O & M Manual For JHVR 6000X PDF

OPERATION
AND
MAINTENANCE MANUAL
FOR
NIRMAL FILTER
TRANSFORMER OIL CONDITIONING MACHINE
MANUAL NO. N.070.0404
FOWLER WESTRUP (INDIA) PVT LTD.,

PLOT No: 60 – 63, KIADB INDUSTRIAL AREA,
IV PHASE, MALUR – 563130.KOLAR DIST,
KARNATAKA. INDIA.
PH – +91 8152 282500
FAX – +91 8152 282523
E-MAIL – fwl@fowlerwestrup.com
WEBSITE - www.fowlerwestrup.com
Fowler Westrup - Creating a greener & cleaner World... Store clean recycle
FOWLER WESTRUPTM (INDIA) PVT LTD., 1

TRANSFORMER OIL CONDITIONING MACHINE
MODEL - JHVR 6000X
CAPACITY - 6000 LPH.
CUSTOMER - M/s. SYNERGY INTERNATIONAL MARKRTING.
P.O. NO. - PO-20180002 DT: 10.01.2018
MACHINE SL. NO. - 1287458
MANUFACTURER - FOWLER WESTRUP (INDIA) PVT. LTD.

PLOT No: 60 – 63, KIADB INDUSTRIAL AREA,
IV PHASE, MALUR – 563130.KOLAR DIST,
KARNATAKA. INDIA.
PH – +91 8152 282500
FAX – +91 8152 282523
E-MAIL – fwl@fowlerwestrup.com
MANUAL NO. - N.070.0404
IN CASE OF QUERIES AND ORDER FOR SPARE PARTS, THE P.O. NUMBER,
MODEL, SERIAL NUMBER OF MACHINE AND MANUAL NUMBER MUST
ALWAYS BE SPECIFIED.
Prepared by Approved by
Chandrashekara.Y.H Yogananda Murthy K.S
Chandrashekara.Y.H Yogananda Murthy K.S
ISSUE NO.01
Date: 22.02.2018 DOC. No.: DS-EGN-NF-02-R0

GENERAL GUARANTEE

The machine has been assembled and tested at the
factory.
Installation and commissioning should be carried out

by skilled personnel familiar with the commissioning
of machines of this type.
We strongly recommend that first Installation and

commissioning be carried out by our trained
personnel.
If Installation and commissioning is carried out by

unskilled personnel, we cannot give any guarantee of
its function and durability.
The guarantee will lapse if the installation and

commissioning has not been done correctly.

DO’S & DONT’S
 Machine should be erected and installed as per the

instructions provided.
 Machine should not be towed beyond a maximum

speed of 30 KMPH.
 Ensure that machine is operated on the jacks to

relieve the loads on the tyres & axles
 Trailer tyres to be properly inflated with a pressure

of 80 psi.
 It is recommended not to operate the machine,

outdoor during rains.

CONTENTS
Description Page No.

I Introduction 6
II General Description 7
III Technical Specification 11
IV Machine Components 12
V Safety Provisions 17
VI Installation and Preparation of machine 18
VII Operation of machine
A) Conditioning of oil 20
B) Hot Oil Circulation 21
C) Shutting down 22
D)Transformer evacuation 22
E) Draining for transport & Maintenance 23
F) Trouble shooting 24
G) Oil sample testing 28
H) Special Note 29
I) Maintenance of oil conditioning machine 30
J) Operator Safety 33
H) Recommended Spares 33
VIII Drawings & Diagrams
I) Flow chart & parts list
II) Electrical diagram & parts list
III) Degassing chamber
IV) Magnetic strainer
V) Filter vessel
VI) Heater vessel
VII) Machine Erection & Installation
VIII) Overall Dimension of machine
IX List of manuals/catalogues enclosed
a) Vacuum pump R50100 F
b) Roots pump WP 500
c) Inlet gear pump RT 125
d) Outlet centrifugal pump 5 HP
e) Pirani Gauge
f) Temperature Indicating Controller
g) Vacuum switch
h) Annunciation system MBAS 9400
i) Flow meter
j)Ball valve
k)Butterfly valve
l)Float switch

I. INTRODUCTION
FOWLER WESTRUPTM (INDIA) PRIVATE LIMITED is a joint venture between

the companies John Fowler (India) Limited, Westrup a/s, Denmark and
Industrialization fund for Developing Countries, Denmark for manufacture and
supply of Transformer Oil Conditioning machines and Seed Processing
machines.
NIRMAL FILTER (NF) Division manufactures Oil conditioning machines for

Transformer oil, Capacitor oil, silicone fluids, and Test beds for Converters and
Valve sets for Locomotive applications. NIRMAL filters for decades have
served the Indian industry as well as industries in various countries across the
globe. Periodic maintenance of transformers by NIRMAL machines ensures
quality power to all the households and industries alike. NIRMAL, true to its
name has been synonymous with providing total customer solution.
FOWLER WESTRUP manufactures 5 models of transformer oil conditioning

machines for various ratings of transformers. They are
Standard JTM model

Medium high vacuum JMHV model
High vacuum JHV model
Ultra high vacuum JHVR model
Regeneration System JTORS model
with flow capacities ranging from 200 to 15000 LPH
The usage of transformer oils:
Oil in power transformers and distribution transformers serve the purpose of

insulation and cooling of windings. After sometime water, gas, impurities, etc.
contaminate the oil and its break down voltage comes down. It is advisable to
condition this oil for efficient performance. This saves cost of using new oil
frequently and also increases the life of the transformer.

II. GENERAL DESCRIPTION
NIRMAL Transformer oil conditioning machine is suitable for conditioning

Transformer oil and drying transformer insulation.
The oil conditioning machine is mounted on a compact under carriage with

suspension springs and pneumatic tyres. Screw jacks are provided to release
load on tyres during operation and to level the machine horizontal on the
ground. The complete machine is provided with sheet metal casing with
necessary doors providing access to all controls and is suitable for out door
operations
The machine is designed for the following operation of oil
1. Degassing, de-watering and filtering of transformer oil.

2. Evacuation of transformer
3. On-site drying of transformer.
1. Conditioning of oil:
The oil, besides acting as a dielectric barrier, also carries the heat way. On the
other hand, it absorbs water and gases from the atmosphere and solid
insulation ageing products during service, resulting in a considerable decrease
in its break down voltage, insulation resistance and increase in dielectric loss
factor. Even commercial oil is seldom sufficiently pure for direct use in high
voltage equipment, being subject to contamination in transport containers and
liable to absorb unacceptable quantities of moisture and air because of contact
with atmosphere.
Conditioning of the oil eliminates,
-Solid impurities
-Free and dissolved water
-Free and dissolved gases
By degassing, de-watering and filtration breakdown voltage of the insulating oil

can be substantially increased.
a. Filtration
1. Ferrous and non-ferrous particles of above one mm in size are arrested

by magnetic filter (2) provided before inlet gear pump.
2. Filtration of solid impurities is carried out by non-hygroscopic filter

cartridges of high dust holding capacity.

b. Degassing and Dehydration
Evacuation of the degassing chamber causes the water content in the

oil to evaporate. The water vapour and gases released by the oil are
extracted out from the degassing chamber by the vacuum pumps. At
entry into the degassing chamber, the oil is distributed and directed
through Raschig ring columns. The packed Raschig ring columns
ensure distribution of oil into a thin film thereby maximizing exposure of
each particle of oil to vacuum.
2. Evacuation of transformer
Provision is made to evacuate the transformer by using the vacuum pumping

system provided in the filter machine, when not being used for filtration system.
3. On site drying of transformer
The oil and other transformer insulation components are liable to absorb
moisture after several years of operation. Substantial ingress of moisture into
transformer is bound to take place, especially during repairs. Transformer
therefore requires drying from time to time.
On account of high cost of transporting a transformer back to factory, the

insulation is normally dried at site. Necessary provision for hot oil circulation
through the transformer and vacuum pumping system for evacuating the
transformer is provided in oil conditioning machine.
4. Erection
A) The machine is made and dispatched in two parts, i.e.
a) Oil conditioning machine.

b) Axels – 2 Nos.
B) These have to be assembled together as per match markings made on

the frame legs of machine and the axels.
C) At a time of assembly of machine over to trailer ensure to bolt outlet pipe

flange of centrifugal pump (23) along with the pump box frame (with
metallic covers).
D) The tow bar is dismantled at a time of dispatch and this has to be

assembled as per sketch enclosed.

E) Also refer the “Machine Erection & Installation Instruction” (as below)
along with drawing “Trailer (Tow Bar and Axel Fixing, N.060.0350X.01)”
attached.
Machine Erection & Installation Instruction:
1) The machine is supplied with the following items( in loose condition):

i) Tow Bar
ii) Front Axel Assembly (with wheels)
iii) Rear Axel Assembly ( with wheels)
iv) Screw Jack (4 Nos.)
v) Outlet Pump Bracket Assembly (with pump and pipe assembly).
vi) Fasteners ( 1Set)
vii) Spreader Bar (2 Nos.)
2) To start with open the wooden boxes and un-fasten all the components
from the boxes.
3) Follow the below recommendation and procedure to lift the machine.
Recommendations:
i) Minimum 2 cranes to be used for erection of the machine.
ii) Individual crane should have a load bearing capacity of minimum
6 tonnes.
iii) Two slings to be used for loading erecting the machine
(as shown in the drawing N.060.0404X.01).
iv) Each sling should be at least 40 feet in length and capable of
lifting 12 tonnes of load.
v) Spreader bars should be used while erecting the machine.
Procedure for Lifting the machine:

i) Fasten the slings into the two eye-hooks from both sides (as
shown in the drawing N.060.0404X.01).
ii) Pass the individual fastened slings through the individual
spreader bars end by creating a gap of at least 3 inches between
the lower surface of the spreader bar and the roof of the machine
(as shown in the drawing N.060.0404X.01).
iii) After carrying out the above procedure, insert the lifting hook of
crane-1 into the front fastened sling and lifting hook of crane-2
into the rear fastened sling.
iv) Now gently lift the machine by using both the cranes
simultaneously and place the machine on the ground.
4) After lifting the machine, assemble and fasten the Screw Jacks (4Nos.)
(Item - 4, as shown in the drawing N.060.0404X.01)
5) Then place the machine along with Screw Jacks on the floor and
assemble the Front Axel Assembly and the Rear Axel Assembly
(Items – 2 & 3, as shown in the drawing N.060.0404X.01) matching the

identification numbers punched on the machine frame leg and the
axels mounting legs.
6) After assembling the axels, assemble and fasten the Tow Bar and the
Connecting Rod (Items – 1 & 18, as shown in the drawing
N.060.0404X.01)
7) Now assemble and fasten the Outlet Pump Bracket Assembly (with
pump and pipe assembly) to the machine frame (Item - 16, as shown in
the drawing N.060.0404X.01). Make sure to remove the cover sheet of
the Pipe Assembly (Item - 17) before assembling the Outlet Pump
Bracket Assembly.
8) Finally, connect and fasten the Pipe Assembly (Item - 17) to the bottom
of the Degassing Chamber (Item-19 as per FLOW CHART, dwg.
N.070.0404)
5. Towing
A turntable with tow bar is provided in the trailer to hitch the machine to a
towing vehicle for towing the machine over motor able roads. The tow bar can
be lifted to hitch up to desired level of towing vehicle. The trailer is fitted with
mechanical overrun brakes and parking brake.
During towing the parking brake of the machine is to be released and the screw
jacks are to be lifted up and bolted as shown in the sketch enclosed.
Connect power supply from prime mover to the indicator lamps of trailer.
5.1 Towing Precautions
i) Always check lug nut torque before each trip to a torque of 15Kgf m
(108-lbf ft). Wheel nut torque is usually much higher than that specified
for passenger car wheels; check the torque on all wheels after the first
25-30 miles of towing. Do not drive a loaded trailer with a missing lug nut
or damaged lug bolts.
ii) Check tyre inflation and tread wear periodically. Inflate the tyres to
match manufacturer‟s guidelines (60 psi). Since tyres with too much or
too little air pressure can cause the trailer to sway.
iii) CAUTION: DO NOT TOW THE MACHINE BEYOND

30 KMPH SPEED

III. TECHNICAL SPECIFICATION
1. Model JHVR 6000X

2. Oil through put 6000 LPH
3. Degree of vacuum in Degassing Less than 0.5torr
Chamber second stage, in final
Pass
4. Nominal filter rating 1 Micron
5. Suction capacity of Rotary vacuum 100 cub.mtr/hr.
Pump
6. Suction capacity of Roots pump 500 cub.mtr/hr.
7. Operating temperature of oil 60 deg. C
Conditioning
8. Total heating power 100 kW
a) Stage I 50 kW
b) Stage II 50 kW
9. Motors
a) Gear pump 3.75 kW
b) Centrifugal pump 3.75 kW
c) Vacuum pump 2.2 kW
d) Roots pump 2.2 kW
10. Total power required 112 kW
11. Supply – Voltage 3 Ph. 415 Volts 50 Hz
12. Approximate qty. of oil required 400 liters
For initial filling
13. Others
a) Total wt. Of machine 4000 kgs ( 200Kgs)
b) Overall dimensions with tow bar 3100L x1900 W x 2750H
in mm
c) Hose connections
d) Oil inlet / outlet 40 NB wire braided nitrile rubber
hose
e) Towing Speed 30 Kmph max.

IV. MACHINE COMPONENTS
Refer flow chart drawing no. N.070.0404
4.1 Valves
a. The valves provided in the oil line, drain line, and aeration line is three-
piece ball valves with Teflon seating and stainless steel balls.
b. The valves provided in the vacuum line are slim seal butterfly valves with
nylon coated disc.
4.2 Magnetic Strainer (2)
The strainer provided in inlet consists of powerful magnets covered by wire

mesh which protects the gear pump (4) by arresting the magnetic particles and
coarse dirt, upto 1 mm in size. The insert can be easily removed for cleaning
without dismantling the assembly from pipeline.
4.3 Dial thermometers (3 & 12)
These thermometers are bimetallic dial type and measure the oil temperature
before inlet pump and after filter. The measuring range is 0-150 deg.c.
4.4 Inlet gear pump (4)
The positive displacement gear pump (4) sucks the oil from
transformer/storage tank and delivers it to oil conditioning system. The pump
is provided with built in pressure relief valve. A flow control valve (5) is
provided across gear pump to control the flow into the system.
4.5 Oil Heater (6)
The oil heater heats the transformer oil to the required set temperature. It is
provided with electrical resistance elements enclosed in M S tubes separating
them from oil. The heat density of these heater tubes is kept as low as 2.0
2
watts/cm to avoid over heating of the oil. Suitably located deflector plates
direct the oil at high flow velocities across the heater tubes, thus ensuring
efficient heat transfer and low heating surface temperature. The heating
elements are divided into two banks each individually controlled by a
Temperature Indicating Controller (7). For the required oil conditioning
temperature of 60 deg. C, This Controller set at 55 and 60 deg. C.

4.6 Safety Thermostat (10)
This safety thermostat is tamper proof and factory set at about 110 deg.C. In
the remote possibility of the regulating thermostats failing to shut off the heater
at the set temperature, the safety thermostat provides a final failsafe
arrangement, to avoid any accidental over heating.
4.7 Safety Relief Valve (11)
This relief valve is set to open at a pressure of 5 kg/sq.cm to take care of any
accidental rise in pressure in the heater vessel.
4.8 Filter (13)
The oil is filtered by special non-hygroscopic filter cartridges, which have a

unique feature of medium being progressively denser in the direction of flow.
Thus coarser particles arrested in the outer layers of the filter cartridge and the
inner layers arrest relatively finer particles. Hence the full depth of the medium
is available for particle retention, thereby ensuring a long cartridge life. The
cartridges can be replaced easily.
The condition of filter cartridge in filter (13) is indicated by the compound gauge
(14) on the filter. The cartridge should be replaced if oil pressure exceeds 3
Kg/sq.cm. The filter is provided with an aeration valve (15) in filter (13) for
purpose of draining the vessel.
4.9 Degassing Chamber (19)
The optimally designed two stage degassing chamber consists of columns of

raschig rings to ensure maximum exposure of oil to the high vacuum, which
causes free & dissolved water and gases to evaporate from oil. Water vapour
and gas thus released are pumped away by the vacuum pumping system. An
illuminated sight glass is provided for each stage, through which oil flow and
level in the Degassing Chamber can be observed.
4.10 Level Monitors (21)
Optical level monitors incorporated in the each stage of degassing chamber

switch OFF inlet feed pump (4), when oil/foam level increases beyond the
stipulated level in the degassing chamber, thereby preventing oil/foam ingress
into the vacuum system.

4.11 Discharge Pump (23)
A special Glandless Centrifugal type pump is provided to suck the oil from
degassing chamber and deliver it to transformer/storage tank. This pump has
no gland or rotary seal and thus ensures total isolation of conditioned oil from
atmosphere.
4.12 Oil Sampling Valve (24)
A ball valve with rubber tubing is provided to collect oil samples after
conditioning. The sample container should be absolutely clean, dry and air
tight.
4.13 Rotary Vacuum pump (29) Model RA0100 F
This pump has sufficient throughput capacity to create and maintain high
degree of vacuum required for conditioning of oil. This pump is provided with
gas ballast facility, to prevent water vapour condensation inside the pump thus
ensuring that the pump oil remains free from contamination. This pump
operates as backing pump to roots pump. (Please refer vacuum pump manual
before operation).
4.14 Roots vacuum pump (28) WP500
This pump provides high suction capacity required for conditioning of oil. The
roots pump starts automatically when the pressure at pump inlet drops to 500
mbar. Which is achieved through backing rotary vacuum pump, a vacuum
switch (38) is provided at roots pump inlet, which senses the vacuum and
switches ON the roots pump.
4.15 Control Cabinet (32)
Besides the normal electrical elements, (Ref. Electrical diagram

Drg. No. N.080.0404) mounted in the control cabinet, the
following instruments are also provided on a separate panel door
attached to the cabinet.
Temperature Indicating Controller (7)
Mimic diagram, which indicates the state of operation of the machine

with the following audiovisual annunciation fault indication.
a. High oil temperature - activated by safety thermostat (10)
b. High oil level - activated by optical level monitors (21)
Low oil level - activated by float switch (39)

Vacuum Pump motor trip - activated by MPCB 1
Roots Pump motor trip - activated by MPCB 2
Outlet Pump motor trip - activated by MCB 3
Inlet Pump motor trip - activated by MCB 4
c. Indicating lamps - provided for all pumps, heaters,

mains and phase indication.
d. Selector switch - provided for all pumps and heaters

ON/OFF type
e. Push button - provided for mains control circuit.
f. Pirani Gauge (37)
g. Ammeter & Voltmeter with selector switch.
4.16 Non return valve (NRV) (25 & 34)
These spring loaded non-return valves ensure that the degassing chamber is
not flooded with oil either from the transformer or the storage tank when there
is shut off of the discharge pump (23), in the event of a sudden power failure.
NRV (25) is rated at around 0.2 Kg/sq.cm and NRV (34) is rated at around 0.8
Kg/sq.cm.
4.17 Vacuum gauge (8, 9) (Range: 0-760 mm of Hg.)
These are Bourdon tube, glycerin filled dial type gauge provided to measure
the vacuum in the first & second stage of the degassing chamber.
4.18 Trap (35)
This trap is incorporated before roots pump in second stage vacuum line and
transformer evacuation for condensation of moisture and oil vapour. One sight
glass and drain valves (36) is provided in the trap.
4.19 Pirani Gauge (37) (Range: ATM-0.001 mbar)
This is a Vacuum-measuring instrument designed for use with thermal

conductivity type gauge head (sensor) having range from 1000 mbar to 0.001
mbar.
This gauge is provided to measure the absolute pressure in second stage
degassing chamber as well as in transformer.

4.20 Float switch (39)
Float switch is incorporated at the outlet of degassing chamber switches OFF

discharge pump (23), when oil level decreases beyond the stipulated level in
the outlet of degassing chamber, thereby preventing dry running of discharge
pump.
4.21 Flow meter (41)

This flow meter is of mechanical type with analog counter. It measures
the oil flow rate in LPH and batch quantity in liters. To protect flow
meter, Strainer (40) is provided at inlet of flow meter.

V SAFETY PROVISIONS
1. Gear pump is protected by a built-in relief valve, which by passes the oil
back to the suction line in the event of excessive pressure buildup.
2. Heater and inlet gear pump are electrically interlocked in such a way that
heater cannot be switched „ON‟, if the inlet gear pump is not working.
3. Adverse effect of heat on oil due to failure of control thermostats and

consequent overheating are prevented by safety thermostat (10).
4. Safety Relief valve (11) opens if the oil pressure in the heater vessel
exceeds the maximum permissible value.
5. Optical level monitor (21) switches off inlet gear pump in the event of
excessive build up of oil/froth level in the degassing tank.
6. Non-return valves are provided at inlet and outlet to prevent suck back of oil
from the transformer in the event of power failure.
7. Low-level float switch (39) prevents dry running of discharge pump.
8. Roots pump puts ÒN‟ only when vacuum pump is switched ÒN‟.
9. Audiovisual annunciation system warns the operator of various process

faults arising in the machine during operation.

VI INSTALLATION AND PREPARATION OF MACHINE:
1 Install the machine horizontal to ground level using screw jacks. Apply
parking brake provided at front end of machine.
2 All valves in oil and vacuum lines are closed. All aeration valves and drain
valves are closed.
3 All switches are in OFF position
4 Connection to power supply:
Connect the power supply cable ensuring

Supply voltage : 415 volts, 3 Ph. AC
Cable size : 3 ½ core x 185 sq.mm Armoured aluminum 1.1 kV
grade OR
4 core x 120 sq.mm Armoured copper 1.1. kV
grade
Earth: Connect earth to the machine earth terminal
5 Check all electrical connection in control panel and on motors physically, if

found loose tighten them & also heater circuit wiring to be check.
6 Oil heater (6)
Set the Temperature Indicating Controller (7) at 60 deg. C. Safety thermostat is

factory preset at 110 deg. C.
7 Filter (13)
Ensure that the filter cartridges are fixed properly as per the sketch enclosed.
Replace used cartridges when choked.
8 Rotary Vacuum pump (29) & Roots pump (28)
a) Drain the water from vacuum pump oil by opening drain valve.
b) Check the oil level and add up further quantity of oil if necessary up to
the level required. Recommended grade of oil for vacuum pump is
Molecularly Distilled Vacuum Pump Oil available from:
i) BUSCH Pumps, Germany

ii) Fowler Westrup (India) Limited
iii) Any reputed vacuum pump manufacturer
NOTE: In case of emergency when molecularly distilled vacuum pump oil

is not available filtered ENKLO 100 grade oil of Hindustan
Petroleum or other equivalent grade oil can be made use of.

9 To avoid unnecessary over loading of the oil conditioning machine, open the
transformer/tank drain valve and run all the dirt and water off i.e. until clean oil
appears at the outlet.
10 Connect oil hose between supply tank/transformer and oil conditioning

machine in the straight and shortest manner possible. If the suction head is
less and/or if the suction line is long, then a feed pump should be connected to
the supply tank.
11 Drain the oil & condensed moisture from trap (35) through drain valve (36)
before switch „ON‟ the machine.

