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WEG at ACHEMA 2015

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Hydrocarbon Engineering,

WEG, a leading manufacturer of drive technology, showcased its latest energy efficient drive solutions at this year’s ACHEMA. Visitors to WEG’s stand learned about the company’s new W22X explosion proof motor in IEC 800 frame size which has outstanding efficiency of up to 97.4%. Other highlights include ATEX compliant geared motors, which combine W22X motors with robust gear units from WEG's subsidiary Watt Drive, as well as high performance variable speed drives, all designed to help process managers increase operational efficiencies.

“ACHEMA is a great opportunity for us to show our commitment to helping the process industry achieve above average efficiency not only in standard applications, but also in hazardous areas,” said Andreas Schulte Mesum, Energy Business Manager at WEG in Germany. “Explosion proof motors are presently excluded from the latest EU IE3 efficiency regulations, however, WEG is committed to offering the highest possible energy efficiency even in demanding applications, where reducing energy costs is top of the agenda.”

Explosion proof motors

WEG has introduced an IE4 Super Premium version of its W22Xd motor, which combines explosion protection with IE4 efficiency levels. The motor, which is the most energy efficient flameproof motor available in the market, has a long service life and low maintenance costs, helping businesses in the process industry increase productivity, improve reliability and cut costs by up to 40% compared to conventional models.

The W22Xd housing features an advanced cooling system with cooling fins that reduce noise emissions while significantly increasing heat dissipation, thus contributing to higher energy efficiency. Mechanical strength is enhanced by sturdy integrated mounting feet to ensure further reliability and durability.

The W22Xd series, available with energy efficiency ratings from IE2 to IE4, is the most energy efficient series of explosion proof low voltage motors presently on the market.

The standard W22Xd series is ATEX certified and designed for use in IEC Zone 1 and 2 hazardous areas and with group IIA, IIB and IIC gases. The W22XdBD and W22XdCD versions provide additional protection against explosive dusts for use in aggressive atmospheres classified as Zone 21 or 22, group IIIA, IIIB or IIIC, and EPL Db. The W22XdM version is suitable for use in coal pits with classification Group I, Category M2 and EPL Mb.

WEG offers one of the broadest ranges of energy efficient explosion proof motors currently available with its WEG22Xd series, which has rated power from 0.12 kW to 5.6 MW and frame sizes from IEC 71 to 800. The company can provide the ideal explosion proof motor for virtually every application, even with extreme operating conditions such as ambient temperatures from -55°C to +80°C and altitudes up to 5000 m.

Large W22X motor model

In addition, WEG has added a larger IEC 800 frame size model to its energy efficient W22X series of explosion proof motors. Designed for medium voltage and high voltage applications, the new frame size motors deliver excellent performance with an efficiency of up to 97.4% and ensure low maintenance and operating costs, making them ideal for applications where harsh environmental conditions demand high reliability and robustness without compromising on energy efficiency.

One reason for the motor’s high efficiency is its innovative stainless steel tubular cooling system (IEC 60034-6 IC511), which provides optimal air flow and delivers maximum cooling capacity in the stator, rotor, and critical components such as bearings. Additionally, aerodynamically designed fans and fan covers help produce effective air flow with the lowest possible noise level. Hot spots are also avoided by ensuring uniform temperature distribution in the entire frame, therefore providing reliable, high performance over a long service life.

The new W22X 800 explosion proof motor for medium voltage and high voltage applications combines robustness with high efficiency.

The W22X 800 motors offer ultimate flexibility to the user as they are available with many mounting options including an IM B3 mounting as standard together with various mounting assembly/terminal box arrangements and a flex resistant welded steel frame with IP55 protection rating and large integrated mounting feet. The robust housing allows the explosion proof motors to be used in the most demanding applications while minimising vibration and noise emissions.

The W22X 800 motor is available as 2, 4, 6 and 8 pole versions with alternative speeds available on request, and is rated from 2 to 5.6 MW with supply voltage from 6.6 to 11 kV at 50 or 60 Hz. It is available to suit different ambient temperatures (-55°C to +60°C), protective devices (surge protectors, capacitors, inverters), terminal boxes (number, position and type), protection ratings (IP56, IP65 or IP66) or variable speed drives.

ATEX compliant geared motors

Furthermore, WEG has launched ATEX compliant geared motors to help companies operating in hazardous areas improve reliability while reducing energy consumption and operating costs. Combining robust gear units from WEG’s subsidiary WATT Drive with energy efficient W22X motors (available in frame sizes from IEC 71 to IEC 800 and energy efficiency classes up to IE4), the new range is ideal for harsh processing applications in nearly all industries worldwide.

Watt Drive’s full range of gear units can be combined with W22X motors using IEC adapters. All gear ratios in the MAS gear unit product line and all drive and flange options are possible, including solid shaft with flange and hollow shaft with shrink disc. The gear units are robust and reliable as they are fully compliant with ATEX standards and feature impact resistant hollow shaft or shrink disc covers. Furthermore, all bolts are secured to prevent accidental loosening and heavy duty high temperature resistant oils are used.

Explosion proof geared motor with a Watt Drive helical gear unit coupled to a W22X motor.

The ATEX 95 certified adapters for motors with frame size from 71 to 225 allow motors with IEC B5 mounting to be attached to modular Watt gear units without modification. When it comes to frame sizes from 100 to 225, torque transfer between the motor and the gear unit is handled by form fitting, zero backlash claw couplings, with vibration and shock effectively dampened by an elastic coupling spider (98 Shore A). On request, return stops can also be integrated into the IEC adapters so that the explosion proof drives can be used in applications where reverse operation must be prevented, such as angled conveyor belts.

The geared motors can be used for equipment group I category M2 and equipment group II in zone 1/21 and 2/22 explosion hazard areas.

Adapted from press releases by Rosalie Starling

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