BUSCH Fossa FO 0015 A User manual

Instruction Manual
Fossa
Scroll Vacuum Pumps
FO 0015 A, FO 0035 A
0870573863/-0002_en / Original instructions / Modifications reserved 14/06/2018
Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland
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Table of Contents
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Table of Contents
1 Safety........................................................................................................................... 3
2 Product Description ..................................................................................................... 4
2.1 Operating Principle...............................................................................................5
2.2 Application ........................................................................................................... 5
2.3 Standard Features.................................................................................................6
2.3.1 Non-return Valve.......................................................................................6
2.3.2 Inlet Screen................................................................................................6
2.3.3 Operating Hours Counter ..........................................................................6
2.3.4 Variable-Frequency Drive (Single-phase Version Only) ..............................6
2.3.5 I/O and Communication Port (Single-phase Version Only) ........................6
2.4 Optional Accessories............................................................................................. 6
2.4.1 Inlet Filter ..................................................................................................6
2.4.2 Exhaust Filter .............................................................................................6
2.4.3 Gas Ballast Valve........................................................................................6
2.4.4 Purge Gas Adapter.....................................................................................6
2.4.5 Wheels ......................................................................................................6
2.5 Optional Variants .................................................................................................7
2.5.1 ATEX (Optional) ........................................................................................7
2.5.2 Oxygen (Optional) ....................................................................................7
3 Transport ..................................................................................................................... 7
4 Storage......................................................................................................................... 8
5 Installation................................................................................................................... 8
5.1 Installation Conditions ..........................................................................................8
5.2 Connecting Lines / Pipes ......................................................................................9
5.2.1 Suction Connection....................................................................................9
5.2.2 Discharge Connection................................................................................9
5.3 Gas ballast Valve Installation (Optional)................................................................ 10
5.4 Electrical Connection ............................................................................................10
5.4.1 Wiring Diagram Three-Phase Motor ..........................................................11
5.5 I/O and Communication Port Schematic (Single-phase Version Only) ..................12
6 Commissioning............................................................................................................ 13
6.1 Conveying Condensable Vapours .........................................................................14
6.1.1 Gas Ballast Valve Adjustment.....................................................................14
7 Maintenance................................................................................................................ 14
7.1 Maintenance Schedule.......................................................................................... 15
7.2 Tip Seal and Non-return Valve Replacement.........................................................15
8 Overhaul...................................................................................................................... 16
9 Decommissioning ........................................................................................................ 16
9.1 Dismantling and Disposal...................................................................................... 16
10 Spare Parts Kits ............................................................................................................ 17
10.1 Overview ............................................................................................................. 17
10.2 Available Kits........................................................................................................17
11 Accessories .................................................................................................................. 18
12 Troubleshooting........................................................................................................... 19
13 Technical Data ............................................................................................................. 20
14 EU Declaration of Conformity ...................................................................................... 21
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Safety | 1
0870573863_FO0015-0035A_-0002_IM_en 3 / 24
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.
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2 | Product Description
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2 Product Description
NP
OUT, NRV IN, IS EB COMOHC MC, OOS
GBC AF
FH
AF Axial fan COM I/O and communication port (single-phase
version only)
EB Eye bolt FH Fuse holder
GBC Gas ballast valve connection IN Suction connection
IS Inlet screen MC Mains connection
NP Nameplate NRV Non-return valve
OHC Operating hours counter OOS On/off-switch (single-phase version only)
OUT Discharge connection
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
pump’.
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Product Description | 2
0870573863_FO0015-0035A_-0002_IM_en 5 / 24
2.1 Operating Principle
Compression cycle
Position 1
Position 4 Position 3
Position 2Position 5
Gas inlet (IN)
Gas outlet (OUT)
Fixed scroll
Orbiting scroll
Gas process pocket
Scroll vacuum pumps consist of both a fixed and an orbiting scroll. As the orbiting scroll
moves, voids are created at the inlet of the pump, drawing in the gas. As the rotor fur-
ther moves, the gas is steadily compressed until it is discharged to atmosphere at the
pump exhaust.
The compression is made without the use of any lubrication whatsoever.
NOTICE
Lubricating a dry running machine (process chamber).
Risk of damage to the machine!
• Do not lubricate the process chamber of the machine with oil or grease.
2.2 Application
The machine is intended for the suction of air and other dry, toxic, non-aggressive and
non-explosive gases.
