BUSCH DUPLEX User manual

Operating instructions
DUPLEX / TRIPLEX
Vacuum systems
VRD 2072
VRD
3108
0870S03226/-0000_en / Translation of the original operating instructions / Subject to change without notice 10.02.2021
Dr.-Ing. K. Busch GmbH
Schauinslandstraße 1, 79689 Maulburg
Germany

2
/ 44 0870S03226_VRD 2072-3108_-
0000_IM_en

1 | Contents
0870S03226_VRD 2072-3108_-0000_IM_en
3/
44
1Contents
1.1 Table of contents
1Contents ......................................................................................... 3
1.1 Table of contents .............................................................................................................3
1.2 Register of tables .............................................................................................................5
1.3 Register of illustrations.....................................................................................................5
2Safety.............................................................................................. 6
2.1 Safety devices..................................................................................................................6
2.2 Emergency information....................................................................................................6
3Product description......................................................................... 7
3.1 View vacuum system VRD (TRIPLEX) ..............................................................................7
3.2 View of the rotary vane vacuum pump RD......................................................................8
3.3 Setup ...............................................................................................................................8
3.4 Function principle ............................................................................................................9
3.4.1 Vacuum system VRD .......................................................................................................9
3.4.2 Rotary vane vacuum pump R5 RD...................................................................................9
3.4.3 Gas ballast valve ..............................................................................................................9
3.5 Intended use....................................................................................................................9
4Transport ...................................................................................... 10
5Storage ......................................................................................... 13
6Installation.................................................................................... 14
6.1 Installation .....................................................................................................................14
6.2 Connection lines/pipes ..................................................................................................15
6.2.1 Gas inlet ........................................................................................................................15
6.2.2 Gas outlet ......................................................................................................................16
6.2.3 Cooling water connection (optional)..............................................................................17
6.3 Electrical connection ......................................................................................................18
6.3.1 Connection of the power supply....................................................................................18
7Start-up......................................................................................... 19
7.1 Indication and control elements .....................................................................................19
7.1.1 Topping up with oil........................................................................................................19
7.1.2 Display and control elements at the switching and control cabinet ................................20
7.1.3 Indicators and control elements on the vacuum system .................................................20
7.2 Operation ......................................................................................................................20
7.3 Conveying condensing vapors .......................................................................................21
8Maintenance................................................................................. 22
8.1 Maintenance plan..........................................................................................................22
8.2 Check oil level................................................................................................................23
8.3 Oil and oil filter change .................................................................................................23
8.4 Replacing the exhaust filters ..........................................................................................25
8.5 Cleaning the air heat exchanger ....................................................................................26

1 | Contents
4
/ 44 0870S03226_VRD 2072-3108_-
0000_IM_en
9Troubleshooting ........................................................................... 27
9.1 General faults ................................................................................................................27
9.2 Failure table and measures.............................................................................................28
10 Spare parts and accessories .......................................................... 30
10.1 Spare parts.....................................................................................................................30
10.2 Accessories ....................................................................................................................30
11 Repair ........................................................................................... 31
12 Decommissioning and disposal .................................................... 32
12.1 Stop operating vacuum system ......................................................................................32
12.2 Disassembly and disposal...............................................................................................32
13 Dimensions sheets........................................................................ 33
14 Connection values of the vacuum system VRD ............................ 38
14.1 Connection values .........................................................................................................38
14.2 Signal exchange.............................................................................................................38
15 Technical data............................................................................... 39
16 Oil ................................................................................................ 40
17 EU Declaration of conformity ....................................................... 41

