Maximum safety and efficiency for your conveying technology – ATEK Drive Solutions offers the appropriate ATEX-certified solution.
What exactly does ATEX mean and why is it so important for my conveyor system in a hazardous area?
ATEX (Atmosphères Explosibles) are EU directives (currently 2014/34/EU) for equipment in explosive atmospheres. Compliance is essential to prevent explosions from gases, vapors, or dust. and ensure the safety of personnel and equipment.A spark or a hot surface of a standard motor can become the ignition source.
How do I determine the correct ATEX zone (e.g., Zone 1, 2, 21, 22) and equipment category for my conveyor?
The zone classification (0, 1, 2 for gas; 20, 21, 22 for dust) depends on the frequency and duration of the explosive atmosphere. This determines the equipment category (1, 2, or 3). Zone 1 (gas, occasionally) requires category 2G, Zone 22 (dust, rarely) requires category 3D. A misassessment can have fatal consequences;ATEK Drive Solutions assists you with the proper classification according to the requirements for ATEX-certified gear motors for hazardous zone conveyors..
What do labels like “II 2G Ex h IIC T4 Gb” on an ATEX gear motor tell me?
This label provides important safety information: ‘II’ stands for equipment group II (non-mining), ‘2G’ for equipment category 2, gas. ‘Ex h’ denotes a type of protection against ignition. ‘IIC’ is the most dangerous gas group (e.g., hydrogen), and ‘T4’ means a maximum surface temperature of 135°C.‘Gb’ is the equipment protection level. The correct selection is crucial for safe operation..
Are there energy-efficient ATEX gear motors and is it worth using them?
Yes, although Ex motors are partially exempt from efficiency regulations, demand for IE2 and IE3 ATEX motors is increasing. Manufacturers like WEG (EUSAS-EX) and SIMOGEAR offer such motors. The use is worthwhile due to lower operating costs and a contribution to sustainability, even in explosive areas. ATEK takes this into account when designing your ATEX-certified gear motor..
Can I use a frequency converter with an ATEX-certified motor?
Yes, but only under strictest adherence to the manufacturer’s specific conditions.The frequency converter is typically installed outside the Ex zone. The parameterization of the converter must exactly meet the specifications, to avoid excessive motor heating and thus an ignition hazard.
What is the difference between integrated ATEX gear motors and modular adapter solutions?
Integrated solutions (e.g., SIMOGEAR for Zones 2/22) have the motor directly mounted on the gearbox, which saves space and simplifies assembly.Modular solutions (e.g., Motive DELPHI Ex with ATEX gearboxes or WEG for Zone 1/21 with IEC adapter) offer greater flexibility in component selection, but may be larger. The choice of the appropriate ATEX-certified gear motor for your hazardous zone conveyor depends on the application and space constraints.
My system exports globally. Do I need to consider other standards in addition to ATEX?
Yes, absolutely. In addition to the EU directive ATEX (2014/34/EU), standards such as IECEx (international), the North American HazLoc system (NEC/CEC) or specific country certifications (formerly e.g., EAC EX) are relevant. ATEK Drive Solutions helps you keep track of the complex international standards landscape. How does ATEK Drive Solutions support me in choosing the right ATEX gear motor for my hazardous zone conveyor?
Wie unterstützt mich ATEK Drive Solutions bei der Auswahl des richtigen ATEX-Getriebemotors für meinen Gefahrenzone-Förderer?
ATEK Drive Solutions acts as a system provider for the complete industrial drive train.We provide comprehensive technical advice, assist with design and optimization, and develop customized special solutions if needed. With our modular system and large inventory, we also realize tailored solutions for ATEX applications. Mit unserem modularen Baukastensystem und großem Lagerbestand realisieren wir auch für ATEX-Anwendungen with quick delivery times..
Die Proper selection of an ATEX-certified gear motor according to zone classification (e.g., Zone 1, 2, 21, 22) and markings (e.g., II 2G Ex h IIC T4 Gb) is crucial for plant safety and compliance with legal regulations in hazardous zone conveyors.
