Robuschi RB-DV Series Manual

N° di serie S/N
Manufacturing year
2016
Type
RB-DV
Operating and maintenance
instructions for blowers.
Instruction for
Transport | Installation | Operation | Maintenance
PD Blower & Vacuum Pump Service & Repair Facility
120 –10293 276 ST, Acheson, Alberta, Canada T7X 6A5
T: 780.962.1827 F: 780.962.1830 E: [email protected]

3
GENERAL INFORMATION
This manual is integral part of the machine follow strictly the
instructions given in this Manual prior to positioning and
operating the blower.
For a quick and rational reading of this manual observe the
following statements and definitions :
Warning : Signals the risk of serious physical
dangers to people and/or serious danger to blower
Note : Signals important technical information for
the operation of the blower
Qualified personnel
It means these persons who, on account of their training,
experience and instruction and their knowledge of relevant
standards, specifications, accident prevention rules and
operating conditions, have been authorized by those
responsible for the safety of the plant to carry out the
necessary work on the blower and who can recognize and
avoid any possible dangers.
Acknowledge of first aid is also required as is information
about local rescue facilities.
The blower is a rotary lobe compressor suitable only for
industrial use as described in this Manual.
Any other use is to be considered improper and is
therefore forbidden.
The blower must be installed in a safe area, accessible only
by qualified personnel.
Warning : Non-qualified personnel are not
permitted to work on or near the blower
The personnel in charge must be well acquainted with this
Manual, and then conserve carefully the Manual in a known
site in order that it is available for future consultations.
The maintenance operations are to be carried out by qualified
personnel following the instructions given in this Manual and
using only original spare parts.
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4
SAFETY INFORMATION
Delivery of ROBUSCHI does not include the design of the
operating environment where the blower will be installed,
nor the power circuits, control circuits and other controls
or equipments required by the specific function of the
blower.
The CUSTOMER therefore must verify that the operating
environment, the power circuits, the control circuits and
the other controls or equipments related to the function of
the blower satisfy the essential safety requirements of the
European Machinery Directive 89/392/EEC and/or of the
corresponding legislation of the country where the blower
is used.
The CUSTOMER must also ensure that the valid
legislation on eletric safety (Low-Voltage Directive) and
Electromagnetic Compatibility of equipment (EMC
Directive) is followed.
Warning : All the personnel that come in contact
with the blower must observe following
safety regulations
During Blower operation
Do not touch external surfaces of the blower and of the outlet
silencer : surfaces temperature above 70 °C.
Do not open oil plugs during operation.
Do not disassemble transmission guard.
Do not approach blower without suitable clothing (avoid large
clothes, neckties, bracelets or necklaces).
Do not use the blower in operating conditions different from
the ones rated in the order confirmation.
Do not touch components under electric supply.
Dispose of fire-fighting equipment close to the
blower
Before any staff service on the Blower
Stop the blower and auxiliary systems as described at par. 5.4
Warning : Disconnect the electric supply, lock the
general switching open position with the key
and conserve it during the service operation
Warning : Insulate the blower from the plant and
restore the atmospheric pressure into it.
Warning : The gas contained in the plant may be
hot, toxic and irritant
Warning : Wait until the blower returns at the
ambient temperature (< 40°C)
During staff service on the blower
Check that all the operations indicated above have been
completed.
Lift the blower and the main piping by a suitable equipment
only.
During cleaning operations involving the use of sprays or
cleaning agents special attention is to be paid to relevant user
information to avoid the poisoning due to fumes or burns due
to caustic substances.
Warning : Do not use non-original spare parts or
accesssories .
Note : ROBUSCHI will not be liable for any
damage, brealdown, injury deriving from
the use of non-original spare parts or accessories
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5
BLOWER IDENTIFICATION
Tipo
Type
N° di serie
S/N
Anno di costruzione
Manufacturing year
Gas convogliato
Conveied gas
Pressione assoluta di aspirazione P1
Absolute intake pressure mbar
Temperatura di aspirazione T1
Intake temperature °C
Portata aspirata Q1
Inlet capacity m3/h
Pressione assoluta di mandata P2
Discharge absolute pressure mbar
Pressione differenziale P2 – P1
Differential pressure mbar
Temperatura di mandata T2
Discharge temperature °C
Velocità di rotazione del soffiatrore n
Blower speed Rpm
Potenza assorbita N
Absorbed power Kw
Potenza del motore
Motor power Kw
Velocità di rotazione del motore
Motor speed Rpm
Rumore emesso SPL
Noise dB(A)
WARRANTY CONDITIONS
The blower, if not stated otherwise by the contract, is
guaranteed for 12 months of operation and in any case for a
maximum of 18 months after the delivery.
