BUSCH R5 PLUS User manual

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R5 PLUS
Oil-Lubricated Rotary Vane Vacuum Pumps
RA 0840 A PLUS without cabinet
Instruction Manual
0870242418 | -0001_en-US | Original instructions 2/22/2023

Table of Contents
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Table of Contents
1 Safety ..................................................................................................................................................................... 4
2 Product Description ............................................................................................................................................. 5
2.1 Operating Principle............................................................................................................................................. 6
2.2 Intended Use ....................................................................................................................................................... 6
2.3 Standard Features............................................................................................................................................... 7
2.3.1 User Interface ....................................................................................................................................... 7
2.3.2 Control Unit........................................................................................................................................... 7
2.3.3 Monitoring Devices .............................................................................................................................. 7
2.3.4 I/O and Communication Port.............................................................................................................. 7
2.3.5 Gas Ballast Valve................................................................................................................................... 7
2.4 Optional Accessories........................................................................................................................................... 7
2.4.1 Inlet Filter .............................................................................................................................................. 7
2.4.2 Inlet Filter Condition Monitoring Kit .................................................................................................. 7
2.4.3 Water-Oil Heat Recovery Unit ............................................................................................................. 7
2.5 P&ID "Piping and Instrumentation Diagram" ................................................................................................. 8
2.6 LED Indicators...................................................................................................................................................... 8
2.7 Description of User Interface Functions .......................................................................................................... 9
2.7.1 Menu Overview..................................................................................................................................... 9
2.7.2 Bottom Bar ............................................................................................................................................ 10
2.7.3 Navigation ............................................................................................................................................. 10
2.7.4 Roles and Users .................................................................................................................................... 11
2.7.5 System Settings .................................................................................................................................... 12
2.7.6 Machine and Software Identification................................................................................................. 13
2.7.7 Ethernet Settings.................................................................................................................................. 13
2.8 Web Visualization ................................................................................................................................................ 14
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.......................................................................................................................... 22
5.2.3 Cooling Water Connection (Optional)................................................................................................ 22
5.2.4 Inlet Filter Condition Monitoring Kit .................................................................................................. 24
5.2.5 External Inlet Pressure Sensor ........................................................................................................... 24
5.3 Filling Oil............................................................................................................................................................... 25
5.4 Fitting the Coupling ............................................................................................................................................ 26
6 Electrical Connection ........................................................................................................................................... 27
6.1 PLUS Machine ...................................................................................................................................................... 27
6.2 Wiring Diagram Control Unit............................................................................................................................. 29
7 Commissioning ..................................................................................................................................................... 31
7.1 Prerequisites Before Use.................................................................................................................................... 31
7.2 Configuration....................................................................................................................................................... 31
7.3 Start Up................................................................................................................................................................. 32
8 In Operation.......................................................................................................................................................... 33
8.1 Control Mode....................................................................................................................................................... 33
8.1.1 Local/Manual......................................................................................................................................... 34
8.1.2 Local/Auto "Week Planner" ................................................................................................................. 34
8.1.3 Remote/Auto......................................................................................................................................... 35

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Instruction Manual R5 RA 0840 A PLUS without cabinet_EN_en 3 | 76
8.2 Operating Mode .................................................................................................................................................. 36
8.2.1 Speed Control ....................................................................................................................................... 36
8.2.2 Pressure Control................................................................................................................................... 37
8.3 Ecomode............................................................................................................................................................... 38
8.4 Gas Ballast Valve Control ................................................................................................................................... 39
8.5 Warm-up / Cool-down Modes............................................................................................................................ 40
8.5.1 Conveying Condensable Vapors......................................................................................................... 41
8.6 Optional Inlet Valve Control............................................................................................................................... 42
8.7 Optional Vacuum Booster Control.................................................................................................................... 44
8.8 Monitoring ........................................................................................................................................................... 46
8.8.1 Operating Information ........................................................................................................................ 46
8.8.2 Operating Data ..................................................................................................................................... 47
8.8.3 History.................................................................................................................................................... 49
8.8.4 Operating Curves ................................................................................................................................. 50
8.9 Dysfunction.......................................................................................................................................................... 51
8.9.1 Warnings and Alarms Thresholds ...................................................................................................... 51
8.9.2 Warning/Alarm Acknowledgment Procedure................................................................................... 53
8.10 Stop the Machine ................................................................................................................................................ 54
9 Maintenance ......................................................................................................................................................... 55
9.1 Maintenance Schedule ....................................................................................................................................... 56
9.2 Oil Level Inspection............................................................................................................................................. 58
9.3 Oil and Oil Filter Change .................................................................................................................................... 58
9.4 Exhaust Filter Change......................................................................................................................................... 60
9.5 Air Heat Exchanger Cleaning............................................................................................................................. 61
10 Overhaul ................................................................................................................................................................ 62
11 Decommissioning ................................................................................................................................................. 63
11.1 Dismantling and Disposal .................................................................................................................................. 63
12 Spare Parts ............................................................................................................................................................ 64
13 Troubleshooting ................................................................................................................................................... 65
14 Technical Data ...................................................................................................................................................... 69
15 Oil ........................................................................................................................................................................... 70
16 EU Declaration of Conformity ............................................................................................................................. 71
17 UK Declaration of Conformity............................................................................................................................. 72

1 | Safety
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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 methods. Never-
theless, residual risks may remain, as described in the following chapters and in accordance with the
chapter Intended Use [➔6]. 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.

