BUSCH SIMPLEX User manual

Operating instructions
SIMPLEX
Vacuum systems
VD 0025 G – 0063 G – 0100 G
0870169324/-0006_en / Translation of the original operating instructions / Subject to change without notice 16.11.2021
Dr.-Ing. K. Busch GmbH
Schauinslandstraße 1
79689 Maulburg
Germany

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1Contents
1.1 Table of contents
1Contents............................................................................................. 3
1.1 Table of contents ......................................................................................................................... 3
1.2 Register of tables ......................................................................................................................... 5
1.3 Register of illustrations................................................................................................................ 5
2Safety................................................................................................. 6
2.1 Safety devices .............................................................................................................................. 6
2.2 Emergency information ............................................................................................................... 6
3Product description ............................................................................ 7
3.1 View vacuum system VD.............................................................................................................. 7
3.2 View of the rotary vane vacuum pump R5 RA............................................................................. 8
3.3 Setup............................................................................................................................................ 8
3.4 Function principle ........................................................................................................................ 9
3.4.1 Vacuum system VD...................................................................................................................... 9
3.4.2 Rotary vane vacuum pump R5 RA ............................................................................................... 9
3.4.3 Gas ballast valve .......................................................................................................................... 9
3.5 Intended use................................................................................................................................ 9
4Transport ..........................................................................................10
5Storage..............................................................................................13
6Installation ........................................................................................14
6.1 Installation ................................................................................................................................. 14
6.2 Connection lines/pipes .............................................................................................................. 15
6.2.1 Gas inlet ..................................................................................................................................... 15
6.2.2 Gas outlet .................................................................................................................................. 16
6.3 Electrical connection ................................................................................................................. 17
6.3.1 Connection of the power supply ............................................................................................... 17
7Start-up .............................................................................................18
7.1 Indication and control elements................................................................................................ 18
7.1.1 Topping up with oil .................................................................................................................... 18
7.1.2 Display and control elements at the switching and control cabinet .........................................19
7.1.3 Indicators and control elements on the vacuum system .......................................................... 19
7.1.4 Setting the target value needle on the contact vacuum gauge................................................. 20
7.2 Operation................................................................................................................................... 21
7.3 Conveying condensing vapors ................................................................................................... 21
8Maintenance .....................................................................................22
8.1 Maintenance plan...................................................................................................................... 22
8.2 Check oil level ............................................................................................................................ 23
8.3 Oil and oil filter change.............................................................................................................. 23
8.4 Replacing the exhaust filters ..................................................................................................... 25
8.5 Changing the air filter insert ...................................................................................................... 26

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9Troubleshooting ................................................................................27
9.1 General faults ............................................................................................................................ 27
9.2 Failure table and measures ....................................................................................................... 28
10 Spare parts and accessories ...............................................................30
10.1 Spare parts ................................................................................................................................ 30
11 Repair................................................................................................31
12 Decommissioning and disposal ..........................................................32
12.1 Stop operating vacuum system................................................................................................. 32
12.2 Disassembly and disposal.......................................................................................................... 32
13 Dimensions sheets.............................................................................33
14 Connection values of the vacuum system VD .....................................39
14.1 Connection values ..................................................................................................................... 39
15 Technical data ...................................................................................40
16 Oil .....................................................................................................41
17 EU Declaration of conformity.............................................................43

