Installation andOperating Instructions

Rotary Vane Vacuum PumpsR 5 RA 0165, 0205, 0255, 0305 D

0.1 mbar versions

Busch LLC516 Viking Drive

Va. Beach, VA 23452Phone: (757) 463-7800

Fax: (757) 463-7407

P/N 0872.929.551 / 0416

 

TABLE OF CONTENTS

GENERALIdentificationOperating Principles

1.0 INSTALLATION1.1 Unpacking1.2 Location1.3 Power Requirements1.4 Vacuum Connections1.5 Oil Filling

2.0 OPERATION2.1 Start-up2.2 Gas Ballast2.3 Process Gas2.4 Stopping Pump2.5 Water-Cooled Pumps (optional)2.6 Oxygen Service Pumps

3.0 MAINTENANCE3.1 Pump Oil3.1.1 Oil Level3.1.2 Oil Type and Quantity3.1.3 Oil and Filter Change3.1.4 Oil Flushing Procedure3.2 Automotive-Type Oil Filter3.3 Exhaust Filter3.4 Inlet Flange3.5 Vacuum Inlet Filter (Optional)3.6 Maintenance Chart3.7 Overhaul Kit/Filter Kit

4.0 TROUBLESHOOTING

5.0 LIMITED STANDARD WARRANTY

Technical DataParts ListExploded View Drawing

Page

222

222233

4444445

555666778999

9

12

131415

We reserve the right to change the product at any time without any form of notification. The information in thispublication is accurate to the best of our ability at the time of printing. Busch LLC will not be responsible for errorsencountered when attempting to perform tasks outlined in this publication which is copyright protected.

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GENERAL

Identification

For model identification, see the nameplate mountedon the side of the exhaust box.

This manual is written to cover installation and opera-tion of the RA pump models 0165, 0205, 0255 and0305 with a "D" appearing as the seventh character inthe model type number stamped into the nameplate.For example it would appear as follows:

RA0XXX - DXXX - XXXX

When ordering parts, it is helpful to include theidentification code stamped into the side of the cylinderas well as the serial number from the nameplate.

Operating Principles

All reference (Ref. XX) numbers listed in the text and onillustrations throughout this manual are related to thedrawings and parts list near the end of this publication.

R 5 Series, Single Stage, Rotary Vacuum Pumps aredirect-driven, air-cooled, oil-sealed rotary vane pumpswhich operate as positive displacement pumps. Theyconsist of a rotor positioned eccentrically in acylindrical stator (see Fig. 1). When the rotor spins,centrifugal force pushes the vanes, which glide in slots,towards the wall of the cylinder. The rotor has threevanes which divide the pump chamber into threesegments. The gas to be pumped enters at the inletport, passes through the inlet screen and the openanti-suck-back valve into the pump chamber. As therotor rotates, the inlet aperture is closed, the gas iscompressed and forced out through one-way valvesbetween the pump cylinder and the exhaust box.Differential pressure constantly causes oil to bepressed into the compression chambers. The gas/oilmixture is separated by the discharge filters (Ref. 120).The oil-free medium is discharged through the exhaustcover plate (Ref. 140) to atmosphere. This operation isrepeated three times each revolution.

All R 5 series pumps are designed to handle air. Vaporin the air stream can be tolerated when the pump isoperated within certain operating parameters asdefined by Busch LLC Engineering (see Section 2.2 -Gas Ballast). When you desire to use the pump on anair stream that contains vapors, contact Busch LLCEngineering for operating recommendations;otherwise, the warranty could be void.

1.0 INSTALLATION

1.1 Unpacking

Inspect the box and pump carefully for any signs ofdamage incurred in transit. R 5 Pumps pass a rigorousoperating test in the factory and are packed carefully toavoid transit damage. Since all pumps are ordinarilyshipped FOB our factory, such damage is the normalresponsibility of the carrier and should be reported tothem.

Remove any nuts from the bottom of the box/crate andpull the pump out of the container using a suitable liftingdevice and the lifting eye bolt (Ref. 391). Then,unscrew any remaining studs that secured the bottomof the rubber feet to the bottom of the crate.

The inlet port of the pump is covered with a plastic capprior to shipment to prevent dirt and other foreignmaterial from entering the pump. Do not remove thiscover until the pump is actually ready for connection toyour system.

1.2 Location

The pump must be installed in a horizontal position ona level surface so that the pump is evenly supported onits rubber feet. To allow for proper cooling, there mustbe a minimum 20 inches of clearance for the oil cooler(Ref. 241) and motor fan (axially). The left and right sideof the pump require a minimum 8 inches of clearance.Adequate ventilation must be provided. Do not locatethe pump in a stagnant air location.

Whenever the pump is transported, be sure to drain theoil prior to shipping to avoid vane breakage whenrestarting 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 levelproperly. Allow clearance at the exhaust flange area toprovide service access to the exhaust filters.

1.3 Power Requirements

The schematic diagram for the electrical connection islocated in the junction box or on the nameplate of thepump motor.

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Fig. 1 - Front of the R 5 RA 0255 D Pump

The motor must be connected according to theelectrical codes governing the installation. The powersupply must be routed through a fused switch to protectthe motor against electrical or mechanical overloads.The motor starter has to be set consistent with themotor current listed on the motor nameplate.

