BUSCH SIMPLEX Operating Instructions Manual Download Page 1

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Operating instructions

SIMPLEX

Vacuum systems

VD 0025 G – 0063 G – 0100 G

0870169324/-0006_en / Translation of the original operating instructions / Subject to change without notice

16.11.2021

Dr.-Ing. K. Busch GmbH

Schauinslandstraße 1

79689 Maulburg

Germany

Summary of Contents for SIMPLEX

Page 1: ...SIMPLEX Vacuum systems VD 0025 G 0063 G 0100 G 0870169324 0006_en Translation of the original operating instructions Subject to change without notice 16 11 2021 Dr Ing K Busch GmbH Schauinslandstraße 1 79689 Maulburg Germany ...

Page 2: ...2 46 0870169324_VD 0025 0100G_ 0006_IM_en ...

Page 3: ... 5 Storage 13 6 Installation 14 6 1 Installation 14 6 2 Connection lines pipes 15 6 2 1 Gas inlet 15 6 2 2 Gas outlet 16 6 3 Electrical connection 17 6 3 1 Connection of the power supply 17 7 Start up 18 7 1 Indication and control elements 18 7 1 1 Topping up with oil 18 7 1 2 Display and control elements at the switching and control cabinet 19 7 1 3 Indicators and control elements on the vacuum s...

Page 4: ... Spare parts and accessories 30 10 1 Spare parts 30 11 Repair 31 12 Decommissioning and disposal 32 12 1 Stop operating vacuum system 32 12 2 Disassembly and disposal 32 13 Dimensions sheets 33 14 Connection values of the vacuum system VD 39 14 1 Connection values 39 15 Technical data 40 16 Oil 41 17 EU Declaration of conformity 43 ...

Page 5: ...ig 4 Transport of the vacuum system 11 Fig 5 Transport of the vacuum pump on the eye bolts 12 Fig 6 Installation environment 14 Fig 7 Gas outlet 16 Fig 8 Topping up oil 19 Fig 9 Switch and control cabinet 19 Fig 10 Contact vacuum gauge 20 Fig 11 Drain oil 23 Fig 12 Replacing the oil filter 24 Fig 13 Filling in oil 24 Fig 14 Remove exhaust filter 25 Fig 15 Insert and tighten the new exhaust filter ...

Page 6: ...ctions Safety and warning notes are marked as follows with the words DAN GER WARNING CAUTION ATTENTION and NOTE DANGER Indicates a threatening hazard Failure to observe safety instructions will result in death or serious injury WARNING Indicates a potential hazard Failure to observe safety instructions may result in death or se rious injury CAUTION Indicates a potential hazard Failure to observe s...

Page 7: ...duct description 3 1 View vacuum system VD IN Gas inlet CC Switch and control cabinet OUT Gas outlet AF Air filter INO Gas inlet optional VV Venting valve RVP Rotary vane vacuum pump RA CPG Contact vacuum gauge NP Name plate VST Vacuum vessel Fig 1 View vacuum system VD ...

Page 8: ...e vacuum pump type R5 RA The vacuum pump is mounted on a vacuum vessel The intake side air filter and the strainer installed in the suction flange prevent the ingression of dirt particles in the vacuum pump The gas ballast valve is used for the addition of a limited quantity of ambient air to the pro cess gas to counteract the condensation of vapor in the vacuum pump In the vacuum vessel is a cont...

Page 9: ...he oil fil ter cleans the circulating oil Then the exhaust filters separate the oil from the discharged gas 3 4 3 Gas ballast valve The vacuum pump is equipped with a gas ballast valve The gas ballast valve is used for the addition of a limited quantity of ambient air to the process gas to counteract the condensa tion of vapor in the vacuum pump The gas ballast valve reduces the final pressure of ...

Page 10: ...rain on the pipe work and vacuum pumps while placing the slings Observe the center of gravity and the lifting points these are indicated in the scale draw ings see chap 13 ATTENTION Damage to the vacuum system The vacuum system is already filled with oil at delivery Drain the oil before transport if transport in horizontal orientation is not possible The vacuum system is packed in a wooden crate I...