The warranty apply only if the contractual and administrative
norms have been observed and if the installation of the blower
and its use comply with the instructions of this manual.
The damaged or defective parts due to manufacturing faults will
be repaired or replaced free of charge.
The following are excluded from this warranty : all parts subject
to wear (air filter, bearings etc..), transport costs and the costs
of the intervention of our technicians for operational faults not
due to manufacturing defects.
The warranty excludes any responsibility for direct or indirect
damage to people and/or objects caused by improper use or
inadequate maintenance of the blower and is limited only to
manufacturing defects.
The warranty is considered void in the event of tampering or
changes (even small ones) and use of non-original spare
parts.
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22
INDEX
1 BLOWER CHARACTERISTICS...............................................................................................22
1.1 Operating principle..............................................................................................................22
1.2 Construction........................................................................................................................22
1.3 Nameplate...........................................................................................................................22
2 PERFORMANCE LIMITS AND WORKING CONDITIONS .....................................................23
2.1 Operating environment and conveyed gas..........................................................................23
2.2 Performance limits ..............................................................................................................23
2.3 Flow adjustment..................................................................................................................23
2.4 Noise level...........................................................................................................................23
2.5 Forbidden uses....................................................................................................................24
2.6 Residual risks......................................................................................................................24
3 STORAGE................................................................................................................................25
3.1 Unpacking ...........................................................................................................................25
3.2 Handling..............................................................................................................................25
3.3 Preservation........................................................................................................................25
4 INSTALLATION........................................................................................................................26
4.1 On-site positioning of blower...............................................................................................26
4.2 Changing the inlet/outlet arrangement................................................................................26
4.3 Direction of rotation – Gas flow direction ............................................................................26
4.4 Coupling..............................................................................................................................27
4.4.1 Direct coupling............................................................................................................27
4.4.2 Belt drive coupling ......................................................................................................28
4.5 System piping......................................................................................................................29
4.5.1 Vacuum operation ......................................................................................................29
4.5.2 Pressure operation.....................................................................................................29
4.5.3 Pressure / Vacuum operation.....................................................................................29
4.6 Cooling circuit (only for /RV)................................................................................................30
4.7 Electric connection..............................................................................................................30
5 OPERATION.............................................................................................................................31
5.1 Preliminary controls.............................................................................................................31
5.2 First start up ........................................................................................................................31
5.3 Operation.............................................................................................................................31
5.4 Stopping the blower.............................................................................................................31
6 MAINTENANCE .......................................................................................................................32
6.1 Oil change...........................................................................................................................32
6.1.1 Oil type and viscosity..................................................................................................32
6.1.2 Recommended mineral oils........................................................................................32
6.2 Replacing the shaft seal......................................................................................................33
6.3 Cleaning compression chamber..........................................................................................33
6.4 Check of the gear clearance...............................................................................................33
6.5 Check of the rotors clearance.............................................................................................33
6.6 Spare parts..........................................................................................................................34
6.7 Demolition of the blower......................................................................................................34
7 TROUBLESHOOTING.............................................................................................................35
8 DISASSEMBLY AND REASSEMBLY .....................................................................................36
8.1 Disassembly........................................................................................................................36
8.1.2 Disassembly of drive side sump.................................................................................36
8.1.3 Disassembly of gear side sump..................................................................................36
8.2 Reassembly.........................................................................................................................36
8.2.1 Reassembly of drive side sump..................................................................................36
8.2.2 Reassembly of gear side sump..................................................................................36
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1 BLOWER CHARACTERISTICS
1.2 Operating principle
RB-DV series blowers are positive displacement
exhausters comprising two conjugate shaped rotors 2
which rotate inside a figure 8 shaped body 1.
The gas enters the blower at pressure P1, below the
atmospheric pressure, and temperature T1 and it is
trapped in the volume V.
The compression of entrained air is carried out by the
injection of cold atmospheric air in the volume V through
the nozzles 3.
The capacity is proportional to the speed of rotation and is
almost constant when the operating pressure varies.
P1 inlet absolute pressure
T1 inlet temperature
P2 outlet absolute pressure
T2 outlet temperature
T3 injection air temperature
Fig. 1
1.2 Construction
The body 1 is closed at both ends by covers 5A and 5B in
which the seals 45 and bearings 31, 32 and 33 are located.
The rotors 2 are synchronized by means of a gear with
involute toothed wheels 11A and 11B.
