Manual de La Koch

Ultravac 500
Vacuum Chamber Packaging Machine
EFFECTIVE SERIAL # 2080 +

860052 Revision Q
Date 9/2011
MAIN: 816-753-2150
TOLL FREE: 800-777-5624
INTERNET: kochequipment.com
E-MAIL: info@kochequipment.com
TABLE OF CONTENTS SCHEMATICS

General................................................III Designation and Function of Controls.....5.1
Specifications........................................ IV 230 Volt, Single Phase, Analog Panel.... 5.2
SAFETY 230 Volt, 3 Phase, Analog Panel........... 5.3
Personal Safety.....................................1.1 380 Volt, 50 Hz, 3 Phase, Analog Panel... 5.4
Food Safety.........................................1.2 230 Volt, Single Phase, Digital Panel..... 5.5
General Safety Guidelines.....................1.2 230 Volt, 3 Phase, Digital Panel............ 5.6
STARTUP 380 Volt, 50 Hz, 3 Phase, Digital Panel.... 5.7
Unpacking...........................................2.1 Non-Gas Flush Pneumatic Diagram...... 5.8
Power Requirements..............................2.1 Gas Flush Pneumatic Diagram.............. 5.9
Grounding Instructions..........................2.1 PARTS
Vacuum Pump..................................... 2.2 Recommended Spare Parts....................6.1
Gas Flush Connection......................... 2.2 Pump and Chassis............................... 6.2
Air-Assist Connection........................... 2.2 Seal Bar............................................. 6.4
Checking Vacuum Pump Rotation......... 2.2 Lid and Hinge System.......................... 6.6
OPERATION Gas Flush Components....................... 6.8
Placement of Product............................3.1 Main Control - Front Side....................6.10
Operation with Analog Control Panel.... 3.2 Analog Control Panel.........................6.12
Operation with Digital Control Panel..... 3.3 Digital Control Panel..........................6.14
Operator Menu on Digital Panel........... 3.4 Main Control - Back Side....................6.15
Selecting a New Program..................... 3.5 Mebner Valve..................................... 6.16
Sealing with Air-Assist.......................... 3.6 Miscellaneous Machine Parts............... 6.17
Gas Flush Option................................ 3.6 REFERENCE MANUALS
Double Seam Seal Option................... 3.6 R5 Series Vacuum Pumps...................... 7.1
MAINTENANCE INDEX............................................... 8.1
Prior to Cleaning..................................4.1
Cleaning Recommendations..................4.1
Vacuum Pump Maintenance................. 4.2
Seal Bar Maintenance.......................... 4.2
Reading the Indicators......................... 4.3
Troubleshooting.................................. 4.3
Supervisor Menu on Digital Panel......... 4.5
Opening Chamber Machine................. 4.8
Changing Vacuum Pump Oil.................4.9
Replacing Potentiometer........................4.9
Replacing Power Cord........................4.10
Maintenance Log...............................4.10
Service Log........................................4.10
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I N T R O D U C T I O N P A G E I
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Ultravac 500
Vacuum Chamber Packaging Machine
Congratulations on your Ultravac 500 vacuum packaging machine purchase. This

machine was designed to provide years of trouble-free operation and to help in the
packaging of your quality food products.
Please read this owners manual to gain the maximum benefits of your vacuum packaging
machine and its different components.
A note about cleaning: Given all the various ways equipment is used in different
environments, we recommend the owner consult sanitation experts on how to properly
clean each piece of machinery in their plant and to do bacterial testing to insure that the
equipment is cleaned properly.
For Sales, Call:

Phone (816) 753-2150 Fax (816) 753-4976
Toll-Free (800) 777-5624
For Replacement Parts, Call:

Phone (816) 753-2150 Fax (816) 561-2854
Toll-Free (800) 746-1723
For Technical Support, Call:

Phone (816) 753-2150 Fax (816) 531-1447
Toll-Free (800) 777-5624
Copyright 2009 Koch Equipment LLC

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I N T R O D U C T I O N P A G E II
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General
This owners manual contains information pertinent to your Ultravac 500. Basic instructions
and maintenance information is provided. Please read carefully. Failure to do so could result
in bodily injury and/or damage to the equipment.
Receiving Problems: As in all cases, before signing the bill of lading, be sure all items
have been received as listed and there is no damage in shipment. If needed, a claim must
be made immediately to the local truck line office and noted on the bill of lading.
Please fill in the information from the bill of lading and the product identification tag.
Model No.
Serial No.
Ship Date:
Owner:
Location:
Electrical service size for your Ultravac 500 (check one):
230 Volt, 3 phase, 60 Hz

230 Volt, Single phase, 60 Hz
380 Volt, 3 phase, 50 Hz
Please fill in the serial number from the pump identification tags:
Serial No.
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I N T R O D U C T I O N P A G E III
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Specifications
Figure 0.1
Length (A): 718mm (28.25-in.)

Width (B): 610mm (24-in.)
Maximum Height (C): 1334mm (52.5-in.)
Working Height (D): 892mm (35.125-in.)
Seal Bar Length: 457mm (18-in.)
Chamber Length (E): 648mm (25.5-in.)
Chamber Width (F): 489mm (19.25-in.)
Chamber Height (G): 229mm (9-in.)
Between Seal Bars (H): 537mm (21.125-in.)
Vacuum Pump: 48m /h (28cfm) 1.5kW (2-hp)
3
70m3/h (41cfm) 2.2kW (3-hp)

Net Weight: 160-kg, 353-lbs.
Electrical Connection: See Power Requirements in Section 2
Capacity: 20-30 seconds per cycle
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I N T R O D U C T I O N P A G E IV
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SAFETY
Personal Safety
The procedures and guidelines herein must be followed precisely to avoid problems that can
result in property damage, personal injury, or death. If you have any questions related to
this information, please contact Koch Equipment Services Inc. at (800) 777-5624.
DANGER Hazardous voltage.

Disconnect and lockout power before servicing machine or cleaning. Do not remove panels
unless power has been disconnected, locked out, and tagged out at risk of electric shock
hazard.

Improper connection of the equipment-grounding conductor can result in a risk of electric
shock.
WARNING
Read and understand owners manual before using this machine. Failure to follow operating
instructions could result in personal injury or damage to equipment.
WARNING Explosion hazard.

Do not use a gas with an oxygen content greater than 22% with gas flush option.
CAUTION Blade hazard.

Do not remove, install, or replace blades without protective gloves. Perforating knife blade
is sharp. Use care when handling.
CAUTION Blade hazard.

Do not remove, install, or replace blades without protective gloves. Precut knife blade is
sharp. Use care when handling.
CAUTION Cleaning agents.

Do not get the cleaning agents in eyes, on skin, or on clothing. Always wear rubber gloves,
goggles, and protective clothing when contact is likely. Consult product manufacturer for
specific details.
Signal words used in classification of potential hazards are defined as follows:

DANGER: Indicates an imminently hazardous situation, which, if not avoided, may result in death or
serious injury.
WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in death or
serious injury.
CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may result in minor or
moderate injury. Caution also indicates actions that may cause property damage.
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S A F E T Y P A G E 1.1
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Food Safety
Food Packaging
While this machine is often used for food packaging and vacuum cooking, there are
inherent risks associated with this packaging technique that could cause serious illness
or death to the consumer of the food product. If you are using this machine for a food
application, you must consult with a reputable food technologist or specialist in vacuum/
modified atmosphere packaging (M.A.P.) to review the safety of your application.
Gas Flush
In order to ensure proper shelf life of the food product packaged in this machine, you
must contact a reputable food technologist or specialist in vacuum/modified atmosphere
packaging (M.A.P.) to review and develop the appropriate gas mixture for your package,
and you must perform quality control and gas analysis on your finished M.A.P. packages.
General Safety Guidelines

Obvious safety guidelines should be observed.
Be sure to turn off power to your packaging machine before any maintenance work is
performed.
Follow approved Lockout/Tagout procedures.
Place machine on a flat, stable surface.
Do not place tools, parts, or other objects on or inside machine while operating.
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S A F E T Y P A G E 1.2
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STARTUP
Unpacking
1. Carefully remove crate from the skid.
2. Remove machine from skid.
3. Wipe down outside of the machine.
Power Requirements
The machine is available with 2 horsepower, or 3 horsepower vacuum pumps.
The owner must supply the correct 3 phase or single phase power source in accordance
with the National Electric Code.
Grounding Instructions
The Ultravac 500 must be grounded. In the event of malfunction or breakdown, grounding
provides a path of least resistance for electric current to reduce the risk of electric shock. All
3 phase units are equipped with a equipment-grounding plug and the single phase units
are equipped with an equipment-grounding conductor cord. The plug must be plugged into
an appropriate outlet that is properly installed and grounded in accordance with all local
codes and ordinances.

Improper connection of the equipment-grounding conductor can result in a risk of electric
shock.
The equipment-grounding conductor outer surface is green with or without yellow

stripes. If repair or replacement of the cord or plug is necessary, do not connect the
equipment-grounding conductor to a live terminal. Check with a qualified electrician or
Koch Equipment Services Inc. technician if the grounding instructions are not completely
understood, or if there is doubt as to whether the unit is properly grounded. Do not modify
the plug provided with the unit if it will not fit the outlet; have a proper outlet installed by
a qualified electrician.
Customer Voltage Pump Motor Full Load Amps

230, 60 Hz 1 Phase 13 Supply conductor shall have an
ampacity not less than 125% of
230, 60 Hz 3 Phase 10 the Pump Motor Full Load Amps
380, 50 Hz 3 Phase 6.3
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S T A R T U P P A G E 2.1
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Vacuum Pump
It is essential to check the oil level daily and to change the oil after every 500 hours of
operation. Read the oil level with the machine turned off. Oil may be added until the level
reaches the MAX level shown in the sight glass on the pump. Refer to the pump manual
supplied with the machine for details on changing the oil.
NOTE: ALL ULTRAVAC 500 CHAMBER MACHINES ARE SHIPPED WITH OIL IN THE PUMP.
ALTHOUGH THE FACTORY RECOMMENDS CHECKING THE OIL LEVEL PRIOR TO FIRST
USE!
Gas Flush Connection

The owner must supply a suitable regulator with a range of 0 to 60 p.s.i. We recommend
using food-grade flexible hose with a 1/4-in. I.D. and a maximum length of 15-ft. Maximum
regulator pressure is 15 p.s.i.
DANGER OXYGEN ENRICHED USE
KOCH TRAY SEALING AND VACUUM CHAMBER MACHINES ARE NOT DESIGNED FOR
USE WITH OXYGEN ENRICHED PROCESS GASES. ANY APPLICATION THAT REQUIRES
A PROCESS GAS CONTAINING 25% OR MORE OXYGEN SHOULD CONTACT KOCH
EQUIPMENT SERVICES AT (800) 777-5624 AS RETROFIT OPTIONS ARE REQUIRED.
RUNNING THIS MACHINE WITH AN OXYGEN ENRICHED PROCESS GAS, WITHOUT THE
NECESSARY RETROFIT KIT COULD CAUSE SEVERE INJURY, DAMAGE OR DEATH.
KOCH TRAY SEALING AND VACUUM CHAMBER THAT ARE RETROFITTED WITH THE
NECESSARY KIT WILL HAVE A DECAL ABOVE OR BESIDE THE GAS SUPPLY CONNECTION
INDICATING THE MACHINES READINESS TO RUN OXYGEN ENRICHED PROCESS GASES.
Checking Vacuum Pump Rotation

