Overview

This document is a comprehensive technical catalogue for Marelli Motori's ATEX-certified explosion-proof electric motors, specifically the D5 and D6 series. These motors are designed for hazardous industrial environments with explosive gas atmospheres, compliant with Group II Category 2G standards and gas group IIC (including hydrogen and acetylene). They are suitable for Zone 1 and Zone 2 hazardous areas but not for Zone 0 or Zone 20.

Company and Contact Information

Marelli Motori S.p.A., headquartered in Arzignano, Italy, operates multiple branches and manufacturing plants worldwide, including Europe, Asia Pacific, South Africa, Spain, and the USA. Contact details for sales and technical support are provided for each region.

Standards and Certifications

• Compliance with IEC 60034 series, IEC 60072-1, EN 50347, EN 60079 series.
• Certified by SABS (South Africa) and Gost R (Russia).
• Conformance with European Directives: ATEX 94/9/EC, EMC 2004/108/EC, Low Voltage Directive 2006/95/EC, Machinery Directive 98/37/EC.

Classification and Protection Types

• Groups: Group II for surface industries; Group I reserved for mining.
• Gas Sub-groups: IIA, IIB, IIC (IIC being the highest risk).
• Protection Types: Ex d (flameproof enclosure), Ex e (increased safety), and combined Ex de.

The motors are certified Ex d/de IIC, suitable for Zone 1 and 2 gas atmospheres.

Technical Specifications

• Operating Temperature: -20°C to +60°C (with +60°C limit for T3 class). Minimum -50°C for Ex d protection requiring pre-heating before start.
• Frame Sizes: 71 to 315 mm.
• Materials: Cast iron or steel frames and endshields; terminal boxes cast with frame for Ex d execution.
• Thermal Protection: Standard 3 PTC sensors on frames ≥90 mm; optional PT100 sensors and space heaters.
• Bearings: Pre-lubricated ball bearings up to size 132; regreasable bearings for 160 and above.
• Surface Protection: Epoxy-vinyl undercoating with polyurethane finishing (standard RAL5010 blue); special coatings and colors available on request.
• Terminal Box and Cable Entry: Top-mounted terminal box (B3 mounting) with 6 terminals, rotatable in 90° steps from size 90 upwards. Cable entries vary by frame size and protection type (M25 to M75 for main, M20 for auxiliary).

Options and Additional Features

• Drainage holes available from frame size 132 (horizontal mounting only).
• Frequency converter supply motors available on request with dedicated data sheets.
• Additional thermal protection options including PTC, PT100 sensors, and anti-condensation heaters.
• Custom surface finishes and colors upon request.

Equipment and Area Classification

Motors are suitable for hazardous zones 1 and 2 (gas) and zones 21 and 22 (dust). Use in zones 0 and 20 is prohibited. Equipment categories correspond to zone classifications, ensuring appropriate protection levels.

Performance Data

• Rated output power ranges from 0.25 kW to 132 kW depending on frame size and pole count.
• Available pole configurations: 2, 4, 6, and 8 poles, with synchronous speeds approximately 3000, 1500, 1000, and 750 rpm respectively.
• Efficiency ranges from ~80% (small motors) to over 94% (large motors).
• Power factor typically between 0.65 and 0.9.
• Starting current is 2 to 3 times rated current; starting torque 1.5 to 3 times rated torque; breakdown torque 2 to 3 times rated torque.
• Motors designed for continuous duty (S1) with insulation class F.
• Motors are not multivoltage; 440V/60Hz versions require dedicated windings.

Mechanical and Dimensional Data

• Frame sizes 71 to 315 with suffixes indicating design variants (e.g., MA, MB, MC).
• Mounting types include IM 1001 (B3), IM 3001 (B5), IM 3601 (B14), and IM 3011 (V1).
• Shaft extensions detailed with diameters, lengths, key sizes, and threaded holes per DIN 332 standards.
• Motor weights range from under 20 kg to over 1000 kg depending on size.
• Moment of inertia values provided for dynamic performance calculations.

Materials and Construction

• Frames and endshields made of cast iron or steel depending on size.
• Fans and fan cowls are thermoplastic or steel.
• Terminal boxes integrated with frame for Ex d protection.
• Surface finishing includes epoxy-vinyl undercoating and polyurethane or polyacrylic topcoats.

Bearings and Thermal Protection

• Pre-lubricated ball bearings for frames up to 132; regreasable bearings for larger frames.
• Standard thermal protection with PTC sensors on frames ≥90 mm; optional PT100 sensors and space heaters available.
• Drainage holes optional from frame size 132 for horizontal mounting.

Terminal Box and Cable Entry

• Terminal box mounted on top (B3), rotatable in 90° increments from size 90 upwards.
• Cable entries sized M25 to M75 for main connections, M20 for auxiliary, varying by frame and protection type.

Key Recommendations and Limitations

• Motors must be operated within specified temperature and zone classifications.
• Pre-heating required before starting at ambient temperatures down to -50°C for Ex d motors.
• Use in Zone 0 and Zone 20 hazardous areas is prohibited.
• Frequency converter supply motors and special options require consultation with Marelli Motori.

Summary

Marelli Motori's ATEX-certified D5 and D6 series motors provide robust, certified solutions for hazardous industrial environments requiring explosion-proof equipment. The catalogue offers detailed electrical, mechanical, thermal, and dimensional data to support precise motor selection, installation, and operation in compliance with international standards and directives.