The shafts have labyrinth seals, gas leaks are collected
into special air spaces in the covers and are discharged
into the atmosphere.
Two sumps 12A and 12B are mounted on the covers which
act as oil tanks for the bath lubrication of the bearings and
of the synchronized gear.
Fig. 2
1.3 Nameplate
-Blower type
1) Size from 45 to 145
2) Version F Flanged
VVertical
HHorizontal
SPWithout feet
RVCooled vertical
3) Execution 0001
-S/N Serial number
-m3/h Capacity
-kW Power
-dp mbar Differential pressure
-n RPM Rotation speed
Note : For a detailed description of the blower materials and all its components see also the catalogue or
consult our technical service.
Type RB-DV 65 / V
S/N 0105116 exec. 0001
m3/h 1000 kW 37
dp 500 n 1450
mbar RPM
(3)
(1)
(2)
1
2
33
11B
12B
32
31
12A
5A
5B
25
11A
3 3
2
V
2
1
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2 PERFORMANCE LIMITS AND WORKING CONDITIONS
2.1 Operating environment and conveyed gas
The blower is suitable to operate only in dust free environment, with no-explosive or corrosive atmosphere
and to convey only atmospheric Air.
The atmospheric air injection can be keeped only from the ambient of installation
Warning : The blower is not suitable to convey explosive, toxic or dangerous gases.
Warning : The suction of liquids damages the blower.
2.2 Performance limits
Size RPM P1
(mbar) P2-P1 (mbar) T1 (°C) T2 (°C) T2-T1 (°C) T3 (°C)
MAX MIN MAX MIN MAX MAX MIN MAX MAX MAX MIN
45 5000 1000 500 150 1000 50 -25 150 130 50 -25
65 4800 900 500 150 1000 50 -25 150 130 50 -25
85 3800 700 500 150 1000 50 -25 150 130 50 -25
105 3000 550 500 150 1000 50 -25 150 130 50 -25
125 2400 450 500 150 1000 50 -25 150 130 50 -25
145 2000 350 500 150 1000 50 -25 150 130 50 -25
To Atmospheric temperature -20°C < To < +45°C Installation altitude < 1000 masl (if not differently specified on page 5)
Po Atmospheric pressure
P1 Blower inlet absolute pressure T1 Blower inlet temperature
P2 Blower outlet absolute pressure T2 Blower outlet temperature
2.3 Flow adjustment
Change transmission ratio
Change frequency of the motor
Use a two-speed motor
Discharge excess flow and silence it
Warning : Do not use relief valve to discharge excess flow
Warning : Do not recirculate flow to blower inlet.
Warning : Do not adjust flow by throttling inlet or outlet pipe.
2.4 Noise level
Noise level of the blower is indicated at page 4 as Sound Pressure Level according to ISO 3476 at 1m
distance from the blower and in free air (tolerance +/- 2dB(A))
Warning : For high compression ratio and for high speed of rotation noise level of blower can
be higher than 85 dB(A).
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2.5 Forbidden uses
Forbidden use Risk Measures
Operation in explosive atmosphere Fire and explosion
Forbidden use
Suction of explosive, toxic and
dangerous gases Fire and explosion Environment pollution
Risk of operators health
Operation with free nozzles Environment pollution
Risk of operators health
Suction of liquids Blower stall and ejection of parts Install a liquid separator on the suction nozzle of
the blower
Operation with shut off valve locked Overheating
Fire
Blower stall and ejection of parts Inform the qualified personnel charged with the
blower
Operation with wrong direction of
rotation Ejection of dangerous substances Blower stall and ejection of parts
Operation with speed higher than
the maximum one Blower stall and ejection of parts Use suitable limits to the motor speed when it is
supplied with frequency converter
Operation with speed lower than the
minimum one
Operation with pressure P1
higher than the maximum one Ejection of dangerous substances Use a safety pressure switch when the blower
sucks from a closed circuit
Operation with pressure P1
lower than the minimum one Blower stall and ejection of parts
Operation with pressure P2-P1
higher than the maximum one Blower stall and ejection of parts Set up the relief valve
Operation with temperature T1
higher than the maximum one Overheating Fire
Blower stall and ejection of parts Use a safety temperature switch when the
blower sucks from a closed circuitOperation with temperature T1
lower than the minimum one Blower stall and ejection of parts
Operation with temperature T2
higher than the maximum one Overheating Fire
Blower stall and ejection of parts
Use a safety temperature switch when the
