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Instruction ManualPLUS Master ControlR5 RA 0760 A PLUS

0870232791/-_en / Original instructions / Modifications reserved 16/09/2021

Table of Contents

2 / 44 Instruction Manual PLUS Master Control R5 PLUS_EN_en

Table of Contents1 Safety .......................................................................................................................................3

2 Introduction..............................................................................................................................4

3 Bottom Bar ...............................................................................................................................4

4 Role and User ...........................................................................................................................6

5 Installation and Commissioning ...............................................................................................7

5.1 Vacuum Pumps Installation .............................................................................................. 7

5.2 Ethernet Network............................................................................................................. 9

5.3 Setting of the PLUS Vacuum Pumps................................................................................. 11

5.4 Setting of the PLUS Master Control.................................................................................. 14

6 In Operation .............................................................................................................................16

6.1 System Activation............................................................................................................. 16

6.2 Week Planner................................................................................................................... 18

6.3 Ecomode .......................................................................................................................... 19

6.4 Warm-up / Cool-down Modes......................................................................................... 20

6.5 Optional Inlet Valve Control............................................................................................. 22

6.6 Vacuum pumps control .................................................................................................... 24

6.7 Trend ............................................................................................................................... 26

6.8 Dysfunction...................................................................................................................... 276.8.1 Warnings / Alarms ................................................................................................ 276.8.2 Warnings / Alarms Thresholds ............................................................................... 286.8.3 Modbus Communication Loss ............................................................................... 28

6.9 Stop the System ............................................................................................................... 29

7 Settings.....................................................................................................................................31

7.1 PLUS Master Control Settings .......................................................................................... 317.1.1 Settings Screen 1 ................................................................................................... 317.1.2 Settings Screen 2 ................................................................................................... 327.1.3 Settings Screen 3 ................................................................................................... 337.1.4 Settings Screen 4 ................................................................................................... 33

7.2 Local Settings of the PLUS Pumps .................................................................................... 34

8 Maintenance.............................................................................................................................35

9 Troubleshooting .......................................................................................................................37

10 Data Logger ..............................................................................................................................40

Safety | 1

Instruction Manual PLUS Master Control R5 PLUS_EN_en 3 / 44

1 SafetyThis supplement for installation shall give further information concerning individual set-ting or data analysis to experienced and trained users. Prior to handling the product, thisdocument should be read and understood. If anything needs to be clarified please con-tact your Busch representative.

Read carefully before use and keep for future reference.

This document remains valid as long as the customer does not change anything on theproduct.

The product is intended for industrial use. It shall be handled only by qualified personnel.

The product has been designed and manufactured according to state-of-the-art meth-ods.Nevertheless, residual risks may remain. This supplement for installation highlights po-tential hazards where appropriate. Safety notes and warning messages are tagged withone of the keywords DANGER, WARNING, CAUTION and NOTICE as follows:

DANGER... indicates an imminent dangerous situation that will result in death or serious injuries ifnot 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 andtrouble-free operation.

2 | Introduction


2 IntroductionPLUS Master Control

The PLUS Master Control makes it possible to interconnect several PLUS units and makesthem work together optimally from the point of view of pressure regulation, overallpower consumption and operating hours.

It is thus easy to create a vacuum system from several PLUS vacuum pumps without theneed for an additional control cabinet.

NOTICEInstallation, settings and operation of the pumps in PLUS Master control mode.

This mode requires the PLUS vacuum pumps to be interconnected with each other viaan Ethernet connection. A total number of 2 to 6 PLUS pumps is supported.

NOTEInstruction manual for the PLUS Master Control.

This document is only delivered on request and intended for "Role 2" and “Role 3” peo-ple, see Role and User [► 6].It contains additional information about advanced settings for the use of the “PLUSMaster control” function.

When mentioned, please refer to the specific document “Pump Control Instructions, art.no. 0870213261”.

Please also refer to the original instruction manual of the corresponding machine whichcontent remains valid.

NOTEIllustrations

In this instruction manual the illustrations may differ from the machine appearance.

3 Bottom BarThe bottom bar provides different pieces of information, in particular the machine stateand warning/alarm status.

?01.08.2020 - 15:00

OFF

RUNNING

WARNING

ALARM

Machine stateWarnings and alarms

status Date and hourScreen

brightness

HelpPLUS Master Control icon

PLUS Vacuum pump icon

The PLUS Master Control interface is accessible on the Master pump control touchscreen(see Installation and Commissioning [► 7] / Setting of the PLUS Vacuum Pumps[► 11]).On this particular pump, which can be freely selected among all pumps in the system, anadditional icon in the status bar toggles between the “PLUS Vacuum pump” interfaceand the “PLUS Master Control” interface.

