OPERATION/MAINTENANCE

INSTRUCTIONS

REGENERATIVE BLOWER

Series and BigBertha Blower Are registered trade marks of All-StarProducts.TMAll-Star HBTM TM

ISO9001

RoHSCompliantCE

Registered and approved by one or more of these standards agency

Sample Installation Layout

Typical VacuumArrangement

Typical Pressure

Blower

Arrangement

Vacuum

Pressure

InletFilter

Flow Meter Inlet Filter

VentLine

CheckValve

PressureReliefValve Pressure

Gauge

3 pipe diameters+/-1 diameter

3 pipe diameters+/-1 diameter System

Discharge

Min 2pipediameters

Min 5pipeDiameters from

Inlet or flowmeter

Blower

Vacuum

Pressure

IntakeSilencer

InletFilter

3 pipe diameters+/-1 diameter

SystemInlet

5 pipediameters

3 pipe diameters+/-1 diameter

2pipediameters

VacuumGauge VacuumRelief

Valve

FlowMeter

DischargeSilencer

-1-

1. Recommended piping should be one diameter larger than the inlet and outllet diameter until piping has reach the working area.2. Due to the high discharge temperature, metal piping is recommended for the first 5 to 8 feet distance from the blower on pressure applications.3 Elbows increase frictional loss. Keep the number of right angle bends to a minimum.4. Pressure relief valves should be installed in a “T” fitting that is at least one pipe diameter than the exhaust port diameter. For safety reasons, it is highly recommended to set the relief valve below the application pressure level.5. Discharge air temperature increases at pressures greater than 65” H2O. All discharge piping must be marked “DANGER-HOT-DO NOT TOUCH”.6. IMPORTANT: To insure warranty coverage on the blower, a properly sized air filter and relief valve must be installed. If not installed, the blower will not be covered by the All-Star warranty.

Mounting Position of Discharge Silencerson 2-Stage High Pressure Models

Standard 2-stage high pressure blowers are now supplied withthe discharge silencer housing facing towards the rear of theblower as shown in Position B, below.

This new mounting position provides a more compact package.

A separate set of mounting parts are included with each blowerto allow customers to change the direction of the mounting flange to position “A”.

If mounting position “B” is desired, the extra mounting parts can be discarded.

Should you have any questions regarding this conversion, feel free to contact All-Star Products at 800-431-8258.

DISCHARGE POSITION “A”

-2-

DISCHARGE POSITION “B”

1 INTRODUCTION

!

!

! DANGER

CAUTION

1.1 Application

1.2 Suction and compressor pressure

1.3 Environment (Ambient) Temperature

-3-

To insure safe operation of your All-Star blower, please read this instruction manual and pay particular attention to the instructionsmarked with the following signs.

Indicates an imminently hazardoussituation which, if not avoided, willresult in death or serious injury.

Indicates a potentially hazardoussituation, which, if not avoided, couldresult in death or serious injury.

WARNING

Indicates a potentially hazardoussituation, which, if not avoided, mayresult in minor or moderate injury.

The All-Star blower is a complete unit, ready for immediateinstallation as a vacuum pump or as a compressor.It is designed for handling air and other non-flammablenon-corrosive and non-explosive gasses only.

The drive motor can be loaded to the total differential pressuregiven in the Technical Data Table. Blowers with limitedperformance curves in the high pressure ranges should befitted with relative pressure relief valves in order to avoidoverloading of the motor. Pressure relief valve can be mounteddirectly on the outlet and vacuum relief valves can be mounteddirectly on the inlet of the blower.

The blower motor rating is based on an ambient temperature of 40 Deg C (104 Deg F). For operation in higher temperature ambients, refer to All-Star Products.

forma ific1.4 Per nce Spec ations

rP iorelMod

HB-1291-HB-129HB-129-12HB 129A-

HB-22 -19H -229B

HB329-1-HB- 932

HB-439

HB- 297HB-829HB-919

B-929HHB 939-

B 3326H -

HB-4 733H -434B 6

HB-6346HB 6355-HB- 3756

H -6455BHB-6475

HB-8310HB-8 153HB-8320

HB-8410HB 8415-

HP oV ltage Current

umMaximP fo aner rm ce

oundSdb(A)