Product Description | 2
Instruction Manual R5 RA 0840 A PLUS without cabinet_EN_en 5 | 76
2 Product Description
NP IN
OF LS
VGESS GB
AHAOUT
EFEB
OSOFPOSGODP
AILHMIPIL
FM
SSB
PWSTSA
PSA1 TS PSA2
MOT
LANCU
Description
IN Suction connection (Inlet) OUT Discharge connection (Outlet)
AHE Air-oil heat exchanger AIL Alarm indicator light
CU Control unit EB Eye bolt
EF Exhaust filter ESS Emergency stop switch
FM Filter material GB Gas ballast valve
HMI User interface (Human-Machine) LAN LAN Communication port (Modbus TCP/IP)
LS Level switch (Oil level) MOT Motor (Pump drive)
NP Nameplate ODP Oil drain plug
OF Oil filter OFP Oil fill plug
OS Oil separator OSG Oil sight glass
PIL Power indicator light PSA1 Pressure transmitter (Inlet gas pressure)
PSA2 Pressure transmitter (Exhaust gas pressure
in the oil separator)
PWS Power supply (Cable gland)
SSB Start/Stop button TSA Resistance thermometer (Oil temperature)
VG Ventilation grid

2 | Product Description
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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.
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 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 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.
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data.

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2.3 Standard Features
2.3.1 User Interface
A user interface, also termed human-machine interface (HMI), allows the control, monitoring and
configuration of the machine via a 7.5” touchscreen.
Further information in the chapter Description of User Interface Functions [➔9].
2.3.2 Control Unit
The control unit is an electrical cabinet where a variable speed drive, a PLC and other electrical com-
ponents are integrated.
The power supply must be connected to it, see Electrical Connection [➔27].
2.3.3 Monitoring Devices
The machine is equipped with several monitoring devices to visualise the operating values, 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 dis-
played when the machine is running, see Monitoring [➔46].
Two signal levels are transmitted, a warning and an alarm/trip, see Dysfunction [➔51].
2.3.4 I/O and Communication Port
The control unit (CU) is equipped with a RJ45 (Modbus) communication port that can allow remote
control and monitoring of the machine.
●Refer to the specific document “Pump Control Instructions, art. no.: 0870213261” for more details
or contact your Busch representative.
2.3.5 Gas Ballast Valve
The gas ballast valve mixes the process gas with a limited quantity of ambient air to counteract the
condensation of vapor inside the machine.
The gas ballast valve has an influence on the ultimate pressure of the machine, see Technical Data.
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 cartridge.
2.4.2 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 replaced when the pres-
sure differential reaches a certain value, which depends on the application 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 recommended, refer to the specific document "Pump Control In-
structions, art. no.: 0870213261".
2.4.3 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].

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2.5 P&ID "Piping and Instrumentation Diagram"
Description
AHE Air-oil heat exchanger (Fan driven by the
pump shaft)
CPL Coupling
GB Gas ballast IF Inlet filter (Optional)
IN Suction connection (Inlet) LS Level switch "alarm/trip” (Oil level)
MOT1 Motor (Pump drive) NRV Non-return valve (Not used as an isolation
valve)
OF Oil filter OUT Discharge connection (Outlet)
PSA1 Pressure transmitter (Inlet gas pressure) PSA2 Pressure transmitter (Counter pression in
the oil separator)
TSA Resistance thermometer (Oil temperature) TS Temperature switch (Exhaust gas tempera-
ture)
TTV Three-way thermostatic valve VP Vacuum pump
2.6 LED Indicators
Next to the user interface, there are three LEDs giving a visual indication of the state of machine.
1 2 3
Description
1 Start/stop button (SSB):
The LED is green when the machine is
running.
2 Power indicator light (PIL):
The LED is green when the machine is
powered.

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Instruction Manual R5 RA 0840 A PLUS without cabinet_EN_en 9 | 76
Description
3 Alarm indicator light (AIL):
The LED flashes in red when a warning
occurred.
The LED is continuously red when an
alarm occurred.
2.7 Description of User Interface Functions
The display is divided into three distinct parts.
1
2
3
Description
1 Menu tabs and sub-tabs 2 Information panel
3 Bottom bar
2.7.1 Menu Overview
The menu consists of four main tabs with their own sub-tabs:
●The "HOME" tab is the main display and is mainly useful for live monitoring.
●The “OPERATIONS” tab displays the operating parameters/modes and allows the control of the
machine.
●The “MAINTENANCE” tab displays the history of malfunctions, maintenance intervals and oper-
ating curves.