VII OPERATION OF MACHINE
A. CONDITIONING OF OIL:
1. Switch the Main MCCB ‘ON’ and check all the 3 phase indication lamps are
glowing.
2. Check voltage 415 V across three phases in voltmeter by selector switch.
3. Switch main control push button „ON‟.
4. Hooter sirens indicating fault conditions.
5. Press Àccept‟ push button.
6. Check for proper direction of rotation of Gear pump motor as marked, by rapid
switching „ON & OFF‟, if found reverse, interchange any two-supply phase of
main incomer.
7. Switch ‘ON’ the vacuum pump (29). Roots pump (28) starts automatically when
the vacuum switch (38) actuates at the set vacuum level of 500 m bar.
8. Open the Gas Ballast valve of vacuum pump (29).
9. Open valve (16).
10. Run vacuum system for 15-20 minutes and open valves (27) and (31).
11. When pressure in degassing chamber drops to 4 mbar, as measured in Pirani
gauge (37) open valves (1 & 26) and open transformer/ oil storage tank inlet
and outlet valves.
12. Switch ‘ON’ the gear pump (4) by keeping all the valves in the oil line in open
condition except for the valves of stand-by equipments.
13. When the oil appears in the degassing chamber up to the level marked on the
sight glass, switch ‘ON’ the centrifugal pump (23).
14. Switch ‘ON’ all the heating banks.
15. If required the flow can be regulated, by opening the valve (5) provided across
inlet gear pump.
16. If froth persists in rising in spite of throttling, open valve (20) until the froth
subsides, then open valve (16) fully.
17. It is recommended that initially till steady operating temperature of 60 deg.C is
reached, the oil is circulated within the machine itself, which is carried out by
opening valve (22) and closing valves (1 & 26).
18. After reaching the steady operating temperature of 60 deg. C, close valve (22)
and open valves (1 & 26).
19. Note down reading in the compound gauge (14) mounted on filter vessel (13),
if it reads beyond 3 Kg/sq.cm, change the filter cartridge.
20. Check the oil temperature in dial thermometer (12), it should be 60 deg. C for
effective conditioning of oil.
21. Gas ballast valve of vacuum pump (29) to be closed when the vacuum in the
system is about 6 mbar as measured in Pirani gauge (37).
22. Circulate the oil till required parameters achieved. On achieving the
parameters, machine can be shut down as per the procedure for `Shutting
down of the machine'.

23. In case of power supply failure, all the motors and heaters circuit will be
isolated. Non-return valves (25 & 34) prevent the flooding of degassing
chamber. A push button is provided to switch the control circuit ÒN’ after
power supply is resumed.
24. Current drawn during operation of machine can be checked using Ammeter.
25. For any fault condition, an audiovisual annunciation hooter alarm turns ÒN’.
Press Àck‟ (Acknowledge) button. Analyze and rectify fault condition and then
press `Reset‟ button.
B. HOT OIL CIRCULATION
When hot oil is to be circulated through the transformer for heating it up to a

temperature of around 80 deg.C., following procedure is adopted.
1. Close all the valves.

2. Connect inlet & outlet hose to transformer.
3. Open inlet valves (1, 26 & 30).
4. Switch the inlet pump (4) ON, wait for oil to flow through outlet.
5. Put all the heaters ON and set the temperature indicating controller to
80 Deg. C. to get required oil temp. of 80 Deg. C.
6. Circulate the oil till the required temperature is reached in the
transformer.
NOTE: At the time of hot oil circulation the degassing chamber and
centrifugal pump are completely by-passed.

C. SHUTTING DOWN
1. Switch all the heaters OFF and leave the oil in circulation for about 15-
20 minutes to dissipate the heat stored in the heater elements.
2. Close the transformer valve connected to inlet of filter machine and
slightly loosen its hose connector to vent the hose. When the decreasing
noise from the gear pump (4) indicates the hose is empty, close inlet.
3. Switch OFF gear pump (4) and centrifugal pump (23).
4. Close valve (27) & (31).
5. Run the vacuum pumps for 20-30 minutes with gas ballast valve open to
dehydrate the pump oil.
6. Switch OFF the vacuum pump (29).
7. Open valve (20) to aerate the degassing chamber.
8. Set all the switches to OFF position.
9. Close all valves in the oil and vacuum line.
10. Drain the oil and condensed moisture from trap (35) through valve (36).
D. TRANSFORMER EVACUATION
Provision is made to evacuate the transformer by using the vacuum pumping

system provided in the filter machine, when not being used for filtration system.
Connect Transformer Evacuation Valve (33) to transformer by a vacuum hose

(50 NB).
Close valve (27) & (31).
Open gas ballast valve of vacuum pump (29).
Switch ON vacuum pump (29). Roots pump (28) starts automatically when the
vacuum switch (38) actuates at the set vacuum level of 30-50 m bar.
After 15 –20 minutes open valve (33) and transformer valve.
Note down the readings in Pirani gauge (37).
Once transformer evacuation operation completes close the valve (27).
Switch off the vacuum pump (29) & roots pump (28).
Open the valve (27&31)

E. DRAINING FOR TRANSPORT AND MAINTENANCE:
1. Switch the main “MCCB” „ON‟.

2. Switch on vacuum pump (29) and open its gas ballast valve.
3. Open valves (16, 26, 27 & 31).
4. Draining the equipment can start when pressure in the degassing
chamber (19) is down to 4 mbar.
a) Draining of filter (13)
Open drain valve (17) and aeration valve (15) of filter. The differential
pressure across degassing tank and filter vessel will cause the oil to
drain into degassing chamber. Close valve (17) if pressure starts
to rise in degassing tank. When the oil in the degassing tank rises above
sight glass level during draining, empty the tank by intermittent operation
of outlet pump (23).
b) Draining the oil heater (6)
Open drain valve (18) and aeration valve (15) of filter. The resulting
differential pressure across degassing tank and oil heater will cause the
oil to drain into degassing tank. Close valve (18) immediately if pressure
starts to rise in degassing tank. When the oil in the degassing tank rises
above sight glass level during draining, empty the degassing tank by
intermittent operation of outlet pump (23).

F. TROUBLE SHOOTING:
Sl.
DESCRIPTION CAUSES REMEDIES
No.
1 Insufficient oil a) Oil feed restriction Clean coarse filter (2) .
flow, owing to clogged condition
cavitation of coarse filter (2) .
noise from b) Defective hosing (cut, Replace faulty hose
gear pump (4) damaged, kinked)
c) Insufficient supply Increase supply head if necessary
head. by providing a centrifugal pump at
the transformer outlet.
d) Inlet solenoid valve Check solenoid valve
(optional-where
applicable) not opened
e) Low / no oil in Check oil is full in transformer
transformer
2 Overfilling of a) Excessive resistance to Close valve (26) and leave it

degassing flow in the pressure line, closed while oil is visible in the
chamber owing to an undersized degassing tank during operation of
(Optical level hose diameter centrifugal pump (23). Check for
monitor air bubbles rising from the suction
indicating high line of centrifugal pump (23).Fit a
oil/foam level) larger diameter hose.
b) Excessive delivery head Verify delivery head should not
exceed 10 meters or as specified
in specification.
c) Half-open valves, Check outlet valve and open fully.
d) A leak on the suction Replace flange "O” ring at suction
side of centrifugal pump side of centrifugal pump.
(23)

3 Continuous a) High gas and water Check initial oil quality, if badly
strong content in the oil inflow contaminated and is more than the
frothing in the initial specified values, carefully
degassing monitor and control the oil flow
chamber under Sec VII A, as specified in
manual
b) Leaks in the suction line Check suction line for leaks
c) Inlet & outlet hoses not Inlet & outlet oil hoses connecting
dipped in oil to transformer are dipped in
transformer oil.
d) Operational procedure i) Check direction of rotation of
faults outlet pump
ii) Throttle inlet valve and open flow
control valve to reduce inlet flow
iii) 1st stage (& 2nd stage -where
applicable) vacuum line valve to be
closed. Gradually open the 2nd
stage valve followed by 1st stage
vacuum line valve on stabilization
of foam level
iv) Alternatively settle the foam by
shutting down the inlet pump and
closing 1st and 2nd stage vacuum
line valves. Restart the inlet pump
and gradually open the 2nd stage
valve followed by 1st stage vacuum
line valve on stabilization of foam
level
v) Slightly open air vent valve (20)
of degassing chamber (only in
emergency)
4 Low vacuum a) No oil in vacuum Ensure use specified grade

level in pump/Specified grade vacuum pump oil & fill oil quantity
degassing vacuum pump oil not used up to mid of vacuum pump sight
chamber. glass
b) Vacuum pump oil Replace vacuum pump oil
excessively contaminated
like emulsion
c) Aeration valves are i) Check aeration valves 15 & 20
open or leaks in system are kept closed
ii) Check for any vacuum leaks in
the system
d) Faulty vacuum gauge Replace vacuum gauge
e) Vacuum pumps running Check rotational direction of
in reverse direction vacuum pumps

5 Frequent a) Vacuum pump system Warm up of vacuum pump system
contamination not warmed up during 15 to 30 minutes as detailed in
of vacuum initial startup vacuum pump.
pump oil b) Gas ballast valve of Gas ballast valve to be kept open
vacuum pump not kept till final vacuum level of 6 mbar is
opened achieved in degassing system
during filtration
c) Condensed water in Drain water from vacuum pump oil
vacuum pump oil before initial starting of vacuum
pumps and top up with vacuum
pump oil till mid level of sight glass
d) High moisture content in Vacuum line valve to be kept
transformer oil and excess closed to avoid transformer oil
foaming in degassing carried through vacuum line to
chamber vacuum pumps.
6 Oil being
drawn into the
degassing
chamber
a) Through a) Improper functioning of i) Check the proper seating of End
NRV valve (25) non-return valve (25). Plates within the NRV.
when pump ii) Change non-return valve (25).
(23) is
inoperative:
b) Through b) Improper functioning of i) Check the proper seating of End
NRV valve 34 non-return valve (34). Plates within the NRV.
during power ii) Change non-return valve (34).
failure
7 Vacuum a) Pumps have been Reduce froth level by throttling flow

pumps filling- drawing froth owing to with inlet valve (1) and flow control
up with excessive froth formation. valve (5). Drain pump oil and refill
transformer Intense oil evaporation in with fresh oil.
oil / oil the degassing tank
overflow: chamber causes
transformer oil to
condense in the
condensers/vacuum
pumps.
b) Excess oil level used in Ensure vacuum oil level at mid of
vacuum pump sight glass of vacuum pump
c) Sudden opening of Vacuum line valves to be opened
vacuum line valves gradually
d) Trap filled with Trap to be drained before starting
transformer oil the vacuum pump

8 Roots pump a) Overloading of roots This is due to sudden opening of
Motor MPCB pump vacuum line valves during initial
trip startup of roots pump. Open
vacuum line valves gradually.
b) Wrong setting of Check settings as per motor
MPCB/MPCB faulty nameplate/ replace MPCB
c) Wrong setting of Verify & set vacuum switch
vacuum switch/vacuum indicator to -0.9 Kg/sq cm by
switch faulty rotating screw provided at top of
vacuum switch. Fine adjust it
suitably to start roots pump at
50m.bar vacuum as measured in
pirani gauge
d) Mechanical jamming of Check by rotating the pump shaft
roots pump coupling by hand.
e) Moisture trap / vacuum Drain oil if any, collected in trap of
line filled with oil. vacuum pipe line before starting
vacuum pumps.
f) Operational procedure Check rotational direction of roots
faults pump
g) Abnormal noise in Check bearings
pump and excessive heat
at shaft end housing
9 Pirani gauge- a) Oil vapor contaminating Clean the sensor using acetone by
No the sensor during foaming removing the sintered filter disc.
display/error Dry & re-assemble the sintered
reading (Also disc
refer b)Sensor filament Check the resistance in sensor
manufacturers damaged/fused leads & should be around 75 ohm's
instruction c) No power supply. Verify power supply of 230 V
manual d) Fuse blown in display Replace fuse
enclosed) unit.
e) Loose connection of Secure end connectors firmly
sensor cable at sensor
head & display unit.
10 Temperature a) No power supply. Verify power supply of 230 V

Indicating b) Loose connection of Retighten the terminal connections
Controller-not sensor cable terminals at
working/no sensor head & display
display (Also unit.
refer
manufacturers
instruction
manual
enclosed)

11 Operating of a) Temperature Indicating Check Temperature Indicating
Safety Controller damaged or set Controller for proper setting.
thermostat (10) too high.
b) The heaters and gear a) Switch gear pump ON &
pump are switched dissipate heat by oil circulation
OFF at the same time b) Safety thermostat should cut
causing the oil heater in again when the oil temperature
temperature to build up falls below 80 - 85 deg. C.
above the permissible limit
owing to the stored heat in
the heater elements.
G. OIL SAMPLE TESTING:
1) Oil sample to be collected in air tight, clean, amber colored glass bottles/SS
bottles.
2) Necessary precaution to be taken to avoid contamination during sampling.
3) Only calibrated and good condition instruments to be used for testing (like
BDV, gas content & etc.)
4) Oil samples to be taken from machine sampling valve and to be tested
immediately to avoid ingress of moisture from atmosphere.

H. SPECIAL NOTE:
Please ensure that the following points are followed during preparation, starting
and running of the machine and which have already been elaborated in the
operation manual.
1. Check the power supply for maximum power supply voltage and
frequency for which the machine is designed.
2. Check for proper direction of rotation of pumps.
3. Centrifugal pump should never run dry.
4. During running of the machine, especially during starting, it should be

carefully and continuously monitored that the oil/foam level never
increases beyond the middle level of the degassing chamber at any
time. This level is clearly marked on the sight glass. During starting of
the machine, when the initial gas content is high, the oil/foam in the
degassing chamber may be more. This oil/foam level can be controlled
by partly throttling inlet valve (1), opening bypass valve (5) across gear
pump, throttling valve (16) and if required by opening partly aeration
valve (20). This precaution is absolutely essential for smooth operation
of the machine till stabilized operative condition is attained.
5. Before stopping of the machine, the heaters provided in heater vessel

should be switched off first and the oil has to be circulated for at least 15
minutes to take away the heat from the heater tubes.
6. Before starting the machine, check the vacuum oil level in the vacuum
pump through the sight glass. The oil level should always be in line with
the indicated level marked on the sight glass. If not, add up further
quantity of oil to the indicated level.
If vacuum oil is contaminated, with excess moisture and contaminants,

like transformer oil, do not add fresh oil. First drain out all the
contaminated oil and then fill the new vacuum pump oil. The
recommended grade of oil for vacuum pump is mentioned in preparation
of machine.
This is very important for smooth running of the machine.

I. MAINTENANCE OF OIL CONDITIONING MACHINE:
The Nirmal HIVAC machine has been designed for minimum maintenance, but
like all machinery, some regular attention is required to ensure trouble-free
operation. Maintenance can be carried out using normal workshop tools.
Before carrying out any maintenance work, make sure that the filter machine is
disconnected electrically & vacuum pressure is completely released.
a) MAGNETIC STRAINER (2) .
The magnetic strainer should be checked and cleaned when there is no suction
of oil from the transformer to the machine, when the inlet pump is switched on.
The strainer element can be removed without dismantling the magnetic strainer
vessel from pipeline. (Refer Sketch)
 Close transformer valves and valve (1).

 Loosen the bolt and open the top flange of the magnetic strainer. Lift the
element assembly.
 Loosen the nut; separate the perforated core mesh and magnet.
 Clean the magnets and core mesh by compressed air and with transformer oil.
Reassemble the core and magnet. Tighten the nut.
 Refit the assembly. Close the top flange, ensuring proper sitting of spring and
„O‟ rings.
b) HEATER ELEMENTS
Heater elements can be dismantled for replacement: (Refer Sketch)
 Switch off the heaters.

 Remove the cover of the heater vessel.
 Disconnect the electrical wiring and copper strips by loosening the nuts on the
heater elements.
 Take the heater element carefully and ensure there is no damage on the
ceramic grooved pieces of heater element.
 Replace with new heater elements and ensure the heater element sits in a slot
to the maximum depth of the heater tube.
 Reconnect with electrical wiring as it was earlier.
 Close the cover of the vessel and tighten the bolts.

c) FILTER ELEMENTS
When the compound gauge (14) shows 3 kg/cm 2 at the rated flow of the
machine, it is necessary to replace the Filter cartridges. (Refer sketch)
Procedure for replacement of cartridges:
 Drain out the oil from the filter vessel through a common drain point by opening
valve no.15 & 17, when the degassing chamber is under vacuum. (Ref. Filter
Vessel draining procedure)
 Switch off the machine.
 Close the inlet and outlet valves of the machine.
 Remove the top flange.
 Loosen the wing nuts.
 Remove the neoprene washer and the plate.
 Take out the filter cartridges.
 Replace with new cartridges and ensure the bottom neoprene washer is placed
in its position properly.
 Ensure „O‟ ring on the filter vessel is not damaged and is seated properly in its
groove on the filter vessel.
 Close the top flange and tighten the bolts and nuts uniformly along with spring
washers
d) INLET GEAR PUMP
The pump requires very little maintenance. During the maintenance of the pumps
the following procedure has to be followed:
 Drain the oil from the heater vessel to the degassing chamber through drain
valve no 18. (Ref. Heater vessel draining procedure)
 Close valve no. (1), (18) & (22).
 Remove the electrical connections of the motor.
 Remove the bolts and nuts of the motor mounted on the frame.
 Pull the motor out by hand and remove the star bush between the pump and
motor shaft.
 Loosen the allen screw with allen keys of the couplings.
 Remove the coupling and ensure there is no damage on the key as well as the
keyway.
 Remove the bolts of the body cover of the pump.
 Remove the circlip inside the pump through the circlip plier.
 Take out the shaft from the backside.
 Remove the oil seals.
 Ensure there is no damage on the shaft motors and bush.
 Replace the worn out parts.

ASSEMBLY OF THE PUMP
 Fix the oil seals and bush.

 Insert the shaft from the backside of the pump.
 Turn the shaft smoothly and see to that the shaft rotates freely by hand.
 Close the back cover.
 Refit the circlip.
 Fix the coupling on the shaft and tighten the allen screws.
 Couple with the motor couplings and ensure free rotation of the shaft and
reconnect electrical wires.
 Alignment between the pump and the motor can be checked using a stand
mounted dial gauge and rotating the shaft.
 Refit the motor to its original position and tighten the bolts.
e) ROTARY VACUUM PUMP (29)
 The vacuum pumps are generally free from maintenance. The following
precautions have to be taken to ensure pumps run smoothly.
 Drain out the contaminated vacuum pump oil and water from pump slowly.
 Tighten the bolt after draining.
 Remove the oil cap and fill oil to the middle level of the sight glass.
 Open the gas ballast valve and run the vacuum pump for sometime to remove the
moisture present inside the pump. (For detailed servicing and over hauling of
pump please refer maintenance manual of pumps).
f) ROOTS PUMP (28)
 To drain the contaminated oil, remove the drain plug.

 The drain plug can be fixed back after the oil is fully drained.
 Remove the oil plug at the top and fill the oil to the middle level of the sight glass.
 Close the oil plug.
g) GAUGES
 While replacing the gauges ensure the threads of the gauges are wrapped with
Teflon tape.
 Tighten gauges to the plug point so that there are no leakages.
h) ELECTRICAL EQUIPMENT
 Electrical faults may be traced with reference to the schematic Electrical Diagram.
If a fault persists check for the cause and rectify the fault before resetting the
circuit breaker.

J. OPERATOR SAFETY:
 Read all instructions carefully and be thoroughly familiar with the oil-
conditioning machine.
 To protect against electrical hazards do not open the control panel, when the
machine is in operation.
 Do not touch the pumps while running.
 Do not touch the heater vessel when the machine is in operation.
 Before doing maintenance, switch „OFF” the main switch.
 De-aerate the degassing chamber after completion of oil processing.
K. RECOMMENDED SPARES FOR NORMAL OPERATION
Sl.no Description Qty. Make

1 Filter cartridge-1 micron 12 nos. Cuno
2 Heater element 4.16 kW 24 nos. Fowler Westrup
3 Dial thermometer 0-150 deg. C 2 nos. Kains
Vacuum gauge 0-760 mm of Hg
4 2 nos. Radix
(Glycerin filled)-100 mm dia
5 Compound gauge –1 to 4 kg/sq.cm 1 no. Kains
6 Optical level monitor 2 nos. Filpro
7 Float switch 1 no. Filpro
8 „O‟ rings 1 set Fowler Westrup
9 M. D. Vacuum pump oil 20 ltrs. Fowler Westrup
10 Vacuum switch (-1 to 0 bar) 1 no. Switzer

OIL IN
OIL OUT
BANGALORE - INDIA
FOWLER WESTRUP (INDIA) PVT LTD.
PARTS LIST (AS BUILT)
TITLE : FLOW CHART PART LIST COMPILED : CGD 18.01.2017

MODEL : JHVR 6000X CHECKED : YM
CAPACITY : 6000 LPH APPROVED : YM
DRG NO. : N.070.0404 PL REV. 0 DOC. NUMBER : F-DGN-NF-09 R0
SHEET 1 OF 2
SL. NO. DESCRIPTION SIZE QTY. MAKE
1 BALL VALVE 40 N.B. 1 VAAS
2 MAGNETIC STRAINER 40 N.B. 1 FOWLER WESTRUP
3 DIAL THERMOMETER 0-150 DEG.C 1 KAINS
4 INLET GEAR PUMP 1 TUSHACO
POSITIVE
TYPE DISPLACEMENT
CAPACITY 6000 LPH
6 HEATER VESSEL 1 FOWLER WESTRUP
CAPACITY 6000 LPH
7 TEMP. INDICATING CONTROLLER 0-150 DEG.C. 1 RADIX
8 VACUUM GUAGE 0-760 mm of Hg. 1 RADIX
9 VACUUM GAUGE 0-760 mm of Hg. 1 RADIX
10 SAFETY THERMOSTAT 1 MARUDHAR ELECTRICALS
11 SAFETY RELIEF VALVE 1/2" B.S.P. 1 MAHAVIR
12 DIAL THERMOMETER 0-150 DEG.C 1 KAINS
13 FILTER VESSEL 1 FOWLER WESTRUP
CAPACITY 6000 LPH
DEGREE OF FILTRATION (NOMINAL) 1 MICRON
14 COMPOUND GAUGE -1 TO 4 Kg/Sq.cm 1 KAINS
19 TWO STAGE DEGASSING CHAMBER 1 FOWLER WESTRUP
21 OPTICAL LEVEL MONITOR 2 FILPRO
23 OUTLET CENTRIFUGAL PUMP 1 FLOWWELL
CAPACITY 6000 LPH
TYPE GLANDLESS
25 NON RETURN VALVE 40 N.B. 1 FOWLER WESTRUP 0.2 Kg/Sq.cm
27 BUTTERFLY VALVE 50 N.B. 1 L&T
28 ROOTS PUMP 1 BUSCH
CAPACITY 500 CU.MTR/HOUR
29 ROTARY VACUUM PUMP 1 BUSCH
CAPACITY 100 CU.MTR/HOUR
Fowler Westrup (I) Pvt Ltd

TITLE : FLOW CHART PART LIST COMPILED : CGD 18.01.2017

DRG NO. : N.070.0404 PL REV. 0 DOC. NUMBER : F-DGN-NF-09 R0
SHEET 2E
32 CONTROL PANEL BOX 1 FOWLER WESTRUP
34 NON RETURN VALVE 40 N.B. 1 FOWLER WESTRUP 0.8 Kg/Sq.cm
35 TRAP 1 FOWLER WESTRUP
37 DIGITAL PIRANI GAUGE ATM - 0.001 mbar 1 HIND HIVAC
38 VACUUM SWITCH -1 TO 0 bar 1 SWITZER
39 FLOAT SWITCH 1 FILPRO
40 STRAINER 1 SCIENTIFIC DEVICES
41 FLOW METER 6000 LPH 1 SCIENTIFIC DEVICES
Fowler Westrup (I) Pvt Ltd

