGearDrive-Standard and VLT OneGearDrive-Hygienic are for use in aggressive areas and are suppliedin IP67 (optionally IP69K).

2.2 Surface Damage

CAUTIONDamage to the protective coatingDamage to the paint coating reduces its protectivefunction.

• Handle the VLT OneGearDrive with care and donot place it on any rough surfaces.

Check the condition of the paint regularly and repair whennecessary, depending on ambient influences. Ensure thatthe paint finish is compatible with the other components.

Contact Danfoss-Service for information on paint repairand approved lacquer.

2.3 Rating Plate

Danfoss geared motors are supplied with a corrosion-proofrating plate as standard. The standard rating plate is madeof special plastic tried and tested in many years ofpractical use and approved for hazardous areas by thePhysikalisch-Technische-Bundesanstalt (PTB).

INmax 7,2 A

nLT 0..370 rpm fmax 250 Hz

tamb 40 °C KTY 84-130

28 kgP3 IP 69K

155 °C (F)

178uxxxxxxxxxxb011

i 8,12

Type OGDHK231K131402L09R1S11P1A9010H1Bxx

Barcode

Made in Germany

MLT 140-65 Nm

2,9 L Optileb GT220

130B

B851

.12

Illustration 2.1

Geared Motors with Permanen... VLT OneGearDrive Operating Instructions


22

2.4 Mounting Arrangement

Cover any drinking water, food, textiles etc. locatedbeneath the geared motor.

Install the drive unit as free from vibration as possible.

Observe the special instructions for installation locationswith abnormal operating conditions (e.g. prolongedexposure to dripping water, high ambient temperaturesabove 40 °C, explosion hazards). The fresh air intake mustnot be restricted by unsuitable installation or by fouling.

Flexible couplings with zero play, if possible, arerecommended for direct power transmission from the gearunit to the driven machine and commercially available slipclutches are recommended if there is a risk of blocking.

Take care when fitting transmission elements onto thehollow shaft of the gear unit, which is finished to ISO h 7.Use the tapped end hole intended for this purposeaccording to DIN 332 if possible. Warming the machinepart to be fitted onto the shaft to approximately 100 °Chas proved to be advantageous. The bore must bedimensioned in accordance with following table andtherefore exhibit the following tolerances:

Nominal size of bore(in mm)

h 7 output shaft Bore H7 withtolerances (in 1/1000 mm)

over 18 to 30over 31 to 50

0 to + 210 to + 25

Table 2.1

2.5 Proposal Assembly Kit

130B

C00

6.10

Illustration 2.2

1 Shaft

2 Disc

3 Retaining ring

4 Lock washer

5 Fixing screw (filister head)

6 Key

Table 2.2

Type Dimensions (mm)

Retaining ring (3)DIN 472

Lock washer (4)DIN 7980

Fixing screw (5)DIN 912-8.8

Key (6)DIN 6885

Width x Height x Length

OGD-K30 30x1.2 10 M10x30 A 8x7x130

OGD-K35 35x1.5 12 M12x35 A 10x8x130

OGD-K40 40x1.75 16 M16x35 A 12x8x130

Table 2.3

The dimensions shown could differ from the customer conditions and must potentially be changed by the customer.



2 2

Mounting Instructions

Rotate the disc (2) and fit it against the retaining ring (3).The fixing screw (5) and lock washer (4) are not included in the delivery. The parts are dependant on the length and size ofthe shaft. For further information refer to the mounting arrangement, see 2.4 Mounting Arrangement.

Shaft Disc

130B

C00

4.11

130B

C00

5.11

Table 2.4

Type

Dimensions (mm)

Shaft Disc

a b c d e f g h i k l m n o p

OGD-K30 30 140 8 4 5 130+0.5 M10 22 30 3 1.5 38 6 29.8 11

OGD-K35 35 140 10 5 5 130+0.5 M12 28 37 3 1.5 43 6 34.8 13

OGD-K40 40 140 12 5 5 130+0.5 M16 36 45 3 2 48 6 39.8 17

Table 2.5

The dimensions shown could differ from the customer conditions and must potentially be changed by the customer.

