Danfoss VLT OneGearDrive User manual

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

Contents
1 Introduction 4
1.1 Purpose of this Instruction Manual 4
1.2 Document Version 4
1.3 Disclaimer 4
1.4 Product Overview 4
1.4.1 Intended Use 4
1.4.2 Foreseeable Misuse 5
1.5 Approvals 5
1.6 Disposal 5
1.7 Service and Support 5
2 Safety 6
2.1 Safety Symbols 6
2.2 Qualified Personnel 6
2.3 Due Diligence 6
2.4 Safety Precautions 6
3 Mechanical Installation 7
3.1 Unpacking 7
3.1.1 Items Supplied 7
3.2 Transportation 7
3.2.1 Inspection on Receipt 7
3.2.2 Transport 7
3.3 Protection Rating 7
3.4 Protective Coating 7
3.5 Mounting Arrangement 7
3.5.1 Mounting Procedure 8
3.6 Assembly Kit 8
3.7 Torque Restraint 10
3.8 Final Assembly 11
4 Electrical Installation 12
4.1 EMC-compliant Installation 12
4.2 Electrical Connection 12
4.3 Terminal Box 13
4.3.1 Connection 14
4.4 Cage Clamp Connection Diagram 15
4.5 CleanConnect®Connection Diagram 16
Contents Instruction Manual
MG75C422 Danfoss A/S © 08/2014 All rights reserved.

4.6 Overload Protection 16
5 Commissioning 17
5.1 Measures before Commissioning 17
5.1.1 Overview 17
5.1.2 Motor Component 17
5.1.3 Gear Unit Component 17
5.2 Commissioning Procedure 17
6 Maintenance, Diagnostics and Troubleshooting 18
6.1 Maintenance 18
6.1.1 Replacing the Brake and Rotor 18
6.1.2 Adjusting the Nominal Brake Torque and Replacing the Springs 19
6.2 Inspection during Operation 20
6.3 Repair 20
6.4 Oil 20
6.4.1 Oil Changes 20
6.4.2 Oil Grade 21
6.4.3 Oil Volume 22
6.4.4 Changing the Oil 22
6.5 Spare Parts 22
7 Decommissioning and Disposal 23
7.1 Dismounting 23
7.2 Product Returns 23
8 Motor Datasheet 24
8.1 Nameplate 24
8.2 Storage 24
8.2.1 Measures during Storage 24
8.2.2 Measures after Storage 24
8.3 Permanent Magnet 3-phase Synchronous Motor 24
8.4 General Specifications and Environmental Conditions 25
8.5 Dimensions 25
8.5.1 OneGearDrive Standard 25
8.5.2 OneGearDrive Standard with Torque Arm in Front Position (optional) 26
8.5.3 OneGearDrive Hygienic 27
8.5.4 OneGearDrive Hygienic with Torque Arm in Front Position (optional) 28
8.6 Options 29
8.6.1 Torque Arm Set 29
Contents Instruction Manual
Danfoss A/S © 08/2014 All rights reserved. MG75C422

8.6.2 Mechanical Brake 30
8.6.2.1 Overview 30
8.6.2.2 Technical Data 30
8.6.2.3 Dimensions 30
8.6.2.4 Connections 31
8.7 Accessories 32
8.7.1 Accessories for OneGearDrive Standard 32
8.7.2 Accessories for OneGearDrive Hygienic 32
9 Appendix 33
9.1 Glossary 33
9.2 Abbreviations and Conventions 33
9.2.1 Abbreviations 33
9.2.2 Conventions 34
Index 35
Contents Instruction Manual
MG75C422 Danfoss A/S © 08/2014 All rights reserved.

1 Introduction
1.1 Purpose of this Instruction Manual
The purpose of this instruction manual is to describe the
VLT®OneGearDrive. This instruction manual contains
information about:
•Safety
•Installation
•Commissioning
•Maintenance and repair
•Specifications
•Options and accessories
NOTICE!
For reasons of clarity, the instruction manual and safety
information do not contain all information relating to all
OneGearDrive types and cannot take into account every
conceivable case of installation, operation, or
maintenance. The information is limited to what is
required for qualified personnel in normal working
situations. Contact Danfoss for further assistance.
This instruction manual is intended for use by qualified
personnel. Read this instruction manual in full in order to
use the OneGearDrive safely and professionally. Pay
particular attention to the safety instructions and general
warnings.