Caution: Check oil level of pump before starting pump (please refer to pump manual).
To check the direction of the pump rotation, briefly engage the POWER ON switch and
observe the motor fan at the end of the pump. The fan should rotate as indicated by the
arrow on the fan cover. To correct the rotation, switch any two phases in the plug.
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S T A R T U P P A G E 2.2
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OPERATION
Placement of Product
For best sealing results, it is important to:
Check the pump oil level daily.
Select a pouch that fits the product.
Carefully load the product into the pouch.
Keep the product and the product residue away from the seal area of the pouch.
Place the product as far into the pouch as possible.
Maintain an equal amount of the product above and below the seal bar (see figure 3.1,
below on use of filler plates).
Use Filler Plates for raising the height of the product.
Lay the pouch flat on the seal area, keeping the pouch free of wrinkles.
Place the pouch so that the open end is inside the chamber when the lid is closed.
PRODUCT HALF HEIGHT

EVEN WITH TOP OF
SEAL BAR
Figure 3.1
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O P E R A T I O N P A G E 3.1
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Operation with Analog Control Panel

The analog control panel is shown below, figure 3.2.
The range for timed vacuum is 0 to 55 seconds and is controlled by the Vacuum
Potentiometer. We suggest an initial setting of 3 on the dial.
Seal impulse is the length of time the seal bar is turned on and can range from 0 to
2 seconds. The impulse time is controlled by the Seal Potentiometer. Koch Equipment
recommends an initial setting of 6 on the potentiometer. This setting will vary according
to the thickness of the pouch. Thinner pouches will require a lower setting while thicker
pouches will require a higher setting.
Experiment with both settings to achieve the best results.
VACUUM SEAL SEAL LIGHT

POWER SWITCH POTENTIOMETER (RED)
POTENTIOMETER
VACUUM LIGHT VACUUM

(GREEN) INDICATOR
Figure 3.2
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Operation with Digital Control Panel

The digital control panel allows the user more options than the standard control panel. The
embedded microprocessor controls each sequence of the packaging operation. Settings for
the vacuum, gas, and sealing are entered as parameters through the keypad. This allows
the user to custom program every step of the packaging process. The precise vacuum
and gas pressures are controlled by a pressure based sensor. The vacuum pressure, gas
pressure, and seal time are displayed on a large 16-character LCD backlit readout, which
is easily readable in all lighting conditions. As each sequence is performed, the real-time
pressure level or cycle time is displayed.
The digital front panel can save up to ten pre-programmed routines, which can be retrieved
at any time for specific packaging applications. With the supervisor security feature turned
on, these programs cannot be inadvertently changed.
The Vacplus option allows the operator to run the pump from 0 to 20 seconds after the set
vacuum level is achieved.
The Gas Flush option allows the operator to introduce an inert gas into the chamber after
the vacuum stage. This option can be used as a filler to prevent crushing of the product
after sealing, as a means to prolong shelf life, or as a means to maintain desirable product
appearance.
The digital front panel has an auto stop, which will automatically seal if the preset vacuum is
not reached. This feature decreases the cycle time and optimizes the vacuum level of each
product.
The digital front panel, which includes the keypad, illuminated display, and microprocessor,
use sealed components and is conformal coated in a moisture-proof coating. The digital
front panel meets or exceeds the requirements of NEMA 4. The front of the digital display is
sealed and flush for easy cleaning.
The digital control has both pulsed vacuum and pulsed venting options for fragile product.
The digital control has a maintenance screen for testing valves and a special loop option for
multiple vacuum/gas cycles before sealing.
Figure 3.3
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Operator Menu on Digital Panel

NOTE: if the supervisor has set security on, these settings cannot be changed.
NOTE: IF THE SUPERVISOR HAS SET SECURITY ON,
THESE SETTINGS CANNOT BE CHANGED
+ YES
This is the Main Menu screen. When

PROGRAM
THIS IS THE MAIN MENU SCREEN. WHEN

the machine starts up, the last program
THE MACHINE STARTS UP, THE LAST PROGRAM
RUNNING PROG: 1 thatWAS
wasRUN
runWILL
will BE
beTHE
theCURRENT
current PROGRAM
program
THAT
shownINinTHE
SHOWN theWINDOW.
window. TOTo SET
set THE
the OPERATING
operating
PARAMETERS FOR THE PROGRAM SHOWN, press
parameters for the program shown
- NO
the MENU
PRESS THE MENUKey.
KEY.
+
PROGRAM
YES
VACUUM is set to % vacuum using the UP
VACUUM IS SET TO
and DOWN % VACUUM
arrow USING
keys. The THE
range
is 30%
UPtoAND DOWN
99%. ARROW KEYS.
VACUUM: 98
THE RANGE IS 30% TO 99%.
Press the MENU Key.
PRESS THE MENU KEY.
- NO
+
PROGRAM
YES VACPLUS may be set greater than zero
to allow
VACPLUS the
MAY BEpump to continue
SET FROM evacuating
0 TO 20 SECONDS.
the chamber (for the specified
A SETTING GREATER THAN ZERO ALLOWS number
THE
VACPLUS: 4.0 of seconds) afterEVACUATING
the pressure in CHAMBER
the
PUMP TO CONTINUE THE
chamber
(FOR has reached
THE SPECIFIED NUMBERtheOF % vacuumAFTER
SECONDS) set
inPRESSURE
the vacuum menu. The HAS
range is 0 to 20
- NO
THE IN THE CHAMBER REACHED
seconds.
THE % VACUUM SET IN THE VACUUM MENU.
THE RANGE
Press theISMENU
0 TO 20Key.
SECONDS.
PRESS THE MENU KEY.
The SEAL setting is in seconds.

+ YES
PROGRAM
THE SEAL
Use theSETTING
UP andIS IN SECONDS.
DOWN arrow keys to
USE THE UP AND DOWN ARROW KEYS TO
SEAL: 1.2 change the seal time. The range is 0 to 2
CHANGE THE SEAL TIME.
seconds.
THE RANGE IS 0 TO 2 SECONDS.
- NO Press
PRESS THEthe MENU
MENU KEY.Key.
Figure 3.4
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Operator Menu on Digital Panel (continued)

+
PROGRAM
YES
If the machine is equipped with the gas
option,
IF YOUR it can be IS
MACHINE turned ON WITH
EQUIPPED or OFF
THEby
GAS
GAS: YES pressing
OPTION, ITthe
CANUPBEorTURNED
DOWN ONarrow keys.
OR OFF BY
Press the THE
PRESSING MENU Key.
UP OR DOWN ARROW KEYS.
- NO
PRESS THE MENU KEY.
+
PROGRAM
YES
GAS is set to % gas using the UP and
DOWN arrow keys. This value also
GAS IS SET TO % GAS USING THE UP
corresponds
AND DOWN ARROWto the KEYS.
vacuum THISreading
VALUE inside
GAS: 75 the chamber. It is recommended to use
ALSO CORRESPONDS TO THE VACUUM
Pulse
READINGVent when
INSIDE THEgas flushing to a low %
CHAMBER.
- NO
vacuum. The rangeTO
IT IS RECOMMENDED is 98% to 30%.
USE PULSE VENT
WHEN GAS FLUSHING
Press the MENU Key. TO A LOW % VACUUM.
THE RANGE IS 98% TO 30%.
Figure 3.5 PRESS THE MENU KEY.

Selecting a New Program
+ YES
PROGRAM
RUNNING PROG: 1 From the Main Menu, use the UP and

DOWN arrow keys to select a new program.
- NO
Press the UP arrow to switch to Program 2

(or any of the 10 programs).
+ YES
PROGRAM
New parameters may be set for Vacuum,
Seal Time, and Gas for Program 2 (following
ENTER PROGAM: 2 the procedures described in the previous
example) or simply close the lid on the
- NO machine and run Program 2.
Figure 3.6
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Sealing with Air-Assist

All machines are equipped with regulators for air-assisted sealing. Set the air pressure
regulator to 20 p.s.i. increasing to a maximum of 40 p.s.i. While a good seal can be
obtained without air-assist, use air-assist when:
Gas back-flushing above average pressure.
Using shrink pouches.
Packaging a product that easily contaminates the seal area of the pouch.
Trying to overlap pouches.
Wrinkles cannot be avoided in the seal area.
Using the Double Seam Seal Option.
Gas Flush Option

Gas flushing is the introduction of an inert gas into the chamber after the vacuum stage
is finished. Gas can be used as a filler to prevent crushing of the product after sealing, as
a means to prolong shelf life, or as a means to maintain desirable product appearance.
Commonly used gasses include nitrogen, carbon dioxide, or a mixture of both. Consult your
local gas supplier to select the proper gas for your product.

Double Seam Seal Option

All machines are equipped with standard seal bars having a single seal element per seal
bar. The Double Seam seal bars have two seal elements per seal bar. We recommend using
air-assisted sealing with this option to achieve best results.
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MAINTENANCE
Prior to Cleaning
Every environment and application is different; therefore, Koch Equipment LLC cannot
provide cleaning instructions to guarantee microbiological sanitation. Koch Equipment
requests that the owner of this machine consult with sanitation experts to review the
unit working in their particular environment to develop a robust cleaning schedule and
methodology, followed by bacterial testing to ensure satisfactory cleaning procedures are
followed.
Cleaning Recommendations
Before cleaning the machine, turn power off; disconnect the main power, and lockout the
connection.

unless power has been disconnected and locked out at risk of electric shock hazard.
Check with the detergent and sanitizer manufacturers that their products are compatible
with the listed materials.
CAUTION Cleaning agents.

