BUSCH R 5 series User manual

Instruction Manual
R 5
Oil-Lubricated Rotary Vane Vacuum Pumps
RAH 200 A, RAH 300 A
0870564399/A0003_en / Original instructions / Modifications reserved 22/02/2018
Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland

Table of Contents
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Table of Contents
1 Safety........................................................................................................................... 3
2 Product Description ..................................................................................................... 4
2.1 Operating Principle............................................................................................... 5
2.2 Application ........................................................................................................... 5
2.3 Standard Features................................................................................................. 5
2.3.1 Water Cooling ...........................................................................................5
2.3.2 Thermometer.............................................................................................5
2.3.3 Gas Ballast Valve........................................................................................5
2.4 Optional Accessories............................................................................................. 6
2.4.1 Inlet Filter ..................................................................................................6
2.4.2 Air-cooled Motor.......................................................................................6
2.4.3 Temperature Switch...................................................................................6
2.4.4 Resistance Thermometer............................................................................6
3 Transport ..................................................................................................................... 6
4 Storage......................................................................................................................... 7
5 Installation................................................................................................................... 8
5.1 Installation Conditions .......................................................................................... 8
5.2 Connecting Lines / Pipes ......................................................................................8
5.2.1 Suction Connection....................................................................................9
5.2.2 Discharge Connection................................................................................9
5.2.3 Cooling Water Connection ........................................................................10
5.3 Filling Oil..............................................................................................................11
5.4 Electrical Connection ............................................................................................11
5.4.1 Wiring Diagram Three-Phase Motor ..........................................................12
5.5 Electrical Connection of the Monitoring Devices ................................................... 13
5.5.1 Wiring Diagram Temperature Switch (Optional) ........................................13
5.5.2 Wiring Diagram Resistance Thermometer (Optional) .................................13
5.5.3 Wiring Diagram Level and Temperature Switch (Optional) ........................13
6 Commissioning............................................................................................................ 14
6.1 Conveying Condensable Vapours ......................................................................... 14
7 Maintenance................................................................................................................ 15
7.1 Maintenance Schedule.......................................................................................... 15
7.2 Oil Level Inspection .............................................................................................. 16
7.3 Oil and Oil Filter Change ......................................................................................16
7.4 Exhaust Filter Change ...........................................................................................18
8 Overhaul...................................................................................................................... 19
9 Decommissioning ........................................................................................................ 20
9.1 Dismantling and Disposal...................................................................................... 20
10 Spare Parts................................................................................................................... 20
11 Troubleshooting........................................................................................................... 21
12 Technical Data ............................................................................................................. 23
13 Oil ............................................................................................................................... 23
14 EU Declaration of Conformity ...................................................................................... 24

Safety | 1
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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.

2 | Product Description
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2 Product Description
OF NP OS EF
IN
OUT OFP
DAMTBEB DAMTB
EB
IN CWO
GB TM
ODP
OSG
WHE
CWO CWI CWI
Air-cooled motor version
(Optional)
Water-cooled motor version
(Standard)
IN Suction connection MTB Motor terminal box
OUT Discharge connection DA Directional arrow
OFP Oil fill plug EF Exhaust filter
OSG Oil sight glass NP Nameplate
ODP Oil drain plug OF Oil filter
EB Eye bolt TM Thermometer
GB Gas ballast valve OS Oil separator
CWI Cooling water inlet CWO Cooling water outlet
WHE Water-oil heat exchanger
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
pump’.

Product Description | 2
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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 capable of maintaining ultimate pressure, see Technical Data [►23].
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [►23].
2.3 Standard Features
2.3.1 Water Cooling
The machine is driven by a water-cooled motor.
The water-oil heat exchanger allows the machine to have a suitable oil cooling.
2.3.2 Thermometer
The thermometer allows a visual display of the oil temperature.
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 [►23].

3 | Transport
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2.4 Optional Accessories
2.4.1 Inlet Filter
The inlet filter protects the machine against dust and other solids in the process gas. The
inlet filter is available with a paper or polyester cartridge.
2.4.2 Air-cooled Motor
An air-cooled motor can be provided instead of the standard water-cooled motor.
2.4.3 Temperature Switch
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 [►23].
2.4.4 Resistance Thermometer
The resistance thermometer monitors the oil temperature of the machine.
Depending on the oil type, a warning and a trip signals must be set, see Oil [►23].
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.

Storage | 4
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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.
4 Storage
• Seal all apertures with adhesive tape or reuse provided caps.
• Make sure that the cooling water has been completely removed, see Decommission-
ing [►20].
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
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5 Installation
5.1 Installation Conditions
~20 cm
~20 cm (with water-cooled motor)
~50 cm (with air-cooled motor)
~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 [►23].
• 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 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.
• Check the oil level, see Oil Level Inspection [►16].
• 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 [►10].
Version with air-cooled motor:
• 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.
If the machine is installed at an altitude greater than 1000 meters above sea level:
• Contact your Busch representative, the motor should be derated or the ambient
temperature limited.
5.2 Connecting Lines / Pipes
• Remove all protective caps before installation.
• Make sure that the connection lines cause no stress on the machine‘s connection; if
necessary use flexible joints.
• Make sure that the line size of the connection lines over the entire length is at least as
large as the connections of the machine.

