Danfoss VLT One Gear Drive Hygienic Installation Guide

Danfoss VLT One Gear Drive Hygienic

Product Information

Specifications

• Efficiency: Up to 70% variant reduction
• Motor Efficiency: 94.9%
• Energy Efficiency Class: IE5
• Applications: Food and beverage industry conveyor drives
• Motor Type: One type is available
• Gear Ratios: Three available

Product Usage Instructions

• The motor concept provides energy-efficient, flexible, and reliable performance.
• It covers all typical versions of conveyor drives in the food and beverage industry with only one motor type and three gear ratios.
• The components offer maximum flexibility with minimal unit variations, resulting in a uniform user interface and functionality.
• This reduces spare parts inventories and overall costs.
• The system reduces the number of drives required for various production stages, leading to cost savings in operations and maintenance.
• The drive/motor combination offers high performance, matching that of servo drives.
• The product’s hygienic design is advantageous for food safety and plant efficiency. It enables flexible plant design with fewer variants, leading to cost savings.
• The drive offers long service intervals and up to 40% energy savings. It is suitable for dry, wet, and washdown aseptic areas, contributing to improved operational efficiency.

FAQ

• Q: What are the benefits of the hygienic design of the product?
• A: The hygienic design reduces the risks of contamination in food and beverage production areas, improving product shelf life and enabling easier cleaning in case of contamination.
• Q: How does the product contribute to cost reductions?
• A: By offering energy-efficient performance, reducing the number of drive variants needed, and providing high performance with long service intervals and energy savings, the product helps in reducing operational and maintenance costs.

Energy-efficient, flexible, reliable

VLT® OneGearDrive® comprises a highefficiency permanent magnet (PM) motor coupled to an optimized bevel gearbox. As part of the Danfoss VLT® FlexConcept®, the drive is an energy-efficient drive system that helps to optimize plant productivity and reduce energy costs. The VLT® FlexConcept® comprises the VLT® OneGearDrive®, combined with a VLT® Decentral Drive FCD 302 or VLT® AutomationDrive FC 302.

Cost reductions with drive control

• The VLT® OneGearDrive® features a PM motor, which is a three-phase synchronous non-salient motor.
• With an efficiency of 94.9% the motor achieves the IE5 Ultra Premium Efficiency Class defined in IEC TS 60034- 30-2 while providing high torque in a compact motor frame.
• With only one motor type and three available gear ratios, the motor concept covers all typical versions of conveyor drives commonly used in the food and beverage industry.
• For conveyor drives in particular, this system dramatically projects whether the plant operator prefers a centralized or decentralized solution.

Optimized components – fewer variants

• The VLT® OneGearDrive® uses optimized bevel gearing, which is more efficient than commonly used worm gears. As a whole, the system of gear motor and AC drive can reach an efficiency level of 89%, yielding energy savings of up to 40% compared with conventional systems.

• The system components allow maximum flexibility with a minimum number of unit variations, such as motors, gear unit sizes or AC drives, all of which offer a uniform user interface concept and the same functionality.
  A reduced number of geared motor unit (GMU) variants across the plant also means smaller spare parts inventories and further cost reductions.

• With the VLT® OneGearDrive® as part of the VLT® FlexConcept®, Danfoss has developed a flexible, standardized and efficient drive system that significantly reduces the number of drive variants, resulting in greatly reduced operating costs, substantial energy savings and carbon dioxide reductions.

Flexible solutions – high-efficiency

• Electric drives play an important role in supporting food and beverage operations to optimize plant efficiency and reduce energy costs.
• The VLT® FlexConcept® takes this effort a crucial step further.

Savings in operations and maintenance

• In the past, the various production areas: manufacturing, filling, packaging, palletizing, and storage required a variety of drive concepts. For example, dozens or even hundreds of drives were needed just to power the conveyors interconnecting the various production stages.
• Previously, motors were not particularly efficient; there was a wide variety of transmissions and drives in use and maintenance costs were high. The consequences were, and still are, high energy costs and maintenance of large stocks of spare parts to minimize down-time. Since then, the evolution of variable speed drives has brought the drive/motor combination to a high peak of performance, capable of matching that of servo drives.