Do not get the cleaning agents in eyes, on skin, or on clothing. Always wear rubber gloves,
goggles, and protective clothing when contact is likely. Consult product manufacturer for
specific details.
Never hose down the machine. Damage caused by hosing or high pressure washing is not
covered under warranty.
1. Filler Plates: Remove filler plates. The filler plates are made from polyethylene. Clean,
sanitize, and dry. High pressure water spray can be used on the filler plates.
2. Lid and Backup Strip: The lid is constructed of acrylic. Use only nonabrasive soap and
water. Do not use window sprays or kitchen scouring compounds. The Backup Strip is
made of silicone. Clean, sanitize, and dry.
3. Seal Bars: Remove the seal bars by first lifting them up off of the guide rods. Remove
the wire connectors from the adapter clips on the seal bar and remove the seal bar from
the machine. The seal bars are made of aluminum and phenolic. Clean, sanitize, and
dry.
4. Chamber and Base: The chamber is made of 304 stainless steel and the base is made
from polyurethane. Clean, sanitize, and dry, including under the seal bar bladder (not
removable).
5. Clean under the machine.
6. Reinstall the seal bar.
7. Use bacteriological testing to insure cleaning process.
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Vacuum Pump Maintenance

Consult the pump manufacturers manual provided with the machine for detailed
information.
Seal Bar Maintenance

The following illustrations show replacement of the seal elements for the seal bars.
Step 1. Step 2.
Remove the seal bars from the machine. Pull Using a 2mm Allen wrench, loosen the set
off the Teflon tape strip and discard. Clean screws for the cut-off wire and the seal
off any remaining Teflon tape adhesive element on both ends of the seal bar and
using acetone or an equivalent solvent. discard. Cut-off
CUT-OFF wire
WIRE
Teflon
tape
TEFLON Seal
SEALelement
ELEMENT
TAPE
Set
SET screw
SCREW
2mm Allen
ALLEN
Figure 4.1 wrench
WRENCH
Figure 4.2
Step 3.
If you are replacing the L-shaped spring retainer and the spring at this time, loosen the set
screw and remove the old spring retainer and spring and install the new ones. Adjust the
spring retainer to allow a 1/8-in. gap between the spring retainer and the seal bar. This will
allow the seal element to remain under tension after tightening the seal element.
Brass contact
BRASS CONTACT
Tightening
TIGHTENING Slotted
SLOTTEDtip
TIP
tool
TOOL SCREWDRIVER
screwdriver
Figure 4.3
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Reading the Indicators

If your machine is controlled by a digital control module (with touch pad), this design to aids
in troubleshooting. The digital panel has indicator lights mounted on the front below the
ON/OFF switch. The indicator lights correspond to the operating devices and should turn on
and off in the following sequence when the machine lid is closed:
1.
1. VACUUM
Vacuum Pump VALVE
[C-1] [SOL-1]
2.
2. Gas Flush
GAS FLUSHValve [SOL-3]
VALVE (Optional)
[SOL-2] (OPTIONAL)
3.
3. Seal Bladder
SEAL BLADDERValveVALVE
[SOL-2][SOL-3]
(Stays onON
(STAYS untilUNTIL
completion of cycle)
COMPLETION OF CYCLE)
4.
4. Seal Impulse Contactor [C-2]
SEAL IMPULSE CONTACTOR [C-2]
5.
5. Ventilation Valve [SOL-1]
VANTILATION VALVE [SOL-4]
The device should be operating when the light is illuminated. If the lights illuminate in the
proper sequence, but there is still a problem, look for the problem in the operating device
itself. If the lights do not sequence properly, look for a problem in the control module.
Troubleshooting
Problem Indications Remedy
Machine will not start Green power ON light not Make sure that the power
lit when switch is turned on requirements match those given
on the nameplate. Also, check
fuse F-2; replace if blown.
Vacuum pump does not run Make sure that the power
requirements match those given
on the nameplate
No vacuum When lid is closed, indicator Check lid switches LS-1 for proper
light (VAC) is OFF on the adjustment.
control module
Vacuum not pulling lid down. Check intake screen in vacuum
pump hose barb for blockage,
pieces of bags, labels, bone, etc.
Longer vacuum cycle times Check intake screen in vacuum
pump hose barb for blockage
No gas flush (optional) If indicator light (GAS) is lit Check for proper gas pressure
going into gas inlet
Check for proper operation of gas
flush valve (SOL-3)
If indicator light (GAS) is not Check gas flush potentiometer on
lit analog control module or possible
defective digital control panel
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Troubleshooting
Problem Indications Remedy
Chamber not venting Lid will not open and red Check ventilation valve SOL-1 for
(lid will not open) indicator light VENT on proper operation
control module is lit
VENT indicator light is not Check cool down potentiometer
lit on analog control module or
NOTE: Lid can be released by pulling the hose off of possible defective digital control
the vacuum gauge to remove product. panel
Improper or no Seal bladder light on control Check to make sure that the
sealing module is lit but the seal bar regulator knob is turned fully
does not go up clockwise, or, if air-assist is used,
set to the recommended pressure
Check seal bladder valve SOL-2
for proper operation
The seal bar is not heating Check seal bar connection points
up even though the red and clips for corrosion and proper
seal light on the front panel tension
comes on
The red seal light on the Check for broken seal element
front panel either does not Check seal bar fuse F-1. Located
light for the proper length of on the analog or digital panel.
time ( to 1 second) or does If the machine is 110VAC, 2 seal
not light at all bar, F-1 is located on the chassis.
Make sure the seal impulse
potentiometer is set high enough
or check for possible defective
digital control panel
NOTE: For proper sealing, three things must occur:
1. The seal bar must come down and place adequate pressure between the seal bar and
the backup strip.
2. The seal element must heat up sufficiently to fuse the pouch.
3. The pouch must be allowed to cool for a time to ensure a good set.
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Supervisor Menu on Digital Panel

Untrained personnel should not alter any setting in the supervisor menu.
This is the Main Menu screen. When
the machine starts up, the last program
+ YES
PROGRAM
that was run will be the current program

RUNNING PROG: 1 shown in the window.
Press and hold down both arrow keys for

- NO
at least 3 seconds to enter the supervisor

menu.
The following are parameters that can
NOTE: If your machine is not installed
only be set in the supervisor menu.
with the precut option, disregard the
PREVAC, CUTTIME, and WAITTIME
parameters.
+
PROGRAM
YES
PREVAC is the % vacuum that you wish to reach
before activating the knife, which makes slits in
PREVAC: 15 the bag for precut. Use the up or down arrow
keys to change the current setting.
The range is from 5% to 20% vacuum.
- NO
Press the MENU key.
+
PROGRAM
YES CUTTIME is the number of seconds that the
seal valve is activated. This is the time when the
CUTTIME: 1 knife actually makes the evacuation slits in the
bag/pouch for precut. The range is from 0 to 3
- NO
seconds.
Press the MENU key.
+ YES
WAITTIME is the number of seconds the machine

PROGRAM
waits for the knife to retract before resuming the

WAITTIME: 3
vacuum cycle. The range is from 0 to 6 seconds.
- NO
Press the MENU key.
Figure 4.4
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COOLDOWN is the time that the machine
+
waits after sealing the bag/pouch before

YES
PROGRAM
the seal bars retract. This allows time for

COOLDOWN: 4.0 the actual seal to cool down and take a
set.
- NO The range is from 1 to 8 seconds.
Press the MENU key.
+ YES
PROGRAM
SECURITY can be turned on by selecting

yes. If security is on, the operator menu
SECURITY: NO will be read only and the operator will not
be able to change any settings.
Press the MENU key.
- NO
This is how you specify the maximum

+
PROGRAM
YES
number of programs that may be saved in
memory. Each program may have its own
# PROGRAMS: 10 set of unique parameters.
This range is from 1 to 10.
- NO Press the MENU key.
If TEST is set to YES (using the up arrow

+ YES
key), the vacuum valve and vent valve
may be operated manually. The up arrow
PROGRAM
key activates the vacuum valve, the down

TEST: YES arrow key activates the vent valve, and
pressing both at the same time turns them
- NO
both off. As you activate either valve, the
vacuum pressure is displayed.
Press the MENU key.
Figure 4.5
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+ YES
PULSE VAC allows for a more controlled
vacuuming process. Rather than simply
PROGRAM
opening up the vacuum valve for a

PULSE VAC: YES continuous vacuum the vacuum valve is
opened and closed repeatedly until the
- NO
chamber reaches the set vacuum level.
Press the MENU Key.
+
PROGRAM
YES This is the % vacuum reached by pulsing
the vacuum valve before the vacuum valve
opens completely to fully evacuate the
PULSE TO: 95
chamber. The range is 99% to 20%.
- NO
Press the MENU Key.
This is how long the vacuum valve is

+ YES
PROGRAM
turned on during the vacuum cycle.

PULSE ON: 1.2 The range is from 0 to 3 seconds.
Press the MENU Key.
- NO
Figure 4.6
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+ YES
This is how long the vacuum valve is turned
off during the vacuum cycle.
PROGRAM
The range is from 0 to 3 seconds.

PULSE OFF: 1.0 Press the MENU key.
- NO
VAC ERROR is an option that is turned ON

+
PROGRAM
YES
or OFF. If set OFF, default, the machine
will time out if the preset vacuum is not
VAC ERROR: ON reached in 30 seconds, and the machine
with complete the cycle. If set ON and the
- NO
machine does not reach the preset vacuum
in 30 seconds, then the panels will display
VAC ERROR and vent the chamber without
Figure 4.7 sealing.
Opening Chamber Machine

1. Turn the power switch to the OFF position and disconnect the power cord from the wall
receptacle.

2. Remove the screws located on the back of the machines stainless steel cabinet. Lift up on
the stainless panel to access inside the machine.
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Changing Vacuum Pump Oil

1. Open the machine (see above).
2. A trough and hole is located toward the front of the machine, between the pump and
front edge of the chassis. Slide the machine over to the edge of the table with the hole
over the edge of the table. Position an oil collection pan underneath this hole.
CAUTION Tip Over Hazard.

Only let the front foot of the chassis hang over the edge of the table.
3. Loosen and remove the Oil Filler Cap with a 1-in. open end wrench.
4. Loosen the Oil Drain Plug located to the front and lower middle on the pump with a
1-in. open end wrench. Remove the plug slowly to control the flow of oil.
5. With the oil drained, replace the Oil Drain Plug and wipe any excess oil out of the trough
in the chassis.
6. Fill the pump with oil until the level is between the minimum and maximum lines on the
Oil Sight Glass. Replace the Oil Filler Cap.
7. Tilt the machine back down onto the chassis. Plug the power cord back into the wall
receptacle.
8. Cycle the machine a couple of times, unplug, and tilt the machine up to check the Oil
Level. Add oil if necessary. Tilt the machine back down and replace the two screws in the
rear of the machine.
Replacing Potentiometer
Refer to Parts, Analog Control Panel, for the disassembly of the panel. Remove the
potentiometer by unbending the mounting tabs holding the potentiometer to the circuit
board. Pull the potentiometer out of the circuit board.
MOUNTING TABS
Figure 4.8
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Replacing Power Cord

1. Turn the power switch to the OFF position and disconnect the power cord from the wall
receptacle.

2. Open the machine as described in Opening Chamber Machine on page 4.8.
3. Loosen the cord grip nut on the rear of the machine. Remove the cord from the cable
clamps on the bottom of the chamber. Disconnect the cord from the control panel.
4. Route the new power cord through the cord grip on the rear and through the cable
clamps on the bottom of the chamber.
5. Connect the new power cord to the control panel as shown in the table below.
Connect to 110 Volt Wire 230 Volt Wire

Terminal Color Color
Terminal 8 Green (Ground) Green/Yellow
Terminal 7 White Brown
Terminal 6 Black Blue
Maintenance Log
A maintenance log is a journal of all maintenance performed. Each entry includes a
date, maintenance performed (details about the type of work done), and technician (who
performed the maintenance). The maintenance log is also a place where a schedule is kept
for further maintenance.
A maintenance log will clearly show oil changes, daily inspections, Teflon tape
replacement, and so on. A master copy has been provided on page 4.11, please create a
copy and store in the back of this owners manual.
Service Log
A service log is a journal of all service work performed. Each entry includes a date, service
provided (details about the type of service), and technician (who performed the service).
A service log will clearly show training provided, frequent wear items, and so on. A master
copy has been provided on page 4.124, please create a copy and store in the back of this
owners manual.
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Maintenance Log
Date Maintenance Performed Technician
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Service Log
Date Service Provided Technician
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SCHEMATICS
Designation and Function of Controls
The following designations are found on the Electrical Diagrams:
Manually Activated Switches and Buttons: Solenoid Valves:
SW-1 On/Off Control Power SOL-1 Vacuum Solenoid
SW-2 On/Off Gas Flush SOL-2 Gas Flush Solenoid
SOL-3 Seal Bladder Solenoid
Limit Switches: SOL-4 Ventilation Solenoid
LS -1 Chamber Cycle Start
Misc. Valves:
Contactors and Relays: V-1 Quick Exhaust Valve
C-1 Vacuum Pump Contactor (Only with gas flush option)
C-2 Seal Impulse Contactor
Overloads and Fusing:

OL-1 Vacuum Pump Motor
F-1 Seal Bar Fuse
F-2 Control Power Fuse
Control Modules:
MCM Master control module
Control Lights:
LT-1 On/Off Control Power
Light (Green)
LT-2 Seal Impulse On
Light (Red)
Transformers:
T-1 Seal Impulse
T-2 Control Power
Motors:
M-1 Vacuum Pump
Potentiometers:
POT-1 Vacuum Time
POT-2 Gas Flush Time
POT-3 Sealing Impulse and
Cool Down
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230 Volt, Single Phase, Analog Panel
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230 Volt, 3 Phase, Analog Panel
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380 Volt, 50 Hz, 3 Phase, Analog Panel
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230 Volt, Single Phase, Digital Panel
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230 Volt, 3 Phase, Digital Panel
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380 Volt, 50 Hz, 3 Phase, Digital Panel
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Non-Gas Flush Pneumatic Diagram
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Gas Flush Pneumatic Diagram
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THIS PAGE LEFT BLANK INTENTIONALLY.
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PARTS
Recommended Spare Parts
Koch
Qty. Description
Part No.
1 ea 861032
Seal Bar Assembly
1 ea 860045Fuse, MDA 10A
6 ft 880431Backup Strip
8 ft 860220Lid Gasket
5 ea 860034Seal Element
10 ft 860170
Teflon Tape
1 ea 840370
DIN Coil
1 ea 860029Lid Switch
5 ft 860035Seal Bar Cut Wire
1 ea 860037Vent Valve
2 qt 884755
Vacuum Pump 30W ND Oil
1 ea Specify Pump
Vacuum Pump Oil Filter
1 ea Bladder Assembly
Select your machines configuration:
1 ea 863088 Single Seam and Cut Wire Contact Kit
1 ea 863081 Double Seam Contact Kit
For Analog Control Panel:
5 ea 860337 Fuse for Control Power, 1A
1 ea 860313 Potentiometer, Evacuation/Gas
1 ea 860314 Potentiometer, Sealing
1 ea 860327 Relay Module
For specific system replacement parts,

Contact a parts representative for further assistance:
Phone (816) 753-2150 Fax (816) 561-2854
Toll-Free (800) 746-1723
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Pump and Chassis

Parts List
Item Koch
Description
No. Part No.
1 840076 Cabinet Assembly
2 900052 Vacuum Pump, 230V, 60Hz, Single Phase, 2-hp
900059 Vacuum Pump, 230/380V, 60Hz, 3 Phase, 2-hp
900042 Vacuum Pump, 230V, 60Hz, Single Phase, 3-hp
900041 Vacuum Pump, 230/380V, 60Hz, 3 Phase, 3-hp
3 860047 Rigid Caster
4 840121 Swivel Caster
5 860800 Oil Drain Extension
6 860799 Oil Drain Gasket
7 866775 Washer, 8mm Flat
8 860287 Bolt, M8x12 Hex Head
9 866246 Plug
10 866844 Screw, M6x20 Flat Socket Head
11 860187 Vacuum Block Cover
12 860188 Vacuum Block Spacer
13 860148 Vacuum Block O-Ring
14 860186 Vacuum Block
15 860140 Hose Barb, 1.50-in.
16 860151 Cover for 2-hp Pump
860152 Cover for 3-hp Pump
18 860260 Washer, 5mm Lock
19 866716 Screw, M5x10 Slotted Panhead
20 860354 Plug for Main Power (230V Only) (Not Shown)
21 860377 Main Power Cable (230V) (Not Shown)
860355 Main Power Cable (380V) (Not Shown)
22 860058 Cord Grip, PG21 (Not Shown)
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Pump and Chassis

Diagram
10
12
11
14
13
15
2
6 16
7
5
19
8 17 18
3
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Seal Bar
Parts List
Item Koch
Description
No. Part No.
1 861032 Seal Bar Assembly
2 861234 Bladder Assembly
3 860149 Gasket for Bladder (two per bladder)
4 860990 Fiberglass Insulator Strip
5 860034 Sealing Element
6 860035 Cutting Wire
7 860170 Teflon Tape
8 860033 Brass Electrical Contact
9 860278 Set Screw, M4x4 Socket
10 860091 Seal Bar Spade
12 860549 Wire for Seal Bar
13 860397 Cord Grip
14 866730 Capscrew, M6x10 Socket Head
15 866784 Washer, 6mm Split
16 860292 Washer, 6mm Custom Flat
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Seal Bar
Diagram
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Lid and Hinge System

Parts List
Item Koch
Description
No. Part No.
1 860094 Lid
2 860220 Lid Gasket
3 861240 Double-Sided Foam Tape
4 860025 Channel for Backup Strip
5 860950 Seal Bar Backup Strip
6 860019 Lid Pivot Block Assy (inludes inserts)
7 861322 Hinge Block Assy (includes inserts)
8 860150 Shaft, Stainless Steel Tube, 1/4-in. x 11-in. Long
9 860038 Gas Spring
10 860026 Anchor Block
11 860028 Ball Stud, 10mm
12 860073 Gas Spring Disconnect
13 860252 Screw, M5x12 Slotted Flathead
16 860286 Bolt, M5x40 Hex Head
17 860029 Lid Switch
18 866729 Capscrew, M5x20 Socket Head
20 860194 Hinge Block Bracket
21 866778 Washer, 5mm Start
22 866791 Washer, 5mm Large OD
23 866764 Nut, 5mm Hex
24 860031 Lid Switch Bracket
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Lid and Hinge System

Diagram
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Gas Flush Components

Parts List
Item Koch
Description
No. Part No.
1 860291 Brass Hex Nut, 3/8-24
2 860109 Fitting, Dual Hose Barb
3 860110 Hose Clamp for 1/4-in. Reinforced Hose
Reinforced Hose, 1/4-in.
4 860106
Connect A-A, B-B, C-C, D-D, J-J, To other side
5 860107 Plastic Hose Tee, 1/4-in.
6 860014 Gas Holddown
7 860691 Gas Holddown Pad
8 860118 Gas Nozzle
9 866273 Fitting, Aluminum Elbow
Gas Hose, Blue
10 860548
Connect E-E, F-F, G-G, H-H, To front and rear nozzles
11 866254 Fitting, Alumimum Tee
12 860514 Hose Barb, 1/4-in. x 1/4-in. Elbow
13 860324 Gas Valve [SOL-2], 2-way Normally Closed
14 840371 DIN Plug
15 860352 Cable
16 860536 Close Nipple, 1/4-in.
17 860501 Brass Elbow, 1/4-in. NPT
18 860533 Quick Exhaust Valve [QEV], 1/4-in. NPT
20 861216 Seal Pilot Valve [SOL-3]. 3-way Normally Closed
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Gas Flush Components

Diagram
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Main Control - Front Side

Parts List
Item Koch
Description
No. Part No.
1 860044 Sealing Transformer, 750VA [T1]
2 860311 Control Power Transformer, 50VA [T3]
3 860041 Seal Contactor
6 860341 Terminal Stop Block
7 860160 Pump Contactor
8 860175 Pump Overload (3-horsepower)
860010 Pump Overload (2-horsepower)
9 860339 Control Power Fuse Holder
860337 Control Power Fuse, GMC 1A [F3]
10 860336 Sealing Fuse Holder
860045 Sealing Fuse, MDA 10 [F10]
11 860342 Ground Block
12 860340 Connection Block
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Main Control - Front Side

Diagram
4
5 3
4 2
12
10
7 11
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Analog Control Panel

Parts List
Item Koch
Description
No. Part No.
861056 Complete Front Panel without Gas Flush (not shown)
861057 Complete Front Panel with Gas Flush
1 860610 Standard Vacuum Gauge
2 860319 Green Lens and Switch Body Assembly
3 860316 Main Power On/Off Switch [SW-1]
4 860316 Selector Switch Lever
5 860320 Red Seal Light Lens
6 860302 Blue Cap for Potentiometer Knob
860315 Potentiometer Knob Only
7 860303 Yellow Cap for Potentiometer Knob (optional with gas flush)
8 860301 Red Cap for Potentiometer Knob
Potentiometer for Vacuum [POT-1] and Gas [POT-2]
9 860313
(Optional with Gas Flush)
860450 Vacuum Potentiometer [POT-1] for Special Produce Product
10 860314 Sealing Potentiometer [POT-3], Standard for extended seal time
11 860328 Connector, 4-pin
15 860332 Connector Retainer
16 860327 Main Control Module, Analog with Gas [MCM]
17 860231 Main Control Module Standoff, 1-in.
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Analog Control Panel

Diagram
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Digital Control Panel

Parts List and Diagram
Item Koch
Description
No. Part No.
1 860995 Front panel assembly
2 860637 Vacuum sensor
3 860316 Main power on/off switch [SW-1]
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Main Control - Back Side

Item Koch
Description
No. Part No.
1 861216 Seal Pilot Valve [SOL-3], 3-way, Normally Closed
4 861221 Screw, 10-32 X 7/16-in
5 890643 Grommet, 17/64-in. ID x 13/32-in. OD
6 890640 Grommet, 3/8-in. ID x 5/8-in. OD
7 860774 Grommet, 3/4-in. ID x 1-1/2-in. OD
8 840371 DIN Plug (Not Shown)
9 861019 Valve Harness, 34-in. LG (not shown)
Port R
To Vacuum 3
5
7
1
7
Port P
Port A
To Atmosphere 6
To Bladder
2
2
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Mebner Valve
Item Koch
Description
No. Part No.
1 890967 Valve, Mebner Vacuum and Vent
2 889559 Fitting, 1--in. 90 Elbow, SS
3 860141 Nipple, Close 1--in.
4 860969 Hose Barb, 1--in. NPT x 1--in. ID Hose
5 860119 Hose Clamp, 1--in.
6 860040 Vacuum Hose, 1--in.
7 860106 Hose, 1/4-in. Reinforced Air
5
6
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Miscellaneous Machine Parts

Item Koch
Description
No. Part No.
1 860050 Filler Plate Set
2 860051 Stainless Steel Product Tray
3 860124 Magnetic Stop for Product Tray
5 860052 Owners Manual
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REFERENCE MANUALS
R5 Series Vacuum Pumps
Included within this Ultravac 500 owners manual is an installation and operating manual
for the vacuum pump equipped with this vacuum chamber machine.
Refer to page 6.1 of the Ultravac 500 owners manual for oil and replacement filter part
numbers for this machine.
For Replacement Parts, Call:

Phone (816) 753-2150 Fax (816) 561-2854
Toll-Free (800) 746-1723
8 6 0 0 5 2 Q
R E F E R E N C E M A N U A L S P A G E 7.1
INSTALLATION
AND
OPERATING MANUAL
R5 Series
Current Models 0025, 0040, 0063, 0100 and 0250
Single Stage Rotary Vane Vacuum Pumps
TABLE OF CONTENTS
GENERAL
Identification
Operating Principles
1.0 INSTALLATION
1.1 Unpacking
1.2 Location
1.3 Power Requirements
1.4 Vacuum Connections
1.5 Oil Filling
2.0 OPERATION
2.1 Start-up
2.2 Gas Ballast
2.3 Stopping Pump
2.4 Water-Cooled Pumps
2.5 Oxygen Service Pumps
3.0 MAINTENANCE
3.1 Pump Oil

