Comprehensive insights into ATEX-certified gear boxes: standards, applications, and selection criteria for explosion hazardous areas.
What is an ATEX gear box and why is it indispensable in certain industrial sectors?
Ein ATEX gear boxes are a drive component specifically designed and certified for use in explosion hazardous areas. It is essential to avoid ignition sources and thus protect people, equipment, and the environment from explosions, as mandated by the EU directive 2014/34/EU .
How do I select the right ATEX gear box for my specific application and explosion protection zone?
Choosing the correct ATEX gear box requires a detailed analysis of the application, particularly the determination of the ATEX zone (e.g., Zone 1, 2, 21, 22), the materials present (gas or dust), and their ignition temperature. Manufacturer specifications and technical data sheets are crucial in this process. ATEK Drive Solutions offers comprehensive consultancy for selection.
What role do ATEX zones (e.g., Zone 1, 21, 2, 22) and device categories play in the selection?
ATEX zones define the likelihood of the occurrence of an explosive atmosphere. Zone 1 (gas) and 21 (dust) represent a higher hazard than Zone 2 and 22. The device category (1, 2, or 3) indicates the required level of protection. A gear box for Zone 22 must not be used in Zone 1..
What maintenance measures are required for ATEX gear boxes to ensure ongoing compliance and safety?
For ATEX gear boxes, regular inspections (visual, close, detailed checks) and maintenance as per manufacturer guidelines are mandatory. This includes checking seals, bearings, lubrication, and surface temperatures. Adherence to these intervals is crucial for maintaining the EU declaration of conformity..
Does ATEK Drive Solutions also offer customized ATEX gear box solutions for complex requirements?
Yes, ATEK Drive Solutions specializes in the development and manufacturing of customized ATEX gear box solutions.With our modular design system and engineering expertise, we can also realize suitable drive solutions for explosion hazardous areas in demanding applications and small series. What are the consequences if the prescribed inspection and maintenance intervals for an ATEX gear box are not met?
Was sind die Konsequenzen, wenn die vorgeschriebenen Inspektions- und Wartungsintervalle für ein ATEX Getriebe nicht eingehalten werden?
Failure to meet the prescribed inspection and maintenance intervals will result in the loss of the EU declaration of conformity of the gear box. More importantly, the gear box will then no longer provide reliable explosion protection, which can lead to catastrophic accidents.
Are there also aspects like energy efficiency or special materials to consider with ATEX gear boxes?
Yes, modern ATEX gear boxes also consider energy efficiency. The choice of materials is critical to avoid sparking from friction or impact (e.g., protection of aluminum parts). Special lubricants and sealing materials are often required to meet the requirements of the respective ATEX zone. Why is the correct selection and monitoring of lubricants and seals so critical in ATEX gear boxes?
Warum ist die korrekte Auswahl und Überwachung von Schmierstoffen und Dichtungen bei ATEX Getrieben so kritisch?
Der Correct lubricant prevents overheating and wear, which can present ignition sources. Intact shaft seals are essential to prevent lubricant leakage, as this poses significant fire and explosion hazards in ATEX zones. Regular checks are therefore indispensable.
ATEX gear boxes are essential for safety in explosion hazardous areas and require strict compliance with the EU directive 2014/34/EU as well as the specific zoning. The correct selection and installation are crucial for the protection of people and equipment.
Regular maintenance, including inspection of seals and bearings as well as the use of correct lubricants, is mandatory for the maintenance of ATEX compliance and the avoidance of dangerous failures. Proactive monitoring can reduce unplanned downtimes by up to 15% and improve plant safety by up to 20%..
ATEK Drive Solutions offers a wide range of ATEX-compliant gear boxes, including customized adjustments and system integration.This is supported by extensive technical expertise and a large inventory of components for fast delivery times and optimized drive performance..Learn everything about ATEX gear boxes: from the latest standards and certifications to selection criteria and maintenance recommendations for explosion hazardous environments. Secure your plants with the right drive solutions!
In explosion hazardous environments, ATEX gear boxes are essential. They offer the highest safety and reliability. This article highlights the key aspects, from selection to maintenance. Do you need personalized advice? Contact us at ATEK Drive Solutions.
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Get a free consultation now!ATEX gear boxes understand: establish the basics for safe operation.
In explosion hazardous areas, selecting suitable components is essential. This article explains how ATEX gear boxes to contribute to safety and efficiency, and discusses standards, selection criteria, and maintenance for installations, supported by ATEK Drive Solutions.
Understand the basics and necessity.
ATEX-compliant gear boxes are designed to minimize ignition hazards in explosion hazardous environments. Compliance with ATEX regulations is a legal requirement to protect people and equipment, as established in the operational safety regulation for Ex zones. Appropriate ATEX solutions are required for this.
Core aspects for maximum safety.
The safe operation of these special gear boxes depends on several factors. The selection must match the respective hazard zone, such as Zone 1 for gases or Zone 21 for dust. Correct installation and regular maintenance are necessary for lasting explosion protection. Manufacturer guidelines, as provided by ATEK for our drive units, should be observed.Ensure ATEX compliance: guidelines and certificates for explosion protection gear boxes. Know
master EU directives and technical standards.
