BUSCH R5 RA 1000 User manual

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R5
Oil-Lubricated Rotary Vane Vacuum Pumps
RA 1000 B, RA 1600 B
RC 1000 B, RC 1600 B
Instruction Manual
0870569784 | -0008_en-US | Original instructions 8/13/2022

Table of Contents
2 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
Table of Contents
1 Safety..................................................................................................................................................................... 4
2 Product Description............................................................................................................................................. 5
2.1 Operating Principle ............................................................................................................................................. 6
2.2 Intended Use ....................................................................................................................................................... 6
2.3 Start Controls....................................................................................................................................................... 6
2.4 Standard Accessories.......................................................................................................................................... 7
2.4.1 Temperature Switch "Gas"................................................................................................................... 7
2.4.2 Level Switch ........................................................................................................................................... 7
2.4.3 Temperature Switch "Oil"..................................................................................................................... 7
2.5 Optional Accessories........................................................................................................................................... 7
2.5.1 Gas Ballast Valve ................................................................................................................................... 7
2.5.2 Inlet Filter............................................................................................................................................... 7
2.5.3 Water-oil Heat Exchanger .................................................................................................................... 7
2.5.4 Resistance Thermometer..................................................................................................................... 7
2.5.5 Pressure Switch..................................................................................................................................... 7
2.5.6 Pressure Transmitter............................................................................................................................ 7
2.5.7 Variable Speed Drive ............................................................................................................................ 8
3 Transport .............................................................................................................................................................. 9
4 Storage .................................................................................................................................................................. 10
5 Installation ........................................................................................................................................................... 11
5.1 Installation Conditions........................................................................................................................................ 11
5.2 Connecting Lines / Pipes .................................................................................................................................... 12
5.2.1 Suction Connection............................................................................................................................... 12
5.2.2 Discharge Connection .......................................................................................................................... 13
5.2.3 Cooling Water Connection (Optional)................................................................................................. 14
5.3 Filling Oil............................................................................................................................................................... 15
5.4 Fitting the Coupling ............................................................................................................................................ 16
6 Electrical Connection........................................................................................................................................... 18
6.1 Machine delivered without Control Box or Variable Speed Drive (VSD)....................................................... 18
6.2 Machine delivered with a Control Box (Option) .............................................................................................. 19
6.3 Machine delivered with a Variable Speed Drive (Option)............................................................................... 20
6.4 Wiring Diagram Three-Phase Motor................................................................................................................. 21
6.5 Electrical Connection of the Monitoring Devices ............................................................................................ 22
6.5.1 Wiring Diagram Temperature Switch "Gas" ...................................................................................... 22
6.5.2 Wiring Diagram Temperature Switch "Oil"........................................................................................ 22
6.5.3 Wiring Diagram Level Switch............................................................................................................... 23
6.5.4 Wiring Diagram Resistance Thermometer (Optional)...................................................................... 23
6.5.5 Wiring Diagram Pressure Switch (Optional)...................................................................................... 23
6.5.6 Wiring Diagram Inlet Pressure Transmitter (Optional).................................................................... 23
6.5.7 Wiring Diagram Exhaust Pressure Transmitter (Optional).............................................................. 23
6.5.8 Wiring Diagram Pressure Switch of Water-oil Heat Exchanger (Optional).................................... 24
7 Commissioning..................................................................................................................................................... 25
7.1 Conveying Condensable Vapors........................................................................................................................ 25
8 Maintenance......................................................................................................................................................... 27
8.1 Maintenance Schedule ....................................................................................................................................... 28
8.2 Oil Level Inspection............................................................................................................................................. 29
8.3 Oil and Oil Filter Change .................................................................................................................................... 29
8.4 Exhaust Filter Change......................................................................................................................................... 31
8.5 Air Heat Exchanger Cleaning ............................................................................................................................. 32

Table of Contents
Instruction Manual R5 RA RC 1000-1600 B_EN_en 3 | 44
9 Overhaul................................................................................................................................................................ 33
10 Decommissioning................................................................................................................................................. 34
10.1 Dismantling and Disposal .................................................................................................................................. 34
11 Spare Parts............................................................................................................................................................ 35
12 Troubleshooting................................................................................................................................................... 36
13 Technical Data...................................................................................................................................................... 38
14 Oil........................................................................................................................................................................... 39
15 EU Declaration of Conformity............................................................................................................................. 40
16 UK Declaration of Conformity ............................................................................................................................ 41