3.1.1 Oil Level
3.1.2 Oil Type and Quantity
3.1.3 Oil and Filter Change
3.2 Automotive-Type Oil Filter
3.3 Exhaust Filter (Ref. 120)
3.4 Vacuum Inlet Filter
3.5 Maintenance Chart
3.6 Overhaul Kit/Filter
4.0 TROUBLESHOOTING
5.0 STANDARD LIMITED WARRANTY
TECHNICAL DATA
MOTOR AND ELECTRICAL DATA
We reserve the right to change the product at any time without any form of notification. The information in this publication is accu-
rate to the best of our ability at the time of printing. Busch, Inc. will not be responsible for errors encountered when attempting to
perform tasks outlined in this publication.
1
GENERAL All R5 series pumps are designed to handle air.
Vapor in the air stream can be tolerated when the
Identification pump is operated within certain operating parame-
ters as defined by Busch, Inc. Engineering (see
For model identification, see the nameplate Section 2.2 Gas Ballast). When you desire to use
mounted on the side of the exhaust box. the pump on an air stream that contains vapors, con-
tact Busch, Inc. Engineering for operating recom-
This manual is written to cover RA and RC ver- mendations; otherwise, the warranty could be void.
sions of models 0025, 0040, 0063, 0100, and 0250
with a "C" or "E" appearing as the seventh character
in the model type number stamped into the name-
plate. For example it would appear as follows:
RAXXXX - CXXX - XXXX
When ordering parts, it is helpful to include the

identification code stamped into the side of the
cylinder as well as the serial number from the name-
plate.
Operating Principles
All reference (Ref. XX) numbers listed in the

text and on illustrations throughout this manual are
related to the drawings and parts list near the center
of this publication.
All R5 Series, Single Stage, Rotary Vacuum

Pumps are direct-driven, air-cooled, oil-sealed Figure 1 Module Cross Section
rotary vane pumps which operate as positive dis-
placement pumps. As Figure 1 shows, they consist
of a rotor mounted concentrically on the drive shaft
and positioned eccentrically in a cylindrical stator.
1.0 INSTALLATION
The rotor has three radially sliding vanes which
divide the pump chamber into three segments. The
1.1 Unpacking
gas to be pumped enters at the inlet port (Ref. 260),
passes through the inlet screen (Ref. 261) and the
Inspect the box and pump carefully for any signs
open anti-suck-back valve (Ref. 251) into the pump
of damage incurred in transit. Since all pumps are
chamber. As the rotor rotates, the inlet aperture is
ordinarily shipped FOB our factory, such damage is
closed, the gas is compressed and forced out through
the normal responsibility of the carrier and should be
one-way valves between the pump cylinder and the
reported to them.
exhaust box. This operation is repeated three times
each revolution.
Remove the nuts from the bottom of the
box/crate and pull the pump out of the container,
then unscrew the studs from the bottom of the rub-
ber feet.
2
The inlet port of the pump is covered with a plas- NOTE: See the motor manufacturers manual
tic cap prior to shipment to prevent dirt and o t h e r for start-up maintenance of the motor.
foreign material from entering the pump. Do not
remove this cover until the pump is actually ready Correct direction of rotation is marked by an
for connection to your system. arrow on the motor fan housing and is counterclock-
wise when looking at the motor from the motor's fan
1.2 Location side.
The pump must be installed in a horizontal posi- Caution: After the electrical connection has
been made, but before the pinup is filled with oil,
tion on a level surface so that the pump is evenly
the rotation of the motor must be checked. Open
supported on its rubber feet. Allow at least one foot
the inlet port and jog the motor briefly to make
(five feet for large pumps) of air space between the
sure rotation is correct. If it runs backwards and
pump and any walls or other obstructions to the flow
if it is wired three phase power, reverse any two
of cooling air.
leads of the three at the power connection.
Also, adequate ventilation must be provided for 1.4 Vacuum Connections
the fans on the pump and motor (i.e., do not locate
the pump in a stagnant air location). Use a line size to the vacuum system that is at
least as large as that of the pump inlet. Smaller lines
Whenever the pump is transported, be sure to will result in lower pumping speeds than the rated
drain the oil prior to shipping to avoid vane break- values.
age when restarting the pump.
Install a drip leg and drain on the vertical pipe
Do not tip the pump over if it is filled with oil. near the pump inlet. Drain the drip leg often to pre-
vent condensation from entering the pump.
Locate the pump for easy access to the oil sight
glass (Ref. 83) in order to inspect and control the oil Caution: The built-in anti-suck-back valve is
level properly. Allow clearance at the exhaust flange not positive action; do not use it as a system
area to provide service access to the exhaust filters. check valve.
1.3 Power Requirements If more than one vacuum pump or a receiver

tank is connected to a common main line, each
The schematic diagram for the electrical connec- pump should have its own manual or automatic
tion is located in the junction box or on the name- operated shut-off valve or positive action check
plate of the pump motor. valve. The built-in anti-suck-back valve should not
be used as a shut-off valve for the vacuum system.
The motor must be connected according to the
electrical codes governing the installation. The Remove the plastic protective cap from the inlet
power supply must be routed through a fused switch port prior to connection of the pump to the system.
to protect the motor against electrical or mechanical
overloads. The motor starter has to be set consistent The following threads are provided at the inlet of
with the motor current listed on the motor name- the R5 Series pumps:
plate.
Pump Size Size Threads
If the pump is supplied with a manual motor
starter, it is preset at the factory in accordance with 0025/0040 1 1/4" Female NPT
the customers specification. For other voltage 0063/0100 1 1/4" Female NPT
requirements, contact the factory for motor and/or 0250 2" Female NPT
starter information.
3
If the gas that is pumped contains dust or other Pump Type Oil Capacity (Qt.)
foreign solid particles, a suitable (10 micron rating
or less) inlet filter should be connected to the inlet 0025/0040 1.4
port. Consult the factory for recommendations. 0063/0100 2.5/2.7
0250 7
Caution: When using PVC pipe or any static
enhancing material for the exhaust piping, make
The oil capacity chart should only be used as a
provisions to safeguard against arcing from stat-
guide, since oil capacity may be slightly lower,
ic electricity. Arcing can ignite oil vapor that
depending on whether the pump was filled previ-
may be present.
ously, and whether all components such as oil filter,
1.5 Oil Filling oil lines, etc., were allowed to completely drain. Use
only the sight glass reading for proper level. Never
The pump is shipped without oil. After level overfill.
installation, and after correct rotation has been
established, fill the pump with the recommended Warning: Keep the oil fill plug tight as pres-
sure in the exhaust box could cause bodily injury
vacuum oil through the oil filling port (Ref. 88),
if the plug is blown out. Do not fill/add the pump
observing the "MAX" and "MIN" position at the oil
with oil through the exhaust/inlet ports as there
sight glass (Ref. 83).
is danger of breaking the vanes!
Non-detergent oil should be used. Do not use For ambient operating temperatures lower than
detergent motor oil as additives in detergent oil 41F, use Busch R580 synthetic oil. If this does not
will plug exhaust filter elements and shorten their help (where the pump has difficulty starting due to
life. high oil viscosity) contact the factory in Virginia
Beach, Virginia.
It is recommended that Busch R500 Series oil be
used to receive the best performance from your vac- Replace the oil fill plug (Ref. 88/90), making
uum equipment. R500 Series oil is a high quality sure that the gasket (Ref. 89) is in place and proper-
vacuum oil which will give longer running time ly seated and secured. Some pumps are equipped
between oil changes, will provide better lubrication with an exhaust pressure gauge as an integral part of
at high operating temperatures, and will prolong the the oil fill plug.
life of exhaust filter elements. This oil can be
obtained directly from Busch, Inc. in Virginia 2.0 OPERATION
Beach, Virginia.
2.1 Start-up
The strict use of Busch oils and parts from the
day of purchase can extend the standard warranty to Check rotation of the motor as described in para-
three years. Contact Busch, Inc. in Virginia Beach, graph 1.3 - Power Requirements.
Virginia for details. Refer to page 20 for the standard
warranty. Fill the pump with oil as described in paragraph
1.5 - Oil Filling.
For general applications, use R530 in most mod-
els. Use R590 or R570 in pumps that are operated Start the pump and immediately close the inlet.
in high ambient temperatures (above 90F) or high Run the pump for a few minutes before checking the
operating pressure when the oil carbonizes (turns oil level again. With the pump shut off, the oil level
black) before the change interval. Use R590 or R570 should be visible in the oil sight glass (Ref. 83),
on 0250 pumps. Contact the factory for recommen- between the "MIN" and "MAX" mark.
dations when using other oils.
Add oil, if necessary, but only add it when the
The following table gives the approximate quan- pump has been shut off and the circulating oil has
tities of oil required for each pump:
4
had sufficient time to return to the oil sump. has a built-in anti-suck-back valve (Ref. 251 thru
255) to prevent the pump from rotating backwards
NOTE: The oil separated by the exhaust filter when it is shut off.
element forms droplets on the outside of the exhaust
Caution: Do not use the anti-suck-back valve
filter which collect at a low point in the upper half of
as a check or shut-off valve for your vacuum sys-
the exhaust box. From there the collected oil is
tem. Do not depend on the anti-suck-back valve
drained back to the oil sump via an oil check valve
to prevent pump oil from migrating through the
(Pos 275) which opens on R5 RA Model Pumps
inlet into the system when the pump is shut
when the pump is shut off. It is necessary to shut off
down.
the RA model pumps after every 8 hours of operation
to allow the check valve to open. If the pump is not Install an automatic operated valve (such as a
shut off after this time period, it is possible to starve check valve) in front of the pump, if more than one
the pump of oil since the oil is not allowed to drain pump is pumping on the same line or if there is a
back into the oil sump and/or oil droplets may be sufficient volume of vacuum in the system to cause
blown out of the exhaust. If the pump is operating at the pump oil to be drawn into the piping when that
high pressure it may be necessary to shut it down pump is shut down.
sooner than 8 hours.
All R5 Series pumps are vented internally to
On R5 (Standard) RC Model Pumps, the collect- atmospheric pressure through venting holes which
ed oil is drawn continuously during operation of the are next to the exhaust valve assembly.
vacuum pump to the inlet flange (Pos 260) via the
oil return line (Pos 290). The oil return line is con- 2.4 Water-Cooled Pumps
nected directly to the area of the exhaust box, down-
stream of the exhaust filter, which is at atmospheric Water-cooled pumps are cooled by circulating
pressure. Therefore, a constant amount of air is the oil through a shell-and-tube type heat exchanger.
sucked into the pump which is an additional reason The circulation of the pump oil through the shell is
that the R5 Standard Series Pumps do not achieve as created by vacuum in the pump, but the circulation
low a vacuum as the R5 Series Super Vacuum of the cooling water through the tubes is thermostat-
Pumps. ically controlled. The flow rate of the cooling water
is controlled by a thermostatically activated valve
2.2 Gas Ballast that senses, through a capillary bulb mounted in the
exhaust box, the pump's oil temperature as it is dis-
All RA Series pumps are equipped with a gas charged from the compression chamber. The valve
ballast valve. The gas ballast valve (Ref. 440) is will open at its set point and close at approximately
located between the inlet port and the exhaust box. 3F to 5F below the set point. The valve set point is
RA Series pumps up to size 100 are equipped with a adjustable as follows:
permanent gas ballast which cannot be shut off
unless the sintered filter is removed and the orifice (a) Rotate the valve adjustment screw counter-
plugged. Larger pumps are equipped with an clockwise to cause the valve to open at a higher
adjustable gas ballast valve. temperature.
The adjustable gas ballast valve should normal- (b) Rotate the valve adjustment screw clockwise
ly be left open. Its primary function is to prevent to make the valve open at a lower temperature.
water vapor from condensing in the pump.
Condensation causes emulsification of the oil, loss The thermostatic valve can be manually opened
of lubricity, and possible rotor seizure. by inserting a screwdriver under each side of the
spring guide and prying the spring and guide upward
2.3 Stopping Pump away from the valve body.
To stop the pump, turn off the power. The pump
5
2.5 Oxygen Service Pumps These Installation and Operating Instructions are
valid for the following vacuum pumps:
Warning: This pump is filled with a special
operating fluid. Do not use any other type of RA/RC 0025 RA/RC 0100
fluid, oil and/or grease. Use one of the following: RA/RC 0040 RA/RC 0250
RA/RC 0063
Fomblln LC 250
Tyreno Fluid 12/25V (perfluorinated poly- These pumps have been manufactured, solvent
ether) washed (to remove organic contaminants) and
KRYTOX Vacuum pump fluid by Du Pont assembled according to the latest technical standards
Company and safety regulations. If this pump is not installed
properly or not used as directed, a dangerous situa-
If you have any questions, please phone our tion or damage might occur.
Customer Service Department for more informa-
tion. It is mandatory that these operating instruc-
tions be read and understood prior to vacuum
Application pump installation and start-up.
If this pump is contaminated by organic com-
pounds do not attempt to use it on oxygen service Pump Overhaul/Repair
until it has been decontaminated. Busch Inc. strongly recommends that all major
repair operations be conducted at the factory.
Improper handling of repairs could result in
extreme danger to personnel operating the pump.
Figure 2 Typical Exhaust Box Cross Section
6
THERMOSTAT pump should be smoking excessively. It is normal
VALVE
for the oil to be foamy and light in color in an oper-
ating pump. However, if the oil is milky colored, it
is an indication that water is present in the oil.
Normally, by operating the pump for an extended
period, with the inlet suction blanked off and the gas
ballast (Pos 440) open on RA pumps, the water will
be purged from the oil. If the oil is dark colored, it
is contaminated or carbonized and must be changed.
3.1.2 Oil Type and Quantity

