RBS s RB500 Republic Blower Systems www.republicsales.com Created 12.05 280-0500 2005 Republic Sales & Manufacturing
s RB500 Republic Blower Systems 5131 Cash Road Dallas, TX 75247 (214) 631-8070 www.republicsales.com info@republicsales.com Warning Service procedures should only be performed by trained service personnel. Important Read the following safety instructions carefully. Disconnect blower from electrical source before attempting service. Republic RBS
Table of Contents Contact Us...2 Safety Instructions...4 Blower Description and Model Identification...5 Specifications and Dimensional Data Baldor RB500 Diagram...6 Reliance RB500 Diagram...7 Equipment Arrival and Inspection...8 Installation...8 Electric Motors Electric Motor Information...9 Baldor...9-23 Reliance... 24-38 Motor Wiring and Start-Up... 38 Motor Pulley Motor Pulley Diagram... 39 Motor Pulley Information... 40 Motor Pulley Installation... 41 Motor Pulley Removal... 42 Blower Head Rotation... 43 Mounting Plate Position... 44 Exploded Parts Drawings RB500 Assembly with 3 HP Motor... 45 RB500 Assembly with 5 HP Motor... 46 RB500 Assembly with 7.5 HP Motor... 47 RB500 Assembly for 90 IEC Frame... 48 RB500 Assembly for 100 IEC Frame... 49 RB500 Filter Assembly... 50 Trouble Shooting Guidelines... 51-52 Warranty Statement... 53 Republic RBS
Safety Instructions 1. Always use qualified electrical and mechanical personnel for installation and maintenance of Republic Blowers and motors. 2. Disconnect the electrical power at the motor starter, fuse box or circuit breaker before working on the system. Take special precautions to make sure the power cannot be turned on while you are working on the blower. Use an approved Lock Out/Tag Out system. 3. Make sure the motor is electrically grounded, the mounting bolts are properly secured, and all guards are in place before start-up. 4. Wear safety glasses and earplugs when working on the blower, air knife or discharge nozzles within a Republic Blower system. 5. Do not operate blower/motor assembly with the belt guard removed. Make sure to install the inlet air filter or piping to blower inlet, before starting the blower/motor. 6. Do not operate blower with the outlet open to atmosphere. Connect system piping or butterfly valve to prevent overloading the motor. Check the final installation for proper amp loads. 7. Keep all tools, lose clothing and hands away from rotating or moving parts while the unit is running. Never run the blower unit without the belt guard installed. 8. Inspect the blower at regular intervals for damaged or worn parts. Replace damaged parts immediately! Do not connect or turn on a damaged blower! 9. Inspect the inlet air filter at regular intervals and replace when necessary. A dirty air filter can cause improper blower performance. 10. Use only genuine Republic Blower brand replacement parts. Republic RBS
Description and Model Identification Republic Blower Systems are industrial grade centrifugal blowers capable of producing high velocity air, for drying or cleaning parts, at low operating costs. Three models are available: RB500: Compact Model with 3-7.5 HP Motor Sizes RB800: Compact Model with or without Motor. 3-15 HP Motor Sizes RB1200HC: Standard Model with or without Motor. 3-25 HP Motor Sizes RB2400: Dual Headed Model with or without Motor. 25-50 HP Motor Sizes Republic Blowers have a nameplate containing the serial and model number located on the blower head near the exhaust port. The motor manufacturers nameplate is located on the motor. When placing a service call, please provide the Republic serial number. Call us at (800) 847-0380 or e-mail warranty@republicsales.com. Republic RBS
HP A B C D E F G H 3 (182T) 17.75 7 1/4 4 1/2 20 1/8 7 1/2 10 1/4 5/8 7 1/2 5 (184T) 17.75 7 1/4 5 1/2 20 1/8 7 1/2 10 1/4 5/8 7 1/2 7 1/2 (213T) 20.36 8 5 1/2 20 7/8 8 1/2 11 3/4 1/8 8 1/4 HP Est. WGT. (lbs) 3 (182T) 124 5 (184T) 132 7 1/2 (213T) 198 Retro Kit Est. WGT. (lbs) 50 Baldor RB500 Blower Dimensions 200-5000 Republic RBS
HP A B C D E F G H 3 (182T) 17.42 7 1/4 4 1/2 20 1/8 7 1/2 10 1/4 5/8 7 1/2 5 (184T) 18.41 7 1/4 5 1/2 20 1/8 7 1/2 10 1/4 5/8 7 1/2 7 1/2 (213T) 20 8 5 1/2 20 7/8 8 1/2 11 3/4 1/8 8 1/4 HP Est. WGT. (lbs) 3 (182T) 128 5 (184T) 142 7 1/2 (213T) 163 Retro Kit Est. WGT. (lbs) 50 Reliance RB500 Blower Dimensions 200-5000 Republic RBS
Equipment Arrival and Inspection Inspect the blower system at time of receipt to ensure that all components and accessories, as noted on the packing slip, were received and in good condition. Verify that the serial number on the packing slip matches the serial number shown on the blower head nameplate. Inspect the blower and motor assembly to ensure that the motor horsepower and voltage are correct. If any equipment was damaged in transit, you will need to make a claim against the freight carrier immediately. If you have any shortages, discrepancies, or damage, please call your Republic Blower Systems Distributor or Republic Blower Systems at (800) 847-0380. Installation Lift the blower system by the lifting eye mounted on the top of the motor or by picking the blower up from underneath the motor. Do not lift the blower by the belt guard. Vibration isolators are included with every blower. Bolt your Republic Blower in place by the mounting brackets supplied with the blower. Use a minimum of four (4) mounting bolts. See the Specifications Section of the manual for equipment weights. 1. Have a qualified electrician configure the motor to your incoming voltage as noted in the Motor Wiring Section of the manual. Refer to the nameplate on the motor for the correct power supply requirements. 2. The blower should be located in a place where the drive belt and intake air filter can be easily serviced and maintained. 3. Avoid any type of liquid over spray or continuous wash down of the blower. Shield the blower if needed. Flooding the blower can cause damage to the system. 4. Double check the pulley alignment and install the belt as shown in the Motor Pulley and Installation Belt diagrams. Be sure to re-fasten the belt guard. 5. Install the inlet air filter Improper filtration will void warranty. Install system piping and check motor amperage draw. High amperage draw may indicate too much flow. Contact Republic Blower Systems or the local distributor with any questions. Republic RBS
