ULTRASOURCE Ultravac 500 Owner'S Manual Download Page 3

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Think

UltraSource

First

. • [email protected] • UltraSourceUSA.com

INTRODUCTION

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

TABLE OF CONTENTS

General III
Specifications IV
Machine Conformity

CE Declaration of Conformity

SAFETY

Personal Safety

1.1

Food Safety

1.2

General Safety Guidelines

1.2

STARTUP

Unpacking 2.1
Power Requirements

2.1

Grounding Instructions

2.1

Vacuum Pump

2.2

Gas Flush Connection

2.2

Air-Assist Connection

2.2

Checking Vacuum Pump Rotation

2.2

OPERATION

Placement of Product

3.1

Operation with Analog Control Panel 3.2
Operation with Digital Control Panel 3.3
Operator Menu on Digital Panel

3.4

Selecting a New Program

3.5

Sealing with Air-Assist

3.6

Gas Flush Option

3.6

Double Seam Seal Option

3.6

MAINTENANCE

Prior to Cleaning

4.1

Cleaning Recommendations

4.1

Vacuum Pump Maintenance

4.2

Seal Bar Maintenance

4.2

Reading the Indicators

4.3

Troubleshooting 4.3
Supervisor Menu on Digital Panel

4.5

Opening Chamber Machine

4.8

Changing Vacuum Pump Oil

4.9

Replacing Potentiometer

4.9

Replacing Power Cord

4.10

Maintenance Log

4.10

Service Log

4.10

SCHEMATICS

Designation and Function of Controls 5.1
230 Volt, Single Phase, Analog Panel 5.2
230 Volt, 3 Phase, Analog Panel

5.3

380 Volt, 50 Hz, 3 Phase, Analog Panel 5.4
230 Volt, Single Phase, Digital Panel 5.5
230 Volt, 3 Phase, Digital Panel

5.6

380 Volt, 50 Hz, 3 Phase, Digital Panel 5.7
Non-Gas Flush Pneumatic Diagram

5.8

Gas Flush Pneumatic Diagram

5.9

PARTS

Recommended Spare Parts

6.1

Pump and Chassis

6.2

Seal Bar

6.4

Lid and Hinge System

6.6

Gas Flush Components

6.8

Main Control - Front Side

6.10

Analog Control Panel

6.12

Digital Control Panel

6.14

Main Control - Back Side

6.15

Mebner Valve

6.16

Miscellaneous Machine Parts

6.17

Inline Filter Kit (Optional)

6.18

REFERENCE MANUALS

R5 Series Vacuum Pumps

7.1

INDEX

INDEX 8.1

Summary of Contents for Ultravac 500

Page 1: ... 5 0 0 Vacuum Chamber Packaging Machine Think UltraSource First Owner s Manual Effective Serial 2247 860052 Revision U 06 01 2013 ...

Page 2: ......

Page 3: ...ecommendations 4 1 Vacuum Pump Maintenance 4 2 Seal Bar Maintenance 4 2 Reading the Indicators 4 3 Troubleshooting 4 3 Supervisor Menu on Digital Panel 4 5 Opening Chamber Machine 4 8 Changing Vacuum Pump Oil 4 9 Replacing Potentiometer 4 9 Replacing Power Cord 4 10 Maintenance Log 4 10 Service Log 4 10 SCHEMATICS Designation and Function of Controls 5 1 230 Volt Single Phase Analog Panel 5 2 230 ...

Page 4: ...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 Tol...

Page 5: ... 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 Locatio...

Page 6: ...5 in Width B 610mm 24 in Maximum Height C 1334mm 52 5 in Working Height D 892mm 35 125 in Seal Bar Length 457mm 18 in Chamber Length E 648mm 25 5 in Chamber Width F 489mm 19 25 in Chamber Height G 229mm 9 in Between Seal Bars H 537mm 21 125 in Vacuum Pump 48m3 h 28cfm 1 5kW 2 hp 70m3 h 41cfm 2 2kW 3 hp Net Weight 160 kg 353 lbs Electrical Connection See Power Requirements in Section 2 Capacity 20 ...

Page 7: ... 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 500 is manufactured...

