5070005-Koch (UV2100 Manual).pdf

Vacuum Chamber Packaging Machine

Owner’s Manual

Effective Serial 5512+

860804• Revision AE • 02/19

THE NEW STANDARD FOR INNOVATION

UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150

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INTRODUCTION

TABLE OF CONTENTS

General ...............................................III

Specifications ....................................... IV

SAFETY

Personal Safety ....................................1.1

Food Safety ........................................1.2

General Safety Guidelines ....................1.2

Safety Decal Locations ........................ 1.3

Machine Conformity ............................1.4

STARTUP

Unpacking ..........................................2.1

Power Requirements ............................. 2.1

Grounding Instructions ........................ 2.2

Vacuum Pump .................................... 2.3

Checking Vacuum Pump Rotation ........ 2.3

Gas Flush Connection ........................ 2.3

Air-Assist Connection .......................... 2.3

Installation of Perforating Knives .......... 2.4

Installation of Precut Knives ................. 2.4

OPERATION

Placement of Product ...........................3.1

Operation with Digital Control Panel .... 3.2

Operator Menu on Digital Panel .......... 3.3

Selecting a New Program .................... 3.5

Operation with Touchscreen ................ 3.6

Sealing with Air-Assist ........................ 3 .11

Gas Flush Option .............................. 3.11

Double Seam Seal Option ................. 3.11

10mm Wide Seam Seal Option .......... 3 .11

Perforating Knife Option ....................3.12

Precut Option ...................................3.12

MAINTENANCE

Prior to Cleaning .................................4.1

Cleaning Recommendations .................4.1

Vacuum Pump Maintenance ................ 4.2

Seal Bar Maintenance ......................... 4.2

Reading the Indicators ........................ 4.4

Troubleshooting ................................. 4.5

Supervisor Menu on Digital Panel ........ 4.7

Supervisor Menu on Touchscreen ........ 4.12

Changing Vacuum Pump Oil and Filter 4.18

Maintenance Log ............................. 4.20

Service Log .......................................4.21

SCHEMATICS

Designation and Function of Controls .... 5.1

230 Volt, Single Phase, Digital Panel .... 5.2

230 Volt, 3 Phase, Digital Panel ........... 5.3

380 Volt, 50 Hz, Digital Panel ............. 5.4

380 Volt, 50 Hz, Digital Panel w/o N ... 5.5

460 Volt, 3 Phase, Digital Panel ........... 5.6

575 Volt, 3 Phase, Digital Panel ........... 5.7

Pneumatic Diagram ............................ 5.8

PARTS

Recommended Spare Parts ...................6.1

Miscellaneous Machine Parts ............... 6.2

Lid, External ....................................... 6.3

Lid, Internal ........................................ 6.4

Legs and Pump .................................. 6.6

Double Seam Seal Bar ........................ 6.8

10mm Wide Seal Bar.......................... 6.9

Single Seam Seal Bar .........................6.10

Vacuum Manifold .............................. 6 .11

Main Electrical Components ...............6.12

Base ................................................6.14

Gas Flush .........................................6.16

Swing Arm Assembly ..........................6.18

Digital Control Panel ........................ 6.20

Touchscreen Control Panel .................6.21

Inline Filter ....................................... 6.22

REFERENCE MANUALS

R5 Series Vacuum Pumps ..................... 7.1

UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150

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INTRODUCTION

ULTRASOURCE LLC

Ultravac

2100

Vacuum Chamber Packaging Machine

Owner’s Manual

Congratulations on your Ultravac

2100 vacuum packaging machine purchase. This

machine was designed to provide years of trouble-free operation and to help in the

packaging of your quality food products.

Please read this owner’s manual to gain the maximum benefits of your vacuum packaging

machine and its different components.

A note about cleaning: Given all the various ways equipment is used in different

environments, we recommend the owner consult sanitation experts on how to properly

clean each piece of machinery in their plant and to do bacterial testing to insure that the

equipment is cleaned properly.

For Sales, Call:

Phone (816) 753-2150 • Fax (816) 753-4976

Toll-Free (800) 777-5624

For Replacement Parts, Call:

Phone (816) 753-2150 • Fax (816) 561-2854

Toll-Free (800) 777-5624

For Technical Support, Call:

Phone (816) 753-2150 • Fax (816) 753-4976

Toll-Free (800) 777-5624

UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150

INTRODUCTION

III

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General

This owner’s manual contains information pertinent to your Ultravac

2100. Basic

instructions and maintenance information is provided. Please read carefully. Failure to do so

could result in bodily injury and/or damage to the equipment.

Receiving Problems: As in all cases, before signing the bill of lading, be sure all items

have been received as listed and there is no damage in shipment. If needed, a claim must

be made immediately to the local truck line office and noted on the bill of lading.

Please fill in the information from the bill of lading and the product identification tag.

Model No.

Serial No.

Ship Date:

Owner:

Location:

Electrical service size for your Ultravac

2100 (check one):

208 Volt, 3 phase, 60 Hz

230 Volt, 3 phase, 60 Hz

230 Volt, Single phase, 60 Hz

380 Volt, 3 phase, 50 Hz

460 Volt, 3 phase, 60 Hz

575 Volt, 3 phase, 60 Hz

Pump horsepower size for your Ultravac

2100 (check one):

5-horsepower

7.5-horsepower

10-horsepower

12-horsepower

Please fill in the serial numbers from the pump identification tags:

Serial No.

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INTRODUCTION

Specifications

Figure 0.1

8-in. Model 12-in. Model

Length (A): 1638mm (64.5-in.) 64.5-in. (1638.3mm)

Width (B): 1067mm (42-in.) 1067mm (42-in.)

Maximum Height (C): 1194 m m (47-in .) 1295mm (51-in.)

Working Height (D): 874mm (34.4-in.) 874mm (34.4-in.)

Chamber Width (E): 785mm (30.9-in.) 785mm (30.9-in.)

Chamber Length (F): 676mm (26.6-in.) 676mm (26.6-in.)

Chamber Depth (G): 203mm (8-in.) 305mm (12-in.)

Between Seal Bars (H): 813mm (32-in.) 813mm (32-in.)

Seal Bar Length: 673mm (26.5-in.) 673mm (26.5-in.)

Vacuum Pump:

200 m

/h, (117 cfm) 5.6 kW (7½ hp) [8-in. Model Only]

306 m

/h, (180 cfm) 7.5 kW (10 hp)

360 m

/h, (212 cfm) 8.9 kW (12 hp)

Cycle Time: 15-25 seconds 15-25 seconds

Net Weight: 5 0 0kg (110 4 -l b s .) 559kg (1232-lbs.)

Construction:

USDA Acceptable for use in

federally-inspected meat/poultry plants

ETL-approved

Cast Aluminum

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1.1

SAFETY

Personal Safety

The procedures and guidelines herein must be followed precisely to avoid problems that can

result in property damage, personal injury, or death. If you have any questions related to

this information, please contact Ultravac Services Inc. at (800) 777-5624.

DANGER

Hazardous voltage.

Disconnect and lockout power before servicing machine or cleaning. Do not remove panels

unless power has been disconnected and locked out at risk of electric shock hazard.

DANGER

Hot oil.

Hot oil poses scalding risk. Take necessary precautions while draining warm oil.

WARNINGWARNING

Read and understand owner’s manual before using this machine. Failure to follow operating

instructions could result in personal injury or damage to equipment.

WARNINGWARNING

Explosion hazard.

Do not use a gas with an oxygen content greater than 22% with gas flush option.

CAUTIONCAUTION

Blade hazard.

Do not remove, install, or replace blades without protective gloves. Perforating knife blade

is sharp. Use care when handling.

CAUTIONCAUTION

Blade hazard.

Do not remove, install, or replace blades without protective gloves. Precut knife blade is

sharp. Use care when handling.

CAUTIONCAUTION

Cleaning agents.

Do not get the cleaning agents in eyes, on skin, or on clothing. Always wear rubber gloves,

goggles, and protective clothing when contact is likely. Consult product manufacturer for

specific details.

Signal words used in classification of potential hazards are defined as follows:

DANGER: Indicates an imminently hazardous situation, which, if not avoided, may result in death or

serious injury.

WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in death or

serious injury.

CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may result in minor or

moderate injury. Caution also indicates actions that may cause property damage.

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1.2

SAFETY

Food Safety

Food Packaging

While this machine is often used for food packaging and vacuum cooking, there are

inherent risks associated with this packaging technique that could cause serious illness

or death to the consumer of the food product. If you are using this machine for a food

application, you must consult with a reputable food technologist or specialist in vacuum/

modified atmosphere packaging (M.A.P.) to review the safety of your application.

Gas Flush

In order to ensure proper shelf life of the food product packaged in this machine, you

must contact a reputable food technologist or specialist in vacuum/modified atmosphere

packaging (M.A.P.) to review and develop the appropriate gas mixture for your package,

and you must perform quality control and gas analysis on your finished M.A.P. packages.

General Safety Guidelines

Obvious safety guidelines should be observed.

 Use a certified electrician to install permanent electrical connection for your packaging

machine. Failure to do so may result in death or serious injury and/or permanent

damage to the machine.

 Be sure to turn off power to your packaging machine before any maintenance work is

performed.

 Disconnect and lockout power to your packaging machine before any maintenance work

is performed.

 Place machine on a flat, stable surface.

 Do not place tools, parts, or other objects on or inside machine while operating.

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1.3

SAFETY

Safety Decal Locations

Part # 860988 (Qty. 1)

Part # 889599 (Qty. 1)

Part # 861196 Qty. 1

(attached to power cord)

Part # 860360 Qty. 1

(attached to power cord)

Factory Tested / Oil Filled

(Hanging Tag)

Part # 835440 (Qty. 2)

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1.4

SAFETY

Machine Conformity

This machine has been manufactured to conform to the following safety standards:

UL 73, Motor Operated Appliances, USA

The Ultravac 2100 is manufactured to conform to the relevant provisions of ANSI/UL-73,

Tenth Edition dated 03/2011, Revised 01/2012.

CSA 22.2, No. 68, Motor Operated Appliances, Canada

The Ultravac 2100 is manufactured to conform to the relevant provisions of CSA C22.2 No.

68-09, Seventh Edition, Update #2 dated 09/2010.

CE Low Voltage Directive (LVD) 2006/95/EC

The Ultravac 2100 is manufactured to conform to the relevant provisions of

• EN 60335-1-2012 relating to “Safety of household and similar electrical appliances,”

• EN 60335-2-64:2000 relating to “Particular requirements for commercial electric kitchen

machines.”

and overall the provisions of Low Voltage Directive (LVD) 2006/95/EC relating to

“Equipment designed for use within certain voltage limits of 12 December 2006.”

CE Electromagnetic Compatibility (EMC) Directive 89/336/EEC

The Ultravac 2100 is manufactured to conform to the relevant provisions of

• EN 61000-6-4 relating to “Emissions, Radiated, 30Mhz - 1Ghz”

• EN 61000-6-2 relating to “Emissions, Conducted, 150kHz - 30Mhz”

• EN 61000-4-2 relating to “Immunity ESD ± 4kV Contact/ ±8kV air discharge “

• EN 61000-4-3 relating to “Immunity Radiated RF, 10V/m, 80Mhz - 2.7Ghz”

• EN 61000-4-4 relating to “Immunity EFT (Mains) ±1kV”

• EN 61000-4-5 relating to “Immunity Surge AC, ±2kV”

• EN 61000-4-6 relating to “Immunity Conducted RF (Mains), 10Vrms.”

and overall the provisions of “Electromagnetic Compatibility (EMC) Directive 89/336/EEC of

15 December 2004.”

USDA / AMI Sanitary Design Standards

The Ultravac 2100 is designed for sanitary conditions in USDA inspected facilities. All

UltraSource equipment is manufactured with respect to AMI Sanitary Design Standards. All

materials that are in food contact areas meet relevant USDA standards.

The Design and Technical Construction files for this machine are maintained at:

UltraSource LLC

1414 West 29th Street

Kansas City, MO 64108-3604 USA

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STARTUP

2.1

STARTUP

Unpacking

1. Carefully remove crate from the skid.

2. Remove machine from skid.

3. Wipe down outside of the machine.

Power Requirements

The machine is available with a 7½ horsepower vacuum pump for the 200mm (8-in.) model

and a 10 horsepower vacuum pump for the 300mm (12-in.) model. The standard machine

is rated 220 volt, 60 Hertz, 3 phase and is supplied with a 30 amp, 250 volt, 3 phase plug.

The owner must supply the correct 3 phase or single phase power source in accordance

with the National Electric Code. The table below is based on the National Electric Code and

is to be used as a guide in wire size selection and short circuit protection. The requirements

noted in the table may change. Please consult an electrician prior to installation.

UV2100 POWER CABLE SIZING CHART

208/230v (5&7.5hp Pumps) 10 gauge/ 4 conductor

380v 12 gauge/ 5 conductor

460v 10 gauge/ 4 conductor

208/230v (10&12hp Pumps) 8 gauge/ 4 conductor

380v w/o neutral 12 gauge/ 4 conductor

Customer Voltage

Pump Motor Full Load Amps

Supply conductor shall Supply conductor shall

have an ampacity not have an ampacity not

less than 125% of the less than 125% of the

Pump Motor Full Load Pump Motor Full Load

AmpsAmps

5 HP 7.5 HP 10 HP 12 HP

208, 60 Hz 3 Phase 21 26.5 32

230, 60 Hz 3 Phase 20.5 26 30

380, 50 Hz 3 Phase 12 14 15

460, 60 Hz 3 Phase 10.5 13 15

575, 60 Hz 3 Phase 9 10.5 12.5

230, 60 Hz Single Phase 22.5 - - -

Customer Voltage

Inverse Time Circuit

Breaker

Fused Disconnect Dual

Element (Time Delay)

5 HP 7.5 HP 10 HP 12 HP 5 HP 7.5 HP 10 HP 12 HP

208, 60 Hz 3 Phase 50 60 70 35 45 50

230, 60 Hz 3 Phase 50 60 60 35 45 50

380, 50 Hz 3 Phase 25 30 35 20 20 25

460, 60 Hz 3 Phase 25 30 35 15 20 25

575, 60 Hz 3 Phase 20 25 30 15 15 20

230, 60 Hz Single Phase 60 - - - 45 - - -

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2.2

STARTUP

Grounding Instructions

The Ultravac

2100 must be grounded. In the event of malfunction or breakdown,

grounding provides a path of least resistance for electric current to reduce the risk of electric

shock. The unit is equipped with an equipment-grounding conductor cord and a grounding

plug. The plug must be plugged into an appropriate outlet that is properly installed and

grounded in accordance with all local codes and ordinances.

DANGER

Hazardous voltage.

Improper connection of the equipment-grounding conductor can result in a risk of electric

shock.

The equipment-grounding conductor outer surface is green with or without yellow

stripes. If repair or replacement of the cord or plug is necessary, do not connect the

equipment-grounding conductor to a live terminal. Check with a qualified electrician

or Ultravac Services Inc. technician if the grounding instructions are not completely

understood, or if there is doubt as to whether the unit is properly grounded. Do not modify

the plug provided with the unit – if it will not fit the outlet; have a proper outlet installed by

a qualified electrician.

DANGER

OXYGEN ENRICHED USE

ULTRASOURCE TRAY SEALING AND VACUUM CHAMBER MACHINES ARE NOT DESIGNED

FOR USE WITH OXYGEN ENRICHED PROCESS GASES. ANY APPLICATION THAT REQUIRES

A PROCESS GAS CONTAINING 25% OR MORE OXYGEN SHOULD CONTACT ULTRAVAC

SERVICES AT (800) 777-5624 AS RETROFIT OPTIONS ARE REQUIRED.

RUNNING THIS MACHINE WITH AN OXYGEN ENRICHED PROCESS GAS, WITHOUT THE

NECESSARY RETROFIT KIT COULD CAUSE SEVERE INJURY, DAMAGE OR DEATH.

ULTRASOURCE TRAY SEALING AND VACUUM CHAMBER THAT ARE RETROFITTED

WITH THE NECESSARY KIT WILL HAVE A DECAL ABOVE OR BESIDE THE GAS SUPPLY

CONNECTION INDICATING THE MACHINE’S READINESS TO RUN OXYGEN ENRICHED

PROCESS GASES.

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STARTUP

2.3

Vacuum Pump

It is essential to check the oil level daily and to change the oil after every 500 hours of

operation. Read the oil level with the machine turned off. Oil may be added until the level

reaches the MAX level shown below. Refer to page 4.18 for details on changing the oil.

NOTE: ALL ULTRAVAC 2100 CHAMBER MACHINES ARE SHIPPED WITH OIL IN THE PUMP.

ALTHOUGH THE FACTORY RECOMMENDS CHECKING THE OIL LEVEL PRIOR TO FIRST

USE!

Checking Vacuum Pump Rotation

Caution: Check oil level of pump before starting pump (please refer to pump manual).

To check the direction of the pump rotation, briefly engage the “POWER ON” switch and

observe the motor fan at the end of the pump. The fan should rotate as indicated by the

arrow on the fan cover. To correct the rotation, switch any two phases in the plug.

Gas Flush Connection

The owner must supply a suitable regulator with a range of 0 to 60 p.s.i. We recommend

using food-grade flexible hose with a 1/4-in. I.D. and a maximum length of 15-ft. Maximum

regulator pressure is 55 p.s.i.

Air-Assist Connection

The machine is equipped with a regulator for air-assisted sealing. The hose barb will

accept 1/4-in. I.D. hose. The recommended air supply is 75 p.s.i. at 6 c.f.m. The maximum

regulator setting is 40 p.s.i.

Figure 2.1

MAX

MIN

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2.4

STARTUP

Installation of Perforating Knives

CAUTIONCAUTION

Blade hazard.

Do not remove, install, or replace blades without protective gloves. Perforating knife blade is

sharp. Use care when handling.

Remove standard seal bars. Install perforating bars with the cutting blade facing toward

the outside of the lid. The use of air-assist is required for proper operation. The air-assist

regulator should be set at 20 to 30 p.s.i., not to exceed 40 p.s.i.

As the backup strip wears, it can be removed and changed end for end for a better surface.

The strip may also be turned upside down when one side is worn.

Installation of Precut Knives

CAUTIONCAUTION

Blade hazard.

Do not remove, install, or replace blades without protective gloves. Precut knife blade is sharp.

Use care when handling

Remove standard seal bars. Install precut seal bars with the blade facing toward the outside

of the lid. The use of air-assist is required for proper operation. The air-assist regulator

should be set at 20 to 30 p.s.i., not to exceed 40 p.s.i.

As the backup strip wears, it can be removed and changed end for end for a better surface.

The strip may also be turned upside down when one side is worn.

Figure 2.2

Precut Knife

this side

Excess Pouch

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3.1

OPERATION

Placement of Product

For best sealing results, it is important to:

• Check the pump oil level daily.

• Select a pouch that fits the product.

• Carefully load the product into the pouch.

• Keep the product and the product residue away from the seal area of the pouch.

• Place the product as far into the pouch as possible.

• Maintain an equal amount of the product above and below the seal bar (see figure

below on use of filler plates).

• Lay the pouch flat on the seal area, keeping the pouch free of wrinkles.

• Place the pouch so that the open end is inside the chamber when the lid is closed.

Figure 3.1

Products containing liquid or loose particles can be packaged by slightly loosening the nuts

on each end of the machine and tilting the machine to the desired angle. Retighten the nuts

to secure the machine.

Figure 3.2

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3.2

OPERATION

Operation with Digital Control Panel

The digital control panel allows the user more options than the standard control panel. The

embedded microprocessor controls each sequence of the packaging operation. Settings for

the vacuum, gas, and sealing are entered as parameters through the keypad. This allows

the user to custom program every step of the packaging process. The precise vacuum

and gas pressures are controlled by a pressure based sensor. The vacuum pressure, gas

pressure, and seal time are displayed on a large 16-character LCD backlit readout, which

is easily readable in all lighting conditions. As each sequence is performed, the real-time

pressure level or cycle time is displayed.

The digital front panel can save up to ten pre-programmed routines, which can be retrieved

at any time for specific packaging applications. With the supervisor security feature turned

on, these programs cannot be inadvertently changed.

The Vacplus option allows the operator to run the pump from 0 to 20 seconds after the set

vacuum level is achieved.

The Gas Flush option allows the operator to introduce an inert gas into the chamber after

the vacuum stage. This option can be used as a filler to prevent crushing of the product

after sealing, as a means to prolong shelf life, or as a means to maintain desirable product

appearance.

