BUSCH DOLPHIN VL Systems Configuration guide

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DOLPHIN VL Systems
Liquid Ring Vacuum Pumps
VL 0100 A, VL 0130 A, VL 0170 A, VL 0180 A, VL 0220 A, VL 0270 A,
VL 0320 A, VL 0430 A, VL 0510 A, VL 0530 A, VL 0630 A, VL 0750 A, VL 0800 A
Instruction Manual Supplement
0870233816 | -0001_en-US | Original instructions 9/23/2022

Table of Contents
2 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
Table of Contents
1 Safety..................................................................................................................................................................... 3
2 Product Description............................................................................................................................................. 4
2.1 Operating Principle ............................................................................................................................................. 6
2.1.1 Once-Through Operation..................................................................................................................... 6
2.1.2 Partial Recovery (Open Circuit)............................................................................................................ 7
2.1.3 Total Recovery (Closed Circuit)............................................................................................................ 7
2.2 VL System Description ........................................................................................................................................ 8
2.3 Start Controls....................................................................................................................................................... 8
2.4 Control Concept................................................................................................................................................... 8
2.4.1 Once Through Operation..................................................................................................................... 8
2.4.2 Partial Recovery (Open Circuit)............................................................................................................ 9
2.4.3 Total Recovery (Closed Circuit)............................................................................................................ 9
3 Transport .............................................................................................................................................................. 10
4 Storage .................................................................................................................................................................. 11
5 Installation ........................................................................................................................................................... 12
5.1 Installation Conditions........................................................................................................................................ 12
5.2 Connecting Lines / Pipes .................................................................................................................................... 12
5.2.1 Operating Liquid Connection .............................................................................................................. 13
6 Electrical Connection........................................................................................................................................... 16
6.1 Machine delivered without Control Box or Variable Speed Drive (VSD)....................................................... 16
6.2 Machine delivered with a Variable Speed Drive (Option)............................................................................... 17
6.3 Wiring Diagram Three-Phase Motor................................................................................................................. 17
6.4 Electrical Connection of the Monitoring Devices ............................................................................................ 18
6.4.1 Wiring Diagram Solenoid Valve........................................................................................................... 18
6.4.2 Wiring Diagram Resistance Thermometer ........................................................................................ 18
6.4.3 Wiring Diagram Level Switches .......................................................................................................... 18
7 Commissioning..................................................................................................................................................... 19
7.1 Preventing Cavitation ......................................................................................................................................... 19
8 Maintenance......................................................................................................................................................... 21
8.1 Maintenance Schedule ....................................................................................................................................... 22
9 Overhaul................................................................................................................................................................ 23
10 Decommissioning................................................................................................................................................. 24
10.1 Dismantling and Disposal .................................................................................................................................. 24
11 Spare Parts............................................................................................................................................................ 25
12 Troubleshooting................................................................................................................................................... 27
13 Technical Data...................................................................................................................................................... 29
14 EU Declaration of Conformity............................................................................................................................. 34
15 UK Declaration of Conformity ............................................................................................................................ 35

Safety | 1
Instruction Manual Supplement DOLPHIN VL Systems_EN_en 3 | 36
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 methods. Never-
theless, residual risks may remain, as described in the following chapters and in accordance with the
chapter Intended Use. This instruction manual highlights potential hazards where appropriate. Safe-
ty 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 trou-
ble-free operation.

2 | Product Description
4 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
2 Product Description
Once through system
IN
OUT OPV
OPO
ACV
BF OPI
STOPC PRV
CG
SV LRP NRV
Partial recovery system
IN
OUT
OPO
ACV
BF
SV LRP NRV
OPD TSA OPC TI
ST PG OPV
LIIV
OPI

Product Description | 2
Instruction Manual Supplement DOLPHIN VL Systems_EN_en 5 | 36
Total recovery system
IN
OUT TI
LS
ACV
OPO BF
NRV
SV LRP
CLO OPD CLI OPCPHE
ST PG OPV
OPI IV LI
Description
ACV Anti-cavitation valve BF Base frame
CG Compound pressure gauge CLI Cooling liquid inlet
CLO Cooling liquid outlet IN Suction connection
IV Fresh liquid isolation valve LI Level indicator
LRP Liquid ring vacuum pump LS Level switch
OPC Operating liquid control valve OPD Operating liquid drain
OPI Operating liquid inlet OPO Operating liquid outlet / overflow
OPV Operating liquid solenoid isolation valve OUT Discharge connection
PG Pressure gauge PRV Pressure reducing valve
PHE Plate heat exchanger NRV Non return valve (suction)
ST Y-strainer / operating liquid filter SV Separator vessel
TI Temperature indicator TSA Resistance thermometer (PT100)
NOTICE
Drainage of the operating liquid.
●Dispose in compliance with applicable regulations.

