Eurus Blower
Eurus Blower
Eurus Blower
04/2011
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Table of Contents
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6.2.1. Direct coupled drive with flexible coupling................................................................................ 20
6.2.2. V-belt drive ................................................................................................................................. 20
6.3 SYSTEM SAFETY EQUIPMENT ............................................................................................................ 21
6.3.1. Safety relief valve........................................................................................................................ 21
6.3.2 Check valve.................................................................................................................................. 22
6.3.3 Visual Indicators of Temperature and Pressure ........................................................................... 22
6.3.4 Monitoring Device switches ........................................................................................................ 22
6.3.5 Noise reduction............................................................................................................................ 23
7. OPERATING A ROTARY BLOWER....................................................................................................................... 24
7.1 PRIOR TO STARTING UNIT FOR FIRST TIME ...................................................................................... 24
7.2 STARTING AND STOPPING THE ROTARY BLOWER ............................................................................. 25
7.3 TROUBLESHOOTING ........................................................................................................................... 25
7.3.1 Trouble Shooting Guide ............................................................................................................... 26
8. MAINTENANCE........................................................................................................................................................ 27
8.1 RULES FOR MAINTENANCE................................................................................................................. 27
8.2 REGULAR MAINTENANCE SCHEDULE ............................................................................................... 27
8.3 OIL LEVEL CHECK .............................................................................................................................. 28
8.3.1 Oil Sight Glasses ......................................................................................................................... 28
8.4 CHANGING THE OIL ........................................................................................................................... 29
9. SPARE PARTS AND AFTER SALES SERVICE ................................................................................................. 30
9.1 GENERAL EXPLODED PARTS DIAGRAM ............................................................................................. 30
Model: ZG-50 Parts List....................................................................................................................... 31
Model: ZG-65 Parts List....................................................................................................................... 32
Model: ZG-80 Parts List....................................................................................................................... 33
Model: ZG-100 Parts List..................................................................................................................... 34
Model: ZG-125 Parts List..................................................................................................................... 35
Model: ZG-150 Parts List..................................................................................................................... 36
Model: ZG-200 Parts List..................................................................................................................... 37
Model: ZG-250 Parts List..................................................................................................................... 38
9.2 GENERAL ITEMIZED DRAWING OF CONFIGURATION ........................................................................ 39
10. MAINTENANCE SCHEDULE SHEET................................................................................................................. 42
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1. Technical Specifications
1.1 Rotary Blower Specifications
Operating Limits
Max RPM 5,000 4,000 3,000 2,050
Max Case Pressure, 25 (psig)
Max Radial Shaft Load 600 (lbf) 850 (lbf) 1,250 (lbf) 1,770 (lbf)
4,5
Max ∆p Blower 15 (psi) 10 (psi)
4,5
Max ∆p Vacuum 15 (inHg)
4
Max Pressure Ratio 2:1 1.67:1
Max Discharge Temp. 335° F
Max Inlet Temp. 120° F
Connection
Inlet Port (ANSI)
NPT 2” NPT 2.5” NPT 4” NPT 5” 5” Flange 6” Flange 8”Flange 10” Flange
Discharge Port (ANSI)
Weight (lb)
101 123 254 298 661 796 1,620 1,907
Notes: 1. The user can select the configuration according to their installation requirements. Standard ZG-200 and
ZG-250 are vertical flow only, for horizontal flow application please contact Eurus Blower’s Engineering
Department first.
2. The effective volume flow is dependent on the speed and the differential pressure.
3. The power consumption is dependent upon the operating point required, e.g. volume-flow and
differential pressure.
4. The ratings based on inlet air at standard pressure of 14.7 psia, standard temperature of 68 degrees F, and
specific gravity of 1.0.
5. ∆p = discharge pressure – inlet pressure
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1.2 Ambient Temperature Limitations
Minimum ambient temperature *……… ............................................................5 °F Maximum
ambient temperature *………………………………………. ............................120 °F
* These temperature limits are based on lubricants specified within this manual. Consult Eurus
Blower for recommendations if operating environment temperatures exceed these limits (see
lubricant recommendations, section 1.4).
