22 Excellent ways to improve safety and reduce total costs of operation 22 Excellent ways The W22X line represents what is most modern in driving equipment for explosive atmosphere environments. As a result of intense research and development, WEG launches its new explosion proof motor line, the W22X, a complete range of hazardous area products of IEC frames 71 to 710 and NEMA frames 143/5T to 586/7T. Incorporating the innovative concepts of the W22 general purpose motors, the W22X line is an evolution in the market of classified area products offering high efficiency levels, energy saving, low operational costs, extended lifetime, low maintenance and assured safety! 1. Worldwide certifications In order to ensure the protection and safety of the W22X line, the motors are under certification process according to the table below: 4 Market Certification Certifying Entity Brazil INMETRO UL/TÜV Canada cCSAus CSA China CQST CNEx Europe ATEX PTB/INERIS India IECEx PTB/INERIS Latin America IECEx PTB/INERIS Oceania (except for Mines) IECEx PTB/INERIS Oceania (Mines) ANZEx TestSafe Russia GOST-R/RTN CCVE South Africa SABS SABS United States cULus UL 22 Excellent ways In short, the line will be certified for application in the following hazardous classified areas: IEC Zone 1 and Zone 2, Groups I, IIA, IIB and IIC, Temperature Class T4 NEC Class I, Division 1, Groups C and D, Temperature Class T4. To enable higher functionality in the W22X line, these motors will be also certified for application in ambients where combustible dusts/fibres are present such as: IEC Zones 21 and 22, Groups IIIA, IIIB and IIIC, Temperature Class T125°C NEC Class II, Division 1, Groups E, F and G, Temperature Class T125°C. In the development process of the W22X, WEG’s main objective was in having a single product which would suit the specific needs of the most varied local standards. As a result of that concern, WEG is now introducing this innovative line, a globally launched product which is acceptable worldwide. Efficiency and reliability tip: Although WEG masters the design and manufacturing process of products for hazardous areas offering a wide range of certified products such as explosion proof, non-sparking, increased safety, dust ignition proof and pressurized enclosure motors, the classification of an industrial plant in hazardous locations is the customer’s responsibility. An accurate classification of a hazardous area is very important for the selection of appropriate equipment and should be carried out by a qualified engineer. 22 Excellent ways 5 2. Efficiency levels The efficiency ratings of the W22X motors follow the efficiency levels given in the IEC 60034-30 standard. The EuP-Directive 2005/32/EC establishes the Ecodesign requirements for electric motors and defines High Efficiency (IE2) as minimum efficiency levels as of 16th June 2011. Even though the directive does not cover explosion proof motors, WEG feels that since the introduction of the ATEX Legislation there has been an increase in demand for these products. Because of this, WEG launches the W22X line with the IE2 efficiency level as standard for IEC motors. NEMA motors are supplied according to NEMA Premium® efficiency levels as standard. The W22X motors play an important role in energy saving with regard to partial loads because their outstanding design allows for constant efficiency from 75% up to rated load. Efficiency and reliability tip: Research indicates that the acquisition cost represents only 2.5% of the total cost of ownership of an electric motor, whereas the other 90% are energy consumption costs! Motors with higher efficiency levels offer very high return on investment levels. Check it out at http://www.weg. net/uk/Products-Services/Motors/Payback-Tool. If you need further information on how new design electric motors with higher efficiency levels can reduce your operational costs, please contact our nearest office. 3. Suitable operation in extreme ambient conditions W22X motors are designed for operation in the following ambient conditions: from -20°C to +40°C and up to 1000 m.a.s.l. However, these motors can be supplied for application in extreme conditions, such as: ambient temperature from -55°C to +80°C and/or altitudes up to 5000 m.a.s.l keeping their main benefit which is the safety of the application. This enables W22X motors to cover the most applications possible. -55ºC (-67ºF) 6 22 Excellent ways +80ºC (+176ºF) 4. Electrical features W22X motors are manufactured according to both IEC and NEMA standards for frequency of 50 or 60 Hz. A complete winding design is available enabling the production of motors in voltages up to 10000 V in F or H insulation class. Rated performance meets or exceeds the applicable rated performance defined by standards in force globally. For the protection of the equipment itself, motors are fitted with thermistors for tripping which ensure the motor will disconnect in case of an unexpected situation such as an overload, large voltage variations, phase unbalance, etc. Efficiency and reliability tip: For VFDs, the utilization of the thermal protectors available in the motor is mandatory and will help protect the motor and driven equipment. 