These instruction manual is an integral part of the
OneGearDrive and also contains important service
information. Keep this instruction manual available with
the OneGearDrive at all times.
Compliance with the information in this instruction manual
is a prerequisite for:
•Trouble-free operation.
•Recognition of product liability claims.
Therefore, read this instruction manual before working on
or with the OneGearDrive.
VLT®is a registered trademark.
1.2 Document Version
This document is reviewed and updated regularly. All
suggestions for improvement are welcome. Table 1.1 shows
the document version.
Edition Remarks
MG75C4xx Replaces MG75C3xx
Table 1.1 Document Version
1.3 Disclaimer
No liability is assumed for any damage or breakdown
resulting from:
•Failure to observe the information in the
instruction manuals.
•Unauthorized modifications to the OneGearDrive.
•Operator error.
•improper work on or with the OneGearDrive.
1.4 Product Overview
1.4.1 Intended Use
The OneGearDrive is intended for commercial installations,
unless otherwise expressly agreed. It complies with the
standards of the series EN 60034/DIN VDE 0530. Use in a
potentially explosive atmosphere is forbidden unless
expressly intended for this purpose. Increased safety
precautions (for example, protecting children from
inserting their fingers) are required in special cases, such as
use in non-commercial installations. Ensure these safety
conditions when setting up the installation. The
OneGearDrive is designed for ambient temperatures
between -4 °F [-2 °C] to 104 °F [40 °C] as well as for instal-
lation heights up to 3,300 ft [1000 m] above sea level. Any
deviations found on the nameplate must be considered.
Ensure that the conditions at the place of work correspond
to all the nameplate data.
Introduction Instruction Manual
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1

CAUTION
Low-voltage machines are components for installation in
machines in the sense of the machinery directive
2006/42/EC.
•Do not use the machine until conformity of the
final product with this directive is established
(refer to EN 60204-01).
1.4.2 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
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Dispose of oils as special waste.
1.7 Service and Support
Contact your local service representative for service and
support:
www.danfoss.com/Contact/Worldwide/
Introduction Instruction Manual
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11

2 Safety
2.1 Safety Symbols
The following symbols are used in this document:
WARNING
Indicates a potentially hazardous situation which could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.
NOTICE!
Indicates important information, including situations that
can result in damage to equipment or property.
2.2 Qualified Personnel
All necessary work on electric drive units may only be
performed by adequately qualified personnel (e.g.,
electrical engineers as specified in draft EN 50 110-1/DIN
VDE 0105), who have access to the instruction manual
provided and other product documentation available
during any corresponding work and who are obliged to
abide by the instructions contained therein. Qualified
personnel are persons who have authorization based on
training, experience, and instruction as well as knowledge
of relevant standards, rules, accident-prevention
regulations, and operating conditions. The person
responsible for the safety of the installation must perform
the activities required in each case and be able to
recognize and avoid potential hazards.
Knowledge of First Aid and of the necessary lifesaving
equipment available is also required.
Unqualified personnel are forbidden to work on the
OneGearDrive.
2.3 Due Diligence
The operator and/or fabricator must ensure that:
•The OneGearDrive is only used as intended.
•The OneGearDrive is only operated in a perfect
operational condition.
•The instruction manual is always available near
the OneGearDrive in complete and readable form.
•The OneGearDrive is only fitted, installed,
commissioned and maintained by adequately
qualified and authorized personnel.
•These personnel are regularly instructed on all
relevant matters of occupational safety and
environmental protection, as well as the contents
of the instruction manual and in particular the
instructions it contains.
•The product markings and identification markings
applied to the OneGearDrive, as well as safety
and warning instructions, are not removed and
are always kept in legible condition.
•The national and international regulations
regarding the control of machinery and
equipment, which are applicable at the place of
use, are complied with.
•The users always have all current information
relevant to their interests about the
OneGearDrive and its use and operation.
2.4 Safety Precautions
WARNING
HIGH VOLTAGE
High voltage, which can lead to death or serious injury,
is present on the connectors.
•Before working on the power connectors
(disconnecting or connecting the cable to the
OneGearDrive), disconnect the power supply to
the adjustable frequency drive and wait for the
discharge time to elapse (see the adjustable
frequency drive instruction manual).
•Installation, start-up, maintenance and
decommissioning must only be performed by
qualified personnel.