2.6 Torque Restraint

Shaft-mounted geared motors require a suitable torquerestraint to resist the reaction torque. Shaft-mounted gearshave cast torque arms as standard. Bevel gears areavailable with bolt-on torque arms on request. The torquearm is screwed onto the front “V” on the side of the gearunit. It is always important to ensure that the torque armdoes not create excessive constraining forces due to thedriven shaft running untrue, for example. Excessive playcan result in excessive shock torques in switching orreversing operations. Consequently, Danfoss recommendsthe use of pre-tensioned rubber damping elements.

2.7 Electrical Connection

When connecting the motor, take note of the rating plateinformation and the connection diagram as well as therelevant safety regulations and rules for the prevention ofaccidents.Unless a special design is concerned, the rating data referto ± 5% voltage tolerance, to -20 to 40°C ambienttemperature and altitudes up to 1000 m above sea level.The permissible switching frequency depends on thedesign of the motors, the load torque and the massmoment of inertia.

When closing the terminal box, particular attention mustbe given to obtaining a perfect seal.



22

To guarantee electromagnetic compatibility (EMC) asdefined in EMC Directive 2004/108/EC, all signal lines mustuse shielded cables. The cable sheath is to be earthed atboth ends. The frequency inverter operating instructionswill indicate whether a shielded cable is necessary for themotor supply line. A shielded motor cable is not required

when connecting to the low-voltage network or to afrequency inverter with an output filter. Signal cables andpower cables should not be laid parallel over longdistances.

2.8 Terminal Box

The cables of motors with and without brakes can be introduced into the motor terminal box.

130B

B498

.12

Illustration 2.3

The standard position for the motor terminal box is shown in the dimensional drawings for the geared motor(see 4.1.1 VLT OneGearDrive Standard).

Screw-on terminal boxes are supplied with a metric screw thread as standard.

M 25 x 1.5

M 25 x 1.5

2 x M 32 x 1.5

130B

C00

3.11

Illustration 2.4



2 2

2.9 Connection Diagram Cage Clamp

CAUTIONRefer to the Operating Instructions for VLT AutomationDrive FC 302 and FCD 302 to connect the terminals.Do not connect the VLT OneGearDrive directly to the power supply.

NOTEThe connection from the resolver to the inverter is based on a VLT AutomationDrive FC302 or FCD302 with an MCB103option. For other connection or for non-Danfoss frequency converters contact Danfoss-Service.

The following graphic shows the VLT OneGearDrive DA09LA10 with terminal box in Y-connection with a thermal protectionconnection resolver.

130B

B869

.11

R1T2T1W1V1U1PE

V1 W1Resolver

U1

L1 L2 L3

S1 S3 S2 S4R2

Illustration 2.5

Input: ER1-R2 = E 0 x sin (ωt)

Output: ES1-S3 = Tr x E R1-R2 x cos Ø

ES2-S4 = Tr x E R1-R2 x sin Ø

Tr = Transformation ratio

Table 2.6

T1KTY 84-130 ZK010.1090-17

T2

Table 2.7

Colour

Motor winding

U1 black

V1 blue

W1 brown

Resolver* optional

R1 → REF+ red/white

R2 → REF- black/white

S1 → COS+ yellow

S3 → COS- blue

S2 → SIN+ red

S4 → SIN- black

Table 2.8



22

2.10 Connection Diagram Three-phase Gear Motors

CAUTIONRefer to the Operating Instructions for VLT AutomationDrive FC 302 and FCD 302 to connect the terminals.Do not connect the VLT OneGearDrive directly to the power supply.

The following graphic shows the connection power plug for VLT OneGearDrive Hygienic DA09LA10 in Y-connection withthermistors.

130B

B868

.11

Illustration 2.6

Pin Cable allocation for plug with connection cable

Motor winding

U1 1 No. 1 (2.5 mm2)

V1 3 No. 2 (2.5 mm2)

W1 4 No. 3 (2.5 mm2)

PE 2

Table 2.9



2 2

2.11 Connection Diagram Signal Plug

NOTEThe connection from the resolver to the inverter is based on a VLT AutomationDrive FC 302 or FCD 302 with an MCB 103option. For other connections or for non-Danfoss frequency converters contact Danfoss-Service.

The following graphic shows the connection signal plug for VLT OneGearDrive Hygienic DA09LA10 resolver connection.

