BUSCH R 5 series User manual

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Instruction Manual
R5
Rotary Vane Vacuum Pumps
KD 0012 A, KD 0020 A
0870214060/-0003_en / Original instructions / Modifications reserved 06/12/2021

Table of Contents
2 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
Table of Contents
1 Safety .......................................................................................................................................3
2 Product Description ..................................................................................................................4
2.1 Operating Principle .......................................................................................................... 4
2.2 Application....................................................................................................................... 5
2.3 Variants............................................................................................................................ 5
2.4 Start Controls ................................................................................................................... 6
2.5 Optional Accessories ........................................................................................................ 6
2.5.1 Rubber feet ...........................................................................................................6
2.5.2 Extension Cables ...................................................................................................6
3 Transport ..................................................................................................................................7
4 Storage .....................................................................................................................................7
5 Installation................................................................................................................................7
5.1 Installation Conditions...................................................................................................... 7
5.2 Connecting Lines / Pipes .................................................................................................. 8
5.2.1 Suction Connection ...............................................................................................8
5.2.2 Discharge Connection ........................................................................................... 8
5.3 Filling Oil.......................................................................................................................... 9
5.4 Electrical Connection ........................................................................................................ 9
5.4.1 Wiring Diagram Single-Phase Motor ..................................................................... 10
5.4.2 Capacitor Installation.............................................................................................11
6 Commissioning.........................................................................................................................12
6.1 Conveying Condensable Vapours..................................................................................... 12
7 Maintenance.............................................................................................................................13
7.1 Maintenance Schedule ..................................................................................................... 14
7.2 Oil Level Inspection.......................................................................................................... 14
7.3 Oil Change....................................................................................................................... 14
7.4 Exhaust Filter Change....................................................................................................... 16
8 Overhaul...................................................................................................................................17
9 Decommissioning.....................................................................................................................17
9.1 Dismantling and Disposal ................................................................................................. 17
10 Spare Parts................................................................................................................................18
11 Troubleshooting .......................................................................................................................18
12 Technical Data..........................................................................................................................20
13 Oil ............................................................................................................................................20
14 EU Declaration of Conformity...................................................................................................21
15 UK Declaration of Conformity ..................................................................................................22

Safety | 1
Instruction Manual R5 KD 0012-0020 A_EN_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
methods. 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.

2 | Product Description
4 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
2 Product Description
OFP
NP
DAOUTEF IN
ODP OSG
TL CC PWS
CS
CAP
IN Suction connection TL Transport lug
OUT Gas discharge CAP Capacitor
OFP Oil fill plug CS Capacitor support
OSG Oil sight glass CC Capacitor connection
ODP Oil drain plug NP Nameplate
PWS Power supply (MATE-N-LOK) EF Exhaust filter
DA Directional arrow
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
pump’.
NOTE
Illustrations
In this instruction manual the illustrations may differ from the machine appearance.

Product Description | 2
Instruction Manual R5 KD 0012-0020 A_EN_en 5 / 24
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.
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 designed to be integrated into vacuum packaging table-top machines.
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 [►20].
Permitted environmental conditions, see Technical Data [►20].
The machine is suitable for intermittent periodic duty as per IEC 60034-1.
Duty type:
S3 S1
S3 60 % - = 100 cycles in series
S3 50 % - unlimited cycles in series*
Independent of the load - unlimited cycles
in series*
* (Depending on the use of the pump under these conditions, other oil types might be
more appropriate! Contact Busch for specification.)
Duty type S3:
Definition: It is a sequence of identical duty cycles, each including a time of operation at
constant load and a time deenergized and a rest.
Cyclic duration factor:
Definition: The cyclic duration factor is defined as the ratio between the periods of load-
ing, including starting and electric braking, and the duration of the duty cycle, expressed
as a percentage.
This means:
During a period of e.g. 10 minutes (100 %) the operating time of the machine is of 6
minutes (60 %) and the standstill of the machine is of 4 minutes (40 %).