Use the recommended grade and viscosity of industrial type, non-detergent, rust inhibiting,
anti-foaming oil (Reference Figure 1 below). The correct oil depends on the range of ambient
temperatures as well as the range of discharge temperatures.
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RECOMMENDED VISCOSITY
Figure 1
Synthetic lubricants are highly recommended over mineral lubricants: synthetics last up to 4
times longer; and a single viscosity can cover a broader temperature range.
1.5 Nameplate
The nameplate of the rotary blower is located on the endplate of the unit.
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1.6 Dimensional Drawings
Documents can be provided by Eurus Blower Customer Service Department
2. Safety Instructions
Read this service manual carefully and abide by all warnings and precautions before installing the
rotary blower and/or before performing any maintenance.
Symbol Meaning
This symbol indicates information that can cause injury or
death. It is critical that these rules are observed and that
extreme care is taken in these cases. For their own protection,
inform all other users of these safety rules. Observe general
safety and accident prevention rules as well as the safety
procedures in this manual.
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This symbol indicates considerable attention must be paid to
recommendations, regulations, references and correct
sequencing so that damage and/or destruction of the rotary
blower and/or other equipment is prevented.
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No open flame or flying sparks should be in the vicinity of unit.
If any welding or grinding work is needed near the rotary blower, ensure that
sparks or high temperatures cannot cause fire or explosion.
Do not stay for long periods in the direct vicinity of operating rotary blowers with
hazardous or dangerous noise levels.
Because of the high temperatures generated (up to 335°F), do not touch pipes or
ancillaries during operation of the rotary blower. Wait until the blower has
cooled down and pressure is vented before performing any repairs.
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3. Arrival and Use of the Rotary Blower
3.1 Arrival Inspection
Before accepting the shipment, perform the following inspections:
Review the packing slip and verify that all components and
accessories are included and undamaged. Uncrate, or remove
packaging from, all items and inspect them thoroughly. Report any
damage or missing items described on the packing slip with the
carrier.
The rotary blower unit is intended solely for the transport of oil-free air or any inert gas
without any liquids or solids; and in conformity with the technical specifications.
Any other use is considered improper and will void the warranty and may cause injury or death. The
manufacturer cannot accept liability for any damage caused by improper use. The user is solely
liable for any risks incurred.
Correct use also means compliance with the installation, removal, commissioning, operational and
maintenance instructions written in this manual.
This service manual is intended for operating, maintenance and supervisory personnel use only.
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4. Moving and Handling
4.1 Handling Instructions
To avoid damage to the rotary blower, it is recommended to use a forklift truck, pallet jack,
hoist, crane, chain, cable or a sling with certified capacities according to safety (see chapter 2).
Abide by all safety and regulatory procedures when handling rotary blowers.
Do not lift rotary blower unit directly with the forks of a forklift or
pallet jack: this can cause injury to operator and damage to the
unit.
When lifting the rotary blower with a crane hook and slings, use the two eyebolts provided.
Screw these eyebolts into the threaded holes in the upper mounting to distribute the load evenly.
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4.4 Storage
Internal:
Mobil Mobilarma 523 or 524
Shell Rimula 30 or Rotella T 20W20
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5. Operational Characteristics and Construction
5.1 Operational Characteristics
To develop pressure and move air, two tri-lobe rotors, synchronized by a pair of timing gears,
rotate in opposite directions in two cylindrical bores within the housing.
A defined quantity of air entering the inlet port is trapped between the rotor and the housing and
is carried over to the discharge port against the pressure from the application. The pressure
developed depends upon the resistance of the system as well as the inlet and discharge pressures.
Each trapped volume occurs three times every revolution for each rotor, commonly referred to as
the volume flow per revolution. Multiplying this by the shaft speed will define the flow rate
entering the inlet port. Changing the rotational speed directly affects the volume flow.
