BUSCH R 5 series User manual

Get technical data, instruction manuals, service kits
Instruction Manual
R5
Oil-Lubricated Rotary Vane Vacuum Pumps
RA 0760 A PLUS
0870211676/-0004_en / Original instructions / Modifications reserved 10/02/2021
Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland

Table of Contents
2 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
Table of Contents
1 Safety .......................................................................................................................................4
2 Product Description ..................................................................................................................5
2.1 Operating Principle .......................................................................................................... 7
2.2 Application....................................................................................................................... 7
2.3 Standard Features ............................................................................................................ 7
2.3.1 User Interface........................................................................................................7
2.3.2 Acoustic Cabinet ................................................................................................... 7
2.3.3 Control Unit .......................................................................................................... 7
2.3.4 Monitoring Devices ............................................................................................... 8
2.3.5 I/O and Communication Port ................................................................................8
2.3.6 Gas Ballast Valve ................................................................................................... 8
2.3.7 Inlet Filter ..............................................................................................................8
2.4 Optional Accessories ........................................................................................................ 8
2.4.1 Inlet Filter Condition Monitoring Kit ...................................................................... 8
2.4.2 Water-Oil Heat Recovery Unit............................................................................... 8
2.5 P&ID "Piping and Instrumentation Diagram"................................................................... 9
2.6 LED Indicators .................................................................................................................. 9
2.7 Description of User Interface Functions ............................................................................ 10
2.7.1 Menu Overview .................................................................................................... 10
2.7.2 Bottom Bar ............................................................................................................11
2.7.3 Navigation............................................................................................................. 11
2.7.4 Role and User........................................................................................................12
2.7.5 System Settings ..................................................................................................... 13
2.7.6 Machine and Software Identification ..................................................................... 14
2.7.7 Ethernet Settings ................................................................................................... 14
2.8 Web Visualization ............................................................................................................ 15
3 Transport ..................................................................................................................................18
4 Storage .....................................................................................................................................19
5 Installation................................................................................................................................20
5.1 Installation Conditions...................................................................................................... 20
5.2 Connecting Lines / Pipes .................................................................................................. 21
5.2.1 Suction Connection ............................................................................................... 21
5.2.2 Discharge Connection ........................................................................................... 21
5.2.3 Cooling Water Connection (Optional) ................................................................... 22
5.2.4 Inlet Filter Condition Monitoring Kit ...................................................................... 23
5.2.5 External Inlet Pressure Sensor ................................................................................ 24
5.3 Filling Oil.......................................................................................................................... 25
5.4 Fitting the Coupling ......................................................................................................... 26
5.5 Electrical Connection ........................................................................................................ 27
5.5.1 Wiring Diagram Control Unit................................................................................. 28
6 Commissioning.........................................................................................................................29
6.1 Prerequisites Before Use ................................................................................................... 29
6.2 Configuration................................................................................................................... 29
6.3 Start Up ........................................................................................................................... 30
7 In Operation .............................................................................................................................31
7.1 Control Mode .................................................................................................................. 31
7.1.1 Local/Manual ........................................................................................................ 32
7.1.2 Local/Auto "Week Planner".................................................................................. 32
7.1.3 Remote/Auto ........................................................................................................ 33