2 | Product Description
6 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
2.3 Variants
Features differentiating variants
Positions of: Oil sight glass (OSG), oil fill plug (OFP) and oil drain plug (ODP).
OFP
OFP
OSG
ODP
OFP
OSG
ODP
OFP
OFP
OSG
ODP
Variant 1 (for KD 0012/0020 A) Variant 2 (for KD 0020 A only)
Variant 3 (for KD 0020 A only)
2.4 Start Controls
The machine comes without start controls. The control of the machine is to be provided
in the course of installation.
The machine can be equipped with a soft-starter.
2.5 Optional Accessories
2.5.1 Rubber feet
The rubber feet isolate and reduce the vibration of the machine.
Fix the pump unit to the housing. Use M6-screws for each rubber foot and tighten them.
2.5.2 Extension Cables
Extension cables see Extension Cable Variants [►10].

Transport | 3
Instruction Manual R5 KD 0012-0020 A_EN_en 7 / 24
3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
Machine weight:
see the technical data or the nameplate (NP)
Use the transport lug (TL) to lift the machine!
• 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.
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.
• 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 environmental conditions comply with the protection class of the
motor and the electrical instruments.

5 | Installation
8 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
• Make sure that the installation space or location is vented such that sufficient cooling
of the machine is provided.
• 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, fill up if necessary, see Filling Oil [►9].
• Make sure that all provided covers, guards, hoods, etc. are mounted.
• Fix the pump unit with M6-screws to the housing of the table top-packing machine.
• You can use the same fixing screws even if you use the rubber feet for absorbing vibrations.
These conditions are recommended installation conditions made by the manufacturer
Busch. If you have questions, contact Busch.
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 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(s):
– G1/2
NOTICE
Using the non-return valve as shut off valve.
Risk of oil mist flow back into the vacuum system.
• It is highly recommended not to use the non-return valve as a shut off 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(s):
– Without connection. The discharged gas is released to the ambient of the machine.

Installation | 5
Instruction Manual R5 KD 0012-0020 A_EN_en 9 / 24
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 [►20] and Oil [►20].
Check oil level
1x o-ring, part no.:
0486 000 590
Max. admissible
torque: 12 Nm
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.
• 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.
• Install the capacitor and connect it to the capacitor connection (CC), see Capacitor In-
stallation [►11].
• Electrically connect the motor.

5 | Installation
10 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
5.4.1 Wiring Diagram Single-Phase Motor
BR = brown
YEGN = yellow/green
BU = blue
WH = white
RD = red
TMP = Thermal motor protection
AMP MATE-N-LOK = Power connector
1~
M
321
LN
RD
YEGN
BU BU
WH / BR
TMP
AMP
MATE-N-LOK
Motor Specifications
Nominal motor rating KD 0012 A: 0.37 kW
KD 0020 A: 0.55 kW
Frame size and flange 71 / B34
Protection class IP 20
Insulation class F
Duty type S3 60 % - = 100 cycles in series
S3 50 % - unlimited cycles in series
(no motor ventilation)
S1 Independent of the load - unlimited cycles in series
(motor ventilated)
Thermal motor protection S3 Bimetallic element:
disconnecting temperature 140 °C
S1 no thermal element:
Due to motor ventilation, no thermal element neces-
sary
Connector type AMP MATE-N-LOK (cable lengths max. 100 mm)
Extension Cable Variants
AMP MATE-N-LOK
to
wire end ferrules
AMP MATE-N-LOK
to
tab receptacles
AMP MATE-N-LOK
to
AMP MATE-N-LOK
For capacitor with
tab receptacles
Length: 1000 mm Length: 490 mm Length: 400 mm Length: 230 mm
Part no.: 0671 212
762
Part no.: 0671 212
763
Part no.: 0671 210
443
Part no.: 0671 213
016

