BUSCH R5 RA 1000-1600 B User manual
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Installation and Retrofit Instructions
R5 RA/RC 1000-1600 B
Fuji Variable-Frequency Drive Installation
0870239775/-_en / Original instructions / Modifications reserved 31/08/2021
Table of Contents
2 / 20 Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en
Table of Contents
1 Safety .......................................................................................................................................3
2 Introduction..............................................................................................................................3
3 Retrofit Kit Description.............................................................................................................4
3.1 Scope of Delivery ............................................................................................................. 4
3.1.1 Variable Frequency Drive Retrofit Kit..................................................................... 4
3.1.2 Motor Retrofit Kit.................................................................................................. 5
3.2 Motor Compatibility......................................................................................................... 5
4 Retrofit Kit Transport................................................................................................................6
5 Storage .....................................................................................................................................7
6 Installation................................................................................................................................7
6.1 Installation Conditions...................................................................................................... 7
6.1.1 Installation Location .............................................................................................. 8
6.1.2 Line Protection ......................................................................................................8
6.1.3 Ambient Conditions............................................................................................... 8
6.1.4 Preventing Electromagnetic Interferences .............................................................. 9
6.2 Variable-Frequency Drive Installation ............................................................................... 10
6.2.1 Mechanical Assembly - Main Holders .................................................................... 10
6.2.2 Mechanical Assembly - VFD and Switch Box Subset .............................................. 11
6.2.3 Mechanical Assembly - Thermal Protection............................................................ 11
6.3 Electrical Connection ........................................................................................................ 12
6.3.1 Connect Variable-Frequency Drive to Motor ......................................................... 12
6.3.2 Device Connection ................................................................................................13
6.3.3 Power Supply ........................................................................................................14
6.3.4 Customer Command .............................................................................................15
7 Commissioning.........................................................................................................................17
8 Troubleshooting .......................................................................................................................18
9 Technical Data..........................................................................................................................19
Safety | 1
Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en 3 / 20
1 Safety
Prior to handling the machine, this instruction manual should be read and understood. If
anything needs to be clarified, please contact your Busch representative.
Read this manual carefully before use and keep for future reference.
This instruction manual remains valid as long as the customer does not change anything
on the product.
The machine is intended for industrial use. It must be handled only by technically trained
personnel.
Always wear appropriate personal protective equipment in accordance with the local
regulations.
The machine has been designed and manufactured according to state-of-the-art meth-
ods. Nevertheless, residual risks may remain. This instruction manual highlights potential
hazards where appropriate. Safety notes and warning messages are tagged with one of
the keywords DANGER, WARNING, CAUTION, NOTICE and NOTE as follows:
DANGER
... indicates an imminent dangerous situation that will result in death or serious injuries if
not prevented.
WARNING
... indicates a potentially dangerous situation that could result in death or serious injuries.
CAUTION
... indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
... indicates a potentially dangerous situation that could result in damage to property.
NOTE
... indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.
2 Introduction
NOTE
Retrofit kit instructions.
This document is delivered along with a vacuum pump with variable frequency drive or
with a retrofit kit.
It only contains information about the machine and the retrofit kit installation as well as
additional information about changes in the use of the initial product.
For all information that is not included in this document, please refer to the original in-
struction manual of the corresponding machine which content remains valid.
3 | Retrofit Kit Description
4 / 20 Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en
3 Retrofit Kit Description
3.1 Scope of Delivery
Different retrofit kits are available, depending on the motor type previously fitted on the
machine.
The retrofit kit without motor is only intended for machines having a compatible motor
with the variable-frequency drive included in this kit, see Motor Compatibility [►5].
3.1.1 Variable Frequency Drive Retrofit Kit
Retrofit kits R5 RA/RC 1000-1600 B VFD
Machine VFD Retrofit Kit number
RA/RC 1000 B VFD 0999 240 073
RA/RC 1600 B VFD 0999 240 074
Pos. Part Qty Part no.