TITLE : ELECTRICAL DIAGRAM PART LIST COMPILED : CGD 10.01.2017

DRG NO. : N.080.0404 PL REV.0 DOC. NUMBER : F-DGN-NF-10 R0
SHEET 1 OF 2
1 CONTACTOR ( KM2 ) 12A 1 ABB
CONTACTOR ADD ON BLOCK
CONTACTOR (KM1,KM3 & KM4) 16A 3 ABB
CONTACTOR ADD ON BLOCK
CONTACTOR (KM5 & KM6) (AC3-100A) 2 ABB
2 MOTOR PROTECTION CIRCUIT BREAKER

MPCB2 4 - 6.3A 1 ABB
MPCB ADD ON BLOCK
MPCB1,MPCB3 & MPCB 4 6.3 - 9A 3 ABB
MPCB ADD ON BLOCK
3 MINIATURE CIRCUIT BREAKER

MCB10 (THREE POLE) 2A 1 ABB
MCB9 (SINGLE POLE) 4A 1 ABB
MCB7 & MCB8 (TWO POLE) 4A 2 ABB
MCB11 (TWO POLE) 2A 1 ABB
4 MOULDED CASE CIRCUIT BREAKER

MCCB 5 & MCCB 6 100A 2 ABB
MCCB WITH ROTARY HANDLE , SHUNT TRIP AND
5 250A 1 ABB
SPREADERS FOR INCOMING SUPPLY
6 TOGGLE SWITCH T1 TO T2 6A 2 SURAJ
7 NEON LAMPS (DIA 8 MM)
L1 TO L7 220V 7 BINAY
8 NEON LAMPS (DIA 22.5 MM)
L8 TO L11 220V 4 SCHNEIDER
9 SELECTOR SWITCH S1 TO S5 5 SCHNEIDER
TWO POLE ÒN/OFF' SWITCH
10 TERMINAL BLOCK FOR MOTOR
4 SQ.MM TERMINAL BLOCK RED 1 WAGO
4 SQ.MM TERMINAL BLOCK YELLOW 1 WAGO
4 SQ.MM TERMINAL BLOCK BLUE 1 WAGO
4 SQ.MM TERMINAL BLOCK GREEN/YELLOW 1 WAGO
END PLATE FOR TERMINAL BLOCK 2 WAGO
11 TERMINAL BLOCK FOR MOTOR
6 SQ.MM TERMINAL BLOCK GREY 4 WAGO
END PLATE FOR TERMINAL BLOCK 2 WAGO
12 TERMINAL BLOCK FOR HEATER
35 SQ.MM TERMINAL BLOCK GREY 6 WAGO
TITLE : ELECTRICAL DIAGRAM PART LIST COMPILED : CGD 10.01.2017

DRG NO. : N.080.0404 PL REV.0 DOC. NUMBER : F-DGN-NF-10 R0
SHEET 2E
13 TERMINAL BLOCK FOR CONTROL
2.5 SQ.MM TERMINAL BLOCK RED 18A 20 WAGO
2.5 SQ.MM TERMINAL BLOCK BLACK 18A 6 WAGO
END PLATE FOR TERMINAL BLOCK 1.5 2 WAGO
14 AMMETER 0-250A 1 MECO
SELECTOR SWITCH FOR AMMETER 6A 1 SALZER (L&T)
15 VOLTMETER 0-500V 1 MECO
SELECTOR SWITCH FOR VOLTMETER 6A 1 SALZER (L&T)
16 AUXILLARY RELAY
KA1 TO KA5 6A-220V (N22E) 5 ABB
L14 - 11W CFL WITH PIN TYPE HOLDER WITH
17 SWITCH T3 ( INSIDE ECP BOX ) 1 PHILIPS
18 PUSH BUTTON (DIA 22.5 MM) NO 1 SCHNEIDER
19 PUSH BUTTON (DIA 22.5 MM) NC 1 SCHNEIDER
20 CURRENT TRANSFORMER 250/5A 3 KALPA
21 HOOTER 220V 1 PARAMOUNT
22 ANNOUNCIATOR 1 MINILEC
23 COOLING FAN 220V, AC 1 HICOOL
24 AIR FILTER 1 JAINSONS
25 EARTH LEAKAGE RELAY(ELR) 300-3000mA 1 PROK DV'S
26 CORE BALANCING CURRENT TRANSFORMER 1 PROK DV'S
(CBCT)
27 ON DELAY TIMER (A1D1X) 0-60 SEC 1 EAPL
28 SPACE HEATER WITH SWITCH T4 60 W 1 GIRISHIGO
MUSHROOM HEAD PUSH BUTTON WITH NC
29 SWITCH NC 1 SCHNEIDER
30 STEP DOWN TRANSFORMER (415V TO 230V) 0.5KVA 1 KALPA
31 MOTOR DETAILS - 415V, 50Hz, 3Ph.

MOTOR FOR VACUUM PUMP 3 HP 1 AS PER PUMP SUPPLIER
MOTOR FOR ROOTS PUMP 3 HP 1 CGL
MOTOR FOR OUTLET PUMP 5 HP 1 FLOWWELL
MOTOR FOR INLET PUMP 5 HP 1 CGL
32 HEATERS 4.16 KW 24 F.W.L
PROVIDED IN 2 BANKS EACH OF 50KW CAPACITY
33 L12 & L13-TUBE LIGHT (DIFFUSER TYPE) 4' LONG 2 CGL
TM
INLET
DIVISION PLATE
SLOTTED TUBE
FIRST STAGE DEGASSING
SIGHT GLASS
SYPHON SEAL
PERFORATED SHEET
SECOND STAGE DEGASSING
RASCHING RING COLUMN OPTICAL LEVEL MONITOR
SIGHT GLASS
OUTLET
DEGASSING CHAMBER
HANDLE
SPRING
HEX.NUT
TOP FLANGE
Ò' RING
HEX.BOLT
HEX.NUT
MAGNETIC DISC
MESH ELEMENT
SHELL
OUTLET
40 MESH
INLET
TM
TOP COVER (M.S.)
WING NUT
WASHER (M.S.)
WASHER (NEOPRENE)
CARTRIDGE
WASHER (NEOPRENE)
NUT (M.S. ZN PLATED)
SHELL (M.S.)
INLET
(M.S.)
OUTLET (M.S.)
TM
BAFFLE PLATE DIVISION PLATE HEATER TUBE

(M.S) (M.S) (M.S)
OUTLET
(M.S)
WASHER
INLET (M.S)
(M.S)
HEATER ELEMENT ASSY BOLT
(M.S)
HEATER VESSEL ASSY
OF
M 2
AR NE-
A
CR
OF
R M E-1
A AN
AR CR
ERB
D
R EA
SP
G
IN
SL
15
3
13
14
17
12
11
7 6
16
4 18 1
10
9 2
NOTE : 1) REFER SHEET 2/2 FOR PARTS LIST

2) ALSO REFER MACHINE ERECTION & INSTALLATION INSTRUCTION SHEET
BANGALORE - INDIA
15
1
6
11 8 B
10
9 7 A 13
5 14
2
12
4 3
18 CONNECTING ROD
17 PIPE ASSEMBLY.
16 OUTLET PUMP BRACKET ASSY.
15 MACHINE
14 M20 SPRING WASHER
13 M20x55 HEX. BOLT
12 M20 HEX. NUT
11 M12 HEX. NUT
10 M12 SPRING WASHER
9 HEX BOLT M12x45
8 SHAKEL BOLT, M16x100(machined)
7 HEX NUT, M16
6 PLAIN WASHER
5 EYE HOOK
4 SCREW JACK
3 REAR AXLE ASSEMBLY
2 FRONT AXLE ASSEMBLY
1 TOW BAR DETAILS @ 'B' DETAILS @ 'A'
ITEM DESCRIPTION
BANGALORE - INDIA
MACHINE ERECTION & INSTALLATION INSTRUCTION:
1) The machine is supplied with the following items( in loose condition):

a) Tow Bar
b) Front Axel Assembly (with wheels)
c) Rear Axel Assembly ( with wheels)
d) Screw Jack (4 Nos.)
e) Outlet Pump Bracket Assembly ( with pump and pipe assembly).
f) Fasteners ( 1Set)
g) Spreader Bar (2 Nos.)
2) To start with open the wooden boxes and un-fasten all the components from the boxes.
3) Follow the below recommendation and procedure to lift the machine.
RECOMMENDATIONS:
a) Minimum 2 cranes to be used for erection of the machine.
b) Individual crane should have a load bearing capacity of minimum 6 tonnes.
c) Two slings to be used for loading erecting the machine (as shown in the drawing
N.060.0404X.01).
d) Each sling should be at least 40 feet in length and capable of lifting 12 tonnes of load.
e) Spreader bars should be used while erecting the machine.
PROCEDURE FOR LIFTING THE MACHINE:

a) Fasten the slings into the two eye-hooks from both sides (as shown in the drawing
N.060.0404X.01).
b) Pass the individual fastened slings through the individual spreader bars end by creating
a gap of at least 3 inches between the lower surface of the spreader bar and the roof of
the machine (as shown in the drawing N.060.0404X.01).
c) After carrying out the above procedure, insert the lifting hook of crane-1into the front
fastened sling and lifting hook of crane-2 into the rear fastened sling.
d) Now gently lift the machine by using both the cranes simultaneously and place the
machine on the ground.
4) After lifting the machine, assemble and fasten the Screw Jack(4Nos.)
(Item - 4, as shown in the drawing N.060.0404X.01)
5) Then place the machine along with Screw Jacks on the floor and assemble the Front Axel
Assembly and the Rear Axel Assembly (Items - 2 & 3, as shown in the drawing
N.060.0404X.01) matching the identification numbers punched (painted in yellow color)
on the machine frame leg and the axels mounting legs.
6) After assembling the axels, assemble and fasten the Tow Bar and the Connecting Rod
(Items - 1 & 18, as shown in the drawing N.060.0404X.01)
7) Now assemble and fasten the Outlet Pump Bracket Assembly (with pump and pipe
assembly) to the machine frame (Item - 16, as shown in the drawing N.060.0404X.01). Make
sure to remove the cover sheet of the Pipe Assembly (Item- ) before assembling the Outlet
Pump Bracket Assembly.
8) Finally, connect and fasten the Pipe Assembly (Item - 17) to the bottom of the Degassing
Chamber (Item-19 as per FLOW CHART, dwg. N.070.0404)
MODEL : JHVR 6000X
T
AS BUIL CAPACITY : 6000 LPH
BANGALORE - INDIA
Installation and
Operating Instructions
Vacuum Pumps
R 5 RA 0063 - 0100 F
Busch Produktions GmbH

Schauinslandstr. 1
79689 Maulburg
Germany
0870139536 / 051214 / Modifications reserved
Table of Contents Preface
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Congratulations on your purchase of the Busch vacuum pump. With
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 watchful observation of the field’s requirements, innovation and steady
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . 3 development Busch delivers modern vacuum and pressure solutions
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 worldwide.
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . 4 These operating instructions contain information for
Oil Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – product description,
On/off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – safety,
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – transport,
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– storage,
Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Emission of Oil Mist . . . . . . . . . . . . . . . . . . . . . . . 5 – installation and commissioning,
Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – maintenance,
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – overhaul,
Transport in Packaging . . . . . . . . . . . . . . . . . . . . . . 5 – troubleshooting and
Transport without Packaging . . . . . . . . . . . . . . . . . . . 5
– spare parts
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Short-term Storage . . . . . . . . . . . . . . . . . . . . . . . . 5 of the vacuum pump.
Conservation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 For the purpose of these instructions, “handling” the vacuum pump
Installation and Commissioning . . . . . . . . . . . . . . . . . . 6 means the transport, storage, installation, commissioning, influence on
Installation Prerequisites . . . . . . . . . . . . . . . . . . . . . 6 operating conditions, maintenance, troubleshooting and overhaul of
Mounting Position and Space . . . . . . . . . . . . . . . . . 6 the vacuum pump.
Suction Connection . . . . . . . . . . . . . . . . . . . . . . 6
Prior to handling the vacuum pump these operating instructions shall
Gas Discharge . . . . . . . . . . . . . . . . . . . . . . . . . 6
be read and understood. If anything remains to be clarified please
Electrical Connection / Controls . . . . . . . . . . . . . . . . 7
contact your Busch representative!
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Keep these operating instructions and, if applicable, other pertinent
Connecting Electrically . . . . . . . . . . . . . . . . . . . . . 7 operating instructions available on site.
Connection Scheme Three-Phase Motor. . . . . . . . . . . 7
Connecting Lines/Pipes . . . . . . . . . . . . . . . . . . . . 7
Filling Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Technical Data
Recording of Operational Parameters . . . . . . . . . . . . . 8
Operation Notes . . . . . . . . . . . . . . . . . . . . . . . . . 8 RA 0063 F:
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nominal suction capacity 3 63 / 76
(50Hz/60Hz) m /h
Oil Return . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 RA 0100 F:
Conveying Condensable Vapours . . . . . . . . . . . . . . . 9 100 / 120
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 RA 0063 F:
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . 9 Suction capacity at 1 mbar 3 40 / 45
(50Hz/60Hz) m /h
RA 0100 F:
Daily: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 60 / 65
Weekly: . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Monthly: . . . . . . . . . . . . . . . . . . . . . . . . . . 9 hPa (=mbar)
Ultimate pressure abs. 0.1
Every 6 Months: . . . . . . . . . . . . . . . . . . . . . . . 9
Every Year: . . . . . . . . . . . . . . . . . . . . . . . . . 10 RA 0063 F:
Every 500 - 2000 Operating Hours (à Oil Life): . . . . . . 10 Motor nominal rating 1.5 / 2.2
(50Hz/60Hz) kW RA 0100 F:
Checking the Oil . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 / 3.0
Checking the Level . . . . . . . . . . . . . . . . . . . . . . 10
Topping up Oil . . . . . . . . . . . . . . . . . . . . . . . . 10 Motor nominal speed –1
min 1500 / 1800
Checking the Colour of the Oil . . . . . . . . . . . . . . . . 10 (50Hz/60Hz)
Oil Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 RA 0063 F:
Oil and Oil Filter Change . . . . . . . . . . . . . . . . . . . . 10 Sound pressure level 64 / 66
dB (A)
Draining Used Oil. . . . . . . . . . . . . . . . . . . . . . . 10 (EN ISO 2151) (50Hz/60Hz) RA 0100 F:
Flushing the Vacuum Pump. . . . . . . . . . . . . . . . . . 11 65 / 68
Checking the Float Valve . . . . . . . . . . . . . . . . . . . 11 Water vapour tolerance max. hPa (=mbar) 40
Replacing the Oil Filter . . . . . . . . . . . . . . . . . . . . 11
RA 0063 F:
Filling in Fresh Oil. . . . . . . . . . . . . . . . . . . . . . . 11 1.8
Exhaust Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Water vapour capacity l/h
RA 0100 F:
Checks during Operation . . . . . . . . . . . . . . . . . . . 11 2.8
Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . 12 RA 0063 F:
Change of the Exhaust Filters . . . . . . . . . . . . . . . . . 12 Operating temperature 84 / 92
Removing the Exhaust Filters. . . . . . . . . . . . . . . . 12 °C
(50Hz/60Hz) RA 0100 F:
Inserting the Exhaust Filters . . . . . . . . . . . . . . . . 12 84 / 93
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Ambient temperature range °C see “Oil”
Removal from Service . . . . . . . . . . . . . . . . . . . . . . . 13 Atmospheric
Temporary Removal from Service . . . . . . . . . . . . . . . . 13 Ambient pressure pressure
Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil quantity l 2.0
Dismantling and Disposal . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 14 RA 0063 F:
52
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Weight approx. (50Hz/60Hz) kg
RA 0100 F:
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 70
Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 EC-Declaration of Conformity . . . . . . . . . . . . . . . . . . . 23
Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Busch – All over the World in Industry . . . . . . . . . . . . . . 24
Preface RA 0063 - 0100 F
page 2 0870139536 / 051214

a b c d e f a Directional arrow
b Terminal box
c Eye bolt
d Gas discharge
e Suction connection
f Axial flow fan
g Oil filter
h Oil return valve (version
with oil return valve only)
i Nameplate, vacuum pump
j Float valve with oil return
line (version with float valve
and oil return line only)
k Oil fill plug
l Oil sight glass
m Oil drain plug
n Oil separator
o Exhaust filter
p Filter spring
q Exhaust valve
r Vane
s Rotor
g h i j k l m d c e t Cylinder
u Oil sump
v Demister
w Service cover
n o k l m p q d r s t
g u v w
In case the vacuum pump is equipped with a gas ballast (optional) wa-
Product Description ter vapour within the gas flow can be tolerated within certain limits
(Ú Installation and Commissioning à Operating Notes à Conveying
Use Condensable Vapours). The conveyance of other vapours shall be
agreed upon with Busch.
The vacuum pump is intended for
The vacuum pump is intended for the placement in a non-potentially
– the suction
explosive environment.
of
Version with float valve (j, 200) and oil return line:
– air and other dry, non-aggressive, non-toxic and non-explosive
The vacuum pump is thermally suitable for continuous operation.
gases
Version with oil return valve (h, 280):
Conveying media with a higher density than air leads to an increased
thermal and mechanical load on the vacuum pump and is permissible The vacuum pump is thermally suitable for continuous operation (ob-
only after prior consultation with Busch. serve the notes with regard to the oil recirculation, Ú Product Descrip-
tion à Oil Recirculation; Ú Installation and Commissioning
Permissible temperature range of the inlet gas: see “Oil”, “Ambient
à Operating Notes à Oil Recirculation).
temperature range”
RA 0063 - 0100 F Product Description

0870139536 / 051214 page 3
The vacuum pump is ultimate pressure proof. Version with oil return valve (h, 280):
At continuous operation this would cause the entire supply of oil to ac-
Principle of Operation cumulate at the bottom of the upper chamber, expel oil droplets
The vacuum pump works on the rotating vane principle. through the gas discharge/pressure connection and let the pump run
dry. Therefore the vacuum pump must be shut down at the latest after
A circular rotor (s, 14) is positioned centrically on the shaft of the 10 hours of continuous operation, depending on the operating condi-
vacuum pump. The shaft of the vacuum pump is driven by the drive tions even after a shorter period, for at least approx. 15 minutes (Ú In-
motor shaft by means of a flexible coupling (310). stallation and Commissioning à Operating Notes). After turning off
The rotor (s, 14) rotates in an also circular, fixed cylinder (t, 1), the the vacuum pump the pressure difference between the inside and the
centreline of which is offset from the centreline of the rotor such that outside of the exhaust filter(s) (o, 122) collapses, hence the two cham-
the rotor and the inner wall of the cylinder almost touch along a line. bers of the oil separator assume an equal pressure level, the oil return
Vanes (f, 22), sliding in slots in the rotor, separate the space between valve (h, 280) between the two chambers opens and the accumulated
the rotor and the cylinder into chambers. At any time gas is sucked in oil in the upper chamber can run down to the bottom chamber.
and at almost any time ejected. Therefore the vacuum pump works al-
most pulsation free. Cooling
In order to avoid the suction of solids, the vacuum pump is equipped The vacuum pump is cooled by
with a screen (261) in the suction connection.
– radiation of heat from the surface of the vacuum pump incl. oil
In order to avoid reverse rotation after switching off, the vacuum separator (n, 75)
pump is equipped with a non-return valve (257). – the air flow from the fan wheel of the drive motor (400)
Note: This valve shall not be used as a non-return valve or shut-off – the process gas
valve to the vacuum system and is no reliable means to prevent suction – the air flow from the fan wheel (f, 321) on the shaft of the vacuum
of oil into the vacuum system while the vacuum pump is shut down. pump
In case the vacuum pump is equipped with a gas ballast (optional):
Through the gas ballast valve (440) a small amount of ambient air is
On/off Switch
sucked into the pump chamber and compressed together with the pro- The vacuum pump comes without on/off switch. The control of the
cess gas. This counteracts the accumulation of condensates from the vacuum pump is to be provided in the course of installation.
process gas inside the vacuum pump (Ú Installation and Commis-
sioning à Operation Notes).
The gas ballast line is equipped with a paper filter.
Safety
Gas ballast version with ball valve: Intended Use
The gas ballast line can be closed partially or completely by means of a Definition: For the purpose of these instructions, “handling” the
ball valve. vacuum pump means the transport, storage, installation, commission-
ing, influence on operating conditions, maintenance, troubleshooting
In order to improve the operating characteristics the outlet of the
and overhaul of the vacuum pump.
pump chamber is equipped with a spring loaded valve (q, 159).
The vacuum pump is intended for industrial use. It shall be handled
Oil Circulation only by qualified personnel.
The vacuum pump requires oil to seal the gaps, to lubricate the vanes The allowed media and operational limits (Ú Product Description)
(f, 22) and to carry away compression heat. and the installation prerequisites (Ú Installation and Commissioning
à Installation Prerequisites) of the vacuum pump shall be observed
The oil reservoir is located on the pressure side of the vacuum pump both by the manufacturer of the machinery into which the vacuum
(i.e. high pressure) at the bottom of the bottom chamber of the oil pump is to be incorporated and by the operator.
separator (n, 75).
The maintenance instructions shall be observed.
The feed openings are located on the suction side of the vacuum pump
(i.e. low pressure). Prior to handling the vacuum pump these operating instructions shall
be read and understood. If anything remains to be clarified please
Forced by the pressure difference between pressure side and suction contact your Busch representative!
side oil is being drawn from the oil separator (n, 75) through the oil
supply lines (210) and injected on the suction side.
Safety Notes
Together with the sucked gas the injected oil gets conveyed through
The vacuum pump has been designed and manufactured according to
the vacuum pump and ejected into the oil separator (n, 75) as oil mist.
the state-of-the-art. Nevertheless, residual risks may remain. These op-
Oil that separates before the exhaust filters (o, 122) accumulates at the
erating instructions inform about potential hazards where appropriate.
bottom of the bottom chamber of the oil separator (n, 75).
Safety notes are tagged with one of the keywords DANGER,
Oil that is separated by the exhaust filters (o, 122) accumulates at the WARNING and CAUTION as follows:
bottom of the upper chamber of the oil separator (n, 75).
The flow resistance of the exhaust filters (o, 122) causes the inside of DANGER_a
the exhaust filters (which is connected to the bottom chamber of the
oil separator) to be on a higher pressure level than the outside of the Disregard of this safety note will always lead to accidents with fa-
exhaust filters (i.e. the upper chamber of the oil separator). Because of tal or serious injuries.
the higher pressure in the bottom chamber it is not possible to let oil
that drips off the exhaust filters simply flow down to the bottom
chamber. WARNING_a
Version with float valve and oil return line to the suction connection (j,
Disregard of this safety note may lead to accidents with fatal or se-
200):
rious injuries.
Therefore the oil that accumulates in the upper chamber is sucked
through the float valve (j, 200) and the oil return line (j, 195) to the
suction connection (250). CAUTION_a
Disregard of this safety note may lead to accidents with minor inju-
ries or property damage.
Safety RA 0063 - 0100 F
page 4 0870139536 / 051214

● Lift the vacuum pump with a crane
Emission of Oil Mist
In case the vacuum pump was bolted to a pallet or a base plate:
CAUTION_a ◆ Remove the stud bolts from the rubber feet
The non-OEM spares market offers exhaust filters that are geomet-
CAUTION_a
rically compatible with Busch-vacuum pumps, but do not feature
the high retention capacity of genuine Busch-exhaust filters.
Tilting a vacuum pump that is already filled with oil can cause large
quantities of oil to ingress into the cylinder.
Increased risk of damage to health.
Starting the vacuum pump with excessive quantities of oil in the cyl-
In order to keep the emission on the lowest possible level only gen-
inder will immediately break the vanes (f, 22) and ruin the vacuum
uine Busch-exhaust filters shall be used.
pump.
The oil in the process gas is separated to the greatest possible extent,
but not perfectly. Once the vacuum pump is filled with oil it shall not be lifted any-
more.
CAUTION_a ● Prior to every transport make sure that the oil is drained
The gas conveyed by the vacuum pump contains remainders of oil.