Conveying of other media leads to an increased thermal and/or mechanical load on the
machine and is permissible only after a consultation with Busch.
Depending on the optional variant, the machine may be used for ATEX or oxygen applic-
ations, see Optional Variants [►7].
The machine is gas tight when a gas ballast valve is not installed.
The machine is intended for the placement in a non-potentially explosive environment.
The machine is suitable for continuous operation.
The continuous operation of FO 0035 A is limited to a suction pressure of 100 hPa
(mbar) abs..
Permitted environmental conditions, see Technical Data [►20].
The machine is capable of conveying gases which contain a certain percentage of water
vapour if the gas ballast valve (accessory) is installed and open. See chapters Conveying
Condensable Vapours [►14] and Technical Data [►20].
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2 | Product Description
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2.3 Standard Features
2.3.1 Non-return Valve
The non-return valve (NRV), integrated to the discharge connection (OUT), protects the
process against suckback.
2.3.2 Inlet Screen
The inlet screen (IS), integrated to the suction connection (IN), prevents large solid
particles from entering into the machine.
2.3.3 Operating Hours Counter
The opperating hours counter allows the reading of the total operating time that the ma-
chine has run.
2.3.4 Variable-Frequency Drive (Single-phase Version Only)
The machine is equipped in standard with a variable-frequency drive.
2.3.5 I/O and Communication Port (Single-phase Version Only)
The D-Sub9 allows the interface with the instrument or the system for both remote con-
trol and monitoring.
2.4 Optional Accessories
2.4.1 Inlet Filter
The inlet filter protects the machine against dust and other solids in the process gas. The
inlet filter is available with a cartridge.
2.4.2 Exhaust Filter
The exhaust filter reduces the exhaust noise and retains the tip seal dust when the ma-
chine cannot be connected to a house exhaust system.
2.4.3 Gas Ballast Valve
The gas ballast valve mixes the process gas with a limited quantity of ambient air to
counteract the condensation of vapour inside the machine.
2.4.4 Purge Gas Adapter
The purge gas adapter can be fitted in place of the gas ballast valve. It allows you to
connect a controlled supply of inert gas to the pump.
2.4.5 Wheels
Four wheels can easily be fitted to the bottom of the machine to facilitate transportation
and installation.
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Transport | 3
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2.5 Optional Variants
2.5.1 ATEX (Optional)
According to ATEX classification, refer to the nameplate (NP), explosive gases and va-
pour mixtures (zone 2) can be drawn in according to the scope of the Directive ATEX
2014/34/EU.
2.5.2 Oxygen (Optional)
The machine is designed for conveying gases with an increased oxygen content (volume
content greater than 21% and up to 100%) if the following label is stuck on the ma-
chine body:
3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
• Make sure that the eyebolt (EB) is in faultless condition, fully screwed in and tightened
by hand.
Machine weight:
see the technical data or the nameplate (NP)
• Check the machine for transport damage.
If the machine is secured to a base plate:
• Remove the machine from the base plate.
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4 | Storage
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4 Storage
• Seal all apertures with adhesive tape or reuse provided caps.
NOTICE
Long storage time.
Risk of damage to the machine!
• Due to a long storage time the capacitors of the drive can lose efficiency because of
electrochemical processes. In worst case it can leads to a shirt-circuit and therefore to
a damage to the drive of the machine.
• Connect the machine every 18 months for 30 minutes to the mains.
If the machine is to be stored for more than 3 months:
• Wrap the machine in a corrosion inhibiting film.
• Store the machine indoors, dry, dust free and if possible in original packaging
preferably at temperatures between -20 ... 60 °C.
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.
~10 cm
~10 cm
~10 cm
~5 cm
• Make sure that the environment of the machine is not potentially explosive.
• Make sure that the ambient conditions comply with the Technical Data [►20].
• Make sure that the installation space or location is vented such that sufficient cooling
of the machine is provided.
• Make sure that cooling air inlets and outlets are not covered or obstructed and that
the cooling air flow is not affected adversely in any other way.
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Installation | 5
0870573863_FO0015-0035A_-0002_IM_en 9 / 24
• Make sure that enough space remains for maintenance work.
• 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 caps 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 very long connection lines it is advisable to use larger line sizes in order to
avoid a loss of efficiency. Seek advice from your Busch representative.
5.2.1 Suction Connection
WARNING
Unprotected suction connection.