WtlbsCFM * V S P *

.25

.25

.33

.33

.67

.67

1.11.1

2

3

8.511.5

152030

3.5

56.1

6.18.5

11.5

8.511.5

11.517.5

25

11.517.5

/61 0/115/230/23/60 08-230/460

11/60/1 5/2303/60/208-230/460

1/60/115/23060 03/ /208-230/46

31/60/115/2 0303/60/208-2 /460

3 /4/60/208-230 60

33/60/208-2 0/4603 /4/60/208-230 60

/23/60 08-230/4608-3/60/20 230/460

23/60/208- 30/460

-3/60/208230/460

03/60/208-23 /460/6 63 0/208-230/4 0

83/60/20 -230/4603/60/208-230/460

33/60/208-2 0/460

0 03/6 /208-230/4603/60/2 8-230/460

23/60/208- 30/46003/60/208-23 /460

/6 63 0/208-230/4 0

083/60/2 -230/4603/60/208-230/460

3.4 / 1.7.94 / .86 / .433.6 / 1.8

.2 / 1.11 4 /.67

5.8 / 2.9.12.4 / 2.2 / 1

14 / 7 / 1.94 / 3.7

/ 4.59.7 / 9.0

28.6 / 26.0 / 13.036.3 / 33.0 / 16.547 .4.4 / 42.8 / 2165 / 59.6 / 29.8

/ 88 93 / 44

0.0 / 91 .1 / 4.6

2.9 / 614.3 / 1 .5 / 7.817.2 / 15.5

17.6 / 16.0 / 8.08.6 / 26.0 /13.02

/ 33.0 /36.3 16.5

/ 12.227.9 / 25.3 35 .2.9 / 32.5 / 16

.3 / 32.536 / 16.253 / 48.0 / 24.0

75.0 / 68.5 / 34.3

38

63

105105

105

551

400850850850

105

165165

230230230

340340

410410410

600600

28

32

67

5858

126

11616076

118173

141

167197

153217271

88102

128240317

60106

28

30

58

5959

102

13976

118151

141

165168

153171

118

80108

371183

68104

55555555

61

6464

73

7979

69

7777

797979

7979

8118

81

8181

151551

15

27

3632

58

172182221

724351

73

8995

521159165

159178

247314353

432309

Model No

RB1-025-1RB1-025-3RB1-033-1RB1-033-3

RBH2-067-1RBH2-067-3

RBH3-101-1RBH3-101-3

H -329AB 1.47 0 03/6 /208-230/46 5.2/4.7/2.4 105 67 73 64 34

RBH3-2-2

HB-449-1H -449B

HB-429

2 2

2.5 1/60/230/63 0/208-230/460

/23/60 08-230/460

11.06.6 / 6.0 / 3.0

7.4 / 6.7 / 3.8

155515

155

7272

89

6464

85

377373

464951

RBH4-2-2RBH4-2-3RBH4-205-2

RBH4-3-3

HB-529 .53 03/60/2 8-230/460 11.8 / 10.7 / 5.4 228 89 88 77 73RBH6-305-3B-529-1H 3.5 1/60/230 21.6 228 89 88 77 73RBH6-305-2

HB-6 92HB-639

56.1

03/60/208-23 /46083/60/20 -230/460

12.9 / 614.3 / .517.2 / 15.5 / 7.8

228228

119129

112125

7777

7848

RBH6-5-3HB-629-1 5 /61/60/30 30.0 228 191 112 77 79RBH6-5-2

RBH6-601-3

RBH8-805-3RBH8-1105-3RBH9-15-3RBH9-20-3RBH9-30-3

HB-3319-2 2.5 13.0 105 117 119 69 56RBH33-205-2

RBH33-305-3

RBH43-5-3RBH43-601-3

RBH63-601-3RBH63-8.5-3RBH63-1105-3

RBH64-805-3RBH64-1105-3

RBH83-1105-3RBH83-1705-3RBH83-25-3

RBH84-1105-3RBH84-1705-3

2 STAGE

-4-

RBH4-105-2 HB-419-1 1.5 1/60/230 8.0 155 59 58 73 48 RBH4-105-3 HB-419 1.5 3/60/28-230/460 5.0 / 4.5 / 2.3 155 59 58 73 46

ll ll

RBH23-101-1 HB-2308 1.1 1/60/115/230 14.0 / 7.0 67 100 98 66 53RBH23-101-3 HB-2308 1.1 3/60/208-230/460 4 / 3.6 / 1.8 67 100 98 66 51

N

All blower motors are 2 pole design and operate at approximately 3450 rpm on

60Hz and 2850 rpm on 50Hz. Motors are suitable for operation on 50Hz at

3/50/220/380 volts. Motor rated current can vary from the table below. It is

recommended to use the name plated current values in those cases.