RA/RC 1000 B RA/RC 1600 B
1 Electric equipment (variable-
frequency drive + switch box +
holders + thermal protection)
1 0985 238 403 0985 238 405
2 Pressure transmitter 1 0653 233 987
3 Inlet flange 1 0246 241 122
4 O-ring 1 0486 000 679
Retrofit Kit Description | 3
Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en 5 / 20
3.1.2 Motor Retrofit Kit
Retrofit kits R5 RA/RC 1000-1600 B VFD
Machine Motor Retrofit Kit number
RA/RC 1000 B VFD 0999 241 749
RA/RC 1600 B VFD 0999 241 755
Pos. Part Qty Part no.
RA/RC 1000 B RA/RC 1600 B
1 Coupling hub - Bowex M80 1 0512000212 0512000214
2 Coupling sleeve 1 0512000016
3 Set screw 1 0414512873
4 Three-phase motor 1 0633570177 0634570178
5 Hexagon head screw 8 0410000641 0410000657
3.2 Motor Compatibility
NOTICE
Non-compatible motor
Risk of damage to the machine and the variable-frequency drive
• Make sure to use a compatible motor and approved by Busch.
The variable-frequency drive is only compatible with the following motor(s):
Machine Motor type Power / Voltage Size Part no.
RA/RC 1000 B Three-phase
motor
25/30 kW /
200-220/346-380 V
225SM/B5-450 0633 570 177
RA/RC 1600 B Three-phase
motor
34/37 kW /
200-220/346-380 V
225SM/B5-550 0633 570 178
NOTE
Refer to the motor nameplate for specific technical information.
4 | Retrofit Kit Transport
6 / 20 Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en
4 Retrofit Kit Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
• Check the complete kit for transport damage.
WARNING
Sharp edges.
Risk of severe injury!
• Wear protective gloves when manipulating the parts.
Pos. Part no. Qty Weight (kg)
1 0926 233 198 2 13
2 0391 237714 or 0391 238587 1 1.5
3 0391 237 713 1 11
4 Switch box + VFD + elements - 150 (approx.)
Storage | 5
Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en 7 / 20
5 Storage
NOTICE
Long storage time.
Risk of damage to the variable-frequency drive!
Due to a long storage time the capacitors of the variable-frequency drive can lose effi-
ciency because of electrochemical processes. In worst case it can lead to a short circuit
and therefore to a damage to the variable-frequency drive.
• Connect the variable-frequency drive every 2 years for 30 minutes to the mains.
• Store the motor with the variable-frequency drive indoor, dry, dust free and if possible
in the original packaging preferably at temperature between -20 … 60 °C.
6 Installation
DANGER
Live wires. Carry out any work on the variable-frequency drive and motor.
Risk of electrical shock!
• Electrical installation work must only be executed by qualified personnel.
DANGER
The installation conditions are not respected.
Risk of electrical shock!
Risk of severe injury!
• Make sure you fully comply with the installation conditions.
CAUTION
The machine can start immediately when power is supplied.
Risk of inadvertent start-up!
• Make sure that a start-up will not lead to a dangerous situation.
6.1 Installation Conditions
• Make sure that the variable-frequency drive and the switch box are de-energised.
• Make sure that the variable-frequency drive and the switch box are grounded in ac-
cordance with DIN EN 61140; VDE 0140, NEC and other relevant standards.
• Make sure that unused open cable ends in the motor terminal box are insulated.
• Make sure that mains connections are hardwired.
• Make sure to use suitable line circuit breakers with the prescribed nominal current be-
tween the mains and the variable-frequency drive, see chapter Line Protection.
• Make sure that the ambient conditions are complied with, see chapter Ambient Con-
ditions.
6 | Installation
8 / 20 Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en
6.1.1 Installation Location
• Make sure that the electrical elements are located as below on the machine.
6.1.2 Line Protection
• Make sure that the cross-section of the supply line is designed according to the trans-
fer category and the maximum permitted current. The contractor commissioning the
device must ensure protection for the power line.