130B

B889

.11

Illustration 2.7

Input: ER1-R2 = E 0 x sin (ωt)

Output: ES1-S3 = Tr x E R1-R2 x cos Ø

ES2-S4 = Tr x E R1-R2 x sin Ø

Tr = Transformation ratio

Table 2.10

Resolver Pin Cable allocation for plug withconnection cable

R1 → REF+ 1 brown

R2 → REF- 2 white

S1 → COS+ 3 yellow

S3 → COS- 4 blue

S2 → SIN+ 5 red

S4 → SIN- 6 black

Table 2.11

For information about resolver-connection when using a Danfoss VLT AutomationDrive FC 302 or a Danfoss FCD 302 withan MCB 103 option, please refer to the operating instructions for those products.



22

2.12 Overload Protection

Take note of the relevant circuit diagram for motors withthermally activated winding protection (e.g. thermostats orthermistors).

Automatic restarting after the winding has cooled must beavoided in most applications.The output of the motors is normally adequately rated.The rated current does not represent a measure of gearunit utilization in these cases and cannot be used asoverload protection for the gear unit. In some cases, theway in which the driven machine is loaded can excludeany overloading as a matter of course. In other cases it isprudent to protect the gear unit by mechanical means (e.g.slip clutch, sliding hub etc.). This depends on themaximum permissible limit torque M2 in continuousrunning duty specified on the rating plate.

2.13 Lubricant Changes

The gear units are supplied with lubricant ready foroperation.

The following table shows the oil change intervals basedon normal operating conditions and a lubricanttemperature of approximately 80°C. The lubrication intervalmust be reduced at higher temperatures (halve it for each10 K increase in the lubricant temperature).

Lubricant type Lubricant change interval

PGLP220 25000 operating hours

Optileb GT220 H1 (food grade) 35000 operating hours

Table 2.12

The gear units have filling plugs and drain plugs. In thestandard designs, these make it possible to change thelubricant without disassembly.

It is also necessary to flush the gear unit enclosure if thelubricant grade or lubricant type is changed.If the motor is only used briefly it is sufficient to drain offthe original oil and use the original lubricant type to refill

the maximum possible amount for the gear unit as definedon the rating plate. Then operate the drive unit brieflyunder no load, drain this oil off again and refill with thenew lubricant as defined on the rating plate.

If necessary, drain off the original lubricant and flush outthe gear unit with petroleum until all traces have beenwashed out. Then perform the procedure described abovefor short-term operation twice before filling with thespecified volume of new lubricant in accordance with therating plate.

It is advisable to inspect, and if necessary replace, the wearparts (bearings and seals) when changing the lubricant.

2.14 Lubricant Grade

Oils PGLP 220 and PGLP 68 comply with DIN 51502 andDIN 51517 and are suitable for lubricating the gear unit.Food grade oils which comply with NSF H1 can be used.

The lubricant must permit low-friction, virtually wear-freecontinuous operation. The damage load level on the FZGtest as specified in DIN 51354 shall be in excess of loadlevel 12, and the specific wear below 0.27 mg/kWh. Thelubricant should not foam, should protect againstcorrosion and should not attack the interior paint, therolling contact bearings, gearwheels and seals.

Lubricants of different types may not be mixed, asotherwise the lubrication characteristics may be impaired.A long service life is only ensured by the use of a lubricantlisted in the following table or equivalent.

If the VLT OneGearDrive is stored for a longer period oftime before installation, refer to chapter “Storage andStartup of geared motors with permanent magnet rotors”.

The wear-protecting EP gear lubricant oils as listed in thefollowing table are recommended.



2 2

Lubricant-manufacturer Standard oilSynthetic oilPGLP 220

Low temperatureSynthetic oilPGLP 68

Foodstuffs industry oilNSFUSDA H1 oil

ARAL Degol GS 220 – Eural Gear 220

BP Enersyn SP-XP 220 – –

CASTROL Alphasyn PG 220OPTIFLEX A 220

– OPTILEB GT 220

FUCHS Renolin PG 220 Renolin PG 68 –

KLÜBER Klübersynth GH 6-220 Klübersynth GH 6-80 Klüberoil 4UH1-220N

MOBIL Glygoyle HE 220Glygoyle 30

– –

OEST – – Cassida Fluid GL 220

SHELL Tivela S220 – –

TEXACO – – NEVASTANE SL220

Table 2.13

NOTESynthetic gear oils with a polyglycol base (e.g. PGLP etc) must be kept separate from mineral oils and disposed of as specialwaste.