Storage
Aspiration of process gas over extended periods can be harmful.
Short-term Storage
The room into which the process gas is discharged must be suffi- Version with gas ballast device with ball-cock:
ciently vented.
◆ Make sure that the ball-cock of the gas ballast device (440) is
Note: The possibly sensible smell is not caused by droplets of oil, closed
though, but either by gaseous process components or by readily vola-
Version with gas ballast device without ball-cock, with paper filter:
tile and thus gaseous components of the oil (particularly additives).
◆ Close the paper filter of the gas ballast device (440) with adhe-
Noise Emission sive tape
For the sound pressure level in free field according to EN ISO 2151 ● Make sure that the suction connection and the gas discharge are
Ú Technical Data. closed (leave the provided plugs in)
● Store the vacuum pump
Transport – if possible in original packaging,
– indoors,
Transport in Packaging – dry,
Packed on a pallet the vacuum pump is to be transported with a – dust free and
forklift. – vibration free
Transport without Packaging Conservation

In case the vacuum pump is packed in a cardboard box with inflated In case of adverse ambient conditions (e.g. aggressive atmosphere, fre-
cushions: quent temperature changes) conserve the vacuum pump immediately.
◆ Remove the inflated cushions from the box In case of favourable ambient conditions conserve the vacuum pump if
a storage of more than 3 months is scheduled.
In case the vacuum pump is in a cardboard box cushioned with rolled
corrugated cardboard: During the test run in the factory the inside of the vacuum pump was
completely wetted with oil. Under normal conditions a treatment with
◆ Remove the corrugated cardboard from the box conservation oil is therefore not required. In case it is advisable to treat
In case the vacuum pump is laid in foam: the vacuum pump with conservation oil because of very adverse stor-
age conditions, seek advice from your Busch representative!
◆ Remove the foam
Version with gas ballast device with ball-cock:
In case the vacuum pump is bolted to a pallet or a base plate:
◆ Make sure that the ball-cock of the gas ballast device (440) is
◆ Remove the bolting between the vacuum pump and the pal- closed
let/base plate
Version with gas ballast device without ball-cock, with paper filter:
In case the vacuum pump is fastened to the pallet by means of tighten-
ing straps: ◆ Close the paper filter of the gas ballast device (440) with adhe-
sive tape
◆ Remove the tightening straps
● Make sure that all ports are firmly closed; seal all ports that are not
sealed with PTFE-tape, gaskets or o-rings with adhesive tape
CAUTION_af
Note: VCI stands for “volatile corrosion inhibitor”. VCI-products (film,
Do not walk, stand or work under suspended loads. paper, cardboard, foam) evaporate a substance that condenses in mo-
lecular thickness on the packed good and by its electro-chemical prop-
Note: The position of the eyebolt (c, 391) fits to the centre of gravity erties effectively suppresses corrosion on metallic surfaces. However,
of a vacuum pump incl. drive motor (400). If a vacuum pump without VCI-products may attack the surfaces of plastics and elastomers. Seek
drive motor is to be lifted, attach another belt/rope at a suitable point. advice from your local packaging dealer! Busch uses CORTEC
VCI 126 R film for the overseas packaging of large equipment.
● Make sure that the eyebolt (c, 391) is fully screwed in
● Wrap the vacuum pump in VCI film
● Attach lifting gear securely to the eyebolt (c, 391) on the oil sepa-
rator ● Store the vacuum pump
● Attach the lifting gear to a crane hook with safety latch – if possible in original packing,
RA 0063 - 0100 F Transport

0870139536 / 051214 page 5
– indoors, ● Make sure that enough space will remain for the removal and the
reinsertion of the exhaust filters (o, 122)
– dry,
– dust free and Suction Connection
– vibration free.
For commissioning after conservation: CAUTION_a
● Make sure that all remains of adhesive tape are removed from the
ports Intruding foreign objects or liquids can destroy the vacuum pump.
● Commission the vacuum pump as described in the chapter Ú In- In case the inlet gas can contain dust or other foreign solid particles:
stallation and Commissioning ◆ Make sure that a suitable filter (5 micron or less) is installed
upstream the vacuum pump
Installation and ● Make sure that the suction line fits to the suction connection (e,
260) of the vacuum pump
Commissioning ● Make sure that the gas will be sucked through a vacuum-tight
flexible hose or a pipe
Installation Prerequisites
In case of using a pipe:
CAUTION_a ◆ Make sure that the pipe will cause no stress on the vacuum
pump’s connection, if necessary use bellows
In case of non-compliance with the installation prerequisites, partic- ● Make sure that the line size of the suction line over the entire
ularly in case of insufficient cooling: length is at least as large as the suction connection (e, 260) of the
vacuum pump
Risk of damage or destruction of the vacuum pump and adjoining
plant components! In case of very long suction lines it is prudent to use larger line sizes in
order to avoid a loss of efficiency. Seek advice from your Busch
Risk of injury! representative!
If two or more vacuum pumps work on the same suction line, if the
The installation prerequisites must be complied with. volume of the vacuum system is large enough to suck back oil or if the
vacuum shall be maintained after switching off the vacuum pump:
● Make sure that the integration of the vacuum pump is carried out
such that the essential safety requirements of the Machine Direc- ◆ Provide a manual or automatic operated valve (= non-return
tive 98/37/EC are complied with (in the responsibility of the de- valve) in the suction line
signer of the machinery into which the vacuum pump is to be
(the standard non-return valve that is installed inside the suction con-
incorporated; note in the Ú EC-Declaration of Conformity)
nection is not meant to be used for this purpose!)
Mounting Position and Space If the vacuum pump is planned to be used for the suction of gas that
● Make sure that the environment of the vacuum pump is not po- contains limited quantities of condensable vapour:
tentially explosive ◆ Provide a shut-off valve, a drip-leg and a drain cock in the suc-
● Make sure that the following ambient conditions will be complied tion line, so that condensates can be drained from the suction
with: line
– Ambient temperature: see “Oil” ● Make sure that the suction line does not contain foreign objects,
e.g. welding scales
– Ambient pressure: atmospheric
● Make sure that the environmental conditions comply with the pro- Gas Discharge
tection class of the drive motor (according to the nameplate) The following guidelines for the discharge line do not apply, if the aspi-
● Make sure that the vacuum pump will be placed or mounted hori- rated air is discharged to the environment right at the vacuum pump.
zontally
● Make sure that in order to warrant a sufficient cooling there will be CAUTION_a
a clearance of minimum 20 cm between the vacuum pump and
nearby walls The discharged air contains small quantities of vacuum oil.
● Make sure that no heat sensitive parts (plastics, wood, cardboard,
Staying in vacuum oil contaminated air bears a risk of damage to
paper, electronics) will touch the surface of the vacuum pump
health.
● Make sure that the installation space or location is vented such
that a sufficient cooling of the vacuum pump is warranted If air is discharged into rooms where persons stay, sufficient ventila-
tion must be provided for.
CAUTION_ac ● Make sure that the discharge line fits to the gas discharge (d, 155)
of the vacuum pump
During operation the surface of the vacuum pump may reach tem-
In case of using a pipe:
peratures of more than 70 °C.
◆ Make sure that the pipe will cause no stress on the vacuum
Risk of burns! pump’s connection, if necessary use bellows
● Make sure that the vacuum pump will not be touched inadver- ● Make sure that the line size of the discharge line over the entire
tently during operation, provide a guard if appropriate length is at least as large as the gas discharge (d, 155) of the
vacuum pump
● Make sure that the sight glass (l, 83) will remain easily accessible
In case the length of the discharge line exceeds 1.3 m it is prudent to
If the oil change is meant to be performed on location: use larger line sizes in order to avoid a loss of efficiency and an over-
◆ Make sure that the drain port (m, 95), the oil filter (g, 100) load of the vacuum pump. Seek advice from your Busch
and the filling port (k, 88) will remain easily accessible representative!
Installation and Commissioning RA 0063 - 0100 F
page 6 0870139536 / 051214

With unrestricted suction the counter pressure at the gas outlet (d, Connection Scheme Three-Phase Motor
155) of the vacuum pump must not exceed 1.3 bar abs 'Absolutdruck
Delta connection (low voltage):
(in case of doubt to be verified during commissioning at a suitable
time).
● Make sure that the discharge line either slopes away from the
vacuum pump or provide a liquid separator or a drip leg with a
drain cock, so that no liquids can back up into the vacuum pump
WARNING_ad
Discharge lines made from non-conducting material can build up

static charge.
Static discharge can cause explosion of potentially existing oil

mist. Star connection (high voltage):
The discharge line must be made of conducting material or provi-

sions must be made against static discharge.
Electrical Connection / Controls

● Make sure that the stipulations acc. to the EMC-Directive
89/336/EEC and Low-Voltage-Directive 73/23/EEC as well as the
EN-standards, electrical and occupational safety directives and the
local or national regulations, respectively, are complied with (this is
in the responsibility of the designer of the machinery into which
the vacuum pump is to be incorporated; Ú note in the EC-Decla-
ration of Conformity).
Double star connection, multi-voltage motor (low voltage):
● Make sure that the power supply for the drive motor is compatible
with the data on the nameplate of the drive motor (400)
● Make sure that an overload protection according to EN 60204-1 is
provided for the drive motor
● Make sure that the drive of the vacuum pump will not be affected
by electric or electromagnetic disturbance from the mains; if neces-
sary seek advice from the Busch service
In case of mobile installation:
◆ Provide the electrical connection with grommets that serve as
strain-relief Star connection, multi-voltage motor (high voltage):
Installation
Mounting
● Make sure that the à Installation Prerequisites are complied with
● Set down or mount the vacuum pump at its location
Connecting Electrically
WARNING_ab
CAUTION_a
Risk of electrical shock, risk of damage to equipment.
Operation in the wrong direction of rotation can destroy the
Electrical installation work must only be executed by qualified per- vacuum pump in short time.
sonnel that knows and observes the following regulations:
- IEC 364 or CENELEC HD 384 or DIN VDE 0100, respectively, Prior to starting-up it must be made sure that the vacuum pump is
- IEC-Report 664 or DIN VDE 0110, operated in the proper direction.
- BGV A2 (VBG 4) or corresponding national accident prevention
Version with three-phase motor:
regulation.
◆ Determine the intended direction of rotation with the arrow (a,
431) (stuck on or cast)
CAUTION_a
◆ “Bump” the drive motor (400)
The connection schemes given below are typical. Depending on the ◆ Watch the fan wheel of the drive motor (400) and determine
specific order or for certain markets deviating connection schemes the direction of rotation just before the fan wheel stops
may apply.
If the rotation must be changed:
Risk of damage to the drive motor! ◆ Switch any two of the drive motor wires (three-phase motor)
The inside of the terminal box shall be checked for drive motor con- Connecting Lines/Pipes
nection instructions/schemes.
In case the suction line is equipped with a shut-off valve:
● Electrically connect the drive motor (400) ◆ Connect the suction line
● Connect the protective earth conductor
RA 0063 - 0100 F Installation and Commissioning

0870139536 / 051214 page 7
● Connect the discharge line ● Shut down the vacuum pump and wait a few minutes
Installation without discharge line: ● Check that the level is between the MIN and the MAX-markings of
the sight glass (l, 83)
◆ Make sure that the gas discharge (d, 155) is open
In case the level has fallen below the MIN-marking:
● Make sure that all provided covers, guards, hoods etc. are
mounted ◆ Top-up oil
● Make sure that cooling air inlets and outlets are not covered or ob- In case the suction line is equipped with a shut-off valve:
structed and that the cooling air flow is not affected adversely in
◆ Open the shut-off valve
any other way
In case the suction line is not equipped with a shut-off valve:
Filling Oil
◆ Remove the piece of rubber mat and connect the suction line
In case the vacuum pump was treated with conservation oil:
◆ Drain the remainders of conservation oil
Recording of Operational Parameters
Version with exhaust filter pressure gauge:
CAUTION_a ◆ Read the scale of the exhaust filter pressure gauge and record
it as reference for future maintenance and troubleshooting
The vacuum pump is shipped without oil. work Störungsbehebungsarbeiten aufzeichnen (Ú Mainte-
nance à Exhaust Filter(s) à Checks during Operation)
Operation without oil will ruin the vacuum pump in short time. As soon as the vacuum pump is operated under normal operating
conditions:
Prior to commissioning it must be made positively sure that oil is
filled in. ● Measure the drive motor current and record it as reference for fu-
ture maintenance and troubleshooting work
The vacuum pump is delivered without oil (oil specification Ú Oil).
● Keep approx. 2.0 litres oil acc. to the table Ú Oil ready Operation Notes
Note: The amount given in these operating instructions is a guide. The Use
sight glass (l, 83) indicates the actual amount to be filled in.
CAUTION_a
CAUTION_a
The vacuum pump is designed for operation under the conditions
Filling oil through the suction connection (e, 260) will result in described below.
breakage of the vanes (f, 22) and destruction of the vacuum pump.
In case of disregard risk of damage or destruction of the vacuum
Oil may be filled through the filling port (k, 88) only. pump and adjoining plant components!
Risk of injury!
CAUTION_a
The vacuum pump must only be operated under the conditions de-
During operation the oil separator is filled with hot, pressurised oil scribed below.
mist.
The vacuum pump is intended for
Risk of injury from hot oil mist with open filling port.
– the suction
Risk of injury if a loosely inserted filling plug (k, 88) is ejected. of
Remove the filling plug (k, 88) only if the vacuum pump is stopped.
– air and other dry, non-aggressive, non-toxic and non-explosive
gases
The vacuum pump must only be operated with the filling plug (k, Conveying media with a higher density than air leads to an increased
88) firmly inserted. thermal and mechanical load on the vacuum pump and is permissible
only after prior consultation with Busch.
● Remove the filling plug (k, 88)
Permissible temperature range of the inlet gas: see “Oil”, “Ambient
● Fill in approx. 2.0 litres of oil temperature range”
● Make sure that the level is between the MIN and the MAX-mark- In case the vacuum pump is equipped with a gas ballast (optional) wa-
ings of the sight glass (l, 83) ter vapour within the gas flow can be tolerated within certain limits
● Make sure that the seal ring (89) is inserted into the filling plug (k, (à Conveying Condensable Vapours). The conveyance of other va-
88) and undamaged, replace if necessary pours shall be agreed upon with Busch.
● Firmly reinsert the filling plug (k, 88) together with the seal ring The vacuum pump is intended for the placement in a non-potentially
(89) explosive environment.
Note: Starting the vacuum pump with cold oil is made easier when at Version with float valve (j, 200) and oil return line:
this very moment the suction line is neither closed nor covered with a The vacuum pump is thermally suitable for continuous operation.
rubber mat.
Version with oil return valve (h, 280):
● Switch on the vacuum pump
The vacuum pump is thermally suitable for continuous operation (ob-
In case the suction line is equipped with a shut-off valve: serve the notes with regard to the oil recirculation, Ú Product Descrip-
◆ Close the shut-off valve tion à Oil Recirculation and Ú Installation and Commissioning
à Operating Notes à Oil Recirculation).
In case the suction line is not equipped with a shut-off valve:
The vacuum pump is ultimate pressure proof.
◆ Cover the suction connection (e, 260) with a piece of rubber
mat
● Let the vacuum pump run for a few minutes
Installation and Commissioning RA 0063 - 0100 F
page 8 0870139536 / 051214

● Operate the vacuum pump for another approx. half an hour
CAUTION_ac
During operation the surface of the vacuum pump may reach tem- Maintenance
peratures of more than 70 °C.
DANGER_age32
Risk of burns!
In case the vacuum pump conveyed gas that was contaminated
The vacuum pump shall be protected against contact during opera- with foreign materials which are dangerous to health, harmful ma-
tion, it shall cool down prior to a required contact or heat protection terial can reside in filters.
gloves shall be worn.
Danger to health during inspection, cleaning or replacement of fil-
CAUTION_a ters.
The gas conveyed by the vacuum pump contains remainders of oil. Danger to the environment.
Aspiration of process gas over extended periods can be harmful. Personal protective equipment must be worn during the handling
of contaminated filters.
The room into which the process gas is discharged must be suffi-
ciently vented. Contaminated filters are special waste and must be disposed of
separately in compliance with applicable regulations.
● Make sure that all provided covers, guards, hoods etc. remain
mounted
CAUTION_ac
● Make sure that protective devices will not be disabled
● Make sure that cooling air inlets and outlets will not be covered or During operation the surface of the vacuum pump may reach tem-
obstructed and that the cooling air flow will not be affected ad- peratures of more than 70 °C.
versely in any other way
Risk of burns!
● Make sure that the installation Prerequisites (Ú Installation and
Commissioning à Installation Prerequisites) are complied with and ● Prior to action that requires touching of the vacuum pump, let the
will remain complied with, particularly that a sufficient cooling will vacuum pump cool down, however, if the oil is to be drained, for
be ensured no more than 20 minutes
● Prior to disconnecting connections make sure that the connected
Oil Return pipes/lines are vented to atmospheric pressure
Only for version with oil return valve (h, 280):
During operation oil accumulates at the bottom of the upper chamber Maintenance Schedule
of the oil separator (n, 75), which cannot flow down into the bottom Note: The maintenance intervals depend very much on the individual
chamber, as long as the vacuum pump runs (for detailed description operating conditions. The intervals given below shall be considered as
Ú Product Description à Oil Recirculation). starting values which should be shortened or extended as appropriate.
At the latest after 10 hours of continuous operation, in case of high Particularly heavy duty operation, such like high dust loads in the envi-
pressure difference between suction side and pressure side after a ronment or in the process gas, other contaminations or ingress of pro-
shorter period, the vacuum pump must be shut down for at least cess material, can make it necessary to shorten the maintenance
15 minutes, so that the oil can run down from the upper chamber of intervals significantly.
the oil separator (n, 75) into the bottom chamber. Note: This is a good
time to check the temperature, the level and the colour of the oil. Daily:
● Check the level and the colour of the oil (Ú Checking the Oil)
Conveying Condensable Vapours
Weekly:
CAUTION_a ● Check the vacuum pump for oil leaks - in case of leaks have the
vacuum pump repaired (Busch service)
Residual condensates dilute the oil, deteriorate its lubricating prop- Monthly:
erties and can cause a seizure of the rotor.
● Check the function of the exhaust filters (o, 122) (Ú Exhaust Fil-
Apply a suitable operating method to make sure that no conden- ters)
sates remain in the vacuum pump. ● Make sure that the vacuum pump is shut down and locked against
inadvertent start up
In order to use the vacuum pump for the conveyance of
condensable vapours, the vacuum pump must be equipped with a In case an inlet air filter is installed:
shut-off valve in the suction line and with a gas ballast valve. ◆ Check the inlet air filter, if necessary clean (with compressed
air) or replace
Version with gas ballast device with ball-cock:
In case of operation in a dusty environment:
◆ Make sure that the ballast valve is open and will remain open
during operation ◆ Clean as described under à Every 6 Months:
● Close the shut-off valve in the suction line Every 6 Months:
● Operate the vacuum pump with the suction line shut off for ● Make sure that the housing is free from dust and dirt, clean if nec-
approx. half an hour, so that the operating temperature rises to essary
approx. 75 °C
● Make sure that the vacuum pump is shut down and locked against
At process start: inadvertent start up
● Open the shut-off valve in the suction line ● Clean the fan cowlings, fan wheels, the ventilation grilles and cool-
ing fins
At the process end:
● Close the shut-off valve in the suction line
RA 0063 - 0100 F Maintenance

0870139536 / 051214 page 9
Every Year: ● Make sure that the level is between the MIN and the MAX-mark-
ings of the sight glass (l, 83)
inadvertent start up ● Make sure that the seal ring (89) is inserted into the filling plug (k,
88) and undamaged, replace if necessary
● Replace the exhaust filters (o, 122) (à Exhaust Filters)
● Firmly reinsert the filling plug (k, 88) together with the seal ring
In case an inlet air filter is installed:
(89)
◆ Clean (with compressed air) or replace the inlet air filter
Checking the Colour of the Oil
● Check the inlet screen (261), clean if necessary
Note: The oil should be light, either transparent, a little foamy or a little
Version with gas ballast with paper filter: tarnished. A milky discolouration that does not vanish after sedation of
◆ Clean the filter (compressed air) or replace the oil indicates contamination with foreign material. Oil that is either
contaminated with foreign material or burnt must be changed (à Oil
Every 500 - 2000 Operating Hours (à Oil Life): Change).
● Change the oil and the oil filter (g, 100) (à Oil and Oil Filter
Change) Oil Life
Version with float valve (j, 200) and oil return line The oil life depends very much on the operating conditions. A clean
and dry air stream and operating temperatures below 100 °C are ideal.
◆ Check the float valve (j, 200) (à Oil and Oil Filter Change
Under these conditions the oil and the oil filter (g, 100) shall be
à Checking the Float Valve)
changed every 500 to 2000 operating hours or after half a year.
Checking the Oil Under very unfavourable operating conditions the oil life can be less
than 500 operating hours. Extremely short life times indicate malfunc-
Checking the Level tions (Ú Troubleshooting) or unsuitable operating conditions, though.
● Make sure that the vacuum pump is shut down and the oil has col- Chosing a synthetic oil instead of a mineral oil can extend the oil life.
lected at the bottom of the oil separator (n, 75) To select the oil best suited for your process please contact your Busch
representative.
● Read the level on the sight glass (l, 83)
If there is no experience available with regard to the oil life under the
In case the level has dropped underneath the MIN-marking: prevailing operation conditions, it is recommended to have an oil ana-
◆ Top up oil (à Topping up Oil) lysis carried out every 500 operating hours and establish the change in-
terval accordingly.
In case the level exceeds the MAX-marking:
◆ Excessive dilution with condensates - change the oil and check Oil and Oil Filter Change
the process
◆ If appropriate retrofit a gas ballast (Busch Service) and observe DANGER_age32
the chapter Ú Installation and Commissioning à Operation
Notes à Conveying Condensable Vapours In case the vacuum pump conveyed gas that was contaminated
with harmful foreign material the oil and the oil filter will be con-
Topping up Oil taminated with harmful material.
Note: Under normal conditions there should be no need to top up oil
during the recommended oil change intervals. A significant level drop Danger to health during the changing of contaminated oil and oil
indicates a malfunction (Ú Troubleshooting). filters.
Note: During operation the exhaust filters get saturated with oil. It is
Danger to the environment.
therefore normal that the oil level will drop slightly after replacement
of the exhaust filters.
Wear personal protective equipment during the changing of con-
taminated oil and oil filters.
CAUTION_a
Contaminated oil and oil filters are special waste and must be dis-
Filling oil through the suction connection (e, 260) will result in posed of separately in compliance with applicable regulations.
breakage of the vanes (f, 22) and destruction of the vacuum pump.
Draining Used Oil
Oil may be filled through the filling port (k, 88) only. Note: After switching off the vacuum pump at normal operating tem-
perature wait no more than 20 minutes before the oil is drained.
CAUTION_a ● Make sure that the vacuum pump is shut down and locked against
During operation the oil separator is filled with hot, pressurised oil
● Make sure that the vacuum pump is vented to atmospheric pres-
mist.
sure
Risk of injury from hot oil mist with open filling port. ● Put a drain tray underneath the drain port (m, 95)
● Remove the drain plug (m, 95) and drain the oil
Risk of injury if a loosely inserted filling plug (k, 88) is ejected.
When the oil stream dwindles:
Remove the filling plug (k, 88) only if the vacuum pump is stopped.
● Reinsert the drain plug (m, 95)
The vacuum pump must only be operated with the filling plug (k, ● Switch the vacuum pump on for a few seconds
88) firmly inserted.
● Make sure that the vacuum pump is shut down and locked against inadvertent start up
inadvertent start up ● Remove the drain plug (m, 95) again and drain the remaining oil
● Remove the filling plug (k, 88) ● Make sure that the seal ring (96) is inserted into the drain plug (m,
● Top up oil until the level reaches the middle of the sight glass (l, 95) and undamaged, replace if necessary
83)
Maintenance RA 0063 - 0100 F
page 10 0870139536 / 051214