2 | Product Description
6 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
NOTE
Illustrations
In this instruction manual the illustrations may differ from the machine appearance.
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘VL System’.
NOTE
Instruction manual supplement.
This document is a supplement to the DOLPHIN LM and LT liquid ring vacuum pump instruction manual
whose content remains valid.
2.1 Operating Principle
2.1.1 Once-Through Operation
12
3
Description
1 Process inlet (IN) 2 Gas discharge (OUT)
3 Operating liquid inlet (OPI)
Continuous flow liquid system does not recover the operating liquid which flows out of the separa-
tor drain having been separated from the discharge gases which vent separately.

Product Description | 2
Instruction Manual Supplement DOLPHIN VL Systems_EN_en 7 | 36
2.1.2 Partial Recovery (Open Circuit)
1
2
4
3
Description
1 Process inlet (IN) 2 Gas discharge (OUT)
3 Operating liquid inlet (OPI) 4 50% of operating liquid liquid recov-
ered
Partial recirculation liquid system reduces the consumption of fresh liquid by recovering and recircu-
lating 50% of the operating liquid. Fresh operation liquid is added to the system via the separator
makeup connection to maintain constant operating liquid temperature to the vacuum pump.
2.1.3 Total Recovery (Closed Circuit)
1
2
3
45
6
Description
1 Process inlet (IN) 2 Gas discharge (OUT)
3 Topping-up operating liquid 4 Cooling water inlet (CWI)
5 Cooling water outlet (CWO) 6 Heat exchange (HE)
Total recirculation liquid system recovers all of the operating liquid which is cooled by a heat ex-
changer.

2 | Product Description
8 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
2.2 VL System Description
The VL system description is written on the system’s nameplate. It is defined as in the following ex-
ample:
VL 0320 A T K O ZE M X
123456789
Description
1 VL = Compact liquid ring vacuum sys-
tem
2 Size of the vacuum pump
3 Design status of vacuum pump 4 M = Single stage (LM) vacuum pump,
T = Two stage (LT) vacuum pump
5 K = Cast iron construction / 316 stain-
less steel,
M = 316 stainless steel throughout
6 O = Once through liquid system,
P = Partial recirculation liquid system,
T = Total recirculation liquid system
(plate heat exchanger),
S = Total recirculation liquid system
(shell and tube exchanger)
7 Motor reference 8 M = Standard seals (Viton),
P = Chemical seals (PTFE/FFKM seals
and elastomers)
9 X = System suitable for non-hazardous
area,
E = ATEX system
2.3 Start Controls
The machine comes without start controls. The control of the machine is to be provided in the
course of installation.
2.4 Control Concept
2.4.1 Once Through Operation
Operating liquid is continuously supplied to the system whilst it is operating via the inlet pipe. The
process gas and operating liquid are discharged from the vacuum pump together into the separator
vessel (SV) where they are separated. The gas leaves through the discharge connection and the op-
erating liquid through the operating liquid outlet connection at the bottom of the separator.
At the operating liquid inlet the Y-strainer (ST) prevents particles greater than 0.1 mm entering the
vacuum pump.
The pressure reducing valve (PRV) reduces the operating liquid supply pressure to 1 bar(g) maxi-
mum. The solenoid valve (OPV) is linked in to the site control (provided by others) to open and close
with the start and stopping of the vacuum pump to prevent flooding the vacuum pump when
stopped.