As long as the ambient temperature does not fall below -10°C, ISO viscosity grade VG 220 (SAE 90) is recommended. This isas specified in the international definition of viscosity grades at 40°C in accordance with ISO 3448 and DIN 51519 and forNorth America, AGMA 5 EP.

For lower ambient temperatures oils of a lower nominal viscosity with correspondingly better starting characteristics shouldbe used, such as PGLP with a nominal viscosity of VG 68 (SAE 80) or AGMA 2 EP. These grades may also be required attemperatures around the freezing point in the following circumstances:

• if the drive unit's breakaway torque has been reduced with a view to achieving soft starting

• if the motor has a relatively low power output

2.15 Lubricant Volume

The recommended lubricant quantity for the particularmounting position is indicated on the motor rating plate.When filling, ensure that the upper gear unit componentsare also well lubricated.

130B

B890

.12

P1 P2 P3

Illustration 2.8 Lubrication Quantity in litres

Gear type P1 P2 P3

VLTOneGearDrive

1.1 2.2 2.9

Table 2.14

Other mounting positions on request!



22

2.16 Changing the oil

CAUTIONDanger of burnsThe surface of the VLT OneGearDrive can reach hightemperatures during operation.

• Do not touch the VLT OneGearDrive until it hascooled down.

CAUTIONDanger of burnsThe oil in the VLT OneGearDrive reaches high temper-atures during operation.

• Do not carry out the oil change until it hascooled down sufficiently.

1

2

130B

C42

4.10

Illustration 2.9 VLT OneGearDrive Oil Screws 1 and 2

Draining the Oil

1. Once the VLT OneGearDrive has cooled down,remove it from your system

2. Bring the VLT OneGearDrive into a verticalposition and remove oil screws 1 and 2

3. Turn the VLT OneGearDrive into a horizontalposition and drain the oil through screw hole 1into a suitable container

4. Turn the VLT OneGearDrive back into a verticalposition

Filling the Oil

NOTEThe required oil quantities can be found on the ratingplate and in chapter 2.15.1 Lubricant Volume.

1. Fill the VLT OneGearDrive with the appropriateamount of oil through screw hole 1

2. Remove all traces of oil from the surface of theVLT OneGearDrive using a soft cloth

3. Reinsert and tighten oil screws 1 and 2

2.17 Bearing Lubrication for Geared Motors

With smaller and middle sized gear units, the inputcomponents and motor components are designed withenclosed ball bearings.

The lubricant should be changed when the bearings arereplaced during maintenance work on the rotary shaftseals. Cleaning and lubrication of the bearings is notrecommended due to the risk of contamination.

2.18 Disposal

The metallic parts of the gear unit and the geared motorcan be disposed of as scrap, segregated into steel, iron,aluminium and copper.The lubricants should be disposed of as waste oil, and thesynthetic oils should be disposed of as special waste.



2 2

3 Storage and Commissioning of Geared Motors with PermanentMagnet Motors

3.1 Storage of Geared Motors withPermanent Magnet Motors

If the VLT OneGearDrive is being stored for an extendedtime before start-up, increased protection against damageby corrosion or humidity can be achieved by observing thefollowing information. The actual load depends verystrongly on local conditions, therefore the time periodstated is only a guide value. Note that this period does notinclude any extension of the warranty. If disassembly isnecessary before start-up, contact Danfoss-Service. Theinstructions contained in this document must be observed.

3.2 Geared Motor Condition and StorageSpace

Check the factory-fitted plugs in all entry holes on theterminal box for damage caused during transportation andfor correct positioning. Replace if necessary.

Remove any present vent valves and replaced them with asuitable cover screw.

Repair any damage to the exterior paint layer or to therust protection of the bright metal shafts, including hollowshafts.

The storage space should be dry, well-ventilated andvibration-free. If the temperature in the space exceeds thenormal range of -20°C to +40°C for an extended period oftime or varies strongly frequently, employ the measuresbefore start-up specified in chapter 3.4 Measures beforeCommissioning, even after short storage times.

3.3 Measures During the Storage Period

It is recommended that the drive units be turned 180°every 12 months so that the lubricant in the gear unitcovers the bearings and gearwheels which have previouslybeen positioned on top. Also, the output shaft should beturned manually in order to churn the rolling-contactbearing grease and distribute it evenly.