Bottom Bar | 3


• When the “PLUS Vacuum pump” control interface is displayed, the “PLUS MasterControl” icon is visible.

>

> >

01.08.2020 - 15:00 ?

HOME

MAIN

OPERATIONS

MONITORING

MAINTENANCE SYSTEM

ALARM

Inlet pressure

< 5 mbar

Rotation speed

0 %

Operating mode

Speed control

Control mode

Local Manual

4000 h

Next service in

60 Hz

Target speed

OFF

PLUS Master Control icon

• When the “PLUS Master Control” interface is displayed, the “PLUS Vacuum pump”icon is visible.

01.08.2020 - 15:00 ?

HOME OPERATIONS TREND SETTINGS

Instant absorbed power

Inlet pressure Target pressure

17.0 kW

20 mbar< 5 mbar

Run

PLUS Master regulation

Running70%

VP1 VP2 VP3 VP4 VP6VP5

Running70%

Running70%

Auto0%

Auto0%

N/A

OFF

PLUS Vacuum pump icon

• Press on the icon to switch from one control interface to the other.

4 | Role and User


4 Role and UserThree roles of user rights are predefined in the system:

– Role 1 ► Operator

This role is intended for machine operators to control the machine (limited rights) ormonitor operating values. It does not require any password.

– Role 2 ► Installation/Maintenance technician

This role is intended for installation/maintenance technicians to configure the machineaccording to the application. The password for this role can be found in the separatesheet attached to this instruction manual and allows an access to the following features:

– change operating mode,

– reset hours before the next service,

– set the remote control and monitoring parameters, refer to the specific document"Pump Control Instructions, art. no.: 0870213261".

– Role 3 ► Busch Service

Only authorized personnel from Busch Service have this level of access rights.

NOTEIn case of any questions related to the machine settings:

• Please contact Busch Service.

When a password is required, the display shows this screen:

Password

CANCEL

***

SAVE

• Press on the three stars.

• Fill the correct password in the number pad according to your access right.

• Save it.

• From now on, the specific rights are open for a limited period ► delay of 5 minutes.

Installation and Commissioning | 5


5 Installation and Commissioning

5.1 Vacuum Pumps Installation

NOTICEInstallation and electrical connection.

Risk of damage to the machine!

• For the installation and electrical connection of each vacuum pump in the vacuum sys-tem, please refer to the instruction manual(s) of the respective pump(s).

WARNINGVacuum line.

Risk of severe injury!

Risk of damage to the machines and the system!

• All PLUS vacuum pumps must be connected on the suction side to a common pipingline. The piping must be sized (diameter, length) according to the total capacity of thevacuum system and the specificities of the process. Contact your Busch representativefor more information.

Vacuum line*

*not included in the scope of delivery of the vacuum pumps

External Pressure Sensor

Optionally, it is possible to control the system from the signal of an external pressuresensor (not included in the scope of delivery of the vacuum pump), installed on a vacu-um tank for example. In this case this sensor must be connected to the PLUS Masterpump. For the electrical connection and setting of the sensor, refer to the instructionmanual(s) of the respective pump(s).

NOTEContact Busch for more information.

5 | Installation and Commissioning


Isolation Valves

Optionally, isolation valves (not included in the scope of delivery of the vacuum pump)can also be installed at the suction side of each pump to isolate them individually fromthe process. In this case, the valves can be directly controlled by the PLUS Master Con-trol.

NOTEContact Busch for more information.

Vacuum line*


Isolation valve*

Vessel*(vacuumtank)

External pressure sensor*

Cable gland

NOTEInstallation of isolation valves.

The installation of controlled isolation valves at the suction side of the vacuum pumpsrequires:

• the installation of an external pressure sensor located upstream of the valves, so thatthe customer's process pressure information is known to the control system,

• the connection of the control signal of each valve to the control unit of the pump onwhich it is mounted, to allow automatic actuation by the system.

ð For more information, refer to the instruction manual(s) of the respective pump(s).

• Busch recommends the installation of an isolation valve in order to prevent themachine from turning backwards.

• Busch recommends the installation of an isolation valve in order to prevent the oilfrom flowing back to the vacuum system.

• Busch recommends the installation of an isolation valve in order to prevent theprocess gases and debris flowing back to the vacuum system.



5.2 Ethernet Network

DANGERLive wires.

Risk of electrical shock.

• Electrical installation work must only be executed by qualified personnel.

• Install the Ethernet switch (not included in the scope of delivery of the vacuumpumps) and supply it with electricity.

• Two configurations are possible:

– The Ethernet switch can be installed inside the Master pump and be poweredwith 24V DC from the terminal board.