1 | Safety
4 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
1 Safety
Prior to handling the machine, this instruction manual should be read and understood. If anything
needs to be clarified, please contact your Busch representative.
Read this manual carefully before use and keep for future reference.
This instruction manual remains valid as long as the customer does not change anything on the
product.
The machine is intended for industrial use. It must be handled only by technically trained personnel.
Always wear appropriate personal protective equipment in accordance with the local regulations.
The machine has been designed and manufactured according to state-of-the-art 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 RC 1000-1600 B_EN_en 5 | 44
2 Product Description
OFPNP EB IN GB 2 OUT 1 AHE
DAMTBOSGODPOF
EF
FMLS
FM GB 1EF
OUT 2
TS 2TS 1
OS
FV
TS 3
Description
IN Suction connection (Inlet) OUT Discharge connection (Outlet)
AHE Air-oil heat exchanger DA Directional arrow
EB Eye bolt EF Exhaust filter
FM Filter material FV Float valve (on RA version only)
GB Gas ballast valve LS Level switch
MTB Motor terminal box NP Nameplate
ODP Oil drain plug OF Oil filter
OFP Oil fill plug OS Oil separator
OSG Oil sight glass TS Temperature switch
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 | Product Description
6 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
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 [➔38].
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [➔38].
2.3 Start Controls
NOTE
To start the machine, Busch recommends the installation of starter devices such as soft-start-
ers or variable speed drives.
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 speed drive.

Product Description | 2
Instruction Manual R5 RA RC 1000-1600 B_EN_en 7 | 44
2.4 Standard Accessories
2.4.1 Temperature Switch "Gas"
The temperature switch “Gas” monitors the gas temperature of the machine.
The machine must be stopped when the gas reaches 110 °C.
2.4.2 Level Switch
The level switch monitors the oil level.
The machine must be stopped when the oil level is too low.
2.4.3 Temperature Switch "Oil"
The temperature switch monitors the oil temperature of the machine.
It has two switch points.
Depending on the oil type, the machine must be stopped when the oil reaches a certain tempera-
ture, see Oil [➔39].
2.5 Optional Accessories
2.5.1 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 vacuum pump.
The gas ballast valve has an influence on the ultimate pressure of the machine, see Technical Data
[➔38].
2.5.2 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.
2.5.3 Water-oil Heat Exchanger
In case of unfavorable ambient conditions a water-oil heat exchanger can be provided.
See Cooling Water Connection (Optional) [➔14].
2.5.4 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 [➔39].
2.5.5 Pressure Switch
The pressure switch monitors the pressure in the oil separator.
The machine must be stopped when the gas reaches a certain pressure, see Wiring Diagram Pressure
Switch (Optional) [➔23].
2.5.6 Pressure Transmitter
The pressure transmitter monitors the pressure in the oil separator.
Warning and trip signals must be set, see Wiring Diagram Pressure Transmitter (Optional).

2 | Product Description
8 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
2.5.7 Variable Speed Drive
The machine can optionally be equipped with a Variable Speed Drive (VSD). A variable speed drive in-
creases the pumping speed of the machine and saves energy. For more information contact your
Busch representative.

Transport | 3
Instruction Manual R5 RA RC 1000-1600 B_EN_en 9 | 44
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 [➔38] or the name-
plate (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.

4 | Storage
10 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
4 Storage
●Seal all apertures with adhesive tape or reuse provided caps.
Version with water-oil heat exchanger:
●Make sure that the cooling water has been completely drained, see Decommissioning [➔34].
If the machine is equipped with a variable speed drive:
NOTICE
Long storage time.
Risk of damage to the machine!
●Due to a long storage time the capacitors of the variable speed drive can lose efficiency because
of electrochemical processes. In the worst case, it can lead to a short-circuit and therefore to a
damage to the variable speed drive of the machine.
●Connect the machine every 18 months for 60 minutes to the mains.
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.

Installation | 5
Instruction Manual R5 RA RC 1000-1600 B_EN_en 11 | 44
5 Installation
5.1 Installation Conditions
NOTICE
Use of the machine outside of the permitted installation conditions.
Risk of premature failure!
Loss of efficiency!
●Take care that the installation conditions are fully complied with.
~50 cm
~50 cm
~100 cm
~100 cm
●Make sure that the environment of the machine is not potentially explosive.
●Make sure that the ambient conditions comply with the Technical Data [➔38].
●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 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 [➔29].
●Make sure that all provided covers, guards, hoods, etc. are mounted.
Version with water-oil heat exchanger:
●Make sure that the cooling water complies with the requirements, see Cooling Water Connection
(Optional) [➔14].
If the machine is installed at an altitude greater than 1000 meters above sea level:

5 | Installation
12 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
●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 ex-
ceeded, see Electrical Connection of the Monitoring Devices [➔22].
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 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.
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):
– DN150 PN16, EN 1092-1
Depending on the specific configuration ordered, 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 flow-
ing back to the vacuum system.

Installation | 5
Instruction Manual R5 RA RC 1000-1600 B_EN_en 13 | 44
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.
NOTICE
Discharge gas flow obstructed.
Risk of damage to the machine!
●Make sure that the discharged gas will flow without obstruction. Do not shut off or throttle the
discharge line or use it as a pressurized air source.
Connection size(s):
– DN125 PN16, EN 1092-1
Depending on the specific configuration ordered, other connection dimensions may apply.
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 sep-
arator or a siphon with a drain cock, so that no liquids can flow back into the machine.