Page 8: ...NTRODUCTION UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 800 777 5624 816 753 2150 VI UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA T 816 753 2150 F 816 753 4976 ...

Page 9: ...injury or damage to equipment WARNING Explosion hazard Do not use a gas with an oxygen content greater than 22 with gas flush option CAUTION Blade hazard Do not remove install or replace blades without protective gloves Perforating knife blade is sharp Use care when handling CAUTION Blade hazard Do not remove install or replace blades without protective gloves Precut knife blade is sharp Use care ...

Page 10: ...dified 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 yo...

Page 11: ...ding conductor cord 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 t...

Page 12: ...um regulator pressure is 15 p s i DANGER OXYGEN ENRICHED USE ULTRAVAC 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 NECES...

Page 13: ...he 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 3 1 below on use of filler plates Use Filler Plates for raising the height of the product Lay the pouch flat on the seal area keeping the pouch free of wrinkles Pla...

Page 14: ...al setting of 3 on the dial Seal impulse is the length of time the seal bar is turned on and can range from 0 to 2 seconds The impulse time is controlled by the Seal Potentiometer UltraSource recommends an initial setting of 6 on the potentiometer This setting will vary according to the thickness of the pouch Thinner pouches will require a lower setting while thicker pouches will require a higher ...

Page 15: ...ons 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 sea...

Page 16: ...SEAL SETTING IS IN SECONDS CHANGE THE SEAL TIME THE RANGE IS 30 TO 99 THE RANGE IS 0 TO 2 SECONDS THE RANGE IS 0 TO 20 SECONDS PRESS THE MENU KEY PRESS THE MENU KEY PRESS THE MENU KEY NO PROGRAM YES NO YES PROGRAM NO YES PROGRAM YES PROGRAM NO Operator Menu on Digital Panel NOTE If the supervisor has set security on these settings cannot be changed This is the Main Menu screen When the machine sta...

Page 17: ...a gas with an oxygen content greater than 22 with gas flush option 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...

Page 18: ...l area or when using the Double Seam Seal 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...

Page 19: ...ble with the listed materials 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 under warranty 1 Filler Plates Remove filler plates The fille...

Page 20: ...s time loosen the set screw and remove the old spring retainer and spring and install the new ones Adjust the spring retainer to allow an 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 TEFLON TAPE CUT OFF WIRE SEAL ELEMENT SET SCREW 2mm ALLEN WRENCH TIGHTENING TOOL BRASS CONTACT SLOTTED TIP SCREWDRI...

Page 21: ... problem in the control module 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 2 replace if blown Vacuum pump does not run Make sure that the power requirements match those given on the nameplate No vacuum When lid is closed indicator li...

Page 22: ...clockwise or if air assist is used set to the recommended pressure Check seal bladder valve SOL 2 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 to 1 second or does not l...

Page 23: ...ow 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 ...

Page 24: ...s 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...

Page 25: ...C allows for a more controlled vacuuming 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 set vacuum level Press the MENU Key This is the vacuum reached by pulsing the vacuum valve before the vacuum valve opens completely to fully evacuate the chamber The range is 99 to 20 Press the MENU Ke...

Page 26: ...time out if the preset vacuum is not reached in 30 seconds and the machine will complete the cycle If set ON and the machine does not reach the preset vacuum in 30 seconds then the panel will display VAC ERROR and vent the chamber without sealing Opening Chamber Machine 1 Turn the power switch to the OFF position and disconnect the power cord from the wall receptacle DANGER Hazardous voltage Disco...

Page 27: ...th the oil drained replace the Oil Drain Plug and wipe away any excess oil 5 Fill the pump with oil until the level is between the minimum and maximum lines on the Oil Sight Glass Replace the Oil Filler Cap 6 Plug the power cord back into the wall receptacle 7 Cycle the machine a couple of times unplug and check the Oil Level Add oil if necessary Replace the rear panel using the provided screws Re...

Page 28: ...r cord to the control panel as shown in the table below Connect to Terminal 110 Volt Wire Color 230 Volt Wire Color Terminal 8 Green Ground Green Yellow Terminal 7 White Brown Terminal 6 Black Blue 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 maintena...