blower sucks from a closed circuit
Operation with temperature T2-T1
higher than the maximum one Blower stall and ejection of parts Use a differential temperature switch when the blower sucks from a closed circuit
Stopping the ROBOX with counter
pressure High current absorption Fire Use a suitable stopping procedure
2.6 Residual risks
Hazard
UNI EN 1012-1 Compressor
Residual risk
Cutting, severing, drawing
in, trapping, entanglement,
friction and abrasion
Do not approach the transmission guard with no suitable clothes
Advice in the manual. Protect cooling port properly to cutting and trapping risk
Fluid ejection Overcoming the operation limits (par. 2.2) can cause the risk of ejection of parts
Ejection of parts Overcoming the operation limits (par. 2.2) can cause the risk of ejection of parts
Loss of stability None
Electric installation
None
The electric equipment is not supplied by ROBUSCHI
Electrostatic phenomena
External influences on
electrical equipment
Thermal safety The surface of the blower and of the discharge silencer can be higher than 70 °C
Label C.7 on the surfaces
Advice in the manual
Noise The sound pressure level can be higher than 85 dB(A)
Wear the noise protection devices
Label C.2 on the inlet filter
Advice in the manual
Suction of liquids Forbidden use can cause the risk of suction of liquids
Gas Forbidden use can cause the risk of suction of dangerous gases
Fire and explosion Overcoming the operation limits (par. 2.2) can cause the risk of fire and explosion
Operation with shut-off valve locked can produce the risk of fire
The not correct maintenance can cause the overheating and the risk of fire
Failure of energy supply Ejection of fluids and parts
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3 STORAGE
3.1 Unpacking
Check always the correspondence between documents and materials and the presence of eventual damages
due to transport.
Warning: Remove with care the packing and clearing all the dangerous elements (nails, splits,
etc…)
3.2 Handling
Blower kg
45 97
65 159
85 250
105 400
125 610
145 1099
Warning : Do not use the holes in the flanges to lift the blower
3.3 Preservation
Keep the blower in a place protected against solar radiation and at following climatic conditions :
Temperature from – 20°C to 40 °C
Relative humidity from 10% to 80%
If different climatic conditions are forecast contact ROBUSCHI.
Do not remove the nozzle protections and renew the preservation every 6 month or more frequently if
humidity is higher than 80% using antirust oil.
Parts Anti-rust oil
Type Trade
Shiny external parts Rustia 27 Rust Ban 397
V-Produkt 9703
AGIP
ESSO
SHELL
Gear and bearings Rustia C 100 Antiruggine MZ 110
Ensis Motor Oil 20
AGIP
ESSO
SHELL
Compression chamber Rustia C 100 Antiruggine MZ 45
Ensis Motor Oil
AGIP
ESSO
SHELL
Warning : Use anti-rust oil with fire point over 200 °C
Warning : Dispose the used anti-rust oil in accordance with local regulations
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4 INSTALLATION
4.1 On-site positioning of blower
The blower has to be set horizontally on a level surface and attached using screws which secure the feet or
the outlet flange ( /F e /SP version).
4.2 Changing the inlet/outlet arrangement
To move from the arrangement with inlet and outlet on a vertical axis to that with inlet and outlet on a
horizontal axis and vice versa exchange the oil levels by changing the position of the plugs in accordance
with Fig. 4 on both blower sumps.
Pos
Description
Ps Left foot
Pd Right foot
Tc Oil fill plug
Ts Oil drain plug
T Plugs
L Oil level plugs
Fig. 4
4.3 Direction of rotation – Gas flow direction
Fig. 5
Warning : Do not use the blower with a direction of rotation or a flow direction different from
that one shown in Fig 5.
Tc
Ts
Pd
L
T
Ts
L
Ps
L
Pd
Ts
Ps
T
L
Ts
Tc
Standard blower
Cooling air inlet
Blower – F.I.
with inverted flow Cooling air inlet
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4.4 Coupling
4.4.1 Direct coupling
Slide the half couplings onto the shaft of the blower and of the motor using suitable tools.
Warning: Do not use a hammer to slide on the half couplings.
Secure the half couplings with security dowels which will push on the keys.
Place the blower at the distance S from the motor as indicated in the table below.
Align the shafts of the blower and of the motor by shims under the feet of the motor and/or blower.