CAUTION
DANGER OF BURNS
The surface of the OneGearDrive and the oil in the
OneGearDrive can reach high temperatures during
operation.
•Do not touch the OneGearDrive until it has
cooled down.
•Do not carry out an oil change until the oil has
cooled down sufficiently.
Safety Instruction Manual
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3 Mechanical Installation
3.1 Unpacking
3.1.1 Items Supplied
The items supplied with the OneGearDrive are:
•OneGearDrive
•This instruction manual
•Eyebolt
•Plastic cap for eyebolt opening
•Hollow shaft cover with three washers and fixing
screws
•Disc and retaining ring
3.2 Transportation
3.2.1 Inspection on Receipt
After receiving the delivery, immediately check whether
the scope of delivery matches the shipping documents.
Danfoss will not honor claims for defects registered later.
Register a complaint immediately:
•With the carrier in case of visible transport
damage.
•With the responsible Danfoss representative in
case of visible defects or incomplete delivery.
Commissioning may have to be suspended if the unit is
damaged.
Check the factory-fitted plugs in all entry holes on the
terminal box for damage caused during transportation and
for correct positioning. Replace if necessary.
3.2.2 Transport
Before transporting the OneGearDrive, the eyebolt
provided must be firmly tightened down to its bearing
surface. The eyebolt can only be used to transport the
OneGearDrive unit and not for lifting attached machines.
3.3 Protection Rating
The OneGearDrive range complies with EN 60529 and
IEC 34-5/529. The drives are totally enclosed and dust-tight
as well as hose-proof.
The OneGearDrive Standard is for use in aggressive areas
and is supplied in protection rating IP67 as standard. The
OneGearDrive Hygienic is rated for both IP67 and IP69K.
3.4 Protective Coating
NOTICE!
Damage to the protective coating
Damage to the paint coating reduces its protective
function.
•Handle the OneGearDrive with care and do not
place it on any rough surfaces.
3.5 Mounting Arrangement
CAUTION
HIGH TORQUE AND FORCE
Depending on the reduction ratio, the OneGearDrive
develops substantially higher torques and forces than
high-speed motors of similar power.
•Rate the mounts, substructure and torque
restraint for the high forces anticipated during
operation. Secure them sufficiently against
loosening.
•Cover the output shaft(s) and any second motor
shaft extension present, as well as the
transmission elements mounted on it
(couplings, chain wheels, etc.) so that they
cannot be touched.
Install the drive unit as free from vibration as possible.
Observe the special instructions for installation locations
with abnormal operating conditions (for example, high
ambient temperatures >104 °F [40 °C]). The fresh air intake
must not be restricted by unsuitable installation or build-
up of dirt.
Use slip clutches if there is a risk of blocking.
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33

Take care when fitting transmission elements onto the
hollow shaft of the OneGearDrive, which is finished to ISO
H7. Use the tapped end hole intended for this purpose
according to DIN 332.
The maximum force based on bearing life is detailed in
(Figure 3.1 and Table 3.1).
130BD895.10
FRzul
X
0
Figure 3.1 Maximum Force
Up to n2
[RPM]
FRZUL [N] up to X (in [mm])1)
0.98
[25]
1.97
[50]
2.95
[75]
3.94
[100]
4.92
[125]
50 170
[4319]
148.2
[3763]
131.3
[3335]
117.9
[2994]
106.9
[2716]
100 119
[3023]
103.7
[2634]
91.9
[2334]
82.5
[2096]
74.8
[1901]
200 68
[1727]
59.3
[1505]
52.5
[1334]
47.2
[1198]
42.8
[1086]
360 55.3
[1404]
48.2
[1223]
42.8
[1084]
38.3
[973]
34.8
[883]
Table 3.1 Maximum Force
1) X is the distance from the surface of the hollow shaft to the force
location.
3.5.1 Mounting Procedure
1. Fasten the drive unit by its flange using the
torque arm (see chapter 8.6.1 Torque Arm Set).
2. Attach the OneGearDrive on to the driven shaft
using the means provided.