Simultaneously, the synchronized rotors and housing serve to prevent back flow by the close
proximity of the rotors to one another and the proximity of the rotors to the housing.
Because there is no contact between the rotors and the case, there is no wear and no lubrication is
required. Oil is, however, required to lubricate the bearings and gears. The lack of contact means
that some leakage occurs and the rate is directly related to the pressure differential between ports.
As the pressure differential increases, the leakage rate increases.
Furthermore, as the leakage rate increases the adiabatic efficiency decreases, increasing the
discharge temperature and power requirement.
The net flow rate and efficiency is then dependent upon the shaft speed, volume flow per
revolution, and leakage rate at the operational pressure point.
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5.2 Construction
As described in operating characteristics 5.1, each blower is constructed for a specific volume
flow rate per revolution and is defined by design and rotor length. The ZG Series offers (8) eight
models to choose from. Each model offers a variety of flow rates by changing the rotational speed.
(See technical specifications 1.1)
To maximize efficiency, materials and clearances are chosen to maintain minimal clearance with
reliable operation up to a limiting differential pressure. Exceeding this pressure can cause thermal
overload. Each model, within the ZG series, is capable of a different differential pressure (see
technical specifications 1.1).
Thermal overload is a point at which the blower cannot dissipate enough heat (thermal energy) to
maintain design clearances due to thermal expansion and deformation.
The drive shaft, located on only one rotor, can be driven in one direction and is suitable for direct
or belt driven. Directly coupling the motor to the driveshaft allows for maximum power
transmission.
The integrated feet on all sides of the housing allow for a universal installation: in both vertical
and horizontal configurations, the blower can be mounted from any side, top or bottom.
Eurus’ standard rotary blowers can be used in both horizontal and vertical flow configurations
(Note:Standard ZG-200 and ZG-250 are vertical flow only, for horizontal flow application
please contact Eurus Blower’s Engineering Department first.).
The drive shaft is located at the upper rotor (Direction of Rotation: CW)
. • See the following diagram for the positions of the oil level sight glasses and oil fill
plugs.
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. • See chapter 1.3 for oil capacities.
The drive shaft is located on the right (CW rotation) or optionally located on left of center
(CCW Rotation)
See the following diagram for the positions of the oil level sight glasses and oil fill plugs.
See section 1.3 for oil capacities.
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6. Installation and Design Requirements
6.1 Installation Requirements
Tapped holes are provided on all sides of case for mounting purposes
Leave the flanged ports blanked off until the piping can be installed on the inlet and outlet flanges
to prevent foreign particles and/or contamination from entering the blower.
Be sure to support the weight of the pipe work, inlet and discharge silencers, and any other
connected components that are attached to the rotary blower: do not rely on the connections with
rotary blower unit to support the weight of these various components.
To isolate vibrations, only flexible pipe connections can be used when connecting the rotary blower
to the rest of the system.
Remove the port covers before connecting piping or accessories to the rotary blower.
Check the drive shaft for ease of rotation by hand after installation.
During installation of the rotary blower, checks that the oil level sight glass and the oil fill plugs are
correctly located according to the intended configuration - change them if necessary (see
Construction chapter 6.3, 6.4).
Observe temperature ratings for all system components connected to the rotary blower - especially
the discharge flex union and the discharge silencer.
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6.1.1 Typical Blower (Positive Pressure) System Diagram
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6.1.2 Typical Vacuum / Exhaust (Negative Pressure) System Diagram
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6.2 Drive Motor
The rotary blower can be driven by all standard drive sources available on the market.
The rated power of the drive source should be greater than power requirements of blower.
Consult industry standard information for their service factor recommendations. Typical minimum
service factors are:
The speed of the drive source must be selected or controlled such that the maximum permissible
rotor speed cannot be exceeded (see chapter 1.1).
Be fitted to the two shafts with line to line up to 0.001” interference (heating of hubs to
facilitate assembly is common practice).