Table of Contents
0870211676_RA0760A_PLUS_-0004_IM_en 3
7.2 Operating Mode .............................................................................................................. 34
7.2.1 Speed Control .......................................................................................................34
7.2.2 Pressure Control ....................................................................................................35
7.3 Ecomode .......................................................................................................................... 36
7.4 Gas Ballast Valve Control ................................................................................................. 37
7.5 Warm-up / Cool-down Modes......................................................................................... 38
7.5.1 Conveying Condensable Vapours ..........................................................................39
7.6 Optional Inlet Valve Control............................................................................................. 40
7.7 Optional Vacuum Booster Control.................................................................................... 42
7.8 Monitoring....................................................................................................................... 44
7.8.1 Operating Information .......................................................................................... 44
7.8.2 Operating Data ..................................................................................................... 45
7.8.3 History .................................................................................................................. 48
7.8.4 Operating Curves ..................................................................................................49
7.9 Dysfunction...................................................................................................................... 51
7.9.1 Warnings and Alarms Thresholds........................................................................... 51
7.9.2 Warning/Alarm Acknowledgment Procedure......................................................... 52
7.10 Stop the Machine............................................................................................................. 53
8 Maintenance.............................................................................................................................53
8.1 Maintenance Schedule ..................................................................................................... 54
8.2 Oil Level Inspection.......................................................................................................... 56
8.3 Oil and Oil Filter Change.................................................................................................. 56
8.4 Exhaust Filter Change....................................................................................................... 58
8.5 Machine Cleaning ............................................................................................................ 59
8.6 Inlet Filter Cartridge Change ............................................................................................ 60
9 Overhaul...................................................................................................................................60
10 Decommissioning.....................................................................................................................61
10.1 Dismantling and Disposal ................................................................................................. 61
11 Spare Parts................................................................................................................................61
12 Troubleshooting .......................................................................................................................62
13 Technical Data..........................................................................................................................66
14 Oil ............................................................................................................................................66
15 EU Declaration of Conformity...................................................................................................67

1 | Safety
4 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
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
0870211676_RA0760A_PLUS_-0004_IM_en 5 / 68
2 Product Description
PWS INOUTCU VP
HMI PIL
CAO NP
ESSAILSSB CAI
AHE
ACA
COM LAN
ACA Acoustic cabinet AHE Air-oil heat exchanger
AIL Alarm indicator light CAI Cooling air inlet
CAO Cooling air outlet COM I/O port (D-Sub 9)
CU Control unit ESS Emergency stop switch
HMI User interface (human-machine) IN Suction connection
LAN Communication port (Modbus TCP/IP) NP Nameplate
OUT Discharge connection PIL Power indicator light
PWS Power supply (cable gland) SSB Start/Stop button
VP Vacuum pump

2 | Product Description
6 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
Vacuum pump (VP)
OS IFOFP EF
TSAOF
GBPSA1 MOT
LS
PSA2
OSGODP
TS
EF Exhaust filter GB Gas ballast valve
IF Inlet filter LS Level switch (oil level)
MOT Motor (pump drive) OF Oil filter
ODP Oil drain plug OFP Oil fill plug
OS Oil separator OSG Oil sight glass
PSA1 Pressure transmitter
(inlet gas pressure)
PSA2 Pressure transmitter
(exhaust gas pressure in the oil separator)
TSA Resistance thermometer (oil temp.)
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
0870211676_RA0760A_PLUS_-0004_IM_en 7 / 68
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.
The machine is cooled by an air-oil heat exchanger (AHE). Due to the pressure differen-
tial, the oil naturally circulates in a closed circuit from the vacuum pump (VP) to the air-
oil heat exchanger.
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 [►66].
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [►66].
2.3 Standard Features
2.3.1 User Interface
A user interface, also termed human-machine interface (HMI), allows the control, monit-
oring and configuration of the machine via a 7.5” touchscreen.
Further information in the chapter Description of User Interface Functions [►10].
2.3.2 Acoustic Cabinet
Stylish and functional, the acoustic cabinet (ACA) significantly reduces the sound emitted
by the vacuum pump.
2.3.3 Control Unit
The control unit is an electrical cabinet where a variable-frequency drive, a PLC and
other electrical components are integrated.
It also supplies the air-oil heat exchanger (AHE) with electrical current.
The power supply must be connected to it, see Electrical Connection [►27].

