BUSCH Mink MV 0040 C User manual

Instruction Manual
Mink
Claw Vacuum Pumps
MV 0040 C, MV 0060 C, MV 0080 C
0870166200/A0004_en / Original instructions / Modifications reserved 19/06/2018
Busch Produktions GmbH
Schauinslandstraße 1, 79689 Maulburg
Germany
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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............................................................................................... 4
2.2 Application ........................................................................................................... 5
2.3 Optional Accessories............................................................................................. 5
2.3.1 Inlet Filter ..................................................................................................5
2.3.2 Pressure Transmitter ..................................................................................5
2.3.3 PC-Software ..............................................................................................5
2.3.4 Manual Control Unit..................................................................................5
2.3.5 Fieldbus Option Board ...............................................................................5
3 Transport ..................................................................................................................... 5
4 Storage......................................................................................................................... 6
5 Installation................................................................................................................... 7
5.1 Installation Conditions .......................................................................................... 7
5.2 Connecting Lines / Pipes ......................................................................................7
5.2.1 Suction Connection....................................................................................8
5.2.2 Discharge Connection................................................................................8
5.3 Filling Oil..............................................................................................................8
5.4 Electrical Connection ............................................................................................9
5.4.1 Wiring Diagram Variable-Frequency Drive.................................................10
5.4.2 Control Unit Connection............................................................................10
5.4.3 DIP Switches..............................................................................................12
6 Commissioning............................................................................................................ 12
6.1 Variable-Frequency Drive Overview ..................................................................... 13
6.2 Pressure Control ................................................................................................... 14
6.3 Fault Reset ........................................................................................................... 14
6.4 Conveying Condensable Vapours ......................................................................... 14
7 Maintenance................................................................................................................ 15
7.1 Maintenance Schedule.......................................................................................... 16
7.2 Oil Level Inspection .............................................................................................. 17
7.3 Cleaning from Dust and Dirt................................................................................. 17
7.4 Oil Change...........................................................................................................17
7.5 Filter change of Condensate Reservoir .................................................................. 19
7.6 Drain Condensate Reservoir.................................................................................. 19
8 Overhaul...................................................................................................................... 20
9 Decommissioning ........................................................................................................ 21
9.1 Dismantling and Disposal...................................................................................... 21
10 Spare Parts................................................................................................................... 21
11 Troubleshooting........................................................................................................... 22
12 Circuit Diagram............................................................................................................ 24
13 Electrical Data of Control Unit Terminals..................................................................... 26
14 Technical Data ............................................................................................................. 27
15 Oil ............................................................................................................................... 27
16 EU Declaration of Conformity ...................................................................................... 28
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Safety | 1
0870166200_MV0040-0080C_A0004_IM_en 3 / 32
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
IN OFP
OUTCAI CD ODP VFD
CAO
MC
IN Suction connection CAO Cooling air outlet
OUT Discharge connection VFD Variable-frequency drive
OFP Oil fill plug (= oil dip stick) CD Condensate drain (Aqua version)
ODP Oil drain plug (under the hood) MC Mains connection
CAI Cooling air inlet
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
pump’.
2.1 Operating Principle
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Transport | 3
0870166200_MV0040-0080C_A0004_IM_en 5 / 32
The machine works on the claw principle.
2.2 Application
The machine is intended for the suction of air and other dry, non-aggressive, non-toxic
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.
The machine is intended for the placement in a non-potentially explosive environment.
The machine is capable of maintaining ultimate pressure, see Technical Data [►27].
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [►27].
2.3 Optional Accessories
2.3.1 Inlet Filter
The inlet filter protects the machine against dust and other solids in the process gas. The
inlet filter is available with a paper or polyester cartridge.
2.3.2 Pressure Transmitter
A pressure transmitter is available to control the pressure on the suction side of the ma-
chine.
2.3.3 PC-Software
For parameter settings with personal computers a PC-software and appropriate connec-
tion cable can be provided.
2.3.4 Manual Control Unit
Control panel can be used for simply controlling the machine and parameter setting in
the field.
2.3.5 Fieldbus Option Board
The machine can be upgraded with fieldbus option boards with different fieldbus sys-
tems.
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.
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4 | Storage
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SCH
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Machine weight:
see the technical data or the nameplate
• Check the machine for transport damage.
If the machine is secured to a base plate:
• Remove the machine from the base plate.
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 0 ... 40 °C.
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Installation | 5
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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.
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~20 cm
~20 cm
• Make sure that the environment of the machine is not potentially explosive.
• Make sure that the ambient conditions comply with the Technical Data [►27].
• Make sure that the environmental conditions comply with the protection class of the
motor.
• 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.
• Make sure that enough space remains for maintenance work.
• Make sure that the machine is placed or mounted horizontally, a maximum of 1° in
any direction.
• Check the oil level, see Oil Level Inspection [►17].
• 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.