Check the alignment by using comparators or gauges with scales as shown in Fig. 6
Coupling diameter
Distance
S
( mm )
Axial
deviation
Ka
( mm )
Standard deviation
Radial
Kr
( mm )
Angular
Kw
( mm )
80 3 1 0.13 0.13
100 3 1 0.15 0.15
130 3 1 0.18 0.18
150 3 1 0.21 0.21
160 4 2 0.27 0.27
180 4 2 0.30 0.30
200 4 2 0.34 0.34
225 4 2 0.38 0.38
250 5.5 2.5 0.42 0.42
280 5.5 2.5 0.47 0.47
315 5.5 2.5 0.52 0.52
350 5.5 2.5 0.58 0.58
Alignment check
Smax < S + Ka
Smin < S – Ka
rpm
Kv = 1.5 -------------
3000
∆r < Kr x Kv
Dw = Smax – Smin
Dw < Kw x Kr
∆r + Dw < Kw x Kv
Fig. 6
Warning : Alignment errors cause premature wearing of the bearings and flexible couplings.
r
S
S Max
S Min
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4.4.2 Belt drive coupling
Utilize pulleys with minimum diameter equal or major than the value indicated in the table below.
Warning : Do not use a hammer to mount the pulleys.
Use suitable equipment to mount the pulleys onto the blower and motor shafts.
Minimum allowed blower pulley pitch diameter
Size Differential pressure ( mbar )
200 300 400 500 600 700 800 900 1000
45 80 80 80 90 100 106 112 118 125
65 80 80 80 90 100 106 112 118 125
85 100 106 112 118 125 132 140 150 160
105 112 118 125 132 140 150 160 180 200
125 118 125 132 140 150 160 180 200 225
145 125 132 140 150 160 180 200 225 250
Mount the drive belts
Produce belt tension by using the motor thrust screws in accordance with the values shown in the table
Belt
profile Force F
[ daN ]
Diameter D
of smaller
pulley
[ mm ]
Costant E
SPZ
XPZ 2.5 95 – 125> 132 1.45 1.30
SPA
XPA 5.0 100 – 140
150 – 200
> 224
2.30
2.10
2.00
SPB
XPB 7.5 160 – 224
236 – 355
> 375
1.55
1.20
1.10
SPC
XPC 12.5 250 – 355 375 - 560 1.80 1.60
e = I x E / 100 Fig. 7
e = I x E / 100, where I is expressed in mm
Warning : Excessive belt tension could damage the blower and the motor
During this phase check the alignment of the pulley by using a scale as per Fig. 7
Secure the feet of the motor
e
F
I
Dp
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4.5 System piping
The diameters of the system piping must be chosen in order to obtain an average gas speed from 15 a 30
m/s and must never be smaller than the diameters of the blower openings, if
the diameters are different, use a taper connector.
The system piping should be properly aligned and supported to prevent stress
on the blower openings
Connect the cooling ports to atmosphere by means of silenced pipings.
Warning:protect consistently the cooling port from the risk of
cutting and trapping.
Provide flexible joints and support the pipes near the nozzles.
Isolate the pipes to avoid heating the environment as well as a precaution to
accidental contact
The pipes must be thoroughly cleaned before connection, in case of vacuum operation install a dirt filter for
the first 100 working hours and provide a vacuometer to check the dirt filter.
The gaskets must not interfere with the gas system.
Warning : Remove the protective covers from the blower openings just before connection.
Warning: The surface of the delivery pipes can exceed 70 °C.
The recommended accessories are the following
4.5.1 Vacuum operation
This is the standard operation of the blower, the relief valve RVV is optional because the blower can operate
with suction nozzle closed
Pos. Description
SA Inlet silencer
SM Discharge silencer
SJ Injection silencer
RVV Relief valve
WR Check valve
4.5.2 Pressure operation
In this case insert a check valve WRi in the injection pipe in order to prevent the back flow of outlet gas.
The operation in this condition must respect the performance limits of the corresponding blower RBS (see the
S12--- manual)
Pos. Description
F Filter
WR Check valve
RVP Relief valve
SPF Inlet silencer
SM Discharge silencer
SJ Injection silencer
WRJ Injection check valve
4.5.3 Pressure / Vacuum operation
With this kind of blower is not possible the Pressure / Vacuum operation
WR
SA
SM
RVV
SJ
SJ
RVP
SM
SA
F
WR
WRJ
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4.6 Cooling circuit (only for /RV)
Pos Description
Rp Pressure reducer
Vi Shut-off valve
M Pressure gauge
Vr Adjusting valve
Fm Flowmeter
Cooling water flow rate
at 20 °C
Size m3/h
85 0,15
125 0,30
145 0,45
Pressure max 6 bar
Fig. 8
Warning : To avoid the danger of winter freezing use anti-freeze (any type used for car radiators)
4.7 Electric connection
Electric connections must be set up by authorized specialists in compliance with regulations applying to the
place of installation and in accordance with the requirements of the local body supplying electrical energy.