Notations: P=Pressure V=Vacuum in inches of water.

3838

38 28 28

32 30

63 67 58 61 27

HB-319-1 471. 11/60/1 5 17 / 8.5 105 76 73 64 33RBH3-105-1 /230

B 339H - 2 3/60/208-230/460 .1/5.56 /2.8 105 9082 64 43

RBH3-2-3HB-339-1 1/60/230 11.0 90

82 64 43

RBH4-205-3HB-429-1

2.5

1/60/230

15513.0 89 85

73 51

400 120

818181

RBH33-2-2 HB-3315-1 2 1/60/230 11.0

HB-3319 2.5 03/60/2 8-230/460 7.4 / 6.7 / 3.8 105 117 119 69 56RBH33-205-31/60/230

105 100 94 69 62

RBH43-305-2 HB-4326 5 1/60/230 21.6 165 155 155 77 81 3. -- .

261

.3 / 32.536 / 16.253 / 48.0 / 24.0

RBH3-105-3

!

2 OPERATION

2.1 Transport and Storage

2.2 Installation

WARNING On installation or after maintenance, it isrequired to check that the blower rotation iscorrect before returning to service.

WARNING Do not operate the blower with the outletblocked or restricted.

!

-5-

When lifted by crane, All-Star blowers must be secured at theeyebolt on the pump casing

Attention should be paid to the load bearing capacity of thehoisting equipment (refer to Table 1 for unit weight).

All-Star blowers can be installed and mounted in any horizontal orvertical position. Quiet vibration-free running is achieved by insuringthe blower is mounted onto a firm foundation or structure.

Keep intake and discharge ventilation openings clear. The directionof flow is indicated by an arrow marked on the silencer housing.

Solid particles and impurities must be filtered and eliminated from theair or gas from entering the blower by installing a filter on the intake.Open discharge or intake are to be fitted with protective screens.

If the blower is mounted on its cover or close to a wall, a minimum of30mm (1-½”) clearance must be maintained between the housing andthe mounting surface or wall.

Oh the discharge side, the cover, impeller, silencer housing must notcome in contact with flammable materials.

2.3 Electrical Connection

DANGER The electric power must be disconnectedbefore any work is performed on the bloweror associated equipment.

!

CAUTION High surface temperatures of more than70 Deg C (158 Deg F) can occur on theblower's surface. No heat-sensitive partssuch as normal electrical leads or electroniccomponents can make contact with or beattached to the blower. Warning signs andprotective screens must be installed aroundthe blower surfaces to prevent accidentalcontact by individuals.

!

-6-

The flow noise is reduced by the built-in silencers. In the case offree-gas intake or exhaust, the noise can be further reduced byattaching silencers to the blower. In order to reduce the noise emissionsfurther, the blowers should not be attached onto components that radiatesound, such as thin-walled structural steel or metal plates. If necessary,intermediate sound absorbent materials should be included in theinstallation.

The system voltage and frequency must be the same as statedon the blower nameplate. +/-5% voltage and +/- 2% frequencyvariations are permitted without affecting the blower performance.The incoming electrical power should be connectedaccording to the wiring diagram located in this brochure or inthe conduit box. The protective earth connections should beconnected to the terminal.

The rated motor current and operating temperatures are based on a 40 Deg C ambient.

Select motor circuit breakers to match the rated motor fullload and starting currents, which typically are 600-650%higher than full current. Due to the high inertia of the blower’simpeller, starting time can extend to 5-9 seconds. As a result“slow blow” fuses should be considered.

All-Star blower motors are suitable for operation on VFDs asstandard. Shielded power leads are recommended to controlhigh requency currents and voltage harmonics caused by EMF(electro-magnetic interference).

When operating the blower with a VFD, the blower speed shouldnot exceed 4000 rpm. For higher speed operation, contact All-Star.

!