3.6 Assembly Kit
6 1 3 2 4 5
Holding
130BC006.11
1 Shaft
2 Disc
3 Retaining ring
4 Lock washer
5 Fixing screw (filister head)
6 Key
Figure 3.2 Assembly Kit
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Type Dimensions (inch)
Retaining ring (3)
ANSI B17.1
Lock washer (4)
ANSI B17.1
Fixing screw (5)
ANSI B17.1
Key (6)
ANSI B17.1
Width x Height x Length
OGD-L1 1.250 x 0.050 0.375 0.500-13 x 1.1875 [M12 x 30] 0.2500 x 0.2500 x 3.9371)
OGD-L2 1.4375 x 0.050 0.500 0.500-13 x 1.3750 [M12 x 35] 0.3750 x 0.3750 x 3.9371)
OGD-L3 1.500 x 0.050 0.625 0.625-11 x 1.6250 [M16 x 35] 0.3750 x 0.3750 x 3.9371)
Table 3.2 Dimensions of Assembly Kit Items
1) Key length required for bmin in Table 3.3. Adapt the key length according to the shaft length used (b) in Table 3.3.
The dimensions shown could differ from the customer conditions and must potentially be changed by the customer.
Mounting instructions
Rotate the disc (2) and fit it against the retaining ring (3). Both items are included in every delivery.
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).
130BD420.10
b
k
30
o
l
m
e
a
h6
ef
CP9
d+0.2
xedges cut
i
h
g
60
o
Chamfer sized to outer diameter of thread
bmax
bmin
p
0-0.1
DiscShaft
n
Figure 3.3 Axial Fastening
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33

max 0.2 mm
130BD764.10
Figure 3.4 Maximum Allowed Eccentricity of the Conveyor Shaft
Type
Dimensions [inch]
Shaft Disc
a bmin bmax c d e f1) g h i k l m n o p
OGD-L1 1.250 4.724 5.512 0.250 0.138 0.195 5.122+0.02 0.500-13
[M12]
0.866 1.181 0.118 0.059 1.496 0.1575 1.236 0.512
OGD-L2 1.4375 4.724 5.512 0.375 0.214 0.195 5.122+0.02 0.500-13
[M12]
1.102 1.457 0.118 0.059 1.693 0.1575 1.425 0.512
OGD-L3 1.500 4.724 5.512 0.375 0.211 0.195 5.122+0.02 0.625-11
[M16]
1.417 1.772 0.118 0.079 1.890 0.1575 1.488 0.669
Table 3.3 Dimensions of the Shaft and Disc
1) Key length required for bmin. Adapt the key length according to the shaft length used (b).
The dimensions shown could differ from the customer conditions and must potentially be changed by the customer.
NOTICE!
Use grease to mount the OneGearDrive onto the shaft. For example, CASTROL Obeen Paste NH1, ARAL Noco Fluid or
similar. Use a key in the same material and quality as the hollow shaft.
3.7 Torque Restraint
The OneGearDrive requires a suitable torque restraint to resist the reaction torque. The torque arm with mounting set is
available as an option (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.
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3.8 Final Assembly
Always assemble the hollow shaft cover (4) with the
delivered screws (5) as shown in Figure 3.5.
130BD421.12
1
4
5
2
3
1 Torque arm (optional)
2 Plastic cap
3 Eyebolt
4 Shaft cover
5 Shaft cover screws
Figure 3.5 Final Assembly
1. Remove the eyebolt (3) and cover the hole with
the plastic cap (2). This ensures the hygienic
features of a smooth surface.
2. Assemble the hollow shaft cover (4) with the
three screws (5) onto the OneGearDrive.
2a Fasten the screws by hand.
2b 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.
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4 Electrical Installation
4.1 EMC-compliant Installation
To guarantee electromagnetic compatibility (EMC) as
defined in EMC Directive 2004/108/EC, all signal lines must
use shielded cables. The cable sheath must be grounded
at both ends. The frequency inverter instruction manual
indicates whether a shielded cable is necessary for the
motor supply line. A shielded motor cable is not required
when connecting to a frequency inverter with an output
filter. Always use shielded cables when laying signal cables
and power cables parallel to each other.
The operation of the low-voltage machine in its intended
application must meet the protection requirements of the
EMC (electromagnetic compatibility) Directive 2004/108/EC.
Correct installation (e.g., shielded cables) is the responsi-
bility of the system’s installers. For systems with adjustable
frequency drives and rectifiers, the manufacturer’s electro-
magnetic compatibility information must also be
considered. 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.
Unless a special design is concerned, the data on the
nameplate refers to:
•A voltage tolerance of ±5 %.