Note: Robuschi refuses all responsibility for electric connection not complying with the law in
force.
Check on the motor plate : Voltage, Absorbed current, Frequency, number of phases.
Check the wiring diagram in the terminal board of the motor, if the diagram has not been supplied request it
from the motor manufacturer.
Use suitable electric cables depending on the nominal current of the electric motor.
Keep the electric cables away from heat sources and/or pointed edges
Protect the motor by means of automatic switch set at the rated current shown on the motor plate
Install an emergency push button between supply line and the motor of the blower
Warning : The operator must easily reach the emergency push-button
For the safety of personnel a suitable grounding device must protect the system
Warning : Blower service must be carried out after disconnecting the electrical supply.
Fm
Vr
Vi RpM
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5 OPERATION
5.1 Preliminary controls
If the blower has been in storage for more than 6 months, check its state of preservation.
Check the alignment of the transmission and eventually the belt tension .
Check that the blower rotate freely by hand.
Check that the safety protection devices have been correctly installed and secured.
Check that the pipes have been internally cleaned and if eventually obstructions have been removed.
Check that all connections between pipes and blower are tightened and sealed.
Fill the blower with oil as described in paragraph 6.1
5.2 First start up
Warning : The personnel must wear the noise protection devices.
Open the shut-off valves on the piping.
Check that the relief valve has been set at the operating value.
Check the rotation direction using a short current pulse.
Warning : Do not rotate the blower in the wrong direction for more than a few revolution.
Open the valve of the cooling circuit (only for /RV)
Start the blower.
Increase the operating pressure gradually until the rated value is reached.
During the first 8 hours of operation check that there are no oil leakage, no cooling liquid leakage (only /RV)
and strange noises or vibrations, if such problems are found stop the blower immediately and contact our PV
service.
5.3 Operation
Start the blower and check what enlisted in the table below.
CHECK PARAMETER FREQUENCY NOTE
h G S M
VISUAL
Pressure 1
Blower in
operation
Temperature 1
Absorbed power 1
Cooling liquid flow 1
Noise 1
LUBRIFICATION
Oil level 500 Blower out of
operation
Oil Leakage 1
Viscosity 500
Oil change 4000 6
FILTER Vacuum 1 < 35 mbar
Clogging 2
TRANSMISSION Wear 2000 Blower out of
operation
Belt tension 2000
Belt change 15000 24
h operation hours G days Note : in case of double indication follow the most limiting one for the
application
S weeks M months
5.4 Stopping the blower
Remove, if possible, the differential pressure.
Note : The blower can also be stopped in the presence of the counter-pressure, but, because
the high current absorption of the motor, problems with the electric circuit may occur.
Stop electric supply and close the cooling water circuit (only for /RV)
Warning : Check that the deceleration of the blower is even and without vibrations.
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6 MAINTENANCE
Stop the blower and auxiliary system as indicated in the paragraph 5.4
Warning : Disconnect the electric supply, lock the general switching open position with the key and
conserve it during service operation
Insulate the blower from the plant and restore the atmospheric pressure into it
Warning : The gas contained in the plant may be hot, toxic and irritant
Warning : Wait until the blower returns at ambient temperature (<40°C)
6.1 Oil change
The first oil change is performed after 500 working hours, further changes as per table in the paragraph 5.3
Change oil in both sides
Fig. 9
Size Oil quantity ( lt ) for /F /SP /V /RV Oil quantity ( lt ) for /H
Gear side Drive side Total Gear side Drive side Total
45 0,75 0,40 1,15 0,45 0,25 0,70
65 1,20 0,60 1,80 0,60 0,30 0,90
85 2,00 0,90 2,90 0,90 0,40 1,30
105 3,50 1,60 5,10 1,60 0,80 2,40
125 4,80 2,80 7,60 3,10 1,80 4,90
145 10,50 6,00 16,50 6,00 3,50 9,50
Warning : Dispose the used oil in accordance with local regulations
6.1.1 Oil type and viscosity
Mineral oil for general use, mineral oil for hydrostatic and hydrodynamic circuits, mineral oil for internal
combustion engines or polialfaolefine base synthetic oil.
Warning : Do not use mineral oil with EP additives or silicon or diester base synthetic oils.