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●The “SYSTEM” tab allows to set or change settings and provides information about the product
and its distributor.
2.7.2 Bottom Bar
The bottom bar provides different pieces of information, in particular the machine state and warn-
ing/alarm status.
1 3 5
76
2 4
Description
1 Machine state 2 Machine state: "OFF" or "RUNNING"
3 Warnings and alarms status 4 Status: "WARNING" or "ALARM"
5 Date and hour 6 Screen brightness
7 Help
2.7.3 Navigation
When several screens/pages are available in the information panel, dots representing the different
screens/pages and “PREVIOUS/NEXT” buttons are displayed above the bottom bar.
●Press either on a dot or “PREVIOUS/NEXT” button to pass from a screen/page to another.
The switch button is black when deactivated and orange when activated.
●Press on the switch button to change its state.
1
2
Description
1 Deactivated (Off) 2 Activated (On)
If a password is required:
●Enter the password, see the chapter Roles and Users [➔11].

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Instruction Manual R5 RA 0840 A PLUS without cabinet_EN_en 11 | 76
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.
1
Description
1 Step further available, press to access
the next dialog window.
If a password is required:
●Enter the password, see the chapter Roles and Users [➔11].
2.7.4 Roles and Users
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 oper-
ating 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 in-
struction 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 Con-
trol 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 the following screen:

2 | Product Description
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●Press on the three stars.
●Enter the correct password in the number pad according to your access right.
●Press “Save”.
●From now on, the specific rights are open for a limited period ► delay of 5 minutes.
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 selected data.

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Instruction Manual R5 RA 0840 A PLUS without cabinet_EN_en 13 | 76
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 docu-
ment "Pump Control Instructions, art. no.: 0870213261".
2.7.6 Machine and Software Identification
To display the machine and software identification:
●Go to “SYSTEM” > “MODEL”.
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 ma-
chine is connected to a computer or to the company network.
●Change the values on the right side of the screen (Change settings), password required ► Role
2, see Roles and Users [➔11].
●Press on the switch button to save the new settings.

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14 | 76 Instruction Manual R5 RA 0840 A PLUS without cabinet_EN_en
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 button:
●New IP address
●New subnet mask
●New gateway
➔To change the Ethernet settings, it is recommended to connect the vacuum pump with the de-
sired equipment beforehand via the Ethernet port available on the right side of the control cab-
inet (LAN - see illustration in the chapter “Product Description” of the instruction manual of the
vacuum pump).
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 optional 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).

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Instruction Manual R5 RA 0840 A PLUS without cabinet_EN_en 15 | 76
●Check the ethernet settings of the machine in the “Ethernet Settings” menu of the User Interface
Display (HMI), see Ethernet Settings [➔13]. 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.
●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 ma-
chine (machine status, operating mode, running hours, inlet pressure…).
●Use the icons in the bottom bar to navigate in the Web visualization interface.

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●The second page “Service” shows the service table of the machine and Busch service contact in-
formation.
●The third page “My vacuum pump” gives general information about the machine.
●The fourth page "Operations" gives remote access to the basic settings of the vacuum pump:
Control mode, Operating mode, Ecomode, Week planner, Warm-up and Cool-down, Gas ballast
valve control, Optional inlet valve control, Optional vacuum booster control.
For more information about these settings, see chapter In Operation [➔33].

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Instruction Manual R5 RA 0840 A PLUS without cabinet_EN_en 17 | 76
NOTE
Remote start/stop.
Remote start/stop of the vacuum pump is not possible via the Web Visualization interface.
NOTE
●Contact Busch:
➔If the Ethernet port of the machine (COM) is already used for remote control / monitoring
purpose.
OR
➔In 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 Display (HMI) on the machine,
see Ethernet Settings [➔13].

3 | Transport
18 | 76 Instruction Manual R5 RA 0840 A PLUS without cabinet_EN_en
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 ingress into
the cylinder. Starting the machine with excessive quantities of oil in the cylinder will immedi-
ately break the vanes and ruin the machine!
●Drain the oil prior to every transport or always horizontally transport the machine.
●To find out the weight of the machine, refer to the chapter Technical Data or the nameplate (NP).
●Make sure that the eye bolt(s) (EB) is/are in faultless condition, fully screwed in and tightened by
hand.
●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 RA 0840 A PLUS without cabinet_EN_en 19 | 76
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 | 76 Instruction Manual R5 RA 0840 A PLUS without cabinet_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.
1
2
3
4
Description
1 ~100 cm 2 ~50 cm
3 ~100 cm 4 ~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.
●Make sure that the environmental conditions comply with the protection class IP54.
●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 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 deviation 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.