22 Excellent ways 7 5. Frequency inverter operation The use of VFDs is recognized to be one of the major driving forces for energy efficiency because it can adjust motor output to best suit load requirements. However, voltage spikes of the PWM waveform can have harmful effects on the motor winding leading to premature failure of the insulation system. This worsens as the switching frequency is increased. a result of a Common Mode voltage effect. To avoid bearing circulation currents, it is generally accepted to isolate one of the machine’s bearings and to short circuit the shaft and frame in the other bearing. For this reason, an Insulated Bearing and shaft grounding kit is available for W22X motors in order to ensure longer operating hours for VFD driven motors. To fully comply with the requirements that VFD applications demand, the W22X line can be W22X motors are fitted with WISE® insulation made in TEBC versions (with forced ventilation (WEG Insulation System Evolution) which permits kit) for operation in low frequency levels and can them to operate driven by a VFD for voltages up to be fitted with an Encoder* for applications which 575 V. The WISE® is a system composed of: class request precision positioning operations. H insulation wire (200°C), enhanced insulation materials and solvent-free resin. Due to their outstanding performance, W22X motors are capable of keeping T4 Large motors may present induced shaft currents temperature class even when driven by a due to the unbalanced waveform and high VFD. frequency components of the power supply. Motors driven by a VFD may also experience *Encoder must be compatible with the electric current circulation through the bearings as hazardous location. Efficiency and reliability tip: Variable frequency drives are the best solution for motors operating in different speed ranges. Advantages of using VFDs: you avoid additional protection circuits as long as these protections are built-in; you keep motor supply levels consistent; you have high torques for starts/stops and you can always run your motor at the optimum performance point. In order to minimize motor total losses, WEG variable frequency drives offer the exclusive Optimal Flux® condition resulting in higher efficiency and, consequently, longer lifetime. 8 22 Excellent ways 6. Flexible and modular design for terminal boxes W22X “Ex d” and “Ex de” motors are equipped with the same terminal box design in order to enable the conversion of “Ex d” motors into “Ex de” motors and the utilization of “Ex de” motors into “Ex d” classified areas. Large motors offer wide terminal box mounting possibilities through the use of adaptors in several designs and different terminal box models (in cast iron, welded carbon or stainless steel). Terminal boxes are also available for: Current Transformers for differential and integral protection, surge arrestors, capacitors, signal transducers, Y connection with accessible neutral, etc. Efficiency and reliability tip: Every intervention which may compromise or which is related to the product must be performed by WEG’s network of certified service centres for explosive atmosphere products. Find the nearest to you at the website www.weg.net or contact your nearest WEG branch. 7. Reduced operating temperatures An electric machine’s lifespan is mainly governed by its insulating material operational hours, which ages proportionally to its operating temperature. For this reason, the cooling system of the W22X range, composed of a fan, fan cover and frame, was designed with the use of “Finite Element Analysis” software resulting in outstanding heat dissipation. This allows for reduced operating temperatures that do not push the insulation material to its limits. It also eliminates any hotspots by providing a uniform temperature distribution through the frame. The motor frame plays a crucial role in its thermal performance because it is responsible for transferring the heat generated inside the motor out to the frame surface where the air blown by the fan will promote heat dissipation. The W22X frame concept (patent pending) takes heat dissipation very seriously with eyebolts positioned in such a way that they do not block any airflow through the fins and also through the position of the terminal box which, for frames IEC 280 (NEMA 444/5T) and above, is placed in the front of the frame. To maximize the heat dissipation area, the cables are led to the terminal box through a channel placed between the front endshield and the terminal box. The area between the fan cover and terminal box is also fitted with cooling fins. The drive endshield design (patent pending) also considered the dimensional