Or

– The Ethernet switch can be installed directly in the utility room and powered in-dependently. This type of installation is recommended because it facilitates thesubstitution of the Master pump in case of maintenance requiring the powersupply to the Master pump to be shut down.

• Connect all the PLUS pumps in the system to the Ethernet switch using ethernet ca-bles (not included in the scope of delivery of the vacuum pumps).

1 2 3 4 5 6 7 8

Ethernet switch*

Ethernet cables*


NOTERecommendation and guidelines about hardware and installation of the Ethernet switchcan be found in the Schematics T579234654 and T579234587.

• Use the LAN ports located on the right side of the control cabinets of the PLUSpumps. For pumps with sound reduction enclosure, route the cable through one ofthe two holes provided for this purpose, on the upper side or on the lower left side atthe back of the cabinet, using the cable glands provided.



2

¼

2x

3

1

1 2 3 4 5 6 7 8

Power supply 1~ 110/230V 50/60Hz

or 24V DC

Quarter turn key(delivered loose)

Remove centralfront cover

LAN Port

Ethernet Switch*


Ethernet cable*

Cable gland

• Refer to the chapter “Ethernet Settings” in the specific document “Pump Control In-structions, art.0870213261” to set the ethernet parameters in the control interface ofeach PLUS vacuum unit.

• A different IP address must be set for each vacuum unit.

192.168.0.22 192.168.0.23 192.168.0.27192.168.0.24

HOME

SETTINGS

OPERATIONS

CONTACT

MAINTENANCE SYSTEM

MODEL ETHERNET

OffEthernet settingsCurrent IP address

192 . 168 . 0 . 22 0 . 0 . 0 . 0

New IP addressChange settings

0 . 0 . 0 . 0

New subnet maskCurrent subnet mask

0 . 0 . 0 . 0

New gatewayCurrent gateway

255 . 255 . 255 . 0

192 . 168 . 0 . 1

/!\ For a modification of the IP address,an active Ethernet connection is necessary.



5.3 Setting of the PLUS Vacuum PumpsThe PLUS Master Control function must be activated in each of the PLUS vacuum pumpsin the system for the PLUS Master Control to operate.

• Go to “SYSTEM” > “SETTINGS”.

>>

>

>>

HOME

SETTINGS

OPERATIONS

CONTACT

MAINTENANCE SYSTEM

MODEL

Date Language

Time Units

mbar

Warnings and alarms thresholds

°C

English01 / 08 / 2020

13 : 48

ETHERNET

Advanced settings

• Press on “Advanced Settings”.

• Enter the password ► Role 3 for visualization and/or modification, see Role and User[► 6].

• Access to the third screen.

HOME

SETTINGS

OPERATIONS

CONTACT

MAINTENANCE SYSTEM

MODEL

Vacuum pump model

ETHERNET

RA 0760 A PLUS

NEXT

Oil type

PREVIOUS

Cooling typeSynthetic Oil Water cooling

PLUS Master control

On

• Switch on the « PLUS Master control » function in the control interface of all PLUSpumps in the system.

ð For further information, refer to the chapter “Advanced Settings” in the specific doc-ument “Pump Control Instructions, art.0870213261”.



• Then define one of the vacuum pumps as the “PLUS Master” and the other pumps as“PLUS Controlled” pumps, in the control mode menu of each pump. The “PLUS Mas-ter Control” interface will be displayed on the screen of the Master pump, see BottomBar [► 4].

In the control interface of the Master vacuum unit:

• Go to “OPERATIONS” > “MODE”.


PREVIOUS

HOME

MODE

OPERATIONS

PARAMETERS

MAINTENANCE SYSTEM

WEEK PLANNER

Control mode

Manual Auto

Modbus control

Start / Stop

Local

Remote Analog speed control

Digital speed control

Plus Master Plus Controlled

• Switch to « Remote / PLUS Master », password required ► Role 2, see Role and User[► 6].

ð For further information, refer to the chapter “Remote Control” in the specific docu-ment “Pump Control Instructions, art.0870213261”.

• A new icon appears in the bottom status bar of the user interface. This icon is used totoggle between the "Home" menus of the pump control interface and the systemcontrol interface display.

01.08.2020 - 15:00 ?

01.08.2020 - 15:00 ?

OFF

OFF

PLUS Master Control icon(appears when the PLUS Vacuum Pump control interface is displayed)

PLUS Vacuum Pump icon(appears when the PLUS Master control interface is displayed)



NOTICEPLUS Master pump.

Only one pump should be declared as “PLUS Master”, the other PLUS pumps in thesystem should be defined as “PLUS Controlled” pumps.

• Any pump can be chosen as “PLUS Master”. As the control interface of the PLUS sys-tem appears only on the touchscreen of the Master pump, it is advisable to select thepump that is most easily accessible.