Modern ATEX drive solutions offer flexibility: integrated designs for Zones 2/22 optimize the space, while modular systems ensure adaptability for Zones 1/21. The use of IE3 efficiency motors can also significantly reduce the energy costs..
ATEK Drive Solutions supports as a system provider with decades of experience and newly built motor competence in selection and configuration. The modular system allows for millions of variations and quick delivery times,with hypo-injection gear units improving the efficiency by up to 30% compared to worm gears. Learn how to operate your conveyors safely and efficiently in explosive areas with ATEX-certified gear motors from ATEK Drive Solutions. Discover the advantages of our customized drive solutions!
In explosive environments, the highest safety standards are essential. ATEK Drive Solutions offers you ATEX-certified gear motors specifically designed for use in such areas. Are you looking for a custom solution? Contact our experts now:
Erfahren Sie, wie Sie mit ATEX-zertifizierten Getriebemotoren von ATEK Drive Solutions Ihre Förderanlagen in explosionsgefährdeten Bereichen sicher und effizient betreiben. Entdecken Sie die Vorteile unserer maßgeschneiderten Antriebslösungen!
In explosionsgefährdeten Umgebungen sind höchste Sicherheitsstandards unerlässlich. ATEK Drive Solutions bietet Ihnen ATEX-zertifizierte Getriebemotoren, die speziell für den Einsatz in solchen Bereichen entwickelt wurden. Sie suchen eine individuelle Lösung? Nehmen Sie jetzt Kontakt zu unseren Experten auf: Contact.
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Introduction to ATEX gear motors for explosive conveying systems.
What does ATEX mean?
Explosions in production facilities can have serious consequences. The ATEX directives of the EU (currently 2014/34/EU) define requirements for equipment and protection systems for explosive areas to prevent this. ATEK Drive Solutions regards compliance with ATEX standards as a commitment to the safety of employees and equipment. Ein ATEX-certified gear motor in a painting facility where solvent vapors may occur (Zone 1 or 2) must be ATEX-compliant to ensure safety in such hazardous areas. Understanding ATEX gearboxes
Why are ATEX gear motors necessary in certain environments?
In industries like chemicals, food processing, or mining, explosive atmospheres can arise from gases, vapors, or dust. A standard gear motor can become an ignition source due to sparks or hot surfaces. ATEX-certified gear motors for hazardous zone conveyors. are designed to prevent this. The selection of the correct ATEX protection level is a matter of regulation and responsibility. In a grain mill, for example, flour dust can create an explosive atmosphere of Zone 21 or 22, requiring special motors, especially when it comes to explosion-proof drives for conveyors in hazardous areas. Ex protection for silo systemsSelection criteria for ATEX gear motors
Zone classification and equipment categories
The frequency and duration of an explosive atmosphere determines the zone classification according to the ATEX directive: Zones 0, 1, 2 for gases and Zones 20, 21, 22 for dust. This leads to equipment categories 1, 2, or 3. Underestimating the zone can lead to undersized protection. Zone 1 (gases, occasionally hazardous) requires equipment of category 2G, Zone 22 (dust, rarely hazardous, short-term) requires equipment of category 3D. ATEK assists in determining the correct zone for conveyors, a critical step in selecting a suitable ATEX-certified gear motor for hazardous zone conveyors.. Learn more about gear motors.
Temperature classes and gas groups
The surface temperature of a motor can trigger an explosion. The marking, e.g., II 2G Ex h IIC T4 Gb or II 2D Ex h IIIC T135°C Db, on an ATEX gear motor informs about the level of protection necessary for the safe operation of a hazardous zone conveyor. is essential. ‘IIC’ denotes the most dangerous gas group (e.g., hydrogen), ‘T4’ means a maximum surface temperature of 135°C. The correct temperature class and gas/dust group must match the specific substance. For acetone (ignition temperature 465°C, group IIA), at least temperature class T2 (300°C) is required; T4 offers a higher safety factor. Experts from ATEK Drive Solutions provide comprehensive advice on this.