5 | Installation
14 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
5.2.3 Cooling Water Connection (Optional)
WHE CWO
CWI
TV PS
MV WF CWICWO
WBV
1 2
WHE
Description
1 Water-oil heat exchanger without inlet
accessories
2 Water-oil heat exchanger with inlet ac-
cessories
Description
CWI Cooling water inlet PS Pressure switch
CWO Cooling water outlet WBV Water bypass valve
WHE Water-oil heat exchanger WF Water filter
TV Thermostatic valve MV Solenoid valve
The thermostatic valve (TV) is used to control the water flow in order to keep a stable vacuum pump
temperature.
The factory default adjustment of the thermostatic valve (TV) is set in position 2 (approx. 75°C oil
temperature).
The pressure switch (PS) is used to monitor the presence of water at the cooling system of the vacu-
um pump.
When the pressure switch detects a pressure lower than 2 bar, the vacuum pump must be stopped.
The water bypass valve (WBV) is used at the first vacuum pump start-up. At that moment it should
be open (approx. 90 seconds) to prime the water heat exchanger, afterwards it should be closed.
The solenoid valve (MV) is used to stop the cooling water circulation when the vacuum pump is not
running.
●Connect the cooling water connections (CWI / CWO) to the water supply.
Connection size:
– 19 mm hose (CWI / CWO)

Installation | 5
Instruction Manual R5 RA RC 1000-1600 B_EN_en 15 | 44
●If necessary, electrically connect the pressure switch (PS), see Wiring Diagram Pressure Switch of
Water-oil Heat Exchanger (Optional).
●If necessary, electrically connect the solenoid valve (MV).
●Make sure that the cooling water complies with the following requirements:
Min. supply capacity l/min 8
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 follow-
ing 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)
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 [➔38] and Oil [➔39].

5 | Installation
16 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
5.4 Fitting the Coupling
NOTE
Radial screw.
For trouble-free operation, use thread locking glue to secure the radial screw.
1 2 3
4
Description
1 Coupling hub (machine side) 2 Coupling sleeve
3 Coupling hub (motor side) 4 Radial screw / max. admissible torque:
17Nm

Installation | 5
Instruction Manual R5 RA RC 1000-1600 B_EN_en 17 | 44
Machine type Coupling size Value “E” (mm) Value “L” (mm)
RA/RC 1000 B
BoWex® I-80 6 186
POLY PKZ 17 4 144
POLY PKZ 20 4 164
RA/RC 1600 B BoWex® I-80 6 186
POLY PKZ 20 4 164
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 manual of the
BoWex® or POLY PKZ coupling.
BoWex®
English German French
Instruction Manual - English Instruction Manual - German Instruction Manual - French
POLY PKZ
English German French
Instruction Manual - English Instruction Manual - German Instruction Manual - French

6 | Electrical Connection
18 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
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 electro- magnetic 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 [➔40] or UK Declaration of Conformity [➔41]).
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.
NOTE
It is recommended that the machine is started either by a soft starter unit or by a variable
speed drive. Supplying power directly to the motor of the machine may reduce the lifetime of
the coupling. When using a soft starter unit or a variable speed drive, make sure that the per-
mitted motor speed range is respected (see Technical Data [➔38]).
Seek advice from your Busch representative.

Electrical Connection | 6
Instruction Manual R5 RA RC 1000-1600 B_EN_en 19 | 44
●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.
●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.
●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 con-
nection instructions/diagrams.
6.2 Machine delivered with a Control Box (Option)
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 control box.
●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.
●If the control box is not equipped with a lockable disconnect switch, provide it on the power line
so that the machine is completely secured during maintenance tasks.
●Provide an overload protection according to EN 60204-1.
●Busch recommends installing a D-curve circuit breaker.
●In case of a soft start, Busch recommends installing a C-curve circuit breaker.
●Connect the protective earth conductor.
●Electrically connect the control box.

6 | Electrical Connection
20 | 44 Instruction Manual R5 RA RC 1000-1600 B_EN_en
NOTICE
Incorrect connection.
Risk of damage to the control box and motor!
●The wiring diagrams given below are typical. Check the inside of the control box for connection
instructions/diagrams.
6.3 Machine delivered with a Variable Speed Drive
(Option)
DANGER
Live wires. Carry out any work on the variable speed drive and motor.
Risk of electrical shock!
●Electrical installation work must only be executed by qualified personnel.
DANGER
Maintenance work without disconnecting the variable speed drive.
Risk of electrical shock.
●Disconnect and isolate the variable speed drive before attempting any work on it.
High voltages are present at the terminals and within the variable speed drive for up to 10 min-
utes after disconnection of the electrical supply.
●Always ensure by using a suitable multimeter that no voltage is present on any drive power termi-
nals prior to commencing any work.
●Make sure that the power supply for the drive is compatible with the data on the nameplate of
the variable speed drive.
●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.
●If the variable speed drive is not equipped with a lockable disconnect switch, provide it on the
power line so that the machine is completely secured during maintenance tasks.
●Provide an overload protection according to EN 60204-1.
●Busch recommends installing a C-curve circuit breaker.
●Connect the protective earth conductor.
NOTICE
The admissible motor speed exceeds the recommendation.
Risk of damage to the machine!
●Check the admissible motor speed range, see Technical Data [➔38].