Installation | 5
Instruction Manual R5 KD 0012-0020 A_EN_en 11 / 24
Motor Variants
Motor voltage Motor frequency Motor speed Capacitor
capacitance
Capacitor volt-
age
220 – 240 V 50 / 60 Hz 3000 /
3600 min-1
20 µF 400 V
110 /
110 – 120 V
50 / 60 Hz 3000 /
3600 min-1
40 µF 250 V
100 V 50 / 60 Hz 3000 /
3600 min-1
40 µF 250 V
5.4.2 Capacitor Installation
The machine needs a suitable capacitor (CAP) to operate, see Motor Variants [►11].
Depending on the order, the scope of delivery contains one of the following delivery options.
1. Delivery option: The capacitor (CAP) is delivered loosely with 2 cable ties
• Install the capacitor (CAP) on the capacitor’s support (CS) of the motor and connect
the capacitor connection (CC).
• For thermal reasons, the capacitor (CAP) can be mounted at a different location.
Maximum distance of 230 mm (cable length) from the capacitor connection (CC).
2. Delivery option: The capacitor (CAP) is installed on the capacitor’s support (CS)
• connect the capacitor connection (CC).
• For thermal reasons, the capacitor (CAP) can be mounted at a different location.
Maximum distance of 230 mm (cable length) from the capacitor connection (CC).
3. Delivery option: No capacitor (CAP)
• Depending on the motor, install a suitable capacitor (CAP), see Motor Variants [►11].
• Install the capacitor (CAP) on the capacitor’s support (CS) of the motor and connect
the capacitor connection (CC). (see above picture)
• For thermal reasons, the capacitor (CAP) can be mounted at a different location.
Maximum distance of 230 mm (cable length) from the capacitor connection (CC).

6 | Commissioning
12 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
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 [►9].
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 pe-
riods:
• Make sure that ear protection is being used.
• Make sure that the installation conditions (see Installation Conditions [►7]) are met.
• Switch on the machine.
• Make sure that the operating conditions comply with the Technical Data [►20].
• After a few minutes of operation, perform an Oil Level Inspection [►14].
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 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:
Before process:
• Warm up the machine for approximately half an hour.
After process:
• Operate the machine for approximately another half an hour.

Maintenance | 7
Instruction Manual R5 KD 0012-0020 A_EN_en 13 / 24
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.
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.
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.
If necessary:
• Disconnect all connections.

7 | Maintenance
14 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
7.1 Maintenance Schedule
The maintenance intervals depend very much on the individual operating conditions. The
intervals given below are considered as starting values which should be shortened or ex-
tended as appropriate. Particularly harsh applications or heavy duty operation, such as
high dust loads in the environment or in the process gas, other contamination or ingress
of process material, can make it necessary to shorten the maintenance intervals signifi-
cantly.
Interval Maintenance Work
Daily • Check the oil level, see Oil Level Inspection [►14].
• Top up the oil, if oil level underneath MIN-marking of
the oil sight glass (OSG).
• Drain the oil, if oil level exceeds MAX-marking of the
oil sight glass (OSG).
• Check the colour of the oil.
• Change the oil, if the oil shows a milky discoloration.
Weekly • Check the oil level, see Oil Level Inspection [►14].
• Check the machine for oil leaks - in case of leaks have
the machine repaired (contact Busch).
Every 2000 hours, or at least
every 6 months
• Change the oil and the exhaust filters (EF).
Every 5 years • Have a major overhaul on the machine (contact
Busch).
7.2 Oil Level Inspection
• Shut down the machine.
• When the machine is stopped, wait 1 minute before checking the oil level.
MAX
MIN
MAX
MIN
MAX
MIN
• Fill up if necessary, see Oil Filling [►9].

Maintenance | 7
Instruction Manual R5 KD 0012-0020 A_EN_en 15 / 24
7.3 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.
Drain pan
1x o-ring, part no.:
0486 000 505
Max. admissible
torque: 12 Nm
For oil type and oil capacity see Technical Data [►20] and Oil [►20].
Check oil level
1x o-ring, part no.:
0486 000 590
Max. admissible
torque: 12 Nm

7 | Maintenance
16 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
7.4 Exhaust Filter Change
Max. admissible
torque: 4 Nm

Overhaul | 8
Instruction Manual R5 KD 0012-0020 A_EN_en 17 / 24
8 Overhaul
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.
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.
In case of the machine having conveyed gas that was contaminated with foreign materi-
als which are dangerous to health:
• Decontaminate the machine as much as possible and state the contamination sta-
tus 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
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.
• Disconnect the power supply.
• Vent the connected lines to atmospheric pressure.
• Disconnect all connections.
If the machine is going to be stored:
• See Storage [►7].
9.1 Dismantling and Disposal
• Loosen the pump screws fixing it to the housing of the table top-packing machine.
• Drain and collect the oil.
• Make sure that no oil drips onto the floor.
• Remove the exhaust filters.
• Separate special waste from the machine.
• Dispose of special waste in compliance with applicable regulations.
• Dispose of the machine as scrap metal.

