BUSCH R 5 series User manual

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Instruction Manual
R5
Oil-Lubricated Rotary Vane Vacuum Pumps
RA 0155 A
0870562170/A0006_en / Original instructions / Modifications reserved 29/09/2021
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Table of Contents
2 / 28 Instruction Manual R5 RA 0155 A_EN_en
Table of Contents
1 Safety .......................................................................................................................................3
2 Product Description ..................................................................................................................4
2.1 Operating Principle .......................................................................................................... 5
2.2 Application....................................................................................................................... 5
2.3 Start Controls ................................................................................................................... 5
2.4 Optional Accessories ........................................................................................................ 5
2.4.1 Gas Ballast Valve ...................................................................................................5
2.4.2 Inlet Filter ..............................................................................................................5
2.4.3 Temperature Switch "Oil".....................................................................................6
2.4.4 Resistance Thermometer ....................................................................................... 6
2.4.5 Level Switch ..........................................................................................................6
3 Transport ..................................................................................................................................6
4 Storage .....................................................................................................................................7
5 Installation................................................................................................................................8
5.1 Installation Conditions...................................................................................................... 8
5.2 Connecting Lines / Pipes .................................................................................................. 9
5.2.1 Suction Connection ...............................................................................................9
5.2.2 Discharge Connection ........................................................................................... 9
5.3 Filling Oil.......................................................................................................................... 10
5.4 Fitting the Coupling ......................................................................................................... 11
5.5 Electrical Connection ........................................................................................................ 11
5.5.1 Wiring Diagram Three-Phase Motor...................................................................... 12
5.6 Electrical Connection of the Monitoring Devices............................................................... 13
5.6.1 Wiring Diagram Level Switch (Optional)................................................................ 13
5.6.2 Wiring Diagram Temperature Switch "Oil" (Optional) .......................................... 13
5.6.3 Wiring Diagram Resistance Thermometer (Optional)............................................. 14
6 Commissioning.........................................................................................................................14
6.1 Conveying Condensable Vapours..................................................................................... 14
7 Maintenance.............................................................................................................................15
7.1 Maintenance Schedule ..................................................................................................... 16
7.2 Oil Level Inspection.......................................................................................................... 16
7.3 Oil and Oil Filter Change.................................................................................................. 17
7.4 Exhaust Filter Change....................................................................................................... 19
8 Overhaul...................................................................................................................................20
9 Decommissioning.....................................................................................................................20
9.1 Dismantling and Disposal ................................................................................................. 20
10 Spare Parts................................................................................................................................21
11 Troubleshooting .......................................................................................................................21
12 Technical Data..........................................................................................................................24
13 Oil ............................................................................................................................................24
14 EU Declaration of Conformity...................................................................................................25
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Safety | 1
Instruction Manual R5 RA 0155 A_EN_en 3 / 28
1 Safety
Prior to handling the machine, this instruction manual should be read and understood. If
anything needs to be clarified, please contact your Busch representative.
Read this manual carefully before use and keep for future reference.
This instruction manual remains valid as long as the customer does not change anything
on the product.
The machine is intended for industrial use. It must be handled only by technically trained
personnel.
Always wear appropriate personal protective equipment in accordance with the local
regulations.
The machine has been designed and manufactured according to state-of-the-art meth-
ods. Nevertheless, residual risks may remain. This instruction manual highlights potential
hazards where appropriate. Safety notes and warning messages are tagged with one of
the keywords DANGER, WARNING, CAUTION, NOTICE and NOTE as follows:
DANGER
... indicates an imminent dangerous situation that will result in death or serious injuries if
not prevented.
WARNING
... indicates a potentially dangerous situation that could result in death or serious injuries.
CAUTION
... indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
... indicates a potentially dangerous situation that could result in damage to property.
NOTE
... indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.
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2 | Product Description
4 / 28 Instruction Manual R5 RA 0155 A_EN_en
2 Product Description
NPOS EB IN GB OUT
AFOFPODPOSGOFMTBDA
EF
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 AF Axial fan
GB Gas ballast valve OS Oil separator
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.
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Product Description | 2
Instruction Manual R5 RA 0155 A_EN_en 5 / 28
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 [►24].
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [►24].
2.3 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 optionally equipped with a starter unit or a variable-frequency drive.
2.4 Optional Accessories
2.4.1 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 [►24].
2.4.2 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.
The clamped design makes it easy to adjust the position to the installation and the o-ring
sealing guaranties the tightness.
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3 | Transport
6 / 28 Instruction Manual R5 RA 0155 A_EN_en
2.4.3 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 [►24].
2.4.4 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 [►24].
2.4.5 Level Switch
The level switch monitors the oil level.
The machine must be stopped when the oil level is too low.
3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
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
shown.
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(s) (EB) is/are in faultless condition, fully screwed in and
tightened by hand.
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Storage | 4
Instruction Manual R5 RA 0155 A_EN_en 7 / 28
Machine weight:
see the technical data or the nameplate (NP)
• 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.
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5 | Installation
8 / 28 Instruction Manual R5 RA 0155 A_EN_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.