If the pump is supplied with a manual motor starter, it ispreset at the factory in accordance with the customer’sspecification. For other voltage requirements, contactthe factory for motor and/or starter information.

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

Correct direction of rotation is marked by an arrow onthe motor fan housing and is counterclockwise whenlooking 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 aslarge as that of the pump inlet. Smaller lines will resultin lower pumping speeds than the rated values.

Install a drip leg and drain on the vertical pipe near thepump inlet. Drain the drip leg often to preventcondensation from entering the pump. Also, wheninstalling discharge piping, a drip leg should beinstalled.

If more than one vacuum pump or a receiver tank isconnected to a common main line, each pump should

have its own manual or automatic operated shut-offvalve or positive action check valve. The built-in anti-suck-back valve should not be used as a shut-off valvefor the vacuum system.

Remove the plastic protective cap from the inlet portprior to connection of the pump to the system. Verticalconnection of the vacuum line can be made directly tothe pump inlet (Ref. 260).

The type and size of the inlet connections of the R 5Series pump is shown in the TECHNICAL DATA page13.

If the gas that is pumped contains dust or other foreignsolid particles, a suitable (10 micron rating or less) inletfilter should be connected to the inlet port. Consult thefactory for recommendations.

1.5 Oil Filling

The pump is shipped without oil. After level installation,after correct rotation has been established and with thepump switched "off" and secured against accidentalstart-up, fill the pump with the recommended vacuumoil 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 usedetergent motor oil as additives in detergent oil willplug exhaust filter elements and shorten their life.

It is recommended that Busch R500 Series oil be usedto receive the best performance from your vacuumequipment. R500 Series oil is a high quality vacuum oilthat will give longer running time between oil changes,will provide better lubrication at highoperating temperatures, and will prolong the life of

Fig. 2 - Basic R 5 RA 0165, 0205, 0255, and 0305 D Series Pump

CAUTION: Do not use the anti-suck-back valve asa check or shut-off valve for your vacuum system.

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CAUTION: After the electrical connection has beenmade, but before the pump is filled with oil, therotation of the motor must be checked. Open theinlet port and jog the motor briefly to make surerotation is correct. If it runs backwards and if it iswired three phase power, reverse any two leads ofthe three at the power connection.

88 83 95 194 22 15 100 Oil

75 159 260 120 140

Inlet

Exhaust

exhaust filter elements. This oil can be obtaineddirectly from Busch LLC in Virginia Beach, Virginia.

The strict use of Busch oils and parts from the day ofpurchase can extend the life of the vacuum pump.

For general applications, use R530. Use R590 or R570in pumps that are operated in high ambienttemperatures (above 90°F) or when the oil carbonizes(turns black) before the change interval. Contact thefactory for recommendations when using other oils.

The TECHNICAL DATA chart on page 13 gives theapproximate quantity of oil required. The oil capacitychart should only be used as a guide, since oilcapacity may be slightly lower, depending on whetherthe pump was filled previously, and whether allcomponents such as oil filter, oil lines, etc., wereallowed to completely drain. Use only the sight glassreading 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 oilviscosity), contact the factory in Virginia Beach,Virginia.

Replace the oil fill plug (Ref. 88), and pressure gauge(Ref. 88), making sure that the gasket (Ref. 89) is inplace and properly seated and secured. Pumps areequipped with an exhaust pressure gauge as anintegral part of the oil fill plug. Switch the power backinto 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 thepump for a few minutes before checking the oil levelagain. With the pump shut off, the oil level should bevisible in the oil sight glass (Ref. 83), between the "MIN"and "MAX" mark.

Add oil, if necessary, but only add it when the pump hasbeen shut off and the circulating oil has had sufficienttime to return to the oil sump.

2.2 Gas Ballast

R 5 Series RA 0165 through 0305 D pumps areequipped with an adjustable gas ballast valve (Ref.470-480). The adjustable gas ballast valve should nor-mally be left open. Its primary function is to preventwater vapor from condensing in the pump.Condensation causes emulsification of the oil, loss oflubricity, and possible rotor seizure.

Check the gas ballast filter periodically to ensure that airis flowing through it properly.

2.3 Process Gas

The R 5 series pumps are designed to pump air and arenot intended for use when water vapor is beingpumped. In some applications, when the quantity of thewater vapor is moderate, R 5 pumps have been usedwith good results. On these occasions, the pump is rununtil it is up to operating temperature before it is allowedto pump the process gas. The pump is also operated fora period of time off process and on air (to clear it ofprocess gas) before it is shut down. This operatingtechnique prevents the vapor from condensing in thepump. Before attempting to pump a gas laden withwater vapor, contact Busch Engineering for advice.

2.4 Stopping pump

To stop the pump, turn off the power. The pump has abuilt-in anti-suck-back valve (Ref. 251 thru 255) toprevent the pump from rotating backwards when it isshut off.

Install a manual or automatic valve or check valve ineach pipe leading to each pump when multiple pumpsare pumping on a common header.

All R 5 Series pumps are vented internally toatmospheric pressure through venting holes which arenext to the exhaust valve assembly.