The digital front panel has an auto stop, which will automatically seal if the preset vacuum is

not reached. This feature decreases the cycle time and optimizes the vacuum level of each

product.

The digital front panel, which includes the keypad, illuminated display, and microprocessor,

use sealed components and is conformal coated in a moisture-proof coating. The digital

front panel meets or exceeds the requirements of NEMA 4. The front of the digital display is

sealed and flush for easy cleaning.

The digital control has both pulsed vacuum and pulsed venting options for fragile product.

The digital control has a maintenance screen for testing valves and a special loop option for

multiple vacuum/gas cycles before sealing.

Figure 3.4

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3.3

OPERATION

Operator Menu on Digital Panel

NOTE: if the supervisor has set security on, these settings cannot be changed.

Figure 3.5

VACPLUS: 4.0

SEAL: 1.2

VACUUM: 98

RUNNING PROG: 1

PROGRAM

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

This is the Main Menu screen. When

the machine starts up, the last program

that was run will be the current program

shown in the window. To set the operating

parameters for the program shown press

the MENU Key.

VACUUM is set to % vacuum using the UP

and DOWN arrow keys. The range is 30%

to 99%.

Press the MENU Key.

VACPLUS may be set greater than zero

to allow the pump to continue evacuating

the chamber (for the specified number

of seconds) after the pressure in the

chamber has reached the % vacuum set

in the vacuum menu. The range is 0 to 20

seconds.

Press the MENU Key.

The SEAL setting is in seconds.

Use the UP and DOWN arrow keys to

change the seal time. The range is 0 to 2

seconds.

Press the MENU Key.

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3.4

OPERATION

Operator Menu on Digital Panel (continued)

WARNINGWARNING

Explosion hazard.

Do not use a gas with an oxygen content greater than 22% with gas flush option.

Figure 3.5

PRECUT: YES

GAS: 65

GAS: YES

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

If the machine is equipped with the gas

option, it can be turned ON or OFF by

pressing the UP or DOWN arrow keys.

Press the MENU Key.

GAS is set to % gas using the UP and

DOWN arrow keys. This value also

corresponds to the vacuum reading inside

the chamber. It is recommended to use

Pulse Vent when gas flushing to a low %

vacuum. The range is 98% to 30%.

Press the MENU Key.

If the machine is equipped with the

PRECUT option, it can be turned ON or

OFF by pressing the UP or DOWN arrow

keys.

Press the MENU Key.

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3.5

OPERATION

Selecting a New Program

Figure 3.6

ENTER PROGAM: 2

RUNNING PROG: 1

PROGRAM

YES

PROGRAM

YES

From the Main Menu, use the UP and

DOWN arrow keys to select a new

program.

Press the UP arrow to switch to Program 2

(or any of the 10 programs).

New parameters may be set for Vacuum,

Seal Time, and Gas for Program 2

(following the procedures described in the

previous example) or simply close the lid

on the machine and run Program 2.

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3.6

OPERATION

Operation with Touch Screen

The touch screen control panel allows the user more options than the digital control panel.

The embedded microprocessor controls each sequence of the packaging operation. Settings

for the vacuum, gas, and sealing are entered as parameters through the keypad. This

allows the user to custom program every step of the packaging process. The precise vacuum

and gas pressures are controlled by a pressure based sensor. The vacuum pressure, gas

pressure, and seal time are displayed on a large 4.3” LCD touch screen, which can be read

easily in all lighting conditions. As each sequence is performed, the real-time pressure level

or cycle time is displayed.

The touch screen panel can save up to 99 pre-programmed routines, which can be retrieved

at any time for specific packaging applications. [With the supervisor security feature turned

on, these programs cannot be inadvertently changed.]

The VACPLUS option allows the operator to run the pump from .1 to 6 seconds after the set

vacuum level is achieved.

The Gas Flush option allows the operator to introduce an inert gas into the chamber after

the vacuum stage. This option can be used as a filler to prevent crushing of the product

after sealing, as a means to prolong shelf life or as a means to maintain desirable product

appearance.

The touch screen panel has an auto stop, which will automatically seal if the preset vacuum

is not reached. This feature decreases the cycle time and optimizes the vacuum level of each

product.

The touch screen panel meets or exceeds the requirements of NEMA 4. The front of the

touch screen is sealed and flush mounted for easy cleaning.

The touch screen has both pulsed vacuum and pulsed venting options for fragile product.

The touch screen has a maintenance screen for testing valves and a special loop option for

multiple vacuum/gas cycles before sealing.

Figure 3.4

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3.7

OPERATION

Operation with Touch Screen (continued)

NOTE: If the supervisor has set security on, program settings cannot be changed.

This is the splash screen. When the machine

starts up, this screen will display for a period

of time during bootup. Once the bootup

sequence has been completed, the screen

will automatically change to the Main Menu.

This is the Main Menu. This screen allows

access to all of the other functions of the

machine. A program can be selected

from this menu, and run from this menu.

Maintenance, Security, and Program

Parameters can also be edited from this

menu if the correct level of access is used.

This is the RUN Screen. This screen shows

the status of the program that is currently

being run, as well as the name of that

program.

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3.8

OPERATION

Operation with Touch Screen (continued)

NOTE: If the supervisor has set security on, program settings cannot be changed.

Some options may not apply to every machine.

This is the Edit Parameters screen. Every

program consists of multiple parameters.

These parameters are defined on the Edit

Parameters screen for each saved program.

VACUUM PERCENT:

This defines the percentage of vacuum to

achieve prior to sealing. The range is up to

99%.

VAC-PLUS:

This may be set from 0.1 to 6 seconds. A

setting greater than 0 allows the pump

to continue evacuating the chamber (for

the specified number of seconds) after the

pressure in the chamber has reached the %

vacuum set in the vacuum menu.

SEAL TIME:

The seal time setting is in seconds. The

range is 0 to 3 seconds.

PULSE VAC:

Pulse Vac allows for a more controlled

vacuuming process. Rather than simply

opening the vacuum valve for a continuous

vacuum, the valve is opened and closed

repeatedly until the chamber reaches the set

“Pulse Vac” vacuum level as defined in the

“Maintenance” screen.

PULSE VENT:

Pulse Vent allows for a more controlled

venting process. Rather than simply opening

up the valve for a continuous vent the

valve is opened and closed repeatedly

until the chamber vents back to the “Pulse

Vent” pressure setting as defined in the

“Maintenance” screen.

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3.9

OPERATION

Operation with Touch Screen (continued)

NOTE: If the supervisor has set security on, program settings cannot be changed.

Some options may not apply to every machine.

GAS OFF:

The Gas state button tells whether Gas

Flushing is turned on or off. Enable Gas by

turning this button to the ON position.

GAS %:

Gas is set to % gas by pressing the value

button on the touch screen and directly

editing the value using the provided

keypad. This value also corresponds to the

vacuum reading inside the chamber. It is

recommended to use pulse vent when gas

flushing to a low % vacuum. The range is

0.1% to 99%.

PRECUT OFF:

If equipped, This activates or deactivates the

Precut knife option

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3.10

OPERATION

Operation with Touch Screen (continued)

NOTE: If the supervisor has set security on, program settings cannot be changed.

Some options may not apply to every machine.

Program selection:

The Program Select feature has 99 different

user definable presets. To set a program

number, use the left and right arrows, or

press on the program select number to

bring up a keypad for number selection..

Once the program number you desire has

been selected, press on the White box to

pull up the keyboard screen, enter a name

for your program (up to 10 characters) and

press enter. You will be returned to the main

menu.

Press Edit Parameters. From the Edit

Parameters screen, enter the desired

settings for your product requirements.

When finished, press Exit. Your parameters

are now saved to the program number you

selected.

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3.11

OPERATION

Sealing with Air-Assist

All machines are equipped with regulators for air-assisted sealing. Set the air pressure

regulator to 20 p.s.i. increasing to a maximum of 40 p.s.i. While a good seal can be

obtained without air-assist, use air-assist when:

• Gas back-flushing above average pressure.

• Using shrink pouches.

• Packaging a product that easily contaminates the seal area of the pouch.

• Trying to overlap pouches.

• Wrinkles cannot be avoided in the seal area.

• Using the Double Seam Seal option.

• Always use air-assist when using the Perforating Knife Option.

• Always use air-assist when using the Precut Option.

• Always use air-assist when using the 10mm Wide Seal Band Option

Gas Flush Option

Gas flushing is the introduction of an inert gas into the chamber after the vacuum stage

is finished. Gas can be used as a filler to prevent crushing of the product after sealing, as

a means to prolong shelf life, or as a means to maintain desirable product appearance.

Commonly used gasses include nitrogen, carbon dioxide, or a mixture of both. Consult your

local gas supplier to select the proper gas for your product.

WARNINGWARNING

Explosion hazard.

Do not use a gas with an oxygen content greater than 22% with gas flush option.

Double Seam Seal Option

All machines are equipped with standard seal bars having a single seal element per

seal bar. The Double Seam seal bars have two seal elements per seal bar. We strongly

recommend using air-assisted sealing with this option to achieve best results.

10mm Wide Seam Seal Option

All machines are equipped with standard seal bars having a single seal element per

seal bar. The 10mm Wide Seam seal bars have a wide seal element. It is required to use

air-assisted sealing with this option to achieve best results.

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3.12

OPERATION

Perforating Knife Option

Perforating knives are used to facilitate the removal of excess pouch material. Perforating

knives are not intended to cut pouches off completely, only to perforate so that excess

material can be easily removed by hand.

Precut Option

The precut option is a patented system designed by UltraSource to increase the versatility

of the Ultravac

2100. This option increases the speed in which this machine can be loaded

with product. The user simply places the pouch full of product into the machine and pulls

it close to the seal bar allowing the excess material to hang on the outside of the machine.

Not only does this increase the loading speed, but it also improves the appearance of the

final product. The precut option also allows the end user to stock fewer sizes of pouches

because excess pouch material is trimmed away.

When using this option, the bag or pouch containing product is placed inside the machine

as usual. However, rather than having to carefully tuck the bag inside the slot in the

machine before closing the lid, the open end of the bag is placed outside the machine by

simply draping the bag over the side of the machine. When the lid is closed, the seal bar is

brought down and the special precut blade cuts evacuation slits in the bag or pouch, which

allow the air inside the bag to escape during the normal evacuation process.

Start by making sure the Precut menu is set to the “ON” position. With precut, air-assisted

sealing is required. Place the bag containing product inside the chamber. Drape the open

end of the bag over the side of the machine and close the lid. When the evacuation process

is finished, the bag will have “slits” pierced in it by the precut knife. The slits allow the air to

be evacuated from the bag. The slits also facilitate the removal of excess bag material after

the completion of the cycle.

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4.1

MAINTENANCE

Prior to Cleaning

Every environment and application is different; therefore, UltraSource LLC cannot provide

cleaning instructions to guarantee microbiological sanitation. UltraSource requests that the

owner of this machine consult with sanitation experts to review the unit working in their

particular environment to develop a robust cleaning schedule and methodology, followed by

bacterial testing to ensure satisfactory cleaning procedures are followed.

Cleaning Recommendations

Before cleaning the machine, turn power off; disconnect the main power, and lockout the

connection.

DANGER

Hazardous voltage.

Disconnect and lockout power before servicing machine or cleaning. Do not remove panels

unless power has been disconnected and locked out at risk of electric shock hazard.

Check with the detergent and sanitizer manufacturers that their products are compatible

with the listed materials.

CAUTIONCAUTION

Cleaning agents.

Do not get the cleaning agents in eyes, on skin, or on clothing. Always wear rubber gloves,

goggles, and protective clothing when contact is likely. Consult product manufacturer for

specific details.

Never hose down the machine. Damage caused by hosing or high pressure washing is not

covered under warranty.

1. Filler Plates: Remove filler plates. The filler plates are made from polyethylene. Clean,

sanitize, and dry. High pressure water spray can be used on the filler plates.

2. Lid, Chamber, and Base: These components are made of aluminum. Clean the lid,

chamber, base, and silicone seal backup strip with a non-ionic cleaning solution such

as Crystal Simple Green.

3. Seal Bars: Remove the seal bars. The seal bars are made of phenolic. Clean, sanitize,

and dry. Also clean under the seal bar bladder in the lid, which is not removable.

4. Clean under the machine.

5. Reinstall the seal bars.

6. Use bacteriological testing to insure cleaning process.

WARNINGWARNING

Electrical Supply Cord.

The supply cord must be replaced by an Ultravac Services Service Technician or similarly

qualified person in order to avoid hazard.

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4.2

MAINTENANCE

Step 1.

Remove the seal bars from the machine. Pull

off the Teflon

tape strip and discard. Clean

off any remaining Teflon

tape adhesive

using acetone or an equivalent solvent.

Step 2.

Using a 2mm Allen wrench, loosen the set

screws for the cut-off wire and the seal

element on both ends of the seal bar and

discard.

Step 3.

If you are replacing the L-shaped spring retainer and the spring at this time, loosen the set

screw and remove the old spring retainer and spring and install the new ones. Adjust the

spring retainer to allow a 1/8-in. gap between the spring retainer and the seal bar. This will

allow the seal element to remain under tension after tightening the seal element.

Vacuum Pump Maintenance

Consult the pump manufacturer’s manual provided with the machine for detailed

information.

Seal Bar Maintenance

The following illustrations show replacement of the seal elements for the seal bars.

Figure 4.1

Figure 4.2

Figure 4.3

Teflon

tape

Clamping

Screw

Spring

Retainer

Brass

Contact

Tightening

Tool

Seal

Element

Spring

Retainer

1/8-in.

Set

Screw

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4.3

MAINTENANCE

Seal Bar Maintenance (continued)

Step 4.

Insert the new seal element through the hole in the brass contact. Leave about 3/4-in.

of excess seal element extending past the brass contact and tighten the clamping screw.

Insert the other end of the element through brass contact on the opposite end of the seal

bar. Place a slotted tip screwdriver on top of the seal element and against the brass contact

where the seal element exits. Using the tightening tool provided (or needle nose pliers),

tighten the seal element as shown.

Step 5.

While maintaining tension on the tightening tool, use the slotted tip screwdriver to tighten

the clamping screw.

NOTE: A 1.5mm Allen wrench will be needed to tighten the clamping screws on a Double

Seam seal bar.

Step 6.

Check the tension of the seal element by pulling it up at the middle of the bar. The seal

element should not pull beyond 3/16-in. of the seal bar. If there is not enough tension,

tighten as necessary. Elements may break in the middle of the bar if tension is not set

properly. Install the new Teflon

tape strip over the bar.

3/16-in. maximum

Figure 4.4

Figure 4.5

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4.4

MAINTENANCE

Reading the Indicators

All machines are controlled by an analog control module (with knobs) or a digital control

module (with touch pad) designed to aid in troubleshooting. The analog control module,

mounted behind the front control panel, has five red indicator lights (LEDs) mounted to it.

To view the indicator lights on the analog control module during operation remove the six

screws on the front of the control panel and pull the control panel out. The digital panel

has indicator lights mounted on the front below the ON/OFF switch. The indicator lights

correspond to the operating devices and should turn on and off in the following sequence

when the machine lid is closed:

1. Vacuum Valve [SOL-1]

2. Gas Flush Valve [SOL-2] (Optional)

3. Seal Bladder Valve [SOL-3]

(Stays on until completion of cycle)

4. Seal Impulse Contractor [C-2]

5. Ventilation Valve [SOL-4]

The device should be operating when the LED is illuminated. If the LEDs illuminate in the

proper sequence, but there is still a problem, look for the problem in the operating device

itself. If the LEDs do not sequence properly, look for a problem in the related potentiometer

or the control module.

1. VACUUM VALVE [SOL-1]

2. GAS FLUSH VALVE [SOL-2] (OPTIONAL)

3. SEAL BLADDER VALVE [SOL-3]

(STAYS ON UNTIL COMPLETION OF CYCLE)

4. SEAL IMPULSE CONTACTOR [C-2]

5. VANTILATION VALVE [SOL-4]

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4.5

MAINTENANCE

Troubleshooting

Problem Indications Remedy

Machine will not start Green power “ON” light not

lit when switch is turned on

Make sure that the power

requirements match those given

on the nameplate. Also, check

fuse F-3; replace if blown.

Vacuum pump does not run Make sure that the power

requirements match those given

on the nameplate. Also, check the

overload OL-1; reset if necessary.

No vacuum When lid is closed, indicator

light (VAC) is “OFF” on the

control module

Check lid switches LS-1 and LS-2

for proper adjustment

Vacuum not pulling lid down

on both sides

Check intake screen in vacuum

pump hose barb for blockage,

pieces of bags, labels, bone, etc.

Longer vacuum cycle times Check intake screen in vacuum

pump hose barb for blockage

No gas flush (optional) If indicator light (GAS) is lit Check for proper gas pressure

going into gas inlet

If indicator light (GAS) is not

lit

Check for proper operation of gas

flush valve (SOL-2)

possible defective control module

Gas flushes to one chamber

side only

Check gas flush selector valve

(V-1) for proper adjust

Chamber not venting

(lid will not open)

Lid will not open and red

indicator light “VENT” on

control module is lit

Check ventilation valve SOL-4 for

proper operation

“VENT” indicator light is not

lit

possible defective control module

NOTE: Lid can be released by pulling the hose off of

the vacuum gauge to remove product.

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4.6

MAINTENANCE

Troubleshooting

Problem Indications Remedy

Improper or no

sealing

Bladder light on control

module is lit but the seal bar

does not come down

Check to make sure that the

regulator knob is turned fully

clockwise, or, if air-assist is used,

set to the recommended pressure

Check seal bladder valve SOL-3

for proper operation

The seal bar is not heating

up even though the red

seal light on the front panel

comes on

Check seal bar connection points

and clips for corrosion and proper

tension

The red seal light on the

front panel either does not

light for the proper length

of time (1/2 to 1 second) or

does not light at all

Check for broken seal element

Check seal bar fuse F-1 for front

seal bar and F-2 for rear seal bar*

Make sure the seal impulse

potentiometer POT-3 is set high

enough or check for defective

control module

Front or rear seal bar

heating, but not both

Check seal bar fuse F-1 for front

seal bar and F-2 for rear seal bar*

* Fuses F-1 and F-2 only apply to machines shipped before 1/1/2006.

NOTE: For proper sealing, three things must occur:

1. The seal bar must come down and place adequate pressure between the seal bar and

the backup strip.

2. The seal element must heat up sufficiently to fuse the pouch.

3. The pouch must be allowed to cool for a time to ensure a good “set.”

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4.7

MAINTENANCE

Supervisor Menu on Digital Panel

Untrained personnel should not alter any setting in the supervisor menu.

Figure 4.6

WAITTIME: 4

CUTTIME: 1.5

PREVAC: 25

RUNNING PROG: 1

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

This is the main menu screen. When

the machine starts up, the last program

that was run will be the current program

shown in the window.

Press and hold down both arrow keys for

at least 3 seconds to enter the supervisor

menu.

NOTE: If your machine is not installed

with the precut option, disregard the

PREVAC, CUTTIME, and WAITTIME

parameters.

PREVAC is the % vacuum that you wish to

reach before activating the knife, which

makes slits in the bag for precut. Use the

up or down arrow keys to change the

current setting.

The range is from 5% to 20% vacuum.

Press the MENU key.

CUTTIME is the number of seconds that

the seal valve is activated. This is the

time when the knife actually makes the

evacuation slits in the bag/pouch for

precut. The range is from 0 to 3 seconds.

Press the MENU key.

WAITTIME is the number of seconds the

machine waits for the knife to retract

before resuming the vacuum cycle. The

range is from 0 to 6 seconds.

Press the MENU key.

The following are parameters that can

only be set in the supervisor menu.

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4.8

MAINTENANCE

Supervisor Menu on Digital Panel

Figure 4.7

# PROGRAMS: 10

SECURITY: NO

COOLDOWN: 4.0

TEST: YES

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

COOLDOWN is the time that the machine

waits after sealing the bag/pouch before

the seal bars retract. This allows time for

the actual seal to cool down and take a set.

The range is from 1 to 8 seconds.

Press the MENU key.

SECURITY can be turned on by selecting

yes. If security is on, the operator menu will

be read only and the operator will not be

able to change any settings.

Press the MENU key.

This is how you specify the maximum

number of programs that may be saved in

memory. Each program may have its own

set of unique parameters.

This range is from 1 to 10.

Press the MENU key.