~20 cm
~50 cm
~20 cm
~50 cm
• Make sure that the environment of the machine is not potentially explosive.
• Make sure that the ambient conditions comply with the Technical Data [►24].
• 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 [►16].
• 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.
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
[►13].
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Installation | 5
Instruction Manual R5 RA 0155 A_EN_en 9 / 28
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 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
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):
– 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(s):
– 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
liquid separator or a siphon with a drain cock, so that no liquids can flow back into the
machine.
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5 | Installation
10 / 28 Instruction Manual R5 RA 0155 A_EN_en
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 [►24] and Oil [►24].
1
4
3
MAX
MIN
2
Busch Oil
Check oil level
1x o-ring, part no.:
0486 000 590
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Installation | 5
Instruction Manual R5 RA 0155 A_EN_en 11 / 28
5.4 Fitting the Coupling
E
L
Coupling hub (machine side) Coupling hub (motor side)Coupling sleeve
Radial screw
Max. admissible
torque: 10 Nm
Machine type Coupling size Value “E” (mm) Value “L” (mm)
RA 0155 A BoWex® M-48 4 104
In case of a machine delivery without motor:
• Fit the second coupling hub on the motor shaft (separately delivered).
• Axially adjust the sleeve in such a way until value "E" (or “L”) is reached.
• When the coupling adjustment is done, lock the coupling hub by tightening the
radial screw.
• Mount the motor on the machine by including the coupling sleeve.
For further coupling information, go to www.ktr.com and download the instruction man-
ual of the BoWex® coupling.
5.5 Electrical Connection
DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
NOTE
The operation with variable speed, i.e. with a variable-frequency drive or a soft starter
unit, is allowed as long as the motor is admitted and the permitted motor speed range is
neither underrun nor exceeded (see Technical Data [►24]).
Seek advice from your Busch representative.
• 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.
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5 | Installation
12 / 28 Instruction Manual R5 RA 0155 A_EN_en
• 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.
• 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.
5.5.1 Wiring Diagram Three-Phase Motor
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.
• 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.
Delta connection (low voltage): Star connection (high voltage):
Double star connection, multi-voltage
motor with 9 pins (low voltage):
Star connection, multi-voltage motor
with 9 pins (high voltage):
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Installation | 5
Instruction Manual R5 RA 0155 A_EN_en 13 / 28
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
5.6 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.
5.6.1 Wiring Diagram Level Switch (Optional)
Part no.: 0652569 236
Connector: M12x1, 4-pin
Electrical data:
U = 10 – 30 V DC
I consumption : <15 mA
I output max : 150 mA
Switch point:
Pin 1 = low level
1
4
3
0.5 A
K
1 = Brown: Supply +24V DC
3 = Blue: Supply 0V DC
4 = Black: Signal low level
NOTE:
For this device, the recommended time de-
lay to prevent nuisance alarms can be up to
240 seconds.
5.6.2 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 [►24].
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6 | Commissioning
14 / 28 Instruction Manual R5 RA 0155 A_EN_en
5.6.3 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 [►24].
1 2
4 3
3
1
+
-
1 = Brown ; 3 = Blue
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 [►10].
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 [►8]) are met.
• 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 [►24].
• 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.
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:
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Maintenance | 7
Instruction Manual R5 RA 0155 A_EN_en 15 / 28
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
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.
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7 | Maintenance
16 / 28 Instruction Manual R5 RA 0155 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.
Maintenance work Interval
Normal application Harsh application
• Check the oil level, see Oil Level Inspec-
tion [►16].
Daily
• Check the machine for oil leaks - in case of
leaks have the machine repaired (contact
Busch).
In case an inlet filter is installed:
• Check the inlet filter cartridge, replace it 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 gas ballast valve.
Every 6 months
• Contact Busch for an inspection.
If required, overhaul the machine.
Every 5 years
* Service interval for synthetic oil, 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
• Fill up if necessary, see Oil Filling [►10].
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Maintenance | 7
Instruction Manual R5 RA 0155 A_EN_en 17 / 28
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.
1
2
Drain pan
1x o-ring, part no.:
0486 000 505
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7 | Maintenance
18 / 28 Instruction Manual R5 RA 0155 A_EN_en
USED
1
USED
2
NEW
0531 000
0531 000
0531 000
001
001
3
Busch genuine spare parts
1x oil filter (OF), part. no.: 0531 000 002
Oil filter wrench
For oil type and oil capacity see Technical Data [►24] and Oil [►24].
1
4
3
MAX
MIN
2
Busch Oil
Check oil level
1x o-ring, part no.:
0486 000 590
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Maintenance | 7
Instruction Manual R5 RA 0155 A_EN_en 19 / 28
7.4 Exhaust Filter Change
5x
1
2
10 mm wrench
2x exhaust filters (EF)
1
5x
2
10 mm wrench
1x flat gasket
part no.: 0480 560 234
Busch genuine spare parts
2x exhaust filter (EF), art. no.: 0532 140 159
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8 | Overhaul
20 / 28 Instruction Manual R5 RA 0155 A_EN_en
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
• Shut down the machine and lock against inadvertent start up.
• 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
• 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.
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