Oil type Viscosity Use
Tambient T2Toil Note
Mineral 100 < 0 < 90 < 50 Check the poor point
Mineral 150 < 35 < 110 < 80
Mineral 220 < 50 < 130 < 110 Installation in soundproof enclosure
Synthetic 220 > 50 > 130 > 110
6.1.2 Recommended mineral oils
Make Type ISO VG - 150 Poor point ISO VG - 220 Poor point
AGIP RADULA 150 -20 220 -18
BP ENERGOL CS 150 -12 CS 220 -12
ESSO NUTO 150 -18 220 -18
MOBIL D.T.E. EXTRAHEAVY -9 BB -7
SHELL TELLUS C 150 -18 C 220 -15
Horizontal
Gear
side Drive
side
Oil fill plug
Oil drain plug
Oil level plugOil level plug
Oil fill plug
Oil drain plug
Oil level with
blower shut down
Vertical
Drive
side
Gear
side
Oil level plugOil level plug
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6.2 Replacing the shaft seal
For the identification of parts see the drawings at pages 37 and 38 .
Disassemble the drive
Empty the lubricating oil out of the sump 12A
Warning : Dispose the used oil in accordance with local regulations
Disassemble the sump 12A
Clean the housing of any residues and/or deposits.
Replace the seal ring pos. 43
Reassemble the sump 12A
Refill the sump 12A with new lubricating oil as per paragraph 6.1.2
Couple the motor as shown in paragraph 4.4.1 o 4.4.2.
6.3 Cleaning of compression chamber
Clean the internal surface of the chamber and the surface of the rotors from any deposits and rust by using
solvents and a scraper
Warning : Keep to prescribed safety rules when using solvents and wear protection glasses
and safety gloves
Note : Do not damage the internal surface of the chamber and the surface of the rotors surface
when using the scraper.
6.4 Check of the gear clearance
For the identification of parts see the sections at pages 37 and 38.
Empty the lubricating oil out of the sump 12B
Warning : Dispose the used oil in accordance with local regulations
Disassemble the gear sump 12B
Measure the clearance between the gear teeth according to the attached table 264468 . In order to do this
secure one of the gears and rotate the other until there is no contact.
Reassemble the sump 12B
Refill the sump 12B with new lubricating oil as shown in paragraph 6.1.2
Send the table 264468 filled out with measured clearances to ROBUSCHI. (or any authorized distributor) for
their review.
6.5 Check of the rotors clearance
Disassemble the inlet piping
Insert gauges into the inlet opening to measure the clearance of the rotors in various positions, turning the
drive shaft by hand according to the attached table 264468.
Warning : During this operation pay attention to rotors, which can cause the squeezing of the
finger and hands.
Reassemble the inlet piping together with the silencer if present
Send the table filled out with measured clearance to ROBUSCHI (or any authorized distributor) for their
review.
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6.6 Spare parts
In the table below are indicated the recommended spare parts for normal use of the blower according the
forecast timing.
For the spare parts of the blower refer to the drawings at pages 37and 38.
Pos. Description Operation
Start-up 2 year 5 year 10 year
11 A - B Gears (couple) - - - 1
16 A - B Lubricating disc (couple) - - - 1
20 Sealing chamber (set) - - - 1
23 A - B - C Oil splash disc (set) - 2 4 8
25 Sealing spacers (set) - 1 2 4
26 Nut (couple) - - 1 2
27 A Nut (RB-DV 115 – 225) - - 1 2
31 - 32 - 33 Bearing (set) - - 1 2
37 Shaft sleeve 1 2 4 8
43 Seal ring 1 2 4 8
45 Flexible piston rings (set) - 1 2 4
50 Gaskets (set) 1 2 4 8
63 - 63 A Compensating ring (set) - 1 2 4
75 - 76 - 77 Oil draining plugs (set) 1 2 4 8
78 Oil level plugs (set) 1 2 4 8
In case of order please quoting always Type, serial number and year of construction of the blower (these
elements are indicated in front page of this manual) and relevant position of spare part indicated in the table
Warning : Do not use non-original spare parts or accessories .
Note : ROBUSCHI will not be liable for any damage, breakdown, and injury deriving from the use
of non-original spare parts or accessories
6.7 Demolition of the blower
In case of demolition of the blower verify the eventual presence of explosive, toxic or dangerous substances
and dispose them in accordance with local regulations.
Warning : Dispose the used oil in accordance with local regulations.
Warning : Dispose the filter element in accordance with local regulations.
Demolish the blower in such a way to make impossible to use again ROBOX as complete unit, or to use
again one or several parts of the blower.