characteristics of the mechanical interface surfaces and the heat dissipation resulting in a stronger design and exposes the bearings to a larger heat dissipation area. Additionally, the fins of the drive endshield are located at the point of highest heat concentration which results in the reduction of the temperature of the bearing. Efficiency and reliability tip: Respect the minimum gap between any walls positioned near the back of the fan cover to allow for air intake. Keep motor surroundings clean and periodically check for any air blockage that can reduce cooling system performance. Remember that the cooler a motor runs, the longer life it will have. 22 Excellent ways 9 8. Complete product range and higher outputs per frame Efficiency and reliability tip: Although new rated outputs are available, the W22X motor respects the kW ratio per frame as defined by DIN EN 50347 which means that you can replace an old explosion proof motor with lower efficiency levels by a W22X High Efficiency – IE2 or even by a W22X Premium Efficiency – IE3 with total reliability. The energy savings will be even greater if the old motor has been subject to repairs during its lifetime. 10 22 Excellent ways One of the greatest benefits of the reduced operating temperatures offered by the W22X motors, besides the longer lifespan, is the possibility of offering greater rated outputs from the same motor frame size. With the launching of the W22X motors, new rated outputs are available for the existing frame sizes and new frame sizes were introduced, offering a complete explosion proof motors range from IEC 71 to 710 and NEMA 143/5T to 586/7T. 9. Reduced sound pressure levels Health and safety regulations push for reduced noise levels which aim to offer better conditions for operators in the industry. As a result, all our 50Hz range, including two pole machines, is limited to 80 dB(A) at 1 meter from the motor for frames sizes up to IEC 400. With W22X motors, the cooling system was designed for optimum balance of airflow and noise level. The fan provides greater amounts of air to cool the motor and the fan cover with its aerodynamic outline (patent pending) is designed to avoid recirculation of air (loss of performance) and to better direct the airflow over the motor fins. Efficiency and reliability tip: Lower noise levels are possible with modifications like single directional fans. Please enquire with WEG about the option of reduced noise levels. 22 Excellent ways 11 10. Fixing bolts protected against shocks and water accumulation With the aim of offering the market a tough and reliable motor, all the housings of the fixing bolts were carefully designed in order to protect the bolts against accidental impacts and water accumulation. This ensures motor explosion proof protection as long as no accidental damage affects the position of the component and compromises the flame path. Efficiency and reliability tip: To ensure motor protection, always follow the required tightening torques for terminal box assembly, power cables and grounding system connections indicated on the motor IOM manual. 11. Solid and integrated feet When converting electrical energy into mechanical energy, the motor requires supporting points where the mechanical thrust, proportional to the demanded load torque, will be applied to the base. These supported points are the motor feet. This said, we can conclude that stronger feet guarantee reliable operation mainly in heavy duty applications, for example crushers. Efficiency and reliability tip: As a manufacturer, WEG makes all efforts to increase mechanical stiffness of its products. Remember that the feet are the motor interface with the base which means that the base must be level and flat in order to ensure less vibration and safer operation which will increase the lifetime of the motor. 12 22 Excellent ways The W22X feet have been designed (patent pending) to a much higher stiffness. They are solid for a better distribution of the mechanical thrust imposed by the load. 12. Terminal box design The terminal box is the main interface of the electric motor for maintenance personnel and was designed to provide easy access and better ergonomics during installation and maintenance operations. W22X motors have an oversized terminal box that fully meet the requirements of international applicable standards and provide optimal conditions for operators to access main and accessory terminals. Due to the increase of the terminal box dimensions, the cable entry holes were increased for large frames facilitating the handling and connection of the cables. Cable entry holes must be fitted with certified cable glands in order to ensure the type and degree of protection indicated on the nameplate. The cable sealing from the inside of the motor to the terminal box is made with threaded bushings in order to ensure a safe protection and insulate the motor enclosure from the inside of the terminal box. As