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1.2 Register of tables
Tab. 1: Connections vacuum system VD 0025 G AAA TAXX........................................33
Tab. 2: Connections vacuum system VD 0025 G AAA TAAX (mobile)..........................34
Tab. 3: Connections vacuum system VD 0063 G AAA TCXX........................................35
Tab. 4: Connections vacuum system VD 0063 G AAA TCAX (mobile)..........................36
Tab. 5: Connections vacuum system VD 0100 G AAA TDXX........................................37
Tab. 6: Connections vacuum system VD 0100 G AAA TDAX (mobile)..........................38
Tab. 7: Connection values of the vacuum systems VD..................................................39
1.3 Register of illustrations
Fig. 1: View vacuum system VD......................................................................................7
Fig. 2: View rotary vane vacuum pump type R5 RA (0025 F).........................................8
Fig. 3: Operating principle of the rotary vane vacuum pump R5 RA...............................9
Fig. 4: Transport of the vacuum system........................................................................11
Fig. 5: Transport of the vacuum pump on the eye bolts................................................12
Fig. 6: Installation environment .....................................................................................14
Fig. 7: Gas outlet ...........................................................................................................16
Fig. 8: Topping up oil.....................................................................................................19
Fig. 9: Switch and control cabinet .................................................................................19
Fig. 10: Contact vacuum gauge ......................................................................................20
Fig. 11: Drain oil ..............................................................................................................23
Fig. 12: Replacing the oil filter .........................................................................................24
Fig. 13: Filling in oil..........................................................................................................24
Fig. 14: Remove exhaust filter.........................................................................................25
Fig. 15: Insert and tighten the new exhaust filter ............................................................25
Fig. 16: Changing the air filter insert ...............................................................................26
Fig. 17: Vacuum pump with components relevant for troubleshooting ...........................27
Fig. 18: Dimensions vacuum system VD 0025 G AAA TAXX .........................................33
Fig. 19: Dimensions vacuum system VD 0025 G AAA TAAX (mobile) ...........................34
Fig. 20: Dimensions vacuum system VD 0063 G AAA TCXX.........................................35
Fig. 21: Dimensions vacuum system VD 0063 G AAA TCAX (mobile)...........................36
Fig. 22: Dimensions vacuum system VD 0100 G AAA TDXX.........................................37
Fig. 23: Dimensions vacuum system VD 0100 G AAA TDAX (mobile)...........................38

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2|Safety
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2Safety
Beforecommissioningofthevacuumsystem,readtheseoperatinginstructionswithcare.
PleasecontactyourcontactpersonfromBuschifthereareanyquestions.
Keeptheoperatinginstructionssothatyoucanusethemforreferenceatalatertimeifnec‐
essary.
Theseoperatinginstructionsremainvalidaslongasthecustomerdoesnotmakeanychanges
totheproduct.
Thevacuumsystemisintendedforindustrialuse.Itmustonlybeoperatedbytechnically
trainedspecialists.
Alwayswearpersonalprotectiveequipmentinaccordancewithlocalregulations.
Thevacuumsystemhasbeendesignedandproducedaccordingtostate‐of‐the‐artmethods.
Nevertheless,aresidualriskremainsinoperation.Potentialdangersarehighlightedinthese
operatinginstructions.Safetyandwarningnotesaremarkedasfollows,withthewordsDAN‐
GER,WARNING,CAUTION,ATTENTIONandNOTE:
DANGER
...Indicatesathreateninghazard.Failuretoobservesafetyinstructionswillresultindeathor
seriousinjury.
WARNING
...Indicatesapotentialhazard.Failuretoobservesafetyinstructionsmayresultindeathorse‐
riousinjury.
CAUTION
...Indicatesapotentialhazard.Failuretoobservesafetyinstructionsmayresultinslightinju‐
ry.
ATTENTION!
...Indicatesapotentialhazard.Failuretoobservesafetyinstructionsmayresultinproperty
damage.
NOTICE
...Indicateshelpfuladviceandrecommendationsaswellasinformationforefficientand
smoothoperation.
2.1 Safetydevices
Themotoroftherotaryvanevacuumpumpissafeguardedbyamotorprotectionswitch.Ifan
overloadoccursthevacuumsystemisshutdown.
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2.2 Emergencyinformation
Inanemergencycase,thevacuumsystemcanbeswitchedoffwiththemainswitchofthe
switchandcontrolcabinet,whichhasthefunctionofanemergency‐stopswitch.

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3|Productdescription
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3Productdescription
3.1 ViewvacuumsystemVD
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INGasinletCCSwitchandcontrolcabinet
OUTGasoutletAFAirfilter
INOGasinlet(optional)VVVentingvalve
RVPRotaryvanevacuumpumpRACPGContactvacuumgauge
NPNameplateVSTVacuumvessel
Fig.1:ViewvacuumsystemVD