Electric Motors Republic motors are selected for their field proven reputation in the industrial environment. All systems are provided with rubber motor mount vibration isolators, which should be inspected periodically for cracks. Each motor is shipped with the motor manufacturer s installation and maintenance instructions attached. Motor bearing lubrication schedules are listed in the motor manufacturer s literature attached with the motor. Integral Horsepower AC Induction Motors ODP Enclosure TEFC Enclosure Explosion Proof Installation & Operating Manual Republic RBS
Table of Contents Section 1 General Information............................................................................... 1-1 Overview..................................................................................... 1-1 Limited Warranty............................................................................... 1-1 Safety Notice.................................................................................. 1- Receiving..................................................................................... 1- Storage....................................................................................... 1- Unpacking.................................................................................... 1- Handling...................................................................................... 1- Section 2 Installation & Operation........................................................................... -1 Overview..................................................................................... -1 Location...................................................................................... -1 Mounting..................................................................................... -1 Alignment..................................................................................... -1 Doweling & Bolting............................................................................. Power Connection Conduit Box AC Power........................................................................................................................................................................................................................................... First Time Start Up............................................................................. Coupled Start Up.............................................................................. Jogging and Repeated Starts.................................................................... Section 3 Maintenance & Troubleshooting.................................................................... -1 General Inspection............................................................................. -1 Lubrication & Bearings.......................................................................... -1 Type of Grease............................................................................ -1 Lubrication Intervals....................................................................... -1 Lubrication Procedure...................................................................... Accessories................................................................................... Troubleshooting Chart.......................................................................... - - - - - - - - - - Republic RBS 10
Section 1 General Information Overview Important: This manual contains general procedures that apply to Baldor Motor products. Be sure to read and understand the Safety Notice statements in this manual. For your protection, do not install, operate or attempt to perform maintenance procedures until you understand the Warning and Caution statements. A Warning statement indicates a possible unsafe condition that can cause harm to personnel. A Caution statement indicates a condition that can cause damage to equipment. This instruction manual is not intended to include a comprehensive listing of all details for all procedures required for installation, operation and maintenance. This manual describes general guidelines that apply to most of the motor products shipped by Baldor. If you have a question about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor distributor for more information or clarification. Before you install, operate or perform maintenance, become familiar with the following: NEMA Publication MG-, Safety Standard for Construction and guide for Selection, Installation and Use of Electric Motors and Generators. The National Electrical Code Local codes and Practices Limited Warranty 1. Baldor Electric motors are warranted for a period of one (1) year, from date of shipment from the factory or factory warehouse against defects in material and workmanship. To allow for stocking and/or fabrication period and to provide one year of actual service, the warranty period is extended for an additional period of six () months for a total of eighteen (1) months from the original date of shipment from the factory or factory warehouse stock. In no case will the warranty period be extended for a longer period. Baldor extends this limited warranty to each buyer of the electric motor for the purpose of resale and to the original purchaser for use.. Baldor will, at its option repair or replace a motor which fails due to defects in material or workmanship during the warranty period if: a. the purchaser presents the defective motor at or ships it prepaid to, the Baldor plant in Fort Smith, Arkansas or one of the Baldor Authorized Service Centers and b. the purchaser gives written notification concerning the motor and the claimed defect including the date purchased, the task performed by the Baldor motor and the problem encountered.. Baldor will not pay the cost of removal of any electric motor from any equipment, the cost of delivery to Fort Smith, Arkansas or a Baldor Authorized Service Center, or the cost of any incidental or consequential damages resulting from the claimed defects. (Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply to you.) Any implied warranty given by laws shall be limited to the duration of the warranty period hereunder. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.). Baldor Authorized Service Centers, when convinced to their satisfaction that a Baldor motor developed defects in material or workmanship within the warranty period, are authorized to proceed with the required repairs to fulfill Baldor s warranty when the cost of such repairs to be paid by Baldor does not exceed Baldor s warranty repair allowance. Baldor will not pay overtime premium repair charges without prior written authorization.. The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paid unless first authorized in writing by Baldor.. Claims by a purchaser that a motor is defective even when a failure results within one hour after being placed into service are not always justified. Therefore, Baldor Authorized Service Centers must determine from the condition of the motor as delivered to the center whether or not the motor is defective. If in the opinion of a Baldor Authorized Service Center, a motor did not fail as a result of defects in material or workmanship, the center is to proceed with repairs only if the purchaser agrees to pay for such repairs. If the decision is in dispute, the purchaser should still pay for the repairs and submit the paid invoice and the Authorized Service Center s signed service report to Baldor for further consideration.. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Note that Baldor Super E Premium Efficiency electric motors are warranted for a period of three () years. All other terms and conditions of the Limited Warranty statement apply. RBS Republic 11
Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt installation, operation and maintenance of electrical equipment. Be sure that you are completely familiar with NEMA publication MG-, safety standards for construction and guide for selection, installation and use of electric motors and generators, the National Electrical Code and local codes and practices. Unsafe installation or use can cause conditions that lead to serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment. Republic RBS 12 WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: WARNING: Do not touch electrical connections before you first ensure that power has been disconnected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment. Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that all grounding instructions have been followed. Electrical shock can cause serious or fatal injury. National Electrical Code and Local codes must be carefully followed. Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective devices to reduce harmful effects to your hearing. This equipment may be connected to other machinery that has rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt to install operate or maintain this equipment. Do not by-pass or disable protective devices or safety guards. Safety features are designed to prevent damage to personnel or equipment. These devices can only provide protection if they remain operative. Avoid the use of automatic reset devices if the automatic restarting of equipment can be hazardous to personnel or equipment. Be sure the load is properly coupled to the motor shaft before applying power. The shaft key must be fully captive by the load device. Improper coupling can cause harm to personnel or equipment if the load decouples from the shaft during operation. Use proper care and procedures that are safe during handling, lifting, installing, operating and maintaining operations. Improper methods may cause muscle strain or other harm. Before performing any motor maintenance procedure, be sure that the equipment connected to the motor shaft cannot cause shaft rotation. If the load can cause shaft rotation, disconnect the load from the motor shaft before maintenance is performed. Unexpected mechanical rotation of the motor parts can cause injury or motor damage. Disconnect all electrical power from the motor windings and accessory devices before disassembly of the motor. Electrical shock can cause serious or fatal injury. Do not use these motors in the presence of flammable or combustible vapors or dust. These motors are not designed for atmospheric conditions that require explosion proof operation.
Safety Notice Continued WARNING: WARNING: Caution: Caution: Caution: Caution: Caution: Motors that are to be used in flammable and/or explosive atmospheres must display the UL label on the nameplate. Specific service conditions for these motors are defined in NEC 70-599. UL rated motors must only be serviced by authorized Baldor Service Centers if these motors are to be returned to a flammable and/or explosive atmosphere. To prevent premature equipment failure or damage, only qualified maintenance personnel should perform maintenance. Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware is adequate for lifting only the motor. Disconnect the load from the motor shaft before moving the motor. If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting direction should not exceed a 20 angle from the shank of the eye bolt or lifting lug. Excessive lifting angles can cause damage. To prevent equipment damage, be sure that the electrical service is not capable of delivering more than the maximum motor rated amps listed on the rating plate. If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and procedure in NEMA MG-1 and MG-2 standards to avoid equipment damage. If you have any questions or are uncertain about any statement or procedure, or if you require additional information please contact your Baldor distributor or an Authorized Baldor Service Center. RBS Republic 13
