Challenge: Failure in ATEX environment
Our customer faced an unexpected failure of the extruder’s original motor – a pressurized and encapsulated design operating in an ATEX-regulated environment. The priority was not only a fast replacement but also seamless integration into a highly sensitive system subject to strict gas explosion protection requirements. The situation was further complicated by major mechanical differences. The original motor had a much larger BG 1000 frame size, while MENZEL’s available stock motor was BG 630. Additional challenges arose on the electrical side. The existing motor used a two-winding configuration, whereas the replacement motor featured four windings. At the same time, the existing frequency inverter needed to remain in operation without extensive system modifications. The different terminal box positions created another obstacle. Despite these constraints, MENZEL delivered a technically precise and reliable solution within an exceptionally short timeframe.
Solution: Exec motor with self-manufactured and certified terminal boxes
MENZEL responded with a focused engineering approach tailored to the customer’s urgent operational needs. The available stock motor was upgraded and certified to II 3 G Ex ec IIC T4 Gc, making it fully compliant with ATEX requirements and suitable for operation in hazardous gas atmospheres. In advance, it was clarified with the operator that explosion protection is allowed at the site of use. To compensate for the significant frame size difference, MENZEL’s engineering team designed and manufactured a custom base frame. This allowed the smaller BG 630 motor to be securely installed in place of the original BG 1000 unit without modifying the existing foundation. Electrical integration was carefully adapted as well. The winding configuration was reconfigured to match the existing frequency inverter, enabling seamless operation without changes to the control hardware. In addition, the terminal boxes were repositioned to align with the existing cable routing. This avoided cable modifications and significantly simplified installation on site. From order to delivery, the entire solution was completedin less than two weeks. The result was a true drop-in replacement, minimizing plant downtime and reducing commissioning risks. After on-site acceptance, the motor was installed and successfully commissioned within a single weekend.
Technical Data
- Motor Type: MEBKSWN630-08
- Rated Power: 1,700 kW
- Rated Voltage: 690 V
- Frequency: 50 Hz
- Rated Speed: 743 min⁻¹
- Number of Poles: 8
- Frame Type: IM 1001 (IM B3)
- Protection Class: IP 55
- Cooling Type: IC 81W
- Weight: 12,000 kg
Our Expertise: Your Advantage
Through custom mechanical adaptations, standard motors can be integrated into existing installations without costly modifications to the foundation or surrounding equipment. At the same time, electrical reconfiguration ensures compatibility with existing control systems and frequency inverters, significantly reducing commissioning effort and plant downtime.
If you are facing similar challenges our experts will be happy to assist. We work closely with you to develop tailored solutions that minimize operational disruptions and integrate seamlessly into your existing infrastructure.
