BUSCH R5 (PB / PC 0008 C) Manual

Also See for R5:

Instruction manual (68 pages)

Instructions manual (52 pages)

Installation and operation manual (24 pages)

Table of Contents

Contents

1 Product Description
2 Transport
3 Storage
4 Installation
5 Electrical Connection
6 Commissioning
7 Maintenance
8 Overhaul
9 Decommissioning
10 Recommissioning
11 Troubleshooting
12 Technical Data
13 Oil
14 Safety
15 Busch Vacuum Solutions
16 Documents / Resources
- 16.1 References
- 16.2 Download manual

BUSCH R5 (PB / PC 0008 C) Manual

Product Description

Description
CAP	Capacitor	ECO	Electrical connection
OUT	Discharge connection	IN	Inlet connection
OFP	Oil fill plug	CO	Cover (for exhaust filter)
OS	Oil separator	ODP	Oil drain plug
OSG	Oil sight glass	DA	Directional arrow
EF	Exhaust filter (inside OS)	NRV	Non-return valve
NP	Nameplate

information NOTE
Technical term.
In this instruction manual, we consider that the term 'machine' refers to the 'vacuum pump'.

information NOTE
Illustrations.
In this instruction manual, the illustrations may differ from the appearance of the machine.

Operating Principle

The machine works on the rotary vane principle.
The oil seals the gaps, lubricates the vanes and takes away compression heat.
In order to avoid reverse rotation after switching off, the machine is equipped with a non-return valve (NRV).
Exhaust filters separate the oil from the discharged gas.
Product Operating Principle

Intended Use

In case of foreseeable misuse outside the intended use of the machine.
Risk of injuries!
Risk of damage to the machine!
Risk of damage 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, non-ignitable and non-explosive gases.
Conveying of other media leads to an increased thermal and/or mechanical load on the machine and is permissible only after a consultation with Busch.
The machine is intended for the placement in a non-potentially explosive environment.
The machine is designed for indoor installations. For outdoor installations, consult your Busch representative for special precautions.
The machine is capable of maintaining ultimate pressure, see Technical Data.
Depending on the version of the machine, limit the operating time as follows:

Machine version	Operating time
PB version Ultimate pressure = p_abs: 2.0 hPa (mbar)*	The machine is suitable for intermittent operation only. At the latest after 30 minutes of continuous operation, the machine must be shut down for at least 5 minutes.
PC version Ultimate pressure = p_abs: 30 hPa (mbar)*	The machine is suitable for continuous operation within a range of 30 to 100 hPa abs.
Version with single-phase motor:	The machine is intended for intermittent operation (S3). The drive is equipped with a thermal protection switch.

* Refer to the nameplate (NP) to identify the machine version.

Note: The non-return valve (NRV) shouldn't be used as a non-return or shut off valve for the System. The non-return valve is only to protect the machine.

If the machine needs to be maintained after shutdown:

Provide an additional manual or automatic operated non-return valve in the suction line.

Permitted environmental conditions, see Technical Data
The machine is a built-in pump designed for vacuum packaging machines.

Start Controls

The machine comes without start controls. The control of the machine is to be provided in the course of installation.
The machine can be equipped with a starter unit or a variable speed drive.
The machine can be equipped with a soft-starter.

Standard Features

Motor Thermal Protection
Single-phase motors are equipped with a thermal protection switch to protect the machine against overload. Three-phase motors are not equipped with a thermal protection switch.

Optional Accessories

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

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 cartridge.

Transport

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 immediately 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).
Check the machine for transport damage.

If the machine is secured to a base plate:

Remove the machine from the base plate.

Storage

Seal hermetically all apertures with the caps provided with the machine, or with adhesive tape if the caps are no longer available.
Store the machine indoors, in a dry place, away from dust and vibrations and if possible, in original packaging, preferably at temperatures between 0... 40°C.

If the machine is to be stored for more than 3 months:

Seal hermetically all apertures with the caps provided with the machine, or with adhesive tape if the caps are no longer available.
Wrap the machine in a corrosion inhibitor film.
Store the machine indoors, in a dry place, away from dust and vibrations and if possible, in original packaging, preferably at temperatures between 0... 40°C.

Installation

Installation Conditions

NOTICE
Use of the machine outside of the permitted installation conditions.
Risk of premature failure!
Loss of efficiency!

Make sure that the installation conditions are fully respected.