2.5 Water-Cooled Pumps (Optional)

Water-cooled pumps are cooled by circulating the oilthrough a shell-and-tube type heat exchanger. Thecirculation of the pump oil through the shell is createdby vacuum in the pump, but the circulation of thecooling water through the tubes is thermostaticallycontrolled. The flow rate of the cooling water iscontrolled by a thermostatically activated valve (seeFig. 3) that senses, through a capillary bulb mounted inthe exhaust box, the pump's oil temperature as it isdischarged from the compression chamber. The valvewill open at its setpoint and close at approximately 3°Fto 5°F below the set point. The valve set point is

WARNING: Keep the oil fill plug tight aspressure in the exhaust box could causebodily injury if the plug is blown out. Do notfill/add the pump with oil through theexhaust/inlet ports as there is danger ofbreaking the vanes!

CAUTION: Do not use the anti-suck-backvalve as a check or shut-off valve for yourvacuum system.

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adjustable as follows:

(a) Rotate the valve adjustment screw counterclockwiseto cause the valve to open at a higher temperature.This makes the pump run hotter.

(b) Rotate the valve adjustment screw clockwise tomake the valve open at a lower temperature. Thismakes the pump run cooler.

Fig. 3 - Water Cooled Pump

The thermostatic valve can be manually opened byinserting a screwdriver under each side of the springguide and prying the spring and guide upward awayfrom the valve body.

The water cooling option can be used to cool pumpsoperating in high ambient temperatures, or it can beused to maintain a pump at elevated temperatures toprevent condensation inside the pump in wetapplications. Contact Busch Engineering in VirginiaBeach for details.

2.6 Oxygen Service Pumps

Oxygen service pumps must be used in oxygenenriched applications that are defined as anyapplication which has a process gas that is 25% ormore oxygen. If this pump is contaminated by organiccompounds do not attempt to use it on oxygen serviceuntil it has been decontaminated.

These pumps have been manufactured, solventwashed (to remove organic contaminants) andassembled according to the latest technical standardsand safety regulations. If this pump is not installedproperly or not used as directed, a dangerous situationor damage might occur.

It is mandatory that these operating instructions beread and understood prior to vacuum pumpinstallation and start-up!

For overhaul/repair of oxygen service pumps,Busch LLC strongly recommends that all major repairoperations be conducted at the factory. Improperhandling of repairs could result in extreme dangerto personnel operating the pump.

3.0 MAINTENANCE

R 5 Series, Single Stage, Rotary Vacuum Pumpsrequire very little maintenance; however, to insure opti-mum pump performance, the following steps arerecommended.

3.1 Pump Oil

3.1.1 Oil Level

With the pump installed relatively level, make sure thatthere is sufficient clean oil in the pump (see Section1.5).The oil level should be observed on a daily basis and/orafter 8 hours of operation and should be replenished ifit drops below the 1/4 mark on the oil sight glass.

Oil level readings should be done only when the pumpis turned off. Oil can be added to the oil fill port (Ref.88)if the pump is shut off and the circulating oil hassufficient time to return to the oil sump. The oil mightappear to be foamy, which is a normal phenomenonwith aerated oil.

Under normal circumstances, it should not benecessary to add or drain oil from the pump betweenrecommended oil changes.

A significant drop in oil level means there is an oil leakor that an exhaust filter is broken, and the pump should

WARNING: This pump is filled with a specialoperating fluid. Do not use any other type of fluid,oil and/or grease. Use one of the following:

• Fomblin Y LVAC 25/6• Tyreno Fluid 12/25V (perfluorinated polyether)• KRYTOX ®Vacuum pump fluid by Du PontCompany

If you have any questions, please phone ourCustomer Service Department for more information.

CAUTION: Do not add oil while the pump is runningsince hot unfiltered oil vapor may escape throughthe oil fill port.

WARNING: Insufficient oil quantity in the pump hasthe potential, under certain conditions, to lead toself-ignition of the remaining oil in the pump.

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be smoking excessively. It is normal for the oil to befoamy and light in color in an operating pump.However, if the oil is milky colored, it is an indicationthat water is present in the oil. Normally, by operatingthe pump for an extended period, with the inlet suctionblanked off and the gas ballast open, the water will bepurged from the oil. If the oil is dark colored, it iscontaminated or carbonized and must be changed.Depending on the severity of the contamination, athorough flushing may be required. Contact the factoryfor flushing oil (Busch R568) and instructions.

3.1.2 Oil Type and Quantity

See Section 1.5 and the Technical Data page 13 fordetails on oil type and quantity.

3.1.3 Oil and Filter Change

Check the oil for contamination on a weekly basis byshutting the pump off and draining some of the oil intoa small glass or a similar transparent container throughthe oil drain port (Ref. 95).

Oil life is dependent upon the conditions to which it isexposed. A clean, dry air stream and an oil operatingtemperature under 210°F are ideal conditions. Oil mustbe 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 changesare made every three (3) to four (4) months or 500 to750 hours of operation, or as necessary if high heat iscontaminating the oil. The use of Busch R570(synthetic) or R590 (semi-synthetic) oil maysignificantly extend the operating hours between oilchanges; however, you may need to flush out the pumpbefore changing. Contact the factory ServiceDepartment for advice or refer to Section 3.1.4 for theflushing procedure.

