BUSCH R 5 series User manual

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R5
Oil-lubricated Rotary Vane Vacuum Pumps
KD 0012 A, KD 0020 A
Instruction Manual
0870214060 | A0004_en-US | Original instructions 1/10/2023

Table of Contents
2 | 32 Instruction Manual R5 KD 0012-0020 A_EN_en
Table of Contents
1 Safety..................................................................................................................................................................... 3
2 Product Description............................................................................................................................................. 4
2.1 Operating Principle ............................................................................................................................................. 5
2.2 Intended Use ....................................................................................................................................................... 5
2.3 Variants................................................................................................................................................................. 6
2.4 Start Controls....................................................................................................................................................... 6
2.5 Optional Accessories........................................................................................................................................... 7
2.5.1 Rubber feet ............................................................................................................................................ 7
2.5.2 Extension Cables ................................................................................................................................... 7
3 Transport .............................................................................................................................................................. 8
4 Storage .................................................................................................................................................................. 9
5 Installation ........................................................................................................................................................... 10
5.1 Installation Conditions........................................................................................................................................ 10
5.2 Connecting Lines / Pipes .................................................................................................................................... 10
5.2.1 Suction Connection............................................................................................................................... 11
5.2.2 Discharge Connection .......................................................................................................................... 11
5.3 Filling Oil............................................................................................................................................................... 11
6 Electrical Connection........................................................................................................................................... 13
6.1 Machine delivered without Control Box or Variable Speed Drive (VSD)....................................................... 13
6.2 Wiring Diagram Single-Phase Motor ................................................................................................................ 14
6.3 Capacitor Installation.......................................................................................................................................... 15
7 Commissioning..................................................................................................................................................... 17
7.1 Conveying Condensable Vapors........................................................................................................................ 17
8 Maintenance......................................................................................................................................................... 18
8.1 Maintenance Schedule ....................................................................................................................................... 19
8.2 Oil Level Inspection............................................................................................................................................. 19
8.3 Oil Change............................................................................................................................................................ 19
8.4 Exhaust Filter Change......................................................................................................................................... 21
9 Overhaul................................................................................................................................................................ 22
10 Decommissioning................................................................................................................................................. 23
10.1 Dismantling and Disposal .................................................................................................................................. 23
11 Spare Parts............................................................................................................................................................ 24
12 Troubleshooting................................................................................................................................................... 25
13 Technical Data...................................................................................................................................................... 27
14 Oil........................................................................................................................................................................... 28
15 EU Declaration of Conformity............................................................................................................................. 29
16 UK Declaration of Conformity ............................................................................................................................ 30

Safety | 1
Instruction Manual R5 KD 0012-0020 A_EN_en 3 | 32
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. Never-
theless, residual risks may remain, as described in the following chapters and in accordance with the
chapter Intended Use [➔5]. This instruction manual highlights potential hazards where appropri-
ate. 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 trou-
ble-free operation.

2 | Product Description
4 | 32 Instruction Manual R5 KD 0012-0020 A_EN_en
2 Product Description
OFP EF OUT TL IN DA CC PWS
CS
ODP OSG NP
CAP
Description
OFP Oil fill plug EF Exhaust filter
OUT Gas discharge TL Transport lug
IN Suction connection DA Directional arrow
CC Capacitor connection PWS Power supply (MATE-N-LOK)
CS Capacitor support ODP Oil drain plug
OSG Oil sight glass NP Nameplate
CAP Capacitor
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 | 32
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.
In order to avoid reverse rotation after switching off, the machine is equipped with a non-return
valve (NRV).
In order to avoid solids from entering, the machine is equipped with an inlet screen (IS).
Exhaust filters separate the oil from the discharged gas.
2.2 Intended Use
WARNING
In case of foreseeable misuse outside the intended use of the machine.
Risk of injuries!
Risk of damages to the machine!
Risk of damages to the environment!
●Make sure to follow all instructions described in this manual.
The machine is intended for the suction of air and other dry, non-aggressive, non-toxic and non-ex-
plosive 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 rep-
resentative in order to take specific precautions.
The machine is capable of maintaining ultimate pressure, see Technical Data [➔27].
Permitted environmental conditions, see Technical Data [➔27].
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 se-
ries*
* (Depending on the use of the pump under these conditions, other oil types might be more ap-
propriate! Contact Busch for specification.)

2 | Product Description
6 | 32 Instruction Manual R5 KD 0012-0020 A_EN_en
Remark Number of cycles for S3 Motors:
The maximum number of cycles is depending on the motor and electrical supply, the evacuated
chamber volume and ambient conditions. The stated values were measured at an ambient tempera-
ture of 20°C.
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 loading, 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 %).
2.3 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
Var. 1 Var. 2
Var. 3
Description
Var. 1 KD 0012 A / KD 0020 A Var. 2 KD 0020 A only
Var. 3 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.

Product Description | 2
Instruction Manual R5 KD 0012-0020 A_EN_en 7 | 32
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 [➔000].

3 | Transport
8 | 32 Instruction Manual R5 KD 0012-0020 A_EN_en
3 Transport
WARNING
Suspended load.
Risk of severe injury!
●Do not walk, stand or work under suspended loads.
●To find out the weight of the machine, refer to the chapter Technical Data [➔27] or the name-
plate (NP).
1
Description
1 Use the transport lug (TL) to lift the ma-
chine!
●Check the machine for transport damage.
If the machine is secured to a base plate:
●Remove the machine from the base plate.