RA 1000 B RA 1600 B
Nominal motor rating Up to 30kW Up to 37kW
Max current 56A 72A
Circuit breaker (MCCB) C-70A* (ICC 10kA @400V) C-80A* (ICC 10 kA @400V)
* Characteristics C = line circuit breaker tripping between 6 … 10 times In.
6.1.3 Ambient Conditions
• Make sure that the housing type (protection class) is suitable for the operating envi-
ronment.
• All unused cable screw connections must be sealed.
• Check that the cover of the drive controller is closed and bolted down tightly.
• Make sure to comply with the following ambient conditions:
Altitude of the installation
location
If the machine is installed at an altitude greater than 1000
meters above sea level, contact your Bush representative,
the motor should be derated or the ambient temperature
limited.
Ambient temperature Inverter allowable -25 °C to +45 °C.
Relative humidity ≤ 90 % at 30°C, condensation not permitted. Inverter is
IP55 rated.
Resistance to vibration
and shock
400 V class series inverters of 90 kW or below.
3 mm: 2 to less than 9 Hz.
10 m/s2: 9 to less than 200 Hz.
Electromagnetic
compatibility
Immune to interference acc. to DIN EN 61800-3
Installation | 6
Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en 9 / 20
Cooling With integrated fans, with active cooling.
NOTE: Do not cover fan/cooling outlets!
6.1.4 Preventing Electromagnetic Interferences
Where possible use shielded lines for control circuits.
The shielding should be applied to the line end with special care and without laying the
leads across longer stretches without shielding.
Ensure that no parasitic currents (compensating currents etc.) can flow via the analogue
cable's shielding.
Route the control lines as far away as possible from the power lines. Under certain cir-
cumstances, separate power ducts should be used.
If lines do cross, an angle of 90° should be observed.
Upstream circuit elements, such as protector switches and brake coils, or circuit elements
that are operated via the outputs of the drive controller have to be interference-sup-
pressed. RC circuits are suitable as AC voltage protector switches, while free-wheeling
diodes or varistors are usually used as DC voltage protector switches. These interference
suppression devices are attached directly to the protector switch coils.
Power connections between the drive controller and motor should always be shielded or
reinforced, and the shielding must have large-scale grounding at both ends! The use of
EMC cable screw connections is recommended. These are not part of the scope of deliv-
ery.
Wiring suitable for EMC must be ensured.
6 | Installation
10 / 20 Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en
6.2 Variable-Frequency Drive Installation
NOTICE
Sealing not correctly mounted.
Loss of the protection class!
• Make sure during assembly tasks to correctly mount all sealing.
• Replace any worn or damaged seal.
WARNING
Sharp edges.
Risk of severe injury!
• Wear protective gloves when manipulating the parts.
6.2.1 Mechanical Assembly - Main Holders
• Assemble the vertical holders on the machine base frame. Each holder is fixed with 3
screws and nuts (provided).
Installation | 6
Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en 11 / 20
6.2.2 Mechanical Assembly - VFD and Switch Box Subset
• Assemble the variable-frequency drive and the switch box subset on the vertical hold-
ers, using the 6 screws and nuts provided.
NOTE
Make sure you use the tooth washers for grounding contact.
6.2.3 Mechanical Assembly - Thermal Protection
• Assemble the thermal protections on the vertical holders, using the 12 screws provid-
ed.
NOTE
Make sure you use the tooth washers for grounding contact.
6 | Installation
12 / 20 Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en
6.3 Electrical Connection
DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
DANGER
Live wires. Carry out any work on the variable-frequency drive and motor.
Risk of electrical shock!
• Electrical installation work must only be executed by qualified personnel.
6.3.1 Connect Variable-Frequency Drive to Motor
Connect the variable-frequency drive to the motor by using the wiring materials (deliv-
ered in the retrofit kit) as follows.
•Motor connection assignment (motor terminals U, V, W):
• Unscrew the four screws from the motor terminal box and take the cover off.
