BUSCH R 5 series User manual

Instruction Manual
R 5
Oil-Lubricated Rotary Vane Vacuum Pumps
RA 0750 A
0870565413/A0001_en / Original instructions / Modifications reserved 08/03/2019
Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland

Table of Contents
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Table of Contents
1 Safety........................................................................................................................... 4
2 Product Description ..................................................................................................... 5
2.1 Operating Principle............................................................................................... 6
2.2 Application ........................................................................................................... 6
2.3 Standard Features................................................................................................. 6
2.3.1 Water Cooling ...........................................................................................6
2.3.2 Variable-Frequency Drive...........................................................................6
2.3.3 Gas Ballast Valve........................................................................................6
2.3.4 Temperature Switch "Gas"........................................................................7
2.4 Optional Accessories............................................................................................. 7
2.4.1 Temperature Switch "Oil" .........................................................................7
2.4.2 Resistance Thermometer............................................................................7
2.4.3 Level and Temperature Switch...................................................................7
2.4.4 Pressure Switch..........................................................................................7
2.4.5 Pressure Transmitter ..................................................................................7
3 Transport ..................................................................................................................... 8
4 Storage......................................................................................................................... 9
5 Installation................................................................................................................... 9
5.1 Installation Conditions .......................................................................................... 9
5.2 Connecting Lines / Pipes ......................................................................................10
5.2.1 Suction Connection....................................................................................11
5.2.2 Discharge Connection................................................................................11
5.2.3 Cooling Water Connection ........................................................................12
5.3 Filling Oil..............................................................................................................13
5.4 Electrical Connection ............................................................................................14
5.4.1 Electrical Connection of the Variable-Frequency Drive (50Hzversion).......14
5.4.2 Wiring Diagram Variable-Frequency Drive.................................................14
5.4.3 Electrical Connection of the Three-Phase Motor (60Hzversion)................14
5.4.4 Wiring Diagram Three-Phase Motor ..........................................................15
5.5 Electrical Connection of the Monitoring Devices ................................................... 16
5.5.1 Wiring Diagram Temperature Switch "Gas" ..............................................16
5.5.2 Wiring Diagram Temperature Switch "Oil" (Optional)...............................16
5.5.3 Wiring Diagram Resistance Thermometer (Optional) .................................16
5.5.4 Wiring Diagram Level and Temperature Switch (Optional) ........................17
5.5.5 Wiring Diagram Pressure Switch (Optional) ...............................................17
5.5.6 Wiring Diagram Pressure Transmitter (Optional)........................................17
6 Commissioning............................................................................................................ 18
6.1 Conveying Condensable Vapours ......................................................................... 19
7 Maintenance................................................................................................................ 19
7.1 Maintenance Schedule.......................................................................................... 21
7.2 Oil Level Inspection .............................................................................................. 21
7.3 Oil and Oil Filter Change ......................................................................................22
7.4 Exhaust Filter Change ...........................................................................................24
8 Overhaul...................................................................................................................... 25
9 Decommissioning ........................................................................................................ 25
9.1 Dismantling and Disposal...................................................................................... 25
10 Spare Parts................................................................................................................... 26
11 Troubleshooting........................................................................................................... 27

Table of Contents
0870565413_RA0750A_A0001_IM_en 3
12 Technical Data ............................................................................................................. 29
13 Oil ............................................................................................................................... 29
14 EU Declaration of Conformity ...................................................................................... 30

1 | Safety
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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.

Product Description | 2
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2 Product Description
OFP NP EB IN GB OUT
OSGODPOF
EF
FM FV
VFD OS
TS DA
CWICWO WHE
IN Suction connection OUT Discharge connection
DA Directional arrow VFD Variable-frequency drive
OFP Oil fill plug EF Exhaust filter
OSG Oil sight glass NP Nameplate
ODP Oil drain plug OF Oil filter
EB Eye bolt OS Oil separator
GB Gas ballast valve FM Filter material
WHE Water-oil heat exchanger TS Temperature switch
FV Float valve CWI Cooling water inlet
CWO Cooling water outlet
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
pump’.