1 | Contents
0870S03226_VRD 2072-3108_-0000_IM_en
5/
44
1.2 Register of tables
Tab. 1: Connections of the vacuum system DUPLEX VRD 2072 ..................................33
Tab. 2:Connections of the vacuum system DUPLEX VRD 2072
(water-cooled version) ........................................................................................34
Tab. 3: Connections of the vacuum system TRIPLEX VRD 3108..................................35
Tab. 4: Connections of the vacuum system DUPLEX VRD (connecting line)................36
Tab. 5: Connections of the vacuum system TRIPLEX VRD (connecting line) ...............37
Tab. 6: Connecting values of the vacuum systems VRD ...............................................38
1.3 Register of illustrations
Fig. 1 : View vacuum system VRD (TRIPLEX) .................................................................7
Fig. 2 : View of the rotary vane vacuum pump type R5 RD 0360 A .................................8
Fig. 3 : Operating principle of the rotary vane vacuum pump R5 RD ...............................9
Fig. 4 : Transport of the vacuum system with a lift truck ................................................11
Fig. 5 : Transport of the vacuum pump on the eye bolts ................................................12
Fig. 6 : Installation environment ......................................................................................14
Fig. 7 : Gas outlet............................................................................................................16
Fig. 8 : Cooling water connection ...................................................................................17
Fig. 9 : Topping up oil .....................................................................................................19
Fig. 10 : Switch and control cabinet .................................................................................20
Fig. 11 : Drain oil ..............................................................................................................23
Fig. 12 : Replacing the oil filter .........................................................................................24
Fig. 13 : Filling in oil..........................................................................................................24
Fig. 14 : Remove the exhaust filter...................................................................................25
Fig. 15 : Insert and tighten the new exhaust filter.............................................................25
Fig. 16 : Cleaning the air heat exchanger ........................................................................26
Fig. 17 : Vacuum pump with components relevant for troubleshooting ...........................27
Fig. 18 : Dimensions of the vacuum system DUPLEX VRD 2072 ...................................33
Fig. 19 : Dimensions of the vacuum system DUPLEX VRD 2072
(water-cooled version) ........................................................................................34
Fig. 20 : Dimensions of the vacuum system TRIPLEX VRD 3108...................................35
Fig. 21 : Dimensions vacuum system DUPLEX VRD (connecting line) ...........................36
Fig. 22 : Dimensions vacuum system TRIPLEX VRD (connecting line) ..........................37

2 | Safety
6
/ 44 0870S03226_VRD 2072-3108_-
0000_IM_en
2Safety
Before commissioning of the vacuum system, read these operating instructions with care.
Please contact your contact person from Busch if there are any questions.
Keep the operating instructions so that you can use them for reference at a later time if
necessary.
These operating instructions remain valid as long as the customer does not make any
changes to the product.
The vacuum system is intended for industrial use. It must only be operated by technically
trained specialists.
Always wear personal protective equipment in accordance with local regulations.
The vacuum system has been designed and produced according to state-of-the-art
methods. Nevertheless, a residual risk remains in operation. Potential dangers are high-
lighted in these operating instructions. Safety and warning notes are marked as follows,
with the words DANGER, WARNING, CAUTION, ATTENTION and NOTE:
DANGER
... Indicates a threatening hazard. Failure to observe safety instructions will result in death
or serious injury.
WARNING
... Indicates a potential hazard. Failure to observe safety instructions may result in death
or serious injury.
CAUTION
... Indicates a potential hazard. Failure to observe safety instructions may result in slight
injury.
ATTENTION!
... Indicates a potential hazard. Failure to observe safety instructions may result in prop-
erty damage.
NOTICE
... Indicates helpful advice and recommendations as well as information for efficient and
smooth operation.
2.1 Safety devices
The motor of the rotary vane vacuum pump is safeguarded by a motor protection switch.
If an overload occurs the vacuum system is shut down.
2.2 Emergency information
In an emergency case, the vacuum system can be switched off with the main switch of
the switch and control cabinet, which has the function of an emergency-stop switch.

