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What Does Ingress Protection Really Mean for Electric Motors?
Electric motors are essential for modern life, but they can be vulnerable to environmental challenges like dust and water. This article delves into the concept of IP ratings and codes, explaining their significance, testing procedures, and the pivotal role they play in enhancing motor durability and consistent performance.
Understanding IP ratings can help you make informed decisions when selecting electric motors for various applications. This article covers several key topics, including:
- What is an IP Rating, and Why Does It Matter?
- Deciphering the Meaning Behind IP Codes
- How Are These Ratings Tested?
- Case Study: IP67-Rated AC Gearmotors
- Case Study: IP67-Rated Brushless Gearmotors
- The Importance of Choosing the Right IP Rating
**What Is an IP Rating, and Why Is It Significant?**
Electric motors can suffer from electrical shorts caused by water or moisture in the windings or connections, which can lead to motor failure, electric shocks, or even fires. Dust or other contaminants can also cause overheating and eventual motor failure. If these motors are powering conveyor systems in a factory, a motor breakdown can disrupt production lines. Without a spare motor on hand, this could result in days of lost productivity.
To address these concerns, a standard rating system was established to verify a motor’s ability to function reliably in specific environments. The International Electrotechnical Commission (IEC) introduced the Ingress Protection (IP) rating system in 1976 under the international standard IEC 60529. The European equivalent is EN 60529, which originated in Germany in 1934 and is now used by the European Union via the European Committee for Electrotechnical Standardization.
Enhanced protection against water or dust often involves improving motor casing designs using O-ring seals, different materials, and specialized connectors. We’ll discuss these improvements later, after we explain the meanings behind the IP codes.
**Deciphering the Meaning Behind IP Codes**
Different levels of protection cater to diverse needs and budgets. Various levels of protection are categorized using IP codes. Each code consists of two numbers. The first digit indicates the level of protection against solid objects, ranging from human hands to fine dust. The second digit specifies the degree of protection against water particles, from simple drips to full submersion. Whether you’re an electrical engineer, maintenance professional, or hobbyist, understanding these codes can aid in making informed choices.
Below is an example of an IP code:
[Image: Example of an IP code]
For a deeper dive into what each number represents in an IP code, refer to the chart below:
[Image: IP Code Chart]
A newer IP69 rating was introduced under IEC 60529 in 1993 for equipment subjected to high-pressure and steam water jets, such as in pharmaceutical manufacturing or food packaging. Another IP69K rating was added by ISO 20653 for equipment installed on road vehicles but has since expanded to include food processing and agriculture. Understanding the differences between IP69 and IP69K can be tricky, so it's always good to double-check with resources like F2 Labs.
**How Are These Ratings Tested?**
Although ingress protection is self-certified, manufacturers or third-party testing facilities must adhere to the defined codes and testing standards. Part of our rigorous testing includes a water spray test, which is conducted under extreme conditions to ensure the highest quality.
Here’s a video showcasing various ingress protection tests:
[Embed Video]
Let’s now explore some examples of IP67-rated motors.
**Case Study: IP67-Rated AC Gearmotors**
Our FPW Series IP67-rated AC gearmotors are perfect for general-purpose washdown applications. They offer dustproof protection and can withstand water jets. The induction motor and gearhead are encapsulated together and coated with special anti-corrosive epoxy paint. The motor has a vacuum-cast design to prevent air bubbles, while the gearbox features a watertight seal. The stainless steel shaft also 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 ranging from 3:1 to 180:1. Variable speed control can be achieved with VFDs, and only three wires are needed for operation. These motors are UL and CSA approved and comply with the China Compulsory Certification System (CCC System). CE marking is applied in accordance with the Low Voltage Directive. Additionally, our extensive product range includes models compatible with the major power supply voltages of Asia, North America, and Europe.
[Image: FPW Series AC Washdown Gearmotor Construction]
**Application Examples**
[Table: IP67 Rated AC Gearmotor Applications]
**Case Study: IP67-Rated Brushless Gearmotors**
Our latest brushless motors feature high-performance magnets and an optimized slim design with high-performance magnetic steel laminations. This reduces the stator thickness to just 11.2 mm—approximately half the size of traditional brushless motors. The efficiency of brushless motors allows for a fan-less casing design, further reducing 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.
Like VFD-controlled AC motors, these brushless motors are ideal for advanced speed control applications requiring multiple speed, acceleration, and deceleration profiles. However, brushless motors surpass AC motors in terms of efficiency, closed-loop speed regulation, and a broader speed range.
These new slim brushless motors come with two different drivers, each offering unique features. You can choose either the BMU Series for basic drivers or the BLE2 Series for advanced drivers. 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, available in various configurations such as parallel shaft, hollow shaft, and right-angle shaft types.
[Image: BLE2 and BMU Series Features]
**Product Videos**
[Video: IP66 Connector]
[Video: IP66 vs IP67 Motor Comparison]
**The Importance of Choosing the Right IP Rating**
Selecting the appropriate IP rating for your motor isn’t a one-size-fits-all decision. It depends on the specific environment and operational conditions. For instance, a motor used in a dusty factory will require a different IP rating compared to one that needs to be regularly washed down. Stainless steel motors are best suited for harsh washdown environments.
Ensure you choose the right IP rating for your motor and 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 factor to consider. Power, efficiency, size, and application-specific requirements also play significant roles. Make sure you select a motor that fulfills all your application needs.
**Regular Maintenance and Inspections**
Regular maintenance and inspections are vital 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.
[Image: IP67 Motor Application Examples]
**When to Consult with Specialists**
If you’re uncertain about the required IP rating for a specific motor application, it’s best to consult with a specialist. Our knowledgeable technical support team can provide expert advice and help you make an informed decision, ensuring the longevity and efficiency of your motor.