2 | Product Description
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2.1 Operating Principle
The machine works on the rotary vane principle.
The oil seals the gaps, lubricates the vanes and takes away compression heat.
The oil filter cleans the circulating oil.
Exhaust filters separate the oil from the discharged gas.
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 designed for indoor installation, in case of outdoor installation, ask your
Busch representative in order to take specific precautions.
The machine is capable of maintaining ultimate pressure, see Technical Data [►29].
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [►29].
2.3 Standard Features
2.3.1 Water Cooling
The water-oil heat exchanger allows the machine to have a suitable oil cooling.
2.3.2 Variable-Frequency Drive
The machine is equipped in standard (50 Hz version) with a variable-frequency drive.
However, a three-phase motor without variable-frequency drive may be optionally de-
livered (60 Hz version).
2.3.3 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.
The gas ballast valve has an influence on the ultimate pressure of the machine, see Tech-
nical Data [►29].

Product Description | 2
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2.3.4 Temperature Switch "Gas"
The temperature switch monitors the gas temperature of the machine.
The machine must be stopped when the gas reaches 110 °C.
2.4 Optional Accessories
2.4.1 Temperature Switch "Oil"
The temperature switch monitors the oil temperature of the machine.
Depending on the oil type, the machine must be stopped when the oil reaches a certain
temperature, see Oil [►29].
2.4.2 Resistance Thermometer
The resistance thermometer monitors the oil temperature of the machine.
Depending on the oil type, warning and trip signals must be set, see Oil [►29].
2.4.3 Level and Temperature Switch
The level switch with integrated temperature switch monitors the oil level and the oil
temperature. It has one level switch point and two temperature switch points.
The machine must be stopped when the oil level is too low or, depending on the oil
type, when the oil reaches a certain temperature, see Oil [►29].
2.4.4 Pressure Switch
The pressure switch monitors the pressure in the oil separator.
The machine must be stopped when the gas reaches a certain pressure, see Wiring Dia-
gram Pressure Switch (Optional) [►17].
2.4.5 Pressure Transmitter
The pressure transmitter monitors the pressure in the oil separator.
Warning and trip signals must be set, see Wiring Diagram Pressure Transmitter (Op-
tional) [►17].

3 | Transport
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3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
NOTICE
In case the machine is already filled with oil.
Tilting a machine that is already filled with oil can cause large quantities of oil to in-
gress into the cylinder. Starting the machine with excessive quantities of oil in the
cylinder will immediately break the vanes and ruin the machine!
• Drain the oil prior to every transport or always horizontally transport the machine.
• 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)
WARNING
Lifting the machine using the motor eye bolt.
Risk of severe injury!
• Do not lift the machine using the eye bolt fitted to the motor. Only lift the machine as
previously shown.
• Check the machine for transport damage.
If the machine is secured to a base plate:
• Remove the machine from the base plate.

Storage | 4
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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 variable-frequency drive can lose effi-
ciency because of electrochemical processes. In worst case it can leads to a shirt-circuit
and therefore to a damage to the variable-frequency drive of the machine.
• Connect the machine every 18 months for 60 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.
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.
~50 cm
~50 cm
~100 cm
~50 cm

5 | Installation
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• Make sure that the environment of the machine is not potentially explosive.
• 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 and the electrical instruments.
• 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 the oil sight glass (OSG) remains easily visible.
• 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 is acceptable.
• Check the oil level, see Oil Level Inspection [►21].
• Make sure that all provided covers, guards, hoods, etc. are mounted.
• Make sure that the cooling water complies with the requirements, see Cooling Water
Connection [►12].
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.
If the machine is equipped with monitoring devices or sensors:
• Make sure that the monitoring devices are correctly connected and integrated into
a control system such that operation of the machine will be inhibited if the safety
limit values are exceeded, see Electrical Connection of the Monitoring Devices
[►16].
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.

