The new W22 industrial motors are being introduced in three different stages covering different frame sizes and outputs, with the 225 - 355 (up to 400 kW) frame size demonstrated by WEG at Hanover 2008, the 132 - 200 size in early 2009 and the 63 - 112 size in mid- 2009.
With losses reduced by 10% to 40 % across the range, W22 industrial motors deliver efficiency improvements equal to or better than EU EFF1. These advances will enable the W22 motors to meet the latest requirements for high energy efficiency. Further development of the W22 motors will enable them to meet the Premium Efficiency Category for the USA, before 2010, and Australia's MEPS (Maximum Efficiency Program Series). To deliver these improvements at lower running and lifetime cost of ownership, WEG has undertaken extensive redesign of key parts of the motors.
Improved efficiency and reliability: the result of improved cooling
A highly critical redesign is the fan cover shape and the ventilation fan itself. The innovative WEG designs provide better airflow over the motor frame, thus maintaining temperatures within the optimum operating range and improving reliability and longevity; the design is subject to international patent applications. Additional aerodynamic improvements to the frame exterior have enhanced the airflow effectiveness and minimised any hotspots, further benefiting eliability. For example the terminal box and the central eyebolt seating have been moved to reduce air flow obstruction. The lower temperature further enhances the benefits of WEG´s unique WISE system (with international patents pending), which offer prolonged resistance to temperature degradation of the insulation.
Built-in inverter compatibility
The W22 industrial motor range has been designed from the start for operation with advanced frequency inverters, to offer flexibility and increased energy efficiency, while resisting voltage spikes and voltage rise times. It is available as a package with WEG's acclaimed CFW11 Optimal Flux Frequency inverter drives.
Substantial noise reductions
Noise levels due to the ventilating system have been substantially reduced, by between 3dB(A) - 8dB(A). This brings the W22 noise levels to between 72dB to 80dB, substantially lower than IEC recommendations and equal to or lower than competitors.
Improved durability and environmental resistance
The W22 industrial motors are constructed from WEG's own high quality cast iron, to ensure maximum durability and life under harsh conditions. Redesign of the fan cover has also ensured greater strength to resist everyday impacts and accidents. In addition, the end cover has been redesigned for improved heat dissipation from the bearings, while being strengthened for increased resistance to deformation and better bolt protection. The feet are now cast integrally with the motor frame, giving greater stiffness, better damping in high vibration installations, and ensuring flatness for easy mounting on the motor plinth. Additionally the strengthened feet have been designed with integral lifting holes; this has enabled the eyebolt seating to be removed from the frame, for more even cooling. Standard environmental protection is IP 55. This is easily upgraded to IP65 with a WEG adaptation kit, comprising a replacement housing with new bearing seals, for improved dust and water ingress protection, enabling high pressure water cleaning to be employed. This can be supplied for customer fitting, or by WEG maintenance service.
Range extensions for the future
Sebastião Nau, R&D Manager concluded: The W22 platform, offering high efficiency and low lifetime costs, will be the basis for further WEG developments during 2008, 2009 and beyond. For example, as well as new Permanent Magnet motors and Exd motors, an Eco design of compact motors with optimised materials of construction are under development offering a reduced frame size per output and a smaller carbon footprint. WEG is confident that the principles of the W22 design are the basis for a highly successful internationally class of electric motors.