Ingress protection (IP) ratings are a standardized method of describing how effectively enclosures of electrical equipment up to 72.5 kV resist the entry of foreign bodies, such as dust and water. For compressors, especially those operating in harsh conditions, ingress protection (or lack thereof) directly affects reliability, longevity, and overall operational efficiency.
What are IP ratings?
IP ratings, according to the international standard IEC 60529, typically consist of two digits:
- First digit: protection against solid particles (dust), ranging from 0 (no protection) to 6 (dust-tight).
- Second digit: protection against liquids (water), ranging from 0 (no protection) to 9 (protection against powerful water jets at high temperatures).
For example, when you see a rating of IP54…
"5" indicates dust protection that prevents ingress harmful enough to impact operation.
"4" signifies protection against water splashes from any direction. An IP5X rating means protection against dust without specifying liquid protection, whereas IPX4 denotes splash protection without specifying dust protection.
An IP5X rating means protection against dust without specifying liquid protection, whereas IPX4 denotes splash protection without specifying dust protection.
The IP standard is widely adopted internationally, except in the United States, where the National Electrical Manufacturers Association (NEMA) standards are used. While IP reflects protection from solid and liquid ingress, NEMA indicates protection from ingress, corrosion, and other factors.
Why IP ratings matter for compressors?
Compressors commonly operate in harsh environments. This means exposure to dust, high humidity, and/or extreme temperatures. These conditions are typical in industries such as mining, construction, and other outdoor operations.
Two critical compressor components particularly vulnerable to environmental exposure are the drive train (motor and compression element) and the electrical cubicle, particularly the inverter or drive in variable speed drive (VSD) compressors.
Drive train protection
The drive train, comprising the motor and compression element, is the core mechanism of a compressor. Exposure to dust and water can accelerate wear, cause corrosion, reduce efficiency, and eventually lead to mechanical failure. A quality enclosure designed to meet least IP54 requirements is standard for compressors operating in normal industrial operations. However, harsher conditions such as mining sites or construction zones, require better protection. To ensure dependable operation in all environments, the drive train of Atlas Copco GA VSD compressors are designed to meet IP66, meaning it is dust-tight and provides protection against high-pressure water jets from any direction.
Electrical cubicle protection
The electrical cubicle houses sensitive components, including the inverter or drive in VSD compressors. These electronic components require robust protection as dust ingress can lead to overheating and short-circuits, while water could cause component failure. For compressors operating in harsh conditions, a quality enclosure rated IP54 provides the necessary protection to maintain system reliability and avoid downtime. For example, Atlas Copco's in-house developed inverter, the Neos Next, comes as standard with an IP54 rating.
The impact of insufficient IP protection
In short, compressors lacking adequate IP protection face:
Increased risk of mechanical failure and premature wear.
Higher maintenance costs and more frequent downtime.
Lower system efficiency because of compromised compressor performance.
Compressor manufacturers typically provide IP ratings suited to general industrial use. However, selecting compressors for more demanding environments, such as mining, marine or outdoor applications, demands higher ratings to safeguard against increased environmental hazards.
IP ratings as a selection criterion
For users looking to buy a new compressor, especially one intended for harsh conditions, IP ratings should be a fundamental selection criterion. The right IP rating protects your investment by ensuring more robust, dependable operation, especially when environmental conditions come with significant operational risks.