Installation | 5
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In case of very long connection lines it is advisable to use larger line sizes in order to
avoid a loss of efficiency. Seek advice from your Busch representative.
5.2.1 Suction Connection
WARNING
Unprotected suction connection.
Risk of severe injury!
• Do not put hand or fingers in the suction connection.
NOTICE
Intruding 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:
– G2
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:
– G2
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
Air-cooled motor version
(Optional)
Water-cooled motor version
(Standard)
CWOCWI WHE CWOCWI 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:
– 19 mm hose (CWI / CWO)
• Make sure that the cooling water complies with the following requirements:
Min. supply capacity l/min 2
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 [►23] and Oil [►23].
1
4
MAX
MIN
3
2
Busch Oil
Check oil level
1x o-ring, part no.:
0486 000 513
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.
• Provide 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.

5 | Installation
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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.
5.4.1 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.
• Determine the intended direction of rotation with the arrow (stuck on or cast).
• Jog the motor briefly.

Installation | 5
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• With a phase rotation tester, check if the wiring corresponds to the correct direction of
rotation.
Version with air-cooled motor:
• Watch the fan wheel of the motor and determine the direction of rotation just be-
fore 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 10 seconds.
5.5.1 Wiring Diagram Temperature Switch (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 [►23].
5.5.2 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 [►23].
1 2
4 3
3
1
+
-
1 = Brown ; 3 = Blue
5.5.3 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
* The switch point value depends on the oil type, see Oil [►23].

6 | Commissioning
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6 Commissioning
NOTICE
The machine is 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 [►11].
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 [►8]) are com-
plied with.
• Open the water supply.
• Switch on the machine.
• Make sure that the maximum permissible number of starts does not exceed 12 starts
per hour.
• Make sure that the operating conditions are complied with, see Technical Data
[►23].
• After 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.
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:

Maintenance | 7
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START
Open the gas ballast
valve* (GB)
Warm up the
machine
30 minutes 30 minutes
• Open the inlet valve
• Perform the process
• Close the inlet valve
Close the gas ballast
valve*
END
* may be considered as optional on certain products
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.
• 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.
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 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 significant-
ly.
Maintenance work Interval
Normal application Harsh application
• Check the oil level, see Oil Level Inspec-
tion [►16].
Daily

7 | Maintenance
16 / 28 0870564399_RAH200-300A_A0003_IM_en
• Check the machine for oil leaks - in case of
leaks have the machine repaired (contact
Busch).
In case of an inlet filter being installed:
• Check the inlet filter cartridge, replace if
necessary.
Monthly
• Change the oil*, the oil filter* (OF) and
the exhaust filters (EF).
Max. after 4000
hours, at the latest
after 1 year
Max. after 2000
hours, at the latest
after 6 months
• Clean the machine from dust and dirt.
In case of a gas ballast valve (GB) being in-
stalled:
• Clean the filter of the gas ballast valve.
In case of a standard air cooler (AHE) being
installed:
• Check and/or clean the air cooler.
In case of a water cooler (WHE) being in-
stalled:
• Check and/or clean the water cooling sys-
tem.
Every 6 months
• Contact Busch for an inspection.
If required, overhaul the machine.
Every 5 years
* Shorten the interval when using mineral oil, contact Busch Service
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
MAX
MIN
MAX
MIN
MAX
MIN
• Fill up if necessary, see Oil Filling [►11].
7.3 Oil and Oil Filter 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.

Maintenance | 7
0870564399_RAH200-300A_A0003_IM_en 17 / 28
1
2
Drain pan
1x o-ring, part no.:
0486 000 505
1
USED
2
3
0531 000
0531 000
0531 000
001
001
Oil filter wrench
Busch genuine spare parts
1x oil filter (OF), part no.: 0531 000 001

7 | Maintenance
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For oil type and oil capacity see Technical Data [►23] and Oil [►23].
1
4
MAX
MIN
3
2
Busch Oil
Check oil level
1x o-ring, part no.:
0486 000 513
7.4 Exhaust Filter Change
4x
1
2
10 mm wrench
3x exhaust filter (EF)

Overhaul | 8
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1
4x
2
10 mm wrench
Max. admissible torque: 8 Nm
1x flat gasket
part no.: 0481 502 721
Busch genuine spare parts
3x exhaust filter (EF), part no.: 0532 140 159
8 Overhaul
NOTICE
Improper assembly.
Risk of premature failure!
Loss of efficiency!
• It is highly recommended that any dismantling of the machine that goes beyond any-
thing that is described in this manual should be done through Busch.
WARNING
Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:
• Wear appropriate personal protective equipment.
In case of the machine having conveyed gas that was contaminated with foreign materi-
als which are dangerous to health:
• Decontaminate the machine as well as possible and state the contamination status
in a ‘Declaration of Contamination’.
Busch will only accept machines that come with a completely filled in and legally binding
signed ‘Declaration of Contamination’.
(Form downloadable from www.buschvacuum.com)

9 | Decommissioning
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9 Decommissioning
• Shut down the machine and lock against inadvertent start up.
• Turn off the water supply.
• Vent the connected lines to atmospheric pressure.
• Blow through the water cooling inlet with compressed air.
• Disconnect all connections.
If the machine is going to be stored:
• See Storage [►7].
9.1 Dismantling and Disposal
• Drain the oil.
• Remove the exhaust filters.
• Remove the oil filter.
• 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
NOTICE
Use of non-Busch genuine spare parts.
Risk of premature failure!
Loss of efficiency!
• The exclusive use of Busch genuine spare parts and consumables is recommended for
the proper function of the machine and for granting of warranty.
Spare parts kit Description Part no.
Service kit
(RAH 200/300A)
Includes all the necessary parts for main-
tenance.
0992 516 595
If other parts are required:
• Contact your Busch representative for the detailed spare parts list.