Turning the drive unit does not have to be carried out ifthe gear unit enclosure is completely filled with lubricantas the result of a special agreement. In this case, thelubricant level before start-up is to be reduced to thedesired value as defined in the operating instructions andthe rating plate.

3.4 Measures before Commissioning

3.4.1.1 Motor Component

• Insulation measurementMeasure the insulation resistance of the windingwith commercially available measuring apparatus(e.g. with a magneto) between all winding partsand between the winding and the enclosure.

Measured value Action/State

> 50 megohm no drying necessary, new condition

< 5 megohm drying advised

approx 50 megohm lowest permissible threshold

Table 3.1

3.4.1.2 Gear Unit Component

• LubricantThe lubricant in the gear unit must be changed ifthe storage period exceeds 3 years or thetemperatures were very harsh throughout ashorter storage period. For detailed instructionsand lubricant recommendations seechapter2.15.1 Lubricant Volume.

• Shaft sealsWhen changing the lubricant, the function of theshaft seals between the motor and gear unit aswell as on the output shaft must also be checked.If a change in shape, colour, hardness or sealingeffect is determined, the shaft seals must bereplaced.

• GasketsIf lubricant is draining out at the connectingpoints on the gear unit enclosure, the sealingcompound must be replaced.

Storage and Commissioning ... VLT OneGearDrive Operating Instructions


33

4 Dimensions

4.1 VLT OneGearDrive Standard

130B

B939

.12

Illustration 4.1 VLT OneGearDrive Standard

130B

B940

.12

Illustration 4.2 Steel 30

130B

B941

.11

Illustration 4.3 Optional: Steel/Stainless Steel 30

Dimensions VLT OneGearDrive Operating Instructions


4 4

130B

B942

.10


130B

B943

.12


4.2 VLT OneGearDrive Standard with Torque Arm in Front Position (optional)

130B

B947

.11

Illustration 4.6 Torque Arm in Front Position



44

4.3 VLT OneGearDrive Hygienic

130B

B888

.13

Illustration 4.7 VLT OneGearDrive Hygienic13

0BB9

35.12

33.337.592.5

37.5

73.5 73.5

185

1.3 H13 1.3 H13

30H7

8JS9

+0.2

Illustration 4.8 Stainless Steel 30

130B

B936

.12

38.337.592.5

37.5

73.5 73.5

185

1.6 H13 1.6 H13

35H7

10JS9

+0.2


130B

B937

.11

43.237.592.5

37.5

73.5 73.5

185

1.85H13 1.85H13

40H7

12JS9

+0.2




4 4

130B

C00

7.10

Illustration 4.11 Connector Position

4.4 VLT OneGearDrive Hygienic with Torque Arm in Front Position (optional)

130B

B946

.12

Illustration 4.12 Torque Arm in Front Position



44

5 Motor Datasheet

5.1 Permanent Magnet Three-phase Synchronous Motor

Rated torque 12.6 Nm

Rated current 7.2 A

Rated speed 3000 rpm

Rated frequency 250 Hz

Motor circuit Y

Winding resistance (Rtt) 1ΩWinding inductivity (Ltt) 9 mH

Inductivity - D axis (Ld) 5 mH

Inductivity - Q axis (Lq) 5 mH

Motor poles (2p) 10

Moment of inertia 0.0043 Kgm²

Back EMF constant (ke) 120V/1000 rpm

Torque constant (kt) 1.75 Nm/A

Table 5.1

5.2 Resolver Data

Poles 2

Input voltage 7 V

Input current 30 mA

Input frequency 10 kHz

Transmission ratio 0.5 ± 10 %

Table 5.2

Motor Datasheet VLT OneGearDrive Operating Instructions


5 5

6 Options

6.1 Torque Arm Set

Part number: 178G5006

A A

R 50

153 15

o30o30

214

185

o

30

60

o30

R 70

R 57.5 95.50.3

A - AR 11

25.2

35

11

6

130B

C426

.10

Illustration 6.1 Torque Arm

Options VLT OneGearDrive Operating Instructions


66

1 2 3

4

8

7

5

6

130B

C425

.10

Illustration 6.2 Mounting Set

Position Description Specification

1 Disc DIN 125-A10 5

2 Nut DIN 934 M10

3 Disc DIN 9021 10, 5x30x25

4 Nut DIN 985 M10

5 Disc Ø73x3 Stainless steel

6 Customer Frame –

7 Barrel POM-C white

8 Bushing Stainless Steel

9 Torque Arm Stainless Steel

Table 6.1

NOTEThe set also contains 3 x DIN 933, M10x25, 8.8, stainless steel screws.