Hygienic design required

• Hygiene compliance rules are extremely demanding — especially in food and beverage production areas, but also in pharmaceutical and cosmetic manufacturing plants.
• That is why Danfoss has designed the VLT® OneGearDrive® to comply with the specifications and guidelines for the comprehensive, proactive protection of food from contamination with bacteria, fungi and yeasts during processing.
• In the VLT® OneGearDrive® Danfoss has utilized years of experience in process and mechanical engineering, as well as knowledge in microbiology, to create a competitive, cost-efficient solution that can easily be integrated into any production setup.
• This is a clear advantage compared to upgrading existing process equipment designs to meet hygienic requirements, which is often both expensive and unsuccessful.

Awarded design
The design of the VLT® OneGearDrive® Hygienic also opens up totally new aesthetic and key stylistic elements in drive techno logy. The motor and gearbox together form a clean, simple entity and the product won the reddot design award 2010 for “high product quality, expressing innovation in form and function in an exemplary manner”.

Use fewer variants – run a higher number of applications

VLT® OneGearDrive® – one gear size
Compared to traditional systems, the compact design of the VLT® OneGearDrive® makes it a strong choice that can provide benefits in transport and conveying systems as well as machines and equipment.
With only one motor type and three gear ratios available, the motor concept covers all typical conveyor drives.
Furthermore, the restricted range of physical configurations of the VLT® OneGearDrive® simplifies spare stock and makes it more cost-efficient, easing engineering and installation thanks to uniform mechanical dimensions.

Flexible plant design
In combination with the VLT® AutomationDrive FC 302 or the VLT® Decentral Drive FCD 302 the VLT® OneGearDrive® is equally suited to central and decentral installations, giving the plant designer complete flexibility from the outset. A high breakaway torque is obtained and three gear ratios (5.92, 14.13, 31.13) are available. With a cable length of 500 ft (150m) shielded and 1000 ft (300m) unshielded between the drive and VLT® OneGearDrive®, all conditions for conveyor drives in the food & beverage applications are fulfilled.

Less expensive, fewer variants
Due to the PM motor there are lower losses, a smaller moment of inertia, a wide torque and speed range and high short-term overload capability, enabling high maximum torque over a wide speed range. This gear motor is a drive that, considered over its lifetime, is less expensive than conventional geared motor units (GMUs).

Long service intervals
The VLT® OneGearDrive® runs 35,000 operating hours in partial operation between oil changes (by using food-grade oil). This means long service intervals, low maintenance costs and effort, and low operating costs.

Up to 40% energy savings were achieved, compared to conventional systems by using VLT® OneGearDrive® together with a VLT® AutomationDrive FC 302 or VLT® Decentral Drive FCD 302

Dry, wet and washdown aseptic areas
The VLT® OneGearDrive® comes in two versions, the VLT® OneGearDrive® Standard for use in dry and wet production areas while the VLT® OneGearDrive® Hygienic for use in aseptic areas heralds a new threshold in food hygiene and cleanability.

Hygienic design

Food safety
In food and beverage production areas where the product may come into direct contact with equipment and motors, the hygienic design of process equipment has a tremendous impact on diminishing the risks of contamination, which also means that the shelf life of products is improved. If the applied process equipment is of poor hygienic design, it is difficult to clean in the event of micro-bacterial contamination.

New hygienic trends
EU regulations for the compliance of hygienic equipment to be used in the manufacture of popular food and beverages are becoming increasingly tight. For example, in the beverage industry, still water, fruit juices and alcohol-free beers are all highly reactive to external influences.
New packaging materials also raise the demands on hygienic conditions. Plastic packaging for cosmetics, including PET bottles in the drinks industry, requires new measures as they do not tolerate heat sterilization or cleaning that previously rendered glass containers aseptic.