The EU directive 2014/34/EU sets the fundamental safety requirements for equipment in explosion hazardous areas and influences the selection of ATEX drives.Technical standards like EN ISO 80079-36 specify details for non-electrical equipment. Manufacturers, such as TANDLER, must certify their products, often through audits by notified bodies.Certified chemical plant gear boxes serve as an application example.
- Consideration of the EU directive 2014/34/EU for fundamental safety requirements.
- Application of technical standards such as EN ISO 80079-36 for non-electrical equipment.
- The necessity of product certification by manufacturers, often via notified bodies.
- Accurate determination of the ATEX zone (e.g., Zone 2, Zone 22) as key to selecting the appropriate explosion-protected gear box..
- Classification into device categories (e.g., 3G, 3D).
- Strict adherence to zone-specific certification (e.g., a Zone 22 gear box is not suitable for Zone 1).
- Consideration of the IECEx system for international conformity.
Zones, categories, and international certificates.
The precise determination of the ATEX zone of an application is essential for selecting the correct ATEX gear box. This includes classification into zones (e.g., Zone 2, Zone 22) and device categories (e.g., 3G, 3D). A gear box certified for Zone 22 (dust) is not permitted for use in Zone 1 (gas). For international markets, such as Australia, the IECEx system is relevant. Manufacturers mark such drive components, for example, with II 2G Ex h IIC T4 Gb. ATEX motors for conveyors require appropriate certifications.Design of ATEX drive technology optimized: minimize ignition sources, choose materials correctly.
Avoiding ignition sources and conscious material selection.
To prevent drive units from becoming ignition sources, for example, due to hot surfaces over 90°C, the design aims to mitigate potential hazards. This includes material pairings that prevent mechanical sparking. Aluminum parts often require protective measures against impact forces to prevent sparking. Special Ex-protected special gear boxes are designed accordingly.
Critical components and modular adaptation.
A defective shaft seal can release lubricant, which poses a significant risk in ATEX zones. The correct selection of lubricant according to the manufacturer’s table and regular seal inspections are necessary for safe operation. Many manufacturers, including ATEK Drive Solutions, offer modular ATEX gear box solutions for timely, customized solutions.Maximize operational safety of Ex gear boxes: master installation, maintenance, and inspection.
Safe commissioning and precise maintenance planning.
Commissioning a ATEX gear box. requires specific procedures. A detailed checklist is used to verify compatibility with the Ex area and the correct oil level. Failure to adhere to prescribed maintenance intervals, such as visual, close, and detailed inspections, can lead to the loss of the EU declaration of conformity. An example of this is checking the surface temperature under maximum load. Explosion-protected gear boxes for milling systems require such checks.
- Carrying out specific procedures during the commissioning of explosion-protected gear boxes..
- Use of a detailed checklist for checking compatibility and oil level.
- Strict compliance with prescribed maintenance intervals (visual, close-up, detailed inspections).
- Avoidance of loss of the EU declaration of conformity through consistent maintenance.
- Use of proactive monitoring methods such as vibration analysis to reduce failures.
- Early detection of bearing damage through temperature measurements to maintain operational safety.
- Mandatory use of exclusively ATEX-certified components for drive and driven elements.
Monitoring and special element requirements
Through proactive bearing monitoring using vibration analysis, a user was able to reduce unplanned failures by 15%. Methods such as temperature measurement help to detect damage to rolling bearings early and maintain operational safety. For drive and driven elements, the exclusive use of ATEX-certified components is prescribed. Mining-safe gear boxes require this.Market overview for ATEX gear boxes gaining: Providers and applications for ATEX solutions
Leading manufacturers and typical application areas
Well-established manufacturers in the market for explosion-protected gear boxes include companies such as NORD, Lenze, and Motive, which offer a wide range of products. Motive, for example, addresses applications in zones 1, 21, 2, and 22 with its BOX Ex series. Such drive units are used in plastic granulate conveyors or ATEX pumps in the paint industry. ATEK Drive Solutions offers compatible drive solutions Information resources and direct sourcing channels.
For selecting the appropriate
ATEX-compliant gear box and accessing documents such as certificates, many manufacturers provide online configurators and catalogs. Blecher Motoren GmbH, for instance, enables direct inquiries for ATEX worm gear boxes. Blecher Motoren GmbH beispielsweise ermöglicht direkte Anfragen für ATEX Schneckengetriebe. The availability of spare parts, as ensured by TANDLER, is a relevant service aspect. Further information on the selection of ATEX drives. is available here.Shaping the future: Innovations for even safer explosion-protected drive technology utilize
material innovations and advanced construction
Development in the field of ATEX gear boxes is continuously progressing. Research focuses on safer materials and advanced constructions to further reduce heat generation and increase lifespan. One development goal is lubricants that function reliably at ambient temperatures of -20°C to +40°C. Safe silo drive units can benefit from such innovations.
Smart technologies: Sensor technology and Industry 4.0
Modern ATEX drive solutions can contribute to early problem detection through integrated sensor technology. The integration of sensors for condition monitoring allows for continuous monitoring and early detection of anomalies, potentially improving plant safety by up to 20%. Industry 4.0 approaches support the optimization of operation and maintenance with ATEX components. Special solutions from ATEK Drive Solutions integrate such technologies.
The selection and operation of ATEX gear boxes require care and specific expertise. Collaboration with experienced partners and the choice of suitable products contribute to the sustainable securing of plants. ATEK Drive Solutions offers expertise for demanding applications in this area.