Note : Destroy the nameplate of the blower and any other document
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7 TROUBLESHOOTING
Operating problems List of causes
The motor does not start up and there is no noise 1-3-4
The motor does not start up, but humming noise is heard 2-3-4-5-6-7
Automatic cut off just after start up 3-4-5-6-7
Inlet pressure different from the rated value 13-17
Outlet pressure different from the rated value
WARNING : STOP THE BLOWER IMMEDIATELY 14-17
Outlet temperature different from the rated value
WARNING : STOP THE BLOWER IMMEDIATELY 8-13-14-15-17-18
High absorbed power 3-5-6-7-9-13-14-17-20-23
Oil and/or liquid leakage 10-11-12-16-20
High oil temperature 13-14-15-16-17-18-19-21-22
Unusual noises and/or vibrations
WARNING : STOP THE BLOWER IMMEDIATELY 5-6-7-8-9-13-14-15-18-23
Po
s Cause Solution Rif.
1 At least 2 of electric connections have been
cut off Check the fuses, terminal boards and connection cables and if required replace them. 4.7
2 1 electric connection has been cut off. See point 1. 4.7
3 Incorrect electric connection Check electric system 4.7
4 Faulty motor Check the electric motor 4.7
5 Rotors making contact Stop the blower immediately and check the
internal clearances of the rotors and of the gear 6.4 6.5
6 Scale deposits in the compression chamber Clean the compression chamber and the rotors,
balance the rotors if necessary 6.3
7 Intake of foreign particles Remove the foreign particles, clean the compression chamber and check the
clearances
6.3
6.3
6.4
8 Rotors are worn Check the internal clearances 6.5
9 Bearing are worn Replace the bearings (1)
10 Gaskets are worn Replace the gaskets (1)
11 Drive shaft seal is worn Replace the seal 6.2
12 Oil level plugs are broken Replace the oil levels (1)
13 Inlet piping is clogged Check piping and remove obstruction 4.5.1
14 Outlet piping is clogged Check piping and remove obstruction 4.5.2
15 Injection piping is clogged Check piping and remove obstruction 4.5.1
16 Cooling circuit damaged (only /RV) Restore the circuit 4.6
17
Speed of rotation different from rated value Reset the rated value (2)
18
Inlet temperature different from rated value Reset the rated value (2)
19
Cooling liquid capacity different from rated
value (only /RV) Reset the rated value 4.6
20 Oil level too high Reset correct oil level 6.1
21 Oil too viscous Use less viscous oil 6.1.1
22 Oil produces foam Change the type of oil 6.1.1
23 Transmission not aligned Check the alignment 4.4
(1) To do this operation see service manual
(2) Check the plant
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8 DISASSEMBLY AND REASSEMBLY
Disassembly the blower within the guarantee period results in the cancellation of the guarantee.
Disassembly, repair work and reassembling of the blower must be carried out only by qualified personnel
and with the aid of suitable equipment and relevant manual.
This manual contains only the instructions for preventative maintenance.
For any references to components see the drawings at pages 37 and 38.
Note : Guarantee does not cover damages caused by operations carried out incorrectly during
disassembly and/or reassembling of the blower.
8.1 Disassembly
Warning : Before starting disassembly stop the blower by following the procedure described at
paragraph 6.
Disassemble the drive components (pulleys or coupling) following the manufacturer’s instructions if there are
locking devices or by means of an extractor if attached directly onto the shaft.
Warning : Do not hammer the shaft coupling or pulley.
Empty the cooling circuit (only /RV) and disconnect the relevant piping.
Drain the lubricating oil from the sumps 12A e 12B
Warning : Dispose the used oil in accordance with local regulations
8.1.2 Disassembly of drive side sump
Remove the key 30.
Lock the cover 5A to the casing with at least 4 clamps.
Loose the fixing screws and extract the sump 12A together with seal ring pos. 43
8.1.3 Disassembly of gear side sump
Lock the cover 5B to the casing with at least 4 clamps.
Loose the fixing screws and extract the sump 12B .
8.2 Reassembling
Before reassembling, thoroughly clean all components and lubricate with oil those components, which have
to slide over each other.
8.2.1 Reassembling of drive side sump.
Mount the seal ring 43 onto sump 12A using special equipment in order to avoid damaging the lip of the seal.
Lubricate the lip of the seal and sliding housing on the shaft with grease.
Mount the sump 12A on the cover 5A with a new gasket 50 in between.
Warning : Do not damage the lip of the ring 43.
Secure the sump 12A with the relevant screws
8.2.2 Reassembling of gear side sump
Mount the sump 12B onto cover 5B with a new gasket 50 in between.
Secure the sump 12B with the relevant screws
PD Blower & Vacuum Pump Service & Repair Facility
120 –10293 276 ST, Acheson, Alberta, Canada T7X 6A5
T: 780.962.1827 F: 780.962.1830 E: [email protected]sal