Hygienic design
After years working with the food and beverage industry, Danfoss knows better than most the need for a robust, watertight construction that resists attack by acids or detergents, doesn’t harbour bacteria and can be cleaned quickly and easily, shortening the maintenance window.

Completely smooth surface
Because these drives do not have fans, they do not suck in airborne germs and blast them back into the surrounding air. The drive units are also available with totally encapsulated brakes.

High degrees of protection
The VLT® OneGearDrive® Hygienic is resistant to detergents and disinfectants (pH 2 ..14). Danfoss supplies the VLT® OneGearDrive® Hygienic with high IP67 or IP69K ingress protection ratings as standard. A proven stainless steel plug-and-socket connector simplifies replacement during maintenance.

IPA certified
The VLT® OneGearDrive® Hygienic is certified as usable for clean rooms and aseptic filling by IPA (Fraunhofer Institute) according to the dedicated “Air Cleanliness Classification“ DIN EN ISO 14644-1.
The VLT® OneGearDrive® is designed to be integrated in the plant equipment and to withstand the same detergents and physical cleaning as the rest of the aseptic production equipment.

Two versions are all you need

The VLT® OneGearDrive® is available in two versions; the VLT® OneGearDrive® Standard for use in dry and wet production areas, and the VLT® OneGearDrive® Hygienic, for areas with high cleaning intensity including aseptic and cleanroom production areas.

Completely smooth surface Fan-free motor, No cooling fins

• In both versions, the completely smooth, easy-to-clean surface free of cooling fins, prevents pockets of dirt from forming and allows detergents to drain off freely.
• The fan-free motor avoids the risk of airborne germs and dirt particles being drawn in and then expelled back into the surrounding air.

High degrees of protection

• IP67 and IP69K (OGD Hygienic) – allows unrestricted use in washdown areas.
• IP67 (OGD Standard) – provides high protection in washdown areas.

10-pole permanent magnet motor obtains a high torque

• High torque availability.

High-efficiency bevel gear
High break-away torque and uniquely compact design.

• = standard for both versions
• H = standard for VLT® OneGearDrive®Hygienic
• S = standard for VLT® OneGearDrive® Standard
• oH = optional for VLT® OneGearDrive® Hygienic
• oS = optional for VLT® OneGearDrive® Standard

Available hollow shaft diameters 30, 35 and 40 mm:

• Allow flexible adaptation to customer standards.

H Motor connection with CleanConnect® stainless steel connectors

• Allows safe connection in wet areas, fast replacement, and high cleanability.
• The proven stainless steel plug-and-socket connectors simplify replacement during maintenance.
• This allows the replacement to be performed by a mechanical service technician alone, without the assistance of an electrician as in the past.

S Motor connection via a terminal box with CageClamp® technology

• Fast, reliable connection that lowers installation costs.

H oS
Stainless steel hollow shaft

• AISI 316 Ti, corrosion resistant.

H S
Food-grade lubricants compliant with FDA and NSF requirements

• Enables reliable and direct use in product handling areas, with up to 35,000 hours between oil changes.

H oS
Certified aseptic coating

• Resistant to detergents and disinfectants (pH 2..14).

Two versions
The VLT® OneGearDrive® Standard with terminal box and to the left, the VLT® OneGearDrive® Hygienic with stainless steel connectors.

Speed/torque characteristics

Nominal current:

• 5.5 A

Gear ratios:

• i = 5.92
• i = 14.13
• i = 31.13

Maximum AC drive power rating:

• 3 kW (nominal 2.2 kW)

Example
Speed/torque characteristics in combination with VLT® AutomationDrive FC 302 or VLT® Decentral Drive FCD 302, for gear ratio i = 31.13

Installation positions

Dimensions

VLT® OneGearDrive® Standard

VLT® OneGearDrive® Hygienic

Ordering type code

NOTE: For the availability of specific options and configurations please refer to the drive configurator at http://driveconfig.danfoss.com.

