ULTRASOURCE ULTRAVAC 2100 Owner'S Manual Download Page 49

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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

5.1

SCHEMA

TICS

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

Summary of Contents for ULTRAVAC 2100

Page 1: ... Vacuum Chamber Packaging Machine Owner s Manual 21 0 0 Effective Serial 5512 860804 Revision AE 02 19 THE NEW STANDARD FOR INNOVATION ...

Page 2: ......

Page 3: ...n 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 Fu...

Page 4: ...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 c...

Page 5: ...e 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 ...

Page 6: ...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 m3 h 117 cfm 5 6 kW 7 hp 8 in Model Only 306 m3 h 180 cfm 7 5 kW 10 hp 360 m3 h 212 cfm 8 9 kW 12 hp Cycle Time 15 25...

Page 7: ...nt WARNING WARNING Explosion hazard Do not use a gas with an oxygen content greater than 22 with gas flush option CAUTION CAUTION Blade hazard Do not remove install or replace blades without protective gloves Perforating knife blade is sharp Use care when handling CAUTION CAUTION Blade hazard Do not remove install or replace blades without protective gloves Precut knife blade is sharp Use care whe...

Page 8: ...fe 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 elect...

Page 9: ...LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 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 ...

Page 10: ...ive 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 Cont...

Page 11: ... 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...

Page 12: ...lug 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 qualifi...

Page 13: ...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 su...

Page 14: ...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 CAUTION CAUTION 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 b...

Page 15: ...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 l...

Page 16: ...he 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 ...

Page 17: ...hine 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 ...

Page 18: ...S GAS 65 GAS YES NO YES PROGRAM NO YES PROGRAM NO 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 t...

Page 19: ...ogram Figure 3 6 ENTER PROGAM 2 RUNNING PROG 1 PROGRAM YES NO PROGRAM YES NO 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 Progra...

Page 20: ...ch 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 b...

Page 21: ... 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 corr...

Page 22: ...et 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 valv...

Page 23: ...t 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 flus...

Page 24: ...re 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 P...

Page 25: ...ption 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 g...

Page 26: ...ut 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 ove...

Page 27: ...izer manufacturers that their products are compatible with the listed materials CAUTION CAUTION 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 und...

Page 28: ...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 ...

Page 29: ...al 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 tensio...

Page 30: ...el 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 ...

Page 31: ...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 oper...

Page 32: ...d 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 he...

Page 33: ...er 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 t...

Page 34: ...m 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...

Page 35: ... 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 secon...

Page 36: ...nting 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...

Page 37: ... 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...

Page 38: ...elated 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 t...

Page 39: ...efore 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...

Page 40: ...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 hou...

Page 41: ...igned 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 ...

Page 42: ...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 ...

Page 43: ...5 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 grea...

Page 44: ...2 Position an oil collection pan underneath the Oil Drain Plug 3 Loosen and remove the Oil Fill Plug with a 1 in open end wrench 4 Loosen the Oil Drain Plug located to the front and lower middle on the pump with a 1 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 han...

Page 45: ...e 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 servi...

Page 46: ...R INNOVATION info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 4 20 MAINTENANCE Maintenance Log Date Maintenance Performed Technician ...

Page 47: ...RD FOR INNOVATION info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 4 21 MAINTENANCE Service Log Date Service Provided Technician ...

Page 48: ...TANDARD FOR INNOVATION info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 4 22 MAINTENANCE THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 49: ...le 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 ...

Page 50: ...STARTUP UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 5 2 SCHEMATICS 230 Volt Single Phase Digital Panel ...

Page 51: ...STARTUP UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 5 3 SCHEMATICS 230 Volt 3 Phase Digital Panel ...

Page 52: ...STARTUP UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 5 4 SCHEMATICS 380 Volt 50 Hz Digital Panel ...

Page 53: ...STARTUP UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 5 5 SCHEMATICS 380 Volt 50 Hz W O Neutral Digital Panel ...

Page 54: ...STARTUP UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 5 6 SCHEMATICS 460 Volt 3 Phase Digital Panel ...

Page 55: ...STARTUP UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 5 7 SCHEMATICS 575 Volt 3 Phase Digital Panel ...

Page 56: ...STARTUP UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 5 8 SCHEMATICS Pneumatic Diagram ...

Page 57: ...906 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 e...

Page 58: ...ous 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 3 4 5 1 ...

Page 59: ...escription 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 860113 Lid Handle 8 860269 Nut M10 Nylon...

Page 60: ...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 861002 Bladde...