2 | Product Description
8 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
2.3.4 Monitoring Devices
The machine is equipped with several monitoring devices to visualise the operating val-
ues, machine conditions and to protect the machine from any severe damage.
The oil temperature, oil level, inlet gas pressure and counter pressure at the discharge
can be displayed when the machine is running, see Monitoring [►44].
Two signal levels are transmitted, a warning and an alarm/trip, see Warning and Alarm
Signals.
2.3.5 I/O and Communication Port
The control unit (CU) is equipped with two types of communication port that can allow
remote control of the machine:
– D-Sub 9 (Analog and Digital)
– RJ45 (Modbus)
• Refer to the specific document “Pump Control Instructions, art. no.: 0870213261” for
more details or contact your Busch representative.
2.3.6 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 [►66].
2.3.7 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 Optional Accessories
2.4.1 Inlet Filter Condition Monitoring Kit
The Inlet filter condition monitoring kit monitors the pressure differential in the inlet filter
cartridge, to detect when replacement is required. The inlet filter cartridge must be re-
placed when the pressure differential reaches a certain value, which depends on the ap-
plication and operating pressure. This pressure differential threshold must be set in the
control unit, so that a warning is displayed when replacing the cartridge is recommen-
ded, refer to the specific document "Pump Control Instructions, art. no.: 0870213261".
2.4.2 Water-Oil Heat Recovery Unit
For heat recovery purpose or in case of unfavorable ambient conditions, a water-oil heat
exchanger can be provided. See Cooling Water Connection (Optional) [►22].

Product Description | 2
0870211676_RA0760A_PLUS_-0004_IM_en 9 / 68
2.5 P&ID "Piping and Instrumentation Diagram"
PSA1
P
M
CPL MOT1
DN80 PN6
GB
Air
NRV
IF
inlet gas
LS
low oil level
alarm (trip)
PSA2
P
TSA
Toil
AHE
DN80 PN6
IN
OUT
OF
TS
Texhaust gas
VP
exhaust gas
M
MOT2
AHE Air-oil heat exchanger CPL Coupling
GB Gas ballast IF Inlet filter
IN Suction connection LS Level switch "alarm/trip” (oil level)
MOT1 Motor (pump drive) MOT2 Motor (heat exchanger)
NRV Non-return valve
(not used as an isolation valve)
OF Oil filter
OUT Discharge connection PSA1 Pressure transmitter
(inlet gas pressure)
PSA2 Pressure transmitter
(counter pression in the oil separator)
TSA Resistance thermometer (oil temp.)
TS Temperature switch (exhaust gas temp.) VP Vacuum pump
2.6 LED Indicators
Next to the user interface, there are three LED’s which give a visual indication of the ma-
chine state.
The LED is green when
the machine is powered
The LED is green when
the machine is running
The LED flashes in red
when a warning occurred /
The LED is continuously
red when an alarm occurred
Power indicator light (PIL)Start/stop button (SSB) Alarm indicator light (AIL)

2 | Product Description
10 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
2.7 Description of User Interface Functions
The display is divided into three distinct parts.
01.08.2020 - 15:00 ?
Menu tabs
Information
panel
Bottom bar
2.7.1 Menu Overview
The menu consists of four main tabs with their own sub-tabs:
– The tab “HOME”, which is the principal display, is mainly useful for live monitoring.
HOME
MAIN
OPERATIONS
MONITORING
MAINTENANCE SYSTEM
ALARM
– The tab “OPERATIONS” displays the operating parameters/modes and allows con-
trol of the machine.
HOME
MODE
OPERATIONS
PARAMETERS
MAINTENANCE SYSTEM
WEEK PLANNER
– The tab “MAINTENANCE” displays the history of malfunctions, maintenance inter-
vals and operating curves.
HOME
HISTORY
OPERATIONS
SERVICE
MAINTENANCE SYSTEM
TREND
– The tab “SYSTEM” allows to set or change settings, provides information about the
product and its distributor.
HOME
SETTINGS
OPERATIONS
CONTACT
MAINTENANCE SYSTEM
MODEL ETHERNET

Product Description | 2
0870211676_RA0760A_PLUS_-0004_IM_en 11 / 68
2.7.2 Bottom Bar
The bottom bar provides different pieces of information, in particular the machine state
and warning/alarm status.
?
01.08.2020 - 15:00
OFF
RUNNING
WARNING
ALARM
Machine state
Warnings and alarms
status Date and hour
Screen
brightness
Help
2.7.3 Navigation
When several screens are available in the information panel, dots and “PREVIOUS/
NEXT” buttons are displayed above the bottom bar.
• Press either on a dot or “PREVIOUS/NEXT” button to pass from a screen to another
one.
PREVIOUS NEXT
The switch button is black when it is disabled and orange when it is enabled.
• Press on the switch button to change its state.
If a password is required:
• Enter the password, see the chapter Role and User [►12].
Disabled
Enabled
Off
On
When the character “>” is displayed in a cell of the information panel, that means a step
further is available. For example: a redirect link to another view or to open a specific
editing view.
• Press in the cell to open the next dialog windows.
If a password is required:
• Enter the password, see the chapter Role and User [►12].
>
>
Date
Target speed
01 / 01 /2019
60 Hz