CAUTIONOnly use the original Danfoss or comparable mounting set to mount the VLT OneGearDrive to the conveyor. The mountingequipment used must ensure the same degree of flexibility as the original Danfoss mounting set. The torque arm cannot bescrewed directly on to the conveyor frame.



6 6

6.2 Mechanical Brake

6.2.1 Overview

The VLT OneGearDrive Standard is available with a DC 180V brake option. This mechanical brake option is intendedfor emergency stop and park brake duty. Normal brakingof a load would still be controlled by the inverter dynamicbrake.

WARNINGDanger of fatal injury if the hoist falls.Severe or fatal injuries.

• The brake must not be used in vertical lifting andhoisting applications.

6.2.2 Technical Data

Voltage VDC 180 ±10 %

Pel W 14.4

Resistance Ω 2250 ±5 %

Current A 0.08

Maximum brake torque Nm 10

Table 6.2

6.2.3 Dimensions

The following graphics show the dimensions of the VLT OneGearDrive with the mechanical brake option

546

130B

C427

.10

Illustration 6.3



66

6.2.4 Connection

The following graphic shows the cage clamp and the connection to VLT® AutomationDrive FC 302.

130B

C428

.10

V1 W1

U1

PE U1 V1 W1 T1 T2 B1 B2

L1 L2 L3

1 2

Illustration 6.4

Pin FC 302

1 AC 400 V power supply

2 Terminal 04

Table 6.3

NOTEConnect terminal 05 on the VLT® AutomationDrive FC 302 to the AC 400 V power supply.

NOTEUsing a VLT® AutomationDrive FC 302 disconnect the bridge rectifier and connect the brake directly as follows:

FCD 302

Brake B1 Terminal 122 (MBR+)

B2 Terminal 123 (MBR–)

Table 6.4

The connection and use of the mechanical brake has been tested and released with VLT® AutomationDrive FC 302 and FCD302. Any other inverter may require a different connection. Contact Danfoss-Service for further information.For information about parameter setting and programming when using a VLT AutomationDrive FC 302 or FCD 302 refer tothe corresponding Operating Instructions.



6 6

6.2.5 Maintenance

6.2.5.1 Illustration

1 2

4

3

5

6

7

8

9

10

130B

C429

.10

Illustration 6.5

1 Rotor width, minimum 5.5 mm

2 Air gap, maximum 0.45 mm

3 Fastening screws

4 Armature plate

5 Magnet

6 Springs

7 Hub for rotor

8 Rotor

9 Friction Plate

10 Hollow screws

Table 6.5

6.2.5.2 Readjusting the Air Gap

The spring-applied brake is virtually maintenance-free.However, when the maximum air gap a(max) is reached, are-adjustment will be required.

• Loosen the fastening screws (3) by turning themhalf a rotation counter-clockwise

• Turn the hollow screws (10) into the magnetbody by turning them counter-clockwise

• Turn the fastening screws (3) clockwise into themotor flange until the nominal air gap is reachedat 3 positions on the circumference

• Reset the hollow screws (10) by turning them outof the magnet body (clockwise) until lockedagainst the counter-friction surface

• Tighten the fastening screws (3)

• Check that the air gap is correct

6.2.5.3 Replacing the Rotor

When the minimum rotor size s(min) is reached, a re-adjustment of the air gap a is no longer possible and therotor has to be replaced.

• Loosen the fastening screws (3) by turning themhalf a rotation counter-clockwise

• Remove the retainer ring and replace the rotor(9) with a new one

• Fix the retainer ring again into the radial grooveof the shaft and assemble the brake (see alsochapter “readjusting the air gap”)

• Install the brake (also see chapter )

• Tighten the fastening screws

CAUTIONEven after the exchange of the rotor, the complete brakingtorque will only be effective after the brake linings at therotor have been run in.