2.4 Commissioning

CAUTION The blower must not be operated with theIntake or outlet closed or blocked.

!

CAUTION If the blower is started without beingbolted to a mounting base, the initialstarting torque of the motor will causethe blower to move suddenly andpossibly topple over.

!

! CAUTION The intake ports must be sited so that noforeign elements are allowed to enter theblower and to be ejected through theexhaust (discharge) port. this is a hazardfor eyes and skin.

CAUTION When air is drawn in from the atmosphere,the intake port must be covered with aprotective screen to prevent foreign matterfrom being sucked into the blower, includingparts of the body and clothing.

-7-

For safe operation, the following conditions, as a minimummust be followed:

1. The blower should be assembled and operated according tothe data on the nameplate.

2. When a VFD is used, the blower motor speed must not exceed4000 rpm, unless the blower has been specifically approved tooperate at a higher speed.

3. The blower must be properly assembled, aligned and connected tothe intake and discharge piping or hose.

4. Installation elevation is taken into account when adjusting the blower’spressure or vacuum relief valves.

5. The direction of the motor rotation is correct.

6. The intake and discharge connections are corrent.

7. All fastenings, bolts and electrical connections are correct.

8. Earth and equi-potential bonding connections are proper.

9. All measures are taken to prevent contact with any movingor energized parts.

3.0 Lubrication

! DANGER

! DANGER

! WARNING After removing the blower cover some parts held withcentering fits and can suddenly separate, fall andpossibly cause injury and damage to the parts. Careneeds to be taken during disassembly to insure all

3.1 Disassembly

Blower models RB8 series and larger and all 2-stage blowers have an

parts are securely held in place.

external grease fitting for the blower end bearing. Other models do not,therefore disassembly is required to lubricate the bearings.

To lubricate the bearings, the rolling contact bearings and adjacentbearing housing should have the spent grease removed and replacedwith resh grease. About 50% of the rolling balls should be filled and notmore than 65% of the adjacent bearing housing should be filled.

Sealed bearings, should be replaced within the above conditions withnew bearings or as conditions warrant.

Lubricating these bearings, the blower needsbe at full operating temperature. REMOVE grease relief located at the6 o’clock position on the blower end cover; add grease through thegrease fitting until new grease begins to discharge from the relief, thenSTOP. Wait for approximately 30 minutes to allow the fresh grease toreach the blower temperature, then install the grease relief plug.

External Grease Fittings:

3.2Shielded and open bearings require lubrication. The frequency of greasing depends upon the application. As a guideline, in normal cleanenvironments with less than a 40 deg C ambient, bearings should berelubricated after approximately 10,000 hours of service or 2.5 years.If service conditions are dusty, dirty or include high operating

Bearing Types

temperatures, bearings should be lubricated more frequently.

Grease Type Mobil Hi-TemperaturePolyrex EP23.3

-8-

The bearings in All-Star blowers are filled with this lubricant, suitable forservice from -30 to + 350 Deg F. Detailed information is available at

http://www.mobil.com/USA-English/Lubes/PDS/NAUSENGRSMOMobil_Polyrex_EP_2.aspx?Print=yes

If possible different manufacturers grease should not be mixed. Checkyour local supplier for a compatible grease.

Before any work is performed on the blower, equipment and especially when removing covers on moving parts, the motor is to be disconnected from electrical power.

Do not connect electrical power supply until the blowerand other equipment are completely re-assembled.

!

WARNING

WARNING

!

TABLE 3.4 Bearing Types,Sizes and Lubricantion

Model

Impeller

Side

BearingType Deg F

MotorFan End

BearingType Deg F

RB1 Series

RBH2 Series

RBH3 Series

RBH4 Series

RBH6 Series

RBH33 Series

RBH43 Series

RBH63 Series

6202zz Shield 285 6201zz Shield 285

6203zz Shield 6202zz Shield 385

6204z Shield 385 6204zz Shield 385

6205zz Shield 385 6204zz Shield 385

6304zz Shield 385 6204zz Shield 385

6205z Shield 385 6204zz Shield 385

6208zShield 385 6209zz Shield 385Open

6206z Shield 385 6207zz Shield 385

6206zz Shield 385 6304zz Shield 385

6206zz Shield 385 6207zz Shield 385

6309zz Shield 385 6208zz Shield 385

6203zz Shield 385 6202zz Shield 385

6207zz Shield 385 6207zz Shield 385

6207zz Shield 385 6209zz Shield 385

Note: Bearing sizes, types and lubricant are subject to change and may be different fromthe bearings in your particular blower model.