To change the oil, the pump must be switched off andventilated to reach atmospheric pressure. Remove theoil drain plug (Ref. 95) and drain the oil. Dispose of theoil 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 pumponce again, and then reopen the drain plug anddischarge any remaining oil.

Refasten the oil drain plug. Remove the oil filter(Ref.100) and replace it with a new one using a Buschgenuine oil filter. Make sure to tighten the filtersecurely against the aluminum sealing surface so thatleaks will not occur.

Excessive Heat

When the pump is subjected to operating conditionsthat will cause the oil to be heated above 210°F, the oilwill carbonize and become contaminated after arelatively low number of operating hours. The higherthe temperature, the quicker the oil becomescontaminated. If the oil temperature is too severe,Busch R570 or R590 synthetic oil should be used towithstand the elevated temperatures. When changingto synthetic oil, the pump should be flushed with BuschR568 oil. Contact the factory for instructions on theflushing procedure. Auxiliary oil cooling is the mostpractical approach to a severe heating problem.

Contaminated Air Stream

When the air stream contains solids and/or liquid thatcontaminate the oil, the oil must be changed moreoften. If the air stream contains a small percentage ofcontaminates and/or they are slightly aggressive* (mildacids, etc.), synthetic oil, such as Busch R570, willresist breakdown better than the standard Busch R530.The solution is to install a filter or knock-out pot to keepthe contaminates out of the pump.

*Process air streams with a large percentage ofcontaminates and/or are more than slightly aggressivemust use a chemical duty pump.

Oil change intervals can only be established byexperience with the pump operating in the actualconditions (see previous paragraph for some of theconditions). Develop the oil change interval byperiodically checking an oil sample removed from thepump. When the oil sample has become dark in color(from solids and carbonized particles) or is milkylooking (from water), it is time to discard it. Asmentioned before, a thorough flushing may be required.

3.1.4 Oil Flushing Procedure

Flushing is needed under certain conditions. Somepumps will be beyond flushing and will need to beoverhauled.

To help determine if flushing is needed, observe thecondition of the oil as it is drained from the pump. Is it

CAUTION: When changing the oil and filters, it maybe necessary to flush the pump to remove anybuild-up of degraded oil from the sumps, oil lines,radiators, etc. to ensure proper oil flow through thepump. Reduced oil flow, especially throughradiators and cooling coils, can cause mechanicaldamage or extreme overheating which could causethe oil vapors to ignite.

WARNING: Always take the necessary precautionsconcerning personal protective equipment whenchanging oil and make sure the pump is switchedto the "off" so that accidental starting will notoccur. Oil temperature can reach 212°F and maypose a danger of scalding.

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black and tar like or contaminated in any way? Was thepump noisy, overheating, or was the motor overloadshutting the pump off? How old is the pump and whenwas the last time the oil was changed?

If the above conditions exist or you don't know when thelast oil change was performed further investigation isneeded. Also, when changing from one oil type such asR530 to another type such as R590 or R570 it will bebeneficial to flush. Although the oils are compatible,mixing a lesser grade oil such as R530 with a syntheticoil like R570 will reduce the effectiveness of thesynthetic oil.

All of the oil will be removed and replaced with theflushing oil (Busch R568), and eventually that will bereplaced by whatever Busch oil is needed for yourparticular application. Have enough oil and oil filters onhand for a couple of flushes. The following describesthe steps in the flushing procedure:

Shut the pump off and drain all the oil from the pumpand remove the access plates (Ref. 205) from theexhaust box (Ref. 075). Remove the metal baffle(Ref.078) and take a good look at the internal walls ofthe oil sump. If the walls are discolored but have nobuild up of any kind one can proceed with the flushing.If gelled or burnt oil is clinging to the walls this materialmust be scraped and removed prior to flushing.Proceed by scraping and cleaning as much of theexhaust box as possible. The more debris that isremoved now the more effective the flushing will belater. Re-install the metal baffle, cover and proceedwith the flushing. At this point one must remember thatthe oil lines and oil cooler might also be plugged to apoint where no amount of flushing will make adifference and a complete overhaul will be the onlyoption. Depending on the severity of the oilcontamination flushing may be a last ditch effort.

Drain all of the oil from the pump. The morecontaminated oil you remove now the more effectivethe oil flushing will be.

Remove the oil filter (Ref. 100) and install a new one. Itis recommended that you do not change the exhaustfilter or filters until after the flushing to preventcontamination of any new filters.

Fill the exhaust box with the proper amount of flushingoil (Busch R-568).

If possible run the pump with the inlet closed and off ofthe process. Run the pump for approximately six hours,shut the pump off and drain a small sample of oil into aclear container.

Examine it. If it is clear to amber run the pump foranother six hours and examine it again. If after the firstsix hours it is black drain it and fill again using another

new oil filter.

If after the second flushing the oil still remains black thepump may have too much contaminated oil in it to flushout properly. There may be residue remaining in thelines and cooler that will not flush out. An overhaul willbe necessary.