• Guide the mains connection cable through the EMC cable glands of the motor ter-
minal box (see pos.1 in the illustration below).
• Unscrew the U, V, W pin terminals of the motor and connect the wiring cables, as
per nameplate connection configuration (see pos.3 in the illustration below).
• Make sure that the correct phase colors and/or identifications are properly in place
and that the ground cable (PE) is connected on the PE terminal (see pos. 3 in the
illustration below).
•Motor PTX/Klixon :
• For specific PTC terminals, connect brown wire on TP1 and white wire on TP2
(see pos. 2 in the illustration below).
Installation | 6
Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en 13 / 20
6.3.2 Device Connection
• Connect all sensors, device and ground of the above illustration, according to the ta-
ble below:
Pos. Device Description Cable
1 Holder ground Control box frame grounding T1
2 Drive 1 Command cable W4
3 Drive 2 Communication cable W5
4 Thermoswitch TSA Oil temperature switch W6
5 Level LS Oil level switch W7
6 Thermoswitch TS1 Exhaust temperature security switch 1 W8
7 Thermoswitch TS2 Exhaust temperature security switch 2 W9
8 Pressure PSA Inlet pressure sensor W10
6 | Installation
14 / 20 Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en
6.3.3 Power Supply
• Inside the switch box, guide the mains connection cable through the cable gland.
• Connect the cables to the terminals as follows: connect the power supply directly on
the main switch terminal and the grounding wire on the PE terminal.
Terminal no. Designation Assignment
1 L1 Mains phase 1
3 L2 Mains phase 2
5 L3 Mains phase 3
PE PE Earth connection
Customer power supply:
L1
L2
L3
PE
L1 L2 L3
F0
PE
Power supply
3L+PE 380-440V +/-5%
50/60Hz
Overload protection
RA 1000 B: C-curve - 70A
RA 1600 B: C-curve - 80A
to the electrical cabinet
Must be provided by the customer
The complete wiring diagram is placed
inside the electrical cabinet.
Wire gauge according to EN 60204-1
Cable gland size of the power input:
– M40 x 1.5 (cable Ø ► 24 … 33 mm)
Installation | 6
Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en 15 / 20
6.3.4 Customer Command
• Inside the switch box, guide the control cable through the EMC cable gland.
• Connect the cables to the terminals as follows:
Cable gland size of the power input:
– M16 x 1.5 (cable Ø ► 6 … 10.5 mm) for EMC shielded cable.
Pos. Description
1 Shielded cable
2 Seal
3 Shield connection
4 Shield
6 | Installation
16 / 20 Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en
Terminals Functions
Terminals 1 and 2 Security chain output
Terminal 3 Customer start
Terminal 4 PID function activation
Terminals 6 and 7 Speed preset digital inputs
Terminals 13 and 14 Speed analog input
Terminals 15, 16 and 17 Alarm relay output
Terminals 18, 19 and 20 Com. RS485 Modbus RTU
Terminals PLC 24Vdc from inverter
The complete wiring diagram is placed inside the electrical cabinet.
• It is possible to connect security elements (digital switches) inside the security chain
between terminal nr.1 and terminal nr.2.
• For customer start, connect NO contact between PLC and terminal nr.3.
• To activate PID functions, install a bridge between PLC and terminal nr.4.
• To select speed function:
• If no preset speed input is connected, the analog speed is automatically used.
• Digital speed selection: connect PLC and terminals nr.6 and/or nr.7 according to the
speed selection table below:
DI1 / DI2 Status
0/0 Analog speed
1/0 Minimum speed
0/1 Intermediate speed
1/1 Maximun speed
• Analog speed selection: connect signal 0-10V to terminal nr.13 (signal) and nr.14
(common).
• Alarm output relay. To monitor the alarm status of the machine, connect terminals
nr.15 (common), nr.16 (NC) and/or nr.17 (NO).
• Communication Modbus RS485 Modbus RTU: connect terminals nr.18 (SD), nr.19
(DX-) and nr. 20 (DX+).