Page 11: ...m by devices of the individual components e g the vacuum pump motor etc Only lift the vacuum system as presented Fig 4 Transport of the vacuum system Screw four M10 eye bolts not included in the scope of delivery into the holes on the feet of the vacuum vessel see fig 4 Pass slings through the openings of the eye bolts and thus lift the vacuum system with a crane or a forklift ...

Page 12: ...m pump only as shown ATTENTION Damage to the vacuum system The vacuum system is already filled with oil at delivery Tilting a vacuum pump that is already filled with oil can cause large amounts of oil to enter the cylinder If the vacuum pump is started while there are excessive amounts of oil in the cylinder this will damage the sliders resulting in a total damage of the vacuum pump Drain the oil ...

Page 13: ...30 minutes eve ry 18 months Proceed as follows for storage Close all openings with the protective caps included in the scope of delivery penetration of dirt and water is prevented If storage for more than 3 months is intended Secure loose cables Drain all process and operating media Clean and dry the vacuum system Prior to storing make absolutely sure that all parts are clean drained and dry Where...

Page 14: ...ion class of the vacuum pump The installation site must be vented so that sufficient cooling of the vacuum system is en sured Ensure that the ventilation openings inlets and outlets are not covered and that the cool ing air can flow unhindered Sufficient space for maintenance work must be ensured Visibility of the oil sight glass OSG fig 2 must be ensured at all times Check the oil level and top u...

Page 15: ...on the intake and pressure sides at an angle to prevent accumulated con densation from entering the vacuum pump The line cross section of the connection lines must have at least the same cross section as the connections of the vacuum system across the entire length In case of very long connection lines it is recommended to use lines with larger cross sections to avoid loss of efficiency Please con...

Page 16: ... Dimensions see scale drawing in the appendix connection size of thread G 1 Ensure that the discharged gas can flow off unhindered Never close the gas outlet line do not throttle it and do not use it as a compressed air source If the air taken in is not discharged to the environment in the direct proximity of the vacuum system observe the following Place the gas outlet line dropping towards the va...

Page 17: ...TTENTION Danger of damage to the vacuum system Wrong connection Wire the vacuum system according to the circuit diagram in the switch and control cabinet Procedure Ensure that the power supply for the vacuum system corresponds to the specifications in the circuit diagram Ensure that the vacuum system is not impaired by electrical or electromagnetic impulses of the power supply Contact Busch if nec...

Page 18: ...ump during and directly after operation ATTENTION Insufficient familiarity with the indicators and operating controls may result in damage to the vacuum system Wrong operation Operating staff must be familiar with the indicating and operating elements ATTENTION Operation of the vacuum pump without oil will cause severe damage to it quickly The vacuum system is already filled with oil at delivery T...

Page 19: ...lights up red when there is an error Operating hours counter 101T1 Displays the operating hours Main switch 100Q1 Switch for switching the supply voltage on and off 7 1 3 Indicators and control elements on the vacuum system The indicating devices are as follows Contact vacuum gauge CPG fig 1 Indicates the pressure in the vacuum vessel The switch on and switch off value pressure range is set on the...

Page 20: ...g accuracy switching safety and service life of the mechanical measuring systems the switching points should be between 10 and 90 of the measuring range Set the set pointers to desired activation and shutdown pressures The clearance between the two set pointers is approx 10 of the scale range When the lower switching point is reached the vacuum pump is switched off and correspond ing when the uppe...

Page 21: ...the pushbutton 101S1 fig 9 on the switch and control cabinet The vacuum pump switches on and off depending on the pressure The vacuum system is in operation Stopping the vacuum system Press the pushbutton 101S1 fig 9 on the switch and control cabinet The motor switches off Set the main switch 100Q1 fig 9 to OFF 7 3 Conveying condensing vapors A certain quantity of water vapor within the gas flow i...

Page 22: ...nce values and should be individually short ened or extended Especially at high stress e g in case of high dust load in the environment or the process gas or in case of other contamination or ingression of process material it may be necessary to shorten the maintenance intervals a lot Interval Maintenance task Rotary vane vacuum pump R5 RA daily Check the oil level see chap 8 2 Monthly Check the v...