Receiving Storage Unpacking Handling Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for shipment. When you receive your motor, there are several things you should do immediately. 1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your motor.. Verify that the part number of the motor you received is the same as the part number listed on your purchase order. If the motor is not put into service immediately, the motor must be stored in a clean, dry and warm location. Several precautionary steps must be performed to avoid motor damage during storage. 1. Use a Megger periodically to ensure that the integrity of the winding insulation has been maintained. Record the Megger readings. Immediately investigate any significant drop in insulation resistance.. Do not lubricate bearings during storage. Motor bearings are packed with grease at the factory. Excessive grease can damage insulation quality.. Rotate motor shaft at least 10 turns every two months during storage (more frequently if possible). This will prevent bearing damage due to storage.. If the storage location is damp or humid, the motor windings must be protected from moisture. This can be done by applying power to the motors space heater (if available) while the motor is in storage. Each Baldor motor is packaged for ease of handling and to prevent entry of contaminants. 1. To avoid condensation inside the motor, do not unpack until the motor has reached room temperature. (Room temperature is the temperature of the room in which it will be installed). The packing provides insulation from temperature changes during transportation.. When the motor has reached room temperature, remove all protective wrapping material from the motor. The motor should be lifted using the lifting lugs or eye bolts provided. 1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional equipment connected to the motor by this method. The lugs or eye bolts provided are designed to lift only the motor. Never lift the motor by the motor shaft.. If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc., it may not be possible to lift the motor alone. For this case, the assembly should be lifted by a sling around the mounting base. The entire assembly can be lifted as an assembly for installation. Do not lift using the motor lugs or eye bolts provided. If the load is unbalanced (as with couplings or additional attachments) additional slings or other means must be used to prevent tipping. In any event, the load must be secure before lifting. Republic RBS 14
Section 2 Installation & Operation Overview Location Mounting Alignment Installation should conform to the National Electrical Code as well as local codes and practices. When other devices are coupled to the motor shaft, be sure to install protective devices to prevent future accidents. Some protective devices include, coupling, belt guard, chain guard, shaft covers etc. These protect against accidental contact with moving parts. Machinery that is accessible to personnel should provide further protection in the form of guard rails, screening, warning signs etc. The motor should be installed in an area that is protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and vibration. Exposure to these can reduce the operating life and degrade performance. Be sure to allow clearance for ventilation and access for cleaning, repair, service and inspections. Ventilation is extremely important. Be sure the area for ventilation is not obstructed. Obstructions will limit the free passage of air. Motors get warm and the heat must be dissipated to prevent damage. These motors are not designed for atmospheric conditions that require explosion proof operation. They must NOT be used in the presence of flammable or combustible vapors or dust. 1. ODP motors are suitable only for indoor applications.. TEFC motors are suitable for indoor or outdoor standard service applications. The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may cause vibration, misalignment and bearing damage. Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these devices are used, be sure that they are evenly supported by the foundation or mounting surface. After installation is complete and accurate alignment of the motor and load is accomplished, the base should be grouted to the foundation to maintain this alignment. The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails are designed for horizontal mounting only. Consult your Baldor distributor or authorized Baldor Service Center for further information. Accurate alignment of the motor with the driven equipment is extremely important. Caution: 1. Direct Coupling For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer for more information. Mechanical vibration and roughness during operation may indicate poor alignment. Use dial indicators to check alignment. The space between coupling hubs should be maintained as recommended by the coupling manufacturer.. End-Play Adjustment The axial position of the motor frame with respect to its load is also extremely important. The motor bearings are not designed for excessive external axial thrust loads. Improper adjustment will cause failure.. Pulley Ratio The pulley ratio should not exceed :1.. Belt Drive Align sheaves carefully to minimize belt wear and axial bearing loads (see End-Play Adjustment). Belt tension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippage may occur during starting. Do not over tension belts. RBS Republic 15