Storage | 4
Instruction Manual R5 KD 0012-0020 A_EN_en 9 | 32
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
10 | 32 Instruction Manual R5 KD 0012-0020 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.
●Make sure that the environment of the machine is not potentially explosive.
●Make sure that the ambient conditions comply with the Technical Data [➔27].
●Make sure that the environmental conditions comply with the protection class of the motor and
the electrical elements.
●Make sure that the installation space or location is protected from weather and lightning.
●Make sure that the installation space or location is vented such that sufficient cooling of the ma-
chine 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 deviation of 1° in any
direction is acceptable.
●Check the oil level, fill up if necessary, see Filling Oil [➔11].
●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 connection of the machine; if neces-
sary 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 effi-
ciency. Seek advice from your Busch representative.

Installation | 5
Instruction Manual R5 KD 0012-0020 A_EN_en 11 | 32
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.
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 [➔27] and Oil [➔28].

5 | Installation
12 | 32 Instruction Manual R5 KD 0012-0020 A_EN_en
Max. admissible
torque: 12 Nm
1
2
Description
1 1x o-ring, part no.: 0486 000 590 2 Max. admissible torque: 12 Nm

Electrical Connection | 6
Instruction Manual R5 KD 0012-0020 A_EN_en 13 | 32
6 Electrical Connection
DANGER
Live wires.
Risk of electrical shock.
●Electrical installation work must only be executed by qualified personnel.
CURRENT PROTECTION OF THE CUSTOMER INSTALLATION:
DANGER
Missing current protection.
Risk of electrical shock.
●Current protection according to EN 60204-1 must be insured by the customer on its installation.
●The electrical installation must comply with the applicable national and international standards.
NOTICE
Electromagnetic compatibility.
●Make sure that the motor of the machine will not be affected by electric or electromagnetic dis-
turbance from the mains, if necessary seek advice from Busch.
●Make sure that the EMC of the machine is compliant with the requirements of your supply net-
work system, if necessary provide further interference suppression (EMC of the machine, see EU
Declaration of Conformity [➔29] or UK Declaration of Conformity [➔30]).
6.1 Machine delivered without Control Box or Variable
Speed Drive (VSD)
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.
●If the machine is equipped with a power connector, install a residual current protective device to
protect persons in case of isolation default.
●Busch recommends installing a type B residual protective device suitable for the electrical in-
stallation.
●Provide a lockable disconnect switch or an emergency stop switch on the power line so that the
machine is completely secured in case of an emergency situation.

6 | Electrical Connection
14 | 32 Instruction Manual R5 KD 0012-0020 A_EN_en
●Provide a lockable disconnect switch on the power line so that the machine is completely secured
during maintenance tasks.
●Provide an overload protection according to EN 60204-1 for the motor.
●Busch recommends installing a D-curve circuit breaker.
●Electrically connect the motor.
6.2 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
(See also page 5)
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 necessary
Connector type AMP MATE-N-LOK (cable lengths max. 100 mm)

Electrical Connection | 6
Instruction Manual R5 KD 0012-0020 A_EN_en 15 | 32
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
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
6.3 Capacitor Installation
The machine needs a suitable capacitor (CAP) to operate, see [➔000].
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

6 | Electrical Connection
16 | 32 Instruction Manual R5 KD 0012-0020 A_EN_en
●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 [➔000].
●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).

Commissioning | 7
Instruction Manual R5 KD 0012-0020 A_EN_en 17 | 32
7 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 [➔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 to wear hearing protection.
●Make sure that the Installation Conditions [➔10] are met.
●Start the machine.
●Make sure that the operating conditions comply with the Technical Data [➔27].
●After a few minutes of operation, perform an Oil Level Inspection [➔19].
As soon as the machine is operated under normal operating conditions:
●Measure the motor current and record it as reference for future maintenance and trouble-
shooting work.
7.1 Conveying Condensable Vapors
Water vapor within the gas flow is tolerated within certain limits. The conveyance of other vapors
shall be agreed upon with Busch.
If condensable vapors 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.

8 | Maintenance
18 | 32 Instruction Manual R5 KD 0012-0020 A_EN_en
8 Maintenance
DANGER
Live wires.
Risk of electrical shock.
●Electrical installation work must only be executed by qualified personnel.
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.
CAUTION
Failing to properly maintain the machine.
Risk of injuries!
Risk of premature failure and loss of efficiency!
●Maintenance work must only be executed by qualified personnel.
●Respect the maintenance intervals or ask your Busch representative for service.
NOTICE
Using inappropriate cleaners.
Risk of removing safety stickers and protective paint!
●Do not use incompatible solvents to clean the machine.
●Shut down the machine and lock against inadvertent start up.
●Vent the connected lines to atmospheric pressure.
If necessary:
●Disconnect all connections.

Maintenance | 8
Instruction Manual R5 KD 0012-0020 A_EN_en 19 | 32
8.1 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 extended as appropri-
ate. Particularly harsh applications or heavy duty operation, such as high dust loads in the environ-
ment or in the process gas, other contamination or ingress of process material, can make it neces-
sary to shorten the maintenance intervals significantly.
Interval Maintenance work
Daily ●Check the oil level, see Oil Level Inspection [➔19].
Weekly ●Check the machine for oil leaks - in case of leaks have the
machine repaired (contact Busch).
Every 2000 hours or every 6
months
●Change the oil and the exhaust filters (EF).
Every 5 years ●Have a major overhaul on the machine (contact Busch).
8.2 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 [➔11].
8.3 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.

8 | Maintenance
20 | 32 Instruction Manual R5 KD 0012-0020 A_EN_en
1
2
Description
1 1x o-ring, part no.: 0486 000 505 2 Max. admissible torque: 12 Nm
For oil type and oil capacity see Technical Data [➔27] and Oil [➔28].
Max. admissible
torque: 12 Nm
1
2
Description
1 1x o-ring, part no.: 0486 000 590 2 Max. admissible torque: 12 Nm