If TEST is set to YES (using the up arrow

key), the vacuum valve and vent valve may

be operated manually. The up arrow key

activates the vacuum valve, the down arrow

key activates the vent valve, and pressing

both at the same time turns them both off.

As you activate either valve, the vacuum

pressure is displayed.

Press the MENU key.

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4.9

MAINTENANCE

Supervisor Menu on Digital Panel

PULSE OFF: 1.0

PULSE ON: 1.2

PULSE TO: 50

PULSE VENT: YES

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

PULSE VAC allows for a more controlled

vacuum process. Rather than simply

opening up the vacuum valve for a

continuous vacuum, the vacuum valve is

opened and closed repeatedly until the

chamber reaches the desired vacuum.

Press the MENU Key.

This is the % vacuum reached by pulsing

the vac valve.

The range is 90% to 30%.

Press the MENU Key.

This is how long the vacuum valve is

turned on during the vacuum cycle.

The range is 0 to 3 seconds.

Press the MENU Key.

This is how long the vacuum valve is

turned off during the vacuum cycle.

The range is 0 to 3 seconds.

Press the MENU Key.

Figure 4.9

PULSE VAC

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4.10

MAINTENANCE

Supervisor Menu on Digital Panel

Figure 4.8

PULSE OFF: 1.0

PULSE ON: 1.2

PULSE TO: 50

PULSE VENT: YES

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

YES

PROGRAM

PULSE VENT allows for a more controlled

venting process. Rather than simply

opening up the vent valve for a continuous

vent, the vent valve is opened and closed

repeatedly until the chamber vents back to

atmospheric pressure.

Press the MENU Key.

This is the % vacuum reached by pulsing

the vent valve before the vent valve opens

completely to fully vent the chamber.

The range is 90% to 30%.

Press the MENU Key.

This is how long the vent valve is turned on

during the vent cycle.

The range is 0 to 3 seconds.

Press the MENU Key.

This is how long the vent valve is turned

off during the vent cycle.

The range is 0 to 3 seconds.

Press the MENU Key.

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4.11

MAINTENANCE

EXIT GAS: YES

LOOP #: 1

YES

PROGRAM

YES

PROGRAM

VAC TIMEOUT: ON

YES

PROGRAM

If the machine is equipped with the LOOP

option, this is the number of vacuum/gas

cycles the control will perform prior to the

seal and vent.

The range is 1 to 5 cycles.

The default value is 1 cycle.

Press the MENU Key.

If the Loop # is set greater than 1, the

control can be set to exit this loop on either

the last gas cycle or the last vacuum cycle

prior to sealing.

The DOWN arrow key indicates NO.

The UP arrow key indicates YES.

Press the MENU Key.

VAC TIMEOUT is an option that is turned

ON or OFF. If set OFF, default, the machine

will time out if the preset vacuum is not

reached in 6 seconds, and the machine

will complete the cycle. If set ON and the

machine does not reach the preset vacuum

in thirty seconds, then the panel will display

VAC ERROR and vent the chamber without

sealing.

Supervisor Menu on Digital Panel

Figure 4.10

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4.12

MAINTENANCE

Supervisor Menu with Touch Screen

NOTE: If the supervisor has set security on, program settings cannot be changed.

This is the Main Menu. This screen allows

access to all of the other functions of

the machine. The supervisory menu can

be accessed by entering the required

maintenance password in Security, and then

pressing the Maintenance button.

Default Maintenance Password is listed in

the security setup section of this manual.

This is the primary Maintenance menu.

This allows access to all of the various

supervisory and maintenance related

screens.

Global Parameters consist of machine

specific global parameters such as Vacuum

Time Out limits, Cool Down times, and

Language Selection.

Security Setup allows the default passwords

to be changed, and allows the supervisor to

restrict the editing of program parameters

to Maintenance level supervisors or to allow

anyone using the machine to make these

changes.

Pulse Vac-Vent Setup allows the supervisor

to configure the behavior of the Pulse Vac

and Pulse Vent operations if being used.

Configuration is a factory configuration

menu that allows the touch screen to

be properly configured for operation on

a specifically equipped machine. These

settings should NEVER be changed in

the field unless instructed to do so by an

Ultravac Services technician.

Precut Options: If the machine is equipped

with the PRECUT option, selecting this icon

allows the parameters to be set. See precut

and looping options for details

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4.13

MAINTENANCE

Supervisor Menu with Touch Screen (continued)

Global Parameters

Cool Down: This parameter determines how

long the cool down period is in each cycle.

This can be set by pressing the value button

and changing the value using the provided

keypad. The range for this value is 0 to 10.

Vac Timeout: The Vacuum Timeout

parameter determines how the machine

behaves if the Vacuum Timeout is reached

before the cycle completes.

Timeout --> Seal: This will cause the

machine to seal the package

immediately if a Vacuum Timeout

fault occurs.

Timeout --> Vent: This will cause the

machine to stop the vacuum process,

vent the chamber and leave the

package unsealed.

Print Options: This is used to enable/disable

the printer function.

# of Programs: This parameter defines the

number of programs that can be stored. The

range for this value is 1 to 99.

Language Select: This allows the user to

select a different operating language for

the touch screen. The machine is equipped

with four base languages including English,

French, German and Spanish. The language

can be selected simply by pressing the flag

like button and cycling through the options.

Press Exit when done and this will save your

changes.

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4.14

MAINTENANCE

Following the selection of Print Options in

Global parameters, this screen will appear.

Enabling or disabling the printer feature is

done by selecting the Print ON/OFF but-

ton.

The Company name field contains up to

12 characters. This field may be used for

any text, such as Lot Number, for any given

product run. Enter desired text, press and

hold Save name until you hear two beeps..

The default time is set to CST (GMT-6:00).

You will need a pencil eraser to perform

this operation. Press the arrow key in the

lower RH corner and the Icon group will

appear to the left. Press the Gear Icon and

the virtual keypad will appear. Press the

number 1 six times, and press enter. The

System settings screen will appear, and

you will be in the network settings tab,

which does not apply to these machines.

Please note the time is formatted as a 24

hour clock!!! Select the Time/Date tab at

the top of the system settings screen, and

using your eraser adjust the time and date.

When finished, press apply, and press OK.

The time and date have now been saved.

The remaining tabs SHOULD NOT be

used! Changes to these features should

only be performed or under direction of a

trained Ultravac Services technician!!

Supervisor Menu with Touch Screen (continued)

Print Options

111111

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4.15

MAINTENANCE

Supervisor Menu with Touch Screen (continued)

Security Setup

The security setup screen allows the

maintenance supervisor to enable a certain

level of security and to change the default

passwords assigned to the machine.

The default passwords are as follows:

Level One: 456

Level Two: 789

Turning Security On in this menu will

restrict the editing of program parameters

to those with a value Level One password.

The Maintenance menu will always remain

secured by the Level Two password.

If Security is set to Security Off (as shown

in the corresponding image to the left),

running program parameters will be

editable by anyone.

Changing the default passwords can be

done by setting the new password in this

screen. Keep in mind that these passwords

are NOT recoverable should they be

forgotten.

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4.16

MAINTENANCE

Supervisor Menu with Touch Screen (continued)

Pulse Vac and Pulse Vent Setup

Pulse Vac and Pulse Vent Setup allows the

maintenance supervisor to configure the

appropriate Pulse Vac and Vent limits.

Pulse Vac On Time:

This value determines how long each pulse

is fired during a Pulse Vac operation.

Pulse Vac Off Time:

This value determines how long each pulse

is in the off position during a Pulse Vac

operation.

Pulse Vac to Percent:

This value determines the final desired

vacuum percentage to be reached during a

Pulse Vac operation.

Pulse Vent On Time:

This value determines how long each pulse

is fired during a Pulse Vent operation.

Pulse Vent Off Time:

This value determines how long each pulse

is in the off position during a Pulse Vent

operation.

Pulse Vent to Percent:

This value determines the final desired

vacuum percentage to be reached during a

Pulse Vent operation.

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4.17

MAINTENANCE

Supervisor Menu with Touch Screen (continued)

Precut and Looping options

Prevac - 0-99% of vacuum before slits

are cut in the bag. Default 25%

Cut time - Amount of time allotted for

the cut cycle, 0.1 - 9 seconds Default 1.5

seconds

Wait time - Amount of time from Cut

cycle finish to Vacuum cycle startup

0.1 - 9 seconds, Default 4 seconds.

If the machine is equipped with the loop

option, this is the number of vacuum/

gas cycles the control will perform prior

to the seal and vent. The range is 1 to 5

cycles. The default is 1.

If the loop # is set to greater than 1,

the control can be set to exit the loop

on either the last gas cycle or the last

vacuum cycle prior to sealing.

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4.18

MAINTENANCE

Changing Vacuum Pump Oil and Filter

NOTE: The pump should have been running for at least 15 minutes to warm the pump oil.

1. Turn the power switch to the “OFF” position and disconnect the power.

DANGER

Hot oil.

Hot oil poses scalding risk. Take necessary precautions while draining warm oil.

DANGER

Hazardous voltage.

Disconnect and lockout power before servicing machine or cleaning. Do not remove panels

unless power has been disconnected and locked out at risk of electric shock hazard.

2. Position an oil collection pan underneath the Oil Drain Plug.

3. Loosen and remove the Oil Fill Plug with a 1¼-in. open end wrench.

4. Loosen the Oil Drain Plug located to the front and lower middle on the pump with a

1¼-in. open end wrench. Remove the plug slowly to control the flow of oil.

5. Replace auto-type oil filter with a filter wrench (strap wrench.) Coat face of gasket on

new filter with oil and hand tighten until gasket contacts base, then tighten two-thirds

turn more. DO NOT OVER TIGHTEN.

6. With the oil drained, replace the Oil Drain Plug and wipe any excess oil off of the pump.

7. Fill the pump with oil until the level is at the maximum lines on the Oil Sight Glass.

Replace the Oil Filler Cap.

8. Reconnect the power cord back into the wall receptacle.

9. Cycle the machine a couple of times, unplug, and check the Oil Level. Add oil to the

maximum line. DO NOT OVER FILL.

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4.19

MAINTENANCE

Maintenance Log

A maintenance log is a journal of all maintenance performed. Each entry includes a

date, maintenance performed (details about the type of work done), and technician (who

performed the maintenance). The maintenance log is also a place where a schedule is kept

for further maintenance.

A maintenance log will clearly show oil changes, daily inspections, Teflon

tape

replacement, and so on. A master copy has been provided on page 4.20, please create a

copy and store in the back of this owner’s manual.

Service Log

A service log is a journal of all service work performed. Each entry includes a date, service

provided (details about the type of service), and technician (who performed the service).

A service log will clearly show training provided, frequent wear items, and so on. A master

copy has been provided on page 4.21, please create a copy and store in the back of this

owner’s manual.

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4.20

MAINTENANCE

Maintenance Log

Date Maintenance Performed Technician

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4.21

MAINTENANCE

Service Log

Date Service Provided Technician

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4.22

MAINTENANCE

THIS PAGE LEFT BLANK INTENTIONALLY.

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5.1

SCHEMATICS

Designation and Function of Controls

The following designations are found on the Electrical Diagrams:

Manually Activated Switches and Buttons:

SW-1 On/off control power

SW-3 On/off gas flush

SW-4 Quick seal (Optional)

Limit Switches:

LS -1 Left chamber cycle start

LS-2 Right chamber cycle start

Contactors:

C-1 Vacuum pump

C-2 Seal impulse

C-3 Redundant seal impluse

Overloads and Fusing:

OL-1 Vacuum pump motor

F-3 Control power fuse

Control Modules:

MCM Master control module

R-1 Redundant seal impluse

contactor timer

Control Lights:

LT-1 On/off control power

light (green)

LT-2 Seal impulse on light

(red)

Transformers:

T-1 Seal impulse, front

T-2 Seal impulse, rear

T-3 Control power

Motors:

M-1 Vacuum pump

Solenoid Valves:

SOL-1 Vacuum flush solenoid

SOL-2 Gas flush solenoid

SOL-3 Seal bladder solenoid

SOL-4 Ventilation solenoid

Mechanically Activated Switches

(Pneumatic Diagram only):

V-1 Gas selector valve

STARTUP

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5.2

SCHEMATICS

230 Volt, Single Phase, Digital Panel

STARTUP

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5.3

SCHEMATICS

230 Volt, 3 Phase, Digital Panel

STARTUP

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5.4

SCHEMATICS

380 Volt, 50 Hz, Digital Panel

STARTUP

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5.5

SCHEMATICS

380 Volt, 50 Hz, W/O Neutral Digital Panel

STARTUP

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5.6

SCHEMATICS

460 Volt, 3 Phase, Digital Panel

STARTUP

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5.7

SCHEMATICS

575 Volt, 3 Phase, Digital Panel

STARTUP

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5.8

SCHEMATICS

Pneumatic Diagram

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6.1

PARTS

Recommended Spare Parts

Qty.

UltraSource

Part No.

Description

1 ea 8610 01 Seal Bar Assembly

10 ft 880431 Back Up Strip

4 ea 880443 Back Up Strip Textured

12 ft 880432 Lid Gasket

1 ea 88 0746 Seal Element

3 ft 885507 Teflon

Tape

1 ea 860908 DIN Coil

1 ea 860906 Vacuum Valve Diaphragm

1 ea 860907 Vent Valve Diaphragm

2 gal Specify pump Vacuum Pump Oil

1 ea Specify pump Vacuum Pump Oil Filter

1 ea 861002 Bladder Assembly

Select your machine’s configuration:

1 ea 860250 Double Seam Seal Bar Contact Kit

1 ea 863016 10mm Wide Seal Bar Contact Kit

1 ea 861013 Single Seam Seal Bar Contact Kit

For Analog Control Panel:

5 ea 860337 Fuse for Control Power, 1A

1 ea 860313 Potentiometer, Evac/Gas

1 ea 860314 Potentiometer, Sealing

1 ea 860327 Relay Module

For specific system replacement parts,

Contact a parts representative for further assistance:

Phone (816) 753-2150 • Fax (816) 561-2854

Toll-Free (800) 777-5624

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6.2

PARTS

Miscellaneous Machine Parts

Parts List and Diagram

Item

No.

UltraSource

Part No.

Description

1 860402 Filler Plate Set (two sets per machine)

3 880431 Chamber Gasket (10-ft. required)

860950

Chamber Gasket, Grey (10-ft. required)

(for precut and perforating knife options)

880443 Chamber Gasket - 4 pcs. - Textured

4 860844 Cover Panel with Latches

5 860409 Latch

861228 Coiled Lanyard (between chassis and cover)

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6.3

PARTS

Lid, External

Parts List

Item No. Part No. Description

860200 Lid casting, 8-in. (Lid Assy available, Call our Parts Dept.)

860201 Lid casting, 12-in. (Lid Assy available, Call our Parts Dept.)

1 880432 Lid Gasket (12-ft. required)

2 860954 Hose, 1/4-in. Reinforced (35-in. required)

3 860110 Hose Clamp for 1/4-in. Reinforced Hose

4 860109 Brass Hose Barb

5 863031 Wire Harness, Complete

6 860009 Cord Grip, 1/2”NPT, .375”-.500”

7 8 6 0113 Lid Handle

8 860269 Nut, M10 Nylon Lock

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6.4

PARTS

Lid, Internal

Parts List

Item

No.

UltraSource

Part No.

Description

1 861071 10mm Wide Seal Bar Complete (refer to page 6.9)

903037-10 10mm Wide Seal Bar with Knife (one complete assembly)

861001 Single Seam Seal Bar Complete (refer to page 6.11)

860001 Single Seam Seal Bar with Knife (one complete assembly)

2 860102 Seal Bar Support

3 860226 Seal Bar Support Washer

4 860254 Screw, M5x25 Slotted Flat Head

5 860261 Nut, 5mm Nylon Lock

6 860258 Screw, M5x8 SHCS

7 860257 Screw, M5x20 Slotted Pan Head

8 860005 Electrical Contact

9 866832 Screw, M5x35 SHCS

10 860260 Washer, 5mm Lock

11 866764 Nut, 5mm Hex

12 860954 1/4-in. Hose (specify length)

13 860107 1/4-in. Hose “T”

14 860110 Hose Clamp

15 860307 Bladder Return Spring

16 860030 Bladder Backup Plate

17 8610 02 Bladder Assembly

18 861232 Swing Arm

19 860202 Swing Arm Tie Block

Kit to add on knife blade (903055) includes:

3 860226 Seal Bar Support Washer

4 860254 Screw, M5x25 Slotted Flat Head

5 860261 Nut, 5mm Nylon Lock

6 860258 Screw, M5x8 SHCS

7 860257 Screw, M5x20 Slotted Pan Head

11 866764 Nut, 5mm Hex

20 860018 Knife Only

21 860991 Pre-cut Shim

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6.5

PARTS

Lid, Internal

Diagram

WITH PERFORATION KNIFE

421

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6.6

PARTS

Legs and Pump

Parts List

Item

No.

UltraSource

Part No.

Description

1 860705 Leg

2 860767 Pump Plate Brace

3 900039 Pump, 5-hp for 230V, 1-phase

900165 Pump, 7-½-hp for 230/380/460V, 3-phase

900166 Pump, 7-½-hp for 575V, 3-phase

900253 Pump, 10-hp for 200V, 3-phase

900255 Pump, 10-hp for 230/380/460V, 3-phase

900257 Pump, 10-hp for 575V, 3-phase

900305-200 Pump, 12-hp for 200V, 3-phase

900305-230 Pump, 12-hp for 230/380/460V, 3-phase

900305-575 Pump, 12-hp for 575V, 3-phase

4 860613 Hose Barb, 2-in.

5 860759 Pump Mounting Plate

6 810109 Bolt, M10x25 Hex Head

7 860268 Washer, 10mm Flat

8 860269 Nut, 10mm Lock

9 86116 4 Bolt, 3/4-10 Thread x 3-3/4-in., Hex Head

10 860733 Nut, 3/4-in. Jam

11 860730 Leg Spacer

12 860732 Washer, 3/4-in. Flat

13 860714 Nut, 3/4-in. Acorn

14 860736 Washer, 3/4-in. Lock

15 863080 Kit, Support Pads with M10x35 SHCS

16 903010 Kit, Caster (optional)

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6.7

PARTS

Legs and Pump

Diagram

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6.8

PARTS

Double Seam Seal Bar

Parts List and Diagram

Item

No.

Description

863017 Double Seam Seal Bar Complete

1 880746 Seal Element

2 885507 Teflon

Tape, (3-ft. required per seal bar) (not shown)

3 860250 Double Seam Seal Contact Kit

Kit (860250) includes:

Element Spring

Element Clip

Double Seam Contact

Screw, M3x12 Slotted Flat Head

Set screw, M4x6 Socket

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6.9

PARTS

10mm Wide Seal Bar

Parts List and Diagram

Item

No.

Description

861071 10mm Wide Seal Bar Complete

1 860512 Seal Element

2 885507 Teflon

Tape, (3-ft. required per seal bar) (not shown)

3 860174 Screw, M4x12 Slotted Flat Head

4 860251 Screw, M5x10 Slotted Flat Head

5 863016 10mm Wide Seal Contact Kit

Kit (863016) includes:

Element Spring

Element Clip

10mm Wide Seam Contact

Set Screw, M5x6 Socket Head

Screw, M3x6 Slotted Flat Head

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6.10

PARTS

Single Seam Seal Bar

Parts List and Diagram

Item

No.

Description

861001 Single Seam Seal Bar Complete

1 8 80746 Seal Element

2 885507 Teflon

Tape, (3-ft. required per seal bar) (not shown)

3 861013 Single Seam Seal Contact Kit

Kit (861013) includes:

Element Spring

Element Clip

Single Seam Contact

Screw, M3x5 Slotted Panhead

Set Screw, M3x5 Socket

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6.11

PARTS

Vacuum Manifold

Parts List and Diagram

Item

No.

Description

1 861152 Manifold Assembly

Assembly (861152) includes:

Valve Manifold Plate

Valve, Mebner Vacuum and Vent

Fitting, 2-in. Close Nipple

Fitting, 2-in. Hose Barb

NOTE: New manifold o-ring (860603) recommended.

2 860618 Hose Clamp, 2-in.

3 860617 Vacuum Hose (to vacuum pump), (5-ft. required)

4 860603 Manifold O-Ring

5 860954 Braided Hose, 1/4-in.

6 861020 Electrical Switch Cable

7 860908 DIN Coil, [SOL-1] [SOL-4]

8 860906 Replacement Vacuum Valve Diaphragm (not shown)

9 860907 Replacement Vent Valve Diaphragm (not shown)

NOTE: Epoxy is applied to fittings at

valve inlets for vacuum integrity.