Doweling & Bolting Power Connection Conduit Box AC Power After proper alignment is verified, dowel pins should be inserted through the motor feet into the foundation. This will maintain the correct motor position should motor removal be required. (Baldor motors are designed for doweling.) 1. Drill dowel holes in diagonally opposite motor feet in the locations provided.. Drill corresponding holes in the foundation.. Ream all holes.. Install proper fitting dowels.. Mounting bolts must be carefully tightened to prevent changes in alignment. Use a flat washer and lock washer under each nut or bolt head to hold the motor feet secure. Flanged nuts or bolts may be used as an alternative to washers. Motor and control wiring, overload protection, disconnects, accessories and grounding should conform to the National Electrical Code and local codes and practices. For ease of making connections, an oversize conduit box is provided. The box can be rotated 0 in 0 increments. Auxiliary conduit boxes are provided on some motors for accessories such as space heaters, RTD s etc. Connect the motor leads as shown on the connection diagram located on the name plate or inside the cover on the conduit box. Be sure the following guidelines are met: 1. AC power is within ±10% of rated voltage with rated frequency. (See motor name plate for ratings). OR. AC power is within ±% of rated frequency with rated voltage. OR. A combined variation in voltage and frequency of ±10% (sum of absolute values) of rated values, provided the frequency variation does not exceed ±% of rated frequency. Performance within these voltage and frequency variations are shown in Figure -1. Republic RBS 16
+0 +1 Figure 2-1 Motor Performance VS Voltage Variations Full -Load Current Maximum Torque Changes in Motor Performance (%) +10 + 0 10 Power Factor Efficiency Full -Load Current Efficiency 1 0 Maximum Torque 1 10 0 + +10 +1 Voltage Variations (%) Power Factor RBS Republic 17
First Time Start Up Coupled Start Up Be sure that all power to motor and accessories is off. Be sure the motor shaft is disconnected from the load and will not cause mechanical rotation of the motor shaft. 1. Make sure that the mechanical installation is secure. All bolts and nuts are tightened etc.. If motor has been in storage or idle for some time, check winding insulation integrity with a Megger.. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical continuity.. Be sure all shipping materials and braces (if used) are removed from motor shaft.. Manually rotate the motor shaft to ensure that it rotates freely.. Replace all panels and covers that were removed during installation.. Momentarily apply power and check the direction of rotation of the motor shaft.. If motor rotation is wrong, be sure power is off and change the motor lead connections. Verify rotation direction before you continue.. Start the motor and ensure operation is smooth without excessive vibration or noise. If so, run the motor for 1 hour with no load connected. 10. After 1 hour of operation, disconnect power and connect the load to the motor shaft. Verify all coupling guards and protective devices are installed. Ensure motor is properly ventilated. This procedure assumes a coupled start up. Also, that the first time start up procedure was successful. 1. Check the coupling and ensure that all guards and protective devices are installed.. Check that the coupling is properly aligned and not binding.. The first coupled start up should be with no load. Apply power and verify that the load is not transmitting excessive vibration back to the motor though the coupling or the foundation. Vibration should be at an acceptable level.. Run for approximately 1 hour with the driven equipment in an unloaded condition. The equipment can now be loaded and operated within specified limits. Do not exceed the name plate ratings for amperes for steady continuous loads. Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motor winding insulation. A much greater amount of heat is produced by each acceleration or jog than than by the same motor under full load. If it is necessary to to repeatedly start or jog the motor, it is advisable to check the application with your local Baldor distributor or Baldor Service Center. Heating - Duty rating and maximum ambient temperature are stated on the motor name plate. Do not exceed these values. If there is any question regarding safe operation, contact your local Baldor distributor or Baldor Service Center. Republic RBS 18
Section 3 Maintenance & Troubleshooting General Inspection Lubrication & Bearings Type of Grease WARNING: UL rated motors must only be serviced by authorized Baldor Service Centers if these motors are to be returned to a flammable and/or explosive atmosphere. Inspect the motor at regular intervals, approximately every 00 hours of operation or every months, whichever occurs first. Keep the motor clean and the ventilation openings clear. The following steps should be performed at each inspection: WARNING: Do not touch electrical connections before you first ensure that power has been disconnected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment. 1. Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor failure.. Use a Megger periodically to ensure that the integrity of the winding insulation has been maintained. Record the Megger readings. Immediately investigate any significant drop in insulation resistance.. Check all electrical connectors to be sure that they are tight. Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating ability of a grease (over time) depends primarily on the type of grease, the size of the bearing, the speed at which the bearing operates and the severity of the operating conditions. Good results can be obtained if the following recommendations are used in your maintenance program. A high grade ball or roller bearing grease should be used. Recommended grease for standard service conditions is Polyrex EM (Exxon Mobil). Equivalent and compatible greases include: Texaco Polystar, Rykon Premium #, Pennzoil Pen Lube and Chevron SRI. Maximum operating temperature for standard motors = 110 C. Shut down temperature in case of a malfunction = 11 C. Lubrication Intervals Recommended lubrication intervals are shown in Table -1. It is important to realize that the recommended intervals of Table -1 are based on average use. Refer to additional information contained in Tables 3-2 and 3-3. Table 3-1 Lubrication Intervals * Rated Speed - RPM NEMA / (IEC) Frame Size 10000 6000 3600 1800 1200 900 Up to 10 incl. (1) ** 00 Hrs. 00 Hrs. 1000 Hrs. 1000 Hrs. 000 Hrs. Over 10 to 0 incl. (10) 00 Hrs. 00 Hrs. 1000 Hrs. 1000 Hrs. Over 0 to 0 incl. () * 00 Hrs. 00 Hrs. 1000 Hrs. 1000 Hrs. Over 0 to 00 incl. (00) *00 Hrs. 00 Hrs. 00 Hrs. 1000 Hrs. * Lubrication intervals are for ball bearings. For roller bearings, divide the listed lubrication interval by. ** For 0 and 0 bearings. For 0 bearings, consult oil mist lubrication (MN01). Relubrication interval for 0 bearing bearing is 10Hrs. (using grease lubrication). Relubrication interval for 0 bearing bearing is 0Hrs. (using grease lubrication). RBS Republic 19