-9-

RBH8 Series

RBH9 Series

RBH23 Series

RBH63 Series

RBH83 Series

RBH84 Series

RBH64 Series

MaxMax

On installation or after maintenance, it isrequired to check that the blower rotation iscorrect before returning to service.

Do not operate the blower with the outlet orinlet blocked or restricted.

385

Open

! DANGER

4 MAINTENANCE

! DANGER

! DANGER

4.1 Cleaning

! WARNING

!

-10-

Covers which prevent contact with rotating partsare not to be opened during operation.

Before any work is performaned on theblower, equipment and especially whenremoving covers on moving parts, themotor needs to be disconnected from theelectrical power supply.

Do not connect the electrical power supplyuntil the blower and other equipment havebeen completely re-assembled.

The surface of the blower should be clean and free from dust orother contaminants. Surface dust can be blown off with a lowpressure air hose periodically to prevent a build-up of material.

When required by the operating conditions, dismantle the coverfrom the blower by removing the screws or nuts on the cover. Donot lose the screws or nuts because they are required for re-assembly.Remove and clean the cover. Clean the impeller and the internalportion of the blower with low pressure air after covering the rollingcontact bearing and the bearing grease housing. Be careful not toblower dirt or contaminants into the bearing grease. If dirt does enterthe lubricant, wash out the contaminated bearing grease, clean thebearing and replenish the bearing with fresh grease.

After removing the blower cover screws or nuts,some parts held with centering fits can suddenlyseparate, fall and possibly cause injury and damage other parts. Care needs to be takenduring re-assembly to insure no parts remain inthe blower and are securely held in place.

Covers which prevent contact with rotating parts are not to be opened during operation.

DANGER

4.2 Troubleshooting

Motor does not start,No rotor noise.

Motor does not start,Humming noise

Motor-protectiveCircuit breaker tripsAgain after motor isSwitched on, powerConsumption too high

No vacuum or tooWeak vacuum isproduced.

Compressor is notAir tight.

At least two powerSupply conductorsinterrupted

Interruption in one powerSupply conductor

Impeller jammed

Impeller defective

Bearing defective

Short circuit inThe winding

Motor overloaded

Compressor jammed

Leak in the system

Wrong direction ofrotation

Compressor too small

Sealing disc defective

Problem Cause CorrectiveSteps

Eliminatei nterruption byMeans of fuses,Terminals or lead feeder.

See"Motor does not start,No running noise."

Open cover, remove foreignmatter, clean; if necessary,check impeller gap andadjust if necessary

Replace impeller

Replace bearing

Inspect motor winding

Reduce operating pressure,clean filter, silencer,connecting pipes.

See "Motor does not start,humming noise."

Make system air tight

Change direction ofrotation

Use larger compressorfit new shaft sealconfirm calculationsclean impellerreplace worn impeller.

Inspect sealing disc

-11-

-12-

5.0 SingleStageSampleAssembly

SIN

GLE

STA

GE

MO

DEL

June 2

013

5.1 Two Stage Sample Assembly

-13-

TWO

STA

GE

MO

DEL

Septe

mber

2007

14

Thermal Overload Connection Diagrams

ModelsRB1-025-1RB1-033-1RBH2-067-1

1. The capacitor connection to W1 and V2 is already connected at the factory.2. Remove the metal spade connectors on the two black wires.3. Connect these two black wires as follows: a. Connect one of the black leads to terminal W2. b. Connect the other black leads to the incoming power.4. Brass metal jumpers (connectors) should be attached as shown above, between V1 and U2; U1 and W2 and for high voltage, between V1 and U1.