If after the second six hour period the oil still remainsclear to amber in color drain it, change the oil filter andfill with the regular oil. At this point also change theexhaust filters.

Run the pump with a fresh charge of the oil to be usedin your application (not R-568), and monitor theoperating conditions closely. Check for noise,overheating and oil condition until a regular oil changeschedule can be established.

Do not let the oil turn black. Change it before it fails. Ifthe oil is kept in good condition the pump will last foryears. If the oil starts to turn black do not hesitate toflush again. Keeping on top of the oil changes willprevent costly overhauls.

If you are just switching from one type of oil to anothera single six hour flush is all that is necessary (follow theabove instructions). Remember to change to a newexhaust 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 oilfilter, use only a Busch genuine filter.

Note: Make sure to tighten the Busch oil filtersecurely against the aluminum sealing surface so thatleaks will not occur.

3.3 Exhaust Filter

Exhaust filters (Ref. 120) should be checked monthly. Apressure gauge (Ref. 88) is supplied with your R 5vacuum pump as part of the oil fill plug. This gauge hasa green field and a red field. A pressure within thegreen field would indicate normal pressure. Anypressure 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 ofthe exhaust filters varies widely with pump application.

WARNING: Always wear safety glasses and otherappropriate personal protective equipment whenperforming any maintenance or repair to your R 5pump.

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WARNING: If the gas entering this pump is a healthhazard, use rubber gloves and all necessarypersonal protection equipment when performingthe exhaust filter replacement operation.

It is only necessary to change the filters when theelements become clogged with foreign material orburned oil. Indications of clogged filters are smoke andoil mist coming from the pump exhaust or higher thannormal motor current.

In order to replace the exhaust filters, unscrew thescrews and washers (Ref. 142/143) from the exhaustcover plate (Ref. 140). Remove the cover plate andgasket (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 unscrewingthe nut (Ref. 134) and removing the lock washer (Ref.132). Carefully slide the assembly out of the exhaustbox (Ref. 75). Stand the filter assembly up on a cleanflat surface.

To have access to the individual filters, unscrew the twocylinder cover screws (Ref. 126), and remove the twolock washers (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) andO-rings (Ref. 119).

Replace the support and O-rings with new ones. Makesure that the O-rings are fitted securely and that thefilter elements (Ref. 120) fit securely into thedepressions on the filter support (Ref. 118). Theindicating arrow on each element must be pointingupward toward the top of the exhaust box after theassembly has been installed.

Carefully position the filter support tube (Ref. 133)between the exhaust filter bracket (Ref. 115) and thefilter support without displacing the filters from theirseated position in the filter support. Install the two lockwashers (Ref. 128) and two screws (Ref. 126).

Insert the support and filter assembly into the exhaustbox using the stud (Ref. 131) as a guide. The studshould slide through the hole in the support (Ref. 133).Secure the assembly with the lock washer (Ref. 132)and hexagon nut (Ref. 134).

Reinstall the sheet metal plate (Ref. 136) and the bafflestrainer (Ref. 130) into the guide track of the exhaustbox (see Fig. 3). Press to the bottom of the exhaustbox. Make sure that the baffle strainer touches all sidesof the exhaust box. Insert the distance sleeve (Ref.137)into the two grooves. This holds the sheet metal plate

Fig. 4 - Exhaust Filters and Strainer

and baffle strainer in place.

Inspect the exhaust box end cover gasket (Ref. 141) fordamage and replace if damaged. With the gasket inplace, secure the exhaust cover end plate (Ref. 140) tothe exhaust box using eight hex head cap screws(Ref.142) and eight lock washers (Ref. 143).

To field test an exhaust filter element, remove it fromthe pump, allow it to cool, clean the sealing end (orO-ring end), and use compressed air to blow throughthe element. Apply approximately 3 to 6 psi, which isthe maximum allowable operating pressure across thefilter.

Use a shop rag to seal off the connection between theair 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 becleaned successfully. Visually inspect the filter elementfor cracks.

Reinstall the filter elements as described previously.

3.4 Inlet Flange

The standard inlet flange assembly contains an inletscreen (Ref. 261) which may require occasionalcleaning. The frequency of cleaning can only bedetermined by experience and is affected by hours ofoperation and particle size being trapped. An optionalvacuum inlet filter is offered and can help minimize theneed or frequency of cleaning the inlet screen.

To clean the screen, disconnect the flange from theprocess piping. Remove the four screws and lockwashers (Ref. 265/266). Remove the inlet flange

CAUTION: Excessively contaminated and/orclogged exhaust filters could possibly lead toelevated pump temperatures which could, undercertain circumstances, cause the lubricating oil toself-ignite.

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(Ref.260). Remove the screen (Ref. 261) and cleanwith compressed air. After cleaning, install the screenand inlet securing them with the screws and lock wash-ers. Make sure the O-ring (Ref. 265) is in place prior tosecuring the screws. Reattach the process piping tothe inlet.

3.5 Vacuum Inlet Filter (optional)

If the pump is equipped with an optional specialvacuum inlet filter in applications where powder, dust orgrit is present, the filter cartridge should be cleaned ona weekly basis, or as required, depending on theamount of foreign particles to which the pump isexposed.