Risk of severe injury!
• Keep long hair, loose articles of clothing, etc. away from suction connection.
NOTICE
Ingress of foreign objects or liquids.
Risk of damage to the machine!
If the inlet gas contains dust or other foreign solid particles:
• Install a suitable filter (5micron or less) upstream from the machine.
Connection size:
– ISO-KF 40
If the machine is used as part of a vacuum system:
• Busch recommends the installation of an isolation valve in order to prevent the
process gases and debris flowing back to the vacuum system.
5.2.2 Discharge Connection
Connection size:
– ISO-KF 16
– Without connection if an exhaust filter is installed.
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5 | Installation
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5.3 Gas ballast Valve Installation (Optional)
1
2
25 mm wrench
Gas ballast valve (GB)
(accessory)
part no.: 0540 559 847
Gas ballast connection (GBC)
5.4 Electrical Connection
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.
• Make sure that the motor of the machine will not be affected by electric or electro-
magnetic disturbance from the mains; if necessary seek advice from Busch.
• Connect the protective earth conductor.
Single-phase version:
• Electrically connect the machine directly to the mains connection (MC).
Connector: EN 60320-C14
On/off-switch (OOS):
O ► OFF = Variable-frequency drive (VFD) not powered
I ► ON = Variable-frequency drive (VFD) powered
Fuse holder (FH): 12.5 A, type F (F12.5)
Three-phase version:
• Provide overload protection according to EN 60204-1 for the motor.
• Electrically connect the machine, see Wiring Diagram Three-Phase Motor
[►11].
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Installation | 5
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5.4.1 Wiring Diagram Three-Phase Motor
Accessing terminals:
Star connection (high voltage):
380-415 V (50 Hz), 380-480 V (60 Hz) ► Factory default setting
W2
V2
U2
U1
W1
V1
L1 L2 L3
PE
F2
F4
F1
H1
F3
H2
F1 ► motor fan wire 1 = White
F2 ► motor fan wire 2 = Brown
F3 ► motor fan wire 3 = Green
F4 ► motor fan wire 4 = Yellow
H1 ► counter wire 1
H2 ► counter wire 2
Delta connection (low voltage):
190-220 V (50 Hz), 200-240 V (60 Hz)
W2
V2
U2
U1 W1 V1
L1 L2 L3
PE
F2
F4
F1
H1
F3
H2
F1 ► motor fan wire 1 = White
F2 ► motor fan wire 2 = Brown
F3 ► motor fan wire 3 = Green
F4 ► motor fan wire 4 = Yellow
H1 ► counter wire 1
H2 ► counter wire 2
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5 | Installation
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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.
• With a phase rotation tester, check if the wiring corresponds to the correct direction of
rotation.
If the rotation of the motor must be changed:
• Switch any two of the motor phase wires.
5.5 I/O and Communication Port Schematic (Single-
phase Version Only)
Connector: D-Sub9, 9-pin, female
5 4 3 2 1
9 8 7 6
Pin Nr. Description Signal
1 24 V Out Power supply (max. 100 mA)
2 0 V / Ground Ground
3 Digital Input 1 Open: Stop
Closed: Start
4 Digital Input 2*
5 Digital Input 3*
6 RS485, D+
7 RS485, D-
8 Fault relay IN
9 Fault relay OUT
*
Preset speed
DI2 / DI3
0 / 0 ►Standard speed
1 / 0 ►Boost speed
0 / 1 ►Idle speed
1 / 1 ►Boost speed
"Logic 0" ►input voltage = 0 … 4 VDC
"Logic 1" ►input voltage = 8 … 30 VDC
For reading status values (current, voltage,
operating hours, etc…) or parameters.
Contact NC (normally closed)
Umax = 100 VDC / Imax = 5 A
Communication port via Modbus (RS485):
Ask your Busch representative for more information.
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Commissioning | 6
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6 Commissioning
WARNING
FO 0035 A operates at 100 hPa (mbar) in continuous operation.
Risk of damage to the machine!
ATEX ► Risk of explosion and injuries!
• Make sure to comply with the maximum continuous suction pressure, see Technical
Data [►20].
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.
NOTE
A small amount of tip seal dust may collect in the exhaust duct of the machine. The dust
may be blown out when the machine is vented.
• Make sure that the installation conditions (see Installation Conditions [►8]) are com-
plied with.
• Switch on the machine.