● Firmly reinsert the drain plug (m, 95) together with the seal ring ● Connect the banjo fitting of the oil return line (j, 195) to the oil
(96) separator (n, 75) with the hollow-core screw and two seal rings
● Dispose of the used oil in compliance with applicable regulations ● Fasten the fan cover (e, 340) to the vacuum pump with the screws
(341)
Flushing the Vacuum Pump Only if the exhaust filters (o, 122) are n o t meant to be changed, too:
◆ Make sure that the seal (141) under the exhaust cover (d, 155)
WARNING_ad is clean and undamaged, if necessary replace with a new seal
(141)
Degraded oil can choke pipes and coolers.
◆ Mount the exhaust cover (d, 155) together with the seal
Risk of damage to the vacuum pump due to insufficient lubrica- (141), hex head screws (146) and lock washers on the oil sep-
tion. arator (n, 75)
◆ If necessary connect the discharge line
Risk of explosion due to overheating.
Replacing the Oil Filter
If there is a suspicion that deposits have gathered inside the
vacuum pump the vacuum pump shall be flushed. ● Make sure that the oil is drained
● Remove the oil filter (g, 100)
● Make sure that all the used oil is drained
● Apply a drop of fresh oil on the seal ring of the new oil filter (g,
● Make sure that the used oil filter (g, 100) is still in place
100)
● Create 2.0 litres flushing agent from 50 percent oil and 50 percent
● Mount the new oil filter (g, 100) and tighten it by hand
paraffin or diesel fuel/fuel oil
● Make sure that the drain plug (m, 95) is firmly inserted Filling in Fresh Oil
● Remove the filling plug (k, 88) ● Keep 2.0 litres oil acc. to the table Ú Oil ready
● Fill in the flushing agent Note: The amount given in these operating instructions is a guide. The
sight glass (l, 83) indicates the actual amount to be filled in.
● Firmly reinsert the filling plug (k, 88)
● Make sure that the oil outlet plug (m, 95) is firmly inserted
● Close the suction line
● Run the vacuum pump for at least half an hour
CAUTION_a
● Drain the flushing agent and dispose of it in compliance with appli-
cable regulations Filling oil through the suction connection (e, 260) will result in
Note: Due to the use of paraffin and even more in case of using diesel breakage of the vanes (f, 22) and destruction of the vacuum pump.
fuel/fuel oil, an unpleasant odour can occur after recommissioning. If
this is a problem, diesel fuel/fuel oil should be avoided and the vacuum Oil may be filled through the filling port (k, 88) only.
pump be run at idle in a suitable place until the unpleasant odour ● Remove the filling plug (k, 88)
vanishes.
● Fill in approx. 2.0 litres of oil
Checking the Float Valve ● Make sure that the level is between the MIN and the MAX-mark-
(version with float valve and oil return line only) ings of the sight glass (l, 83)
Note: It is essential that the float valve (j, 200) works properly, so that ● Make sure that the seal ring (89) is inserted into the filling plug (k,
the vacuum pump will achieve the intended ultimate pressure and no 88) and undamaged, replace if necessary
oil will be expelled out of the discharge connection (d, 155).
● Firmly reinsert the filling plug (k, 88) together with the seal ring
● Make sure that the vacuum pump is shut down and locked against (89)
● Prior to disconnecting pipes/lines make sure that the connected Exhaust Filters
pipes/lines are vented to atmospheric pressure
Checks during Operation
● Remove the discharge line, if necessary
Busch recommends the use of a filter pressure gauge (available as ac-
● Remove the exhaust cover (d, 155) above the float valve (j, 200) cessory, Ú Accessories). Without filter pressure gauge the filter resis-
tance shall be assessed on the basis of the drive motor current drawn.
● Remove the oil from the floater chamber with the aid of a suction
hose or a wash bottle Version with exhaust filter pressure gauge:
● Undo the screws (341) and remove the fan cover (e, 340) ◆ Remove the suction line from suction connection (e, 260) (un-
restricted suction!)
Note: While undoing the banjo fitting of the oil return line (j, 195) a
small amount of oil will leak out: keep a cleaning rag ready. Be careful ◆ Check that the reading on the filter pressure gauge is in the
not to lose the sealing rings of the banjo fitting. green field
● Undo the banjo fitting of the oil return line (j, 195) from the oil ◆ Reconnect the suction line to the suction connection (e, 260)
separator (n, 75) and bend the oil return line a little bit aside
Version without filter pressure gauge:
● Undo the two screws of the flange of the float valve (j, 200) and
◆ Make sure that the vacuum pump is running
pull the float valve out of the oil separator (n, 75)
◆ Check that the drive motor current drawn is in the usual range
● Check the cleanliness and function of the float valve (j, 200), blow
out with compressed air, if necessary Version with oil return valve (h, 280):
● Make sure that the o-ring on the flange of the float valve is in Note: The discharged gas will also contain oil if the vacuum pump is
place and undamaged, replace with a new o-ring, if necessary operated without interruption for too long a period (Ú Installation and
Commissioning à Operation Notes).
● Insert the float valve (j, 200) in the proper orientation into the oil
separator (n, 75) and fasten it with two screws and lock washers ● Check that the discharged gas is free from oil
RA 0063 - 0100 F Maintenance

0870139536 / 051214 page 11
Assessment ● Remove the discharge line, if necessary
If ● Remove the exhaust covers (d, 155) from the oil separator (n, 75)
the reading on the filter pressure gauge is in the red field, ● Loosen the screws in the centre of the exhaust filter retaining
springs (p, 125), but do not remove them
or
● With the aid of the special tool press the exhaust filter retaining
the drive motor draws too much current and/or the pump flow rate springs (p, 125) out of the indents and rotate them
has dropped,
● Remove the exhaust filter retaining springs (p, 125) from the oil
then the exhaust filters (o, 122) are clogged and must be replaced. separator
Note: Exhaust filters cannot be cleaned successfully. Clogged exhaust ● Pull the exhaust filters (o, 122) out of the oil separator (n, 75)
filters must be replaced with new ones.
Inserting the Exhaust Filters
If
the filter pressure gauge indicates a lower pressure than usual,
CAUTION_a
or
The non-OEM spares market offers exhaust filters that are geomet-
the drive motor draws less current than usual,
rically compatible with Busch-vacuum pumps, but do not feature
then one exhaust filter (o, 122) is broken through, the exhaust filters the high retention capacity of genuine Busch-exhaust filters and de-
must be replaced. teriorate the service life and the efficiency of the vacuum pump due
to their increased back pressure.
If the discharged gas contains oil,
the exhaust filters (o, 122) can either be clogged or broken through Increased risk of damage to health.
and, if applicable, must be replaced.
Adverse effect on efficiency and service life.
Change of the Exhaust Filters
In order to keep the emission on the lowest possible level and to
preserve efficiency and service life only genuine Busch-exhaust fil-
DANGER_age32
ters shall be used.
In case the vacuum pump conveyed gas that was contaminated ● Make sure that the new exhaust filters (o, 122) are equipped with
with harmful foreign material the exhaust filters will be contami- new o-rings
nated with harmful material.
● Insert the exhaust filters (o, 122) such that their ports are properly
Danger to health during the changing of the contaminated exhaust seated in their receptacles in the oil separator (n, 75)
filters. ● Make sure that the tips of the screws in the centre of the exhaust
filter retaining springs (p, 125) protrude the retaining springs by
Danger to the environment. about 2 - 5 revolutions
Wear personal protective equipment during the changing of the ● With the aid of the special tool insert the exhaust filter retaining
contaminated exhaust filters. springs (p, 125) such that their ends are secured in their recepta-
cles in the oil separator (n, 75) by the protrusions and that the tips
Used exhaust filters are special waste and must be disposed of of the screws snap into the indent of the exhaust filters (o, 122)
separately in compliance with applicable regulations. ● Tighten the screws in the exhaust filter retaining springs (p, 125)
such that the screw heads touch the spring steel sheets
CAUTION_a1 ● Make sure that the seals (141) under the exhaust covers (d, 155)
are clean and undamaged, if necessary replace with new seals
The filter springs (p, 125) can fly out of the exhaust port during re- (141)
moval or insertion. ● Mount the exhaust covers (d, 155) together with the seals (141),
hex head screws (146) and lock washers on the oil separator (n,
Risk of eye injury. 75)
Eye protection goggles must be worn while handling filter springs ● If necessary connect the discharge line
(p, 125). Note: During operation the exhaust filters get saturated with oil. It is
Note: In order to facilitate the removal and insertion of filter springs (p, therefore normal that the oil level will drop slightly after replacement
125) it is recommend to make a special tool: of the exhaust filters.
◆ Make a fork acc. to the sketch from

Overhaul
approx. 2 mm steel plate
◆ Weld the bottom end of the fork to CAUTION_a
the tip of a medium size slotted head
screw driver In order to achieve best efficiency and a long life the vacuum pump
was assembled and adjusted with precisely defined tolerances.
This adjustment will be lost during dismantling of the vacuum

pump.
Removing the Exhaust Filters It is therefore strictly recommended that any dismantling of the
vacuum pump that is beyond of what is described in this manual
shall be done by Busch service.
● Prior to disconnecting pipes/lines make sure that the connected
pipes/lines are vented to atmospheric pressure
Overhaul RA 0063 - 0100 F
page 12 0870139536 / 051214

Dismantling and Disposal
DANGER_age32
In case the vacuum pump conveyed gas that was contaminated DANGER_age32
with harmful foreign material the oil, the oil filter and the exhaust
filter(s) will be contaminated with harmful material. In case the vacuum pump conveyed gas that was contaminated
with harmful foreign material the oil, the oil filter and the exhaust
Harmful material can reside in pores, gaps and internal spaces of filter(s) will be contaminated with harmful material.
the vacuum pump.
Harmful material can reside in pores, gaps and internal spaces of
Danger to health during dismantling of the vacuum pump. the vacuum pump.
Danger to the environment. Danger to health during dismantling of the vacuum pump.
Prior to shipping the vacuum pump shall be decontaminated as Danger to the environment.
good as possible and the contamination status shall be stated in a
“Declaration of Contamination” (form downloadable from During dismantling of the vacuum pump personal protective
www.busch-vacuum.com). equipment must be worn.
Busch service will only accept vacuum pumps that come with a com- The vacuum pump must be decontaminated prior to disposal.
pletely filled in and legally binding signed “Declaration of Contamina-
tion” (form downloadable from www.busch-vacuum.com). Oil, oil filters and exhaust filters must be disposed of separately in
compliance with applicable regulations.
Removal from Service
CAUTION_a
Temporary Removal from Service
Used oil, used exhaust filters and used oil filters are special waste
● Prior to disconnecting pipes/lines make sure that all pipes/lines are
and must be disposed of in compliance with applicable regulations.
vented to atmospheric pressure
Recommissioning CAUTION_a1
The filter springs (p, 125) can fly out of the exhaust port during re-
CAUTION_a moval.
Vanes (f, 22) can stick after a long period of standstill. Risk of eye injury.
Risk of vane breakage if the vacuum pump is started with the drive Eye protection goggles must be worn while handling filter springs.
motor.
● Remove the exhaust filters (o, 122) (Ú Maintenance à Exhaust
After longer periods of standstill the vacuum pump shall be turned Filters)
by hand.
● Drain the oil
After longer periods of standstill: ● Remove the oil filter (g, 100)
◆ Make sure that the vacuum pump is locked against inadvertent ● Make sure that materials and components to be treated as special
start up waste have been separated from the vacuum pump
◆ Remove the cover around the fan of the drive motor (400) ● Make sure that the vacuum pump is not contaminated with harm-
◆ Slowly rotate the fan wheel by hand several revolutions in the ful foreign material
intended direction of rotation (see stuck on or cast arrow (a, According to the best knowledge at the time of printing of this manual
431)) the materials used for the manufacture of the vacuum pump involve
◆ Mount the cover around the fan wheel of the drive motor no risk.
(400) ● Dispose of the used oil in compliance with applicable regulations
If deposits could have gathered in the vacuum pump: ● Dispose of special waste in compliance with applicable regulations
◆ Flush the vacuum pump (Ú Maintenance) ● Dispose of the vacuum pump as scrap metal
● Observe the chapter Ú Installation and Commissioning
RA 0063 - 0100 F Removal from Service

0870139536 / 051214 page 13
Troubleshooting
WARNING_ab
Risk of electrical shock, risk of damage to equipment.
Electrical installation work must only be executed by qualified personnel that knows and observes the following regulations:
- IEC 364 or CENELEC HD 384 or DIN VDE 0100, respectively,
- IEC-Report 664 or DIN VDE 0110,
- BGV A2 (VBG 4) or equivalent national accident prevention regulation.
CAUTION_ac
During operation the surface of the vacuum pump may reach temperatures of more than 70 °C.
Risk of burns!
Let the vacuum pump cool down prior to a required contact or wear heat protection gloves.
Problem Possible Cause Remedy
The vacuum pump does not reach the usual The vacuum system or suction line is not Check the hose or pipe connections for possi-
pressure leak-tight ble leak
The drive motor draws a too high current
(compare with initial value after commission-
ing)
Evacuation of the system takes too long
In case a vacuum relief valve/regulating system Adjust, repair or replace, respectively

is installed:
The vacuum relief valve/regulating system is
misadjusted or defective
Contaminated oil (the most common cause) Change the oil

(Ú Maintenance)
No or not enough oil in the reservoir Top up oil

(Ú Maintenance)
The exhaust filters (o, 122) are partially Replace the exhaust filters (o, 122)
clogged (Ú Maintenance)
The oil filter (g, 100) is clogged (the oil flows Replace the oil filter (g, 100)
through the bypass only, the oil does not get (Ú Maintenance)
filtered any more)
The screen (261) in the suction connection (e, Clean the screen (261)
260) is partially clogged If cleaning is required too frequently install a
filter upstream
In case a filter is installed on the suction Clean or replace the inlet air filter, respectively
connection (e, 260):
The filter on the suction connection (e, 260) is
partially clogged
Partial clogging in the suction, discharge or Remove the clogging

pressure line
Long suction, discharge or pressure line with Use larger diameter

too small diameter
The valve disk of the inlet non-return valve is Disassemble the inlet, clean the screen (261)
stuck in closed or partially open position and the valve (257) as required and reassem-
ble
The oil tubing is defective or leaking Tighten the connections

The oil return line (j, 195) is broken Replace the connections and/or the tubing
(replace with identically dimensioned parts
only)
Troubleshooting RA 0063 - 0100 F
page 14 0870139536 / 051214

Version with float valve (j, 200) and oil return Make the float valve (j, 200) movable, replace
line if necessary (Ú Maintanance à Oil and Oil
Filter Change à Checking the Float Valve)
The float valve (j, 200) is stuck in open posi-
tion
A shaft seal is leaking Replace the shaft seal ring (Busch service)
An/The exhaust valve (q, 159) is not properly Disassemble and reassemble the exhaust
seated or stuck in partially open position valve(s) (q, 159) (Busch service)
A vane (f, 22) is blocked in the rotor or other- Free the vanes (f, 22) or replace with new
wise damaged ones (Busch service)
The radial clearance between the rotor (s, 14) Readjust the vacuum pump (Busch service)
and the cylinder (t, 1) is no longer adequate
Internal parts worn or damaged Repair the vacuum pump (Busch service)
The gas conveyed by the vacuum pump smells Process components evaporating under vac- Check the process, if applicable
displeasing uum Use a different type of oil, if applicable
Readily volatile and thus gaseous components
of the oil, e.g. additives, particularly right after
an oil change.
Note: This is no indication of a malfunction of
the oil separator. The oil separator is able to
retain droplets of oil, however no gaseous
components of it.
The vacuum pump does not start The drive motor (400) is not supplied with the Supply the drive motor (400) with the correct
correct voltage or is overloaded voltage
The drive motor starter overload protection is Compare the trip level of the drive motor
too small or trip level is too low starter overload protection with the data on
the nameplate, correct if necessary
In case of high ambient temperature: set the
trip level of the drive motor starter overload
protection 5 percent above the nominal drive
motor current
One of the fuses has blown Check the fuses
Version with alternating current motor: Repair the drive (Busch service)
The drive motor capacitor is defective
The connection cable is too small or too long Use sufficiently dimensioned cable
causing a voltage drop at the vacuum pump
The vacuum pump or the drive motor is Make sure the drive motor is disconnected
blocked from the power supply
Remove the fan cover
Try to turn the drive motor with the vacuum
pump by hand
If the unit is still frozen: remove the drive mo-
tor and check the drive motor and the vacuum
pump separately
If the vacuum pump is blocked:
Repair the vacuum pump (Busch service)
The drive motor (400) is defective Replace the drive motor (Busch service)
The vacuum pump is blocked Solid foreign matter has entered the vacuum Repair the vacuum pump (Busch service)
pump Make sure the suction line is equipped with a
screen
If necessary additionally provide a filter
Corrosion in the vacuum pump from remain- Repair the vacuum pump (Busch service)
ing condensate Check the process
Observe the chapter Ú Installation and Com-
missioning à Operating Notes à Conveying
Condensable Vapours
RA 0063 - 0100 F Troubleshooting

0870139536 / 051214 page 15
Version with three-phase motor: Repair the vacuum pump (Busch service)
When connecting the vacuum pump make
The vacuum pump was run in the wrong di-
sure the vacuum pump will run in the correct
rection
direction (Ú Installation)
After shutting down the vacuum pump the Repair the vacuum pump (Busch service)
vacuum system exerted underpressure onto Make sure the vacuum system will not exert
the pump chamber which sucked back exces- underpressure onto the shut-down vacuum
sive oil from the oil separator into the pump pump, if necessary provide an additional
chamber shut-off valve or non-return valve
When the vacuum pump was restarted too
much oil was enclosed between the vanes (f,
22)
Oil could not be compressed and thus broke a
vane (f, 22)
After shutting down the vacuum pump con- Repair the vacuum pump (Busch service)
densate ran into the pump chamber Make sure no condensate will enter the
When the vacuum pump was restarted too vacuum pump, if necessary provide a drip leg
much condensate was enclosed between the and a drain cock
vanes (f, 22) Drain condensate regularly
Condensate could not be compressed and
thus broke a vane (f, 22)
The drive motor is running, but the vacuum The coupling (310) between the drive motor Replace the coupling element (310)
pump stands still and the vacuum pump is defective
The vacuum pump starts, but labours or runs Loose connection(s) in the drive motor termi- Check the proper connection of the wires
noisily or rattles nal box against the connection diagram
The drive motor draws a too high current Version with three-phase-motor: (particularly on motors with six coils)
(compare with initial value after commission- Tighten or replace loose connections
ing) Not all drive motor coils are properly con-
nected
The drive motor operates on two phases only
Version with three-phase motor: Verification and rectification Ú Installation

and Commissioning
The vacuum pump runs in the wrong direction
Standstill over several weeks or months Let the vacuum pump run warm with inlet
closed
Oil viscosity is too high for the ambient tem- Use synthetic oil, if necessary use oil of the
perature next lower viscosity class (CAUTION: opera-
tion with too low viscosity can cause chatter
marks inside the cylinder)
Warm up the oil with a heater prior to starting
up the vacuum pump, or run the vacuum
pump in intervals in order not to let it get too
cold
Improper oil quantity, unsuitable oil type Use the proper quantity of one of the recom-
mended oils
(Ú Oil,
Oil change: Ú Maintenance)
No oil change over extended period of time Perform oil change incl. flushing and oil filter
replacement
(Ú Maintenance)
The exhaust filters (o, 122) are clogged and Flush the vacuum pump
appear black from burnt oil Replace the oil filter (g, 100)
Replace the exhaust filters (o, 122)
Fill in new oil
(Ú Maintenance)
In case the oil life is too short: use oil with
better heat resistance (Ú Oil) or retrofit cool-
ing
Foreign objects in the vacuum pump Repair the vacuum pump (Busch service)
Broken vanes (f, 22)
Stuck bearings
page 16 0870139536 / 051214

The vacuum pump runs very noisily Defective bearings Repair the vacuum pump (Busch service)
Worn coupling element (310) Replace the coupling element (310)
Stuck vanes (f, 22) Repair the vacuum pump (Busch service)
Use only recommended oils (Ú Oil) and
change more frequently
The vacuum pump runs very hot Insufficient air ventilation Make sure that the cooling of the vacuum
(the oil sump temperature shall not exceed pump is not impeded by dust/dirt
100 °C) Clean the fan cowlings, the fan wheels, the
ventilation grilles and the cooling fins
Install the vacuum pump in a narrow space
only if sufficient ventilation is ensured
On a vacuum pump with oil-cooler: clean the
intermediate spaces of the finned tube
Ambient temperature too high Observe the permitted ambient temperatures
Temperature of the inlet gas too high Observe the permitted temperatures for the
inlet gas
The exhaust filters (o, 122) are partially Replace the exhaust filters (o, 122)
clogged
The oil filter (g, 100) is clogged (the oil flows Replace the oil filter (g, 100)
through the bypass only, the oil does not get (Ú Maintenance)
filtered any more)
Not enough oil in the reservoir Top up oil
Oil burnt from overheating Flush the vacuum pump

Replace the oil filter (g, 100)
Fill in new oil
(Ú Maintenance)
ing
Mains frequency or voltage outside tolerance Provide a more stable power supply
range
Partial clogging of filters or screens Remove the clogging

Partial clogging in the suction, discharge or
pressure line
Long suction, discharge or pressure line with Use larger diameter

too small diameter
The vacuum pump fumes or expels oil drop- An exhaust filter (o, 122) is not properly Check the proper position of the exhaust fil-
lets through the gas discharge seated ters (o, 122), if necessary insert properly
The oil level drops (Ú Maintenance)
An o-ring is missing or damaged Add an o-ring

(Ú Maintenance)
An exhaust filter (o, 122) shows cracks Replace the exhaust filter (o, 122)
(Ú Maintenance)
The exhaust filters (o, 122) are clogged with Replace the exhaust filters (o, 122)
foreign matter (Ú Maintenance)
Note: The saturation of the exhaust filters
with oil is no fault and does not impair the
function of the exhaust filters! Oil dropping
down from the exhaust filters is returned to
the oil circulation.
RA 0063 - 0100 F Troubleshooting