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6.12

PARTS

Main Electrical Components

Parts List

Item

No.

Description

1 8 6 0 311 Transformer, Control, 50VA, 460, 230/115 VAC

860394 Transformer, Control, 50VA, 208/115 VAC

809207 Transformer, 50VA, 380/400/415V-110/230V

2 860255 Screw, M5x6 Slotted Pan Head

3 860312 Transformer, Seal, 300KVA, 460, 230, 208/115 VAC

860059 Transformer, Seal, 600VA, 460/230, 48 VAC (double seam seal)

861286 Transformer, 380/400/415 24/48 350VA

861289 Transformer, 380V, 48V, 600VA

864106 Transformer, 480V 1500KV (Wideband seal only)

4 860703 Relay, Interval 4 sec. for Sealing

5 860793 Contactor, Sealing

6 860341 Terminal, End Cap

7 861179 Contactor, Pump, 32A, 600V, 110 Volt Coil

8 860339 Fuse Holder, Control

860337 Fuse, 1A (not shown)

9 860340 Terminal Block

10 860342 Terminal, Ground Block

11 See Overload Table below

Pump

Size

Voltage

Overload

Part No.

Pump

Size

Voltage

Overload

Part No.

7 ½ HP

208V

860795

230V

380V

861214460V

575V

10 HP

208V

860796

230V

380V 860797

460V 861214

575V 860797

5 HP 230V 1 PH 860796 12 HP

208V

860835

230V

380V

860797460V

575V

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6.13

PARTS

Main Electrical Components

Diagram

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6.14

PARTS

Base

Parts List

Item

No.

UltraSource

Part No.

Description

1 863012 Wire Harness, Complete

2 860954 1/4-in. Reinforced Hose (34-in. required)

3 861018 Cycle Switch Assembly Complete with Harness

860309 Cycle Switch [LS-1] [LS-2]

4 861020 Harness for Valve, Complete with DIN Plug

5 861023 Valve Assembly, Seal Pilot with Fittings [SOL-3]

Valve Assembly (861023) includes:

Valve, 3-Way, NC, 1/4 NPT Ports, 120 Volt

Hose Barb, 1/4-in. - 1/4-in. Elbow

Hose Barb, 1/4-in. - 1/8-in. Elbow

6 860404 Brass Fitting

7 860775 Air Pressure Regulator and Gauge Assembly

8 860514 Hose Barb, 1/4-in. - 1/4-in. Elbow

9 861178 Electrical Compression Fitting, 230/460 Volt

861131 Electrical Compression Fitting, 380 Volt

10 861045

Pump Harness, 208/230/460V, 5- and 7-½-hp

Pump Harness, 460V, 10- and 12-hp

861046 Pump Harness, 380V, 5-, 7-½-, 10-, and 12-hp

861288 Pump Harness, 380V w/o Neutral (Special Option)

861176 Pump Harness, 208/230V, 10- and 12-hp

11 861035 Power Harness, 208/230V, 5- and 7-½-hp

861035-0 01 Power Harness, 230V,SINGLE PHASE 5-hp

861036 Power Harness, 380V, 5-, 7-½-, 10-, and 12-hp

861287 Power Harness, 380V w/o Neutral (Special Option)

861037 Power Harness, 460V, 5-, 7-½-, 10-, and 12-hp

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6.15

PARTS

Base

Diagram

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6.16

PARTS

Gas Flush

Parts List

Item

No.

Description

1 860352 Electrical Switch Cable

2 861024 Valve Assembly, Gas Pilot with Fitting

Valve Assembly (861024) includes:

Two-way Pilot Valve for Gas [SOL-2]

Hose Barb, 1/4-in. - 1/4-in. Elbow

3 860404 Brass Fitting

4 860513 Gas Inlet Barb, 1/4-in.

5 860514 Hose Barb, 1/4-in. - 1/4-in. Elbow

6 861025 Valve Assembly, Gas Switching with Plate

Valve Assembly (861025) includes:

Gas Flush Selector Valve [V-1] (Serial #2090-Current)

Hose Barb, 1/4-in. - 1/4-in. Elbow

Valve Plate

Nut, 6mm Nylon Lock

Screw, M6x40 SHCS

861010 Assembly, Gas Flush Hose [Items 7, 8, 9]

NOTE: Shown is 1/2 of the gas flush hose assembly (861010). One assembly required per

chamber side.

7 860954 Reinforced Hose, 1/4-in. (specify length)

8 860107 Hose Barb, ‘T’, 1/4-in.

9 860507 Gas Nozzle

10 863024 Bag Holder with Foam Padding (in machine lid)

860203 Replacement Foam Padding Only

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6.17

PARTS

Gas Flush

Diagram

861344

861345

835514

THESE

NOZZLES

APPLY TO

SERIAL

NUMBERS

6108 AND

6046 ONLY

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6.18

PARTS

Swing Arm Assembly

Parts List

Item

No.

Description

861158 Lid Lever Shaft and Cam with Dowel Assembly [Items 1, 2, 3, 4]

1 861155 Lid Lever Shaft

2 860403 Connecting Shaft

3 861156 Dowel, M10x25mm long, Stainless Steel (Serial #4606 - Current)

4 8 61157 Cam Lever Complete Assembly

Assembly (861157) includes:

Cam Lever

Cam Bushing

Screw, M8x30 Socket Head

5 866766 Nut, M8

6 860424 Spring Retainer

7 866742 Screw, M10x35 Socket Head

8 860244 Lid Spring

9 861008 Bearing Hub Assembly

Assembly (861008) includes:

Bearing Retainer

Shaft Bearing

Bearing Hub

10 866739 Screw, M8x25 Socket Head

11 86 0114 Lid Lever

86 0111 Lid Lever for Utilities Clamp (backside of machine)

12 860749 Utilities Clamp

13 860754 Button, Cable Clamp

14 866729 Screw, M5x20 Socket Head

15 860414 Bushing Spacer

16 860401

Lid Lever Bushing

UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150

THE NEW STANDARD FOR INNOVATION • [email protected] • UltraSourceUSA.com

6.19

PARTS

Swing Arm Assembly

Diagram

THE NEW STANDARD FOR INNOVATION • [email protected] • UltraSourceUSA.com

UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150

6.20

PARTS

Digital Control Panel

Parts List and Diagram

Item

No.

UltraSource

Part No.

Description

1 860995 Front Panel Assembly

2 860673 Vacuum Sensor

3 860316 Main Power On/Off Switch [SW-1]

4 860683 Fitting 1/4 x 1/8 Reducer

5 866728 Screw, M5x16 SHCS, SS

6 866773 Washer, M5 Flat

NOTE: Torque specification for 866728 (item 5) is 20 inch-pound.

UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150

THE NEW STANDARD FOR INNOVATION • [email protected] • UltraSourceUSA.com

6.21

PARTS

Touchscreen Control Panel 861300

ITEM PART NUMBER DESCRIPTION QTY

1 861301 BEZEL, TOUCHSCREEN PANEL 1

2 861302 DECAL, TOUCHSCREEN 1

3 861304 PWB TOUCHSCREEN HMI5043N 1

4 866783 WASHER, M4, SPLIT LOCK, SS 1

5 861382 T.S. HMI5043LB, PROG’D, ZPL 1

6 869628 SCREW, 8-23 X 3/8-IN. 1

7 861324 STANDOFF, 8-32 X 1 1

8 861320 SCREW, M4 X 40 PAN HEAD 6

9 861325 SPACER, NYLON, 5/16” X 1 1/4” 6

10 861306 DECAL, CORELOK, F/TOUCH SCREEN (N/A) 1

11 860316 SWITCH, POWER ON/OFF & BODY ASSY 1

THE NEW STANDARD FOR INNOVATION • [email protected] • UltraSourceUSA.com

UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150

6.22

PARTS

Filter Inlet

Pump Inlet

Direction

of Flow

Inline Filter

Parts List and Diagram

Item

No.

UltraSource

Part No.

Description

861153 Inline Filter Complete

1 835427 Tube, Inlet Filter

2 884250 Filter Screen

3 835429 Gasket, Inlet Filter

Hardware included in complete assembly (861153):

Screw, M8x120 Hex Head

Nut, 8mm Hex

Nut, 8mm Wing

NOTE: Epoxy is applied to fittings at filter and pump inlets for vacuum integrity.

UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150

THE NEW STANDARD FOR INNOVATION • [email protected] • UltraSourceUSA.com

7.1

REFERENCE

REFERENCE MANUALS

R5 Series Vacuum Pumps

Included within Ultravac

2100 owner’s manual is an installation and operating manual for

the vacuum pump equipped with this vacuum chamber machine.

Refer to page 6.1 of the Ultravac

2100 owner’s manual for oil and replacement filter part

numbers for this machine.

For Replacement Parts, Call:

Phone (816) 753-2150 • Fax (816) 561-2854

Toll-Free (800) 777-5624

INSTALLATION

AND

OPERATING MANUAL

R5 Series

Current Models 0025, 0040, 0063, 0100 and 0250

Single Stage Rotary Vane Vacuum Pumps

TABLE OF CONTENTS

GENERAL

Identification

Operating Principles

1.0 INSTALLATION

1.1 Unpacking

1.2 Location

1.3 Power Requirements

1.4 Vacuum Connections

1.5 Oil Filling

2.0 OPERATION

2.1 Start-up

2.2 Gas Ballast

2.3 Stopping Pump

2.4 Water-Cooled Pumps

2.5 Oxygen Service Pumps

3.0 MAINTENANCE

3.1 Pump Oil

3.1.1 Oil Level

3.1.2 Oil Type and Quantity

3.1.3 Oil and Filter Change

3.2 Automotive-Type Oil Filter

3.3 Exhaust Filter (Ref. 120)

3.4 Vacuum Inlet Filter

3.5 Maintenance Chart

3.6 Overhaul Kit/Filter

4.0 TROUBLESHOOTING

5.0 STANDARD LIMITED WARRANTY

TECHNICAL DATA

MOTOR AND ELECTRICAL DATA

We reserve the right to change the product at any time without any form of notification. The information in this publication is accu-

rate to the best of our ability at the time of printing. Busch, Inc. will not be responsible for errors encountered when attempting to

perform tasks outlined in this publication.

GENERAL

Identification

For model identification, see the nameplate

mounted on the side of the exhaust box.

This manual is written to cover RA and RC ver-

sions of models 0025, 0040, 0063, 0100, and 0250

with a "C" or "E" appearing as the seventh character

in the model type number stamped into the name-

plate. For example it would appear as follows:

RAXXXX - C

XXX - XXXX

When ordering parts, it is helpful to include the

identification code stamped into the side of the

cylinder as well as the serial number from the name-

plate.

Operating Principles

All reference (Ref. XX) numbers listed in the

text and on illustrations throughout this manual are

related to the drawings and parts list near the center

of this publication.

All R5 Series, Single Stage, Rotary Vacuum

Pumps are direct-driven, air-cooled, oil-sealed

rotary vane pumps which operate as positive dis-

placement pumps. As Figure 1 shows, they consist

of a rotor mounted concentrically on the drive shaft

and positioned eccentrically in a cylindrical stator.

The rotor has three radially sliding vanes which

divide the pump chamber into three segments. The

gas to be pumped enters at the inlet port (Ref. 260),

passes through the inlet screen (Ref. 261) and the

open anti-suck-back valve (Ref. 251) into the pump

chamber. As the rotor rotates, the inlet aperture is

closed, the gas is compressed and forced out through

one-way valves between the pump cylinder and the

exhaust box. This operation is repeated three times

each revolution.

1.0 INSTALLATION

1.1 Unpacking

Inspect the box and pump carefully for any signs

of damage incurred in transit. Since all pumps are

ordinarily shipped FOB our factory, such damage is

the normal responsibility of the carrier and should be

reported to them.

Remove the nuts from the bottom of the

box/crate and pull the pump out of the container,

then unscrew the studs from the bottom of the rub-

ber feet.

All R5 series pumps are designed to handle air.

Vapor in the air stream can be tolerated when the

pump is operated within certain operating parame-

ters as defined by Busch, Inc. Engineering (see

Section 2.2 Gas Ballast). When you desire to use

the pump on an air stream that contains vapors, con-

tact Busch, Inc. Engineering for operating recom-

mendations; otherwise, the warranty could be void.

Figure 1 Module Cross Section

The inlet port of the pump is covered with a plas-

tic cap prior to shipment to prevent dirt and other

foreign material from entering the pump. Do not

remove this cover until the pump is actually ready

for connection to your system.

1.2 Location

The pump must be installed in a horizontal posi-

tion on a level surface so that the pump is evenly

supported on its rubber feet. Allow at least one foot

(five feet for large pumps) of air space between the

pump and any walls or other obstructions to the flow

of cooling air.

Also, adequate ventilation must be provided for

the fans on the pump and motor (i.e., do not locate

the pump in a stagnant air location).

Whenever the pump is transported, be sure to

drain the oil prior to shipping to avoid vane break-

age when restarting the pump.

Do not tip the pump over if it is filled with oil.

Locate the pump for easy access to the oil sight

glass (Ref. 83) in order to inspect and control the oil

level properly. Allow clearance at the exhaust flange

area to provide service access to the exhaust filters.

1.3 Power Requirements

The schematic diagram for the electrical connec-

tion is located in the junction box or on the name-

plate of the pump motor.

The motor must be connected according to the

electrical codes governing the installation. The

power supply must be routed through a fused switch

to protect the motor against electrical or mechanical

overloads. The motor starter has to be set consistent

with the motor current listed on the motor name-

plate.

If the pump is supplied with a manual motor

starter, it is preset at the factory in accordance with

the customer’s specification. For other voltage

requirements, contact the factory for motor and/or

starter information.

NOTE: See the motor manufacturer’s manual

for start-up maintenance of the motor.

Correct direction of rotation is marked by an

arrow on the motor fan housing and is counterclock-

wise when looking at the motor from the motor's fan

side.

1.4 Vacuum Connections

Use a line size to the vacuum system that is at

least as large as that of the pump inlet. Smaller lines

will result in lower pumping speeds than the rated

values.

Install a drip leg and drain on the vertical pipe

near the pump inlet. Drain the drip leg often to pre-

vent condensation from entering the pump.

If more than one vacuum pump or a receiver

tank is connected to a common main line, each

pump should have its own manual or automatic

operated shut-off valve or positive action check

valve. The built-in anti-suck-back valve should not

be used as a shut-off valve for the vacuum system.

Remove the plastic protective cap from the inlet

port prior to connection of the pump to the system.

The following threads are provided at the inlet of

the R5 Series pumps:

Pump Size Size Threads

0025/0040 1 1/4" Female NPT

0063/0100 1 1/4" Female NPT

0250 2" Female NPT

Caution: After the electrical connection has

been made, but before the pinup is filled with oil,

the rotation of the motor must be checked. Open

the inlet port and jog the motor briefly to make

sure rotation is correct. If it runs backwards and

if it is wired three phase power, reverse any two

leads of the three at the power connection.

Caution: The built-in anti-suck-back valve is

not positive action; do not use it as a system

check valve.

If the gas that is pumped contains dust or other

foreign solid particles, a suitable (10 micron rating

or less) inlet filter should be connected to the inlet

port. Consult the factory for recommendations.

1.5 Oil Filling

The pump is shipped without oil. After level

installation, and after correct rotation has been

established, fill the pump with the recommended

vacuum oil through the oil filling port (Ref. 88),

observing the "MAX" and "MIN" position at the oil

sight glass (Ref. 83).

Non-detergent oil should be used. Do not use

detergent motor oil as additives in detergent oil

will plug exhaust filter elements and shorten their

life.

It is recommended that Busch R500 Series oil be

used to receive the best performance from your vac-

uum equipment. R500 Series oil is a high quality

vacuum oil which will give longer running time

between oil changes, will provide better lubrication

at high operating temperatures, and will prolong the

life of exhaust filter elements. This oil can be

obtained directly from Busch, Inc. in Virginia

Beach, Virginia.

The strict use of Busch oils and parts from the

day of purchase can extend the standard warranty to

three years. Contact Busch, Inc. in Virginia Beach,

Virginia for details. Refer to page 20 for the standard

warranty.

For general applications, use R530 in most mod-

els. Use R590 or R570 in pumps that are operated

in high ambient temperatures (above 90°F) or high

operating pressure when the oil carbonizes (turns

black) before the change interval. Use R590 or R570

on 0250 pumps. Contact the factory for recommen-

dations when using other oils.

The following table gives the approximate quan-

tities of oil required for each pump:

Pump Type Oil Capacity (Qt.)

0025/0040 1.4

0063/0100 2.5/2.7

0250 7

The oil capacity chart should only be used as a

guide, since oil capacity may be slightly lower,

depending on whether the pump was filled previ-

ously, and whether all components such as oil filter,

oil lines, etc., were allowed to completely drain. Use

only the sight glass reading for proper level. Never

overfill.

For ambient operating temperatures lower than

41°F, use Busch R580 synthetic oil. If this does not

help (where the pump has difficulty starting due to

high oil viscosity) contact the factory in Virginia

Beach, Virginia.

Replace the oil fill plug (Ref. 88/90), making

sure that the gasket (Ref. 89) is in place and proper-

ly seated and secured. Some pumps are equipped

with an exhaust pressure gauge as an integral part of

the oil fill plug.

2.0 OPERATION

2.1 Start-up

Check rotation of the motor as described in para-

graph 1.3 - Power Requirements.

Fill the pump with oil as described in paragraph

1.5 - Oil Filling.

Start the pump and immediately close the inlet.

Run the pump for a few minutes before checking the

oil level again. With the pump shut off, the oil level

should be visible in the oil sight glass (Ref. 83),

between the "MIN" and "MAX" mark.

Add oil, if necessary, but only add it when the

pump has been shut off and the circulating oil has

Caution: When using PVC pipe or any static

enhancing material for the exhaust piping, make

provisions to safeguard against arcing from stat-

ic electricity. Arcing can ignite oil vapor that

may be present.

Warning: Keep the oil fill plug tight as pres-

sure in the exhaust box could cause bodily injury

if the plug is blown out. Do not fill/add the pump

with oil through the exhaust/inlet ports as there

is danger of breaking the vanes!

had sufficient time to return to the oil sump.

NOTE: The oil separated by the exhaust filter

element forms droplets on the outside of the exhaust

filter which collect at a low point in the upper half of

the exhaust box. From there the collected oil is

drained back to the oil sump via an oil check valve

(Pos 275) which opens on R5 RA Model Pumps

when the pump is shut off. It is necessary to shut off

the RA model pumps after every 8 hours of operation

to allow the check valve to open. If the pump is not

shut off after this time period, it is possible to starve

the pump of oil since the oil is not allowed to drain

back into the oil sump and/or oil droplets may be

blown out of the exhaust. If the pump is operating at

high pressure it may be necessary to shut it down

sooner than 8 hours.

On R5 (Standard) RC Model Pumps, the collect-

ed oil is drawn continuously during operation of the

vacuum pump to the inlet flange (Pos 260) via the

oil return line (Pos 290). The oil return line is con-

nected directly to the area of the exhaust box, down-

stream of the exhaust filter, which is at atmospheric

pressure. Therefore, a constant amount of air is

sucked into the pump which is an additional reason

that the R5 Standard Series Pumps do not achieve as

low a vacuum as the R5 Series Super Vacuum

Pumps.

2.2 Gas Ballast

All RA Series pumps are equipped with a gas

ballast valve. The gas ballast valve (Ref. 440) is

located between the inlet port and the exhaust box.

RA Series pumps up to size 100 are equipped with a

permanent gas ballast which cannot be shut off

unless the sintered filter is removed and the orifice

plugged. Larger pumps are equipped with an

adjustable gas ballast valve.

The adjustable gas ballast valve should normal-

ly be left open. Its primary function is to prevent

water vapor from condensing in the pump.

Condensation causes emulsification of the oil, loss

of lubricity, and possible rotor seizure.

2.3 Stopping Pump

To stop the pump, turn off the power. The pump

has a built-in anti-suck-back valve (Ref. 251 thru

255) to prevent the pump from rotating backwards

when it is shut off.

Install an automatic operated valve (such as a

check valve) in front of the pump, if more than one

pump is pumping on the same line or if there is a

sufficient volume of vacuum in the system to cause

the pump oil to be drawn into the piping when that

pump is shut down.

All R5 Series pumps are vented internally to

atmospheric pressure through venting holes which

are next to the exhaust valve assembly.