Product Description | 2
Instruction Manual Supplement DOLPHIN VL Systems_EN_en 9 | 36
Operating liquid control valve (OPC) allows the operating liquid flow rate to be regulated for opti-
mum performance of the system, with compound pressure gauge (CG) indicating the operating liq-
uid pressure at the vacuum pump inlet.
The suction non-return valve (NRV) prevents operating liquid from flowing back into the process
when the system stops under vacuum.
2.4.2 Partial Recovery (Open Circuit)
Approximately 50% of the operating liquid is recirculated within the system whilst additional liquid is
added via the fresh liquid line to maintain the liquid temperature. The process gas and operating liq-
uid are discharged from the vacuum pump together into the separator vessel (SV) where they are
separated. The gas leaves through the discharge connection, whilst the operating liquid level is
maintained as excess liquid drains from the separator overflow connection (OPO). The level indicator
(LI) provides visual indicator of the liquid level in the system.
Through the site control system (by others) the operating liquid temperature is monitored by resis-
tance thermometer (TSA1) opening and closing the solenoid valve (OPV) to allow fresh cooler liquid
into the system. Recommended temperature variation around the set point for switching is 3°C.
At the operating liquid inlet the Y-strainer (ST) prevents particles greater than 0.1 mm entering the
vacuum pump.
The manual fresh liquid isolation valve (IV) allows the system liquid inlet to be isolated whilst the
strainer is cleaned.
Operating liquid control valve (OPC) allows the operating liquid flow rate to be regulated for opti-
mum performance of the system.
Suction non return valve (NRV) prevents operating liquid from flowing back into the process when
the system stops under vacuum.
2.4.3 Total Recovery (Closed Circuit)
All the operating fluid is recirculated within the system allowing liquid other than water to be used
as the operating liquid. Constant liquid temperature in the system is maintained by a heat exchang-
er with a separate cooling liquid supply. The process gas and operating liquid are discharged from
the vacuum pump together into the separator vessel (SV), where they are separated. The gas leaves
through the discharge connection whilst high operating liquid level (condensing suction load) is pre-
vented by excess liquid draining from the separator overflow connection (OPO).
Through the site control system (by others) the operating liquid level is increased by the solenoid
valve (OPV) opening with low level signal from the low level switch. Valve closes on signal from the
high level switch. The level indicator (LI) provide visual indication of the liquid level in the system. At
the operating liquid inlet the strainer (ST) prevents particles greater than 0.1 mm entering the vacu-
um pump.
The manual fresh liquid isolation valve (IV) allows the system liquid inlet to be isolated whilst the Y-
strainer is cleaned.
Operating liquid control valve (OPC) allows the operating liquid flow rate to be regulated for opti-
mum performance of the system.
Suction non return valve (NRV) prevents operating liquid from flowing back into the process when
the system stops under vacuum.

3 | Transport
10 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
3 Transport
WARNING
Suspended load.
Risk of severe injury!
●Do not walk, stand or work under suspended loads.
WARNING
Lifting the VL system incorrectly.
Risk of severe injury!
Risk of damage to the machine!
●Do not lift the entire system by the vacuum pump and the motor.
●Check the machine for transport damage.
●To find out the weight of the machine, refer to the chapter Technical Data [➔29] or the name-
plate (NP).
●Use appropriate slings.
●When disassembling the system lift each component separately.
●Make sure to comply with the suitable lifting method which is described in each instruction manu-
al of the separate machine.
Different lifting variants are possible.

Storage | 4
Instruction Manual Supplement DOLPHIN VL Systems_EN_en 11 | 36
4 Storage
NOTICE
Storage temperature below +5°C.
Risk of damage to the machine!
●Drain the operating liquid from the machine and the system before storage.
●Or add an anti-freeze solution.
After testing, all Busch DOLPHIN vacuum pumps are vented and drained.

5 | Installation
12 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
5 Installation
5.1 Installation Conditions
NOTICE
Use of the machine outside of the permitted installation conditions.
Risk of premature failure!
Loss of efficiency!
●Take care that the installation conditions are fully complied with.
●Make sure that the environment of the machine is not potentially explosive.
If there is Ex(o) sign written on the nameplate:
●Please refer to the ATEX supplement for additional safety information.
●Make sure that the ambient conditions comply with the Technical Data [➔29].
●Make sure that the environmental conditions comply with the protection class of the motor.
●Make sure that the installation space or location is protected from weather and lightning.
●Make sure that the installation space or location is vented such that sufficient cooling of the ma-
chine is provided.
●Make sure that cooling air inlets and outlets of the motor fan are not covered or obstructed and
that the cooling air flow is not affected adversely in any other way.
●Make sure that enough space remains for maintenance work.
●Make sure that the machine is placed or mounted horizontally on a flat surface.
●Make sure that all provided covers, guards, hoods, etc. are mounted.
If the machine is installed at an altitude greater than 1000 meters above sea level:
●Contact your Busch representative, the motor should be derated or the ambient temperature
limited.
5.2 Connecting Lines / Pipes
●Remove all protective covers before installation.
●Make sure that the connection lines cause no stress on the machine‘s connection; if necessary use
flexible joints.
●Make sure that the line size of the connection lines over the entire length is at least as large as
the connections of the machine.
In case of long connection lines it is advisable to use larger line sizes in order to avoid a loss of effi-
ciency. Seek advice from your Busch representative.
NOTICE
Ingress of foreign objects.
Risk of damage to the machine!
If the inlet gas contains foreign solid particles:
●Install a suitable inlet screen (smaller than 0.1 mm mesh size) upstream of the machine.

