Upgrading from a legacy blower to a regenerative (RC) blower can improve performance, reduce maintenance, and lower operating costs—but only if the replacement is properly matched to your system. Below are the key factors to evaluate when making the switch:
- Operating Pressure and Vacuum Requirements
- Determine system specs: What pressure or vacuum level does your application require?
- Match performance curves: RC blowers operate best in low to moderate pressure/vacuum ranges (typically up to ~7 psi or -14 inHg).
- If your legacy blower was oversized, an RC model may achieve the same results with better efficiency.
- Flow Rate (CFM)
- Compare the actual flow demand of your system (not just nameplate ratings).
- RC blowers often deliver higher flow at lower pressures, so a single-stage model might replace a legacy blower more effectively than expected.
- Use manufacturer-provided performance curves to match flow and pressure points.
- Motor Power and Energy Efficiency
- Check the horsepower/kW of your legacy unit.
- RC blowers typically use TEFC motors and can be paired with VFDs for better control and energy savings.
- Ensure your power supply (voltage/phase) is compatible with the new unit.
- Mounting and Footprint
- Legacy blowers may differ in size, orientation, and mounting dimensions.
- Check blower dimensions and footprint to ensure a proper fit—or plan for minor modifications to brackets or base plates.
- Noise Levels
- Legacy blowers—especially positive displacement or vane types—can be noisy.
- RC blowers generally operate more quietly; consider this an added benefit in noise-sensitive areas like labs or workstations.
- Maintenance and Reliability
- Legacy units may require frequent lubrication, belt replacement, or rebuilds.
- RC blowers have fewer moving parts and no oil or belts, which drastically reduces maintenance.
- Verify expected service life and bearing replacement intervals for the RC model.
- Application Compatibility
- Ensure the RC blower is suitable for the medium you’re handling (clean air, humid air, dust, etc.).
- Some RC models can be used with filters, silencers, or corrosion-resistant coatings depending on the environment.
- Compliance and Certifications
- Confirm that the new blower meets industry-specific certifications (e.g., UL, CE, RoHS).
- This is especially important in pharma, food, or hazardous area installations.
- One-Stage vs. Two-Stage RC
- If your legacy blower delivered higher pressure, you may need a two-stage RC blower.
- For high volume, low pressure, a single-stage will likely suffice.
Pro Tip:
Don’t just match horsepower—match performance.
Focus on system duty points (CFM and pressure) rather than replacing “like-for-like” on nameplate specs.