To clean the inlet filter, unsnap the lid clamps or removethe knobs and lift off the filter lid. Remove cartridge,being careful not to knock any foreign particles presentinside the canister into the pump suction. Clean foreignparticles from the canister with an air hose, andcarefully back flush the filter cartridge with shop air. Ifthe filter cartridge has been subjected to moisture or isextremely dirty it may need replacement.

3.6 Maintenance Chart

Note: See the motor manufacturer’s manual for theperiodic motor maintenance.

Note: Lack of proper maintenance can result in blockedfilters, radiators, oil lines, etc. This condition can leadto excessive heat causing mechanical failure or ignitionof 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 hoursof operation, or as necessary: See 3.1.3 and 1.5.Drain and discard oil from the hot pump. Replace theautomotive-type oil filter and refill with fresh oil throughthe fill plug (see 3.1.2 through 3.2).

Every nine (9) to twelve (12) months, or asnecessary: Replace exhaust filter elements (see 3.3).

As necessary: Check and/or clean the standard inletscreen. If the optional inlet filter is used, replace thefilter material as practice determines.

As necessary: The radiator (Ref. 241), fan hood (Ref.244) and motor cover should be inspected regularly fordebris. Soiling prevents cool air intake and may lead tooverheating 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 andtaper pins, is available from the factory. Also, a filter kitcontaining oil drain plug, gaskets, automotive type oilfilter, exhaust filter and synthetic baffle strainer isavailable from the factory. When ordering, pleasespecify 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" pressurewhich is the lowest absolute pressure (bestvacuum) when running with the inlet closed via ablank flange or a valve; or the pump takes too longto evacuate the system. "Blank-off" pressure canbe measured by using a good quality capsulegauge.

Possible Cause: Contaminated oil is by far the mostcommon cause of not reaching the ultimate pressure.

Remedy: Shut off the pump, after the operatingtemperature has been reached, drain the warm oil frompump and exchange the automotive-type oil filter, ifnecessary. Flush and fill the pump with new oil andtake a new "blank-off” measurement after operatingtemperature is reached (at least 20-30 minutes).

Possible Cause: The vacuum system or vacuumpiping is not leak-tight.

Remedy: Check the hose and pipe connections forpossible leak.

Possible Cause: The wire mesh inlet screen isplugged (Ref. 261).

Remedy: Clean the wire mesh inlet screen. Install aninlet filter if the problem repeats frequently.

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

Remedy: Shut off the pump, add the necessary oil, orif oil seems contaminated, drain the balance of the oilfrom the pump, exchange the automotive oil filter, andrefill with fresh oil. Flush if necessary.

Possible Cause: The automotive-type oil filter is dirtyor clogged .

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 positiondue to contamination.

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Remedy: Disassemble the inlet valve and screen.Clean as required.

Possible Cause: The oil tubing fittings are loose andleaking.

Remedy: Replace or retighten the oil fittings or oiltubing. Replace only with same size tubing.

Possible Cause: Shaft seal leaking.

Remedy: Replace the shaft seal following disassemblyand assembly steps outlined in the Maintenance andRepair Manual. Check the shaft seal. It should have aspring installed inside and around the shaft sealing lip.

Possible Cause: Exhaust valve (Ref. 159) is notproperly seated or it is partially stuck open.

Remedy: Contact the nearest Busch Factory ServiceCenter for instructions.

Possible Cause: Vanes are blocked in rotor or areotherwise damaged.

Remedy: Free vanes or replace with new ones.Contact the nearest Busch Factory Service Center forinstructions.

Possible Cause: The radial clearance between therotor and cylinder is no longer adequate.

Remedy: Contact the nearest Busch Factory ServiceCenter for instructions.

Possible Cause: The internal parts are worn ordamaged.

Remedy: Contact the nearest Busch Factory ServiceCenter for instructions.

Possible Cause: The inlet filter is clogged due toprocess material.

Remedy: Contact the factory for recommendation onproper filter cartridge.

4.2 Trouble

Pump will not start.

Possible Cause: The motor does not have the propersupply voltage or is overloaded; the motor starteroverload 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; checkoverload settings in motor starter for size and setting

according to motor nameplate data; check fuses; andinstall proper size wire. If the ambient temperature ishigh, 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 pumpand motor by hand. If frozen, remove the motor fromthe pump and check the motor and the pumpseparately. If the pump is frozen, contact the nearestBusch Factory Service Center for instructions.

4.3 Trouble

The pump starts, but labors and draws a very highcurrent.

Possible Cause: The oil is too heavy (viscosity toohigh) or the ambient temperature is below 5 degrees C(41°F).

Remedy: Change to R580 vacuum oil if very cold, orwarm up the oil before filling.

Possible Cause: Pump is running in the wrongdirection.

Remedy: Check for the correct rotation which iscounterclockwise when looking at the motor from themotor's fan side. Reverse any two leads on the motorto change the direction of rotation.

Possible Cause: The pump is over filled with oil or thewrong kind of oil is used.

Remedy: Correct the oil level and quality per Section1.5 and use recommended motor oil.

Possible Cause: Exhaust filters in exhaust chamberare clogged and appear burned black with pump oil.