these bushings are thread fastened, they allow an easy replacement if needed and also the inclusion of accessories as thermal protectors or space heaters keeping the motor safe. 13. Drain system Depending on the ambient relative humidity, moisturized air may reach the interior of the enclosure. This moisture will eventually condense so the motor design should have means to allow this water to be drained out of the frame. W22X motors can be fitted with threaded drain plugs installed in the lower part of the enclosures ensuring continuous and efficient condensed water draining from the motor. For large motors, threaded drain plugs are also available for terminal boxes in order to meet specific customer specification. Efficiency and reliability tip: Be sure to include the drain operation during periodic maintenance on your checklist. If high moisture is present, space heaters can be fitted to minimize water condensation. 22 Excellent ways 13 14. Eyebolts equipped In order to ensure safety to the operators, all the W22X range is fitted with lifting eyebolts offering easy handling, shipment and storage. This allows the W22X motors to meet the specific local applicable standards and directives regarding product lifting. Efficiency and reliability tip: Always handle the motor carefully in order to prevent impacts and damages to the bearings and always install the shaft locking device (if supplied) when transporting the motor. Use only the eyebolts to lift the motor as they are designed for the weight of the motor and should never be used to lift additional loads coupled to it. 15. Reliability of enclosures: withstands IK10 impact test One way to verify if the motor is suitable for harsh, tough applications is by checking its mechanical envelope against impacts. The EN 62262 – Degree of protection provided by enclosures for electrical equipment against external mechanical impacts (IK code) ranks motor enclosures by specifying in Joules a scale which a motor must withstand. W22X motor enclosures and terminal boxes are made entirely in cast iron for IEC frames up to 500, the industrial preference for reliability in tough ambient applications. Fan covers can be supplied in cast iron or steel according to customer needs or motor classification. Efficiency and reliability tip: Tough motors must be used for tough applications! The cast iron used for manufacturing W22X motors is produced at WEG foundries. It is the “grey” type FC-200, exceeding the material requirements defined by standards for explosion proof motor enclosures. It provides a higher additional strength and durability to W22X motors. 14 22 Excellent ways 16. Improved degree of protection The W22X motors have IP55 degree of protection as standard. They can be supplied with bearing caps which allows replacement of the shaft sealing system thus increasing the protection of the motors against contaminant dust and liquids up to IP66 rating. Efficiency and reliability tip: Proper dimensioning of a product consists of defining not only the kW rating and speed but also analysing the overall operational and environmental conditions in which the motor will be applied. This analysis should highlight conditions, accessories and requirements that the motor must comply with. Not sure about the right motor for your application? Enquire at the nearest WEG office. 22 Excellent ways 15 17. Paint plans In order to offer a proper protection against corrosion, chemical agents and severe ambient conditions, the WEG Coatings division developed special paint plans for the W22X motors. These coatings meet the strictest performance criteria indicated in the ISO 12944 standard and the requirements for hazardous location products ensuring additional protection in aggressive environments. 18. Mounting configurations In the development process of the W22X line, one important concern was the product versatility, WEG wanted to provide a motor which could be applied to a wide range of applications. For this reason, the W22X was designed to be adapted for various mounting configurations. The motors can be supplied with or without feet, flanges, a fan, horizontal or vertical terminal boxes and a Pad-Mounted version for fan applications. Efficiency and reliability tip: Motors installed outdoors or in the vertical position require the use of additional shelter to protect them from contaminants; for instance, the use of a drip cover or slinger. 16 22 Excellent ways Efficiency and reliability tip: Motors which may have a potential risk of electrostatic charge accumulation will be identified by the manufacturer and must receive proper cleaning and maintenance interventions, avoiding electrostatic discharges and excessive dust layers. 