Page 23: ...e checking the oil level Top up with oil if necessary 8 3 Oil and oil filter change ATTENTION Operation of the vacuum pump without oil will cause severe damage to it quickly Only use oils approved by Busch For information to the oil type and oil volume see the technical data chap 15 and oil chap 16 Follow the figures Fig 11 Drain oil 1 x sealing ring part no 0486 000 505 Drain pan ...

Page 24: ...9324_VD 0025 0100G_ 0006_IM_en Fig 12 Replacing the oil filter Fig 13 Filling in oil Original spare parts from Busch 1 x oil filter OF part no 0531 000 002 Oil filter wrench 1 x sealing ring part no 0486 000 590 Check oil level ...

Page 25: ...tighten the new exhaust filter 10 mm wrench RA 0025 0040 F 1 x exhaust filter EF RA 0063 0100 F 2 x exhaust filter EF 10 mm wrench Original spare parts from Busch RA 0025 0040 F 1 x exhaust filter EF part no 0532 140 156 RA 0063 0100 F 2 x exhaust filter EF part no 0532 140 157 O ring RA 0025 0040 F 1 x gasket RA 0063 0100 F 2 x gasket Part no 0480 000 112 ...

Page 26: ...025 0100G_ 0006_IM_en 8 5 Changing the air filter insert Fig 16 Changing the air filter insert Proceed as follows Open the quick clamps and remove the filter insert Insert a new filter Original spare part from Busch Parts no 0532 000 003 ...

Page 27: ...pump is disconnected from the electrical supply and secured against uninten tional start up vacuum system and pipes are not under pressure hot surfaces are cooled down Disconnect the vacuum system from the process and make sure that there is ambient pres sure in the vacuum system Procedure Close the shut off device on the inlet side not includ ed in the scope of delivery and slowly open the ventin...

Page 28: ...e the air filter insert The venting valve VV fig 1 is open Close the venting valve The oil level is too low Top up oil Inner components are worn or damaged Have the vacuum pump repaired Busch Service Leak in piping system Locate and repair leakage High noise development during operation of the vacuum pump The bearings are defec tive Have the vacuum pump repaired Busch Service The coupling CPL fig ...

Page 29: ...l is black The periods between the oil changes are too long Flush the vacuum pump Please contact your con tact person from Busch for this The air filter AF fig 1 is defective Replace air filter There is a high heat devel opment during operation of the vacuum pump See High noise develop ment during operation of the vacuum pump The oil is emulsified Liquids or large amounts of vapors have been sucke...

Page 30: ...1 x maintenance kit RA 0025 D 0992 101 463 1 x air filter insert paper for suc tion filter 0532 000 003 1 x vacuum pump oil VM 100 package size 1 liter 0831 000 060 Maintenance kit VD 0063 0100 G Contains all spare parts needed for maintenance comprising 0992 S01 701 1 x maintenance kit RA 0063 F RA 0100 F 0992 106 214 1 x air filter insert paper for suc tion filter 0532 000 003 1 x vacuum pump oi...

Page 31: ...he vacuum pump was used to transport gas contaminated with for eign substances hazardous to health Decontaminate the vacuum pump and indicate the contamination status based on a Con formation declaration Busch accepts only vacuum pumps that include a completed and legally signed Contamina tion declaration The form can be downloaded from www buschvacuum com ...

Page 32: ...re Disconnect all connections If the vacuum system has to be stocked observe following For more information see storage chap 5 12 2 Disassembly and disposal Drain the oil Remove the exhaust filters Remove the oil filter Remove all electrical components Separate the hazardous waste from the vacuum pump Dispose of hazardous waste according to the applicable legal provisions Dispose of the vacuum sys...

Page 33: ... system VD 0025 G AAA TAXX Fig 18 Dimensions vacuum system VD 0025 G AAA TAXX Center of gravity Lifting point Pos Designation Connection Standard N1 Gas inlet G 1 1 4 female thread ISO 228 1 N2 Gas outlet G 1 1 4 female thread ISO 228 1 N3 Venting valve Tab 1 Connections vacuum system VD 0025 G AAA TAXX ...