2.4 Water-Cooled Pumps

Water-cooled pumps are cooled by circulating

the oil through a shell-and-tube type heat exchanger.

The circulation of the pump oil through the shell is

created by vacuum in the pump, but the circulation

of the cooling water through the tubes is thermostat-

ically controlled. The flow rate of the cooling water

is controlled by a thermostatically activated valve

that senses, through a capillary bulb mounted in the

exhaust box, the pump's oil temperature as it is dis-

charged from the compression chamber. The valve

will open at its set point and close at approximately

3°F to 5°F below the set point. The valve set point is

adjustable as follows:

(a) Rotate the valve adjustment screw counter-

clockwise to cause the valve to open at a higher

temperature.

(b) Rotate the valve adjustment screw clockwise

to make the valve open at a lower temperature.

The thermostatic valve can be manually opened

by inserting a screwdriver under each side of the

spring guide and prying the spring and guide upward

away from the valve body.

Caution: Do not use the anti-suck-back valve

as a check or shut-off valve for your vacuum sys-

tem. Do not depend on the anti-suck-back valve

to prevent pump oil from migrating through the

inlet into the system when the pump is shut

down.

2.5 Oxygen Service Pumps

Application

If this pump is contaminated by organic com-

pounds do not attempt to use it on oxygen service

until it has been decontaminated.

These Installation and Operating Instructions are

valid for the following vacuum pumps:

RA/RC 0025 RA/RC 0100

RA/RC 0040 RA/RC 0250

RA/RC 0063

These pumps have been manufactured, solvent

washed (to remove organic contaminants) and

assembled according to the latest technical standards

and safety regulations. If this pump is not installed

properly or not used as directed, a dangerous situa-

tion or damage might occur.

It is mandatory that these operating instruc-

tions be read and understood prior to vacuum

pump installation and start-up.

Pump Overhaul/Repair

Busch Inc. strongly recommends that all major

repair operations be conducted at the factory.

Improper handling of repairs could result in

extreme danger to personnel operating the pump.

Warning: This pump is filled with a special

operating fluid. Do not use any other type of

fluid, oil and/or grease. Use one of the following:

• Fomblln LC 250

• Tyreno Fluid 12/25V (perfluorinated poly-

ether)

• KRYTOX ®Vacuum pump fluid by Du Pont

Company

If you have any questions, please phone our

Customer Service Department for more informa-

tion.

Figure 2 Typical Exhaust Box Cross Section

3.0 MAINTENANCE

R5 Series, Single Stage, Rotary Vacuum Pumps

require very little maintenance; however, to insure

optimum pump performance, the following steps are

recommended:

3.1 Pump Oil

3.1.1 Oil Level

With the pump installed relatively level, make

sure that there is sufficient clean oil in the pump.

The oil level should be observed on a daily basis

and/or after 8 hours of operation and should be

replenished if it drops below the 1/4 mark on the oil

sight glass. On R5 series pumps you must first shut

the pump off in order to let the oil flow back into the

oil sump prior to checking the sight glass. Allowing

insufficient time for the oil to drain back into the

sump on R5 series pumps prior to adding oil could

result in overfilling.

Oil level readings should be done only when the

pump is turned off. Oil can be added to the oil fill

port (Pos 88) if the pump is shut off and the circu-

lating oil has sufficient time to return to the oil

sump.

Under normal circumstances, it should not be

necessary to add or drain oil from the pump between

recommended oil changes.

A significant drop in oil level means there is an

oil leak or that an exhaust filter is broken, and the

pump should be smoking excessively. It is normal

for the oil to be foamy and light in color in an oper-

ating pump. However, if the oil is milky colored, it

is an indication that water is present in the oil.

Normally, by operating the pump for an extended

period, with the inlet suction blanked off and the gas

ballast (Pos 440) open on RA pumps, the water will

be purged from the oil. If the oil is dark colored, it

is contaminated or carbonized and must be changed.

3.1.2 Oil Type and Quantity

See Section 1.5 - Oil Filling - for details on oil

type and quantity.

3.1.3 Oil and Filter Change

Oil life is dependent upon the conditions to

which it is exposed. A clean, dry air stream and an

oil operating temperature under 210°F are ideal

conditions. When using R530 (hydrocarbon oil) it

is recommended that oil changes are made every

three (3) to four (4) months or 500 to 750 hours of

operation, or as necessary if high heat is contami-

nating the oil. The use of Busch R570 or R590 syn-

thetic oils could extend the operating hours between

oil changes under ideal conditions. Oil samples

should be taken regularly when exceeding the 500-

750 hour recommendation.

Excessive Heat

When the pump is subjected to operating condi-

tions that will cause the oil to be heated above

210°F, the oil will carbonize and become contami-

nated after a relatively low number of operating

hours. The higher the temperature, the quicker the

oil becomes contaminated. If the oil temperature is

too severe, Busch R570 or R590 synthetic oil should

be used to withstand the elevated temperatures. If

synthetic oil is used, the pump should be flushed

with Busch R568 oil as outlined in the Maintenance

Figure 3 - Water Cooled Pump

THERMOSTAT

VALVE

Caution: Do not add oil while the pump is

running since hot unfiltered oil vapor may

escape through the oil fill port.

Caution: When changing the oil and filters, it

may be necessary to flush the pump to remove

any build-up of degraded oil from the sumps, oil

lines, radiators, etc. to ensure proper oil flow

through the pump. Reduced oil flow, especially

through radiators and cooling coils, can cause

mechanical damage or extreme overheating

which could cause the oil vapors to ignite.

and Repair Manual. Auxiliary oil cooling is the

most practical approach to a severe heating prob-

lem.

Contaminated Air Stream

When the air stream contains solids and/or liq-

uid that contaminate the oil, it must be changed

more often. If the air stream contains a small per-

centage of contaminates and/or they are slightly

aggressive* (mild acids, etc.), synthetic oil, such as

Busch R570, will resist breakdown better than the

standard Busch R530. The solution is to install a fil-

ter or knock-out pot to keep the contaminates out of

the pump.

*Process air streams with a large percentage of contami-

nates and/or are more than slightly aggressive must use a

Once-Through-Sealant or dry type pump.

Oil change intervals can only be established by

experience with the pump operating in the actual

conditions (see previous paragraph for some of the

conditions). Develop the oil change interval by peri-

odically checking an oil sample removed from the

pump. When the oil sample has become dark in

color (from solids and carbonized particles) or is

milky looking (from solids), it is time to discard it.

3.2 Automotive-Type Oil Filter

The 0025-0250 Series, Single Stage, Rotary

Vacuum Pumps are equipped with an automotive-

type oil filter (Ref. 100). When replacing the auto-

motive-type oil filter, use only a Busch genuine fil-

ter.

Note: Make sure to tighten the Busch oil filter

securely against the aluminum sealing surface so

that leaks will not occur.

3.3 Exhaust Filter (Ref. 120)

Every nine (9) to twelve (12) months, or as nec-

essary, replace the exhaust filter elements. The serv-

ice life of the exhaust filters varies widely with

pump application. It is only necessary to change the

filters when the elements become clogged with for-

eign material or burned oil. Indications of clogged

filters are smoke and oil mist coming from the pump

exhaust, higher than normal motor current or oil

leaking from the gas ballast valve on RA models.

A pressure gauge (Pos 90) is now supplied with

your R5 vacuum pump as part of the oil fill plug.

This gauge has a green field and a red field. A pres-

sure within the green field would indicate normal

pressure. Any pressure, in or close to the red field,

Figure 4 - Removing Exhaust Housing

Figure 5 - Removing Filter Spring

WARNING: If the gas entering this pump is

a health hazard, use rubber gloves and all neces-

sary personal protection equipment when per-

forming the exhaust filter replacement opera-

tion.

WARNING: Wear safety glasses when

installing or removing the spring retainers. The

retainers can, if not secured correctly, slip off

and fly out of the exhaust box.

Ref Description

1 Cylinder

5 Socket set screw

15 Rotor

18 Bearing sleeve

22 Vane

25 Endplate, motor side

26 Endplate, fan side

30 Bearing

31 Spacer, bearing to Seal

35 Shaft seal

42 Retainer ring

43 Screw, hex head

46 Gasket-ring

47 Plug

49 O-ring

50 O-ring

53 Screw, hex head

54 Lockwasher

57 Hex head screw

58 Lockwasher

60 Taper pin

63 Plug

64 Gasket-ring

65 Shaft key

66 Shaft key

75 Exhaust box

78 Baffle, expanded metal

79 Demister pad

80 Sheet metal baffle

83 Oil sight glass

84 Gasket ring, sight glass

88 Oil fill plug

89 Gasket ring, fill plug

90 Exhaust pressure gauge

95 Oil drain plug

96 O-ring

99 Pipe nipple

100 Oil filter

105 Cover, exhaust box

106 Gasket, exhaust box cover

107 Screw, exhaust box

108 Lockwasher

115 Exhaust filter bracket

120 Exhaust filter

121 O-ring

125 Filter spring assembly

126 Filter spring screw

130 Strainer

136 Gasket, exh. box, service block

137 Lockwasher

138 Screw

139 Service block

140 Exhaust cover plate

141 Exhaust cover gasket

142 Socket head cap screw

143 Lockwasher

144 Retaining ring

145 Housing, exhaust port

146 Screw, exhaust housing

148 Service block oil baffle

149 Socket head cap screw

150 Lockwasher

Ref Description

151 Exh. Screen, coarse

152 Exh. Screen, fine

159 Valve assembly, exhaust

161 Oil service block

162 Oil service block gasket

163 Hex head cap screw

164 Lockwasher

165 Socket head cap screw

166 Lockwasher

168 O-ring

169 Exhaust valve cover plate

175 Socket head cap screw

176 Lockwasher

185 Gasket, cylinder/exhaust box

186 Stud

187 Lockwasher

189 Stud

190 Lockwasher

191 Nut

205 Exhaust cover side plate

206 Cover plate gasket

207 Socket head cap screw

208 Lockwasher

221 Hydraulic fitting banjo

222 Hydraulic fitting, straight

223 Hydraulic fitting, elbow/banjo

224 Pipe adapter

225 Hydraulic fitting

230 Oil tubing

231 Oil tubing

232 Oil tubing

238 Socket head cap screw

239 Lockwasher

241 Oil cooler

242 O-ring

244 Fan cover

247 Socket head cap screw

250 Housing, lower, inlet

251 Valve plate, inlet

252 Valve plate guide

253 O-ring

254 Spring, valve plate

255 O-ring

260 Inlet flange, upper

261 Inlet screen

265 Screw, hex head cap

266 Lockwasher

270 Plug

271 Gasket ring

275 Oil return valve

276 Gasket ring

284 Hydraulic, fitting banjo

285 Screw, oil recirculation

286 Banjo fitting housing

288 Gasket ring

289 Screw

290 Oil return line, RA version

291 Hyd. fitting, straight

292 Carburator jet

293 Oil return line, RC version

297 Screen fan guard

300 Motor mounting bracket

Ref Description

301 Screw hex head cap

302 Lockwasher

306 Motor adapter flange

307 Lockwasher

311 Coupling half, pump side

312 Coupling insert

313 Coupling half, motor side

315 Plastic clip

320 Spacer

321 Fan

322 Axial fan

323 Socket set screw

326 Retainer ring

331 Set screw

333 Set screw

340 Fan guard

341 Screw, self tapping

342 Sleeve, plastic

345 Fan cover shield

353 Socket head cap screw

360 Lockwasher

390 Eye bolt adapter

391 Eye bolt

392 Lockwasher

393 Hex head screw

400 Motor

401 Screw, hex head cap

402 Lockwasher

409 Motor foot spacer

411 Flat Washer

413 Slotted set screw

415 Screw, hex. head cap

416 Stud, motor foot

417 Set screw

419 Spacer, motor foot

421 Foot, rubber

422 Foot, rubber

423 Lockwasher

424 Hex nut

425 Stud

430 Name plate

431 Label "arrow"

436 Maintenance label

440 Gas Ballast Assembly

470 Hyd. fitting banjo

471 Tubing, gas ballast

472 Valve, check gas ballast

473 Coupling

474 Filter, gas ballast

475 Valve, pet cock

476 Gas ballast elbow

477 Pet cock valve

478 Hex head cap screw

479 Lockwasher

Note: This parts list includes parts for all the

pumps covered by this manual. Your specif-

ic model might not necessarily have all the

part5 indicated in this list. Refer to the illus-

tratior for your specific model pump when

comparing part numbers or consult the fac-

tory.

0025 - 0250 "C" & "E" Parts List

12, 13

requires an immediate change of the exhaust filter.

In order to replace the filter, remove the four

socket head cap screws (Ref. 155, 146) retaining the

exhaust port housing. Pull the housing off the

exhaust box and set it aside. Use a slotted head

screw driver to loosen the exhaust filter retaining

spring, then rotate and remove the spring. Pull the

filter cartridge (Ref. 120) out of the exhaust box.

To field test an exhaust filter element, remove it

from the pump, allow it to cool, clean the sealing

end (or O-ring end), and use compressed air to blow

through the element. Apply approximately 3 to 6

psi, which is the maximum allowable operating

pressure across the filter. Note: Use a shop rag to

seal off the connection between the air hose and the

filter. If you can blow through it, the element is

good. If not, discard it and install a new one. The

filter cannot be cleaned successfully. Visually

inspect the filter element for cracks.

Reinstall the filter elements. Make sure the open

end of the element is properly seated down in its

recess in the exhaust box (see Figure 3) with the O-

ring (Ref. 121) correctly positioned. Retain the filter

with the spring clip, tighten the tension screw until

the filter is secure. Place the exhaust port gasket and

housing in position on the exhaust box and retain

with the cap screws.

3.4 Vacuum Inlet Filter

If the pump is equipped with a special vacuum

inlet filter in applications where powder, dust or grit

is present, the filter cartridge should be cleaned on a

weekly basis, or as required, depending on the

amount of foreign particles to which the pump is

exposed.

3.5 Maintenance Chart

Daily: Visually check oil level (see 3.1.1 and

3.1.2).

Weekly: Check oil for contamination (see

3.1.3). Inspect inlet filter (see Section 3.4).

Every three (3) or four (4) months, 500 to 750

hours of operation, or as necessary: See 3.1.3 and

1.5. Drain and discard oil from the hot pump.

Replace the automotive-type oil filter and refill with

fresh oil through the fill plug (see 3.1.2 through

3.1.3 and 3.2).

Every nine (9) to twelve (12) months, or as

necessary: Replace exhaust filter elements (see

3.3).

3.6 Overhaul Kit/Filter

An overhaul kit containing a set of gaskets and

O-rings, vanes, bearings and bearing sleeves, shaft

seals and taper pins, is available from the factory.

Also, a filter kit containing oil drain plug, gas-

kets, automotive type oil filter (where applicable),

exhaust filter, and exhaust filter, is available from

the factory.

When ordering, please specify pump size and

model (a 3-digit suffix after size), and serial number.

4.0 TROUBLESHOOTING

4.1 Trouble

Pump does not reach “blank-off” pressure which

is the lowest absolute pressure (best vacuum) when

running with the inlet closed via a blank flange or a

valve; or the pump takes too long to evacuate the

system. “Blank-off” pressure can be measured by

using a good quality capsule gauge.

4.1.1 Possible Cause

Contaminated oil is by far the most common

cause of not reaching the ultimate pressure.

Remedy:

Shut off pump, after operating temperature has

been reached, drain the warm oil from pump and

exchange automotive-type oil filter (where applica-

ble), if necessary. Flush and fill pump with new oil

and take new “blank-off” measurement after operat-

WARNING: Do not inhale through the filter

or allow your mouth to come in direct contact

with the filter.

ing temperature is reached (at least 20-30 minutes).

4.1.2 Possible Cause

Vacuum system or vacuum piping not leak-tight.

Remedy:

Check hose and pipe connections for possible

leak.

4.1.3 Possible Cause

Wire mesh inlet screen plugged (Ref. 261).

Remedy:

Clean wire mesh inlet screen. Install inlet filter

if problem repeats frequently.

4.1.4 Possible Cause

No oil or not enough oil in oil reservoir.

Remedy:

Shut off the pump, add the necessary oil, or if oil

seems contaminated, drain balance of oil from

pump, exchange automotive oil filter, and refill with

fresh oil.

4.1.5 Possible Cause

Automotive-type oil filter is dirty or clogged

(where applicable).

Remedy:

Replace automotive-type oil filter, exchange oil,

if necessary, and refill with fresh oil.

4.1.6 Possible Cause

Inlet valve plate (Ref. 251) stuck in closed or

partially open position due to contamination.

Remedy:

Disassemble inlet valve and screen. Clean as

required.

4.1.7 Possible Cause

Oil tubing defect and/or leaking. Oil return line

broken on RC model.

Remedy:

Replace or retighten the oil fittings or oil tubing.

Replace only with same size tubing.

4.1.8 Possible Cause

Shaft seal leaking.

Remedy:

Replace the shaft seal following disassembly

and assembly steps outlined in the Maintenance and

Repair Manual. Check the shaft seal. It should have

a spring installed inside and around the shaft sealing

lip.

4.1.9 Possible Cause

Exhaust valve (Ref. 159) is not properly seated

or it is partially stuck open.

Remedy:

Follow disassembly and assembly steps outlined

in the Maintenance and Repair Manual.

4.1.10 Possible Cause

The vanes are blocked in the rotor or are other-

wise damaged.

Remedy:

Free vanes or replace with new ones following

disassembly and assembly steps outlined in the

Maintenance and Repair Manual.

4.1.11 Possible Cause

Radial clearance between the rotor and cylinder

is no longer adequate.

Remedy:

Follow disassembly and assembly steps outlined

in the Maintenance and Repair Manual on resetting

the radial clearance correctly.

4.1.12 Possible Cause

Internal parts worn or damaged.

Remedy:

Follow disassembly and assembly steps outlined

in the Maintenance and Repair Manual and replace

worn or damaged parts.

4.1.13 Possible Cause on RC Models Only

The oil return line (Ref. 290) is connected

directly to atmospheric pressure in the exhaust area.

On small model pumps, a fairly large amount of air

is sucked through the oil return line, and it may not

be possible to reach 15 torr or 29.4 inches Hg.

blank-off on the inlet of the pump under these con-

ditions.

Blank-off of 29.4 inches Hg or 15 torr can be

reached by temporarily disconnecting and closing

the oil return line; also by squirting oil through the

exhaust opening into the exhaust filter area. Oil will

be sucked into the oil return line, and no air will

reach the inlet, thus affecting the "blank-off' pres-

sure.

4.2 Trouble

Pump will not start.

4.2.1 Possible Cause

Motor does not have proper supply voltage or is

overloaded; motor starter overload settings are too

low or wrong setting; fuses are burned; or wire is

too small or too long, causing a voltage drop at the

pump.

Remedy:

Check correct supply voltage; check overload

settings in motor starter for size and setting accord-

ing to motor nameplate data; check fuses; and install

proper size wire. If ambient temperature is high, use

larger size overloads or adjust setting 5% above

nominal motor nameplate value.

4.2.2 Possible Cause

Pump or motor is blocked.

Remedy:

Remove fan cover and try to turn pump and

motor by hand. If frozen, remove motor from pump

and check motor and pump separately. If pump is

frozen, disassemble completely per the Maintenance

and Repair Manual and remove foreign objects in

the pump or replace broken vanes.

4.3 Trouble

Pump starts, but labors and draws a very high

current.

4.3.1 Possible Cause

Oil too heavy (viscosity too high) or ambient

temperature below 5 degrees C (41°F).

Remedy:

Change to R580 vacuum oil if very cold, or

warm up oil before filling.

4.3.2 Possible Cause

Pump runs in the wrong direction.

Remedy:

Check for correct rotation which is counter-

clockwise when looking at the motor from the

motor's fan side.

4.3.3 Possible Cause

Pump is overfilled with oil or the wrong kind of

oil is used.

Remedy:

Correct the oil level and quality per Section 1.5

and use recommended motor oil.

4.3.4 Possible Cause

Exhaust filters in exhaust chamber are clogged

and appear burned black with pump oil.

Remedy:

Replace exhaust filters, maintain proper oil con-

dition, oil level, and use only Busch recommended

vacuum oil.

4.3.5 Possible Cause

The exhaust filter is clogged due to process

material.

Remedy:

Contact the factory for recommendation or prop-

er filter cartridge.

4.3.6 Possible Cause

Loose connection in motor terminal box; not all

motor coils are properly connected. Motor operates

on two phases only.