•An ambient temperature of -4 °F [-20] to 104 °F
[40 °C].
•Altitudes up to 3,300 ft [1000 m] above sea level.
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4.3 Terminal Box
Feed the motor cables (motor with or without brakes) into the motor terminal box and connect them.
Ensure a perfect seal when closing the terminal box.
130BB498.13
Figure 4.1 Terminal Box
CAUTION
Never alter the position of the terminal box or open any screws unless instructed to in this instruction manual. Doing so
may cause damage to the OneGearDrive and will invalidate the warranty.
Screw-on terminal boxes are supplied with a metric screw thread as standard.
130BC003.12
M20x1.5 M20x1.5
M20x1.5
1x M20x1.5
Figure 4.2 Terminal Box Screws
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4.3.1 Connection
The terminal box may only be opened once it has been
ensured that the power is switched off. The information on
voltage and frequency on the nameplate must correspond
with the AC line voltage under observance of the terminal
circuit. Exceeding the tolerances as in EN 60034/DIN VDE
0530, i.e., voltages ±5%, frequency ±2%, cam form,
symmetry, increases heating and reduces service life.
Observe any accompanying connection diagrams, partic-
ularly for special equipment (e.g., thermistor protection,
etc.). The type and cross-section of the main conductors, as
well as the protective conductors and any potential equali-
zation which may become necessary, must correspond to
the general and local installation regulations. With
switching duty, take the starting current into account.
Protect the drive unit against overload and, in dangerous
situations, against unintended starts.
Lock the terminal box again to protect against contact
with live components.
CAUTION
RISK OF SHORT CIRCUITS
Short circuits can occur if water penetrates through the
cables into the terminal box. The installed end caps on
the terminal box support the IP protection rating of the
OneGearDrive (see also chapter 3.3 Protection Rating).
•Always use the adequate sealed components
when removing the end caps and plugging the
wire connection.
•Always ensure that the terminal box is closed
properly.
NOTICE!
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.
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4.4 Cage Clamp Connection Diagram
Figure 4.3 shows the OneGearDrive DA09LA10 with terminal box in Y-connection and the connection to the thermal
protection.
130BD422.10
V1 W1
U1
U V W
PEU V W T1 T2
Figure 4.3 Cage Clamp Connection Diagram
Description Inverter output Color Typical cross-section Maximum cross-section
Motor winding
U Black 1.5 mm2/AWG 16 2.5 mm2/AWG 14
V Blue
W Brown
Protective ground PE Yellow/green 1.5 mm2/AWG 16 2.5 mm2/AWG 14
Temperature protection1)
KTY 84-130
T1 White 0.75 mm2/AWG 20 1.5 mm2/AWG 16
T2 Brown
Table 4.1 Cage Clamp Connections
1) When connected to VLT
®
AutomationDrive FC 302 and VLT
®
Decentral Drive FCD 302, use analog input terminal 54, KTY sensor 1. For
information about parameter setting and programming, refer to the corresponding instruction manual.
T1
KTY 84-130
VLT®AutomationDrive FC 3021) VLT®Decentral Drive FCD 3021)
T2 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.
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4.5 CleanConnect®Connection Diagram
Figure 4.4 shows the connection power plug for OneGearDrive Hygienic DA09LA10 in Y-connection with thermistors.
130BB868.12
V1 W1
U1
U
V
W
2
3D
C
A
B
1
4
T1
T2
Figure 4.4 CleanConnect®OneGearDrive Connection
Description Inverter output Pin Typical cross-section Maximum cross-section
Motor winding
U 1
1.5 mm2/AWG 16 2.5 mm2/AWG 14
V 3
W 4
Protective ground PE 2 1.5 mm2/AWG 16 2.5 mm2/AWG 14
Temperature protection1)
KTY 84-130
T1 A 0.75 mm2/AWG 20 1.5 mm2/AWG 16
T2 B
Table 4.3 CleanConnect®OneGearDrive Connection
1) When connected to VLT
®
AutomationDrive FC 302 and VLT
®
Decentral Drive FCD 302, use analog input terminal 54, KTY sensor 1. For
information about parameter setting and programming, refer to the corresponding instruction manual.