Page 29: ...ce First info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 4 11 MAINTENANCE Maintenance Log Date Maintenance Performed Technician ...

Page 30: ...rce First info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 800 777 5624 816 753 2150 4 12 MAINTENANCE MAINTENANCE Service Log Date Service Provided Technician ...

Page 31: ...s and Relays C 1 Vacuum Pump Contactor C 2 Seal Impulse Contactor Overloads and Fusing OL 1 Vacuum Pump Motor F 1 Seal Bar Fuse F 2 Control Power Fuse Control Modules MCM Master Control Module Control Lights LT 1 On Off Control Power Light Green LT 2 Seal Impulse On Light Red Transformers T 1 Seal Impulse T 2 Control Power Motors M 1 Vacuum Pump Potentiometers POT 1 Vacuum Time POT 2 Gas Flush Tim...

Page 32: ...traSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 SCHEMATICS Think UltraSource First info UltraSourceUSA com UltraSourceUSA com 230 Volt Single Phase Analog Panel ...

Page 33: ...UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 SCHEMATICS Think UltraSource First info UltraSourceUSA com UltraSourceUSA com 230 Volt 3 Phase Analog Panel ...

Page 34: ...raSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 SCHEMATICS Think UltraSource First info UltraSourceUSA com UltraSourceUSA com 380 Volt 50 Hz 3 Phase Analog Panel ...

Page 35: ...raSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 SCHEMATICS Think UltraSource First info UltraSourceUSA com UltraSourceUSA com 230 Volt Single Phase Digital Panel ...

Page 36: ...UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 SCHEMATICS Think UltraSource First info UltraSourceUSA com UltraSourceUSA com 230 Volt 3 Phase Digital Panel ...

Page 37: ...raSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 SCHEMATICS Think UltraSource First info UltraSourceUSA com UltraSourceUSA com 380 Volt 50 Hz 3 Phase Digital Panel ...

Page 38: ...ltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 SCHEMATICS Think UltraSource First info UltraSourceUSA com UltraSourceUSA com Non Gas Flush Pneumatic Diagram ...

Page 39: ...UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 SCHEMATICS Think UltraSource First info UltraSourceUSA com UltraSourceUSA com Gas Flush Pneumatic Diagram ...

Page 40: ... ea 860029 Lid Switch 5 ft 860035 Seal Bar Cut Wire 1 ea 860037 Vent Valve 2 qt 884755 Vacuum Pump 30W ND Oil 1 ea Specify Pump Vacuum Pump Oil Filter 1 ea 861003 Bladder Assembly Select your machine s configuration 1 ea 863088 Single Seam and Cut Wire Contact Kit 1 ea 863081 Double Seam Contact Kit For Analog Control Panel 5 ea 860337 Fuse for Control Power 1A 1 ea 860313 Potentiometer Evacuation...

Page 41: ... 860047 Rigid Caster 4 840121 Swivel Caster 5 860800 Oil Drain Extension 6 860799 Oil Drain Gasket 7 866775 Washer 8mm Flat 8 860287 Bolt M8x12 Hex Head 9 866246 Plug 10 866844 Screw M6x20 Flat Socket Head 11 860187 Vacuum Block Cover 12 860188 Vacuum Block Spacer 13 860148 Vacuum Block O Ring 14 860186 Vacuum Block 15 860140 Hose Barb 1 50 in 16 860151 Cover for 2 hp Pump 860152 Cover for 3 hp Pu...

Page 42: ...t info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 6 3 PARTS Pump and Chassis Diagram 4 3 7 8 8 6 5 16 17 18 19 1 15 14 13 12 11 10 9 2 ...

Page 43: ...t for Bladder two per bladder 866777 M12 Flat Washer for Seal Bladder M12 Hex Nut for Seal Bladder 4 860990 Fiberglass Insulator Strip 5 860034 Sealing Element 6 860035 Cutting Wire 7 840170 Teflon Tape 8 860033 Brass Electrical Contact 9 860278 Set Screw M4x4 Socket 10 Seal Bar Spade See Seal Bar Wire Assemblies 11 860270 Screw M4x12 Slotted Panhead 12 Wire for Seal Bar See Seal Bar Wire Assembli...