Figure 3 - Water Cooled Pump
3.0 MAINTENANCE See Section 1.5 - Oil Filling - for details on oil
type and quantity.
R5 Series, Single Stage, Rotary Vacuum Pumps
require very little maintenance; however, to insure 3.1.3 Oil and Filter Change
optimum pump performance, the following steps are
recommended: Caution: When changing the oil and filters, it
may be necessary to flush the pump to remove
3.1 Pump Oil any build-up of degraded oil from the sumps, oil
lines, radiators, etc. to ensure proper oil flow
3.1.1 Oil Level through the pump. Reduced oil flow, especially
through radiators and cooling coils, can cause
With the pump installed relatively level, make mechanical damage or extreme overheating
sure that there is sufficient clean oil in the pump. which could cause the oil vapors to ignite.
The oil level should be observed on a daily basis Oil life is dependent upon the conditions to
and/or after 8 hours of operation and should be which it is exposed. A clean, dry air stream and an
replenished if it drops below the 1/4 mark on the oil oil operating temperature under 210F are ideal
sight glass. On R5 series pumps you must first shut conditions. When using R530 (hydrocarbon oil) it
the pump off in order to let the oil flow back into the is recommended that oil changes are made every
oil sump prior to checking the sight glass. Allowing three (3) to four (4) months or 500 to 750 hours of
insufficient time for the oil to drain back into the operation, or as necessary if high heat is contami-
sump on R5 series pumps prior to adding oil could nating the oil. The use of Busch R570 or R590 syn-
result in overfilling. thetic oils could extend the operating hours between
oil changes under ideal conditions. Oil samples
Oil level readings should be done only when the should be taken regularly when exceeding the 500-
pump is turned off. Oil can be added to the oil fill 750 hour recommendation.
port (Pos 88) if the pump is shut off and the circu-
lating oil has sufficient time to return to the oil Excessive Heat
sump.
Caution: Do not add oil while the pump is When the pump is subjected to operating condi-
running since hot unfiltered oil vapor may tions that will cause the oil to be heated above
escape through the oil fill port. 210F, the oil will carbonize and become contami-
nated after a relatively low number of operating
Under normal circumstances, it should not be hours. The higher the temperature, the quicker the
necessary to add or drain oil from the pump between oil becomes contaminated. If the oil temperature is
recommended oil changes. too severe, Busch R570 or R590 synthetic oil should
be used to withstand the elevated temperatures. If
A significant drop in oil level means there is an synthetic oil is used, the pump should be flushed
oil leak or that an exhaust filter is broken, and the with Busch R568 oil as outlined in the Maintenance
7
and Repair Manual. Auxiliary oil cooling is the WARNING: If the gas entering this pump is
most practical approach to a severe heating prob- a health hazard, use rubber gloves and all neces-
lem. sary personal protection equipment when per-
forming the exhaust filter replacement opera-
tion.
WARNING: Wear safety glasses when

installing or removing the spring retainers. The
retainers can, if not secured correctly, slip off
and fly out of the exhaust box.
Oil change intervals can only be established by
experience with the pump operating in the actual
conditions (see previous paragraph for some of the
conditions). Develop the oil change interval by peri-
odically checking an oil sample removed from the
pump. When the oil sample has become dark in
Figure 4 - Removing Exhaust Housing color (from solids and carbonized particles) or is
milky looking (from solids), it is time to discard it.
3.2 Automotive-Type Oil Filter
The 0025-0250 Series, Single Stage, Rotary

Vacuum Pumps are equipped with an automotive-
type oil filter (Ref. 100). When replacing the auto-
motive-type oil filter, use only a Busch genuine fil-
ter.
Note: Make sure to tighten the Busch oil filter