Description
1	min. 2 cm

Make sure that the environment of the machine is not potentially explosive.
Make sure that the ambient conditions comply with theTechnical Data
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 machine is provided.
Make sure that cooling air inlets and outlets are not covered or obstructed and that the cooling air flow is not affected adversely in any other way.
Make sure that the oil sight glass (OSG) remains easily visible.
Make sure that enough space remains for maintenance work.
Make sure that the machine is placed or mounted horizontally, a maximum deviation of 1° in any direction is acceptable.
Check the oil level, fill up if necessary, see Filling Oil
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 must be derated or the ambient temperature limited.

Connecting Lines / Pipes

Remove all protective covers before installation.
Make sure that the connection lines cause no stress on the connections of the machine. Therefore, we recommend installing flexible lines on the suction connection.
Make sure that the diameter 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:

Use larger diameters to avoid a loss of efficiency.
Contact your Busch representative for more information.

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):

G 3/8"

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 machine from turning backwards.
Busch recommends the installation of an isolation valve in order to prevent the oil from flowing back to the vacuum system.

NOTICE
Using the non-return valve as shut off valve.
Risk of oil mist flow back into the vacuum system.

It is highly recommended not to use the non-return valve as a shut off system.

Make sure that the connection lines cause no stress on the connections of the machine. Therefore, we recommend installing flexible lines on the suction connection.

Discharge Connection

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):

Without connection. The discharged gas is released to the ambient of the machine.

Depending on the specific configuration ordered, other connection dimensions may apply.

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 and Oil.

Installation - Filling Oil

Description
1	Oil fill plug (OFP) with seal ring, part no. 0415 000 071

Electrical Connection

Live wires.
Risk of electrical shock!

Electrical installation work must only be executed by qualified personnel.

INSTALLATION(S) CURRENT PROTECTION:

Missing current protection.
Risk of electrical shock!

Provide current protection in accordance with EN 60204-1 on your installation(s).
The electrical installation must comply with the applicable national and international standards.

NOTICE
Electromagnetic compatibility.

Make sure that the motor of the machine will not be affected by electric or electromagnetic disturbance from the mains. If necessary, contact your Busch representative for more information.
Make sure that the EMC of the machine is compliant with the requirements of your supply network system, if necessary, provide further interference suppression.

Machine delivered without Control Box or Variable Speed Drive

Live wires.
Risk of electrical shock!

Electrical installation work must only be executed by qualified personnel.

Make sure that the power supply for the motor is compatible with the data on the nameplate of the motor.
If the machine is equipped with a power connector, install a residual current protective device to protect persons in case of a defective insulation.
- Busch recommends installing a type B residual protective device suitable for the electrical installation.
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.
Connect the protective earth conductor.
Electrically connect the motor.

NOTICE
Incorrect connection.
Risk of damage to the motor!

The wiring diagrams given below are typical. Check the inside of the terminal box for motor connection instructions/diagrams.

Wiring Diagram Single-Phase Motor

Motor with cable and MATE-N-LOK connector:
Ha = Main phase
Hi = Auxiliary phase
Tw = Thermal protector
C_B = Permanent capacitor
bk = Black
bn = Brown
bu = Blue
ye/gn = Yellow/green

information NOTE
MATE-N-LOK-connections feature no strain relief.

Wiring Diagram Three-Phase Motor

NOTICE
Incorrect direction of rotation.
Risk of damage to the machine!

Operation in the wrong direction of rotation can destroy the machine in a short time! Prior to start-up, ensure that the machine is operated in the right direction.

Determine the intended direction of rotation with the arrow (stuck on or cast).
Jog the motor briefly.

If the rotation of the motor must be changed:

Switch any two of the motor phase wires.

Delta connection (low voltage)

Star connection (high voltage)

Commissioning

During operation the surface of the machine may reach temperatures of more than 70°C.
Risk of burns!

Avoid contact with the machine during and directly after operation.

NOTICE
The machine can be shipped without oil.
Operation without oil will ruin the machine in short time!

Prior to commissioning, the machine must be filled with oil, see Filling Oil

Make sure that the Installation Conditions are met.
Start the machine.
Make sure that the maximum permissible number of starts does not exceed 30 starts per hour. Those starts should be spread within the hour.
Make sure that the operating conditions comply with theTechnical Data
After a few minutes of operation, check the oil level and top up if necessary.

As soon as the machine is operated under normal operating conditions:

Measure the motor current and record it as reference for future maintenance and troubleshooting work.

Conveying Condensable Vapors
Water vapor within the gas flow is tolerated within certain limits. The conveyance of other vapors shall be agreed upon with Busch.
If condensable vapors are to be conveyed:

START

Close the isolation valve*
Warm up the machine for 30 minutes
Open the isolation valve* and perform the process
Close the isolation valve*
Wait 30 minutes

END
* Not included in the scope of delivery.