Page 44: ...ource First info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 6 5 PARTS Seal Bar Diagram 12 13 14 2 16 15 1 6 4 5 7 8 9 10 11 3 ...

Page 45: ...ock Assembly inludes inserts 7 861322 Hinge Block Assembly includes inserts 8 860150 Shaft Stainless Steel Tube 1 4 in x 11 in Long 9 860038 Gas Spring 10 860026 Anchor Block 11 860028 Ball Stud 10mm 12 860073 Gas Spring Disconnect 13 860252 Screw M5x12 Slotted Flathead 14 866773 Washer 5mm Flat 15 860256 Screw M5x12 Slotted Panhead 16 860286 Bolt M5x40 Hex Head 17 860029 Lid Switch 18 866729 Caps...

Page 46: ...urceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 6 7 PARTS Lid and Hinge System Diagram 1 17 15 2 3 4 5 13 7 8 6 12 9 11 10 14 15 18 17 24 19 23 21 20 22 18 21 22 ...

Page 47: ...er side 5 860107 Plastic Hose Tee 1 4 in 6 860014 Gas Holddown 7 860691 Gas Holddown Pad 846008 Double Sided Foam Tape for Gas Holddown 8 860118 Gas Nozzle 9 866273 Fitting Aluminum Elbow 10 860548 Gas Hose Blue Connect E E F F G G H H to front and rear nozzles 11 866254 Fitting Alumimum Tee 12 835572 Hose Barb 1 4 in x 1 4 in Elbow 13 861217 Gas Valve SOL 2 2 way Normally Closed 14 840371 DIN Plu...

Page 48: ...4 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 6 9 PARTS Gas Flush Components Diagram 1 3 1 2 5 A A B C Port A To Bladder 20 19 16 17 18 12 Port R To Vacuum B 14 13 12 15 J D 5 11 3 To Other Side C D To Rear Nozzle To Front Nozzle H H G J G E F F E 9 8 6 7 12 ...

Page 49: ...mer 750VA T1 2 860311 Control Power Transformer 50VA T3 3 860041 Seal Contactor 4 860256 Screw M5x12 Slotted Panhead 5 866713 Screw M4x6 Slotted Panhead 6 860341 Terminal Stop Block 7 860160 Pump Contactor 8 860175 Pump Overload 3PH 3 horsepower 860010 Pump Overload 3PH 2 horsepower 860176 Pump Overload 1PH 2 horsepower 9 860339 Control Power Fuse Holder 860337 Control Power Fuse GMC 1A F3 10 8603...

Page 50: ...e First info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 6 11 PARTS 4 2 4 5 3 1 6 7 8 9 6 10 11 12 Main Control Front Side Diagram ...

Page 51: ...otentiometer Knob Only 6 860303 Yellow Cap for Potentiometer Knob Optional with Gas Flush 860315 Potentiometer Knob Only 7 860301 Red Cap for Potentiometer Knob 860315 Potentiometer Knob Only 8 860313 Potentiometer for Vacuum POT 1 and Gas POT 2 Optional with Gas Flush 860450 Vacuum Potentiometer POT 1 for Special Produce Product 9 860314 Sealing Potentiometer POT 3 Standard for Extended Seal Time...

Page 52: ...UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 6 13 PARTS Analog Control Panel Diagram 1 2 3 3 4 5 6 7 8 9 10 19 18 17 13 14 12 11 15 16 18 20 21 ...

Page 53: ... LLC 1414 West 29th Street Kansas City MO 64108 3604 800 777 5624 816 753 2150 6 14 PARTS PARTS Digital Control Panel Parts List and Diagram Item No UltraSource Part No Description 1 860995 Front Panel Assembly 2 860637 Vacuum sensor 3 860316 Main Power On Off Switch SW 1 3 3 2 1 ...