Installation | 5
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5.2.1 Suction Connection
WARNING
Unprotected suction connection.
Risk of severe injury!
• Do not put hand or fingers in the 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-K 100
Depending on the specific order, other connection dimensions may apply.
If the machine is used as part of a vacuum system:
• Busch recommends the installation of an isolation valve in order to prevent the oil
from flowing back to the vacuum system.
5.2.2 Discharge Connection
CAUTION
The discharge gas contains small quantities of oil.
Risk to health!
If air is discharged into rooms where persons are present:
• Make sure that sufficient ventilation is provided.
Connection size:
– ISO-K 100
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 | Installation
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5.2.3 Cooling Water Connection
CWICWO WHE
CWI Cooling water inlet CWO Cooling water outlet
WHE Water-oil heat exchanger
• Connect the cooling water connections (CWI / CWO) to the water supply.
Connection size:
– G1/2, ISO 228-1 (CWI / CWO)
• Make sure that the cooling water complies with the following requirements:
Min. supply capacity l/min 5
Water pressure bar 2 ... 6
Supply temperature °C +5 ... +35
Required pressure differential across supply
and return
bar ≥ 1
• To reduce the maintenance effort and ensure a long product lifetime we recommend
the following cooling water quality:
Hardness mg/l (ppm) < 90
Properties Clean & clear
PH value 7 … 8
Particle size µm < 200
Chloride mg/l < 100
Electrical conductivity µS/cm ≤ 100
Free chloride mg/l < 0.3
Materials in contact with the cooling water Stainless steel, copper and cast iron
NOTE
Water hardness unit conversion.
1 mg/l (ppm) = 0.056 °dh (german degree) = 0.07 °e (english degree) = 0.1 °fH (french
degree)

Installation | 5
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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.
For oil type and oil capacity see Technical Data [►29] and Oil [►29].
1
4
MAX
MIN
3
Busch Oil
2
Check oil level

5 | Installation
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5.4 Electrical Connection
DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
5.4.1 Electrical Connection of the Variable-Frequency Drive
(50Hzversion)
• 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.
• Connect the protective earth conductor.
• Electrically connect the variable-frequency drive (VFD).
5.4.2 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.
PEL1 L2 L3
VFD
L1
L2
L3
PE
M
Already wired
5.4.3 Electrical Connection of the Three-Phase Motor
(60Hzversion)
• Make sure that the power supply for the motor is compatible with the data on the
nameplate of the motor.
• The electrical installation must comply with applicable national and international
standards.
• Provide a lockable disconnect switch on the power line so that the machine is com-
pletely secured during maintenance tasks.
• Provide an overload protection according to EN 60204-1 for the motor.
• Busch recommends installing a D-curve circuit breaker.
• 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.

Installation | 5
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• Electrically connect the motor.
NOTICE
Incorrect connection.
Risk of damage to the motor!
• The wiring diagrams given below are typical. Check the inside of the terminal box for
motor connection instructions/diagrams.
5.4.4 Wiring Diagram Three-Phase Motor
Delta connection (low voltage): Star connection (high voltage):
Double star connection, multi-voltage
motor with 12 pins (low voltage):
4
4
4
Star connection, multi-voltage motor
with 12 pins (high voltage):
4
4
4
Delta connection, multi-voltage motor
with 12 pins (middle voltage):
4
4
4
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.

5 | Installation
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• Determine the intended direction of rotation with the arrow (stuck on or cast).
• Jog the motor briefly.
• Watch the fan wheel of the motor and determine the direction of rotation just before
the fan wheel stops.
If the rotation of the motor must be changed:
• Switch any two of the motor phase wires.
5.5 Electrical Connection of the Monitoring Devices
NOTE
In order to prevent potential nuisance alarms, Busch recommends that the control system
is configured with a time delay of at least 20 seconds.
5.5.1 Wiring Diagram Temperature Switch "Gas"
Part no.: 0651563747
Connector: M12x1, 4-pin
Electrical data:
U = ≤ 250 V AC/DC (50/60 Hz) ; I = ≤ 1 A
Switch point: T1 pin 1 + 2 = 110 °C
1 2
4 3
2
1
T1
4
3
T2
1 = Brown ; 2 = White ;
3 = Blue ; 4 = Black
5.5.2 Wiring Diagram Temperature Switch "Oil" (Optional)
Part no.: 0651563747
Connector: M12x1, 4-pin
Electrical data:
U = ≤ 250 V AC/DC (50/60 Hz) ; I = ≤ 1 A
Switch point:
T1 pin 1 + 2 = 110 °C*
T2 pin 3 + 4 = 130 °C*
1 2
4 3
2
1
T1
4
3
T2
1 = Brown ; 2 = White ;
3 = Blue ; 4 = Black
* The switch point value depends on the oil type, see Oil [►29].
5.5.3 Wiring Diagram Resistance Thermometer (Optional)
Part no.: 0651563753
Connector: M12x1, 4-pin
Electrical data:
U = 10 … 35 VDC
4 ... 20 mA ► 0 ... 150 °C
Warning / trip signals: see Oil [►29].
1 2
4 3
3
1
+
-
1 = Brown ; 3 = Blue