Maintenance

Live wires.
Risk of electrical shock!

Electrical installation work must only be executed by qualified personnel.

The machine is contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:

Wear appropriate personal protective equipment.

Hot surface.
Risk of burns!

Before doing anything that requires touching the machine, let it cool down first.

Failing to properly maintain the machine.
Risk of injuries!
Risk of premature failure and loss of efficiency!

Maintenance work must only be executed by qualified personnel.
Respect the maintenance intervals or ask your Busch representative for service.

NOTICE
Using inappropriate cleaners.
Risk of removing safety stickers and protective paint!

Do not use incompatible solvents to clean the machine.

Stop the machine and lock it to prevent accidental start-up.
Vent the connected lines to atmospheric pressure.

If necessary:

Disconnect all connections.

Maintenance Schedule

The maintenance intervals depend very much on the individual operating conditions. The intervals given below are considered as starting values which should be individually shortened or extended as appropriate.

Particularly harsh applications or heavy duty operation, such as high dust loads in the environment or in the process gas, other contamination or ingress of process material, can make it necessary to shorten the maintenance intervals significantly.

Interval	Maintenance work
Weekly	Check the oil level, see Oil Level Inspection Check the machine for oil leaks - in case of leaks have the machine repaired (contact Busch).
Monthly	In case of an inlet filter being installed: Check the inlet filter cartridge, replace if necessary.
Every 2000 hours or every 6 months	Change the oil and the exhaust filters (EF).
Every 5 years	Have a major overhaul on the machine (contact Busch).

Oil Level Inspection

Stop the machine.
Wait 1 minute.
Check the oil level.
Fill up if necessary, see Filling Oil

Oil Change

NOTICE
Use of an inappropriate oil.
Risk of premature failure!
Loss of efficiency!

Only use an oil type which has previously been approved and recommended by Busch.

Oil Change - Draining the oil

Description
1	Oil fill plug (OFP) with seal ring, part no. 0415 000 071

For oil type and oil capacity see Technical Data and Oil

Maintenance - Oil filling

Description
1	Oil drain plug (ODP) with seal ring, part no. 0415 000 071

Exhaust Filter Change

Maintenance - Changing Exhaust Filter

Description
1	Exhaust filter (EF) with o-ring, part no. 0532 140 152	2	O-ring, part no. 0486 124 845
3	Cover (CO), part no. 0710 138 179

Overhaul

The machine is contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:

Wear appropriate personal protective equipment.

NOTICE
Improper assembly.
Risk of premature failure!
Loss of efficiency!

Any dismantling of the machine that goes beyond anything that is described in this manual should be done by Busch authorized technicians.

If the machine has conveyed gas contaminated with foreign materials which are hazardous to health:

Decontaminate the machine as much as possible and state the contamination status in a 'Declaration of Contamination'.

Decommissioning

Live wires.
Risk of electrical shock!

Electrical installation work must only be executed by qualified personnel.

Hot surface.
Risk of burns!

Before doing anything that requires touching the machine, let it cool down first.

Stop the machine and lock it to prevent accidental start-up.
Disconnect the power supply.
Vent the connected lines to atmospheric pressure.
Disconnect all connections.

If the machine is to be stored:

See Storage

Dismantling and Disposal

Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:

Wear appropriate personal protective equipment.

Drain and collect the oil.
Make sure that no oil drips onto the floor.
Remove the exhaust filters.
Separate special waste from the machine.
Dispose of special waste in compliance with applicable regulations.
Dispose of the machine as scrap metal.

Recommissioning

Risk of property damage.
Vanes can stick together after a longer standstill.
Danger of vane breakage if the machine is started with the drive motor.
After a longer standstill, the machine must be turned by hand.

After longer periods of standstill:

Make sure that the machine is locked against inadvertent start up.
Remove the cover around the fan of the drive motor.
Slowly rotate the fan wheel by hand several revolutions in the intended direction of rotation (see stuck on or cast arrow).
Mount the cover around the fan wheel of the drive motor.

If deposits could have gathered in the machine:

Spare Parts

NOTICE
Use of non-Busch original spare parts.
Risk of premature failure!
Loss of efficiency!

Use only original Busch spare parts, consumables and supplies to ensure correct operation of the machine and to validate the warranty.