2 | Product Description
12 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
2.7.4 Role and User
Three roles of user rights are predefined in the system:
– Role 1 ► Operator
This role is intended for machine operators to control the machine (limited rights) or
monitor operating values. It does not require any password.
– Role 2 ► Installation/Maintenance technician
This role is intended for installation/maintenance technicians to configure the machine
according to the application. The password for this role can be found in the separate
sheet attached to this instruction manual and allows an access to the following features:
– change operating mode,
– reset hours before the next service,
– set the remote control and monitoring parameters, refer to the specific document
"Pump Control Instructions, art. no.: 0870213261".
– Role 3 ► Busch Service
Only authorized personnel from Busch Service have this level of access rights.
NOTE
In case of any questions related to the machine settings:
• Please contact Busch Service.
When a password is required, the display shows this screen:
Password
CANCEL
***
SAVE
• Press on the three stars.
• Fill the correct password in the number pad according to your access right.
• Save it.
• From now on, the specific rights are open for a limited period ► delay of 5 minutes.

Product Description | 2
0870211676_RA0760A_PLUS_-0004_IM_en 13 / 68
2.7.5 System Settings
To edit the system settings (such as date/time, language and units):
• Go to “SYSTEM” > “SETTINGS”.
• Press on the value to change the data.
>
>
>
>
>
HOME
SETTINGS
OPERATIONS
CONTACT
MAINTENANCE SYSTEM
MODEL
Date Language
Time Units
mbar
Warnings and alarms thresholds
°C
English01 / 08 / 2020
13 : 48
ETHERNET
Advanced settings
NOTE
Warnings and alarms thresholds
Thresholds can only be changed by Busch Service “Role 3”, see the predefined factory
settings in the chapter Warnings and Alarms Thresholds [►51].
NOTE
Advanced settings
Advanced settings can only be changed by Busch Service “Role 3”, refer to the specific
document "Pump Control Instructions, art. no.: 0870213261".

2 | Product Description
14 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
2.7.6 Machine and Software Identification
To display the machine and software identification:
• Go to “SYSTEM” > “MODEL”.
HOME
SETTINGS
OPERATIONS
CONTACT
MAINTENANCE SYSTEM
MODEL
Vacuum pump type Vacuum pump model
Software HMI Software PLC
Serial number
R5 PLUS RA 0760 A
2.02.0
CHM120400012
ETHERNET
2.7.7 Ethernet Settings
To configure the ethernet settings according to your network:
• Go to “SYSTEM” > “ETHERNET”.
• Make sure that the Ethernet port (COM) on the right side of the control unit (CU) of
the machine is connected to a computer or to the company network.
• Change the values on the right side of the screen (Change settings), password re-
quired ► Role 2, see Role and User [►12].
• Press on the switch button to save the new settings.
NOTE
The current Ethernet values are displayed in the left side of the screen (Ethernet settings).
To change these values, it is necessary to fill in all the fields in the right side of the
screen (Change settings) before applying the changes by pressing on the switch but-
ton:
• New IP address
• New subnet mask
• New gateway
ðTo change the Ethernet settings, it is necessary to connect the PLUS pump with the
desired equipment beforehand via the Ethernet port available on the right side of the
control cabinet (LAN - see illustration in the chapter “Product Description” of the in-
struction manual of the vacuum pump).

