Electric motors are the backbone of modern industry, but they can be vulnerable to environmental factors like dust and water. This article delves into the concept of IP ratings and codes, explaining what they represent, how they are tested, and why they are essential for motor durability and reliable performance.
Topics Covered:
- What is an IP Rating, and Why is It Important?
- Understanding the IP Codes
- How Are These Tests Conducted?
- Exhibit A: IP67 Rated AC Gearmotors
- Exhibit B: IP67 Rated Brushless Gearmotors
- The Highest Rating Isn’t Always the Best Option
What Is an IP Rating, and Why Is It Important?
Water or moisture can lead to electrical shorts in motor windings or connections, causing motor failures, electric shocks, or even fires. Similarly, dust or other pollutants can cause motors to overheat and fail. If these motors are powering conveyor systems in a factory production line, a motor failure can disrupt operations. Without a spare motor on hand, this could result in days of lost productivity.
To ensure motors operate reliably in specific environments, an IP (Ingress Protection) rating system was established in 1976 by the International Electrotechnical Commission (IEC) under the global standard IEC 60529. The European equivalent is EN 60529, which was first introduced in Germany in 1934 and later adopted by the European Union. Higher levels of water or dust protection often necessitate design improvements using o-ring seals, different materials, and specialized connectors. We’ll discuss these aspects after exploring the IP code definitions.
What Do the IP Codes Mean?
Different levels of protection cater to varying needs and budgets. Levels of protection are categorized by IP codes, each consisting of two digits. The first digit indicates the degree of protection against solid objects, ranging from human hands to dust. The second digit represents the level of protection against water particles, from droplets to full submersion. Whether you’re an electrical engineer, a maintenance professional, or a hobbyist, understanding these codes can help you make well-informed choices.
Here’s an example of an IP code:
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IP Codes Defined
Below is a detailed explanation of what each digit signifies in an IP code.
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A newer IP69 rating was introduced in 1993 under IEC 60529 for equipment exposed to high-pressure and steam water jets, such as in pharmaceutical manufacturing or food packaging. Additionally, an IP69K rating was added by ISO 20653 for equipment installed on road vehicles, now extending to food processing and agriculture. Here’s a comparison between IP69 and IP69K, which can sometimes be confusing.
How Are These Tests Conducted?
Though ingress protection is self-certified, manufacturers or third-party testing facilities must adhere to the code definitions and testing standards. Part of our comprehensive testing involves a water spray test, which includes heat shock and vibration tests.
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Let’s explore some examples of IP67 motors.
Exhibit A: IP67 Rated AC Gearmotors
Our FPW Series IP67-rated AC gearmotors are perfect for general-purpose washdown applications. They are dustproof and can withstand water jets. Both the induction motor and gearhead are encapsulated and coated with special anti-corrosive epoxy paint. The motor is vacuum-cast to prevent air bubbles, the gearbox has a watertight seal, and the stainless steel shaft provides oil-shield protection.
The FPW Series lineup includes 25 W, 40 W, 60 W, and 90 W single-phase and three-phase gearmotors with gear ratios from 3:1 to 180:1. Variable speed control can be achieved via VFDs, requiring only three wires for operation. These motors are UL and CSA recognized and comply with the China Compulsory Certification System (CCC System). CE Marking is applied according to the Low Voltage Directive. Furthermore, our extensive product range includes options compatible with major countries’ power supply voltages across Asia, North America, and Europe.
Application Examples:
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Exhibit B: IP67 Rated Brushless Gearmotors
Our latest brushless motors boast a high-performance magnet and an optimized slim design with high-performance magnetic steel laminations, reducing the stator to just 11.2 mm—about half the thickness of a traditional brushless motor. The efficiency of brushless motors enables a fan-less casing structure, further shortening the motor length. Compared to an AC motor, a 200 W (1/2 HP) brushless motor can be 83 mm shorter and 3.3 kg lighter.
Similar to VFD-controlled AC motors, these brushless motors excel in advanced speed control applications requiring multiple speed, acceleration, and deceleration profiles. However, brushless motors surpass them in efficiency, closed-loop speed regulation, and a broader speed range.
These new slim brushless motors come paired with two different drivers, each offering distinct features. You can opt for the BMU Series to pair the motor with a basic driver or choose the BLE2 Series for an advanced driver. IP ratings are available in IP65, IP66, and IP67. Output wattages range from 30 W to 400 W, with gear ratios from 5:1 to 1200:1 in various types like parallel shaft, hollow shaft, and right-angle shaft configurations.
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For the IP67-rated version of the motor (currently available for 200 W, 300 W, and 400 W models), we’ve enhanced the casing structure by adding O-rings to improve sealing performance, incorporated a special anti-corrosive coating, standardized the use of a stainless steel output shaft (with parallel keys/screws), implemented rust prevention measures, and adopted a metal lever for the motor connector. These motors undergo rigorous water spray tests, including exposure to saltwater. Additionally, we’ve transitioned to a one-cable design, eliminating the need for relay boxes to extend the cable to the driver.
Product Videos:
[Insert videos demonstrating IP66 connectors and comparing IP66 vs IP67 motors]
The Highest Rating Doesn’t Always Mean the Best Choice
Selecting the appropriate IP rating for your motor isn’t a one-size-fits-all decision. It depends on the specific environment and conditions in which the motor will operate. For instance, a motor used in a dusty factory will require a different IP rating than one that needs to be periodically washed down, and stainless steel motors perform best in caustic washdown environments.
Ensure you choose the right IP rating for your motor (and your budget). We’re here to assist if you need help.
Factors to Consider Beyond IP Ratings
While IP ratings are crucial, they aren’t the sole consideration. Power, efficiency, size, and application-specific requirements also play a vital role. Make sure you select a motor that fulfills all your application requirements.
Regular Maintenance and Inspections
Routine maintenance and inspections are essential for preserving the ingress protection level of electric motors. This includes tasks like proper installation, replacing gaskets, and checking for any signs of damage. Over time, ingress protection can degrade.
Some application examples for IP67 motors include a washdown belt conveyor and a sawing roller conveyor.
[Insert images showing IP67 motor applications]
Consult with Specialists
If you’re uncertain about the necessary IP rating for a specific motor application, it’s best to consult with a specialist. Our knowledgeable technical support team can offer expert advice and help you make an informed decision, ensuring the longevity and efficiency of your motor.
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In conclusion, choosing the right motor with the appropriate IP rating is critical for its intended use. By considering all relevant factors and consulting with experts when needed, you can ensure optimal performance and reliability.
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