• Make sure that the maximum permissible number of starts does not exceed 6 starts
per hour.
NOTE
For the single phase version, take into account a delay of 5 seconds between power-up
and the machine start up.
• Make sure that the operating conditions are complied with, see Technical Data
[►20].
As soon as the machine is operated under normal operating conditions:
• Measure the motor current and record it as reference for future maintenance and
troubleshooting work.
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7 | Maintenance
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6.1 Conveying Condensable Vapours
START
Open the gas ballast
valve* (GB)
Warm up the
machine
30 minutes 30 minutes
• Open the inlet valve
• Perform the process
• Close the inlet valve
Close the gas ballast
valve*
END
* may be considered as optional on certain products
6.1.1 Gas Ballast Valve Adjustment
8 mm hex key
Open
Close
NOTE
Risk of back-flow when the gas ballast is open.
7 Maintenance
WARNING
Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:
• Wear appropriate personal protective equipment.
WARNING
Version intended for oxygen application.
Risk of fire!
• Do not perform maintenance task before being informed about oxygen requirements.
• Ask your Busch representative for more information.
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Maintenance | 7
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CAUTION
Hot surface.
Risk of burns!
• Prior to any action requiring touching the machine, let the machine cool down first.
• Shut down the machine and lock against inadvertent start up.
• Vent the connected lines to atmospheric pressure.
If necessary:
• Disconnect all connections.
7.1 Maintenance Schedule
The maintenance intervals depend very much on the individual operating conditions. The
intervals given below are desired to be considered as starting values which should be
shortened or extended as appropriate. Particularly harsh applications or heavy duty oper-
ation, such as high dust loads in the environment or in the process gas, other contamina-
tion or ingress of process material, can make it necessary to shorten the maintenance in-
tervals significantly.
Interval Maintenance work
Every 6 months or as required • Clean the machine from dust and dirt.
• Check the inlet screen (IS), clean if necessary.
• Flush the machine by running it at atmospheric pres-
sure for about 1 minute.
In case of an inlet filter being installed:
• Check the inlet filter cartridge, clean if necessary.
In case of a gas ballast valve being installed:
• Clean the filter of the gas ballast valve.
Annually or as required • Replace the tip seal and the non-return valve (NRV),
see Tip Seal and Non-return Valve Replacement
[►15].
Every 4 years, the latest after
20000 hours
• Have a major overhaul on the machine (contact
Busch).
7.2 Tip Seal and Non-return Valve Replacement
NOTICE
Changing the tip seals without training.
Loss of Busch liability!
Loss of efficiency!
• Ask your Busch representative before performing this maintenance task.
• Order the Busch genuine service kit.
• Follow the service instructions (document ref. 0870 202 845) delivered with the ser-
vice kit (see Spare Parts) before performing this maintenance task.
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8 | Overhaul
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8 Overhaul
NOTICE
Improper assembly.
Risk of premature failure!
Loss of efficiency!
• It is highly recommended that any dismantling of the machine that goes beyond any-
thing that is described in this manual should be done through Busch.
WARNING
Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:
• Wear appropriate personal protective equipment.
In case of the machine having conveyed gas that was contaminated with foreign materi-
als which are dangerous to health:
• Decontaminate the machine as well as possible and state the contamination status
in a ‘Declaration of Contamination’.
Busch will only accept machines that come with a completely filled in and legally binding
signed ‘Declaration of Contamination’.
(Form downloadable from www.buschvacuum.com)
9 Decommissioning
• Shut down the machine and lock against inadvertent start up.
• Vent the connected lines to atmospheric pressure.
• Disconnect all connections.
If the machine is going to be stored:
• See Storage [►8].
9.1 Dismantling and Disposal
• Separate special waste from the machine.
• Dispose of special waste in compliance with applicable regulations.
• Dispose of the machine as scrap metal.
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Spare Parts Kits | 10
0870573863_FO0015-0035A_-0002_IM_en 17 / 24
10 Spare Parts Kits
NOTICE
Use of non-Busch genuine spare parts.
Risk of premature failure!
Loss of efficiency!
• The exclusive use of Busch genuine spare parts and consumables is recommended for
the proper function of the machine and for granting of warranty.
10.1 Overview
Pos. 8
Pos. 8
Pos. 26
Pos. 81
Pos. 83
Pos. 87
Pos. 82
Pos. 86
10.2 Available Kits
Spare parts kit Description Part no.