Table 3-2 Service Conditions Severity of Service Ambient Temperature Atmospheric Type of Bearing Maximum Contamination Standard 0 C Clean, Little Corrosion Deep Groove Ball Bearing Severe 0 C Moderate dirt, Corrosion Ball Thrust, Roller Extreme >0 C* or Severe dirt, Abrasive dust, All Bearings Class H Insulation Corrosion Low Temperature < 0 C ** * Special high temperature grease is recommended (Dow Corning DC). Note that Dow Corning DC grease does not mix with other grease types. Thoroughly clean bearing & cavity before adding grease. ** Special low temperature grease is recommended (Aeroshell ). Table 3-3 Lubrication Interval Multiplier Severity of Service Multiplier Standard 1.0 Severe 0. Extreme 0.1 Low Temperature 1.0 Table 3-4 Bearings Sizes and Types Frame Size NEMA (IEC) Bearing Description (These are the Large bearings (Shaft End) in each frame size) Bearing OD D mm Width B mm Weight of Grease to Volume of grease to be added add * oz (Grams) in 3 teaspoon Up to 10 incl. (1) 0 0 1 0.0 (. ) 0..0 Over 10 to 0 incl. (10) 11 10 0.1 (1 ) 1.. Over 0 to 0 incl. () 1 10 0.1 ( ) 1.. Over 0 to incl. (0) NU1 00.1 (0).1 1. Over 000 to 00 incl. () NU 00.0 (10). 0.0 Spindle Motors Frame 0 1 0. (.1) 0. 1. Frame 10 0 0 0. (.0) 0..1 0 Frame 1 10 0. (1.0) 0.. * Weight in grams =.00 DB Republic RBS 20
Lubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease already in the motor. Consult your Baldor distributor or an authorized service center if a grease other than the recommended type is to be used. Caution: Sample Lubrication Determination To avoid damage to motor bearings, grease must be kept free of dirt. For an extremely dirty environment, contact your Baldor distributor or an authorized Baldor Service Center for additional information. With Grease Outlet Plug 1. Clean all grease fittings.. Remove grease outlet plug.. If motor is stopped, add the recommended amount of grease. If motor is to be greased while running, a slightly greater quantity of grease will have to be added. Add grease slowly until new grease appears at shaft hole in the endplate or purge outlet plug.. Re-install grease outlet plug. Without Grease Outlet Plug 1. Disassemble motor.. Add recommended amount of grease to bearing and bearing cavity. (Bearing should be about 1/ full of grease and outboard bearing cavity should be about 1/ full of grease.) Note: Bearing is 1/ full when only one side of bearing is completely full of grease.. Assemble motor. Assume - NEMA T (IEC 10), 10 RPM motor driving an exhaust fan in an ambient temperature of C and the atmosphere is moderately corrosive. 1. Table -1 list 00 hours for standard conditions.. Table - classifies severity of service as Severe.. Table - lists a multiplier value of 0. for Severe conditions.. Table - shows that 1. in or. teaspoon of grease is to be added. Note: Smaller bearings in size category may require reduced amounts of grease. RBS Republic 21
General Information Accessories Republic RBS 22 The following is a partial list of accessories available from Baldor. Contact your Baldor distributor for availability and pricing information. Note: Space heaters and RTD s are standard on some motors. Bearing RTD RTD (Resistance Temperature Detector) devices are used to measure or monitor the temperature of the motor bearing during operation. Bearing Thermocouples Used to measure or monitor bearing temperatures. Bearing Thermostat Temperature device that activates when bearing temperatures are excessive. Used with an external circuit to warn of excessive bearing temperature or to shut down a motor. Conduit Boxes Optional conduit boxes are available in various sizes to accommodate accessory devices. Cord & Plug Assembly Adds a line cord and plug for portable applications. Drains and Breathers Stainless steel drains with separate breathers are available. Drip Covers Designed for use when motor is mounted in a vertical position. Contact your Baldor distributor to confirm that the motor is designed for vertical mounting. Fan Cover & Lint Screen To prevent build-up of debris on the cooling fan. Nameplate Additional stainless steel nameplates are available. Roller Bearings Recommended for belt drive applications with a speed of 100 RPM or less. Rotation Arrow Labels Rotation arrows are supplied on motors designed to operate in one direction only. Additional rotation arrows are available. Space Heater Added to prevent condensation of moisture within the motor enclosure during periods of shut down or storage. Stainless Hardware Stainless steel hardware is available. Standard hardware is corrosion resistant zinc plated steel. Winding RTD RTD (Resistance Temperature Detector) devices are used to measure or monitor the temperature of the motor winding during operation. Winding Thermocouples Used to measure or monitor winding temperatures. Winding Thermostat Temperature device that activates when winding temperatures are excessive. Used with an external circuit to warn of excessive winding temperature or to shut down a motor. Note: On some motors, leads for accessory devices are brought out to a separate conduit box located on the side of the motor housing (unless otherwise specified).