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3.2 ViewoftherotaryvanevacuumpumpR5RA
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INSuctionconnectionMTBMotorterminalbox
OUTGasoutletDARotationdirectionarrowmotor
OFPOilfillplugEFExhaustfilter
OSGOilsightglassNPNameplate
ODPOildrainplugOFOilfilter
EBEyeboltAFAxialfan
GBGasballastvalveOSOilseparator
Fig.2:ViewrotaryvanevacuumpumptypeR5RA(0025F)
3.3 Setup
ThevacuumsystemSIMPLEXVDcomprisesofasingle‐stagerotaryvanevacuumpump
typeR5RA.Thevacuumpumpismountedonavacuumvessel.
Theintake‐sideairfilterandthestrainerinstalledinthesuctionflangepreventtheingression
ofdirtparticlesinthevacuumpump.
Thegasballastvalveisusedfortheadditionofalimitedquantityofambientairtothepro‐
cessgas,tocounteractthecondensationofvaporinthevacuumpump.
Inthevacuumvesselisacontactvacuumgaugeinstalledforthe2‐pointcontrolwhichdis‐
playsthepressureinthevacuumvessel.
Thevacuumsystemiscompletelypipedandtheelectricalcomponentsarewiredonaswitch
andcontrolcabinet.
Thevacuumsystemisalsoavailableasamobileversiononapushbarcartwithfourrolls.

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3.4 Functionprinciple
3.4.1 VacuumsystemVD
Gasdeliveryfromthevacuumvesseliseffectedbythesingle‐stagerotaryvanevacuumpump.
Pressuregasisexhaustedagainsttheatmosphere.
Thetargetvaluesaresettothedesiredswitch‐onandswitch‐offvaluesonthecontactvacu‐
umgaugeonthevacuumvessel.Whenthelowerswitchingpointisreached,thevacuum
pumpisswitchedoff.Whenthevacuuminthevacuumvesselisusedup,thepressureinthe
vesselincreasesandwhentheupperswitchingpointisreached,thevacuumpumpisswitched
onagainandevacuatesthevacuumvessel.
3.4.2 RotaryvanevacuumpumpR5RA
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Fig.3:OperatingprincipleoftherotaryvanevacuumpumpR5RA
ThevacuumpumpR5RAworksaccordingtotherotaryvaneprinciple.
Theoilsealsthespaces,lubricatestheslidersanddischargesthecompressionheat.Theoilfil‐
tercleansthecirculatingoil.
Thentheexhaustfiltersseparatetheoilfromthedischargedgas.
3.4.3 Gasballastvalve
Thevacuumpumpisequippedwithagasballastvalve.Thegasballastvalveisusedforthe
additionofalimitedquantityofambientairtotheprocessgas,tocounteractthecondensa‐
tionofvaporinthevacuumpump.Thegasballastvalvereducesthefinalpressureofthevac‐
uumpump,see“Technicaldata”inchap.15.
3.5 Intendeduse
Thevacuumsystemwasdesignedforconveyingairandotherdry,non‐aggressive,non‐toxic
andnon‐explosivegases.
Conveyinganyothermedialeadstoincreasedthermaland/ormechanicalstressofthevacu‐
umsystemandisonlypermittedincoordinationwithBusch.
Thevacuumsystemisdesignedforoperationinanon‐hazardousarea.Thevacuumsystem
canbeoperatedcontinuouslyatfinalpressureandissuitableforcontinuousoperation.The
permittedambianceconditionscanbefoundinthetechnicaldata(chap.15).
Thevacuumsystemisdesignedforindooruse;foroutdoorinstallation,contactBuschto
makespecialarrangementsifnecessary.