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5 | Installation
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• 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
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:
– G1 1/4
Depending on the specific order, other connection dimensions may apply.
5.2.2 Discharge Connection
Connection size:
– G3/4
Depending on the specific order, other connection dimensions may apply.
• Make sure that the discharged gas will flow without obstruction. Do not shut off or
throttle the discharge line or use it as a pressurised air source.
Unless the aspirated air is discharged to the environment right at the machine:
• Make sure that the discharge line either slopes away from the machine or provide a li-
quid separator or a siphon with a drain cock, so that no liquids can flow back into the
machine.
5.3 Filling Oil
NOTICE
Use of an inappropriate oil.
Risk of premature failure!
Loss of efficiency!
• Only use an oil type which has previously been approved and recommended by
Busch.
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Installation | 5
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For oil type and oil capacity see Technical Data [►27] and Oil [►27].
Check oil level
The oil level should stay constant over the lifetime of the oil. If the level does fall, this in-
dicates a leak and the machine requires repair.
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 drive is compatible with the data on the
nameplate of the variable-frequency drive.
• 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.
• Make sure that the EMC-class of the machine confirms with the requirements of your
supply network system, if necessary provide further interference suppression (EMC-
Class of the machine see Technical Data [►27]).
• We recommend to use gG/gL (IEC 60269-1): 16 A / (class T for UL/CSA): 15 A fuses.
Make sure that the response time is below 0.4 seconds.
In case of using a residual current protective device:
• Use an all-current sensitive residual current protective device (type B).
• Electrically connect the variable-frequency drive (VFD).
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5 | Installation
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5.4.1 Wiring Diagram Variable-Frequency Drive
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.
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PE2
single-phase
version
three-phase
version
The leakage current exceeds 3.5 mA. According to EN 61800-5-1 an additional protect-
ive earth conductor (PE2) must be provided:
• Connect the additional protective earth conductor (PE2). Use at least the same cross
section as for PE.
5.4.2 Control Unit Connection
SCH
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BU
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Installation | 5
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The machine is preset ex-works in such a way that the machine starts automatically and
accelerates to the maximum speed when connected to the power.
The control of the machine can be changed as followed by respectively connections on
the control unit:
• Start / stop the machine by using a digital signal (terminal 8: digital input 1).
• Speed or pressure control of the machine (terminal 9: digital input 2).
• The ready for operation signal can be read via terminal 20 (digital output).
Terminal
Signal
20
Digital Out
Ready for operation (open collector)
18
Analogue Out
Output frequency:
0 V = 0 min-1
10 V = nmax
16
Digital In 6
not available
15
Digital In 5
freely available
14
Digital In 4
Maintenance counter reset
13
Digital Out Ground
5
Ground
4
Analogue In 2*
Busch pressure transmitter
4 ... 20 mA
0 .... 2 bar
10
Digital In 3
Fault reset
9
Digital In 2
open = speed control
contact = pressure control
8
Digital In 1
open = stop
contact = start
7
Digital Ground
6
24 V Out
3
Ground
2
Analogue In 1*
speed control:
0 V / 0 mA = n = 1200 minmin -1
10 V / 20 mA = nmax
setpoint pressure control:
0 V / 0 mA = 0 bar abs.
10 V / 20 mA = 1 bar abs.
1
10 V Out
A
RS485
B
RS485
reference
potentiometer
1 ... 10 k
V
*Selectable with DIP switches between voltage and current signal.
The left side shows the connection diagram ex-works. The right side shows examples of
possible connections.
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6 | Commissioning
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5.4.3 DIP Switches
SCH
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DIP Switches Description Default
SW4 Not available 0
SW3 0 = Analogue Input 2 works in current mode (4 ... 20 mA)
1 = Analogue Input 2 works in voltage mode (2 … 10 V)
0
SW2 0 = Analogue Input 1 works in current mode (4 ... 20 mA)
1 = Analogue Input 1 works in voltage mode (2 … 10 V)
1
SW1 0 = Digital Inputs are connected to the ground
1 = Digital Inputs are isolated from the ground
0
6 Commissioning
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.
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.
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Commissioning | 6
0870166200_MV0040-0080C_A0004_IM_en 13 / 32
CAUTION
Noise of running machine.
Risk of damage to hearing!
If persons are present in the vicinity of a non noise insulated machine over extended
periods:
• Make sure that ear protection is being used.
• Make sure that the installation conditions (see Installation Conditions [►7]) are com-
plied with.
• Switch on the machine.
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. 1x 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.
• Maximum permissible number of starts by using the digital signal: unlimited
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.
6.1 Variable-Frequency Drive Overview
LED Description
PWR Lights when the machine is connected to the power supply.
RUN Lights during operation of the machine.
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6 | Commissioning
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LED Description
FLT Lights when a fault occurs.
Blinks if maintenance is necessary (every 8000 operating hours). Main-
tenance counter can be reset via terminal 14 (Digital In 4) of the control
unit.