Performance characteristics and designs
The choice of design is application-specific. Manufacturers like WEG offer direct motor mounts for Zones 2/22 on WG20 gearboxes, which saves space and increases efficiency. For Zones 1/21, IEC adapters are often standard. Direct mounting or adapter solution influences dimensions, system stiffness, and potential sources of error. Energy efficiency is relevant: Despite exemptions for Ex motors from efficiency regulations, demand for IE2 and IE3 motors, such as SIMOGEAR up to 22 kW, is increasing. ATEK takes this into account when designing the drive train for conveyors in explosive areas to ensure the optimal performance of the ATEX-certified gear motor.Manufacturer overview and product samples: Finding the right ATEX drive.
Integrated vs. Modular Solutions
The choice is between integrated ATEX solutions and modular construction. SIMOGEAR offers integrated gear motors without adapters for Zones 2 (gas) and 22 (dust), simplifying selection (motor shaft heights 71-180, up to 22 kW IE3). Advantages include compact dimensions and simpler ordering (one order number). Modular approaches, such as drives with the DELPHI Ex motor series (Zone 1, 2, 21, 22) and ATEX gear boxes, offer flexibility. ATEK Drive Solutions analyzes requirements for the optimal configuration, whether for a standard conveyor or a special hazard zone conveyor, that requires an ATEX certified drive.
- There is a choice between integrated ATEX drive solutions and a modular structure.
- Integrated systems, such as SIMOGEAR for Zones 2 (Gas) and 22 (Dust), operate without adapters and simplify selection.
- The advantages of integrated solutions include compact dimensions and simplified ordering with a single order number.
- For example, SIMOGEAR offers integrated geared motors with motor shaft heights from 71 to 180 and up to 22 kW power in IE3 efficiency.
- Modular approaches, like those pursued by drives with the DELPHI Ex motor series (for Zones 1, 2, 21, 22) and ATEX gear boxes, are characterized by high flexibility.
- ATEK Drive Solutions supports the analysis of specific requirements to find the optimal configuration.
Specialized drives for particular requirements
For highly dynamic applications in Ex areas, there are ATEX servomotors, e.g. EY series (Zone 2) and EX series (Zone 1) from Parker, often with ATEX gear boxes like the GXA series (up to 41 Nm, 2500 min-1). These special solutions are suitable for precise positioning tasks in the packaging or pharmaceutical industry. Pneumatic ATEX motors like the PMO1800 (oil/silicone-free, Zones 1, 2, 21, 22) provide high torques with low energy consumption for conveying tasks, including for hazard zone conveyors. ATEK also integrates such specific drive solutions to meet the requirements of ATEX certified geared motors. ATEX brakes for chemical plants
Global applicability and energy efficiency
For worldwide use, motors like the EUSAS-EX from WEG (0.12-75 kW, IE3) with wide range winding suitable for EU, USA, and Asia. It meets NEC/CEC Class I Div 2 and Class II Div 2. Global standards and energy efficiency standards are important factors. Despite exceptions from EU Regulation 640/2009 for Ex motors, IE2 and IE3 drives are preferred for cost reduction and more sustainable production. ATEK supports the selection of energy-efficient ATEX solutions suitable for use in hazard zone conveyors and meeting the strict requirements for explosion-proof drives. ATEX motors for oil & gasStandards and regulations in the ATEX environment
EU Directive 2014/34/EU and global equivalents
The EU Directive 2014/34/EU regulates the marketing of products for Ex areas in Europe, covering electrical and mechanical components comprehensively. For export, standards such as IECEx, the North American HazLoc system (NEC/CEC), or formerly EAC EX (Russia, Belarus, etc.) must be considered. Getriebebau NORD, for example, has not renewed EAC EX certifications for gear boxes as of June 30, 2023. ATEK Drive Solutions helps maintain an overview of the standards landscape relevant for each ATEX certified geared motor for hazard zone conveyors and its operators.
- The EU Directive 2014/34/EU is the fundamental regulation for the marketing of products in explosion-hazardous areas within Europe.
- This directive covers both electrical and mechanical components.
- For international trade, especially exports, global standards such as IECEx must be observed.
- The North American HazLoc system, based on NEC/CEC, is relevant for the market in the USA and Canada.
- Regional certifications such as the former EAC EX (for countries like Russia, Belarus) also play a role, whose validity may change.