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4|Transport
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4Transport
WARNING
Dangerofsevereinjury!
Suspendedload.
•Neverwalk,standorworkbelowsuspendedloads.
WARNING
Hazardfromvacuumsystemfallingortippingover!
Theweightofthevacuumsystemcankillapersonorcauseseverecrushing.
•Useapalletappropriatetotheweightandsizeofthesystemonwhichitcanbemovedby
aforklifttruck.Orliftthevacuumsystemusingslingsandsuitableliftinggearswithafork‐
liftorlifttrucktomoveitorremovethepallet.
•Takecaretoavoidstrainonthepipeworkandvacuumpumpswhileplacingtheslings.
•Observethecenterofgravityandtheliftingpoints;theseareindicatedinthescaledraw‐
ings,seechap.13.
ATTENTION!
Damagetothevacuumsystem!
Thevacuumsystemisalreadyfilledwithoilatdelivery.
•Draintheoilbeforetransportiftransportinhorizontalorientationisnotpossible.
Thevacuumsystemispackedinawoodencrate.Itprotectsthesystemfromdamageduring
transport.
Thevacuumsystemispackedinawoodenstructureandcanbemovedusingaforklift.
Unpackthevacuumsystemasneartotheinstallationsiteaspossible.
Checkscopeofdeliveryforcompleteness.
Checkthevacuumsystemfortransportdamage.
Disposeofpackingmaterialasrequiredbycurrentregulations.
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4|Transport
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WARNING
Dangerofsevereinjury!
Liftthevacuumsystembydevicesoftheindividualcomponents.
•Donotliftthevacuumsystembydevicesoftheindividualcomponents,
e.g.thevacuumpump,motor,etc.
•Onlyliftthevacuumsystemaspresented.
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Fig.4:Transportofthevacuumsystem
ScrewfourM10eyebolts(notincludedinthescopeofdelivery)intotheholesonthefeetof
thevacuumvessel(seefig.4).Passslingsthroughtheopeningsoftheeyeboltsandthuslift
thevacuumsystemwithacraneoraforklift.
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12 /460870169324_VD0025‐0100G_‐0006_IM_en
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Thevacuumpumpcanbeliftedbytheeyebolts.
WARNING
Dangerofsevereinjury!
Suspendedload.
•Neverwalk,standandworkbelowsuspendedloads!
•Theeyebolts(EB)mustbeinperfectconditionandcompletelyscrewedintothemachine
andhand‐tightened!
•Donotliftthevacuumpumponaneyeboltofthemotor.Liftthevacuumpumponlyas
shown.
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ATTENTION!
Damagetothevacuumsystem!
Thevacuumsystemisalreadyfilledwithoilatdelivery.
Tiltingavacuumpumpthatisalreadyfilledwithoilcancauselargeamountsofoiltoenter
thecylinder.Ifthevacuumpumpisstartedwhilethereareexcessiveamountsofoilinthe
cylinder,thiswilldamagethesliders,resultinginatotaldamageofthevacuumpump.
•Draintheoilbeforetransportiftransportinhorizontalorientationisnotpossible.


Fig.5:Transportofthevacuumpumpontheeyebolts


Machineweight:
seetechnicaldataornameplate(NP)



5|Storage
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0870169324_VD0025‐0100G_‐0006_IM_en13 /46
5Storage
ATTENTION!
Dangerofdamagetothevacuumpumpdrive!
Longstorageperiodsmaycausecapacitorsinthedrivetobeweakenedbyelectro‐chemical
condensation.Inthemostdetrimentalcase,thismaycauseshort‐circuitandtherebydestruc‐
tionofthedrive.
•Thevacuumpumpshouldthereforebeconnectedtothepowersupplyfor30minuteseve‐
ry18months.
Proceedasfollowsforstorage:
Closeallopeningswiththeprotectivecapsincludedinthescopeofdelivery(penetrationof
dirtandwaterisprevented)
Ifstorageformorethan3monthsisintended:
Secureloosecables
Drainallprocessandoperatingmedia
Cleananddrythevacuumsystem(Priortostoringmakeabsolutelysurethatallpartsare
clean,drainedanddry)
Wherenecessaryuseoilforconservation
Wrapthevacuumsystemincorrosion‐inhibitingfilm.
Storethevacuumsysteminaprotected,dryanddust‐freeroomatatemperaturebetween
0and40°C.

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6|Installation
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6Installation
6.1 Installation

Fig.6:Installationenvironment
Ensurethatthevacuumsystemissetuphorizontally(deviation1°max.)andanchoritinthe
groundwithfourboltsifnecessary.
Technicaldatamustbecompliedwith.
Theambianceconditionsmustmeettheprotectionclassofthevacuumpump.
Theinstallationsitemustbeventedsothatsufficientcoolingofthevacuumsystemisen‐
sured.
Ensurethattheventilationopenings(inletsandoutlets)arenotcoveredandthatthecool‐
ingaircanflowunhindered.
Sufficientspaceformaintenanceworkmustbeensured.
Visibilityoftheoilsightglass(OSG,fig.2)mustbeensuredatalltimes.
Checktheoillevelandtopupoilifnecessary(formoreinformation,seetoppingupwithoil
(chap.7.1.1)).
Ensurethatallcovers,safetydevices,etc.areinstalled.