Commissioning | 7
Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en 17 / 20
NOTICE
Incorrect direction of rotation.
Risk of damage to the machine!
• Operation in the wrong direction of rotation can destroy the machine in a short time!
Prior to start-up, ensure that the machine is operated in the right direction.
• Determine the intended direction of rotation with the arrow (stuck on or cast).
• Jog the motor briefly.
• Watch the fan wheel of the motor and determine the direction of rotation just before
the fan wheel stops.
If the rotation of the motor must be changed:
• Switch any two of the motor phase wires.
NOTE
To change the motor phase wire, refer to the chapter Variable-Frequency Drive Installa-
tion [►10].
7 Commissioning
NOTE: PC - Ensure you are using the latest software version.
The machine is configured to run in speed control mode at maximum rotational speed,
and to be remotely started/stopped with a digital signal (factory setting):
Machine type Motor frequency
R5 RA/RC 1000 B 60 Hz
R5 RA/RC 1600 B 60 Hz
• Refer to the original instruction manual of the corresponding machine for the com-
plete commissioning procedure.
• Maximum permissible number of starts by using the digital signal: unlimited
As soon as the machine is operated under normal operating conditions:
• Measure the mains current or read it via PC-Software or controller.
For setting of the speed target, operation of the machine in pressure control mode or
start/stop of the machine locally via the built-in keypad, refer to the Pump Control In-
structions no. 0870239468.
NOTICE
Frequent starts and stops by connecting and disconnecting from the power supply.
Risk of damage to the machine!
Starting the machine by connecting and disconnecting the power supply is permitted
max. 2x per minute. Between disconnecting and connecting at least 10 seconds must
have been passed. If the process requires more frequent starts/stops of the machine:
• Use the digital start signal.
NOTE
To change the variable frequency drive settings and adjust the operating parameters of
the machine, refer to the Pump Control Instructions no. 0870239468.
8 | Troubleshooting
18 / 20 Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en
8 Troubleshooting
DANGER
Live wires. Carry out any work on the variable-frequency drive and motor.
Risk of electrical shock!
• Electrical installation work must only be executed by qualified personnel.
NOTICE
Variable-frequency drive maintenance.
Risk of damage to the variable-frequency drive!
• Maintenance and adjustment must only be executed by qualified personnel.
Problem Possible Cause Remedy
The machine does not start. The variable-frequency drive
(VFD) is not supplied with
the correct voltage.
• Check the power supply.
No start signal. • Check the connection.
The motor or the variable
frequency drive (VFD) is de-
fective.
• Check the LED on the
variable-frequency drive
display, if red, it is faulty
(contact Busch or read er-
ror with software).
Technical Data | 9
Installation and Retrofit Instructions R5 RA_RC 1000-1600 B_EN_en 19 / 20
9 Technical Data
Below additional technical data once the variable-frequency drive has been installed on
the motor.
The technical datas of the machine in the original instruction manual remain valid after
the retrofitting.
RA/RC 1000-1600 B with VFD
Allowed frequency range
(inlet pressure 0.3 to 120 mbar) 25 … 60 Hz
Allowed frequency range
(inlet pressure 120 mbar to at-
mospheric pressure)
35 … 60 Hz
Installation altitude 100% load capacity (no derating) up to 1000 m
Supply network TN- and TT-network
(cannot be used with corner grounded networks)
Immunity EN 61800-3, 2nd environment
Emissions EN 61800-3, category C2 as standard
Argentina
Australia
Austria
Bangladesh
Belgium
Brazil
Canada
Chile
China
Colombia
Czech Republic
Denmark
Finland
France
Germany
Hungary
India
Ireland
Israel
Italy
Japan
Korea
Malaysia
Mexico
Netherlands
New Zealand
Norway
Peru
Poland
Portugal
Romania
Russia
Singapore
South Africa
Spain
Sweden
Switzerland
Taiwan
Thailand
Turkey
United Arab Emirates
United Kingdom
USA
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