RDY Lights when the machine is ready for operation and no faults occur.
Blinks in case of a warning.
6.2 Pressure Control
Pressure control of the machine requires a pressure transmitter. A suitable Busch pressure
transmitter is available as accessory.
In case of dusty application a filter must be installed upstream the pressure transmitter to
avoid malfunction or damage to the pressure transmitter.
Depends on the pressure transmitter the DIP switch SW3 must be switched either to cur-
rent mode (4 ... 20 mA) or to voltage mode (2 ... 10 V) (see DIP Switches [►12]).
During pressure control the machine controls the speed according to deviation between
the actual value and the desired pressure value.
In case of the actual value is above the desired pressure value the speed of the machine
increases. Drops the actual value below the desired pressure value the speed of the ma-
chine decreases.
In case of a long operation with the minimum speed the machine switches to the sleep
mode, that means the machine stops and starts automatically when the actual value ex-
ceeds the desired pressure value by 50 mbar.
6.3 Fault Reset
A fault is indicated by lighting of the LED ‘FLT’ (see Variable-Frequency Drive Overview
[►13]) and if connected by the not existing ready for operation signal (terminal 20 of
the control unit).
• Prior to reset a fault find out the possible cause and remedy the fault.
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.
• Reset the fault by disconnecting and reconnecting the power supply for at least 30
seconds or by using a digital signal on terminal 10 (Digital In 3) of the control unit.
6.4 Conveying Condensable Vapours
Use the machine in Aqua version for conveying water vapour or other condensable va-
pours. The machine in Aqua version is able to convey up to 100% saturated water va-
pour.
The conveyance of other vapours than water vapour shall be agreed upon with Busch.
• Make sure that any condensate from the suction side will not enter the non-operating
machine.
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Maintenance | 7
0870166200_MV0040-0080C_A0004_IM_en 15 / 32
CD-L CD-R
• Before process:
• Warm up the machine by running the machine with closed suction side for ap-
proximately 15 minutes.
• After process:
• During process condensate may occur in the machine. To remove the condensate
from the machine convey dry air at 200-400 mbar with the machine’s maximum
speed after the process. The condensate drain (CD-L) must be opened constantly.
The condensate drain (CD-R) must be opened for at least 1 minute.
NOTE
Condensate drains.
In case of very high condensate formation the condensate drain (CD-L) can remain
open during the process. The opening of the condensate drain (CD-R) leads to a strong
increase of the noise level and is not necessary during the process.
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.
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7 | Maintenance
16 / 32 0870166200_MV0040-0080C_A0004_IM_en
CAUTION
Hot surface.
Risk of burns!
• Prior to any action requiring touching the machine, let the machine cool down first.
NOTICE
Using inappropriate cleaners.
Risk of removing safety stickers and protective paint!
• Do not use incompatible solvents to clean the machine out.
NOTICE
Failing to properly maintain the machine.
Risk of premature failure!
Loss of efficiency!
• Respect the maintenance intervals or ask your Busch representative for service.
• 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
Monthly • Check the inlet filter cartridge of the condensate
reservoir, replace if necessary.
In case of an inlet filter being installed:
• Check the inlet filter cartridge, replace if neces-
sary.
Every 3 months • Check the oil level, see Oil Level Inspection [►17].
Every 6 months • Clean the machine from dust and dirt.
Every 8000 hours, at the latest
once a year
• Change the oil.
• Reset the maintenance counter via terminal 14 (Di-
gital In 4) of the control unit.
• Drain the condensate reservoir.
Every 6 years • Have a major overhaul on the machine (contact
Busch).
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Maintenance | 7
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7.2 Oil Level Inspection
• Shut down the machine.
• When the machine is stopped, wait 1 minute before checking the oil level.
The oil level should stay constant over the lifetime of the oil. If the level does fall, this in-
dicates a leak and the machine requires repair.
• Fill up if necessary, see Oil Filling [►8].
7.3 Cleaning from Dust and Dirt
Clean the ventilation grilles
and cooling fins
7.4 Oil Change
NOTICE
Use of an inappropriate oil.
Risk of premature failure!
Loss of efficiency!
• Only use an oil type which has previously been approved and recommended by
Busch.
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7 | Maintenance
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2
1
3
Drain pan
Cleaning cloth
For oil type and oil capacity see Technical Data [►27] and Oil [►27].
Check oil level
The oil level should stay constant over the lifetime of the oil. If the level does fall, this in-
dicates a leak and the machine requires repair.
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Maintenance | 7
0870166200_MV0040-0080C_A0004_IM_en 19 / 32
7.5 Filter change of Condensate Reservoir
1
2
2
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Remove the cover from the filter and
replace the filter cartridge if necessary
7.6 Drain Condensate Reservoir
1
2
3
Drain the condensate reservoir
Condensate reservoir
Remove both hoses from
the condensate reservoir
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8 | Overhaul
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1
2
Remount both hoses to
the condensate reservoir
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)
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