Remedy: Replace the exhaust filters, maintain properoil condition, oil level, and use only Buschrecommended vacuum oil and filters.

Possible Cause: Loose connection in motor terminalbox; not all motor coils are properly connected. Themotor operates on two phases only.

Remedy: Check the motor wiring diagram for properhookup, especially on motors with six internal motorwindings, tighten and/or replace loose connections.

Possible Cause: Foreign particle in pump, vanesbroken, bearings seized.

Remedy:Contact the nearest Busch Factory ServiceCenter for instructions.

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4.4 Trouble

Pump smokes at the exhaust side or expels oildroplets from the exhaust.

Possible Cause: Inlet to pump is in a wide opencondition.

Remedy: Do not operate pump at high inlet pressuresfor more than a few minutes (pressures = 0.00-10.0" Hgvac.)

Possible Cause: The exhaust filter is not properlyseated with the O-ring (Ref. 121) in filter base or thefilter material is cracked.

Remedy: Check the condition and check for properseating of the exhaust filters. Replace if necessary.Also, check the filter spring clips for tightness.

Possible Cause: The exhaust filter is clogged withforeign particles.

Remedy: Replace the exhaust filter.

4.5 Trouble

Pump runs very noisily.

Possible Cause: Coupling insert is worn.

Remedy: Replace the coupling insert in motor/pumpcoupling.

Possible Cause: Bearing noise.

Remedy: Contact the nearest Busch Factory ServiceCenter for instructions.

Possible Cause: Vanes stuck.

Remedy: Contact the nearest Busch Factory ServiceCenter for instructions. Use only the recommendedBusch oil and change oil more frequently.

4.6 Trouble

The pump runs very hot.

Note: The oil temperature with a closed inlet should beapproximately 185-225°F depending on pump type. At24 in. Hg, the oil in the pump can go above 225°F.These values are taken at an ambient temperature of68°F. The maximum recommended ambient operatingtemperature for an R 5 is 100°F on a continuous basis.When it is necessary to operate a pump in ambienttemperatures above this limit, careful oil monitoringand/or optional water cooling is necessary. Contact thefactory at Virginia Beach for details.

Possible Cause: Not enough air ventilation to thepump.

Remedy: Clean the motor and pump air grills. Cleanthe radiator. Do not install the pump in an enclosedcabinet unless a sufficient amount of fresh air issupplied to the pump. Bring the ambient airtemperature down.

Possible Cause: The automotive-type oil filter cloggedand pump does not receive enough oil.

Remedy: Change the automotive oil filter.

Possible Cause: Not enough oil in oil reservoir or badlyburned oil is used for pump lubrication.

Remedy: Drain and refill the pump only withnon-detergent oil and increase oil change intervals.

Note: On some high temperature applications, it maybenecessary to change to a high temperature oil such asR590 or R570. Contact the factory forrecommendations.

4.7 Trouble

Pump is seized.

Possible Cause: The pump operated without oil andvanes broke.

Remedy: Contact the nearest Busch Factory ServiceCenter for instructions.

Possible Cause: The pump was operated for anextended period of time in the wrong rotation.

Remedy: Inspect vanes and replace. Contact thenearest Busch Factory Service Center for instructions.

Possible Cause: Liquid carry over into the pumpcylinder broke vanes while pump was running, or oilbroke vanes on start-up.

Remedy: Install a condensate trap on the inlet of thepump. Or, pump was over filled with oil in oil reservoir.Follow oil filling procedure (see Section 1.5) and do notoverfill. Or, the built-in anti-suck-back valve (Ref. 250through 255) is leaking while pump was shut down andvacuum was left in manifold. Clean the valve seat andcheck that anti-suck-back valve holds vacuum on inletwhen pump is shut down.

4.8 Trouble

The automotive-type oil filter (Ref.100) does not getwarm within two to five minutes when cold pump isstarted.

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Possible Cause: The automotive-type oil filter isclogged.

Remedy: Replace the automotive-type filter perSection 3.2 and exchange oil per Section 1.5.

Possible Cause: The wrong automotive-type filter isused and/or oil lines leading to pump are clogged.

Remedy: Use only automotive filter as listed in Section3.2 and blow lines free. Flush oil cooler.

Possible Cause: The oil cooler is plugged internallywith burnt oil.

Remedy: Remove oil cooler and flush. Pump mayhave to be disassembled completely to correct aseverely contaminated condition.

5.0 LIMITED STANDARD WARRANTY

Busch LLC warrants that all products furnished by it arefree from defects in material and workmanship at thetime of shipment for a period of 18 months from thedate of shipment, or 12 months from the date ofinstallation, whichever occurs first. Claims must bemade during that period and are limited to thereplacement or repair of parts claimed to be defective.

In the case of components purchased by Busch LLC,such as starters, controls, mechanical seals, motors,couplings, etc., the warranty of that manufacturer will beextended to the purchaser in lieu of any warranty byBusch LLC. The replacement of wear items including,but not limited to, seals, bearings, couplings, exhaustcover gaskets, oil drain plugs, oil fill plugs etc., made inconnection with normal service, are not covered by thisWarranty.