Remedy:

Check motor wiring diagram for proper hookup,

especially on motors with six internal motor wind-

ings, tighten and/or replace loose connections.

4.3.7 Possible Cause

Foreign particle in pump, vanes broken, bearing

seizing.

Remedy:

Follow disassembly and assembly steps outlined

in the Maintenance and Repair Manual and remove

foreign parts, and replace vanes and bearings.

4.4 Trouble

Pump smokes at the exhaust side or expels oil

droplets from the exhaust.

4.4.1 Possible Cause

Exhaust filter is not properly seated with O-ring

(Ref. 121) in filter base or filter material is cracked.

Remedy:

Check condition and placement of exhaust fil-

ters in filter base. Replace if necessary.

4.4.2 Possible Cause

Exhaust filter is clogged with foreign particles.

Remedy:

Replace exhaust filter. Install other factory rec-

ommended filter cartridges if pump application

requires other filter cartridges.

4.4.3 Possible Cause

The oil return valve (Ref. 275) is not properly

working, clogged. Proper function is that when

blowing into check valve, it should close. When

applying vacuum on it, check valve should open.

Remedy:

Free or replace the oil return check valve.

4.4.4 Possible Cause

If RA Series vacuum pumps run continuously

over 8 hours without ever being shut down, it may

be possible that oil accumulates behind the exhaust

box cover (Ref. 275) to the extent that oil is blown

out of the exhaust with the exhaust gas.

Remedy:

Shut pump down during break periods or install

an additional oil return line assembly. Check that oil

return valve (Ref. 275) is free and drains oil back

into pump when RA Series pump is stopped.

WARNING: Do not apply pressure or vacu-

um by mouth.

4.4.5 Possible Cause

Oil return line (Ref. 290) on RC Standard pump

is clogged or broken.

Remedy:

Free clogged line, replace broken line, but only

with proper size, and check that oil is pumped out of

oil sump while vacuum pump is operating.

NOTE: An oil filling plug with pressure gauge is

provided on all R5 Series pumps, so that the pres-

sure in front of the exhaust filters can be monitored.

The green field indicates that the filters are still

effective. Any back pressure close to the red field

requires immediate change of the exhaust filter (Ref

120).

4.5 Trouble

Pump runs very noisly.

4.5.1 Possible Cause

Coupling insert worn.

Remedy:

Replace coupling insert in motor/pump cou-

pling.

4.5.2 Possible Cause

Bearing noise.

Remedy:

Follow disassembly and assembly steps outlined

in the Maintenance and Repair Manual and replace

bearings.

4.5.3 Possible Cause

Vanes stuck.

Remedy:

Follow disassembly/assembly instructions out-

lined in the Maintenance and Repair Manual and

replace vanes.

4.6 Trouble

The pump runs very hot. See Technical Data for

typical oil sump temperature.

4.6.1 Possible Cause

Not enough air ventilation to the pump.

Remedy:

Clean motor and pump air grills. Do not install

the pump in an enclosed cabinet unless a sufficient

amount of fresh air is supplied to the pump. On

pumps with oil cooling coils, clean outside fin

assembly. Bring ambient air temperature down.

4.6.2 Possible Cause

Automotive-type oil filter clogged and pump

does not receive enough oil.

Remedy:

Change automotive oil filter.

4.6.3 Possible Cause

Not enough oil in oil reservoir or badly burned

oil is used for pump lubrication.

Remedy:

Drain and refill only with non-detergent oil,

increase oil change intervals.

NOTE: On some high temperature applications,

it may be necessary to change to a high temperature

oil such as R590 or R570. Contact the factory for

recommendations.

4.7 Trouble

Pump is seized.

4.7.1 Possible Cause

Pump operated without oil and vanes broke.

Remedy:

Disassemble and exchange vanes as outlined in

the Maintenance and Repair Manual.

4.7.2 Possible Cause

Pump was operated for an extended period of

time in the wrong rotation.

Remedy:

Inspect vanes and replace.

4.7.3 Possible Cause

Liquid carryover into the pump cylinder broke

vanes while pump was running, or oil broke vanes

on start-up.

Remedy:

(a) Install condensate trap on the inlet of the

pump.

(b) Pump was overfilled with oil in oil reservoir.

Follow oil filling procedure (see Section 1.5) and do

not overfill.

through 255) leaking while pump was shut down

and vacuum was left in manifold. Clean valve seat

and check that anti-suck-back valve holds vacuum

on inlet when pump is shut down.

(d) Two pumps or a receiver is on the same main

line. Install a manual or automatic operated valve in

front of each pump.

4.8 Trouble

Automotive-type oil filter (Ref. 100) does not

get warm within two to five minutes when cold

pump is started.

4.8.1 Possible Cause

Automotive-type oil filter is clogged.

Remedy:

Replace automotive-type filter per Section 3.2

and exchange oil per Section 1.5.

4.8.2 Possible Cause

Wrong automotive-type filter is used and/or oil

lines leading to pump are clogged.

Remedy:

Use only automotive filter as listed in Section

3.2 and blow lines free.

5.0 LIMITED STANDARD WARRANTY

Busch, Inc. warrants that all products furnished

by it are free from defects in material and work-

manship at the time of shipment for a period of 18

months from the date of shipment, or 12 months

from the date of installation, whichever occurs first.

Claims must be made during that period and are lim-

ited to the replacement or repair of parts claimed to

be defective.

In the case of components purchased by Busch,

Inc., such as starters, controls, mechanical seals,

motors, couplings, etc., the warranty of that manu-

facturer will be extended to the purchaser in lieu of

any warranty by Busch, Inc. The replacement of

wear items including, but not limited to, seals, bear-

ings, couplings, exhaust cover gaskets, oil drain

plugs, oil fill plugs etc., made in connection with

normal service, are not covered by this Warranty.

The Limited Standard Warranty is valid only

when the product has been properly installed, used

in a normal manner, and serviced according to the

operating manual. This warranty shall not extend to

products that have been misused, neglected, altered,

or repaired without factory authorization during the

warranty period. We highly recommend the use of

Busch oils and parts to achieve documented per-

formance and efficient operation. The use of oils or

parts other than Busch could limit the life expectan-

cy of the equipment and could void any warranties

if they are the cause of any damage. Operating con-

ditions beyond our control such as improper voltage

or water pressure, excessive ambient temperatures,

or other conditions that would affect the perform-

ance or life of the product will also cause the war-

ranty to become void.

Permission to return parts for warranty repair

must be obtained, and all returns must be prepaid to

the factory. If, after examination, the product or part

is found to be defective, it will be repaired or

replaced on a no-charge basis and returned, FOB the

factory. If it is determined that the Warranty has not

been breached by Busch, Inc., then the usual charges

for repair or replacement will be made, FOB the fac-

tory. Parts or products that are obsolete or those

made to special order are not returnable.

This Limited Standard Warranty applies only to

the above and is for the period set forth. Busch,

Inc.'s maximum liability shall not, in any case,

exceed the contract price for the product, part, or

component claimed to be defective; and Busch, Inc.

assumes no liability for any special, indirect, or con-

sequential damages arising from defective equip-

ment.

THERE ARE NO WARRANTIES IMPLIED

OR EXPRESSED THAT EXTEND BEYOND

THOSE CONTAINED IN THIS LIMITED

STANDARD WARRANTY.

Note: For extended warranties on your new equip-

ment contact Busch, Inc. Headquarters at:

1-800-USA-PUMP

* Maximum oil temperature with 80°F ambient temperature and no supplemental oil cooling.

Busch Inc. Factory Service Centers

California Illinois

Kurt Kauffman Steve Looman

13826 Struikman Road 430 Windy Point Drive

Cerritos, CA 90703 Glendale Heights, IL 60139

562-926-8422 630-545-1310

New Jersey

Puerto Rico

Jose Concepcion Carlos Ortiz

39 Davis Street #420 E. Street, Suite 4

South Plainfield, NJ 07080 Minillas Industrial Park

908-561-3233 Bayamon, PR 00959-1901

787-798-5045

exas Virginia

Dave Parsons Clayton McClenny

15411 Vantage Pkwy W., Suite 216 516 Viking Drive

Houston, TX 77032 Virginia Beach, VA 23452

281-449-2381 757-463-7800

Installation and Operating

Instructions

Rotary Vane Vacuum Pumps

R 5 RA 0165, 0205, 0255 and 0305 D

Busch, Inc.

516 Viking Drive

Va. Beach, VA 23452

Phone: (757) 463-7800

Fax: (757) 463-7407

P/N 0872.911.978/ 0806

TABLE OF CONTENTS

Page

GENERAL 2

Identification 2

Operating Principles 2

1.0 INSTALLATION 2

1.1 Unpacking 2

1.2 Location 2

1.3 Power Requirements 2

1.4 Vacuum Connections 3

1.5 Oil Filling 3

2.0 OPERATION 4

2.1 Start-up 4

2.2 Gas Ballast 4

2.3 Process Gas 4

2.4 Stopping Pump 4

2.5 Water-Cooled Pumps (optional) 4

2.6 Oxygen Service Pumps 5

3.0 MAINTENANCE 5

3.1 Pump Oil 5

3.1.1 Oil Level 5

3.1.2 Oil Type and Quantity 6

3.1.3 Oil and Filter Change 6

3.1.4 Oil Flushing Procedure 6

3.2 Automotive-Type Oil Filter 6

3.3 Exhaust Filter 7

3.4 Inlet Flange 8

3.5 Vacuum Inlet Filter (Optional) 8

3.6 Maintenance Chart 8

3.7 Overhaul Kit/Filter Kit 8

4.0 TROUBLESHOOTING 8

5.0 LIMITED STANDARD WARRANTY 12

Technical Data 13

Parts List 14

Illustration of RA 0165/0205/0255/0305 15

Busch, Inc. Factory Service Center 16

We reserve the right to change the product at any time without any form of notification. The information in this pub-

lication is accurate to the best of our ability at the time of printing. Busch, Inc. will not be responsible for errors

encountered when attempting to perform tasks outlined in this publication which is copyright protected.

GENERAL

Identification

For model identification, see the nameplate mounted on

the side of the exhaust box.

This manual is written to cover installation and opera-

tion of the RA version of models 0165, 0205, 0255 and

0305 with a "D" appearing as the seventh character in

the model type number stamped into the nameplate.

For example it would appear as follows:

RA0XXX - D

XXX - XXXX

When ordering parts, it is helpful to include the identifi-

cation code stamped into the side of the cylinder as well

as the serial number from the nameplate.

Operating Principles

All reference (Ref. XX) numbers listed in the text and on

illustrations throughout this manual are related to the

drawings and parts list near the end of this publication.

R 5 Series, Single Stage, Rotary Vacuum Pumps are

direct-driven, air-cooled, oil-sealed rotary vane pumps

which operate as positive displacement pumps (see

Fig. 1). They consist of a rotor positioned eccentrically

in a cylindrical stator (see Fig. 2). When the rotor spins,

centrifugal force pushes the vanes, which glide in slots,

towards the wall of the cylinder. The rotor has three

vanes which divide the pump chamber into three seg-

ments. The gas to be pumped enters at the inlet port,

passes through the inlet screen and the open anti-suck-

back valve into the pump chamber. As the rotor rotates,

the inlet aperture is closed, the gas is compressed and

forced out through one-way valves between the pump

cylinder and the exhaust box. Differential pressure con-

stantly causes oil to be pressed into the compression

chambers. The gas/oil mixture is separated by the dis-

charge filters (Ref. 120). The oil-free medium is dis-

charged through the exhaust cover plate (Ref. 140) to

atmosphere. This operation is repeated three times

each revolution.

1.0 INSTALLATION

1.1 Unpacking

Inspect the box and pump carefully for any signs of

damage incurred in transit. R 5 Pumps pass a rigorous

operating test in the factory and are packed carefully to

avoid transit damage. Since all pumps are ordinarily

shipped FOB our factory, such damage is the normal

responsibility of the carrier and should be reported to

them.

Remove any nuts from the bottom of the box/crate and

pull the pump out of the container using a suitable lifting

device and the lifting eye bolt (Ref. 391). Then,

unscrew any remaining studs that secured the bottom

of the rubber feet to the bottom of the crate.

The inlet port of the pump is covered with a plastic cap

prior to shipment to prevent dirt and other foreign mate-

rial from entering the pump. Do not remove this cover

until the pump is actually ready for connection to your

system.

1.2 Location

The pump must be installed in a horizontal position on

a level surface so that the pump is evenly supported on

its rubber feet. Allow sufficient air space between the

pump and any walls or other obstructions; adequate

ventilation must be provided for the fans on the pump

and motor (i.e., do not locate the pump in a stagnant air

location).

Whenever the pump is transported, be sure to drain the

oil prior to shipping to avoid vane breakage when

restarting the pump.

Do not tip the pump over if it is filled with oil.

Locate the pump for easy access to the oil sight glass

(Ref. 83) in order to inspect and control the oil level

properly. Allow clearance at the exhaust flange area to

provide service access to the exhaust filters.

1.3 Power Requirements

The schematic diagram for the electrical connection is

located in the junction box or on the nameplate of the

pump motor.

Fig. 1 - R 5 0255 D Pump

All R 5 series pumps are designed to handle air.

Vapor in the air stream can be tolerated when the

pump is operated within certain operating parameters

as defined by Busch, Inc. Engineering (see Section

2.2 - Gas Ballast). When you desire to use the pump

on an air stream that contains vapors, contact Busch,

Inc. Engineering for operating recommendations; oth-

erwise, the warranty could be void.

The motor must be connected according to the electri-

cal codes governing the installation. The power supply

must be routed through a fused switch to protect the

motor against electrical or mechanical overloads. The

motor starter has to be set consistent with the motor

current listed on the motor nameplate.

If the pump is supplied with a manual motor starter, it is

preset at the factory in accordance with the customer’s

specification. For other voltage requirements, contact

the factory for motor and/or starter information.

Note: See the motor manufacturer’s manual for start-

up maintenance of the motor.

Correct direction of rotation is marked by an arrow on

the motor fan housing and is counterclockwise when

looking at the motor from the motor's fan side.

1.4 Vacuum Connections

Use a line size to the vacuum system that is at least as

large as that of the pump inlet. Smaller lines will result

in lower pumping speeds than the rated values.

Install a drip leg and drain on the vertical pipe near the

pump inlet. Drain the drip leg often to prevent conden-

sation from entering the pump. Also, when installing

discharge piping, a drip leg should be installed.

If more than one vacuum pump or a receiver tank is

connected to a common main line, each pump should

have its own manual or automatic operated shut-off

valve or positive action check valve. The built-in anti-

suck-back valve should not be used as a shut-off valve

for the vacuum system.

Remove the plastic protective cap from the inlet port

prior to connection of the pump to the system. Vertical

connection of the vacuum line can be made directly to

the pump inlet (Ref. 260).

The type and size of the inlet connections of the R 5

Series pump is shown in the TECHNICAL DATA page

12.

If the gas that is pumped contains dust or other foreign

solid particles, a suitable (10 micron rating or less) inlet

filter should be connected to the inlet port. Consult the

factory for recommendations.

1.5 Oil Filling

The pump is shipped without oil. After level installation,

after correct rotation has been established and with the

pump switched "off" and secured against accidental

start-up, fill the pump with the recommended vacuum

oil through the oil filling port (Ref. 88), observing the

"MAX" and "MIN" position at the oil sight glass (Ref.

83).

Non-detergent oil should be used. Do not use

detergent motor oil as additives in detergent oil will

plug exhaust filter elements and shorten their life.

CAUTION: After the electrical connection

has been made, but before the pump is

filled with oil, the rotation of the motor

must be checked. Open the inlet port and

jog the motor briefly to make sure rotation

is correct. If it runs backwards and if it is

wired three phase power, reverse any two

leads of the three at the power connection.

CAUTION: Do not use the anti-suck-back

valve as a check or shut-off valve for your

vacuum system.

Fig. 2 - Basic R 5 RA0165, 0205, 0255 and 0305 D Series Pump

159

260

Inlet

1001522194958390

Oil

120

140

Exhaust

It is recommended that Busch R500 Series oil be used

to receive the best performance from your vacuum

equipment. R500 Series oil is a high quality vacuum oil

which will give longer running time between oil

changes, will provide better lubrication at high operating

temperatures, and will prolong the life of exhaust filter

elements. This oil can be obtained directly from Busch,

Inc. in Virginia Beach, Virginia.

The strict use of Busch oils and parts from the day of

purchase can extend the standard warranty to three

years. Contact Busch, Inc. in Virginia Beach, Virginia

for details. Refer to page 11 for the Limited Standard

Warranty.

For general applications, use R530 in most models cov-

ered by this manual. Use R590 or R570 in pumps that

are operated in high ambient temperatures (above

90°F) or when the oil can carbonize (turns black) before

the change interval. Contact the factory for recommen-

dations when using other oils.

The TECHNICAL DATA chart on page 13 gives the

approximate quantities of oil required for each pump.

The oil capacity chart should only be used as a guide,

since oil capacity may be slightly lower, depending on

whether the pump was filled previously, and whether all

components such as oil filter, oil lines, etc., were

allowed to completely drain. Use only the sight glass

reading for proper level. Never overfill!

For ambient operating temperatures lower than 41°F,

use Busch R580 synthetic oil. If this does not help

(where the pump has difficulty starting due to high oil

viscosity) contact the factory in Virginia Beach, Virginia.

Replace the oil fill plug (Ref. 88) and pressure gauge

(Ref. 90), making sure that the gasket (Ref. 89) is in

place and properly seated and secured. Pumps are

equipped with an exhaust pressure gauge as an inte-

gral part of the oil fill plug. Switch the power back into

the "on" position.

2.0 OPERATION

2.1 Start-up

Check rotation of the motor as described in Section 1.3

- Power Requirements.

Fill the pump with oil as described in Section 1.5 - Oil

Filling.

Start the pump and immediately close the inlet. Run the

pump for a few minutes before checking the oil level

again. With the pump shut off, the oil level should be

visible in the oil sight glass (Ref. 83), between the "MIN"

and "MAX" mark.

Add oil, if necessary, but only add it when the pump has

been shut off and the circulating oil has had sufficient

time to return to the oil sump.

2.2 Gas Ballast

R 5 Series RA 0165 through 0305 D pumps are

equipped with an adjustable gas ballast valve (Ref.

474). The adjustable gas ballast valve should normally

be left open. Its primary function is to prevent water

vapor from condensing in the pump. Condensation

causes emulsification of the oil, loss of lubricity, and

possible rotor seizure.

Check the gas ballast filter periodically to ensure that air

is flowing through it properly.

2.3 Process Gas

The R 5 series pumps are designed to pump air and are

not intended for use when water vapor is being

pumped. In some applications, when the quantity of the

water vapor is moderate, R 5 pumps have been used

with good results. On these occasions, the pump is run

until it is up to operating temperature before it is allowed

to pump the process gas. The pump is also operated

for a period of time off process and on air (to clear it of

process gas) before it is shut down. This operating

technique prevents the vapor from condensing in the

pump. Before attempting to pump a gas laden with

water vapor, contact Busch Engineering for advice.

2.4 Stopping Pump

To stop the pump, turn off the power. The pump has a

built-in anti-suck-back valve (Ref. 251 thru 255) to pre-

vent the pump from rotating backwards when it is shut

off.

Install a manual or automatic valve or check valve in

each pipe leading to each pump when multiple pumps

are pumping on a common header.

All R 5 Series pumps are vented internally to atmos-

pheric pressure through venting holes which are next to

the exhaust valve assembly.

2.5 Water-Cooled Pumps (Optional)

Water-cooled pumps are cooled by circulating the oil

WARNING: Keep the oil fill plug tight as

pressure in the exhaust box could cause

bodily injury if the plug is blown out. Do not

fill/add the pump with oil through the

exhaust/inlet ports as there is danger of

breaking the vanes!

CAUTION: Do not use the anti-suck-back

valve as a check or shut-off valve for your

vacuum system.

through a shell-and-tube type heat exchanger. The cir-

culation of the pump oil through the shell is created by

vacuum in the pump, but the circulation of the cooling

water through the tubes is thermostatically controlled.

The flow rate of the cooling water is controlled by a ther-

mostatically activated valve (see Fig. 3) that senses,

through a capillary bulb mounted in the exhaust box,

the pump's oil temperature as it is discharged from the

compression chamber. The valve will open at its set

point and close at approximately 3°F to 5°F below the

set point. The valve set point is adjustable as follows:

(a) Rotate the valve adjustment screw counter-

clockwise to cause the valve to open at a higher tem-

perature. This makes the pump run hotter.