Page 54: ...Description 1 861216 Seal Pilot Valve SOL 3 3 way Normally Closed 2 835572 Hose Barb 1 4 in x 1 4 in Elbow 3 860511 Hose Barb 1 4 in x 1 8 in Elbow 4 861221 Screw 10 32 x 7 16 in 5 890643 Grommet 17 64 in ID x 13 32 in OD 6 890640 Grommet 3 8 in ID x 5 8 in OD 7 860774 Grommet 3 4 in ID x 1 1 2 in OD 8 840371 DIN Plug Not Shown 9 861019 Valve Harness 34 in LG Not Shown 1 2 2 3 5 4 6 7 5 7 Port R T...

Page 55: ... 16 PARTS PARTS Mebner Valve Parts List and Diagram Item No UltraSource Part No Description 1 860967 Valve Mebner Vacuum and Vent 2 889559 Fitting 1 in 90 Elbow SS 3 860141 Nipple Close 1 in 4 860969 Hose Barb 1 in NPT x 1 in ID Hose 5 860119 Hose Clamp 1 in 6 860040 Vacuum Hose 1 in 7 860106 Hose 1 4 in Reinforced Air 860908 Coil Mebner Valve 1 4 2 3 5 6 7 ...

Page 56: ...ty MO 64108 3604 USA 800 777 5624 816 753 2150 6 17 PARTS 2 1 Miscellaneous Machine Parts Parts List and Diagram Item No UltraSource Part No Description 1 860050 Filler Plate Set 2 860051 Stainless Steel Product Tray 3 860124 Magnetic Stop for Product Tray 4 866713 Screw M4x6 Slotted Panhead 5 860052 Owner s Manual ...

Page 57: ...REE 800 777 5624 INTERNET UltraSourceUSA com E MAIL info UltraSourceUSA com SPARE PARTS DIAGRAM Inline Filter Kit Parts List and Diagram Item No UltraSource Part No Description 1 843034 Filter Vacuum 1 1 2 NPT 2 860600 Reducer 1 1 2 to 1 1 4 3 860771 Piping 1 1 4 NPT Male X Female SS 4 860969 Piping Hose Barb 1 1 2 x 1 1 4 5 860040 Vacuum Hose 1 1 2 6 860119 Hose Clamp 1 1 2 7 860868 Bracket Filte...

Page 58: ...ink UltraSource First info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 6 19 PARTS THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 59: ...RENCE MANUALS R5 Series Vacuum Pumps Included within this Ultravac 500 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 500 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 60: ...INSTALLATION AND OPERATING MANUAL R5 Series Current Models 0025 0040 0063 0100 and 0250 Single Stage Rotary Vane Vacuum Pumps ...

Page 61: ...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 62: ... 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 63: ... 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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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...

Page 69: ...9 ...

Page 70: ...10 ...

Page 71: ...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 72: ...12 13 ...

Page 73: ...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 74: ...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 75: ...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 76: ...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 77: ... 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 78: ... 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 79: ...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 80: ...21 Maximum oil temperature with 80 F ambient temperature and no supplemental oil cooling ...

Page 81: ...22 ...

Page 82: ...k UltraSource First info UltraSourceUSA com UltraSourceUSA com UltraSource LLC 1414 West 29th Street Kansas City MO 64108 3604 USA 800 777 5624 816 753 2150 7 26 REFERENCE THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 83: ... 4 4 L Lid 4 1 4 4 6 6 M Machine Will Not Start 4 3 Main Menu 3 4 Maintenance Log 4 10 4 11 Mebner Valve 6 16 Miscellaneous Machine Parts 6 17 N No Gas Flush 4 3 Non Gas Flush Pneumatic Diagram 5 8 No Vacuum 4 3 O Oil 2 2 Oil Drain Plug 4 9 Oil Filler Cap 4 9 Opening Chamber Machine 4 8 4 10 P Personal Safety 1 1 Placement of Product 3 1 Potentiometer 4 9 Power Cord 4 10 Power Requirements 2 1 PRE...

Page 84: ... City MO 64108 USA Phone 816 753 2150 Fax 816 753 4976 info UltraSourceUSA com UltraSourceUSA com Replacement Parts Toll Free 800 777 5624 Fax 816 561 2854 Ultravac Services Inc Technical Support Toll Free 800 777 5624 Fax 816 753 4976 Think UltraSource First ...

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