6.2.5.4 Adjusting the Nominal BrakingTorque and Replacing the Springs

The nominal braking torque can be adjusted and brokensprings can be replaced. Follow the instruction in chapter to open the brake as reference for the nominal braketorque:

Nominal braking torque in Nm Number of springs

10 7

7 5

6 4

4 3

Table 6.6



66

Index

AAir Gap (Brake)....................................................................................... 26

Approvals................................................................................................... 3

Assembly Kit............................................................................................. 8

Axial Fastening......................................................................................... 8

BBrake

Option: Dimensions........................................................................ 24Option: Maintenance...................................................................... 26Option: Overview............................................................................. 24

Braking Torque (Nominal)................................................................. 26

CCage Clamp Connection.................................................................... 10

Commissioning........................................................................................ 5

Connection:Cage Clamp........................................................................................ 10Electrical................................................................................................. 8Mechnical Brake Option................................................................ 25Safety...................................................................................................... 4Signal Plug.......................................................................................... 12Three-phase Gear Motors............................................................. 11

Current (rated)....................................................................................... 21

DDamage To Surface................................................................................ 6

Dimensions:Mechanical Brake Option.............................................................. 24VLT OneGearDrive Hygienic......................................................... 19VLT OneGearDrive Hygienic With Torque Arm In Front Po-

sition...... 20VLT OneGearDrive Standard........................................................ 17VLT OneGearDrive Standard With Torque Arm In Front Po-

sition...... 18

Disposal Of Parts................................................................................... 15

EElectrical Connection, Safety.............................................................. 8

Electromagnetic Compatibility.......................................................... 5

FFaults, Safety............................................................................................. 5

Frequency (rated)................................................................................. 21

GGaskets..................................................................................................... 16

IInductivity............................................................................................... 21

Inertia........................................................................................................ 21

Intended Use............................................................................................ 4

LLiability....................................................................................................... 5

Lubricant:Bearing Lubricant............................................................................. 15Change Intervals.............................................................................. 13Gear Unit............................................................................................. 16Grades.................................................................................................. 13How To Change................................................................................ 15Types.................................................................................................... 13Volume................................................................................................. 14

MMaintenance............................................................................................. 5

Maintenance: Mechanical Brake Option...................................... 26

MechanicalBrake Option: Air Gap..................................................................... 26Brake Option: Connection............................................................ 25Brake Option: Dimensions............................................................ 24Brake Option: Maintenance......................................................... 26Brake Option: Overview................................................................. 24Brake Option: Rotor......................................................................... 26Brake Option: Springs..................................................................... 26Brake Option: Technical Data...................................................... 24

MotorCircuit................................................................................................... 21Torque.................................................................................................. 21

MountingMounting............................................................................................... 4Arrangement........................................................................................ 7Set For Torque Arm......................................................................... 22

OOil:

Bearing Oil.......................................................................................... 15Change Intervals.............................................................................. 13Grades.................................................................................................. 13How To Change................................................................................ 15Types.................................................................................................... 13Volume................................................................................................. 14

Operation, Safety.................................................................................... 5

Overload Protection............................................................................ 13

PProtection

Protection.............................................................................................. 6Against Overload............................................................................. 13

Protective Coating.................................................................................. 6

Index VLT OneGearDrive Operating Instructions


RRating Plate............................................................................................... 6

Recycling................................................................................................. 15

Rotor (Brake)........................................................................................... 26

SSafety:

Connection........................................................................................... 4Faults....................................................................................................... 5General................................................................................................... 3Intended Use........................................................................................ 4Mounting............................................................................................... 4Operation.............................................................................................. 5Personnel............................................................................................... 3Spring-loaded Brakes........................................................................ 5

Shaft Seals............................................................................................... 16

Signal Plug, Connection..................................................................... 12

Speed (rated).......................................................................................... 21

Spring-loaded Brakes, Safety.............................................................. 5

Springs (Brake)....................................................................................... 26

Start-up: Measures Before Commissioning............................ 5, 16

Storage................................................................................................. 4, 16

Storage:Conditions.......................................................................................... 16Measures During Storage............................................................. 16

Surface Damage...................................................................................... 6

Symbols...................................................................................................... 3

TTechnical

Data: Motor........................................................................................ 21Data: Resolver.................................................................................... 21

Terminal Box............................................................................................. 9

Three-phase Gear Motors, Connection........................................ 11

TorqueArm Set................................................................................................ 22Mounting Set..................................................................................... 22Restraint................................................................................................. 8

Torque: Motor........................................................................................ 21

Transportation......................................................................................... 4

WWarranty..................................................................................................... 5

Winding.................................................................................................... 21

Index VLT OneGearDrive Operating Instructions


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