(b) Rotate the valve adjustment screw clockwise to

make the valve open at a lower temperature. This

makes the pump run cooler.

The thermostatic valve can be manually opened by

inserting a screwdriver under each side of the spring

guide and prying the spring and guide upward away

from the valve body.

The water cooling option can be used to cool pumps

operating in high ambient temperatures, or it can be

used to maintain a pump at elevated temperatures to

prevent condensation inside the pump in wet applica-

tions. Contact Busch Engineering in Virginia Beach for

details.

2.6 Oxygen Service Pumps

Oxygen service pumps must be used in oxygen

enriched applications that are defined as any applica-

tion which has a process gas that is 25% or more oxy-

gen. If this pump is contaminated by organic com-

pounds do not attempt to use it on oxygen service until

it has been decontaminated.

These pumps have been manufactured, solvent

washed (to remove organic contaminants) and assem-

bled according to the latest technical standards and

safety regulations. If this pump is not installed properly

or not used as directed, a dangerous situation or dam-

age might occur.

It is mandatory that these operating instruc-

tions be read and understood prior to vacu-

um pump installation and start-up!

For overhaul/repair of oxygen service pumps,

Busch Inc. strongly recommends that all major repair

operations be conducted at the factory. Improper

handling of repairs could result in extreme

danger to personnel operating the pump.

3.0 MAINTENANCE

R5 Series, Single Stage, Rotary Vacuum Pumps require

very little maintenance; however, to insure optimum

pump performance, the following steps are recom-

mended.

3.1 Pump Oil

3.1.1

Oil Level

With the pump installed relatively level, make sure that

there is sufficient clean oil in the pump (see Section

1.5). The oil level should be observed on a daily basis

and/or after 8 hours of operation and should be replen-

ished if it drops below the 1/4 mark on the oil sight

glass.

Oil level readings should be done only when the pump

is turned off. Oil can be added to the oil fill port (Ref.

88) if the pump is shut off and the circulating oil has suf-

ficient time to return to the oil sump. The oil might

appear to be foamy, which is a normal phenomenon

with aerated oil.

Thermostat valve

Fig. 3 - Water Cooled Pump

WARNING: This pump is filled with a special

operating fluid. Do not use any other type

of fluid, oil and/or grease. Use one of the

following:

• Fomblin LC 250

• Tyreno Fluid 12/25V (perfluorinated poly

ether)

• KRYTOX ®Vacuum pump fluid by Du Pont

Company

If you have any questions, please phone our

Customer Service Department for more information.

CAUTION: Do not add oil while the pump is

running since hot unfiltered oil vapor may

escape through the oil fill port.

WARNING: Insufficient oil quantity in the

pump has the potential, under certain con-

ditions, to lead to self-ignition of the

remaining oil in the pump.

Under normal circumstances, it should not be neces-

sary to add or drain oil from the pump between recom-

mended oil changes.

A significant drop in oil level means there is an oil leak

or that an exhaust filter is broken, and the pump should

be smoking excessively. It is normal for the oil to be

foamy and light in color in an operating pump.

However, if the oil is milky colored, it is an indication

that water is present in the oil. Normally, by operating

the pump for an extended period, with the inlet suction

blanked off and the gas ballast open, the water will be

purged from the oil. If the oil is dark colored, it is con-

taminated or carbonized and must be changed.

Depending on the severity of the contamination, a thor-

ough flushing may be required. Contact the factory for

flushing oil (Busch R568) and instructions.

3.1.2

Oil Type and Quantity

See Section 1.5 and the Technical Data page 13 for

details on oil type and quantity.

3.1.3

Oil and Filter Change

Check the oil for contamination on a weekly basis by

shutting the pump off and draining some of the oil into

a small glass or a similar transparent container through

the oil drain port (Ref. 95).

Oil life is dependent upon the conditions to which it is

exposed. A clean, dry air stream and an oil operating

temperature under 210°F are ideal conditions. Oil must

be changed after the first 100 initial hours of operation.

After the initial oil change, and when using R530

(hydrocarbon oil), it is recommended that oil changes

are made every three (3) to four (4) months or 500 to

750 hours of operation, or as necessary if high heat is

contaminating the oil. The use of Busch R570 (syn-

thetic) or R590 (semi-synthetic) oil may significantly

extend the operating hours between oil changes; how-

ever, you may need to flush out the pump before chang-

ing. Contact the factory Service Department for advice

or refer to Section 3.1.4 for the flushing procedure.

To change the oil, the pump must be switched off and

ventilated to reach atmospheric pressure. Remove the

oil drain plug (Ref. 95) and drain the oil. Dispose of the

oil in compliance with local or national regulations.

When the oil stops draining, replace the oil drain plug.

Start the pump again for a few seconds. Stop the pump

once again, and then reopen the drain plug and dis-

charge any remaining oil.

Refasten the oil drain plug. Remove the oil filter (Ref.

100) and replace it with a new one using a Busch gen-

uine oil filter. Make sure to tighten the filter securely

against the aluminum sealing surface so that leaks will

not occur.

Excessive Heat

When the pump is subjected to operating conditions

that will cause the oil to be heated above 210°F, the oil

will carbonize and become contaminated after a rela-

tively low number of operating hours. The higher the

temperature, the quicker the oil becomes contaminated.

If the oil temperature is too severe, Busch R570 or

R590 synthetic oil should be used to withstand the ele-

vated temperatures. When changing to synthetic oil,

the pump should be flushed with Busch R568 oil.

Contact the factory for instructions on the flushing pro-

cedure. Auxiliary oil cooling is the most practical

approach to a severe heating problem.

Contaminated Air Stream

When the air stream contains solids and/or liquid that

contaminate the oil, the oil must be changed more

often. If the air stream contains a small percentage of

contaminates and/or they are slightly aggressive* (mild

acids, etc.), synthetic oil, such as Busch R570, will

resist breakdown better than the standard Busch R530.

The solution is to install a filter or knock-out pot to keep

the contaminates out of the pump.

*Process air streams with a large percentage of con-

taminates and/or are more than slightly aggressive

must use a chemical duty pump.

Oil change intervals can only be established by experi-

ence with the pump operating in the actual conditions

(see previous paragraph for some of the conditions).

Develop the oil change interval by periodically checking

an oil sample removed from the pump. When the oil

sample has become dark in color (from solids and car-

bonized particles) or is milky looking (from water), it is

time to discard it. As mentioned before, a thorough

flushing may be required.

CAUTION: When changing the oil and fil-

ters, it may be necessary to flush the pump

to remove any build-up of degraded oil from

the sumps, oil lines, radiators, etc. to

ensure proper oil flow through the pump.

Reduced oil flow, especially through radia-

tors and cooling coils, can cause mechani-

cal damage or extreme overheating which

could cause the oil vapors to ignite.

WARNING: Always take the necessary pre-

cautions concerning personal protective

equipment when changing oil and make

sure the pump is switched to the "off" so

that accidental starting will not occur. Oil

temperature can reach 212°F and may pose

a danger of scalding.

3.1.4 Oil Flushing Procedure

Flushing is needed under certain conditions. Some

pumps will be beyond flushing and will need to be over-

hauled.

To help determine if flushing is needed, observe the

condition of the oil as it is drained from the pump. Is it

black and tar like or contaminated in any way? Was the

pump noisy, overheating, or was the motor overload

shutting the pump off? How old is the pump and when

was the last time the oil was changed?

If the above conditions exist or you don't know when the

last oil change was performed further investigation is

needed. Also, when changing from one oil type such as

R530 to another type such as R590 or R570 it will be

beneficial to flush. Although the oils are compatible,

mixing a lesser grade oil such as R530 with a synthetic

oil like R570 will reduce the effectiveness of the syn-

thetic oil.

All of the oil will be removed and replaced with the

flushing oil (Busch R-568), and eventually that will be

replaced by whatever Busch oil is needed for your par-

ticular application. Have enough oil and oil filters on

hand for a couple of flushes. The following describes

the steps in the flushing procedure:

Shut the pump off and drain all the oil from the pump

and remove the access plates (Ref. 205) from the

exhaust box (Ref. 075). Remove the metal baffle (Ref.

078) and take a good look at the internal walls of the oil

sump. If the walls are discolored but have no build up

of any kind one can proceed with the flushing. If gelled

or burnt oil is clinging to the walls this material must be

scraped and removed prior to flushing. Proceed by

scraping and cleaning as much of the exhaust box as

possible. The more debris that is removed now the

more effective the flushing will be later. Re-install the

metal baffle, cover and proceed with the flushing. At

this point one must remember that the oil lines and oil

cooler might also be plugged to a point where no

amount of flushing will make a difference and a com-

plete overhaul will be the only option. Depending on

the severity of the oil contamination flushing may be a

last ditch effort.

Drain all of the oil from the pump. The more contami-

nated oil you remove now the more effective the oil

flushing will be.

Remove the oil filter (Ref. 100) and install a new one. It

is recommended that you do not change the exhaust fil-

ter or filters until after the flushing to prevent contami-

nation of any new filters.

Fill the exhaust box with the proper amount of flushing

oil (Busch R-568).

If possible run the pump with the inlet closed and off of

the process. Run the pump for approximately six hours,

shut the pump off and drain a small sample of oil into a

clear container.

Examine it. If it is clear to amber run the pump for

another six hours and examine it again. If after the first

six hours it is black drain it and fill again using another

new oil filter.

If after the second flushing the oil still remains black the

pump may have too much contaminated oil in it to flush

out properly. There may be residue remaining in the

lines and cooler that will not flush out. An overhaul will

be necessary.

If after the second six hour period the oil still remains

clear to amber in color drain it, change the oil filter and

fill with the regular oil. At this point also change the

exhaust filters.

Run the pump with a fresh charge of the oil to be used

in your application (not R-568), and monitor the operat-

ing conditions closely. Check for noise, overheating

and oil condition until a regular oil change schedule can

be established.

Do not let the oil turn black. Change it before it fails. If

the oil is kept in good condition the pump will last for

years. If the oil starts to turn black do not hesitate to

flush again. Keeping on top of the oil changes will pre-

vent costly overhauls.

If you are just switching from one type of oil to another

a single six hour flush is all that is necessary (follow the

above instructions). Remember to change to a new

exhaust filter or filters after the flushing and not before.

3.2 Automotive-Type Oil Filter

The pump is equipped with an automotive-type oil filter

(Ref. 100). When replacing the automotive-type oil fil-

ter, use only a Busch genuine filter.

Note: Make sure to tighten the Busch oil filter secure-

ly against the aluminum sealing surface so that leaks

will not occur.

3.3 Exhaust Filter

WARNING: Always wear safety glasses and

other appropriate personal protective

equipment when performing any mainte-

nance or repair to your R 5 pump.

WARNING: If the gas entering this pump is

a health hazard, use rubber gloves and all

necessary personal protection equipment

when performing the exhaust filter replace-

ment operation.

Exhaust filters (Ref. 120) should be checked monthly.

A pressure gauge (Ref. 90) is supplied with your R5

vacuum pump as part of the oil fill plug. This gauge has

a green field and a red field. A pressure within the

green field would indicate normal pressure. Any pres-

sure in the red field (for a continuos period of time)

requires an immediate change of the exhaust filter(s).

Every nine (9) to twelve (12) months, or as necessary,

replace the exhaust filter elements. The service life of

the exhaust filters varies widely with pump application.

It is only necessary to change the filters when the ele-

ments become clogged with foreign material or burned

oil. Indications of clogged filters are smoke and oil mist

coming from the pump exhaust or higher than normal

motor current.

In order to replace the exhaust filters, unscrew the

screws and washers (Ref. 142/143) from the exhaust

cover plate (Ref. 140). Remove the cover plate and

gasket (Ref. 141).

Remove the distance pin (Ref. 137), the baffle strainer

(Ref. 130) and the sheet metal plate (Ref. 136).

Remove the discharge filter assembly by unscrewing

the nut (Ref. 134) and removing the lockwasher (Ref.

132). Carefully slide the assembly out of the exhaust

box (Ref. 75). Stand the filter assembly up on a clean

flat surface.

To have access to the individual filters, unscrew the two

cylinder cover screws (Fig. 126), and remove the two

lockwashers (Ref. 128) and the exhaust filter grip plate

(Ref. 115).

Remove the exhaust filters (Ref. 120) and O-rings (Ref.

121). Remove the filter support (Ref. 118) and O-rings

(Ref. 119).

Replace the support and O-rings with new ones. Make

sure that the O-rings are fitted securely and that the fil-

ter elements (Ref. 120) fit securely into the depressions

on the filter support (Ref. 118). The indicating arrow on

each element must be pointing upward toward the top

of the exhaust box after the assembly has been

installed.

Carefully position the filter support tube (Ref. 133)

between the exhaust filter grip (Ref. 115) and the filter

support without displacing the filters from their seated

position in the filter support. Install the two lockwashers

(Ref. 128) and two screws (Ref. 126).

Insert the support and filter assembly into the exhaust

box using the stud (Ref. 131) as a guide. The stud

should slide through the hole in the support (Ref. 133).

Secure the assembly with the lockwasher (Ref. 132)

and hexagon nut (Ref. 134).

Reinstall the sheet metal plate (Ref. 136) and the baffle

strainer (Ref. 130) into the guide track of the exhaust

box (see Fig. 4). Press to the bottom of the exhaust

box. Make sure that the baffle strainer touches all sides

of the exhaust box. Insert the distance sleeve (Ref.

137) into the two grooves. This holds the sheet metal

plate and baffle strainer in place.

Inspect the exhaust box end cover gasket (Ref. 141) for

damage and replace if damaged. With the gasket in

place, secure the exhaust cover end plate (Ref. 140) to

the exhaust box using eight hex head cap screws (Ref.

142) and eight lockwashers (Ref. 143).

To field test an exhaust filter element, remove it from

the pump, allow it to cool, clean the sealing end (or O-

ring end), and use compressed air to blow through the

element. Apply approximately 3 to 6 psi, which is the

maximum allowable operating pressure across the fil-

ter.

Use a shop rag to seal off the connection between the

air hose and the filter.

If you can blow through it, the element is good. If not,

discard it and install a new one. The filter cannot be

cleaned successfully. Visually inspect the filter element

for cracks.

Reinstall the filter elements as described previously.

3.4 Inlet Flange

The standard inlet flange assembly contains an inlet

screen (Ref. 261) which may require occasional clean-

ly. The frequency of cleaning can only be determined

Fig. 4 - Exhaust Filters and Strainer

Track

136

130

137

120

115

134

CAUTION: Excessively contaminated and/or

clogged exhaust filters could possibly lead

to elevated pump temperatures which

could, under certain circumstances, cause

the lubricating oil to self-ignite.

by experience and is affected by hours of operation and

particle size being trapped. An optional vacuum inlet fil-

ter is offered and can help minimize the need or fre-

quency of cleaning the inlet screen.

To clean the screen, disconnect the flange from the

process piping. Remove the four screws and lock-

washers (Ref. 265/266). Remove the inlet flange (Ref.

260). Remove the screen (Ref. 261) and clean with

compressed air. After cleaning, install the screen and

inlet securing them with the screws and lockwashers.

Make sure the O-ring (Ref. 265) is in place prior to

securing the screws. Reattach the process piping to

the inlet.

3.5 Vacuum Inlet Filter (optional)

If the pump is equipped with an optional special vacu-

um inlet filter in applications where powder, dust or grit

is present, the filter cartridge should be cleaned on a

weekly basis, or as required, depending on the amount

of foreign particles to which the pump is exposed.

To clean the inlet filter, unsnap the lid clamps or remove

the knobs and lift off the filter lid. Remove cartridge,

being careful not to knock any foreign particles present

inside the canister into the pump suction. Clean foreign

particles from the canister with an air hose, and care-

fully back flush the filter cartridge with shop air. If the fil-

ter cartridge has been subjected to moisture or is

extremely dirty, it may need replacement.

3.6 Maintenance Chart

Note: See the motor manufacturer’s manual for the

periodic motor maintenance.

Note: Lack of proper maintenance can result in

blocked filters, radiators, oil lines, etc. This condition

can lead to excessive heat causing mechanical failure

or ignition of the oil vapors.

Daily: Visually check oil level (see 3.1.1 and 3.1.2).

Weekly: Check oil for contamination (see 3.1.3).

Inspect inlet filter (see Section 3.5).

Every three (3) or four (4) months, 500 to 750

hours of operation, or as necessary: See 3.1.3

and 1.5. Drain and discard oil from the hot pump.

Replace the automotive-type oil filter and refill with

fresh oil through the fill plug (see 3.1.2 through 3.2).

Every nine (9) to twelve (12) months, or as

necessary: Replace exhaust filter elements (see

3.3).

As necessary: Check and/or clean the standard inlet

screen. If the optional inlet filter is used, replace the fil-

ter material as practice determines.

As necessary: The radiator (Ref. 241), fan hood

(Ref. 244) and motor cover should be inspected regu-

larly for debris. Soiling prevents cool air intake and may

lead to overheating of the pump.

3.7 Overhaul Kit/Filter Kit

An overhaul kit containing a set of gaskets and O-rings,

vanes, bearings and bearing sleeves, shaft seals and

taper pins, is available from the factory. Also, a filter kit

containing oil drain plug, gaskets, automotive type oil fil-

ter, exhaust filter and synthetic baffle strainer is avail-

able from the factory. When ordering, please specify

pump size and model (a 4-digit suffix after size), and

serial number.

4.0 TROUBLESHOOTING

4.1 Trouble

The pump does not reach "blank-off" pres-

sure which is the lowest absolute pressure

(best vacuum) when running with the inlet

closed via a blank flange or a valve; or the

pump takes too long to evacuate the system.

"Blank-off" pressure can be measured by

using a good quality capsule gauge.

Possible Cause: Contaminated oil is by far the most

common cause of not reaching the ultimate pressure.

Remedy: Shut off the pump, after the operating tem-

perature has been reached, drain the warm oil from

pump and exchange the automotive-type oil filter

(where applicable), if necessary. Flush and fill the

pump with new oil and take a new "blank-off" measure-

ment after operating temperature is reached (at least

20-30 minutes).

Possible Cause: The vacuum system or vacuum

piping is not leak-tight.

Remedy: Check the hose and pipe connections for

possible leak.

Possible Cause: The wire mesh inlet screen is

plugged (Ref. 261).

Remedy: Clean the wire mesh inlet screen. Install an

inlet filter if the problem repeats frequently.

Possible Cause: No oil or not enough oil in the oil

reservoir.

Remedy: Shut off the pump, add the necessary oil, or

if oil seems contaminated, drain the balance of the oil

from the pump, exchange the automotive oil filter, and

refill with fresh oil. Flush if necessary.

Possible Cause: The automotive-type oil filter is dirty

or clogged (where applicable).

Remedy: Replace the automotive-type oil filter,

exchange the oil, if necessary, and refill with fresh oil.

Possible Cause: The inlet anti-suck-back valve plate

(Ref. 251) is stuck in closed or partially open position

due to contamination.

Remedy: Disassemble the inlet valve and screen.

Clean as required.

Possible Cause: The oil tubing fittings are loose and

leaking.

Remedy: Replace or retighten the oil fittings or oil tub-

ing. Replace only with same size tubing.

Possible Cause: Shaft seal leaking.

Remedy: Replace the shaft seal following disassem-

bly and assembly steps outlined in the Maintenance

and Repair Manual. Check the shaft seal. It should

have a spring installed inside and around the shaft seal-

ing lip.

Possible Cause: Exhaust valve (Ref. 159) is not

properly seated or it is partially stuck open.

Remedy: Contact the nearest Busch Factory Service

Center for instructions.

Possible Cause: Vanes are blocked in rotor or are

otherwise damaged.

Remedy: Free vanes or replace with new ones.

Contact the nearest Busch Factory Service Center for

instructions.

Possible Cause: The radial clearance between the

rotor and cylinder is no longer adequate.

Remedy: Contact the nearest Busch Factory Service

Center for instructions.

Possible Cause: The internal parts are worn or dam-

aged.

Remedy: Contact the nearest Busch Factory Service

Center for instructions.

Possible Cause: The inlet filter is clogged due to

process material.

Remedy: Contact the factory for recommendation on

proper filter cartridge.

4.2 Trouble

Pump will not start.

Possible Cause: The motor does not have the prop-

er supply voltage or is overloaded; the motor starter

overload settings are too low or are the wrong setting;

fuses are burned; or the wire is too small or too long,

causing a voltage drop at the pump.