Installation | 5
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5.5.4 Wiring Diagram Level and Temperature Switch (Optional)
Part no.: 0652563748
Connector: M12x1, 4-pin
Electrical data:
U = ≤ 230 V AC (50/60 Hz) ;
U = ≤ 100 V DC (50/60 Hz) ;
I = ≤ 0.5 A
Switch point:
L pin 1 + 4 = low level
T1 pin 1 + 2 = 110 °C*
T2 pin 1 + 3 = 130 °C*
1 2
4 3
4
1
L
2
1
T1
3
1
T2
1 = Brown ; 2 = White ;
3 = Blue ; 4 = Black
NOTE:
For this device, the recommended time
delay to prevent nuisance alarms can be up
to 240 seconds.
* The switch point value depends on the oil type, see Oil [►29].
5.5.5 Wiring Diagram Pressure Switch (Optional)
Part no.: 0653563750
Connector: M12x1, 4-pin
Electrical data:
U = ≤ 250 V AC/DC (50/60 Hz) ; I = ≤ 4 A
Switch point:
P pin 1 + 2 = 0.6 bar (overpressure)
1 2
4 3
2
1
P
1 = Brown ; 2 = White
5.5.6 Wiring Diagram Pressure Transmitter (Optional)
Part no.: 0653 204 444
Connector: M12x1, 4-pin
Electrical data:
U = 10 ... 35 VDC
4 ... 20 mA ► 0 ... 1.6 bar (abs.)
1 2
4 3
3
1
+
-
1 = Brown ; 3 = Blue
Warning signal:
Pwarning = 0.4 bar (overpressure)
Trip signal:
Ptrip = 0.6 bar (overpressure)

6 | Commissioning
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6 Commissioning
NOTICE
The machine can be shipped without oil.
Operation without oil will ruin the machine in short time!
• Prior to commissioning, the machine must be filled with oil, see Filling Oil [►13].
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.
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 [►9]) are met.
• Turn on the water supply.
• Switch on the machine.
• Make sure that the maximum permissible number of starts does not exceed 12 starts
per hour. Those starts should be spread within the hour.
• Make sure that the operating conditions comply with the Technical Data [►29].
• After a few minutes of operation, check the oil level and top up if necessary.
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.

Maintenance | 7
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6.1 Conveying Condensable Vapours
Water vapour within the gas flow is tolerated within certain limits. The conveyance of
other vapours shall be agreed upon with Busch.
If condensable vapours are to be conveyed:
30 minutes
* not included in the scope of delivery
• Close the isolation
valve* and
open the gas ballast
valve** (GB)
• Warm up the machine
• Open the isolation
valve and perform the
process
• Close the isolation
valve
END
START
30 minutes
• Close the gas ballast
valve
** may be considered as optional on certain products
7 Maintenance
DANGER
Maintenance work without disconnecting the variable-frequency drive.
Risk of electrical shock.
• Disconnect and isolate the variable-frequency drive before attempting any work on it.
High voltages are present at the terminals and within the variable-frequency drive for
up to 10 minutes after disconnection of the electrical supply.
• Always ensure by using a suitable multimeter that no voltage is present on any drive
power terminals prior to commencing any work.
DANGER
The STOP function does not remove potentially lethal high voltages.
Risk of electrical shock.
• Wait 10 minutes before starting any work on it. Never carry out any work on the vari-
able frequency drive, motor or motor cable whilst the input power is still applied.
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.

7 | Maintenance
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CAUTION
Hot surface.
Risk of burns!
• Prior to any action requiring touching the machine, let the machine cool down first.
NOTICE
Variable-frequency drive maintenance.
Risk of damage to the variable-frequency drive!
• Maintenance and adjustment must only be executed by qualified personnel.
NOTICE
Using inappropriate cleaners.
Risk of removing safety stickers and protective paint!
• Do not use incompatible solvents to clean the machine.
CAUTION
Failing to properly maintain the machine.
Risk of injuries!
Risk of premature failure and 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.
• Turn off the water supply.
If necessary:
• Disconnect all connections.