3 | Product description
0870S03226_VRD 2072-3108_-0000_IM_en
7/
44
3Product description
3.1 View vacuum system VRD (TRIPLEX)
IN
Gas inlet
RDV
Rotary vane vacuum pump RD
OUT
Gas outlet
CC
Switch and control cabinet
NP
Name plate
Fig. 1 : View vacuum system VRD (TRIPLEX)

3 | Product description
8
/ 44 0870S03226_VRD 2072-3108_-
0000_IM_en
3.2 View of the rotary vane vacuum pump RD
AHE
Air-oil heat exchanger
DA
Rotation direction arrow motor
EB
Eye bolt
EF
Exhaust filter
GB
Gas ballast valve
IN
Suction connection
MTB
Motor terminal box
NP
Name plate
ODP
Oil drain plug
OF
Oil filter
OFP
Oil fill plug
OS
Oil separator
OSG
Oil sight glass
OUT
Gas outlet
Fig. 2 : View of the rotary vane vacuum pump type R5 RD 0360 A
3.3 Setup
The vacuum system DUPLEX / TRIPLEX VRD consists of two or three rotary vane vacu-
um pumps of the type R 5 RD 0360 A. These are arranged horizontally one above the
other in a base frame and connected on the suction side to a collecting line.
The strainer installed in the suction flange prevents the ingression of dirt particles into the
vacuum pump.
The gas ballast valve is used for the addition of a limited quantity of ambient air to the
process gas, to counteract the condensation of vapor in the vacuum pump.
The vacuum system is completely piped and the electrical components are wired on a
switch and control cabinet.

3 | Product description
0870S03226_VRD 2072-3108_-0000_IM_en
9/
44
3.4 Function principle
3.4.1 Vacuum system VRD
The switch and control cabinet is installed on the vacuum system. The rotary vane vacu-
um pumps are activated with soft-starters to avoid excessive mains loads. When
switched on, the first rotary vane vacuum pump starts immediately, the other rotary
vane vacuum pumps are switched on one after the other with a time offset of 10 s.
Gas delivery is effected by the one-stage rotary vane vacuum pumps. Pressure gas is ex-
hausted against the atmosphere.
3.4.2 Rotary vane vacuum pump R5 RD
Fig. 3 : Operating principle of the rotary vane vacuum pump R5 RD
The vacuum pump R5 RD works according to the rotary vane principle.
The oil seals the spaces, lubricates the sliders and discharges the compression heat. The
oil filter cleans the circulating oil.
Then the exhaust filters separate the oil from the discharged gas.
3.4.3 Gas ballast valve
The vacuum pumps are equipped with a gas ballast valve. The gas ballast valve is used
for the addition of a limited quantity of ambient air to the process gas, to counteract the
condensation of vapor in the vacuum pump. The gas ballast valve reduces the final pres-
sure of the vacuum pump, see “Technical data” in chap. 15.
3.5 Intended use
The vacuum system was designed for conveying air and other dry, non-aggressive, non-
toxic and non-explosive gases.
Conveying any other media leads to increased thermal and/or mechanical stress of the
vacuum system and is only permitted in coordination with Busch.
The vacuum system is designed for operation in a non-hazardous area. The vacuum sys-
tem can be operated continuously at final pressure and is suitable for continuous opera-
tion at up to 100 mbar. The permitted ambiance conditions can be found in the technical
data (chap. 15).
The vacuum system is designed for indoor use; for outdoor installation, contact Busch to
make special arrangements if necessary.

4 | Transport
10
/ 44 0870S03226_VRD 2072-3108_-
0000_IM_en
4Transport
WARNING
Danger of severe injury!
Suspended load.
•Never walk, stand or work below suspended loads.
WARNING
Hazard from vacuum system falling or tipping over!
The weight of the vacuum system can kill a person or cause severe crushing.
•The vacuum system can be moved with a forklift or lift truck.
Observe the center of gravity and the lifting points; these are indicated in the scale
drawings, see chap. 13.
ATTENTION!
Damage to the vacuum system!
If the vacuum system is already filled with oil.
•Drain the oil before transport if transport in horizontal orientation is not possible.
The vacuum system is packed in a wooden crate. It protects the system from damage
during transport.
The vacuum system is packed in a wooden structure and can be moved using a forklift.
•Unpack the vacuum system as near to the installation site as possible.
•Check scope of delivery for completeness.
•Check the vacuum system for transport damage.
•Dispose of packing material as required by current regulations.