- ATEK Drive Solutions offers support to keep track of the complex international standards landscape.
The importance of audits and certifications
Compliance with ATEX requirements by suppliers is ensured through audits. Manufacturing and quality assurance processes, e.g. at NORD DRIVESYSTEMS, are audited by notified bodies (EU 2014/34/EU). Ex testing laboratories and certification bodies (e.g. PTB) are responsible for IECEx certificates. External reviews confirm product reliability and safety. ATEK Drive Solutions ensures that components for ATEX geared motors used in hazard zone conveyors are implemented with valid certifications and complete documentation to facilitate the conformity assessment of the entire drive system.Integration and operation of ATEX geared motors in conveyor systems
Safe installation and maintenance
The safe operation of an ATEX drive, especially a ATEX-certified gear motor for hazardous zone conveyors., requires correct installation according to manufacturer’s specifications and standards, including proper electrical connections, seal tests, and grounding. Regular maintenance, such as checking for damage or overheating, is necessary for explosion protection. In dust-explosive hazard zone 21, no hazardous dust deposits may form that could obstruct cooling or be a source of ignition. ATEK provides documentation and support for maintenance questions for such specialized drive units with ATEX approval.
Compatibility with frequency converters and control
ATEX motors may only be operated with frequency converters under manufacturer-specific conditions. The frequency converter is usually installed outside of the Ex zone (e.g. SIMOGEAR ATEX motors with SINAMICS converters). The parameterization of the converter must comply with the specifications to avoid inadmissible motor overheating. ATEK Drive Solutions ensures compatibility of all components (sensors, controls) for safe, efficient operation during system design for hazard zone conveyor . An example is the correct setting of the maximum output frequency to meet the temperature class of the ATEX motor.
Application examples from industry
ATEX geared motors are used in many industries, often as the heart of hazard zone conveyors: chemical/petrochemical (aggressive media), food/beverage industry (dusty ingredients like flour/sugar, e.g. in bakeries), renewable energies (biogas plants), mining, and cement industry. Each application has specific requirements for material, protection class, and temperature resistance. ATEK Drive Solutions has experience in these industries and develops tailored drive solutions, including compatible ATEX certified geared motors for hazard zone conveyors (e.g. hygienic design or stainless steel versions for the food industry). Discover integrated drive unitsFuture-proof ATEX drive solutions for your conveyor technology
Innovations for greater safety and efficiency
Future developments in Ex drives aim for higher energy efficiency (IE4 level) and smarter system solutions. The integration of sensors for condition monitoring (predictive maintenance) in ATEX versions is an important aspect. Integrated temperature sensors could warn early of overheating. ATEK Drive Solutions monitors these developments to offer technologically current and safe solutions for ATEX-certified gear motors for hazardous zone conveyors. , based on a modular system and custom adjustments for explosion-proof applications.
- A central goal of future developments in Ex drives is to increase energy efficiency, ideally up to IE4 level.
- At the same time, efforts are being made to realize smarter system solutions.
- The integration of advanced sensors for condition monitoring, known as predictive maintenance, is also gaining importance in ATEX versions.
- Through predictive maintenance, maintenance work can be better planned and downtimes minimized.
- Integrated temperature sensors are an example of this, as they can warn early of critical overheating.
- ATEK Drive Solutions closely monitors these technological advances to ensure current and safe drive solutions can always be offered.
- These solutions rely on a flexible modular system and allow for custom adaptations.
Sustainability in focus
Sustainable production in Ex areas focuses on reduced energy consumption. Energy-efficient motors (IE3+) and optimally designed gear boxes lower operating costs and CO2 emissions. ATEK Drive Solutions supports the fulfillment of safety requirements and sustainability goals. Choosing a hypoid gear box instead of a worm gear box can improve efficiency by up to 30%. Consulting helps to combine safety and sustainability for drives in explosion-hazard areas, especially with hazard zone conveyors, Hypoid gear boxes for heavy loads
The careful selection of the appropriate ATEX-certified gear motor for hazardous zone conveyors. is essential for safety and productivity. ATEK Drive Solutions offers expertise for customized drive solutions and is available for consultation to find the optimal explosion-proof drive for your specific application.