Service kit
(FO0015 A)
Includes:
1x o-ring (pos. 26)
2x tip seal (pos. 8)
non-return valve parts (pos. 81/82/83/86/87)
0992 205 441
Service kit
(FO0035 A)
Includes:
1x o-ring (pos. 26)
3x tip seal (pos. 8)
non-return valve parts (pos. 81/82/83/86/87)
0992 205 442
Service kit
(FO0035 A for oxy-
gen application)
Includes:
1x o-ring (pos. 26)
3x tip seal (pos. 8)
non-return valve parts (pos. 81/82/83/86/87)
Specifically prepared for oxygen application
0992 205 443
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11 | Accessories
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11 Accessories
Accessory Part No.
Inlet filter 0530 566 434
Exhaust Filter 0562 566 435
Gas ballast adapter 0916 566 457
Gas ballast valve 0540 559 847
Kit of wheels 0999 569 268
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Troubleshooting | 12
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12 Troubleshooting
Problem Possible Cause Remedy
The machine does not start. The motor is not supplied
with the correct voltage.
• Check the power supply.
Internal parts are worn or
damaged
• Repair the machine (con-
tact Busch).
The fuse has blown. • Check the electrical in-
stallation.
• Replace the fuse.
The motor is defective. • Repair the machine (con-
tact Busch).
The machine does not reach
the usual pressure on the
suction connection.
The inlet screen is partially
clogged.
• Clean the inlet screen.
The inlet filter cartridge (op-
tional) is partially clogged.
• Replace the inlet filter
cartridge.
Measurement method or
reading is false.
• Check gauge, check final
pressure without installa-
tion connected.
Leak in the system. • Repair leak.
Worn tip seal. • Replace tip seal, see Tip
Seal and Non-return
Valve Replacement
[►15].
Internal parts are worn or
damaged.
• Repair the machine (con-
tact Busch).
The machine runs very nois-
ily.
The machine runs too hot. • See problem “The ma-
chine runs too hot”.
Internal parts are worn or
damaged.
• Repair the machine (con-
tact Busch).
The machine runs too hot. Insufficient cooling. • Check the ventilation.
Ambient temperature too
high.
• Observe the permitted
ambient temperature.
The machine is contamin-
ated by process residuals.
• Repair the machine (con-
tact Busch).
Discharge pipe obstructed. • Check the discharge line.
The motor is defective. • Repair the machine (con-
tact Busch).
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13 | Technical Data
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13 Technical Data
FO 0015 A FO 0035 A
Nominal pumping speed
Single-phase version: (normal / boost)*
Three-phase version: (50Hz / 60Hz)
m³/h
l/min
cfm
15 / 18
250 / 300
8.8 / 10.6
35 / 42
583 / 700
20.6 / 24.7
Ultimate pressure (gas ballast closed) hPa (mbar) abs.
Torr
0.025
0.018
0.02
0.015
Ultimate pressure (gas ballast open) hPa (mbar) abs.
Torr
0.09
0.067
Max. continuous suction pressure hPa (mbar) abs.
Torr
1000
1125
100
75
Max. allowable gas inlet temperature °C 70
Max. allowable discharge pressure hPa (mbar) rel.
PSIG
500
7.3
200
2.9
Water vapour capacity g/h 300 400
Leak rate (helium) mbar·L·s-1 (sccs) ≤1 x 10-6
Nominal motor rating W
HP
400
0.5
750
1
Operating voltages (single-phase version)* V (50/60 Hz) 100-240, 50/60 Hz
Operating voltages (three-phase version) V (50 Hz)
V (60Hz)
190-220 / 380-415
200-240 / 380-480
Nominal motor speed min-1 1480 / 1780
Noise level (ENISO2151) (idle speed)* dB(A) 42 43
Max. noise level (ENISO2151) dB(A) 59 60
Vibration level at inlet (EN ISO 10816-1) mm s-1 Class 1B, < 1.5 mm/sec
Ambient temperature range °C 5 … 40
Dimensions (L x W x H) mm 450 x 338 x 369 462 x 338 x 369
Weight approx. kg 48 50
* with integrated variable-frequency drive
Certifications
TÜV Süd NRTL mark (cTÜVus) UL 61010-1
CAN/CSA C22.2 No. 61010-1
TÜV Süd CB-certificate and report IEC 61010-1 with all national deviations
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