securely against the aluminum sealing surface so
that leaks will not occur.
3.3 Exhaust Filter (Ref. 120)
Figure 5 - Removing Filter Spring Every nine (9) to twelve (12) months, or as nec-
essary, replace the exhaust filter elements. The serv-
Contaminated Air Stream ice life of the exhaust filters varies widely with
pump application. It is only necessary to change the
When the air stream contains solids and/or liq- filters when the elements become clogged with for-
uid that contaminate the oil, it must be changed eign material or burned oil. Indications of clogged
more often. If the air stream contains a small per- filters are smoke and oil mist coming from the pump
centage of contaminates and/or they are slightly exhaust, higher than normal motor current or oil
aggressive* (mild acids, etc.), synthetic oil, such as leaking from the gas ballast valve on RA models.
Busch R570, will resist breakdown better than the
standard Busch R530. The solution is to install a fil- A pressure gauge (Pos 90) is now supplied with
ter or knock-out pot to keep the contaminates out of your R5 vacuum pump as part of the oil fill plug.
the pump. This gauge has a green field and a red field. A pres-
sure within the green field would indicate normal
*Process air streams with a large percentage of contami- pressure. Any pressure, in or close to the red field,
nates and/or are more than slightly aggressive must use a
Once-Through-Sealant or dry type pump.
8
9
10
0025 - 0250 "C" & "E" Parts List
Ref Description Ref Description Ref Description
1 Cylinder 151 Exh. Screen, coarse 301 Screw hex head cap
5 Socket set screw 152 Exh. Screen, fine 302 Lockwasher
15 Rotor 159 Valve assembly, exhaust 306 Motor adapter flange
18 Bearing sleeve 161 Oil service block 307 Lockwasher
22 Vane 162 Oil service block gasket 311 Coupling half, pump side
25 Endplate, motor side 163 Hex head cap screw 312 Coupling insert
26 Endplate, fan side 164 Lockwasher 313 Coupling half, motor side
30 Bearing 165 Socket head cap screw 315 Plastic clip
31 Spacer, bearing to Seal 166 Lockwasher 320 Spacer
35 Shaft seal 168 O-ring 321 Fan
42 Retainer ring 169 Exhaust valve cover plate 322 Axial fan
43 Screw, hex head 175 Socket head cap screw 323 Socket set screw
46 Gasket-ring 176 Lockwasher 326 Retainer ring
47 Plug 185 Gasket, cylinder/exhaust box 331 Set screw
49 O-ring 186 Stud 333 Set screw
50 O-ring 187 Lockwasher 340 Fan guard
53 Screw, hex head 189 Stud 341 Screw, self tapping
54 Lockwasher 190 Lockwasher 342 Sleeve, plastic
57 Hex head screw 191 Nut 345 Fan cover shield
58 Lockwasher 205 Exhaust cover side plate 353 Socket head cap screw
60 Taper pin 206 Cover plate gasket 360 Lockwasher
63 Plug 207 Socket head cap screw 390 Eye bolt adapter
64 Gasket-ring 208 Lockwasher 391 Eye bolt
65 Shaft key 221 Hydraulic fitting banjo 392 Lockwasher
66 Shaft key 222 Hydraulic fitting, straight 393 Hex head screw
75 Exhaust box 223 Hydraulic fitting, elbow/banjo 400 Motor
78 Baffle, expanded metal 224 Pipe adapter 401 Screw, hex head cap
79 Demister pad 225 Hydraulic fitting 402 Lockwasher
80 Sheet metal baffle 230 Oil tubing 409 Motor foot spacer
83 Oil sight glass 231 Oil tubing 411 Flat Washer
84 Gasket ring, sight glass 232 Oil tubing 413 Slotted set screw
88 Oil fill plug 238 Socket head cap screw 415 Screw, hex. head cap
89 Gasket ring, fill plug 239 Lockwasher 416 Stud, motor foot
90 Exhaust pressure gauge 241 Oil cooler 417 Set screw
95 Oil drain plug 242 O-ring 419 Spacer, motor foot
96 O-ring 244 Fan cover 421 Foot, rubber
99 Pipe nipple 247 Socket head cap screw 422 Foot, rubber
100 Oil filter 250 Housing, lower, inlet 423 Lockwasher
105 Cover, exhaust box 251 Valve plate, inlet 424 Hex nut
106 Gasket, exhaust box cover 252 Valve plate guide 425 Stud
107 Screw, exhaust box 253 O-ring 430 Name plate
108 Lockwasher 254 Spring, valve plate 431 Label "arrow"
115 Exhaust filter bracket 255 O-ring 436 Maintenance label
120 Exhaust filter 260 Inlet flange, upper 440 Gas Ballast Assembly
121 O-ring 261 Inlet screen 470 Hyd. fitting banjo
125 Filter spring assembly 265 Screw, hex head cap 471 Tubing, gas ballast
126 Filter spring screw 266 Lockwasher 472 Valve, check gas ballast
130 Strainer 270 Plug 473 Coupling
136 Gasket, exh. box, service block 271 Gasket ring 474 Filter, gas ballast
137 Lockwasher 275 Oil return valve 475 Valve, pet cock
138 Screw 276 Gasket ring 476 Gas ballast elbow
139 Service block 284 Hydraulic, fitting banjo 477 Pet cock valve
140 Exhaust cover plate 285 Screw, oil recirculation 478 Hex head cap screw
141 Exhaust cover gasket 286 Banjo fitting housing 479 Lockwasher
142 Socket head cap screw 288 Gasket ring
143 Lockwasher 289 Screw Note: This parts list includes parts for all the
144 Retaining ring 290 Oil return line, RA version pumps covered by this manual. Your specif-
145 Housing, exhaust port 291 Hyd. fitting, straight ic model might not necessarily have all the
146 Screw, exhaust housing 292 Carburator jet part5 indicated in this list. Refer to the illus-
148 Service block oil baffle 293 Oil return line, RC version tratior for your specific model pump when
149 Socket head cap screw 297 Screen fan guard comparing part numbers or consult the fac-
150 Lockwasher 300 Motor mounting bracket tory.
11
12, 13
requires an immediate change of the exhaust filter. 3.1.3). Inspect inlet filter (see Section 3.4).
In order to replace the filter, remove the four Every three (3) or four (4) months, 500 to 750
socket head cap screws (Ref. 155, 146) retaining the hours of operation, or as necessary: See 3.1.3 and
exhaust port housing. Pull the housing off the 1.5. Drain and discard oil from the hot pump.
exhaust box and set it aside. Use a slotted head Replace the automotive-type oil filter and refill with
screw driver to loosen the exhaust filter retaining fresh oil through the fill plug (see 3.1.2 through
spring, then rotate and remove the spring. Pull the 3.1.3 and 3.2).
filter cartridge (Ref. 120) out of the exhaust box.
Every nine (9) to twelve (12) months, or as
To field test an exhaust filter element, remove it necessary: Replace exhaust filter elements (see
from the pump, allow it to cool, clean the sealing 3.3).
end (or O-ring end), and use compressed air to blow
through the element. Apply approximately 3 to 6 3.6 Overhaul Kit/Filter
psi, which is the maximum allowable operating
pressure across the filter. Note: Use a shop rag to An overhaul kit containing a set of gaskets and
seal off the connection between the air hose and the O-rings, vanes, bearings and bearing sleeves, shaft
filter. If you can blow through it, the element is seals and taper pins, is available from the factory.
good. If not, discard it and install a new one. The
filter cannot be cleaned successfully. Visually Also, a filter kit containing oil drain plug, gas-
inspect the filter element for cracks. kets, automotive type oil filter (where applicable),
exhaust filter, and exhaust filter, is available from
WARNING: Do not inhale through the filter the factory.
or allow your mouth to come in direct contact
with the filter. When ordering, please specify pump size and
model (a 3-digit suffix after size), and serial number.
Reinstall the filter elements. Make sure the open
end of the element is properly seated down in its 4.0 TROUBLESHOOTING
recess in the exhaust box (see Figure 3) with the O-
ring (Ref. 121) correctly positioned. Retain the filter 4.1 Trouble
with the spring clip, tighten the tension screw until
the filter is secure. Place the exhaust port gasket and Pump does not reach blank-off pressure which
housing in position on the exhaust box and retain is the lowest absolute pressure (best vacuum) when
with the cap screws. running with the inlet closed via a blank flange or a
valve; or the pump takes too long to evacuate the
3.4 Vacuum Inlet Filter system. Blank-off pressure can be measured by
using a good quality capsule gauge.
If the pump is equipped with a special vacuum
inlet filter in applications where powder, dust or grit 4.1.1 Possible Cause
is present, the filter cartridge should be cleaned on a
weekly basis, or as required, depending on the Contaminated oil is by far the most common
amount of foreign particles to which the pump is cause of not reaching the ultimate pressure.
exposed.
Remedy:
3.5 Maintenance Chart
Shut off pump, after operating temperature has
Daily: Visually check oil level (see 3.1.1 and been reached, drain the warm oil from pump and
3.1.2). exchange automotive-type oil filter (where applica-
ble), if necessary. Flush and fill pump with new oil
Weekly: Check oil for contamination (see and take new blank-off measurement after operat-
14
ing temperature is reached (at least 20-30 minutes). 4.1.7 Possible Cause
4.1.2 Possible Cause Oil tubing defect and/or leaking. Oil return line
broken on RC model.
Vacuum system or vacuum piping not leak-tight.
Remedy:
Remedy:
Replace or retighten the oil fittings or oil tubing.
Check hose and pipe connections for possible Replace only with same size tubing.
leak.
4.1.8 Possible Cause
Shaft seal leaking.
Wire mesh inlet screen plugged (Ref. 261).
Remedy:
Remedy:
Replace the shaft seal following disassembly
Clean wire mesh inlet screen. Install inlet filter and assembly steps outlined in the Maintenance and
if problem repeats frequently. Repair Manual. Check the shaft seal. It should have
a spring installed inside and around the shaft sealing
4.1.4 Possible Cause lip.
No oil or not enough oil in oil reservoir. 4.1.9 Possible Cause
Remedy: Exhaust valve (Ref. 159) is not properly seated

or it is partially stuck open.
Shut off the pump, add the necessary oil, or if oil
seems contaminated, drain balance of oil from Remedy:
pump, exchange automotive oil filter, and refill with
fresh oil. Follow disassembly and assembly steps outlined
in the Maintenance and Repair Manual.
Automotive-type oil filter is dirty or clogged
(where applicable). The vanes are blocked in the rotor or are other-
wise damaged.
Remedy:
Remedy:
Replace automotive-type oil filter, exchange oil,
if necessary, and refill with fresh oil. Free vanes or replace with new ones following
disassembly and assembly steps outlined in the
4.1.6 Possible Cause Maintenance and Repair Manual.
Inlet valve plate (Ref. 251) stuck in closed or 4.1.11 Possible Cause
partially open position due to contamination.
Radial clearance between the rotor and cylinder
Remedy: is no longer adequate.
Disassemble inlet valve and screen. Clean as

required.
15
Remedy: ing to motor nameplate data; check fuses; and install
proper size wire. If ambient temperature is high, use
Follow disassembly and assembly steps outlined larger size overloads or adjust setting 5% above
in the Maintenance and Repair Manual on resetting nominal motor nameplate value.
the radial clearance correctly.
Pump or motor is blocked.
Internal parts worn or damaged.
Remedy:
Remedy:
Remove fan cover and try to turn pump and
Follow disassembly and assembly steps outlined motor by hand. If frozen, remove motor from pump
in the Maintenance and Repair Manual and replace and check motor and pump separately. If pump is
worn or damaged parts. frozen, disassemble completely per the Maintenance
and Repair Manual and remove foreign objects in
4.1.13 Possible Cause on RC Models Only the pump or replace broken vanes.
The oil return line (Ref. 290) is connected 4.3 Trouble

directly to atmospheric pressure in the exhaust area.
On small model pumps, a fairly large amount of air Pump starts, but labors and draws a very high
is sucked through the oil return line, and it may not current.
be possible to reach 15 torr or 29.4 inches Hg.
blank-off on the inlet of the pump under these con- 4.3.1 Possible Cause
ditions.
Oil too heavy (viscosity too high) or ambient
Blank-off of 29.4 inches Hg or 15 torr can be temperature below 5 degrees C (41F).
reached by temporarily disconnecting and closing
the oil return line; also by squirting oil through the Remedy:
exhaust opening into the exhaust filter area. Oil will
be sucked into the oil return line, and no air will Change to R580 vacuum oil if very cold, or
reach the inlet, thus affecting the "blank-off' pres- warm up oil before filling.
sure.
4.2 Trouble
Pump runs in the wrong direction.
Pump will not start.
Remedy:
Check for correct rotation which is counter-
Motor does not have proper supply voltage or is clockwise when looking at the motor from the
overloaded; motor starter overload settings are too motor's fan side.
low or wrong setting; fuses are burned; or wire is
too small or too long, causing a voltage drop at the 4.3.3 Possible Cause
pump.
Pump is overfilled with oil or the wrong kind of
Remedy: oil is used.
Check correct supply voltage; check overload

settings in motor starter for size and setting accord-
16
Remedy: Pump smokes at the exhaust side or expels oil
droplets from the exhaust.
Correct the oil level and quality per Section 1.5
and use recommended motor oil. 4.4.1 Possible Cause
4.3.4 Possible Cause Exhaust filter is not properly seated with O-ring
(Ref. 121) in filter base or filter material is cracked.
Exhaust filters in exhaust chamber are clogged
and appear burned black with pump oil. Remedy:
Remedy: Check condition and placement of exhaust fil-

ters in filter base. Replace if necessary.
Replace exhaust filters, maintain proper oil con-
dition, oil level, and use only Busch recommended 4.4.2 Possible Cause
vacuum oil.
Exhaust filter is clogged with foreign particles.
Remedy:
The exhaust filter is clogged due to process
material. Replace exhaust filter. Install other factory rec-
ommended filter cartridges if pump application
Remedy: requires other filter cartridges.
Contact the factory for recommendation or prop- 4.4.3 Possible Cause

er filter cartridge.
The oil return valve (Ref. 275) is not properly
4.3.6 Possible Cause working, clogged. Proper function is that when
blowing into check valve, it should close. When
Loose connection in motor terminal box; not all applying vacuum on it, check valve should open.
motor coils are properly connected. Motor operates
WARNING: Do not apply pressure or vacu-
on two phases only.
um by mouth.
Remedy: Remedy:
Check motor wiring diagram for proper hookup, Free or replace the oil return check valve.
especially on motors with six internal motor wind-
ings, tighten and/or replace loose connections. 4.4.4 Possible Cause
4.3.7 Possible Cause If RA Series vacuum pumps run continuously

over 8 hours without ever being shut down, it may
Foreign particle in pump, vanes broken, bearing be possible that oil accumulates behind the exhaust
seizing. box cover (Ref. 275) to the extent that oil is blown
out of the exhaust with the exhaust gas.
Remedy:
Remedy:
Follow disassembly and assembly steps outlined
in the Maintenance and Repair Manual and remove Shut pump down during break periods or install
foreign parts, and replace vanes and bearings. an additional oil return line assembly. Check that oil
return valve (Ref. 275) is free and drains oil back
4.4 Trouble into pump when RA Series pump is stopped.
17
4.4.5 Possible Cause replace vanes.
Oil return line (Ref. 290) on RC Standard pump 4.6 Trouble

is clogged or broken.
The pump runs very hot. See Technical Data for
Remedy: typical oil sump temperature.
Free clogged line, replace broken line, but only 4.6.1 Possible Cause
with proper size, and check that oil is pumped out of
oil sump while vacuum pump is operating. Not enough air ventilation to the pump.
NOTE: An oil filling plug with pressure gauge is Remedy:

provided on all R5 Series pumps, so that the pres-
sure in front of the exhaust filters can be monitored. Clean motor and pump air grills. Do not install
The green field indicates that the filters are still the pump in an enclosed cabinet unless a sufficient
effective. Any back pressure close to the red field amount of fresh air is supplied to the pump. On
requires immediate change of the exhaust filter (Ref pumps with oil cooling coils, clean outside fin
120). assembly. Bring ambient air temperature down.
4.5 Trouble 4.6.2 Possible Cause
Pump runs very noisly. Automotive-type oil filter clogged and pump
does not receive enough oil.
Remedy:
Coupling insert worn.
Change automotive oil filter.
Remedy:
Replace coupling insert in motor/pump cou-
pling. Not enough oil in oil reservoir or badly burned
oil is used for pump lubrication.
Remedy:
Bearing noise.
Drain and refill only with non-detergent oil,
Remedy: increase oil change intervals.
Follow disassembly and assembly steps outlined NOTE: On some high temperature applications,
in the Maintenance and Repair Manual and replace it may be necessary to change to a high temperature
bearings. oil such as R590 or R570. Contact the factory for
recommendations.
4.7 Trouble
Vanes stuck.
Pump is seized.
Remedy:
Follow disassembly/assembly instructions out-
lined in the Maintenance and Repair Manual and Pump operated without oil and vanes broke.
18
Remedy: Remedy:
Disassemble and exchange vanes as outlined in Replace automotive-type filter per Section 3.2
the Maintenance and Repair Manual. and exchange oil per Section 1.5.
4.7.2 Possible Cause 4.8.2 Possible Cause
Pump was operated for an extended period of Wrong automotive-type filter is used and/or oil
time in the wrong rotation. lines leading to pump are clogged.
Remedy: Remedy:
Inspect vanes and replace. Use only automotive filter as listed in Section
3.2 and blow lines free.
Liquid carryover into the pump cylinder broke

vanes while pump was running, or oil broke vanes
on start-up.
Remedy:
(a) Install condensate trap on the inlet of the

pump.
(b) Pump was overfilled with oil in oil reservoir.