The Limited Standard Warranty is valid only when theproduct has been properly installed, used in a normalmanner, and serviced according to the operatingmanual. This warranty shall not extend to products thathave been misused, neglected, altered, or repairedwithout factory authorization during the warranty period.We highly recommend the use of Busch oils and partsto achieve documented performance and efficientoperation. The use of oils or parts other than Buschcould limit the life expectancy of the equipment andcould void any warranties if they are the cause of anydamage. Operating conditions beyond our control suchas improper voltage or water pressure, excessiveambient temperatures, or other conditions that wouldaffect the performance or life of the product will alsocause the warranty to become void.

Permission to return parts for warranty repair must beobtained, and all returns must be prepaid to the factory.If, after examination, the product or part is found to bedefective, it will be repaired or replaced on a no-charge

basis and returned, FOB the factory. If it is determinedthat the Warranty has not been breached by Busch LLCthen the usual charges for repair or replacement will bemade, FOB the factory. Parts or products that areobsolete or those made to special order are not return-able.

This Limited Standard Warranty applies only to theabove and is for the period set forth. Busch LLC's max-imum liability shall not, in any case, exceed the contractprice for the product, part, or component claimed to bedefective; and Busch LLC assumes no liability for anyspecial, indirect, or consequential damages arisingfrom defective equipment.

THERE ARE NO WARRANTIES IMPLIED OREXPRESSED THAT EXTEND BEYOND THOSECONTAINED IN THIS LIMITED STANDARDWARRANTY.

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TECHNICAL DATA

Model 165 205 255 305Nominal pumping speed ACFM 115 130 170 196Ultimate Pressure torr 0.075 0.075 0.075 0.075Nominal motor rating HP 7.5 7.5 10 12Nominal motor speed RPM 1800 1800 1800 1800Sound level (ISO 2151) dB(A) 72 74 74 76Oil capacity Qts 7 7 7 7Gas inlet / outlet NPT 2" / 2” 2" / 2” 2" / 2” 2" / 2”Approximate weight lbs 445 445 515 515

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Parts List for 0165-0305 D

Ref Description

140 Exhaust cover plate141 Exhaust cover gasket142 Hex head cap screw149 Socket head cap screw159 Exhaust valve162 O-ring169 Exhaust valve cover plate171 Oil tube insert175 Socket head screw185 Gasket189 Stud191 Hex nut194 Oil return float valve complete195 Oil return float valve mount196 Socket head cap set screw 197 O-ring198 Socket head cap screw205 Side cover plate206 Side cover plate gasket207 Socket head cap screw222 Hyd. fitting, elbow223 Hyd. fitting, elbow225 Hyd. fitting, banjo228 Hyd. fitting, couplng229 Hyd. fitting, straight230 Oil tubing231 Oil tubing232 Oil tubing235 Hydraulic fitting, straight238 Socket head cap screw239 Lock washer241 Oil cooler242 O-ring244 Fan cover247 Socket head cap screw250 Lower inlet flange251/2/4 Anti-suckback valve253 O-ring255 O-ring260 Upper inlet flange261 Inlet screen265 Hex head cap screw266 Lock washer270 Hydraulic fitting, elbow290 Teflon tubing291 Hydraulic fitting, elbow300 Motor bracket301 Hex head cap screw302 Lock washer306 C-face adapter flange307 Socket head cap screw311 Coupling half, motor side312 Coupling insert313 Coupling half, pump side319 Motor spacer321 B-side fan

Ref Description

0 Module1 Cylinder5 Plug, screw6 Socket pipe plug15 Rotor18 Shaft seal sleeve22 Vane25 Endplate, motor side26 Endplate, fan side30 Roller bearing31 Endplate spacer35 Shaft seal42 Shaft seal retaining plate43 Screw, hex head49 O-ring50 O-ring53 Hex head screw54 Lock washer57 Socket head cap screw58 Lock washer60 Taper pin61 Parallel pin65 Shaft key66 Shaft key75 Exhaust box80 Sheet metal baffle83 Oil sight glass84 Sight glass gasket85 Socket head plug87 Oil fill elbow88 Oil fill plug89 Ring gasket90 Fill plug with gauge90.1 Exhaust pressure gauge92 Socket head plug95 Oil drain plug96 O-ring99 Nipple100 Oil Filter105 Front cover plate106 Front cover plate gasket107 Socket head cap screw115 Exhaust filter bracket118 Exhaust filter mount119 O-ring120 Exhaust filter126 Socket head screw127 Distance rod128 Lock washer130 Baffle strainer131 Stud132 Flat washer133 Exhaust filter support tube134 Hex nut136 Baffle strainer screw137 Distance sleeve

Ref Description

322 A-side fan326 Fan retaining ring353 Socket head cap screw360 Lock washer390 Eyebolt adapter391 Eyebolt392 Lock washer393 Hex head cap screw400 Motor401 Hex head cap screw402 Lock washer417 Socket head cap screw421 Rubber foot422 Rubber foot431 Directional arrow label436 Pump label470-80 Gas ballast assembly488 Plug with seal492 Screw plug496 Socket head plug498 Plug with seal530 B-side fan spacer9000 Socket head plug9013 Plug

14

15

Fig. 5 - Exploded View Drawing

 

 

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