Accessories

Features and Benefits

power savings compared to conventional systems
High-efficiency permanent magnet three-phase synchronous 10-pole motor with bevel gear drive| –  Ultra Premium Efficiency class IE5 with a motor efficiency of 94.9%.

–  Will comply with the highest IES2 class with FC 302

Available hollow shaft diameters:

30, 35, 40 mm and 3 impartial shaft sizes

| – Flexible adaption to customer standards
Completely smooth enclosure leaves no crevices or dirt traps| –  Easy to clean

–  Safe production

Motor connection with Danfoss CleanConnect® stainless steel circular connector| –  Safe connection in wet areas

–  Fast installation and replacement

–  High cleanability

Motor and brake connections via a terminal box with CageClamp® technology| – Fast, reliable connection

–  Lower installation cost

Aseptic coating| – Resistant to detergents and disinfectants (pH 2..14)
Antibac® antibacterial coating (on request)| – Reduced cleaning time and costs
Gearbox without breather vents and use of food-grade lubricants compliant with FDA and NSF requirements| – Up to 35,000 operating hours in partial load between oil change
High degrees of protection:

–  IP67 and IP69K (OGD- H)

–  IP67 (OGD- S)

| –  Unrestricted use in washdown areas

–  High protection in washdown areas

Fan-free operation

| –  Less noise emission

–  No airborne germs and dirt particles are drawn into the motor and then expelled back into the surrounding air

Only 3 gearbox ratios in one common design| – Up to 70% reduction in variants reduces spare part stock
Compatible with all Danfoss drives, FC 302 and FCD 302 from 0.75 to 3 kW| – Free choice of central or decentral installation

Specifications

VLT® OneGearDrive®

Power rating| 0.75-2.2 kW
Speed max.| 3000 rpm
Frequency max.| 250 Hz
Nominal current| 5.5 A
Torque| 2.35 Nm/A
Back-EMF| 155 V/1000 rpm
Weight

Motor efficiency

| Approx. 22 kg

IE5 Ultra Premium (94.9%)

A better tomorrow is driven by drives

• Danfoss Drives is a world leader in variable speed control of electric motors.
• We offer you an unparalleled competitive edge through quality, application-optimized products and a comprehensive range of product lifecycle services.

• You can rely on us to share your goals. Striving for the best possible performance in your applications is our focus. We achieve this by providing the innovative products and application know-how required to optimize efficiency, enhance usability, and reduce complexity.
• From supplying individual drive components to planning and delivering complete drive systems; our experts are ready to support you all the way.
• You will find it easy to do business with us. Online, and locally in more than 50 countries, our experts are never far away, reacting fast when you need them.
• You gain the benefit of decades of experience, since 1968. Our low-voltage and medium-voltage AC drives are used with all major motor brands and technologies in power sizes from small to large.

VACON® drives combine innovation and high durability for the sustainable industries of tomorrow.
For a long lifetime, top performance, and full-throttle process throughput, equip your demanding process industries and marine applications with VACON® single or system drives.

• Marine and Offshore
• Oil and Gas
• Metals
• Mining and Minerals
• Pulp and Paper
• Energy
• Elevators and Escalators
• Chemical
• Other heavy-duty industries

VLT® drives play a key role in rapid urbanization through an uninterrupted cold chain, fresh food supply, building comfort, clean water and environmental protection.
Outmaneuvering other precision drives, they excel, with remarkable fit, functionality and diverse connectivity.

• Food and Beverage
• Water and Wastewater
• HVAC
• Refrigeration
• Material Handling
• Textile

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are the property of the respective companies. Danfoss and the Danfoss loaotvoe are trademarks of Danfoss A/S. All riahts reserved.

CONTACT

• Tel. +1 (888) DANFOSS | www.danfossdrives.com | E-mail: salesinformation@danfoss.com
• Danfoss Drives: Houston, TX
• Loves Park, IL
• Milwaukee, WI
• Raleigh, NC
• Stoney Creek, ON

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