Installation | 5
Instruction Manual Supplement DOLPHIN VL Systems_EN_en 13 | 36
CAUTION
Restriction of the separator vent.
Will cause back pressure and possible separator failure.
●The separator vent piping should not be restricted as separator vessel is not pressure rated.
NOTICE
Discharge gas flow obstructed.
Risk of damage to the machine!
●Make sure that the discharged gas will flow without obstruction. Do not shut off or throttle the
discharge line or use it as a pressurized air source.
5.2.1 Operating Liquid Connection
DOLPHIN VL 0100-0800 A Once through
IN
OPO
OPI
OUT

5 | Installation
14 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
DOLPHIN VL 0100-0800 A Partial recovery
IN
OPO
OPI
OUT
OPD
DOLPHIN VL 0100-0800 A Total recovery - Plate heat exchanger
IN
OPO OPI
OUT
OPD CLI
CLO

Installation | 5
Instruction Manual Supplement DOLPHIN VL Systems_EN_en 15 | 36
DOLPHIN VL 0100-0800 A Total recovery - Shell and tube heat exchanger
IN
OPI OPD1
OUT
CLO1 OPO
CLI1
Connection size:
Machine type IN OUT OPO OPI OPD CLO CLI OPD1 CLI1 CLO1
VL 0100 - 0270 A G1 ½ R2 R1 ½ G½ G½ G½ G½ G½ G1 G1
VL 0320 - 0530 A G2 R3 R2 G½ G¾ G¾ G¾ G1 G1 G1
VL 0630 – 0800 A G2 ½ R4 R2 G½ G¾ G¾ G¾ G1 G1 G1
●Make sure that the cooling liquid complies with the requirements, see Technical Data [➔29].

6 | Electrical Connection
16 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
6 Electrical Connection
DANGER
Live wires.
Risk of electrical shock.
●Electrical installation work must only be executed by qualified personnel.
CURRENT PROTECTION OF THE CUSTOMER INSTALLATION:
DANGER
Missing current protection.
Risk of electrical shock.
●Current protection according to EN 60204-1 must be insured by the customer on its installation.
●The electrical installation must comply with the applicable national and international standards.
NOTICE
Electromagnetic compatibility.
●Make sure that the motor of the machine will not be affected by electric or electro- magnetic dis-
turbance from the mains, if necessary seek advice from Busch.
●Make sure that the EMC of the machine is compliant with the requirements of your supply net-
work system, if necessary provide further interference suppression (EMC of the machine, see EU
Declaration of Conformity [➔34] or UK Declaration of Conformity [➔35]).
6.1 Machine delivered without Control Box or Variable
Speed Drive (VSD)
DANGER
Live wires.
Risk of electrical shock.
●Electrical installation work must only be executed by qualified personnel.
●Make sure that the power supply for the motor is compatible with the data on the nameplate of
the motor.
●If the machine is equipped with a power connector, install a residual current protective device to
protect persons in case of isolation default.
●Busch recommends installing a type B residual protective device suitable for the electrical in-
stallation.
●Provide a lockable disconnect switch or an emergency stop switch on the power line so that the
machine is completely secured in case of an emergency situation.

Electrical Connection | 6
Instruction Manual Supplement DOLPHIN VL Systems_EN_en 17 | 36
●Provide a lockable disconnect switch on the power line so that the machine is completely secured
during maintenance tasks.
●Provide an overload protection according to EN 60204-1 for the motor.
●Connect the protective earth conductor.
●Electrically connect the motor.
6.2 Machine delivered with a Variable Speed Drive
(Option)
●If the machine is equipped with a power connector, install a residual current protective device to
protect persons in case of isolation default.
●Busch recommends installing a type B residual protective device suitable for the electrical in-
stallation.
●If the variable speed drive is not equipped with a lockable disconnect switch, provide it on the
power line so that the machine is completely secured during maintenance tasks.
●Provide an overload protection according to EN 60204-1.
●Connect the protective earth conductor.
NOTICE
Incorrect connection.
Risk of damage to the variable speed drive!
●The wiring diagrams given below are typical. Check the connection instructions/diagrams.
6.3 Wiring Diagram Three-Phase Motor
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.
NOTICE
Incorrect direction of rotation.
Risk of damage to the vacuum system!
●Operating the vacuum system with the rotation in the wrong direction can result in the operating
liquid flowing back to the vacuum system. Prior to start-up, check for correct direction of rotation.
If the rotation of the motor must be changed:
●Switch any two of the motor phase wires.