Page 34: ...5 G AAA TAAX mobile Fig 19 Dimensions vacuum system VD 0025 G AAA TAAX mobile Center of gravity Pos Designation Connection Standard N1 Gas inlet G 1 1 4 female thread ISO 228 1 N2 Gas outlet G 1 1 4 female thread ISO 228 1 N3 Venting valve Tab 2 Connections vacuum system VD 0025 G AAA TAAX mobile ...

Page 35: ...0063 G AAA TCXX Fig 20 Dimensions vacuum system VD 0063 G AAA TCXX Center of gravity Lifting point Pos Designation Connection Standard N1 Gas inlet G 1 1 4 female thread ISO 228 1 N2 Gas outlet G 1 1 4 female thread ISO 228 1 N3 Venting valve Tab 3 Connections vacuum system VD 0063 G AAA TCXX ...

Page 36: ...3 G AAA TCAX mobile Fig 21 Dimensions vacuum system VD 0063 G AAA TCAX mobile Center of gravity Pos Designation Connection Standard N1 Gas inlet G 1 1 4 female thread ISO 228 1 N2 Gas outlet G 1 1 4 female thread ISO 228 1 N3 Venting valve Tab 4 Connections vacuum system VD 0063 G AAA TCAX mobile ...

Page 37: ...0100 G AAA TDXX Fig 22 Dimensions vacuum system VD 0100 G AAA TDXX Center of gravity Lifting point Pos Designation Connection Standard N1 Gas inlet G 1 1 4 female thread ISO 228 1 N2 Gas outlet G 1 1 4 female thread ISO 228 1 N3 Venting valve Tab 5 Connections vacuum system VD 0100 G AAA TDXX ...

Page 38: ...0 G AAA TDAX mobile Fig 23 Dimensions vacuum system VD 0100 G AAA TDAX mobile Center of gravity Pos Designation Connection Standard N1 Gas inlet G 1 1 4 female thread ISO 228 1 N2 Gas outlet G 1 1 4 female thread ISO 228 1 N3 Venting valve Tab 6 Connections vacuum system VD 0100 G AAA TDAX mobile ...

Page 39: ...current Max perm pre fuse VD 0025 G 3 x 380 400 V AC PE 230 V AC 50 Hz 1 5 kW 3 A 16 A VD 0063 G 3 x 380 400 V AC PE 230 V AC 50 Hz 2 5 kW 5 A 16 A VD 0100 G 3 x 380 400 V AC PE 230 V AC 50 Hz 3 0 kW 6 A 16 A Tab 7 Connection values of the vacuum systems VD ATTENTION Damage to the drives Before commissioning the circuit breaker 101Q1 must be set to the rated current of the motor see circuit diagra...

Page 40: ... 2 7 Connected load switch and control cabinet 50 Hz kW 1 5 2 5 3 0 Sound pressure level according to EN ISO 2151 at 50 Hz dB A 60 64 65 Max water vapor compatibility with gas ballast valve at 50 Hz hPa mbar 40 Water vapor capacity with gas ballast valve 50 Hz kg h 0 9 1 8 2 8 Ambient temperature range C see oil chap 16 Ambient pressure Atmospheric pressure Oil volume l 1 0 2 0 2 0 Oil type see oi...

Page 41: ...ng 0831 000 060 0831 163 968 0831 168 356 0831 168 351 Part number 5 l packaging 0831 000 059 0831 136 969 0831 168 357 0831 168 352 Check the name plate NP fig 2 to see which oil the vacuum pump was filled with for applications in the food industry H1 corrosion protection not suitable for continuous operation If necessary an oil with a different viscosity can be used for unfavorable room temperat...

Page 42: ...42 46 0870169324_VD 0025 0100G_ 0006_IM_en ...

Page 43: ...ances in electrical and electronic devices and according to the corresponding standards Standard Name of the standard EN ISO 12100 2010 Safety of machinery General principles for design risk assessment and risk reduction EN ISO 13857 2019 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs EN 1012 1 2010 EN 1012 2 1996 A1 2009 Compressors and vacuum ...

Page 44: ...44 46 0870169324_VD 0025 0100G_ 0006_IM_en ...

Page 45: ...Notes ...

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