Some axial loading of the drive shaft is permitted, but should be avoided. Static axial loads
during assembly can be fully supported without damage. Dynamic (in operation) axial loading will,
in some cases, decrease bearing life. If a known dynamic axial load (over 50 Lbs.) is transmitted by
the drive source, consult Eurus Blower’s Engineering Department.
Always use the threaded holes at the end of the shafts for alignment when using a gear puller to
remove any accessories or components on the shaft.
All drive system components should have a guard that protects people in the vicinity of the unit
from the exposed rotating components. Be sure that the guard is selected and installed with regard
to all safety regulations, including OSHA CFR 29, 1910. (See chapter 2).
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6.2.1. Direct coupled drive with flexible coupling
To directly couple the motor to the input shaft with a flexible coupling:
The drive and driven shafts must be accurately aligned and have a sufficient gap to
minimize axial and radial forces;
Maximum deviation in offset between drive and driven shaft centerline should not exceed
0.005” TIR (Total Indicated Runout) referenced from both hubs; and
Maximum deviation from parallel off centerline or hub faces should not exceed 0.001”
when checked at a minimum of four points around center.
When using V-belts to connect the motor and rotary blower, consider the following:
Misalignment of the V-belt drive should not exceed ±0.5° in both parallel and
perpendicular planes.
Use the largest sheave diameters permitted by speed rating to maximize power transfer
through the V-belt (This is opposite to economically driven belt drive selection, resulting
in small-underrated drives).
Use belt lengths that keep the center distance between shafts more than 24” and less than
48”.
Larger center distances are used and favor longer belt life; however, the tendency for
V-belts to vibrate at resonate frequencies should be reviewed.
Shorter distances mean less misalignment forgiveness, shorter V-belt life, and low speed
ratio selection (compact V-belt drives are common, but should be used on low power, low
ratio, drive system with higher service factor rating, above 1.5).
Check the tension of the V-belts and adjust, if necessary, when installing the unit.
Manual tension adjustment systems need the V-belts checked for tension 30 minutes and
24 hours after every adjustment. Tension should not drift below values recommended by
the belt manufacturer.
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Use of small V-belt cross section for high belt speeds is recommended.
A relief valve(s), pressure or vacuum, is necessary to prevent the rotary blower from operating
above maximum pressure differential.
A vacuum relief valve should be located before the inlet port if there is any possibility of a
blockage in flow to exist which would exceed the maximum pressure differential -especially
blowers operating with negative inlet pressure.
A pressure relief valve should be located after the discharge port if any possibility of increased
resistance exists to exceed maximum pressure differential - especial blowers operating with positive
discharge pressures.
Be sure that pressure relief valves are rated for temperatures above the discharge temperatures
expected during operation.
Set Point
The set point on the relief valve must correspond to the designed operating pressures and the
range of conditions under which the unit will operate.
The required relief valve flow rate should be equivalent to the maximum flow delivered by the
rotary blower under those inlet and discharge conditions.
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6.3.2 Check valve
A check valve is necessary to prevent a reversal of flow whenever the rotary blower starts and stops.
Be located after the discharge port for positive pressure (at the inlet port for vacuum); and
Limits should be displayed on visual indicators for quick assessment of the operating condition.
For safest operation, the operating parameters (temperature and differential pressure) of the unit
should be continuously monitored to be sure that they are within the limits set by the
manufacturer.
Because it may take a gauge some time to respond to a change in temperature, sensitive
applications should directly monitor the pressure differential.
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When a parameter falls out of its limits, corrective action should be quickly initiated to reduce
the air resistance or reduce the rotational speed of the rotary blower.
For best results, the measuring devices should trigger the motor controls to immediately
shutdown the motor.
Most designs incorporate some means of noise reduction. Here are a few points on reducing
noise:
Choose chamber type silencers if rotary blower speed is below 2,250 rpm.
Choose absorption/chamber combination silencer when operating rotary blower above 2,250
rpm.
Use large silencer volumes in excess of 15 times volume flow per revolution to minimize
pulsations.