6 | Electrical Connection
18 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
6.4 Electrical Connection of the Monitoring Devices
NOTE
The accessories below are considered as standard.
If other specific components should be used, refer to the instruction manual of the accessory
in question.
6.4.1 Wiring Diagram Solenoid Valve
Part no.: VZS/0.50/DW/M/V1
Supplier reference : Model CLO3EB13T
Pilot Diaphragm
Electrical data :
Ui = 24 VDC ; Pi = 5.5 W ; IP 65
Contact: Normally closed
IN OUT
In : IN
Out : OUT
Coil de-energised : IN and OUT close
Coil energized : IN to OUT
6.4.2 Wiring Diagram Resistance Thermometer
Part no.: TS/2745
Supplier reference : H&B Sensors
PRT Probe 3 wire Class B
Electrical data :
4 … 20 mA > -50 … + 250 °C
3 WIRE PT100 CLASS B
TO BS EN 60751
6.4.3 Wiring Diagram Level Switches
Part no.: 0652700908
Supplier reference :
WIKA: BGU-1 PVC
Electrical data :
Maximum switching capacity: 230V; 40VA; 1A / DC
230V; 20W; 0.5A
IP 65, Integral 1m PVC cable provided with each
switch
Blue / grey
brown
black

Commissioning | 7
Instruction Manual Supplement DOLPHIN VL Systems_EN_en 19 | 36
7 Commissioning
CAUTION
During operation the surface of the machine may reach temperatures of more than 70°C.
Risk of burns!
●Avoid contact with the machine during and directly after operation.
NOTICE
The machine is running without operating liquid system.
Will ruin the machine in short time!
●Prior to commissioning, the operating and cooling liquid system must be connected and open.
●Make sure that the installation conditions (see Installation Conditions) are met.
Before operating the machine:
1. Fill with operating liquid by opening the solenoid valve until the level is at the vacuum pump shaft
center – overflow on separator. Ensure operating liquid control valve is open during this process.
2. Check the operation of all automatic valves before start up.
●Switch on the machine.
●Make sure that the maximum permissible number of starts does not exceed the recommendation
from the motor manufacturer.
After a few seconds of operation:
●Turn on/activate the operating (and cooling) liquid system device.
●Make sure that the operating conditions comply with the Technical Data [➔29] or the Operating
Limits.
As soon as the machine is operated under normal operating conditions:
●Measure the motor current and record it as reference for future maintenance and trouble-
shooting work.
7.1 Preventing Cavitation
NOTICE
Cavitation.
Risk of damage to the machine!
If you hear crackling noise:
●Control the pressure.
At very low pressures and sufficiently high temperatures the operating liquid can locally transfer in-
to the vapor phase, creating bubbles within the operating liquid. As the pressure rises towards the
outlet slot the bubbles collapse. This process is called cavitation.
In case of bubbles that have been located on surfaces the operating liquid cannot intrude the cavity
left by the bubble equally from all directions. Instead the inflowing liquid hits the surface with high
speed. This causes erosion, which can destroy the machine rapidly. The formation of bubbles also
deteriorates the pump performance. Cavitation is clearly audible by its crackling noise.

7 | Commissioning
20 | 36 Instruction Manual Supplement DOLPHIN VL Systems_EN_en
The working pressure of the vacuum pump shall therefore be sufficiently above the vapor pressure
of the operating liquid. In particular the pressure control in the vacuum system must by no means
be achieved by throttling or even closing of the suction line!
The vapor pressure of the operating liquid and consequently the ultimate pressure can be reduced
by cooling. However, this increases the cooling water flow considerably. In most cases the low ulti-
mate pressure is not required and cavitation shall be avoided by means of vacuum limitation rather
than cooling.
The machine is fitted with anti-cavitation line and valve (ACV). When cavitation is observed, open the
valve to bleed gas into the vacuum pump to reduce cavitation.