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6|Installation
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0870169324_VD0025‐0100G_‐0006_IM_en15 /46
6.2 Connectionlines/pipes
ATTENTION!
Dangerofdamagetothevacuumsystemfromforeignbodiesinthepipes.
•Removeallforeignmatter(weldingbeads,filings,etc.)fromthepipelines!Thismaybe
donebyflushingorblowingthroughpipelines.
•Theclientmustensurethatthepipeworkattheinletisclean.
.ATTENTION!
Vacuumsystemcanbedamagedbytensileorcompressivestressesonpipelineconnec‐
tions!
•Ifstressescouldoccur,usecompensatorstoconnectpipelines.
ATTENTION!
Condensatedamagesvacuumpumps!
•Laythepipingontheintakeandpressuresidesatanangletopreventaccumulatedcon‐
densationfromenteringthevacuumpump.
Thelinecross‐sectionoftheconnectionlinesmusthaveatleastthesamecross‐sectionasthe
connectionsofthevacuumsystemacrosstheentirelength.
Incaseofverylongconnectionlines,itisrecommendedtouselineswithlargercross‐sections
toavoidlossofefficiency.PleasecontactyourcontactpersonfromBusch.
6.2.1 Gasinlet
WARNING
Dangerofsevereinjury!
Opengasinlet!
•Neverinsertyourhandorfingersintothegasinlet!
Connectthesuctionsidepipelinetothegasinletofthevacuumsystem(IN,fig.1).
NOTICE
Beforeinitialstart‐upcheckthepipelinestothevacuumsystemforleaks.Rectifyanyleaks.
Dimensionsseescaledrawingsintheappendix.



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6.2.2 Gasoutlet
CAUTION
Healthrisk!
Thedischargedgascontainssmallamountsofoil.
Ensuresufficientventilationintheinstallationroomwhentheairisroutedintoroomswhere
therearepeople.
Connectthegasoutletlinetobothgasoutletopeningsofthevacuumpumpifrequired.
Dimensions,seescaledrawingintheappendix;connectionsizeofthread:G1¼“.
Ensurethatthedischargedgascanflowoffunhindered.Neverclosethegasoutletline,do
notthrottleitanddonotuseitasacompressedairsource.
Iftheairtakeninisnotdischargedtotheenvironmentinthedirectproximityofthevacuum
system,observethefollowing:
Placethegasoutletlinedroppingtowardsthevacuumsystemorinstallaliquidseparatoror
asiphonwithadrainvalvesothatnoliquidcanflowbackintothevacuumsystem.


Fig.7:Gasoutlet



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6|Installation
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0870169324_VD0025‐0100G_‐0006_IM_en17 /46
6.3 Electricalconnection
DANGER
Dangerfromelectricshock!
Electricshockwillcausedeathorseriousinjury.
•Alllivelinesmustbepowereddownbeforetheelectricalinstallation!
•Beforeanyelectricalwork,ensurethatthevacuumpumpisdisconnectedfromthepower
supplyandsecuredagainstaccidentalactivation.
•Electricalinstallationworkmustonlybeperformedbytrainedspecialists.
ATTENTION!
Incorrectrotationofdrivemotorscanseriouslydamagethevacuumsystem!
Switchvacuumpumpsbrieflyonandoffagaintochecktherotationaldirectionofthemotor.
Therotationaldirectionismarkedbyadirectionofrotationarrowonthemotor.
Ifthedirectioniswrong,reversetwoconnectionphasepoles.
6.3.1 Connectionofthepowersupply
ATTENTION!
Dangerofdamagetothevacuumsystem.
Wrongconnection.
Wirethevacuumsystemaccordingtothecircuitdiagramintheswitchandcontrol
cabinet.
Procedure:
Ensurethatthepowersupplyforthevacuumsystemcorrespondstothespecificationsin
thecircuitdiagram.
Ensurethatthevacuumsystemisnotimpairedbyelectricalorelectromagneticimpulsesof
thepowersupply.ContactBuschifnecessary.
Connecttheswitchandcontrolcabinettothepowersupply(connectionvalues,see
chap.14).