Discharge silencers must be rated for temperatures above expected discharge temperatures
during operation.
Sound enclosures are required to achieve lower noise levels, contact Eurus Blower for
further information
Sound enclosures must have adequately ventilated to maintain normal ambient operating
temperatures.
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7. Operating a Rotary Blower
7.1 Prior to Starting Unit for First Time
Every rotary blower undergoes a mechanical run test at maximum pressure prior to leaving the
factory. During the test, key indicators, such as vibration and temperature, are monitored for
unit quality ensuring conformity to specifications.
It is expected that the user employs safe working practices, and that all lawful operating and
safety regulations are followed when operating this rotary blower.
Do not operate this rotary blower in spaces where heavy dust conditions, poisonous or
corrosive gasses could exist.
The installation and operating procedures for all ancillary equipment must be observed.
When starting the unit for the first time, do the following:
Check the oil level and top up if necessary (see chapter 8.3)
Take time to learn the operational characteristics and unit controls before full duty
service.
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7.2 Starting and Stopping the Rotary Blower
The rotary blower itself can be stopped and started repeatedly; however, most drive systems
should not be subjected to repeated starts and stops. Doing this without increased service
factors for all components may decrease the service life of these components.
After stopping the rotary blower, always wait for full stop before restarting.
Avoid current inrush to drive source: use starters that allow gradual speed control.
Start rotary blower under low load condition if possible.
If possible allow the rotary blower to operate at reduced load for 5-10 minutes prior to
shutdown to reduce the blower temperature.
7.3 Troubleshooting
If there is a problem with the operation of the unit, consult the following table.
Be sure to note the actions and events that occurred prior to the problem.
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7.3.1 Trouble Shooting Guide
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8. Maintenance
8.1 Rules for maintenance
Observe the following rules during all maintenance and service work:
Only specially trained personnel should perform work on power driven
equipment;
Stop the blower;
Lock out and tag out the main disconnect switch to prevent restarting;
Isolate and de-pressurize the blower and attached piping to zero psig.
Ensure that all oil, solvents and used parts are disposed of
according to federal and local environmental regulations.
The maintenance period can vary depending on the service and environmental conditions.
The oil should be changed at least once a year, even if the blower is not operated.
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Record maintenance work done (see section 10)
Stop the rotary blower before checking the oil level. Use the sight glasses to determine the oil level
as instructed below.
Check oil level on both sides of each end as the rotary blower can be off level. An oil level 1/4"
below the center line is in DANGER of failure; an oil level 1/8” below the centerline indicated
the oil level is low.
Note: Oil level should be between the center line and 1/8”above center line; if the oil level is more
than ¼” above the centerline, there is a risk of oil leakage.
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2. Check the lubrication oil level at all oil level sight glasses.
To initially fill the lubricating oil:
1. Stop the rotary blower (see chapter 8.1) and lock-out the power source to prevent a restart;
2. Unscrew the fill plug on top of the unit;
3. Pour the indicated amount of oil into the port and look at the new oil level in the sight
glasses;
4. Fill with lubricating oil to the correct height;
5. Fill both ends (drive and gear side);
6. Screw the oil fill plug marked red back in again;
7. Check for leaks.
8.4 Changing the Oil
Stop the rotary blower (see chapter 8.1 and lock out the power to prevent a restart.)
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9. Spare Parts and After Sales Service
9.1 General Exploded parts Diagram
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Model: ZG-50 Parts List
All Configurations
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Model: ZG-65 Parts List
All Configurations
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Model: ZG-80 Parts List
All Configurations
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Model: ZG-100 Parts List
All Configurations
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Model: ZG-125 Parts List
All Configurations
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Model: ZG-150 Parts List
All Configurations
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Model: ZG-200 Parts List
All Configurations
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Model: ZG-250 Parts List
All Configurations
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9.2 General Itemized Drawing of Configuration
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ZG-80 All Configurations
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ZG-200 All Configurations
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10. Maintenance Schedule Sheet
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