Product Description | 2
0870211676_RA0760A_PLUS_-0004_IM_en 15 / 68
HOME
SETTINGS
OPERATIONS
CONTACT
MAINTENANCE SYSTEM
MODEL ETHERNET
Off
Ethernet settings
Current IP address
192 . 168 . 0 . 22 0 . 0 . 0 . 0
New IP address
Change settings
0 . 0 . 0 . 0
New subnet maskCurrent subnet mask
0 . 0 . 0 . 0
New gatewayCurrent gateway
255 . 255 . 255 . 0
192 . 168 . 0 . 1
/!\ For a modification of the IP address,
an active Ethernet connection is necessary.
Description Default value
IP address 192.168.0.22
Subnet mask 255.255.255.0
Gateway 192.168.0.1
PLC port (0-65535) 502 (cannot be changed)
PLC Slave no. 247 (F7) (cannot be changed)
2.8 Web Visualization
Each machine has a built-in Web visualization interface, which allows remote monitoring
of the main operating parameters from a computer (via a LAN connection or via an op-
tional WIFI connection), a tablet or a smartphone (via an optional WIFI connection).
To use the Web visualization interface via a LAN connection:
• Connect an Ethernet cable to the Ethernet port (COM) on the right side of the control
unit (CU) of the machine.
• Connect the Ethernet cable to the company network or to the computer. To connect
the Ethernet cable to the computer, use a USB/LAN adapter or connect it directly to
the Ethernet port of the computer and use the internal network card (administrator
access required).
• Check the ethernet settings of the machine in the “Ethernet Settings” menu of the
User Interface Display (HMI), see Ethernet Settings [►14]. By default, the ethernet
settings are:
– IP address: 192.168.0.22
– Subnet mask: 255.255.255.0
– Gateway: 192.168.0.1
• Check the ethernet settings of the computer network (Internet Protocol Version 4
(TCP/IPv4) Properties). The Subnet mask and the first 3 bytes of the IP address must
be the same as on the PLUS machine.

2 | Product Description
16 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
• Open your web browser (full screen window) and type the IP address of the machine
to monitor in the address bar, followed by: :8080/smartpump.htm. By default, the
whole address to be typed in the web browser is: 192.168.0.22:8080/smartpump.htm
• When the Web visualization interface opens, select “Computer” as monitoring device.
• The main screen, “Dashboard”, shows the main operating parameters and settings of
the machine (machine status, operating mode, running hours, inlet pressure,…).
• Use the icons in the bottom bar to navigate in the Web visualization interface.

Product Description | 2
0870211676_RA0760A_PLUS_-0004_IM_en 17 / 68
• The second page “Service” shows the service table of the machine and Busch service
contact information.
• The third page “My vacuum pump” gives general information about the machine.
NOTE
• Contact Busch:
ðIf the Ethernet port of the machine (COM) is already used for remote control /
monitoring purpose.
OR
ðIn order to use the Web visualization function via a WIFI connection (requires an
optional WIFI module).
• The Web visualization interface is optimized for Google Chrome.
• To change the IP address of the machine (in the event it is already used by another
machine for instance), go to the “Ethernet Settings” menu of the User Interface Dis-
play (HMI) on the machine, see Ethernet Settings [►14].

3 | Transport
18 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
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.
• Check the machine for transport damage.
If the machine is secured to a base plate:
• Remove the machine from the base plate.

Storage | 4
0870211676_RA0760A_PLUS_-0004_IM_en 19 / 68
As soon as the machine is placed at its final location:
• Remove the reinforcement bar as it can hinder a technician when performing main-
tenance tasks.
• Conserve and remount it for future machine transport.
1
¼
3x
3
2
2x
Remove side
cover
13 mm wrench
• Replace the side cover.
WARNING
Transport and lifting.
Risk of severe injury!
• Handle the machine from its base frame with care to prevent the load from tipping
over.
• Do not use straps, ropes or other lifting means.
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 ... 30 °C.

5 | Installation
20 / 68 0870211676_RA0760A_PLUS_-0004_IM_en
5 Installation
5.1 Installation Conditions
NOTICE
Use of the machine outside of the permitted installation conditions.
Risk of premature failure!
Loss of efficiency!
• Take care that the installation conditions are fully complied with.
~50 cm
~5 cm ~5 cm
~100 cm
~100 cm
• Make sure that the environment of the machine is not potentially explosive.
• Make sure that the ambient conditions comply with the Technical Data [►66].
• Make sure that the environmental conditions comply with the protection class IP54.
• 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 is acceptable.
• Check the oil level, see Oil Level Inspection.
• 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.