Table 3-5 Troubleshooting Chart Symptom Possible Causes Possible Solutions Motor will not start Usually caused by line trouble, such as, single phasing at the starter. Check source of power. Check overloads, fuses, controls, etc. Excessive humming High Voltage. Check input line connections. Eccentric air gap. Have motor serviced at local Baldor service center. Motor Over Heating Overload. Compare actual amps (measured) with nameplate rating. Locate and remove source of excessive friction in motor or load. Reduce load or replace with motor of greater capacity. Single Phasing. Check current at all phases (should be approximately equal) to isolate and correct the problem. Improper ventilation. Check external cooling fan to be sure air is moving properly across cooling fins. Excessive dirt build-up on motor. Clean motor. Unbalanced voltage. Check voltage at all phases (should be approximately equal) to isolate and correct the problem. Rotor rubbing on stator. Check air gap clearance and bearings. Tighten Thru Bolts. Over voltage or under voltage. Check input voltage at each phase to motor. Open stator winding. Check stator resistance at all three phases for balance. Grounded winding. Perform dielectric test and repair as required. Improper connections. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical continuity. Refer to motor lead connection diagram. Bearing Over Heating Misalignment. Check and align motor and driven equipment. Excessive belt tension. Reduce belt tension to proper point for load. Excessive end thrust. Reduce the end thrust from driven machine. Excessive grease in bearing. Remove grease until cavity is approximately / filled. Insufficient grease in bearing. Add grease until cavity is approximately / filled. Dirt in bearing. Clean bearing cavity and bearing. Repack with correct grease until cavity is approximately / filled. Vibration Misalignment. Check and align motor and driven equipment. Rubbing between rotating parts and Isolate and eliminate cause of rubbing. stationary parts. Rotor out of balance. Have rotor balance checked are repaired at your Baldor Service Center. Resonance. Tune system or contact your Baldor Service Center for assistance. Noise Foreign material in air gap or ventilation openings. Remove rotor and foreign material. Reinstall rotor. Check insulation integrity. Clean ventilation openings. Growling or whining Bad bearing. Replace bearing. Clean all grease from cavity and new bearing. Repack with correct grease until cavity is approximately / filled. RBS Republic 23
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Motor Wiring and Start-Up Only qualified personnel should perform wiring or maintenance on the blower assembly Never run a centrifugal blower to atmosphere, as this can cause overloading and damage the motor. Always check your installation to make sure the motor is running within the motor manufacturers specified amp ranges. Republic blowers are shipped with the belts removed. Motor rotation must be checked prior to installing the belt! Running the blower/motor assembly backwards will cause improper performance and damage the blower. With the belt removed, bump the power to determine rotation of motor. The blower should be rotating clockwise (CW) from the belt side of the blower, counter-clockwise (CCW) if you are on the motor side or impeller side of the blower. Rotation arrows on the blower cast housing (Motor Side) show correct rotation of impeller rotation. If the motor is going the wrong direction, then have your qualified electrician change the direction of rotation. If the blower is allowed to run in the wrong direction, you could cause damage to the idler pulley assembly spring or belt. Even in reverse, a centrifugal blower will still provide a substantial amount of airflow and pressure, but it will not perform to your satisfaction. Republic RBS 38
Insert install tool into motor pulley as shown in Figure 1. Slip belt over motor pulley. Slide belt over blower pulley. Rotate motor pulley with install tool and apply pressure on belt to work belt over belt grooves. Work belt until belt groves and pully grooves align. Use a wire tie or plastic zip tie to attach the belt to the motor pulley if needed. RBS Republic 39
Motor Pulley Information When installing a new motor pulley or servicing your existing unit, make sure that the outer grooves on both the motor pulley and blower pulley are not damaged, nicked or dinged. Damaged pulley grooves can cause premature belt failures or higher than normal levels of vibration. Be sure to use a Torque wrench when installing the Motor Pulley. Torque the set screws to 36 ft./lbs. or 430 in./lbs. Torque the set screws evenly to ensure proper alignment. Blower Pulley Motor 1/2-13 Hex Head Screw 4 Pls Taper-Lock Bushing Set Screws Motor Pulley Face Blower Pulley Face Republic RBS 40
Motor Pulley Installation 0 TO ± 1/32 Straight Edge Radially Rotate the Straight Edge to Align Blower Pulley Straight Edge Middle Hole is for Removal Additional two (2) holes are for installation Mounting Plate Motor Pulley Installation Procedure: 1. Install Bushing into Motor Pulley with set screws. Then install the Motor Pulley Assembly onto the motor s shaft. 2. Use a straight edge to align the Motor Pulley Face with the Blower Pulley Face. Alignment must be within 0 to ± 1/32. The straight edge must be able to rotate radially and lay flush on two faces of the motor pulley while lying flush on the face of the blower pulley to insure proper alignment (see Detail C). 3. Insert a screw driver through one of the Motor Pulley s and Mounting Plate s holes to keep the Motor Pulley from rotating while tightening the set screws. 4. Using a Torque wrench, set the torque to 36 ft./lbs.. and then torque the set screws equally. Detail C Motor Pulley Installation MtrPullInstall RBS Republic 41