Low Voltage1/60/115

W1 V1 U1

V2 U2 W2

CAPA

CITO

R

THERM

AL PR

OTEC

TOR

INCOMING POWER

High Voltage1/60/50/230

W1 V1 U1

V2 U2 W2

CAPA

CITO

R

INCOMING POWER

Blue

RB1-025-1RB1-033-1RBH2-067-1

Low Voltage1/60/115

W1 V1 U1

V2 U2 W2

CAPA

CITO

R

THERM

AL PR

OTEC

TOR

INCOMING POWER

High Voltage

1/60/50/230

W1 V1 U1

V2 U2 W2

CAPA

CITO

R

THERM

AL PR

OTEC

TOR

INCOMING POWER

Black

BlackBlack

Black

AUTO RESTART DUAL VOLTAGE MOTORS WIRED WITH THERMAL OVERLOAD IN CIRCUIT

** Note: The thermal protector in these models can be wired for Auto or Pilot Duty.

White

Black

THERM

AL PR

OTEC

TOR

Blue

Black

X

Whi

te

ModelRBH3-101-1

June, 2013

Models High Voltage1/60/50/230

W1 V1 U1

V2 U2 W2

CAPA

CITO

R

THERM

AL PR

OTEC

TOR

INCOMING POWER

Black

BlackRBH3-105-2RBH3-2-2RBH33-2-2RBH4-105-2RBH4-2-2RBH4-205-2RBH43-305-2RBH6-305-2RBH6-5-2

SINGLE VOLTAGE 1/60/50/230 - PILOT DUTY ONLY - zREQUIRES A MOTOR STARTER WITH AN AUXILARY RELAY

Low Voltage1/60/115

W1 V1 U1

V2 U2 W2

CAPA

CITO

R

THERM

AL PR

OTEC

TOR

INCOMING POWER

High Voltage1/60/50/230

W1 V1 U1

V2 U2 W2

CAPA

CITO

R

THERM

AL PR

OTEC

TOR

INCOMING POWER

Black

BlackBlack

Black

Models

PILOT DUTY DUAL VOLTAGE MOTORS - REQUIRES A MOTOR STARTER WITH AN AUXILLARY RELAY

Thermal protectors are supplied loose as standard in all single phase motors. If you choose to wire the thermal protector into your powercircuit, you need to follow the instructions below. Depending on the blower model, the thermal protector can be wired to operate in either an automatic or pilot duty mode only. For use in a pilot duty mode, a starter with an auxiliary relay is required. Two black leads(except for the RB3-101-1 which has three leads) in the conduit box belong to the thermal protector and are referred to below.

Note: As noted below, the RB3-101-1 has three leads to connect the thermal protector.

15

For more detailed information, visit http://www.all-star-usa.com

All-Star Products IncSales Office & National Warehouse

2095 Exeter Rd Ste 80-324 Memphis TN 38138Tel 800-431-8258 Tel 901-755-9613 Fax 901-758-0816

All Star blowers are high quality engineered and manufactured blowers. They

service@all-star-usa.com

Are designed to meet international standards and have received approvals andRecognition from the following agencies.

Warranty

All Star Products warrants all of its products against defects in material andto a maximum of eighteen (18) months from the date of shipment, which ever occursfirst. Purchaser is responsible for providing adequate and approved storage duringthe18 month period. Not withstanding the foregoing, any equipment or componentsof the products not of All StarsProducts own manufacture and/or specified by the

Purchaser, is sold under only such warranty as the maker thereof extends to All StarProducts and All Star Products is able to enforce, but such items are not warrantedby All Star Products in anyway. All Star Products is not responsible for productfailures caused by the purchaser or their custome rmisapplying the product, operatingthe product beyond the published ratings and values, misuse, field alterations andchanges, lack of proper maintenance or improper storage, neglect or accidents arealso excluded from this Limited Warranty. This Limited Warranty is effective, provided

(1)The purchaser immediately notifies All Star Products in writing of the allegeddefect after it becomes known to the purchaser and (2) no alterations, repairs orservices have been performed by the purchaser or third parties on the product,

This Warranty is in lieu of all other expressed or implied warranties, including any warranty of merchantability or fitness for any purpose.

The warranty does not cover misuse or misapplication, abuse, neglect or othercauses of failure beyond the manufacture's control. Do not disassemble or try torepair the blower/pump or any component. Any attempt to repair or correct a problem

by the customer or their agent will void the warranty. A disassembled unit will not be

considered as a warranted failure under any circumstances.

This warranty is voided unless an air filter has been installed and a correctly set pressureor valcuum relief valve has been installed.

ISO9001

RoHSCompliantCE

Registered and approved by one or more of these standards agency