0870139536 / 051214 page 17
Version with oil return valve (h, 280): Regularly shut down the vacuum pump for
short periods of time. Check that the oil return
In case the vacuum pump runs for more than valve (h, 280) functions properly and lets oil
10 hours without interruption, oil can collect run from the upper into the bottom chamber
in the upper chamber of the oil separator (n, of the oil separator (n, 75) as soon as the
75) to an extent that it gets expelled together vacuum pump is shut down (Ú Product De-
with the discharged gas scription à Oil Recirculation)
Version with oil return valve (h, 280): Clean or replace the oil return valve (h, 280)
The oil return valve (h, 280) does not work

properly or is clogged (proper function is
when blowing into the valve it should close,
when vacuum is applied, the valve should
open; CAUTION: do not let your mouth get in
direct contact with the oil return valve, do not
inhale through the oil return valve!)
Version with float valve (j, 200) and oil return Make the float valve (j, 200) movable, replace
line if necessary (Ú Maintanance à Oil and Oil
Filter Change à Checking the Float Valve)
The float valve (j, 200) is stuck in closed posi-
tion
The oil return line (j, 195) is clogged or broken Clean a clogged oil return line (j, 195)
Replace a broken oil return line (j, 195) with
an identically dimensioned line, top up oil (if
necessary by Busch service)
The oil is black Oil change intervals are too long Flush the vacuum pump
The oil was overheated Replace the oil filter (g, 100)
Fill in new oil
(Ú Maintenance)
ing
The oil is watery and coloured white The vacuum pump aspirated water or signifi- Flush the vacuum pump
cant amounts of humidity Replace the oil filter (g, 100)
Fill in new oil
(Ú Maintenance)
Modify the operational mode
(Ú Installation and Commissioning à Oper-
ating Notes à Conveying Condensable
Vapours)
The oil is resinous and/or sticky Improper oil type, perhaps in confusion Flush the vacuum pump
Topping up of incompatible oil Replace the oil filter (g, 100)
Fill in new oil
(Ú Maintenance)
Make sure the proper oil is used for changing
and topping up
The oil foams Mixing of incompatible oils Flush the vacuum pump
Replace the oil filter (g, 100)
Fill in new oil
(Ú Maintenance)
Make sure the proper oil is used for topping
up
page 18 0870139536 / 051214

0870139536 / 051214
RA 0063 - 0100 F
Exploded View
xx* Nur Ausführung mit Ölrücklaufventil

Version with oil return valve only
xx** Nur Ausführung mit Schwimmerventil und Ölrücksaugleitung

Version with float valve and oil return line only
page 19
Exploded View
Spare Parts 159
185
Exhaust valve, complete
Gasket
2
1
0916 126 769
0480 000 150
Note: When ordering spare parts or accessories acc. to the table below
please always quote the type and the serial no. of the vacuum pump. 186 Stud bolt 4 0412 104 730
This will allow Busch service to check if the vacuum pump is compati- 187 Spring lock washer 4 0432 000 012
ble with a modified or improved part.
191 Hex nut 4 0420 000 035
This parts list applies to a typical configuration of the vacuum pump 195 Oil return line, complete 1 0946 139 103
RA 0063 - 0100 F. Depending on the specific order deviating parts
data may apply. 200 Float valve, complete 1 0947 138 417
Oil supply (RA 0063 F),
210 1 0913 117 027
Pos. Part Qty Part no. complete
1 Cylinder (RA 0063 F) 1 0223 137 495 Oil supply (RA 0100 F),
210 1 0913 135 939
complete
1 Cylinder (RA 0100 F) 1 0223 136 239
250 Inlet flange, lower part 1 0246 101 999
Rotor with shaft sleeves
14 1 0950 108 821 255 O-ring 2 0486 000 526
(RA 0063 F)
Rotor with shaft sleeves 257 Valve insert, complete 1 0916 125 491
14 1 0950 108 822
(RA 0100 F) 260 Inlet flange 1 0246 000 541
22 Vane (RA 0063 F) 3 0722 000 330 261 Screen 1 0534 000 018
22 Vane (RA 0100 F) 3 0722 000 360 265 Hex head screw/lock washer 4 0947 127 453
Cylinder cover A-side, 280 Oil return valve, complete 1 0946 139 037
24 1 0952 137 028
complete
300 Motor flange 1 0247 107 490
27 Cylinder cover B-side, complete 1 0952 139 111
301 Hex head screw/lock washer 3 0947 127 451
42 Supporting washer 2 0391 000 601
Coupling, complete, for 3phase
43 Hex head screw 4 0410 000 023 310 1 0510 000 014
motor, motor shaftØ 24 mm
46 Seal ring 1 0484 000 029 Coupling, complete, for 3phase
47 Plug 1 0415 000 002 310 motor, motor shaftØ 28 mm 1 0510 000 015
(not for motor 0621 129 389)
50 O-ring 2 0486 000 539
Coupling, complete, for motor
310 1 0510 000 037
53 Hex head screw/lock washer 6 0947 127 452 0621 129 389
57 Parallel pin 1 0437 138 870 Coupling, complete, for AC
310 1 0510 000 507
60 Taper pin (RA 0063 F) 4 0437 104 545
Coupling, complete, for AC
60 Taper pin (RA 0100 F) 4 0437 000 074 310 1 0510 000 506
65 Parallel key 1 0434 000 044 310 couplings for other motors 1 on request
66 Parallel key 1 0434 000 044 Coupling sleeve, for AC motor
312 1 0512 000 004
(not for motor 0621 129 389)
Oil separator (version with float
75 1 0266 137 792
valve and oil return line) Coupling sleeve, for motor
312 1 0512 000 005
0621 129 389
Oil separator (version with oil
75 1 0266 138 129
return valve) Rubber coupling insert, for AC
312 1 0512 000 109
motor
78 Expanded metal 1 0534 101 306
315 Protection clip (RA 0063 F) 3 0710 109 012
79 Demister 1 0534 101 308
321 Axial flow fan (RA 0063 F) 1 0524 121 854
83 Sight glass 1 0583 000 001
321 Axial flow fan (RA 0100 F) 1 0524 108 653
84 Gasket 1 0480 000 271
326 Locking ring 1 0432 000 380
88 Plug 1 0710 000 009
340 Fan cover 1 0713 000 108
89 O-ring 1 0486 000 590
341 Tapping screw 3 0416 120 665
95 Plug 1 0710 000 010
345 Protective grid 1 0713 108 129
96 O-ring 1 0486 000 505
391 Eye bolt 1 0416 000 023
99 Nipple 1 0461 000 061
3phase motor
100 Oil filter 1 0531 000 002 1.5 kW, 230/400 V,
400 50 Hz, 1500 min-1, 1 0616 127 187
105 Cover 1 0360 108 294
shaft Ø24 x 50 mm
106 Gasket 1 0480 108 718
3phase motor
107 Hex head screw/lock washer 8 0947 127 445 1.8 kW, 190-210/380-420 V,
400 50 Hz, 1500 min-1; 1 0620 129 388
122 Exhaust filter with o-ring 1 0992 130 806 2.2 kW, 190-240/380-480 V,
125 Filter spring 2 0947 000 720 60 Hz, 1800 min-1,
shaft Ø28 x 60 mm
136 Round gasket-service cover 1 0486 114 368
3phase motor
138 Hex head screw/lock washer 4 0947 127 447 2.2 kW, 230/400 V,
400 50 Hz, 1500 min-1, 1 0620 127 188
139 Service cover 1 0247 113 773 shaft Ø28 x 60 mm
141 Gasket 2 0480 000 112
146 Hex head screw/lock washer 8 0947 127 445
155 Exhaust cover plate, complete 2 0947 125 296
Spare Parts RA 0063 - 0100 F
page 20 0870139536 / 051214

3phase motor Set of
all necessary seals, except
2.5 kW, 190-210/380-420 V, seals/gaskets
for the seal of the float 0990 106 211
50 Hz, 1500min-1; valve
400 1 0621 129 389
3.0 kW, 190-240/380-480 V,
60 Hz, 1800 min-1, service kit, set of seals
shaft Ø28 x 60 mm and all overhaul parts,
Overhaul kit
except for the float valve 0993 106 212
(RA 0063 F)
3phase motor and the seal of the float
3.0 kW, 230/400 V, valve
400 1 0620 127 189
50 Hz, 1500 min-1,
shaft Ø28 x 60 mm service kit, set of seals
and all overhaul parts,
Overhaul kit
AC motor 1.8 kW, 220-240 V, (RA 0100 F)
except for the float valve 0993 106 213
400 50 Hz, 1500 min-1, 1 0620 000 340 and the seal of the float
shaft Ø24 x 50 mm valve
AC motor 2.0 kW, 220-240 V,
400 60 Hz, 1800 min-1, 1 0620 000 341
400
shaft Ø28 x 60 mm
other motors 1 on request
Accessories
401 Hex head screw/lock washer 2 0947 127 450 Accessories Description Part no.
411 Hex head screw/lock washer 2 0947 127 451 RA 0063 F, inlet-side,
vertical, with paper
412 Foot 1 0391 107 504 Inlet air filter 0945 000 132
cartridge, to separate
415 Hex head screw/lock washer 1 0947 127 450 solids
421 Rubber foot 1 0561 000 001 RA 0100 F, inlet-side,
vertical, with paper
422 Rubber foot 2 0561 000 030 Inlet air filter 0945 000 134
solids
425 Washer 1 0431 000 132
RA 0063 F, inlet-side,
430 Nameplate 1 0565 102 562 horizontal, with paper
Inlet air filter 0945 000 133
431 Directional arrow 1 0565 000 003 cartridge, to separate
solids
432 Label before installation 1 0565 104 694
434 Label hot surface 1 0565 531 032 horizontal, with paper
436 Label Busch R 5 1 0565 138 308 solids
440 Gas ballast (optional) 1 0916 101 781 RA 0063 F, inlet-side,
Gas ballast, adjustable vertical, with polyester
440 1 on request Inlet air filter 0945 121 873
(optional) cartridge, food proof, to
separate solids
— Filter for gas ballast 1 0531 126 699
Air filter with paper cartridge vertical, with polyester
540 (RA 0063 F, not shown, 1 0530 000 002 cartridge, food proof, to
optional) separate solids
Paper cartridge for air filter RA 0063 F, inlet-side,
— (RA 0063 F, not shown, 1 0532 000 002 horizontal, with polyester
optional) cartridge, food proof, to
separate solids
Air filter with paper cartridge
540 (RA 0100 F, not shown, 1 0530 000 003 RA 0100 F, inlet-side,
optional) horizontal, with polyester
cartridge, food proof, to
Paper cartridge for air filter separate solids
— (RA 0100 F, not shown, 1 0532 000 003
optional) for easy checking of the
Filter pressure
degree of clogging of the 0946 000 100
Air filter with polyester gauge
exhaust filter
540 cartridge (RA 0063 F, not 1 0530 121 867
shown, optional) to adjust the required
Vacuum regulating
working pressure; 0947 000 449
Polyester cartridge for air filter unit
connection R 1¼ inch
— (RA 0063 F, not shown, 1 0532 121 862
optional) for the conveying of
Gas ballast,
condensable vapours, 0916 101 781
Air filter with polyester complete with paper filter
540 cartridge (RA 0100 F, not 1 0530 121 868
shown, optional) for the conveying of
Gas ballast,
adjustable, condensable vapours, on request
Polyester cartridge for air filter with paper filter and ball
— (RA 0100 F, not shown, 1 0532 121 863 complete
valve
optional)
Motor safety adjustment range: 0985 000 248
Double nipple (not shown, for switch 1.6 – 2.4 A, 3 Ph.
541 1 0456 000 328
air filter, optional)
Motor safety adjustment range:
Bend (not shown, for 0985 000 249
— 1 0456 000 327 switch 2.4 – 4.0 A, 3 Ph.
horizontal air filter, optional)
Motor safety adjustment range: 0985 104 496
switch 4.0 – 6.0 A, 3 Ph.
Spare Parts Kits Motor safety

switch
adjustment range:
6.0 – 10.0 A, 3 Ph.
0985 104 497
Motor safety adjustment range:

Spare parts kit Description Part no. switch 10.0 – 16.0 A, 3 Ph. 0985 104 498
oil filter, exhaust filter Motor safety adjustment range:

Service kit and pertinent seals 0992 106 214 0985 101 152
switch 10.0 – 16.0 A, 1 Ph.
RA 0063 - 0100 F Spare Parts Kits

0870139536 / 051214 page 21
Oil
Denomination VM 032 VM 068 VM 100 VE 101 VMH 100 VSL 032 VSL 068 VSL 100
ISO-VG 32 68 100 100 100 32 68 100
Base Mineral oil Mineral oil Mineral oil Diester Mineral oil PAO PAO PAO
3
Density [g/cm ] 0.872 0.884 0.888 0.96 0.87 0.83 0.83 0.84
Ambient temperature range
<5 5 ...20 12 ... 30 12 ... 40 12 ... 30 <5 5 ...20 10 ... 40
[°C]
Kinematic viscosity at 40 °C
2
[mm /s] 30 68 110 95 94 32 68 96
Kinematic
2
viscosity at 100 °C 5 8.5 11.5 9.5 — 6 10 13
[mm /s]
Flashpoint [°C] 225 235 260 255 264 240 240 240
Pourpoint [°C] –15 –15 –15 –30 –15 –60 –55 –50
Part no. 1 l packaging 0831 000 086 0831 102 492 0831 000 060 0831 000 099 0831 133 403 0831 122 575 0831 131 846 0831 122 573
Part no. 5 l packaging 0831 000 087 0831 102 493 0831 000 059 0831 000 100 — 0831 131 845 0831 131 847 0831 122 572
Standard oil Standard oil Standard oil For thermally

For ultimate
for non-de- for non-de- for non-de- and chemically Food applica- Food applica- Food applica-
Remark pressure criti-
manding appli- manding appli- manding appli- demanding tions (NSF H1) tions (NSF H1) tions (NSF H1)
cal applications
cations cations cations applications
Filling quantity, approx. [l] 2.0
Oil RA 0063 - 0100 F
page 22 0870139536 / 051214

EC-Declaration of Conformity
Note: This Declaration of Conformity and the -mark affixed to the nameplate are valid for the vacuum pump within the Busch-scope of delivery.
When this vacuum pump is integrated into a superordinate machinery the manufacturer of the superordinate machinery (this can be the operating
company, too) must conduct the conformity assessment process acc. to the Directive Machinery 98/37/EC for the superordinate machine, issue the
Declaration of Conformity for it and affix the -mark.
We
Busch Produktions GmbH
Schauinslandstr. 1
79689 Maulburg
Germany
declare that vacuum pumps RA 0063 - 0100 F
in accordance with the European Directives
“Machinery” 98/37/EC,
“Electrical Equipment Designed for Use within Certain Voltage Limits” (so called “Low Voltage”) 73/23/EEC,
“Electromagnetic Compatibility” 89/336/EEC
have been designed and manufactured to the following specifications:
Standard Title of the Standard
Harmonised Standards
EN 12100-1 Safety of machinery - Basic concepts, general principles of design - Part 1 and 2
EN 12100-2
EN 294 Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs
EN 1012-1 Compressors and vacuum pumps - Safety requirements - Part 1 and 2
EN 1012-2
EN ISO 2151 Acoustics - Noise test code for compressors and vacuum pumps - Engineering method (grade 2)
EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements
EN 61000-6-1 Electromagnetic compatibility (EMC) - Generic immunity standards
EN 61000-6-2
EN 61000-6-3 Electromagnetic compatibility (EMC) - Generic emission standards
EN 61000-6-4
Manufacturer
Dr.-Ing. Karl Busch

General director
RA 0063 - 0100 F EC-Declaration of Conformity

0870139536 / 051214 page 23
Busch – All over the World in Industry www.busch-vacuum.com
Australia Dr.-Ing. K. Busch GmbH Norway
Niederlassung Nord
Busch Australia Pty. Ltd. Ernst-Abbe-Str. 1-3 Busch Vakuumteknikk AS
30 Lakeside Drive 25451 Quickborn Hestehagen 2
Broadmeadows, Vic. 3047 Tel: (0 41 06) 7 99 67-0 1440 Drøbak
Tel: (03) 93 55 06 00 Fax: (0 41 06) 7 99 67-77 Tel: 64 98 98 50
Fax: (03) 93 55 06 99 Fax: 64 93 66 21
Dr.-Ing. K. Busch GmbH
Austria Niederlassung West Poland
Busch Austria GmbH Nordring 35
64807 Dieburg Busch Polska Sp. z o.o.
Industriepark Nord Ul. Chopina 27
2100 Korneuburg Tel: (0 60 71) 92 82-0
Fax: (0 60 71) 14 71 87800 W»oc»awek
Tel: 02262 / 756 65-0 Tel: (054) 2315400
Fax: 02262 / 756 65-20 Dr.-Ing. K. Busch GmbH Fax: (054) 2327076
Niederlassung Süd-Ost
Belgium Gewerbestraße 3 Singapore
Busch N.V./Busch SA 90579 Langenzenn
Tel: (09 01) 90 25-0 Busch Vacuum Singapore Pte Ltd
Kruinstraat 7 20 Shaw Road
9160 Lokeren Fax: (09 01) 90 25-25
#01-03 Ching Shine Building
Tel: (0)9 / 348 47 22 Dr.-Ing. K. Busch GmbH Singapore 36 79 56
Fax: (0)9 / 348 65 35 Außenstelle Zella-Mehlis Tel: (65) 6488 0866
Brazil Am Rain 11 Fax: (65) 6288 0877
98544 Zella-Mehlis
Busch do Brasil Ltda. Tel: (0 36 82) 46 92 71 Spain
Rod. Edgard Máximo Zambotto, Km 64 Fax: (0 36 82) 46 92 73
13240-000 Jarinú-SP Busch Ibérica S.A.
Tel: (55) 11-4016 1400 Ireland C/. Penedès, 47-49
Fax: (55) 11-4016 1077 08192 Sant Quirze del Vallès
Busch Ireland Ltd. Tel: 93 721 77 77
Canada A10-11 Howth Junction Business Centre Fax: 93 721 42 07
Kilbarrack, Dublin 5
Busch Vacuum Technics Inc. Tel: 00353 1 832 1466 Sweden
1740, Boulevard Lionel Bertrand Fax: 00353 1 832 1470
Boisbriand (Montréal) Busch Vakuumteknik AB
Québec J7H 1N7
Italy Bråta Industriområde
Tel: 450 435 6899 Busch Italia S.r.l. 435 33 Mölnlycke
Fax: 450 430 5132 Via Ettore Majorana, 16 Tel: 031 - 338 00 80
20054 Nova Milanese Fax: 031 - 338 00 89
China Tel: 0362 370 91 Switzerland
Busch Vacuum (Shanghai) Co., Ltd Fax: 0362 370 999
18 Bin Yang Road, Shanghai Japan Busch AG
China 200235 Waldweg 22
Tel: +86 21 6436 1919 Nippon Busch K.K. 4312 Magden
Fax: +86 21 5031 5766 1-23-33, Megumigaoka Tel: 061 / 845 90 90
Hiratsuka City, Kanagawa Fax: 061 / 845 90 99
Czech Republic Japan 259-1220
Tel: 0463-50-4000 Taiwan
Busch Vakuum s.r.o.
Pra ákova 10 Fax: 0463-50-4004
Busch Taiwan Corporation
619 00 Horní Heršpice Korea No. 69, Sec. 3, Pei Shen Rd.
Brno Shen Keng Hsiang,
Tel.: +420 543 42 48 55 Busch Korea Ltd. Taipei Hsien,
Fax: +420 543 42 48 56 392-1 Yangji-Ri, Yangji-Myun, Taiwan (222), R.O.C
Yongin-si, Kyunggi-Do Tel: (02) 2662 0775
Denmark Tel: 031) 321-8114 Fax: (02) 2662 0796
Fax: 031) 321 4330
Busch Vakuumteknik A/S
Parallelvej 11 Malaysia Turkey
8680 Ry VAKUTEK
Tel: +45 87 88 07 77 Busch (Malaysia) Sdn Bhd.
6 Jalan Taboh 33/22 Emlak Kredi Ishani No: 179
Fax: +45 87 88 07 88 81130 Üsküdar-Istanbul
Shah Alam Technology Park
Finland Section 33 Tel: (216) 310 0573
40400 Shah Alam Fax: (216) 343 5126
Busch Vakuumteknik Oy Selangor D. E.
Sinikellonpolku 3 United Kingdom
Tel: 03 5122 2128
01300 VANTAA Fax: 03 5122 2108 Busch (UK) Ltd
Tel: 09 774 60 60
Netherlands Hortonwood 30-35
Fax: 09 774 60 666
Telford
France Busch B.V. Shropshire
Pompmolenlaan 2 TF1 7YB
Busch France S.A. 3447 GK Woerden Tel: 01952 677 432
Parc Technologique Postbus 2091 Fax: 01952 677 423
de Bois Chaland CE 2922 3440 DB Woerden
91029 Evry Cedex Tel: (0)348 - 462300 USA
Tel: 01 69 89 89 89 Fax: (0)348 - 422939
Fax: 01 60 86 16 74 Busch, Inc.
New Zealand 516-B Viking Drive
Germany Virginia Beach, VA 23452
Busch New Zealand Ltd. Tel: (757) 463-7800
Dr.-Ing. K. Busch GmbH Unit D, Arrenway Drive Fax: (757) 463 7407
Schauinslandstr. 1 Albany, Auckland 1311
79689 Maulburg P O Box 302696 Semiconductor Vacuum Group Inc.
Tel: (0 76 22) 6 81-0 North Harbour, Auckland 1330 Morgan Hill, CA 95037
Fax: (0 76 22) 6 81-194 Tel: 0-9-414 7782 Tel: (408) 955 1900
e-mail: sec.bu@busch.de Fax: 0-9-414 7783 Fax: (408) 955 0229
Instruction Manual
Puma
Vacuum Booster
WP 0250 D4, WP 0500 D2/D4, WP 0700 D2,
WP 1000 D2/D4, WP 1250 D2, WP 2000 D2
Ateliers Busch S.A.

Zone industrielle, 2906 Chevenez
Switzerland
0870571055/-0001_en / Original instructions / Modifications reserved 11/04/2016

Table of Contents
Table of Contents
1 Safety........................................................................................................................... 3
2 Product Description ..................................................................................................... 4
2.1 Operating Principle............................................................................................... 5
2.2 Application ........................................................................................................... 5
2.3 Variants ................................................................................................................ 5
2.3.1 D2 Versions ...............................................................................................5
2.3.2 D4 Versions ...............................................................................................6
2.3.3 Water Cooling ..........................................................................................6
3 Transport ..................................................................................................................... 6
4 Storage......................................................................................................................... 7
5 Installation................................................................................................................... 7
5.1 Installation Conditions .......................................................................................... 7
5.2 Connecting Lines / Pipes ...................................................................................... 7
5.2.1 Gas Flow Variants ......................................................................................8
5.2.2 Suction Connection....................................................................................8
5.2.3 Discharge Connection................................................................................8
5.2.4 Cooling Water Connection ........................................................................9
5.3 Filling Oil .............................................................................................................. 10
5.4 Electrical Connection ............................................................................................ 11
5.4.1 Wiring Diagram Three-Phase Motor ..........................................................11
6 Commissioning............................................................................................................ 12
7 Maintenance ................................................................................................................ 13
7.1 Maintenance Schedule.......................................................................................... 14
7.2 Oil Level Inspection .............................................................................................. 14
7.3 Oil Colour Inspection............................................................................................ 14
7.4 Oil Change ........................................................................................................... 15
8 Overhaul...................................................................................................................... 17
9 Decommissioning ........................................................................................................ 17
9.1 Dismantling and Disposal...................................................................................... 17
10 Spare Parts ................................................................................................................... 18
11 Troubleshooting........................................................................................................... 18
12 Technical Data ............................................................................................................. 20
13 Oil ............................................................................................................................... 20
14 EU Declaration of Conformity ...................................................................................... 21
2 / 24 0870571055_WP0250-2000D_-0001_IM_en
Safety | 1
1 Safety
Prior to handling the machine this instruction manual should be read and understood. If
anything needs to be clarified please contact your Busch representative.
Read carefully before use and keep for future reference.
This instruction manual remains valid as long as the customer does not change anything
on the product.
The machine is intended for industrial use. It must be handled only by technically trained
personnel.
The machine has been designed and manufactured according to state-of-the-art meth-
ods. Nevertheless, residual risks may remain. This instruction manual highlights potential
hazards where appropriate. Safety notes and warning messages are tagged with one of
the keywords DANGER, WARNING, CAUTION, NOTICE and NOTE as follows:
DANGER
... indicates an imminent dangerous situation that will result in death or serious injuries if
not prevented.
WARNING
... indicates a potentially dangerous situation that could result in death or serious injuries.
CAUTION
... indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
... indicates a potentially dangerous situation that could result in damage to property.
NOTE
... indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.
0870571055_WP0250-2000D_-0001_IM_en 3 / 24
2 | Product Description
2 Product Description
OR IN NP OSG
CWC
WP 1000 D4 / WP 2000 D2
ODP, MP OUT ODP, MP
OFP OSG MTB DA

IN Suction connection MTB Motor terminal box
OUT Discharge connection DA Directional arrow
MP Magnetic plug NP Nameplate
OFP Oil fill plug ODP Oil drain plug
OSG Oil sight glass OR Oiler
CWC Cooling water connection (WP 1000 D4 / WP 2000 D2 only)
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
booster’.
4 / 24 0870571055_WP0250-2000D_-0001_IM_en
Product Description | 2
2.1 Operating Principle
The machine works on the Roots blower principle.