Motor Pulley Removal Blower Pulley Motor 1/2-13 Hex Head Screw 4 Pls Taper-Lock Bushing Middle Hole in Bushing is for Removal Set Screws Motor Pulley Face Blower Pulley Face Mounting Plate Set Screw Installation Holes Mounting Plate Hole Detail A Motor Pulley Removal Procedure: 1. Line up one Motor Pulley Hole to Mounting Plate Hole and insert a screw driver through, restricting the Motor Pulley rotation. 2. Use a 1/4 Allen wrench and remove the two (2) set screws from the Motor Pulley and Bushing. 3. Insert one of the removed set screws into the top Middle Hole of the Bushing. 4. While still keeping the Motor Pulley from rotating, tighten the Middle Hole set screw until the Motor Pulley separates from the Bushing. 5. When the Motor Pulley is loose, slide it off the motor shaft. 6. Be careful not the drop the Motor Pulley and damage the grooves. Republic RBS 42 Motor Pulley Removal MtrPulRemoval
Blower Housing can rotate cw or ccw as shown in these views. Blower Housing Band Clamp Loop Detail A Hex Nut Blower Housing Rotational Procedures: 1. Loosen Hex Nut on Band Clamp using 3/8 nut driver. 2. Rotate Blower Housing to desired position, then hand tighten Hex Nut until Band Clamp Loops are 1 apart. 1 Loop to Loop Band Clamp Blower Head Rotation BLWRHDROTA RBS Republic 43
4 3 Position No. 5 is standard unless otherwise specified by customer. 5 6 1 2 9 8 7 10 11 12 13 14 15 16 18 17 Mounting Plate Position MTPLPOS Republic RBS 44
RB500 Blower Assy. w/3hp Motor 200-5003 RBS Republic 45
RB500 Blower Assy. w/5hp Motor 200-5005 Republic RBS 46
RB500 Blower Assy. w/7.5hp Motor 200-5075 RBS Republic 47
RB500 Blower Assy. - 90 IEC Frame 200-5090 Republic RBS 48
RB500 Blower Assy. - 100 IEC Frame 200-5100 RBS Republic 49
RB500 Filter Assembly 250-0920 Republic RBS 50
Low Flow, Pressure or Vacuum Trouble Shooting Guidelines Blower is rotating backwards (Check the motor wiring) Dirty or contaminated filter Electrical Overloading Irregular Noise Collapsed flex hose or piping Worn or damage Impeller Worn belt (slipping) Butterfly valve is closed Piping design too small for the application Improper blower application Air leakage Exceeding the designed CFM of the blower motor Blower RPM too high Damaged motor bearing or winding Electrical supply problems Blower not connected to air knives or pipe Blockage in the air lines or piping Leakage in the pipes, cracked or loose flex hose Frayed or a bad belt Bolts loose on the motor mounts Blower bearings are worn Motor bearings worn or motor fan is rubbing Blower is receiving vibration from other equipment in the vicinity Replace hose or piping Replace Impeller Replace belt Open Butterfly and check amperage Call Republic Blower Systems or Local Distributor Call Republic Blower Systems or Local Distributor Check all connections Replace belt Bearing Housing Assy. Belt Slipping Worn belt Replace belt Belt Tension Spring worn-out/missing Belt is contaminated due to the environment Replace belt Clean or replace belt RBS Republic 51
Trouble Shooting Guidelines (cont.) Pulley grooves worn, check both pulleys Dirt, dust or debris pulled inside the belt guard area Incorrect belt size Replace pulley(s) Clean area Low belt tension Residue build-up on pulley(s) Dirty contaminated filter Bearings seized Foreign material preventing Bearing Housing from rotating freely Replace belt Clean pulley(s) with a brass brush Replace filter Replace Bearing Housing Clean Bearing Housing and Impeller Belt Fraying Foreign material rubbing on belt Remove foreign material, change belt Belt is Jumping or Disintegrating Belt is not seated correctly on pulleys and overlapping edges Worn belt Motor Pulley out of alignment Worn belt Belt Tension Spring worn-out/missing Pulley grooves worn, check both pulleys Belt is contaminated Low belt tension Residue build-up on pulley(s) Bearings seized Foreign material preventing Bearing Housing from rotating freely Frequent motor starting and stopping Align belt correctly, change belt Replace belt See alignment guidelines Replace belt Replace belt Replace pulley(s) Clean or replace belt Check tension setting Clean pulley(s) with a brass brush Replace Bearing Housing Clean Bearing Housing and Impeller Attach soft start Republic RBS 52
Republic Blower Systems Warranty Terms and Conditions Republic Sales & Manufacturing Company warrants all finished Republic Blower Systems products to be free from functional defects in material and workmanship for a period of twelve (12) months from the date of installation, or no longer than eighteen (18) months from shipment. Wear parts such as drive belts, filter elements, hoses and pulleys are not covered by the 12 to 18 month warranty. DISASSEMBLY OF BLOWER MAY VOID WARRANTY. To obtain service within the warranty period, first contact your authorized Republic Sales and Manufacturing dealer or Republic Sales and Manufacturing Service Department. Republic s responsibility under this warranty shall be to provide an analysis of the blower, which will determine course of action. Any product found to be defective within the warranty period will merit either: a. A no charge repair of existing blower. Any freight charges will be the purchaser s responsibility. b. A replacement blower*. Any freight charges will be the purchaser s responsibility. *This option would be chargeable replacement until the original blower is received by Republic Sales & Manufacturing, and warranty is approved. Republic Sales & Manufacturing shall not be liable for incidental nor consequential damages resulting from the use of this product. There are no expressed nor implied warranties, which extend beyond the warranty of merchantability or fitness for a particular purpose to the equipment and/or its parts and components. RBS Republic 53
Republic Blower Systems 5131 Cash Road Dallas, TX 75247 P. 214.631.8070 F. 214.631.3673 www.republicsales.com B l o w e r S y s t e m s www.republicsales.com Created 12.05 280-0500 2005 Republic Sales & Manufacturing