10 | Spare Parts
18 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
10 Spare Parts
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 correct functioning of the machine and to validate the warranty.
Spare part kits Description Part no.
Service Kit Exhaust filter
O-rings
Flat gasket
0992217026
Gasket Kit O-rings
Flat gasket
Sealing ring
0990217025
If other parts are required:
• Contact your Busch representative.
11 Troubleshooting
DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
CAUTION
Hot surface.
Risk of burns!
• Prior to any action requiring touching the machine, let the machine cool down first.
Illustration showing parts that may be involved during troubleshooting:
EF IS
Max. admissible
torque: 10 Nm
Max. admissible
torque: 4 Nm

Troubleshooting | 11
Instruction Manual R5 KD 0012-0020 A_EN_en 19 / 24
Problem Possible Cause Remedy
The machine does not start. The motor is not supplied
with the correct voltage.
• Check the power supply.
• Have the machine re-
paired (contact Busch Ser-
vice).
The capacitor is defective.
(Single phase motor only)
• Check the capacitor as
well as the capacitor con-
nection (CC).
The machine heated up, dis-
connection by bimetallic ele-
ment.
• Have the machine cool
down.
The machine does not reach
the usual pressure on the
suction connection.
Oil level too low. • Top up oil.
The inlet screen (IS) is par-
tially clogged.
• Clean the inlet screen (IS).
Internal parts are worn or
damaged.
• Repair the machine (con-
tact Busch).
The machine runs very noisi-
ly.
Stuck vanes. • Repair the machine (con-
tact Busch).
Defective bearings. • Repair the machine (con-
tact Busch).
The machine runs too hot. Insufficient cooling. • Remove dust and dirt
from the machine.
Ambient temperature too
high.
• Observe the permitted
ambient temperature.
Oil level too low. • Top up oil.
The exhaust filters (EF) are
partially clogged.
• Replace the exhaust filters
(EF).
The machine fumes or ex-
pels oil droplets through the
gas discharge.
The exhaust filters (EF) are
partially clogged.
• Replace the exhaust filters
(EF).
An exhaust filter (EF) with o-
ring is not fitted properly.
• Ensure the correct posi-
tion of the exhaust filters
(EF) and the o-rings.
The oil is black. Oil change intervals are too
long.
• Flush the machine (con-
tact Busch).
The machine runs too hot. • See problem "The ma-
chine runs too hot".
The oil is emulsified. The machine sucked in liq-
uids or significant amounts
of vapour.
• Flush the machine (con-
tact Busch).
For the solution of problems not mentioned in the troubleshooting chart contact your
Busch representative.

12 | Technical Data
20 / 24 Instruction Manual R5 KD 0012-0020 A_EN_en
12 Technical Data
KD 0012 A KD 0020 A
Nominal pumping speed (50Hz / 60Hz) m³/h 10/12 16 / 20
Ultimate pressure (50Hz / 60 Hz) hPa (mbar)
abs.
2 / 2
Nominal motor rating (50Hz / 60Hz) kW 0.37 / 0.37 0.55 / 0.55
Duty type S3 60 % - = 100 cycles in series
50 % - unlimited cycles in series**
S1 Independent of the load - unlimited cycles in se-
ries**
Nominal motor speed (50Hz / 60Hz) min-1 3000 / 3600
Ambient temperature range °C 5 … 40
Gas inlet temperature °C 5 … 40
Ambient pressure Atmospheric pressure
Oil capacity l 0.35
Weight approx. kg 14 15
** Depending on the use of the pump under these conditions, other oil types might be more appropriate! Contact
Busch for specification.
13 Oil
VSA 032
ISO-VG 32
Oil type Synthetic oil
Certifications H1
Kosher*
Halal*
Part number: 1L packaging 0831 163 958
Part number: 5L packaging 0831 163 961
Remark Food applications (H1);
Anti-corrosion;
Not suitable for continuous operation
*Certificates are available on request or per download under www.buschvacuum.com.
In case of unfavourable ambient temperature, other oil viscosities may be used. Please consult your Busch repre-
sentative for more details.