T1
KTY 84-130
VLT®AutomationDrive FC 3021) VLT®Decentral Drive FCD 3021)
T2 KTY sensor 1
Analog input 54
Table 4.4 Connections T1 and T2
1) Only if connected
4.6 Overload Protection
Take note of the relevant circuit diagram for motors with thermally activated winding protection (see chapter 4.4 Cage
Clamp Connection Diagram).
Avoid automatic resetting after the winding has cooled.
The output of the motors is normally adequately rated. The rated current does not represent a measure of gear unit
utilization in these cases and cannot be used as overload protection for the gear unit. In some cases, the way in which the
machine being driven is loaded can exclude any overloading as a matter of course. 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 MLT in continuous running duty specified on the nameplate.
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5 Commissioning
5.1 Measures before Commissioning
5.1.1 Overview
If the OneGearDrive has been stored, take the measures
detailed in chapter 5.1.2 Motor Component and
chapter 5.1.3 Gear Unit Component.
5.1.2 Motor Component
Insulation measurement
Measure the insulation resistance of the winding with a
commercially available measuring tool
(for example, Megger) between all winding parts and
between the winding and the enclosure.
Measured value Action/state
>50 MΩNo drying necessary, new condition
<5 MΩDrying advised
approximately 50 MΩLowest permissible threshold
Table 5.1 Insulation Measurement Values
5.1.3 Gear Unit Component
•Oil
Change the oil in the gear unit if the storage
period exceeds five years or the temperatures
were harsh throughout a shorter storage period.
For detailed instructions and oil recommen-
dations, see chapter 6.4.3 Oil Volume.
•Shaft seals
Lubricate the hollow shaft seal with grease if the
storage period exceeds two years. When
changing the oil, the function of the shaft seals
between the motor and gear unit as well as on
the output shaft must also be checked. The shaft
seals must be replaced if any change in shape,
color, hardness or sealing effect is detected.
5.2 Commissioning Procedure
1. Remove the protective films.
2. Disconnect the mechanical connection to the
machine being driven as far as possible and
examine the direction of rotation in the no-load
state.
3. Remove the feather keys or secure them in such
a way that they cannot be ejected.
4. Ensure that the current draw in the loaded
condition does not exceed the rated current
indicated on the nameplate for any length of
time.
5. After first commissioning, observe the
OneGearDrive for at least hour hour to detect any
unusual heat or noise.
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6 Maintenance, Diagnostics and Troubleshooting
WARNING
HIGH VOLTAGE
High voltage, which can lead to death or serious injury,
is present on the connectors.
•Before working on the power connectors
(disconnecting or connecting the cable),
disconnect the power supply module from line
power and wait for the discharge time to
elapse.
•Installation, start-up, maintenance, and
decommissioning must be performed by
qualified personnel only.
CAUTION
DANGER OF BURNS
The surface of the OneGearDrive and the oil in the
OneGearDrive can reach high temperatures during
operation.
•Do not touch the OneGearDrive until it has
cooled down.
•Do not carry out an oil change until the oil has
cooled down sufficiently.
6.1 Maintenance
To prevent breakdown, danger and damage, examine the
OneGearDrive at regular intervals depending on the
operating conditions. Replace worn or damaged parts
using original spare parts or standard parts.
Contact your local service representative for service and
support:
www.danfoss.com/Contact/Worldwide/
The OneGearDrives are largely maintenance free. The
maintenance tasks listed in Table 6.1 may be performed by
the customer. No other tasks are required.
Component Maintenance
task
Maintenance
interval
Instruction
OneGearDrive Check for
abnormal
noise and
vibration.
Every 6
months.
Contact
Danfoss
Service.
Protective
coating
Check for
damage.
Every 6
months.
Repair damage
using the
Danfoss paint
repair set.
Hollow shaft
seal (stainless
steel shaft)
Check the
condition and
check for
leakage.
Every 6
months.
If damaged,
replace with a
Viton seal.
Hollow shaft
seal (mild steel
shaft)
Check the
condition and
check for
leakage.
Every 6
months.
If damaged,
replace with
an NBR seal.
Oil Change the oil. Standard oil:
After 25,000
operating
hours.
Food grade oil:
After 35,000
operating
hours.
See
chapter 6.4.4 C
hanging the
Oil.
Check for oil
leakage on
gear and
motor housing.
Every 12
months.
Replace the
OneGearDrive.
Table 6.1 Overview of Maintenance Tasks
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.
Maintenance, Diagnostics an... Instruction Manual
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