The two oil housings (on each side) allow the lubrication of the gears, bearings and in
certain versions the oil lubricated mechanical seals.
2.2 Application
The machine is intended for the suction of air and other dry, non-aggressive, non-toxic
and non-explosive gases.
Conveying of other media leads to an increased thermal and/or mechanical load on the
machine and is permissible only after a consultation with Busch.
The machine is intended for the placement in a non-potentially explosive environment.
The vacuum booster is used in combination with a backing pump in vacuum system.
The machine is capable of maintaining ultimate pressure.
Permitted environmental conditions see Technical Data [} 20].
NOTICE
Chemical compatibility of the process gases with the machine component materials.
Risk of corrosion inside the compression chamber which can reduce performance and
its lifetime!
• Check if the process gases are compatible with those following materials:
- Cast iron
- Steel
- Aluminium
- Fluoroelastomer (FKM/FPM)
• In doubt, please contact your Busch representative.
2.3 Variants
2.3.1 D2 Versions
The D2 versions (ex: WP 0500 D2) have a differential pressure of 50 hPa with a max-
imum motor speed of 3600 min-1 at 60 Hz.
Refer to the nameplate (NP) in order to know what the machine version is.
0870571055_WP0250-2000D_-0001_IM_en 5 / 24
3 | Transport
2.3.2 D4 Versions
The D4 versions (ex: WP 0500 D4) are characterised by a particularly high differential
pressure of 80 hPa with a maximum motor speed of 1800 min-1 at 60 Hz.
Refer to the nameplate (NP) in order to know what the machine version is.
2.3.3 Water Cooling

The versions WP 1000 D4 and WP 2000 D2 must be cooled by water. There are four
cooling water connections (CWC), two on each side, intended for the water inlet and
outlet.
3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
NOTICE
In case the machine is already filled with oil.
Tilting a machine that is already filled with oil can cause large quantities of oil to in-
gress into the cylinder.
• Drain the oil prior to every transport or always horizontally transport the machine.
Machine weight:
see the technical data or the nameplate (NP)
Use appropriate slings
• Check the machine for transport damage.

In case of the machine being secured to a base plate:
• Remove the fixations.
6 / 24 0870571055_WP0250-2000D_-0001_IM_en
Storage | 4
WARNING
Lifting the machine using the motor eye bolt.
• Do not lift the machine using the eye bolt fitted to the motor. Only lift the machine as
previously shown.
4 Storage
• Seal all apertures with adhesive tape or reuse provided caps.
In case of storage of more than 3 months is scheduled:
• Wrap the machine in a corrosion inhibiting film.
• Store the machine indoors, dry, dust free and if possible in original packaging
preferably at temperatures between -20 ... 55 °C.
5 Installation
5.1 Installation Conditions
• Make sure that the environment of the machine is not potentially explosive.
• Make sure that the ambient conditions comply with the Technical Data [} 20].
• Make sure to use a suitable backing pump, if necessary seek advice from your Busch
representative
• Make sure that the environmental conditions comply with the protection class of the
motor.
• Make sure that the installation space or location is vented such that sufficient cooling
of the machine is provided.
• Make sure that cooling air inlets and outlets are not covered or obstructed and that
the cooling air flow is not affected adversely in any other way.
• Make sure that the oil sight glass (OSG) remains easily visible.
• Make sure that enough space remains for maintenance work.
• Make sure that the machine is placed or mounted horizontally, a maximum of 1° in
any direction.
• Make sure that the machine is secured either from the four feet or from the discharge
flange.
• Check the oil level, fill up if necessary, see Filling Oil [} 10].
• Make sure that all provided covers, guards, hoods, etc. are mounted.
For versions WP 1000 D4 and WP 2000 D2:
• Make sure that the cooling water complies with the requirements, see Cooling
Water Connection [} 9].
5.2 Connecting Lines / Pipes

• Make sure that the connection lines cause no stress on the machine‘s connection, if
necessary use flexible joints.
• Make sure that the line size of the connection lines over the entire length is at least as
large as the connections of the machine.
0870571055_WP0250-2000D_-0001_IM_en 7 / 24
5 | Installation
In case of very long connection lines it is advisable to use larger line sizes in order to
avoid a loss of efficiency. Seek advice from your Busch representative.
5.2.1 Gas Flow Variants

The machine can be installed in different ways:
Vertical gas flow Horizontal gas flow (Optional)
5.2.2 Suction Connection
WARNING
Unprotected suction connection.
• Do not put hand or fingers in the suction connection.
NOTICE
Intruding foreign objects or liquids.
Risk of damage to the machine!
In case of the inlet gas contains dust or other foreign solid particles:
• Install a suitable filter (5 micron or less) upstream the machine.
Standard dimensions:
– DN63 (DIN 28404) for WP 0250-0500 D
– DN100 (DIN 28404) for WP 0700 D
– DN160 (DIN 28404) for WP 1000-2000 D
Depending on the specific order, other connection dimensions may apply.
5.2.3 Discharge Connection

– DN63 (DIN 28404) for WP 0250-0500 D
– DN100 (DIN 28404) for WP 0700 D
– DN160 (DIN 28404) for WP 1000-2000 D
Depending on the specific order, other connection dimensions may apply.
• Make sure that the discharged gas will flow without obstruction. Do not shut off or
throttle the discharge line or use it as a pressurised air source.
8 / 24 0870571055_WP0250-2000D_-0001_IM_en
Installation | 5
5.2.4 Cooling Water Connection

Only requier for the Puma versions WP 1000 D4 and WP 2000 D2
2x CWC 2x CWC Suggestion of connection
CWC Cooling water connections

2 connections on each side (cooling water inlet and outlet)
– G1/4 (CWC)
• Make sure that the cooling water complies with the following requirements:
Min. supply capacity l/min 2
Water pressure bar 2 ... 5
Supply temperature °C +10 ... +15
Required pressure differential across supply bar ≥1
and return
• To reduce the maintenance effort and ensure a long product lifetime we recommend
the following cooling water quality:
Hardness mg/l (ppm) < 90
Properties Clean & clear
PH value 7…8
Particle size µm < 200
Chloride mg/l < 100
Electrical conductivity µS/cm ≤ 100
Free chloride mg/l < 0.3
Materials in contact with the cooling water Stainless steel, copper and cast iron
NOTE
Water hardness unit conversion.
1 mg/l (ppm) = 0.056 °dh (german degree) = 0.07 °e (english degree) = 0.1 °fH (french
degree)
0870571055_WP0250-2000D_-0001_IM_en 9 / 24
5 | Installation
5.3 Filling Oil

For oil type and oil capacity see Technical Data [} 20] and Oil [} 20].
Oil filling at the motor side

2 1
Bus
5
ch
Oil
4
3
Oil
sch
Bu
Fill up until the oiler (OR)

is at least two thirds full
Check oil level
Oil filling at the gear side
1
4
2
3
l
Oi
sch
MAX
Bu
MIN
Check oil level
10 / 24 0870571055_WP0250-2000D_-0001_IM_en
Installation | 5
5.4 Electrical Connection

DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
• Make sure that the power supply for the motor is compatible with the data on the
nameplate of the motor.
• Provide an overload protection according to EN 60204-1 for the motor.
• Make sure that the motor of the machine will not be affected by electric or electro-
magnetic disturbance from the mains; if necessary seek advice from Busch.
• Connect the protective earth conductor.
• Electrically connect the motor.
NOTICE
Incorrect connection.
Risk of damage to the motor!
• The wiring diagrams given below are typical. Check the inside of the terminal box for
motor connection instructions/diagrams.
5.4.1 Wiring Diagram Three-Phase Motor

Delta connection (low voltage): Star connection (high voltage):
Double star connection, multi-voltage Star connection, multi-voltage motor

motor with 9 pins (low voltage): with 9 pins (high voltage):
0870571055_WP0250-2000D_-0001_IM_en 11 / 24
6 | Commissioning
Double star connection, multi-voltage Star connection, multi-voltage motor

motor with 12 pins (low voltage): with 12 pins (high voltage):
4 4
4 4
4 4
Delta connection, multi-voltage motor

with 12 pins (middle voltage):
NOTICE
Incorrect direction of rotation.
Risk of damage to the motor!
• Operation in the wrong direction of rotation can destroy the machine in a short time!
Prior to starting-up make sure that the machine is operated in the right direction.
• Determine the intended direction of rotation with the arrow (stuck on or cast).
• ‘Bump’ the motor.
• Watch the fan wheel of the motor and determine the direction of rotation just before
the fan wheel stops.
If the rotation must be changed:
• Switch any two of the motor phase wires.
6 Commissioning
NOTICE
The machine is shipped without oil.
Operation without oil will ruin the machine in short time!
• Prior to commissioning, the machine must be filled with oil, see Filling Oil [} 10].
NOTICE
Lubricating a dry running machine (process chamber).
Risk of damage to the machine!
• Do not lubricate the process chamber of the machine with oil or grease
12 / 24 0870571055_WP0250-2000D_-0001_IM_en
Maintenance | 7
CAUTION
During operation the surface of the machine may reach temperatures of more than
70°C.
Risk of burns!
• Avoid contact with the machine during and directly after operation.
CAUTION
Noise of running machine.
Risk of damage to hearing!
If persons are present in the vicinity of a non noise insulated machine over extended
periods:
• Make sure that ear protection is being used.
• Make sure that the installation conditions (see Installation Conditions [} 7]) are com-
plied with.
• Switch on the machine.
• Make sure that the maximum permissible number of starts does not exceed 6 starts
per hour.
• Open the water supply.
As soon as the machine is operated under normal operating conditions:
• Measure the motor current and record it as reference for future maintenance and
troubleshooting work.
• After few minutes of operation, perform an Oil Level Inspection [} 14].
7 Maintenance
WARNING
Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:
• Wear appropriate personal protective equipment.
CAUTION
Hot surface.
Risk of burns!
• Prior to any action requiring touching the machine, let the machine cool down first.
• Shut down the machine and lock against inadvertent start up.
• Turn off the water supply.
• Vent the connected lines to atmospheric pressure.
0870571055_WP0250-2000D_-0001_IM_en 13 / 24
7 | Maintenance
If necessary:
• Disconnect all connections.
7.1 Maintenance Schedule

The maintenance intervals depend very much on the individual operating conditions. The
intervals given below are desired to be considered as starting values which should be
shortened or extended as appropriate. Particularly heavy duty operation, such as high
dust loads in the environment or in the process gas, other contamination or ingress of
process material, can make it necessary to shorten the maintenance intervals significant-
ly.
Interval Maintenance work
Monthly • Check the oil level, see Oil Level Inspection [} 14].
• Check the machine for oil leaks - in case of leaks have
the machine repaired (contact Busch).
After the first 500 hours • Change the oil of the gear and bearing housings
(both sides), see Oil Change [} 15].
Every 6 months • Perform an oil inspection; change it if the oil has
changed its initial colour, see Oil Colour Inspection
[} 14].
Every 5000 hours, at the latest • Change the oil of the gear and bearing housings
after 1 year (both sides)
• Clean the magnetic plugs (MP)
Every 8 years • Have a major overhaul on the machine (contact
Busch).
7.2 Oil Level Inspection

• Shut down the machine.
• When the machine is stopped, wait 1 minute before checking the oil level with the oil
sight glasses (OSG).
MAX MAX
MIN MIN
• Fill up if necessary, see Oil Filling [} 10].
7.3 Oil Colour Inspection

• Make sure that the oil is either light or transparent.
If the oil becomes dark or looks different from the initial colour:
• Change the oil immediately, see Oil Change [} 15].
MAX MAX
MIN MIN
You can consult your Busch representative in order to find out why this colour change
has occurred.
14 / 24 0870571055_WP0250-2000D_-0001_IM_en
Maintenance | 7
7.4 Oil Change

Oil draining at the motor side
3
Cleaning cloth
Drain pan
Oil draining at the gear side
2
1
Cleaning cloth Drain pan
0870571055_WP0250-2000D_-0001_IM_en 15 / 24
7 | Maintenance
For oil type and oil capacity see Technical Data [} 20] and Oil [} 20].
Oil filling at the motor side

2 1
Bus
5
ch
Oil
4
3
Oil
sch
Bu
Fill up until the oiler (OR)

is at least two thirds full
Check oil level
Oil filling at the gear side
1
4
2
3
l
Oi
sch
MAX
Bu
MIN
Check oil level
16 / 24 0870571055_WP0250-2000D_-0001_IM_en
Overhaul | 8
8 Overhaul
NOTICE
Improper assembly.
Risk of premature failure!
Loss of efficiency!
• It is highly recommended that any dismantling of the machine that goes beyond any-
thing that is described in this manual should be done through Busch.
WARNING
Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:
• Wear appropriate personal protective equipment.
In case of the machine having conveyed gas that was contaminated with foreign materi-
als which are dangerous to health:
• Decontaminate the machine as good as possible and state the contamination
status in a ‘Declaration of Contamination’.
Busch will only accept machines that come with a complete filled in and legally binding
signed ‘Declaration of Contamination’.
(Form downloadable from www.buschvacuum.com)
9 Decommissioning
• Shut down the machine and lock against inadvertent start up.
• Vent the connected lines to atmospheric pressure.
• Turn off the water supply.
• Disconnect the water supply.
• Blow through the water cooling inlet with compressed air.
• Disconnect all connections.
In case of storage is planned:
• See Storage [} 7].
9.1 Dismantling and Disposal

• Drain the oil.
• Separate special waste from the machine.
• Dispose of special waste in compliance with applicable regulations.
• Dispose of the machine as scrap metal.
0870571055_WP0250-2000D_-0001_IM_en 17 / 24
10 | Spare Parts
10 Spare Parts
NOTICE
Use of non-Busch genuine spare parts.
Risk of premature failure!
Loss of efficiency!
• The exclusive use of Busch genuine spare parts and consumables is recommended for
the proper function of the machine and for granting of warranty.
There is no standard spare parts kits available for this product, if you require Busch gen-
uine parts:
• Contact your Busch representative for the detailed spare parts list.
11 Troubleshooting
DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
CAUTION
Hot surface.
Risk of burns!
• Prior to any action requiring touching the machine, let the machine cool down first.
Problem Possible Cause Remedy

The machine does not start. The motor is not supplied • Check the power supply.
with the correct voltage.
The lobes are jammed or • Lobes inspection or repair
seized. the machine (contact
Busch).
Solid foreign matter has • Remove the solid foreign
entered the machine. matter or repair the ma-
chine (contact Busch).
• Equip the machine with a
mesh screen at the suc-
tion connection.
The motor is defective. • Replace the motor.
18 / 24 0870571055_WP0250-2000D_-0001_IM_en
Troubleshooting | 11
The machine does not reach Suction or discharge lines • Use larger diameter or
the usual pressure. too long or section diameter shorter lines.
too small. • Seek advice from your
local Busch representa-
tive.
The backing pump is not • Contact Busch.
correctly defined.
The machine runs in the • Check the direction of ro-
wrong direction. tation, see Wiring Dia-
gram Three-Phase Motor
[} 11].
Internal parts are worn or • Repair the machine (con-
damaged. tact Busch).
The machine runs very nois- Wrong oil quantity or un- • Use one of the recom-
ily. suitable oil type. mended oils in the correct
quantity, see Oil [} 20].
Defective gears, bearings or • Repair machine (contact
coupling element. Busch).
The machine runs too hot. Insufficient cooling. For versions WP 1000 D4
and WP 2000 D2:
• Make sure to comply with
the cooling water require-
ments, see Cooling Water
Connection [} 9].
Ambient temperature too • Observe the permitted
high. ambient temperature, see
Technical Data [} 20].
Temperature of the process • Observe the permitted
gases at the inlet too high. gas inlet temperature, see
Technical Data [} 20].
Oil level too low. • Top up oil.
The backing pump is not • Contact Busch.
correctly defined.
The oil is black. Oil change intervals are too • Drain the oil and fill in
long. new oil, see Oil Change
[} 15].
The machine runs too hot. • See problem "The ma-
chine runs too hot".
For the solution of problems not mentioned in the troubleshooting chart contact your
Busch representative.
0870571055_WP0250-2000D_-0001_IM_en 19 / 24
12 | Technical Data
12 Technical Data
WP 0250 D4 WP 0500 D2 WP 0500 D4 WP 0700 D2
Nominal pumping speed m³/h 250 / 300 500 / 600 500 / 600 700 / 840
(50Hz / 60Hz)
Max. differential pressure hPa (mbar) 80 50 80 50
Nominal motor rating kW 1.1 / 1.5 2.2 / 3.0 1.5 / 2.2 3.0 / 4.0
(50Hz / 60Hz)
Nominal motor speed min-1 1500 / 1800 3000 / 3600 1500 / 1800 3000 / 3600
(50Hz / 60Hz)
Ambient temperature range °C 5 … 40
Max. gas inlet temperature °C 200
(P <10 hPa, staging ratio of 4)
Relative humidity at 30°C 90%
Oil capacity (Motor side) l 0.6 (vertical gas flow) / 0.4 (horizontal gas flow)
Oil capacity (Gear side) l 0.8 (vertical gas flow) / 0.5 (horizontal gas flow)
Oil capacity (Oiler) l 0.26
Weight approx. kg 150 150 200 200
WP 1000 D2 WP 1000 D4 WP 1250 D2 WP 2000 D2

Nominal suction capacity m³/h 1000 / 1200 1010 / 1220 1250 / 1500 2000 / 2400
(50Hz / 60Hz)
Max. differential pressure hPa (mbar) 50 80 50 50
Motor nominal rating kW 3.0 / 4.0 3.0 / 4.2 4.0 / 5.5 5.5 / 7.5
(50Hz / 60Hz)
Motor nominal speed min-1 3000 / 3600 1500 / 1800 3000 / 3600 3000 / 3600
(50Hz / 60Hz)
Ambient temperature range °C 5 … 40
Max. gas inlet temperature °C 200
(P <10 hPa, staging ratio of 4)
Relative humidity at 30°C 90%
Oil quantity (Motor side) l 0.6 (vertical gas flow) / 0.4 (horizontal gas flow) 1.2 (vert. gas
flow / 0.8 (hor.
gas flow)
Oil quantity (Gear side) l 0.8 (vertical gas flow) / 0.5 (horizontal gas flow) 1.5 (vert. gas
flow / 0.9 (hor.
gas flow)
Oil quantity (Oiler) l 0.26
Weight approx. kg 200 350 250 350
13 Oil
VE 101 VSL 100
ISO-VG 100 100
Part number 1 L packaging 0831 000 099 0831 122 573
Part number 5 L packaging 0831 000 100 0831 122 572
To know which oil has been filled in the machine, please refer to the nameplate (NP).
20 / 24 0870571055_WP0250-2000D_-0001_IM_en
EU Declaration of Conformity | 14
14 EU Declaration of Conformity
This Declaration of Conformity and the CE-mark affixed to the nameplate are valid for the machine within the
Busch scope of delivery. This Declaration of Conformity is issued under the sole responsibility of the manufacturer.
When this machine is integrated into a superordinate machinery the manufacturer of the superordinate machinery
(this can be the operating company, too) must conduct the conformity assessment process for the superordinate
machine or plant, issue the Declaration of Conformity for it and affix the CE-mark.
The manufacturer Ateliers Busch S.A.

Zone Industrielle
CH-2906 Chevenez
declare that the machine(s): Puma WP 0250 D2; WP 0500 D2/D4; WP 0750 D2; WP 1000 D2/D4; WP 1250 D2;
WP 2000 D2
with a serial number from C1601… to C1752…
has (have) been manufactured in accordance with the European Directives:
– ‘Machinery’ 2006/42/EC
– ‘Electromagnetic Compatibility’ 2014/30/EU
– ‘RoHS’ 2011/65/EU, restriction of the use of certain hazardous substances in electrical and electronic equip-
ment
and following the standards.
Standard Title of the Standard
EN ISO 12100:2010 Safety of machinery - Basic concepts, general principles of design
EN ISO 13857:2008 Safety of machinery - Safety distances to prevent hazard zones being reached
by the upper and lower limbs
EN 1012-1:2010 Compressors and vacuum pumps - Safety requirements - Part 1 and Part 2
EN 1012-2:1996 + A1:2009
EN ISO 2151:2008 Acoustics - Noise test code for compressors and vacuum pumps - Engineering
method (grade 2)
EN 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part 1: General re-
quirements
EN 61000-6-2:2005 Electromagnetic compatibility (EMC) - Generic standards. Immunity for indus-
trial environments
EN 61000-6-4:2007 + A1:2011 Electromagnetic compatibility (EMC) - Generic standards. Emission standard
for industrial environments
EN ISO 13849-1:2015 (1) Safety of machinery - Safety-related parts of control systems - Part 1: General
principles for design
Person authorised to compile the technical file: Gerd Rohweder

Busch Dienste GmbH
Schauinslandstr. 1
DE-79689 Maulburg
Chevenez, 16.03.2016
Christian Hoffmann, General director
(1)
In case control systems are integrated.
For ATEX certified machines, the directive and standards are mentioned in the EC-Declaration of Conformity of the
ATEX documentation provided with the product.
0870571055_WP0250-2000D_-0001_IM_en 21 / 24
Note
Note
Busch Vacuum Pumps
and Systems
All over the World in Industry
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www.busch-vacuum.com.ar www.buschvacuum.hu www.busch.pt
Australia India Russia

www.busch.com.au www.buschindia.com www.busch.ru
Austria Ireland Singapore

www.busch.at www.busch.ie www.busch.com.sg
Belgium Israel South Africa

www.busch.be www.busch.co.il www.busch.co.za
Brazil Italy Spain

www.buschdobrasil.com.br www.busch.it www.buschiberica.es
Canada Japan Sweden

www.busch.ca www.busch.co.jp www.busch.se
Chile Korea Switzerland

www.busch.cl www.busch.co.kr www.busch.ch
China Malaysia Taiwan

www.busch-china.com www.busch.com.my www.busch.com.tw
Colombia Mexico Thailand

www.buschvacuum.co www.busch.com.mx www.busch.co.th
Czech Republic Netherlands Turkey

www.buschvacuum.cz www.busch.nl www.buschvacuum.com
Denmark New Zealand United Arab Emirates

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Users Hand Book & Technical Manual DHPG-222
USER’S MANUAL
MODELS: DHPG-222
DIGITAL HI. PR. PIRANI GAUGE

& CONTROLLER
User’s Hand Book

&
Technical Manual
Published By:
Hind High Vacuum Co Pvt. Ltd,

# 17, Phase – 1,
Peenya Industrial Area,
Bangalore – 560 058.
Ph: + 9180 41931000
USER’S HANDBOOK AND

TECHNICAL MANUAL
DHPG-222
NOTE – 1
€ This Publication is applicable for HHV Make gauges only.
€ The serial number of the Gauge is located at Back Panel.
NOTE – 2
• Users are also cautioned not to photocopy the manual in full or in parts as the
photocopy pages may remain unaccounted, and therefore, it may remain
un-amended even when the authorities issue Amendment Orders to this
publication.
Model Description:
DHPG-222: Two gauge heads and two channel display. Two independent
set point controllers available.
CONTENTS
Chapter Topic Page

• Record of changes 5
• First Aid In Case of Electric Shock 7
• Safety Warning 8
• Safety Precautions – Do’s and Don’ts 9
• Users feedback reports and observations 10
• Intentionally Left Blank 11
1 Packaging, Storage And Transportation Instructions 12
2 Standard Equipment List 13
3 Gauge Specifications 14
4 General Description 15
5 Principle of Operation 16
6 Technical Description 17
7 Preparation For Use 18
8 Gauge head cleaning instruction 19
9 Trouble Shooting 20
• Notes 21
RECORD OF CHANGES
Incorporated by,
Pages Change / Amendment order ‘Name and rank’
Initials with date
Affected no. and last 3 digits of
service no.
Pages Change / Amendment order Incorporated by, Initials with date

Affected no. ‘Name and rank’
and last 3 digits of

service no.
FIRST AID IN CASE OF ELECTRICAL SHOCK
1. Switch off the mains power supply immediately. If this is not possible, protect yourself
with dry insulating material and put the victim away from the conductor. Do not touch
the victim with your bare hands until he is cleared off the conductor.
2. Place the victim in the supine position. Keep the air passage clear by turning the head
on one side. Open the patient’s mouth and clear it of water saline, mucus or blood,
which might have accumulated.
3. If the jaw is rigid, try to open the mouth by pressure on the gum behind the last molar
teeth of the lower jaw. When the upper air passages are cleared, tilt the head
backward and force the jaw forward from the angle of the jaw in front of the ears. This
would prevent mechanical obstructions to the upper air passages.
4. Then hold the chin up and forward with one hand and pinch the nostrils of the victim
with the other. Take a very deep breath and put your mouth to that of the victim and
blow into his mouth, until the chest of the victim moves up indicating filling of the lungs.
5. When the chest has moved up, withdraw your mouth and allow the chest to sink back.
Repeat this process every three to four seconds until the victim begins to breathe
again or until he is taken over by a medical attendant. This process should continue in
the ambulance also, during the transit of the patient from the site of accident to the
nearest medical center. Keep patient warm and loosen his clothing.
6. Do not give liquids until the patient is conscious.