Spare part	Description	Part no.
Exhaust filter (EF)	Includes appropriate o-ring	0532 140 152
Cover (CO)	For exhaust filter (EF)	0710 138 179
O-ring	For cover (CO) for exhaust filter (EF)	0486 124 845
Oil fill plug (OFP)	Includes appropriate seal ring	0415 000 071
Oil sight glass (OSG)	Includes appropriate seal ring	0583 151 312
Oil drain plug (ODP)	Includes appropriate seal ring	0415 000 071

If other parts are required:

Contact your Busch representative.

Troubleshooting

Live wires.
Risk of electrical shock!

Electrical installation work must only be executed by qualified personnel.

Hot surface.
Risk of burns!

Before doing anything that requires touching the machine, let it cool down first.

Illustration showing parts that may be involved during troubleshooting

Problem	Possible Cause	Remedy
The machine does not start	The motor is not supplied with the correct voltage.	Check the power supply.
The machine does not start	The motor is defective.	Repair the machine (contact Busch).
The machine does not reach the usual pressure on the suction connection	Oil level too low.	Top up oil.
	The inlet filter cartridge (optional) is partially clogged.	Replace the inlet filter cartridge.
	Internal parts are worn or damaged.	Repair the machine (contact Busch).
The machine runs very noisily	Stuck vanes.	Repair the machine (contact Busch).
The machine runs very noisily	Defective bearings.	Repair the machine (contact Busch).
The machine runs too hot	Insufficient cooling.	Remove dust and dirt from the machine. Check the cooling fan.
	Ambient temperature too high.	Observe the permitted ambient temperature.
	Oil level too low.	Top up oil.
	The exhaust filters (EF) are partially clogged.	Replace the exhaust filters (EF).
The machine fumes or expels oil droplets through the gas discharge	The exhaust filters (EF) are partially clogged.	Replace the exhaust filters (EF).
	An exhaust filter (EF) with oring is not fitted properly.	Ensure the correct position of the exhaust filters (EF) and the o-rings.
The oil is black	Oil change intervals are too long.	Flush the machine (contact Busch).
	The inlet filter (optional) is defective.	Replace the inlet filter.
	The machine runs too hot.	See problem "The machine runs too hot".
The oil is emulsified	The machine sucked in liquids or significant amounts of vapor.	Flush the machine (contact Busch).

For resolution of problems not listed in the troubleshooting table, contact your Busch representative.

Technical Data

		PB 0008 C
Nominal pumping speed (50 / 60 Hz)	m³/h	8.0 / 9.6
Ultimate pressure (50 / 60 Hz)	hPa (mbar)	2.0
Nominal motor rating (50 / 60 Hz)	kW	0.35 / 0.45
Nominal motor speed (50 / 60 Hz)	min⁻¹	3000 / 3600
Sound pressure level (ISO 2151), KpA = 3 dB (50 / 60 Hz)	dB(A)	60 / 64
Ambient temperature range	°C	5... 40 *
Inlet gas temperature range	°C	5... 40 *
Ambient pressure		Atmospheric pressure
Oil capacity	l	0.25
Weight approx.	kg	12

* In case of higher or lower temperatures, please consult your Busch representative.

Oil

	VM 032	VSA 032	VSB 032
ISO-VG	32	32	32
Part number 1 L packaging	0831 000 086	0831 163 958	0831 168 343
Part number 5 L packaging	0831 000 087	0831 163 961	0831 168 344

In case of unfavorable ambient temperature, other oil viscosities may be used. Please consult your Busch representative for more details.
To find out which oil needs to be filled into the machine, please refer to the nameplate (NP).

Oil suitability

Oil VM 032: Standard oil for operating temperatures <70°C.
Oil VSA 032: Suitable for food applications (H1)
- With additives against corrosion
- Light cycle operation (long downtime)
- Operating oil temperature <100°C
- Compliant with kosher and halal standards.
Oil VSB 032: Suitable for food applications (H1)
- Continuous and harsh cycle operation
- Compliant with kosher and halal standards.

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 in accordance with the state-of-the-art methods. Nevertheless, residual risks may remain, as described in the following chapters and in accordance with the chapter Intended Use.
This instruction manual highlights potential hazards where appropriate. Safety notes and warning messages are tagged with one of the keywords DANGER, WARNING, CAUTION, NOTICE and NOTE as follows:

indicates an imminent dangerous situation that will result in death or serious injuries if not prevented.

indicates a potentially dangerous situation that could result in death or serious injuries.

indicates a potentially dangerous situation that could result in minor injuries.

NOTICE
indicates a potentially dangerous situation that could result in damage to property.

NOTE
indicates helpful tips and recommendations, as well as information for efficient and trouble-free operation.

Busch Vacuum Solutions

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