Remedy: Check correct supply voltage; check over-

load settings in motor starter for size and setting

according to motor nameplate data; check fuses; and

install proper size wire. If the ambient temperature is

high, use larger size overloads or adjust the setting 5%

above nominal motor nameplate value.

Possible Cause: The pump or motor is blocked.

Remedy: Remove the fan cover and try to turn pump

and motor by hand. If frozen, remove the motor from

the pump and check the motor and the pump separate-

ly. If the pump is frozen, contact the nearest Busch

Factory Service Center for instructions.

4.3 Trouble

The pump starts, but labors and draws a

very high current.

Possible Cause: The oil is too heavy (viscosity too

high) or the ambient temperature is below 5 degrees C

(41°F).

Remedy: Change to R580 vacuum oil if very cold, or

warm up the oil before filling.

Possible Cause: Pump is running in the wrong direc-

tion.

Remedy: Check for the correct rotation which is coun-

terclockwise when looking at the motor from the motor's

fan side. Reverse any two leads on the motor to

change the direction of rotation.

Possible Cause: The pump is overfilled with oil or

the wrong kind of oil is used.

Remedy: Correct the oil level and quality per Section

1.5 and use recommended motor oil.

Possible Cause: Exhaust filters in exhaust chamber

are clogged and appear burned black with pump oil.

Remedy: Replace the exhaust filters, maintain proper

oil condition, oil level, and use only Busch recommend-

ed vacuum oil and filters.

Possible Cause: Loose connection in motor terminal

box; not all motor coils are properly connected. The

motor operates on two phases only.

Remedy: Check the motor wiring diagram for proper

hookup, especially on motors with six internal motor

windings, tighten and/or replace loose connections.

Possible Cause: Foreign particle in pump, vanes

broken, bearings seized.

Remedy: Contact the nearest Busch Factory Service

Center for instructions.

4.4 Trouble

Pump smokes at the exhaust side or expels

oil droplets from the exhaust.

Possible Cause: Inlet to pump is in a wide open con-

dition.

Remedy: Do not operate pump at high inlet pressures

for more than a few minutes (pressures = 0.00-10.0" Hg

vac.)

Possible Cause: The exhaust filter is not properly

seated with the O-ring (Ref. 121) in filter base or the fil-

ter material is cracked.

Remedy: Check the condition and check for proper

seating of the exhaust filters. Replace if necessary.

Also, check the filter spring clips for tightness.

Possible Cause: The exhaust filter is clogged with

foreign particles.

Remedy: Replace the exhaust filter.

Possible Cause: The oil return float valve (Ref. 194)

is not working properly.

Remedy: Make sure the float valve and oil return line

are not plugged. Replace components if necessary.

4.5 Trouble

Pump runs very noisily.

Possible Cause: Coupling insert is worn.

Remedy: Replace the coupling insert in motor/pump

coupling.

Possible Cause: Bearing noise.

Remedy: Contact the nearest Busch Factory Service

Center for instructions.

Possible Cause: Vanes stuck.

Remedy: Contact the nearest Busch Factory Service

Center for instructions. Use only the recommended

Busch oil and change oil more frequently.

4.6 Trouble

The pump runs very hot. See Technical Data

for typical oil sump temperature.

Note: The oil temperature with a closed inlet should be

approximately 185-225°F depending on pump type. At

24 in. Hg, the oil in the pump can go above 225°F.

These values are taken at an ambient temperature of

68°F. The maximum recommended ambient operating

temperature for an R 5 is 100°F on a continuous basis.

When it is necessary to operate a pump in ambient tem-

peratures above this limit, careful oil monitoring and/or

optional water cooling is necessary. Contact the facto-

ry at Virginia Beach for details.

Possible Cause: Not enough air ventilation to the

pump.

Remedy: Clean the motor and pump air grills. Clean

the radiator. Do not install the pump in an enclosed

cabinet unless a sufficient amount of fresh air is sup-

plied to the pump. Bring the ambient air temperature

down.

Possible Cause: The automotive-type oil filter

clogged and pump does not receive enough oil.

Remedy: Change the automotive oil filter.

Possible Cause: Not enough oil in oil reservoir or

badly burned oil is used for pump lubrication.

Remedy: Drain and refill the pump only with non-

detergent oil and increase oil change intervals.

Note: On some high temperature applications, it may

be necessary to change to a high temperature oil such

as R590 or R570. Contact the factory for recommen-

dations.

4.7 Trouble

Pump is seized.

Possible Cause: The pump operated without oil and

vanes broke.

Remedy: Contact the nearest Busch Factory Service

Center for instructions.

Possible Cause: The pump was operated for an

extended period of time in the wrong rotation.

Remedy: Inspect vanes and replace. Contact the

nearest Busch Factory Service Center for instructions.

Possible Cause: Liquid carryover into the pump

cylinder broke vanes while pump was running, or oil

broke vanes on start-up.

Remedy: Install a condensate trap on the inlet of the

pump. Or, pump was overfilled with oil in oil reservoir.

Follow oil filling procedure (see Section 1.5) and do not

overfill. Or, the built-in anti-suck-back valve (Ref. 250

through 255) is leaking while pump was shut down and

vacuum was left in manifold. Clean the valve seat and

check that anti-suck-back valve holds vacuum on inlet

when pump is shut down.

4.8 Trouble

The automotive-type oil filter (Ref. 100) does

not get warm within two to five minutes

when cold pump is started.

Possible Cause: The automotive-type oil filter is

clogged.

Remedy: Replace the automotive-type filter per

Section 3.2 and exchange oil per Section 1.5.

Possible Cause: The wrong automotive-type filter is

used and/or oil lines leading to pump are clogged.

Remedy: Use only automotive filter as listed in

Section 3.2 and blow lines free

. Flush oil cooler.

Possible Cause: The oil cooler is plugged internally

with burnt oil.

Remedy: Remove oil cooler and flush. Pump may

have to be disassembled completely to correct a

severely contaminated condition.

5.0 LIMITED STANDARD WARRANTY

Busch, Inc. warrants that all products furnished by it are

free from defects in material and workmanship at the

time of shipment for a period of 18 months from the

date of shipment, or 12 months from the date of instal-

lation, whichever occurs first. Claims must be made

during that period and are limited to the replacement or

repair of parts claimed to be defective.

In the case of components purchased by Busch, Inc.,

such as starters, controls, mechanical seals, motors,

couplings, etc., the warranty of that manufacturer will be

extended to the purchaser in lieu of any warranty by

Busch, Inc. The replacement of wear items including,

but not limited to, seals, bearings, couplings, exhaust

cover gaskets, oil drain plugs, oil fill plugs etc., made in

connection with normal service, are not covered by this

Warranty.

The Limited Standard Warranty is valid only when the

product has been properly installed, used in a normal

manner, and serviced according to the operating man-

ual. This warranty shall not extend to products that

have been misused, neglected, altered, or repaired

without factory authorization during the warranty period.

We highly recommend the use of Busch oils and parts

to achieve documented performance and efficient oper-

ation. The use of oils or parts other than Busch could

limit the life expectancy of the equipment and could void

any warranties if they are the cause of any damage.

Operating conditions beyond our control such as

improper voltage or water pressure, excessive ambient

temperatures, or other conditions that would affect the

performance or life of the product will also cause the

warranty to become void.

Permission to return parts for warranty repair must be

obtained, and all returns must be prepaid to the factory.

If, after examination, the product or part is found to be

defective, it will be repaired or replaced on a no-charge

basis and returned, FOB the factory. If it is determined

that the Warranty has not been breached by Busch,

Inc., then the usual charges for repair or replacement

will be made, FOB the factory. Parts or products that

are obsolete or those made to special order are not

returnable.

This Limited Standard Warranty applies only to the

above and is for the period set forth. Busch, Inc.'s max-

imum liability shall not, in any case, exceed the contract

price for the product, part, or component claimed to be

defective; and Busch, Inc. assumes no liability for any

special, indirect, or consequential damages arising

from defective equipment.

THERE ARE NO WARRANTIES IMPLIED OR

EXPRESSED THAT EXTEND BEYOND THOSE

CONTAINED IN THIS LIMITED STANDARD

WARRANTY.

Note: For extended warranties on your new equipment

contact Busch Headquarters at 1-800-USA-PUMP.

Model 0165 0205 0255 0305

Nominal pumping speed (ACFM) 115 130 170 196

Free air displacement (CFM) 117 141 180 212

End Vacuum (Torr) .5 .5 .5 .5

End Vacuum (inches Hg) 29.9 29.9 29.9 29.9

Maximum sound level (dBA) 79 80 81 81

Motor size - 3 phase (HP) 7.5 7.5 10 12

Nominal motor speed (RPM) 1750 1750 1750 1750

Motor frame size 213TC 213TC 215TCZ 215TCZ

Nominal motor amps (@230/460v) 20.4/10.2 20.4/10.2 25.6/12.8 29/14.9

Oil capacity (Quarts) 6.9 6.9 6.9 6.9

Inlet connection (NPT) 2" 2" 2" 2"

Exhaust connection (NPT) 2" 2" 2" 2"

Approximate weight (lbs.) 416 435 460 575

TECHNICAL DATA

Ref Description

1 Cylinder

5 Set screw plug

15 Rotor

18 Bearing sleeve

22 Vane

25 Endplate, motor side

26 Endplate, fan side

30 Needle bearing

31 Endplate spacer

35 Shaft seal

42 Shaft seal retaining plate

43 Screw, hex head

49 O-ring

50 O-ring

53 Screw, hex head

54 Lockwasher

57 Hex head screw

58 Lockwasher

60 Taper pin

65 Shaft key

66 Shaft key

75 Exhaust box

80 Sheet metal baffle

83 Oil sight glass

84 Gasket, oil sight glass

87 Elbow, oil fill

88 Oil fill plug

89 Gasket ring, fill plug

90 Exhaust pressure gauge

92 Socket head plug

95 Oil drain plug

96 O-ring

99 Pipe nipple

100 Oil filter, automotive type

105 Cover, exhaust box

106 Gasket, exhaust box cover

107 Hex head cap screw

108 Lockwasher

115 Exhaust filter grip plate

118 Filter support

119 O-ring

120 Exhaust filter

121 O-ring

126 Screw, socket head cap

127 Distance sleeve

128 Lockwasher

130 Baffle strainer

131 Stud

132 Washer

133 Filter support tube

134 Hex nut

136 Exh. baffle strainer screen

137 Distance sleeve

140 Exhaust cover plate

141 Exhaust cover gasket

142 Socket head cap screw

Ref Description

143 Lockwasher

146 Hex head cap screw

149 Socket head cap screw

150 Lockwasher

152 Lockwasher

153 Exhaust adapter

154 Exh. cover adapter gasket

159 Exhaust valve

162 Oil fill elbow gasket

169 Valve cover plate

171 Insert, gas ballast

175 Socket head cap screw

176 Lockwasher

185 Gasket, cylinder/exh. box

189 Stud

190 Lockwasher

191 Nut

194 Level switch

195 Level switch support

196 Socket set screw

197 O-ring

198 Socket head screw

205 Exh. cover side plate

206 Exh. cover plate gasket

207 Socket head cap screw

208 Lockwasher

224 Pipe adapter

225 Hydraulic fitting

228 Hydraulic fitting

230 Oil tubing

238 Socket head cap screw

239 Lockwasher

241 Oil cooler

242 O-ring

244 Fan cover

247 Socket head cap screw

250 Flange, lower, inlet

251 Valve plate, inlet

252 Valve plate guide

253 O-ring

254 Spring, valve plate

255 O-ring

260 Inlet flange, upper

261 Inlet screen

265 Screw, hex head cap

266 Lockwasher

270 Hyd. fitting, elbow

290 Oil return line

291 Hyd. fitting, elbow

300 Motor mounting bracket

301 Screw hex head cap

302 Lockwasher

306 Motor adapter flange

307 Socket head screw

311 Coupling half, motor side

312 Coupling insert

Ref Description

313 Coupling half, pump side

319 Motor spacer

321 Fan

322 Axial fan

326 Retainer ring

353 Socket head cap screw

360 Lockwasher

390 Eye bolt adapter

391 Eye bolt

392 Lockwasher

393 Hex head screw

400 Motor

401 Screw, hex head cap

402 Lockwasher

417 Set screw

421 Foot, rubber

422 Foot, rubber

429 Screw

430 Name plate

431 Label "arrow"

470 Hyd. fitting banjo

471 Tubing, gas ballast

472 Hyd. fitting, straight

474 Filter, gas ballast

475 Bracket

476 Elbow

477 Ball valve

478 Hex head cap screw

480 Oil tube insert

9000 Plug, socket

9011 Endplate spacer

Parts List for 0165, 0205, 0255 and 0305

RA 0165/0205/02550/0305 D

(Ref. BMC Dwg. T111.911.728 D)

Fig. 5 - Exploded View Drawing of Pump

Busch Inc. Factory Service Centers

California Illinois

13826 Struikman Road 430 Windy Point Drive

Cerritos, CA 90703 Glendale Heights, IL 60139

Phone (562) 926-8422 Phone (630) 545-1310

Fax (562) 926-7262 Fax (630) 545-1384

[email protected] [email protected]

New Jersey Puerto Rico

39 Davis Street 420 E Street, Suite 4

South Plainfield, NJ 07080 Minillas Industrial Park

Phone (908) 561-3233 Bayamon, PR 00959-1901

Fax (908) 561-3909 Phone (787) 798-5045

[email protected] Fax (787) 798-5033

[email protected]

Texas Virginia

1901 South Starpoint Drive 516 Viking Drive

Houston, TX 77032 Virginia Beach, VA 23452

Phone (281) 214-8400 Phone (757) 463-7800

Fax (281) 214-8410 Fax (757) 463-7407

[email protected] [email protected]

THE NEW STANDARD FOR INNOVATION

Australia

Busch Australia Pty. Ltd.

30 Lakeside Drive

Broadmeadows, Vic. 3047

Tel: (03) 93 55 06 00

Fax: (03) 93 55 06 99

Austria

Busch Austria GmbH

Industriepark Nord

2100 Korneuburg

Tel: 02262 / 756 65-0

Fax: 02262 / 756 65-20

Belgium

Busch N.V./Busch SA

Kruinstraat 7

9160 Lokeren

Tel: (0)9 / 348 47 22

Fax: (0)9 / 348 65 35

Brazil

Busch do Brasil Ltda.

Rod. Edgard Máximo Zambotto, Km 64

13240-000 Jarinú-SP

Tel: (55) 11-4016 1400

Fax: (55) 11-4016 1077

Canada

Busch Vacuum Technics Inc.

1740, Boulevard Lionel Bertrand

Boisbriand (Montréal)

Québec J7H 1N7

Tel: 450 435 6899

Fax: 450 430 5132

China

Busch Vacuum (Shanghai) Co., Ltd

18 Bin Yang Road, Shanghai

China 200235

Tel: +86 21 6436 1919

Fax: +86 21 5031 5766

Czech Republic

Busch Vakuum s.r.o.

Pra ákova 10

619 00 Horní Heršpice

Brno

Tel.: +420 543 42 48 55

Fax: +420 543 42 48 56

Denmark

Busch Vakuumteknik A/S

Parallelvej 11

8680 Ry

Tel: +45 87 88 07 77

Fax: +45 87 88 07 88

Finland

Busch Vakuumteknik Oy

Sinikellonpolku 3

01300 VANTAA

Tel: 09 774 60 60

Fax: 09 774 60 666

France

Busch France S.A.

Parc Technologique

de Bois Chaland CE 2922

91029 Evry Cedex

Tel: 01 69 89 89 89

Fax: 01 60 86 16 74

Germany

Dr.-Ing. K. Busch GmbH

Schauinslandstr. 1

79689 Maulburg

Tel: (0 76 22) 6 81-0

Fax: (0 76 22) 6 81-194

e-mail: [email protected]

Busch – All over the World in Industry www.busch-vacuum.com

Dr.-Ing. K. Busch GmbH

Niederlassung Nord

Ernst-Abbe-Str. 1-3

25451 Quickborn

Tel: (0 41 06) 7 99 67-0

Fax: (0 41 06) 7 99 67-77

Dr.-Ing. K. Busch GmbH

Niederlassung West

Nordring 35

64807 Dieburg

Tel: (0 60 71) 92 82-0

Fax: (0 60 71) 14 71

Dr.-Ing. K. Busch GmbH

Niederlassung Süd-Ost

Gewerbestraße 3

90579 Langenzenn

Tel: (09 01) 90 25-0

Fax: (09 01) 90 25-25

Dr.-Ing. K. Busch GmbH

Außenstelle Zella-Mehlis

Am Rain 11

98544 Zella-Mehlis

Tel: (0 36 82) 46 92 71

Fax: (0 36 82) 46 92 73

Ireland

Busch Ireland Ltd.

A10-11 Howth Junction Business Centre

Kilbarrack, Dublin 5

Tel: 00353 1 832 1466

Fax: 00353 1 832 1470

Italy

Busch Italia S.r.l.

Via Ettore Majorana, 16

20054 Nova Milanese

Tel: 0362 370 91

Fax: 0362 370 999

Japan

Nippon Busch K.K.

1-23-33, Megumigaoka

Hiratsuka City, Kanagawa

Japan 259-1220

Tel: 0463-50-4000

Fax: 0463-50-4004

Korea

Busch Korea Ltd.

392-1 Yangji-Ri, Yangji-Myun,

Yongin-si, Kyunggi-Do

Tel: 031) 321-8114

Fax: 031) 321 4330

Malaysia

Busch (Malaysia) Sdn Bhd.

6 Jalan Taboh 33/22

Shah Alam Technology Park

Section 33

40400 Shah Alam

Selangor D. E.

Tel: 03 5122 2128

Fax: 03 5122 2108

Netherlands

Busch B.V.

Pompmolenlaan 2

3447 GK Woerden

Postbus 2091

3440 DB Woerden

Tel: (0)348 - 462300

Fax: (0)348 - 422939

New Zealand

Busch New Zealand Ltd.

Unit D, Arrenway Drive

Albany, Auckland 1311

P O Box 302696

North Harbour, Auckland 1330

Tel: 0-9-414 7782

Fax: 0-9-414 7783

Norway

Busch Vakuumteknikk AS

Hestehagen 2

1440 Drøbak

Tel: 64 98 98 50

Fax: 64 93 66 21

Poland

Busch Polska Sp. z o.o.

UI. Chopina 27

87800 Wtoctawek

Tel: (054) 2315400

Fax: (054) 2327076

Singapore

Busch Vacuum Singapore Pte Ltd

20 Shaw Road

#01-03 Ching Shine Building

Singapore 36 79 56

Tel: (65) 6 408 0866

Fax: (65) 6 288 0877

Spain

Busch Ibérica S.A.

C/. Penedès, 47-49

08192 Sant Quirze del Vallès

Tel: 93 721 77 77

Fax: 93 721 42 07

Sweden

Busch Vakuumteknik AB

Bråta Industriområde

435 33 Mölnlycke

Tel: 031 - 338 00 80

Fax: 031 - 338 00 89

Switzerland

Busch AG

Waldweg 22

4312 Magden

Tel: 061 / 845 90 90

Fax: 061 / 845 90 99

Taiwan

Busch Taiwan Corporation

8F, No.5, Lane 155, Sec. 3, Pei Shen Rd.

Shen Keng Hsiang,

Taipei Hsien,

Taiwan (222), R.O.C

Tel: (02) 2662 0775

Fax: (02) 2662 0796

Turkey

VAKUTEK

Emlak Kredi Ishani No: 179

81130 Üsküdar-Istanbul

Tel: (216) 310 0573

Fax: (216) 343 5126

United Kingdom

Busch (UK) Ltd

Hortonwood 30-35

Telford

Shropshire

TF1 7YB

Tel: 01952 677 432

Fax: 01952 677 423

USA

Busch, Inc.

516 Viking Drive

Virginia Beach, VA 23452

Tel: (757) 463-7800

Fax: (757) 463-7407

Semiconductor Vacuum Group Inc.

Morgan Hill, CA 95037

Tel: (408) 955 1900

Fax: (408) 955 0229

800.777.5624

UltraSource LLC

1414 West 29th Street

Kansas City, MO 64108 USA

Phone 816.753.2150 • Fax 816.753.4976

info@UltraSourceUSA.com • UltraSourceUSA.com

UltraSource Technical Service

Replacement Parts

Toll-Free 800.777.5624

Parts Fax 816.561.2854

Service Fax 816.753.4976

THE NEW STANDARD FOR INNOVATION