SAFETY WARNING
7. When operating the gauge, keep in mind that its circuits have voltages upto 3500 V AC or
DC, which are dangerous to life.
8. When you are operating the unit, use probes and end-pieces protected with insulators to
Handle 5000 VAC minimum.
9. The floor near the stand or table with the equipment should be covered with insulating
mats.
10. Do not open any panels when the gauge, is powered up.
11. The user is advised to study manuals before using the tester associated with this
equipment well.
12. Do not handle the switches and connectors rough, as delicate parts are involved.
13. When the equipment is handled for servicing and calibration, use of anti static gears are
strongly recommended to prevent damage to electro static sensitive electronic
components.
14. Unauthorized persons (other than authorized by this manual) at field are not allowed to
attempt any rectification of this equipment.
15. During warranty period and contract service and maintenance period, Hind High Vacuum
(HHV) will carry out repairs. After expiry of such periods, User himself will take over the
repair work as per the guidelines or contact HHV service dept.
16. The cables must be securely attached to the respective connectors and Power supplies.
17. Never undertake any test when any damage is suspected, damage is visible on
connectors, cables or equipment.
18. The voltages employed in the equipment are sufficiently high to endanger human life.
Power must be switched off before servicing the equipment. However, if adjustments have
to be made in “POWER ON” mode, great care should be taken and anti-static procedure
must be followed.
19. This equipment is highly sophisticated and precise. A detailed study of the user’s hand-
book should be done prior to using the equipment. Failure to do so may result in the
following.
a. Damage to certain parts of the equipment due to wrong usage.
b. Inability on the part of the operator to obtain the desired performance of the equipment to
the specifications outlined.
20. Servicing by users should be restricted. Only trained and highly skilled personnel with
adequate test equipment and tools should attempt fault location or repair. They should
also take all the precautions mentioned in the technical manual. Failure to do so may
cause damage to the internal circuits like semiconductors, integrated circuits, printed wiring
tracks etc.
21. The equipment requires input voltage 230 VAC supplied through cable. This voltage must
be ensured before connecting the equipment.
9
10
SAFETY PRECAUTIONS Do’s and Don’t’s
1. Do’s:
a. To begin with, study the manual in details.
b. Ensure availability of proper power supplies required for operation.
c. Ensure availability of other test and measuring equipments required for testing
alongwith this equipment.
d. Use proper tools and avoid unnecessary tampering of the gauge.
e. Ensure that all seals are intact.
f. Ensure that the unit housings are free from mechanical damages.
g. Before using the gauge, examine the connecting loom and the connectors. The
connectors should be free of deformation.
h. Ensure pins of plug and adapter aren’t bent.
i. Ensure power supply and allied test and measuring equipments are properly
connected.
j. Strictly follow the sequence of operations mentioned in test schedule. If any one
of the operations is skipped unknowingly, please start checking from initial
condition. This is very important as missing the sequence may lead to incorrect
results and the tester in that case would be prone to malfunctioning.
k. Always work with one other person who is equally qualified during operation of
the equipment.
2. Don’t’s:
a. Do not try to attempt to change the fuse or any other component on the gauge
when it is in ‘ON’ condition.
b. If any fault is observed, immediately switch off the gauge. Do not attempt to
operate gauge until fault is rectified.
c. Do not switch off the gauge by switching off the mains supply. Switching off
should be done only with the tester ON / OFF Switch.
d. Do not forget to handle the gauge carefully; this shall give extended services.
11
12
USER’S FEED BACK REPORTS AND OBSERVATION IF TO BE RECORDED
SL. NAME OF THE

DATE OBSERVATION
NO. PERSON
______________________________________________________________________
13
Intentionally Left Blank

14
PACKAGING, STORAGE AND TRANSPORTATION

INSTRUCTIONS
1. The Gauge with all the accessories shall be packed in a suitable packing case.
2. The equipment should be wrapped in polythene sheet and bubble sheet and then
placed in the packing box.
3. The cushioning material of proper thickness should be pasted on all inner sides of
the packing box so as to avoid damage to the equipment during transit.
4. All the item(s) shall be packed according to delivery note / certificate / Standard
equipment list contained in this publication.
5. Receiving inspection – When the Gauge is received check for evidence of damage
to equipment and the packing case. Take care in removing the instrument from the
packing box and check immediately for evidence of shipping damage, loose or
broken control knobs, bent or broken connector dents or scratches on the panels. If
damage is found notify the consignor and all concerned agencies immediately.
6. The packed gauge set should be stored in a well-ventilated room / lab at an ambient
temperature but not exceeding 00 to +550 C and a relative humidity between 40 to
70%. Rapid changes in temperature and humidity should be avoided. The room / lab
should be carefully protected against ingress of various gases. The gauge should
not come in direct contact with chemicals, acids and alkalis.
7. Transportation of the gauge set is permitted by Air, Sea and Road means. Stacking
during transportation and storage in original packing case is permitted. During inter-
unit shipment, the test sets must be transported in the suitable Packing Case. Care
must be taken not to subject the tester to impact loading (e.g. dropping).
15
STANDARD EQUIPMENT LIST
The Standard equipment list consists of following items, accessories, spares and
publications.
Sl. No. ITEM Quantity

1. HHV GAUGE: MODEL: DHPG - 222 01 No.
2. Power Card 01 No.
3. Gauge Head Connecting Cable 02 Nos.
4. Gauge Heads Model: HPS-2 02 Nos.
5. Fuses 0.5 Amps 01 No.
PUBLICATION
6. Users Hand Book & Tech. Manual 01 No.
16
GAUGE SPECIFICATIONS
Specifications for the Gauge DHPG-222
Sl.
Parameter Values
No.
1. Relay contacts COM-N.O. 2amps 230V AC resistive
2. Range 1 x 10+3 to 1 x 10-3m.bar
3. Resolution 0.1 count of Mantissa
4. Power Supply 220V AC 50 Hz ±15%
5. Indicator LED Display
6. Keys 1. ENTER
2. INC
3. DEC
7. Analog output 0 to 10VDC for the gauge full range.
8. Gauge Dimension 96 X 96mm Din Standard Panel Mounting
Type Depth: 150mm
9. Weight 1.0 kg
10. Cut out dimension 91mm X 91mm
11. No. of Channels / GH 2/2 (Model: HPS – 2)
12. Set point controller 2 In Model: DHPG-222
13. Accuracy ± 20%
14. Relative humidity Upto 95% at 400C temp.
17
GENERAL DESCRIPTION
4.0. Front Panel controls of the GAUGE set are as follows:
1. Switches:
1.1. POWER ON Switch

1.1.1. This is used to Switch on the Power to the equipment.
1.2. AC Input Inlet: Located at the Back Panel.
2. Fuse:
2.1. 500mA Fuse: Protection Voltage Output range
3. Display
3.1. Two Line LED Display to show the Pressure of two channels.
4. Output Control:
4.1. Two Relays for two channel
5. Connectors at the Back Panel
5.1. Mains input. (230V AC)

5.2. Gauge head connectors two Numbers.
5.3. Analog Output for two channels.
5.4. In 9 pin D connector pin no.6 GH-1, pin no.7 COM , pin no.9 GH-2
18
PRINICPLE OF OPERATION
Change of pressure in vacuum system brings about a rise or fall in number of gas
molecules present and hence a rise or fall in the thermal conductivity of the gas. Thus
the heat loss of constant input voltage heated filament in the system varies with the
pressure. The Pirani gauge head filament has high temperature co-efficient of
resistance. So a slight change in system pressure brings about useful change in
filament resistance resulting in an out of balance of wheat stone bridge where filament
forms one of the arms. In this mode the bridges balanced at pressure less than 10-3
m.bar. Any increased pressure unbalances the bridge and results in a pressure
dependent deflection in the meter, which is calibrated in terms of m.bar. The Pirani
gauge head indicates the total pressure of combined gases and condensable vapours
in the system as the heated wire can lose heat to both gas and vapour molecules.
19
TECHNICAL DESCRIPTION
When the gauge is switched on the power supplied + 26 volts unregulated (varies
+21 to 34 volts) + 18 volts, - 12 volts and + 5 volts regulated power supplied are
available.
When gauge head is connected into the rear socket and the power supplies are
available. The wheat stone bridge configuration completes through 550 ohm, 130
ohm and sensor filament 72 ohm, and to start up the auto balancing, a small amount
of voltage derived from +18 volts through 39K ohm is fed to the bridge circuit. This
generates differential voltage across the input terminals of IC Lm747, which
produces an output voltage at the base of transistor 2N 1711 through 100 ohm,
which in turn controls the bridge voltage to balance the bridge automatically. As the
gauge head is evacuated to a higher degree of vacuum. Due to thermal conductivity
change with gas pressure, the filament temperature will try to rise and since it is a
closed loop control the bridge voltage drops down to bring back the filament
temperature. In this process the bridge voltage is highest when sensor is at
atmospheric pressure and lowest, when the sensor is at 10e-3 m.bar or better.
The IC 747 stage 1 provides ATM (999) m.bar and zero (0.001) Adjustments for
calibrations of the sensor head.
The IC 747 stage 2 provides, signal conditioning of the non-linear signal into a
logarithmic signal by means of diode resister network.
This stage generates an output of 0-10 volts corresponding to 999 m.bar to 0.001
m.bar. which is used to drive the digital display. The signal also can be used for
recorder or for external process control. The analog signal 0-10 volt after necessary
voltage divider is fed to a micro controller.
20
PREPARATION FOR USE
7.1. GENERAL:
7.2. INSTALLATION
7.2.1. The said gauge is highly sophisticated in nature hence it is recommended that
the suitable location in the laboratory should be selected to install this gauge
equipment.
7.2.2 Ensure that the location selected has atleast one-plug points each of mains
power supply available, so that the gauge equipment can be connected
comfortably.
7.2.3 Required power supplies: 230V AC 50 Hz
7.2.4 Check Fuse F1 for proper rating.

21
GAUGE HEAD CLEANING INSTRUCTIONS
8.1.1 When the fine sensor wire is contaminated with oil or other deposits that is
emissivity or its diameter is appreciably altered, and a change of calibration will
result. Cleaning with the tri chloroethylene, Toluene or Acetone is possible.
Keep the gauge head upright position and clamp it in suitable place. Pour
slowly through the opening and fill completely with clean solvent. Keep it
overnight and remove it next day morning completely by holding down ward,
pour fresh solvent and shake it slowly and drain it again. Dry it thoroughly and
prepare for re-calibrations.
22
TROUBLE SHOOTING
SL.
NO TROUBLE CAUSE REMEDY
.
1. DISP Does not glow Improper i/p voltage or no Check mains voltage.
when switch in On voltage.
Socket or power cord Check power cords.
faulty.
2. Lamp at the Power on 1. Check the Mains Fuse. 1. Replace the similar fuse.
switch is OK. But No 2. Check the Voltage as 2. Replace appropriate
message at the Display. per the wiring Diagram. components.
No Back Lit 3. LED BAD SEGMENT 3. Replace LED SEGMENT
4. Internal Power supply is 4. Replace the corresponding
not present. regulators.
3. In Current Mode, AC 1. Transformer bad. 1. Replace proper
output is not available. transformer
2. Relays bad a. Check relays wiring
b. Replace the relays
After a major faulty system is repaired it is recommended that a calibration should take
place.
For Service and Calibration Contact our nearest Branch Office
Sl. No. Places Phones Nos.

1 BANGALORE (Head Office) 41931000
2 MUMBAI (Branch Office) 25567733
3 VADODARA (Branch Office) 2331578 / 2359039
4 NEW DELHI (Branch Office) 26282410
5 KOLKATTA (Branch Office) 24661462 / 24649182
6 HYDERABAD (Branch Office) 23313721
7 PUNE (Branch Office) 25466095
8 CHENNAI (Branch Office) 24891061
23
NOTES
24
25
26
27
28
29
34
DIGITAL HIGH PRESSURE PIRANI GAUGE (DHPG-222)
Two gauge heads and two channel display with two independent set point
controllers.
35
PRESS BUTTON - POWER ON
PROCEDURE TO SET AND ADJUST SET POINT CONTROLLER IN GAUGE
2. Setting preset value for HL-1(High Level-1).

a. Press Enter/Next push button switch.
b. HL-1 display will appear as in the picture below.
c. Using ↓ and ↑
switches vary the higher
limit value of gauge head
-1 as required.
36
d. Press “Enter/next”
Above procedure will set the HL-1 limit.
3. Setting preset value for LL-1(Lower Level-1).
Soon after HL-1 setting LL-1 setting display will appear as shown in the picture
below.
4. Using ↓ and ↑ Switches vary the lower limit value of gauge head -1 as
required.
5. Press “Enter/Next” to complete the LL 1 setting.
4. Setting preset value for HL-2(High Level-2).

37
Soon after LL-1 setting HL-2 setting display will appear as shown in the picture
below.
c. Using ↓ and ↑ Switches vary the higher limit value of gauge head -2 as
required.
d. Press “Enter/Next” to complete the HL-2 setting.
5. Setting preset value for LL-2(Lower Level-2).
Soon after HL-2 setting LL-2 setting display will appear as shown in the picture
below.
Using ↓ and ↑ Switches vary the lower limit value of gauge head-2 as required.
Press “Enter/Next” to complete the LL-2 setting.

38
6. Setting RY-1 (Relay 1) to forward or Reverse.
RY-1 forward means enable HL-1 and LL-1 settings.
RY-1 reverse means disable HL-1 and LL-1 settings.
22. Forward or Reverse order can be adjusted using ↓ and ↑

Switches.
23.Press “Enter/Next” to complete the setting.
7. Setting RY-2 (Relay 2) to forward or Reverse.
RY-2 forward means enable HL-2 and LL-2 settings.
RY-2 reverse means disable HL-2 and LL-2 settings.
e. Forward or Reverse order can be adjusted using ↓ and ↑ Switches.

39
f. Press “Enter/Next” to complete the RL-2 setting.
8. After above setting the screen will return to Main display

(Default screen)
NOTE: - Above displayed set values are shown only for illustration
purpose. Customer can set values as per application
cycle time.
8. Analog out put pin details given below in 9 pin D connector:-
G H – 1 Pin No. 6
COM Pin No. 7
G H – 2 Pin No. 9
HRBCNlm . VAAS
Series 40 Ball Valves
Company:
HABONIM worldwide operations have strategic locations

at U.K., U.S.A., Israel, India etc., to meet global demands
of ball valves with stringent specific'ations.
HABONIM manufactures High Quality Ball Valves and

the world's only FOUR PISTON Pneumatic Actuator.
HABONIM also manufactures a range of Ultra Clean Ball

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Features:
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Size: 8 - 50mm (Full bore)
8 - 65mm (Regular bore)
End Conn: Flanged (ANSI 150#, 300#)
Class 800 - Threaded (NPT, BSP, BSPT)
Class 800 - Welded (Socket weld, Butt weld

to various pipe
schedules)
Blow-out proof stem
Live Loaded Packing
Exposed Bolting
Applications:
General purpose services in Chemical, Petro Chemical,

Food & Pharma, Power, Paper, Pulp and other industries.
Also available - Firesafe valves, Speciality valves, COm~Ci Piston actuators

~ ~ Imt
~ ~ UKAS
".\:"'
USA I UK I ISRAEL I INDIA ISO 9001 :2000 00.
( .
Ball Valves Series 40
Material of Construction .Item No. Description Material
1 Body Carbon Steel/SS316
2 Ends Carbon Steel/SS316
3 Ball SS 316
~~~
4 Stem SS 316
~/ 5 Seat Ring PIFE
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6 Body Seal PIFE
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7 Stem Ihrust Seal Carbon filled PIFE
8 Gland Packing Carbon filled PIFE
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9 Gland SS 316
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10 Disk Spring SS 304
~ ~" ' ~ ~
11 Locking Clip SS 316
G:{ '~"
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12 Gland Nut SS Plated
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13 Serrated Washer SS Plated

14 Handle CS Plated/SS
m-~: 15 Body Connector Bolt HIS Plated/SS
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16
17
Body Connector Nut
Stop Pin
Other materials on request
HIS Plated/SS
SS
Series 40 - Regular Bore Ball Valves

-(
==n I Valve Port

IhreadedlWelded Valves
A B wt
size
I
dia. [ B
[ C IApp.wt
(kg)
15 11.1 66 48 115 0.5 108 93 150 1.3
PORT
DIA
20 14.3 71 48 115 0.8 117 93 150 1.8
25 19.1 94 61 150 1.3 127 106 175 2.3
32 25.4 108 66 150 2.0 140 108 175 3.7
L A
40 31.8 115 80 180 3.5 165 122 175 4.0
50 38.1 128 84 180 4.5 178 124 200 5.2
65 50.8 158 115 237 8.5 190 115 237 9.0
Series B40 - Full Bore Ball Valves

(
Valve
size
I Port
dia. [ A Jffi I C[ wt:! A ffi i[ C [App.wt
(g)
15 14.3 71 48 115 0.6 108 93 150 1.5
I
PORT
20 19.1 94 61 150 0.8 117 106 150 2.0
DIA 25 25.4 108 66 150 1.3 127 108 175 2.8
I
32 31.8 115 80 160 2.2 140 122 175 4.5
40 38.1 128 84 160 3.2 165 124 200 5.7
50 50.8 152 115 178 4.3 203 115 235 10.5
A
HRBIJNlm .
V AAS AUTOMATION PVT LTD
5/216, Old Mahabalipuram Road
Kandanchavadi, Chennai - 600 096, India
Iel: + 91 4424964656/24965500 Fax: + 91 4424965452/24965453
E-mail: support@vaasval.com Web: www.vaasval.com
HV AU40/5000/12/2002

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OPERATION

MANUAL NO. N.070.0404

FOWLER WESTRUP (INDIA) PVT LTD.,

FOWLER WESTRUPTM (INDIA) PVT LTD., 1

MODEL - JHVR 6000X

CAPACITY - 6000 LPH.

CUSTOMER - M/s. SYNERGY INTERNATIONAL MARKRTING.

P.O. NO. - PO-20180002 DT: 10.01.2018

MACHINE SL. NO. - 1287458

MANUFACTURER - FOWLER WESTRUP (INDIA) PVT. LTD.

MANUAL NO. - N.070.0404

FOWLER WESTRUPTM (INDIA) PVT LTD., 2

Installation and commissioning should be carried out

We strongly recommend that first Installation and

If Installation and commissioning is carried out by

The guarantee will lapse if the installation and

FOWLER WESTRUPTM (INDIA) PVT LTD., 3

 Machine should be erected and installed as per the

 Machine should not be towed beyond a maximum

 Ensure that machine is operated on the jacks to

 Trailer tyres to be properly inflated with a pressure

 It is recommended not to operate the machine,

FOWLER WESTRUPTM (INDIA) PVT LTD., 4

Description Page No.

FOWLER WESTRUPTM (INDIA) PVT LTD., 5

FOWLER WESTRUPTM (INDIA) PRIVATE LIMITED is a joint venture between

NIRMAL FILTER (NF) Division manufactures Oil conditioning machines for

FOWLER WESTRUP manufactures 5 models of transformer oil conditioning

Standard JTM model

with flow capacities ranging from 200 to 15000 LPH

The usage of transformer oils:

Oil in power transformers and distribution transformers serve the purpose of

FOWLER WESTRUPTM (INDIA) PVT LTD., 6

NIRMAL Transformer oil conditioning machine is suitable for conditioning

The oil conditioning machine is mounted on a compact under carriage with

The machine is designed for the following operation of oil

1. Degassing, de-watering and filtering of transformer oil.

Conditioning of the oil eliminates,

By degassing, de-watering and filtration breakdown voltage of the insulating oil

1. Ferrous and non-ferrous particles of above one mm in size are arrested

2. Filtration of solid impurities is carried out by non-hygroscopic filter

FOWLER WESTRUPTM (INDIA) PVT LTD., 7

Evacuation of the degassing chamber causes the water content in the

Provision is made to evacuate the transformer by using the vacuum pumping

3. On site drying of transformer

On account of high cost of transporting a transformer back to factory, the

A) The machine is made and dispatched in two parts, i.e.

a) Oil conditioning machine.

B) These have to be assembled together as per match markings made on

C) At a time of assembly of machine over to trailer ensure to bolt outlet pipe

D) The tow bar is dismantled at a time of dispatch and this has to be

FOWLER WESTRUPTM (INDIA) PVT LTD., 8

Machine Erection & Installation Instruction:

1) The machine is supplied with the following items( in loose condition):

3) Follow the below recommendation and procedure to lift the machine.

Procedure for Lifting the machine:

FOWLER WESTRUPTM (INDIA) PVT LTD., 9

5.1 Towing Precautions

iii) CAUTION: DO NOT TOW THE MACHINE BEYOND

FOWLER WESTRUPTM (INDIA) PVT LTD., 10

1. Model JHVR 6000X

FOWLER WESTRUPTM (INDIA) PVT LTD., 11

Refer flow chart drawing no. N.070.0404