ATTENTION!
Dangerofdamagetothemotor
Wrongrotatingdirection.
•Operationinthewrongrotatingdirectionmaydamagethevacuumsystemafteravery
brieftime.Ensurethattherotatingdirectioniscorrectbeforecommissioning.
Usetheglued‐on/cast‐inarrowtodeterminetheintendedrotatingdirection.
Switchonthevacuumpumpforafractionofasecond.
Observethefanwheelanddeterminetherotatingdirectionjustbeforestandstill.
Tochangetherotatingdirection:
Swapanytwophasesofthepowersupply.

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7Start‐up
7.1 Indicationandcontrolelements
DANGER
Dangerfromelectricshock!
Electricshockwillcausedeathorseriousinjury.
•Beforecommissioning,ensurethatallelectricallinesarecoveredandthattheterminalbox
isclosed!
CAUTION
Burnhazard!
Thesurfaceofthevacuumpumpmayreachoperatingtemperaturesinexcessof70°Cin
operation.
Donottouchthevacuumpumpduringanddirectlyafteroperation.
ATTENTION!
Insufficientfamiliaritywiththeindicatorsandoperatingcontrolsmayresultindamageto
thevacuumsystem.
Wrongoperation.
•Operatingstaffmustbefamiliarwiththeindicatingandoperatingelements.
ATTENTION!
Operationofthevacuumpumpwithoutoilwillcauseseveredamagetoitquickly.
•Thevacuumsystemisalreadyfilledwithoilatdelivery.Theoillevelmustbecheckedand,
ifnecessary,toppedupbeforecommissioning.
7.1.1 Toppingupwithoil
Foroiltypeandoilquantity,seeTechnicaldata(chap.15)andOil(chap.16).

1xsealingring,partno.:
0486000590
Checkoillevel

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7|Start‐up
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0870169324_VD0025‐0100G_‐0006_IM_en19 /46
Fig.8:Toppingupoil
7.1.2 Displayandcontrolelementsattheswitchingandcontrolcab‐
inet

Fig.9:Switchandcontrolcabinet
Pushbuttonwithindicatorlamp(101S1)
Pushbuttonforswitchingthevacuumsystemonandoff
Indicatorlamplightsupduringoperation
Indicatorlampofthecollectivefailure(101H1)
Indicatorlamplightsupredwhenthereisanerror
Operatinghourscounter(101T1)
Displaystheoperatinghours
Mainswitch(100Q1)
Switchforswitchingthesupplyvoltageonandoff
7.1.3 Indicatorsandcontrolelementsonthevacuumsystem
Theindicatingdevicesareasfollows:
Contactvacuumgauge(CPG,fig.1)
Indicatesthepressureinthevacuumvessel.
Theswitch‐onandswitch‐offvalue(pressurerange)issetonthecontactvacuumgauge.
Ventingvalve(VV,fig.1)
Thevacuumsystemisventedtoatmosphericpressureviathisvalveformaintenancework.
Oilsightglass(OSG,fig.2)atthevacuumpump


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7|Start‐up
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20 /460870169324_VD0025‐0100G_‐0006_IM_en
7.1.4 Settingthetargetvalueneedleonthecontactvacuumgauge
Thetargetvaluesaresetviatheadjustmentlockinthesightdiscusingtheadjustmentkey
(enclosed,canbefoundonthesideofthecablesocket).Toadjustthesetpointer,placethe
adjustmentkeyattheadjustmentlock,pressitinandsettherequiredsetpoint.


Fig.10:Contactvacuumgauge
Thesetpointersofthelimitswitchescanbeadjustedfreelythroughoutthescalerange.For
reasonsofswitchingaccuracy,switchingsafetyandservicelifeofthemechanicalmeasuring
systems,theswitchingpointsshouldbebetween10%and90%ofthemeasuringrange.
Setthesetpointerstodesiredactivationandshutdownpressures.Theclearancebetweenthe
twosetpointersisapprox.10%ofthescalerange.
Whenthelowerswitchingpointisreached,thevacuumpumpisswitchedoffandcorrespond‐
ing,whentheupperswitchingpointisreached,againswitchedon.
Factorysettingsoftheswitchingpoints:
lowerswitchingpoint:‐0.9bar(90%)
upperswitchingpoint:‐0.8bar(80%)

NOTICE
Therecommendedminimumclearancebetweentwocontactsis10%ofthemeasuringspan.
Theswitchhysteresisis2…5%.



Setpointers
Removable
adjustmentkey
Adjustmentlock