Follow oil filling procedure (see Section 1.5) and do
not overfill.
(c) Built-in anti-suck-back valve (Ref. 250

through 255) leaking while pump was shut down
and vacuum was left in manifold. Clean valve seat
and check that anti-suck-back valve holds vacuum
on inlet when pump is shut down.
(d) Two pumps or a receiver is on the same main

line. Install a manual or automatic operated valve in
front of each pump.
4.8 Trouble
Automotive-type oil filter (Ref. 100) does not

get warm within two to five minutes when cold
pump is started.
Automotive-type oil filter is clogged.
19
5.0 LIMITED STANDARD WARRANTY This Limited Standard Warranty applies only to
the above and is for the period set forth. Busch,
Busch, Inc. warrants that all products furnished Inc.'s maximum liability shall not, in any case,
by it are free from defects in material and work- exceed the contract price for the product, part, or
manship at the time of shipment for a period of 18 component claimed to be defective; and Busch, Inc.
months from the date of shipment, or 12 months assumes no liability for any special, indirect, or con-
from the date of installation, whichever occurs first. sequential damages arising from defective equip-
Claims must be made during that period and are lim- ment.
ited to the replacement or repair of parts claimed to
be defective. THERE ARE NO WARRANTIES IMPLIED
OR EXPRESSED THAT EXTEND BEYOND
In the case of components purchased by Busch, THOSE CONTAINED IN THIS LIMITED
Inc., such as starters, controls, mechanical seals, STANDARD WARRANTY.
motors, couplings, etc., the warranty of that manu-
facturer will be extended to the purchaser in lieu of Note: For extended warranties on your new equip-
any warranty by Busch, Inc. The replacement of ment contact Busch, Inc. Headquarters at:
wear items including, but not limited to, seals, bear-
ings, couplings, exhaust cover gaskets, oil drain 1-800-USA-PUMP
plugs, oil fill plugs etc., made in connection with
normal service, are not covered by this Warranty.
The Limited Standard Warranty is valid only

when the product has been properly installed, used
in a normal manner, and serviced according to the
operating manual. This warranty shall not extend to
products that have been misused, neglected, altered,
or repaired without factory authorization during the
warranty period. We highly recommend the use of
Busch oils and parts to achieve documented per-
formance and efficient operation. The use of oils or
parts other than Busch could limit the life expectan-
cy of the equipment and could void any warranties
if they are the cause of any damage. Operating con-
ditions beyond our control such as improper voltage
or water pressure, excessive ambient temperatures,
or other conditions that would affect the perform-
ance or life of the product will also cause the war-
ranty to become void.
Permission to return parts for warranty repair

must be obtained, and all returns must be prepaid to
the factory. If, after examination, the product or part
is found to be defective, it will be repaired or
replaced on a no-charge basis and returned, FOB the
factory. If it is determined that the Warranty has not
been breached by Busch, Inc., then the usual charges
for repair or replacement will be made, FOB the fac-
tory. Parts or products that are obsolete or those
made to special order are not returnable.
20
* Maximum oil temperature with 80F ambient temperature and no supplemental oil cooling.
21
22
Busch Inc. Factory Service Centers
California Illinois
Kurt Kauffman Steve Looman

13826 Struikman Road 430 Windy Point Drive
Cerritos, CA 90703 Glendale Heights, IL 60139
562-926-8422 630-545-1310
New Jersey Puerto Rico
Jose Concepcion Carlos Ortiz

39 Davis Street #420 E. Street, Suite 4
South Plainfield, NJ 07080 Minillas Industrial Park
908-561-3233 Bayamon, PR 00959-1901
787-798-5045
Texas Virginia
Dave Parsons Clayton McClenny

15411 Vantage Pkwy W., Suite 216 516 Viking Drive
Houston, TX 77032 Virginia Beach, VA 23452
281-449-2381 757-463-7800
Busch, Inc.
516 Viking Drive
P/N 0872.900.823 Virginia Beach, Virginia 23452
R5/C&E Series I/O-2M-8/01 Phone: (757) 463-7800
FAX: (757 4630-7407
MAIN: 816-753-2150
TOLL FREE: 800-777-5624
8 6 0 0 5 2 Q
R E F E R E N C E M A N U A L S P A G E 7.26
MAIN: 816-753-2150
TOLL FREE: 800-777-5624
Index
A L S
Lid 4.1, 4.4, 6.6 Safety Guidelines 1.2
Air-Assist 2.2, 3.6
Seal Bar 4.1, 4.2, 4.4, 6.4
Analog Control Panel 3.2, 4.9, M Seal Bar Maintenance 4.2
6.12
Machine will not start 4.3 Seal Bladder Valve 4.3
Auto Stop 3.3
Main Menu 3.4 Seal Element 4.4
B Maintenance Log 4.10, 4.11 Seal Impulse 3.2, 4.3
Mebner Valve 6.16 Security 4.6
Back up Strip 4.1 Service Log 4.10, 4.12
Miscellaneous Machine Parts 6.17
Bacteriological Testing 4.1 Shrink Pouches 3.6
Base 4.1 N Spare Parts 6.1
Specifications IV
C No gas flush 4.3 Startup 2.2
Non-Gas Flush Pneumatic Supervisor Menu 4.5
Caution 1.1
Diagram 5.8
Chamber 4.1
Chamber not venting 4.4
No vacuum 4.3 T
Chassis 6.2 O Teflon Tape 4.2
Cleaning Recommendations 4.1 Tip Over Hazard 4.9
Cooldown 4.6 Oil 2.2 Troubleshooting 4.3, 4.4
CUTTIME 4.5 Oil Drain Plug 4.9
Oil Filler Cap 4.9 U
D Opening Chamber Machine 4.8,
4.10 Unpacking 2.1
Danger 1.1
Designation and Function of P V
Controls 5.1
Personal Safety 1.1 VACPLUS 3.4
Digital Control Panel 3.3, 6.14
Placement of Product 3.1 Vacplus 3.3
Double Seam Seal Option 3.6
Potentiometer 4.9 Vacuum 3.4
E Power Cord 4.10 Vacuum Potentiometer 3.2
Power Requirements 2.1 Vacuum Pump 2.2, 4.2, 4.3, 4.9
Explosion hazard 1.1, 3.5, 3.6 Ventilation Valve 4.3
PREVAC 4.5
F Prior to Cleaning 4.1 W
Proper Sealing 4.4
Filler Plates 3.1, 4.1 Pulse Vent 4.7 WAITTIME 4.5
Food Safety 1.2 Pump 6.2 Warning 1.1
Function of Controls 5.1 Pump Rotation 2.2
G R
Gas 3.5 Reading the Indicators 4.3
Gas Flush 1.2, 2.2, 3.3, 3.6, 6.8 Replacing Power Cord 4.10
Gas Flush Pneumatic Diagram 5.9
Gas Flush Valve 4.3
H
Hazardous voltage 1.1, 4.8, 4.10
Hinge System 6.6
I
Improper or no sealing 4.4
8 6 0 0 5 2 Q
I N D E X P A G E 8.1
MAIN: 816-753-2150
TOLL FREE: 800-777-5624
8 6 0 0 5 2 Q
I N D E X P A G E 8.2
800-777-5624
1414 West 29th Street

Kansas City, MO 64108
Phone (816) 753-2150 Fax (816) 753-4976
info@kochequipment.com kochequipment.com
Replacement Parts
Toll-Free (800) 746-1723
Fax (816) 561-2854
Technical Support
Toll-Free (800) 777-5624
Fax (816) 531-1447

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Ultravac 500

Vacuum Chamber Packaging Machine

EFFECTIVE SERIAL # 2080 +

TABLE OF CONTENTS SCHEMATICS

Congratulations on your Ultravac 500 vacuum packaging machine purchase. This

For Sales, Call:

For Replacement Parts, Call:

For Technical Support, Call:

Copyright 2009 Koch Equipment LLC

Electrical service size for your Ultravac 500 (check one):

230 Volt, 3 phase, 60 Hz

Length (A): 718mm (28.25-in.)

70m3/h (41cfm) 2.2kW (3-hp)

DANGER Hazardous voltage.

DANGER Hazardous voltage.

WARNING Explosion hazard.

CAUTION Blade hazard.

CAUTION Blade hazard.

CAUTION Cleaning agents.

Signal words used in classification of potential hazards are defined as follows:

General Safety Guidelines

Follow approved Lockout/Tagout procedures.

Place machine on a flat, stable surface.

DANGER Hazardous voltage.

The equipment-grounding conductor outer surface is green with or without yellow

Customer Voltage Pump Motor Full Load Amps

Gas Flush Connection

DANGER OXYGEN ENRICHED USE

Checking Vacuum Pump Rotation

PRODUCT HALF HEIGHT

Operation with Analog Control Panel

Experiment with both settings to achieve the best results.

VACUUM SEAL SEAL LIGHT

VACUUM LIGHT VACUUM

Operation with Digital Control Panel

Operator Menu on Digital Panel

This is the Main Menu screen. When

THIS IS THE MAIN MENU SCREEN. WHEN

The SEAL setting is in seconds.

Operator Menu on Digital Panel (continued)

WARNING Explosion hazard.

RUNNING PROG: 1 From the Main Menu, use the UP and

Press the UP arrow to switch to Program 2

Sealing with Air-Assist

Gas Flush Option

WARNING Explosion hazard.

Double Seam Seal Option

DANGER Hazardous voltage.

CAUTION Cleaning agents.

Vacuum Pump Maintenance

Seal Bar Maintenance

Reading the Indicators

NOTE: For proper sealing, three things must occur:

Supervisor Menu on Digital Panel

that was run will be the current program

Press and hold down both arrow keys for

at least 3 seconds to enter the supervisor

Press the MENU key.

WAITTIME is the number of seconds the machine

waits for the knife to retract before resuming the