Page 61: ...sas City MO 64108 3604 USA 800 777 5624 816 753 2150 THE NEW STANDARD FOR INNOVATION info UltraSourceUSA com UltraSourceUSA com 6 5 PARTS Lid Internal Diagram WITH PERFORATION KNIFE 4 21 5 3 6 1 7 20 17 19 5 11 8 13 9 18 15 16 10 10 6 14 12 2 ...

Page 62: ...0 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 861164 Bolt 3 4 10 Thread x 3 3 4 in Hex ...

Page 63: ...st 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 THE NEW STANDARD FOR INNOVATION info UltraSourceUSA com UltraSourceUSA com 6 7 PARTS Legs and Pump Diagram 1 2 3 4 5 6 7 8 9 9 10 11 13 12 13 16 15 14 12 ...

Page 64: ...753 2150 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 3 1 ...

Page 65: ...ts 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 4 1 ...

Page 66: ... 753 2150 6 10 PARTS Single Seam Seal Bar Parts List and Diagram Item No Description 861001 Single Seam Seal Bar Complete 1 880746 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 1 3 ...

Page 67: ...te 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 Val...

Page 68: ...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 ...

Page 69: ... West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 THE NEW STANDARD FOR INNOVATION info UltraSourceUSA com UltraSourceUSA com 6 13 PARTS Main Electrical Components Diagram 6 10 9 8 5 2 4 5 11 7 3 3 1 ...

Page 70: ...y 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 hp Pump Harness 460V 10 and 12 hp 861046 Pump Harness 3...

Page 71: ...ce LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 THE NEW STANDARD FOR INNOVATION info UltraSourceUSA com UltraSourceUSA com 6 15 PARTS 10 9 9 6 8 7 4 3 3 1 2 11 5 Base Diagram ...

Page 72: ...s 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 r...

Page 73: ... MO 64108 3604 USA 800 777 5624 816 753 2150 THE NEW STANDARD FOR INNOVATION info UltraSourceUSA com UltraSourceUSA com 6 17 PARTS 2 1 3 4 6 7 8 9 10 5 5 Gas Flush Diagram 861344 861345 835514 9 THESE NOZZLES APPLY TO SERIAL NUMBERS 6108 AND 6046 ONLY ...

Page 74: ...ess Steel Serial 4606 Current 4 861157 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 860114 Lid Lever 860111 Lid Leve...

Page 75: ...t 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 THE NEW STANDARD FOR INNOVATION info UltraSourceUSA com UltraSourceUSA com 6 19 PARTS 1 2 5 8 6 7 4 3 15 14 12 11 7 10 9 16 7 13 Swing Arm Assembly Diagram ...

Page 76: ...624 816 753 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 ...

Page 77: ...ol 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 8...

Page 78: ... 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 ...

Page 79: ...FERENCE 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 ...

Page 80: ...INSTALLATION AND OPERATING MANUAL R5 Series Current Models 0025 0040 0063 0100 and 0250 Single Stage Rotary Vane Vacuum Pumps ...

Page 81: ......

Page 82: ...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...

Page 83: ... 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 ti...

Page 84: ... 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...

Page 85: ...s 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 f...

Page 86: ...por 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 p...

Page 87: ...ous 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 6 Warning This pump is filled with a s...

Page 88: ...ed 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 ar...

Page 89: ...th 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 var...

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Page 92: ...ing 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 Hy...

Page 93: ...12 13 ...

Page 94: ...reign 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 ...

Page 95: ...ion 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 Maint...

Page 96: ...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 adj...

Page 97: ...els 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 cartrid...

Page 98: ... 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 p...

Page 99: ... 250 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 ...

Page 100: ...he 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 Permi...

Page 101: ...21 Maximum oil temperature with 80 F ambient temperature and no supplemental oil cooling ...

Page 102: ...22 ...

Page 103: ...2 926 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 Texas 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 ...

Page 104: ...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 ...

Page 105: ......

Page 106: ...cedure 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 a...

Page 107: ...red 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 ey...

Page 108: ...d 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 fore...

Page 109: ...ew 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 ball...

Page 110: ...he 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 conduct...

Page 111: ...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 tivel...

Page 112: ...ter 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 sampl...

Page 113: ...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 ass...

Page 114: ... 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 l...

Page 115: ...gs 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 nomina...

Page 116: ...ure 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 opti...

Page 117: ...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...

Page 118: ...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 13 ...

Page 119: ...allast 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 2...

Page 120: ...RA 0165 0205 0255 0 0305 D Ref BMC Dwg T111 911 728 D 15 Fig 5 Exploded View Drawing of Pump ...

Page 121: ... 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 service nj buschinc com Fax 787 798 5033 service pr buschinc com 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 ...

Page 122: ...owth 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...

Page 123: ...ansas 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 ...

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ULTRASOURCE ULTRAVAC 2100, Owner'S Manual

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