19. Wide range of accessories The new W22X line offers an extensive range of accessories that may be supplied with the motors which make them suitable for a wide variety of specific customer specifications without losing its focus on the safety of the application. Amongst the most used accessories are space heaters, winding or bearing thermal protections, an additional terminal box for accessories and drain plugs for condensed water. In order to offer an easy and safe connection and accessibility to the motor accessories, the W22X terminal box features a new connector configuration that does not require bolts to fasten the accessories. Furthermore, this connector can easily accommodate extra modules for additional accessories. Alternatively, the motors can be supplied with bolt fastening connectors. All leads are firmly assembled assuring reliable operation. Efficiency and reliability tip: Always select the accessories that best suit your application. For instance, for continuous temperature monitoring RTDs (PT-100) can be chosen. For ambients with constant presence of moisture, space heaters are advisable and so forth. Please contact WEG for more information. 20. Easy installation One of the main functions of an electric motor frame is to provide mechanical protection to the winding. It also provides the interface for installation through feet or flanges. For this reason, the W22X motor feet are double drilled in order to simplify the replacement of existing motors. The integrated feet still have provisions for dowell pins making the alignment of motors easier when removed for maintenance from their mounting base. To further assist an easy installation, jacking screws are also available on motor feet. Efficiency and reliability tip: The driving elements, such as pulleys and couplings, must be balanced before they are mounted on the shaft according to the motor balancing to avoid unexpected vibration levels which may damage the entire equipment. 22 Excellent ways 17 21. Simplified maintenance Extended lubrication intervals are reached mainly due to the reduced bearing temperature rise, a benefit obtained with the revolutionary motor cooling system, provided by the drive endshield design. Motors can also be supplied with sleeve bearings (only for large machines with IEC groups I and IIB classification) or an oil mist lubrication system for a safer operation and featuring a longer lifetime for the bearings. Motors in frame sizes IEC 71 to 200 and NEMA 143/5T to 324/6T have shielded bearings as standard. The lifetime of these bearings is two times longer on average when compared to opened bearings resulting in less intervention. As any intervention relies on personnel and equipment, the less the equipment requires maintenance, the less the total cost of the ownership. Periodical monitoring of vibration levels gives a good indication of bearing conditions and overall application behaviour with the W22X range having as a standard feature, for frames IEC 160 (NEMA 254/6T) and above, flat surfaces for vibration monitoring. Efficiency and reliability tip: Maintenance is one of the main items to ensure a long lifespan for motors. For this reason regular inspection is recommended. Inspect the seals, the fastening bolts, the bearings, the drain operation, etc. Always lubricate the bearings following the information indicated on the motor nameplate and do not over lubricate. Periodical analysis of bearing vibration can help to identify several kinds of problems, not only to the motor but to the entire application. Keeping records of the main processes and machine vibration behaviour will provide reliable data to maintenance managers and help minimize production breakdown. 18 22 Excellent ways 22. WQuattro and Wmagnet IE4 motors available The W22X line is designed to be constructed not only as ordinary induction motors, but also as permanent magnet motors. This means that the certification of the new W22X line covers the production of WQuattro and Wmagnet explosion proof motors. The WQuattro motors are dedicated for users who consider energy saving a priority, achieving the proposed IE4 efficiency levels. They are environmentally friendly motors that due to their very efficient performance will demand less energy from the grid. Due to this technology, they can DOL (direct on line) start. WQuattro motors are available in frame sizes IEC 80 to 132M/L and NEMA 143/5T to 213/5T. The Wmagnet is also one of the motors with the greatest efficiency and savings on the market achieving IE4 efficiency levels for the entire range. Its rotor with permanent magnets ensures high performance making it possible to draw more power per frame and reduce installation space and noise in addition to reaching very high efficiency levels. The motor is driven by a WEG CFW11 frequency inverter and offers constant torque in a wide speed range ensuring operation at low speeds with no need for a forced ventilation kit. Wmagnet motors are available in frame sizes IEC 132S to 250S/M and NEMA 213/5T to 404/5T. 22 Excellent ways 22 Excellent ways 19 WEG Worldwide Operations AUSTRALIA WEG AUSTRALIA PTY. 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