In the control interface of the other vacuum units:

• Go to “OPERATIONS” > “MODE”.


PREVIOUS

HOME

MODE

OPERATIONS

PARAMETERS

MAINTENANCE SYSTEM

WEEK PLANNER

Control mode

Manual Auto

Modbus control

Start / Stop

Local

Remote Analog speed control

Digital speed control

Plus Master Plus Controlled

• Switch to « Remote / PLUS Controlled », password required ► Role 2, see Role andUser [► 6].

ð For further information, refer to the chapter “Remote Control” in the specific docu-ment “Pump Control Instructions, art.0870213261”.

NOTICEPLUS Controlled pumps.

All vacuum pumps, except the “PLUS Master” pump, must be declared as “PLUS Con-trolled” pumps in a PLUS system.

• Any pump can be chosen as “PLUS Master”. As the control interface of the PLUS sys-tem appears only on the touchscreen of the Master pump, it is advisable to select thepump that is most easily accessible.



5.4 Setting of the PLUS Master ControlOnce all the PLUS vacuum pumps have been configured, the PLUS Master Control sys-tem itself must be configured to complete the installation.

• In the control interface of the Master pump, press on the PLUS Master Control icon inthe status bottom bar to display the PLUS Master Control interface, see Bottom Bar[► 4].

• Go to "SETTINGS".



NEXTPREVIOUS

Ethernet settings VP1

192 . 168 . 0 . 22

MasterIP address


192 . 168 . 0 . 24

MasterIP address


192 . 168 . 0 . 26

MasterIP address


192 . 168 . 0 . 25

MasterIP address


192 . 168 . 0 . 23

MasterIP address


000 . 000 . 0 . 00

MasterIP address

• Enter the IP addresses of all the PLUS vacuum pumps, as defined in the Ethernet set-tings menu of each pump, by pressing in the address fields highlighted in dark gray,password required ► Role 2, see Role and User [► 6].

• Define one of the PLUS vacuum pumps as the Master pump by checking the "Mas-ter" button for this pump. The button is displayed in orange when the pump is select-ed.

NOTEWhen Modbus communication is established between the PLUS pumps and the PLUSMaster Control system, the communication status LED are displayed in green in the Eth-ernet settings menu.

If they are displayed in red, communication is not established.

• In this case, check the Ethernet settings in the control interface of the correspondingpump(s) and acknowledge alarms related to communication if any. Refer to the Warn-ing/Alarm Acknowledgment procedure described in the instruction manual(s) of therespective pump(s).

Then activate all PLUS vacuum pumps to be integrated into the system in the PLUS Mas-ter Control interface.

• Go to "OPERATIONS > PUMPS".



• In the page specific to each of the PLUS pumps in the system (VP1, VP2,...), switchthe pump to the “Auto” mode, password required ► Role 2, see Role and User [► 6].


Running hours

15792 hRA 0760 A PLUS

MasterAuto0%


VP1

Next service

2340 h

Serial number

CHM120400012 Disabled

Auto

PUMPS ECOMODE WEEK PLANNER PARAMETERS

NEXTPREVIOUS

Once Ethernet communication is established and the pumps are set to “Auto” mode, thesetting of the PLUS Master Control system is completed.

All vacuum pumps in the system and their status are displayed in the main screen of thePLUS Master Control interface. The PLUS pumps in “Auto” status are integrated into thesystem and ready for operation. The vacuum pumps with “N/A” status are not parame-terized, and correspond to pumps that can be added to the system at a later stage incase of extension.

?01.08.2020 - 15:00




17.0 kW

50 mbar49 mbar



Auto0%

Auto0%

N/A

RUNNING

Stop

Auto0%

Auto0%

Auto0%

6 | In Operation


NOTEIf one or more pumps are in “Auto” mode and the button indicating the pump name(VP1, VP2,...) under the pump symbol flashes.

This indicates a communication problem.

• In this case, check the Ethernet settings in the control interface of the correspondingpump(s) and acknowledge alarms related to communication if any. Refer to the Warn-ing/Alarm Acknowledgment procedure described in the instruction manual(s) of therespective pump(s).

6 In Operation

CAUTIONDuring operation the surface of the suction and exhaust connections may reach temper-atures of more than 70°C.

Risk of burns!

• Avoid contact with these surfaces during and directly after operation.

NOTEIn the following CAUTION message(s), the term “machine” refers to each of the PLUSpumps integrated into the system.

CAUTIONRemove covers during operation.

Risk of burns!

• If a cover is removed when the machine is operating, avoid contact with surfaces in-side the acoustic cabinet.

CAUTIONNoise of running machine.

Risk of damage to hearing!

If persons are present in the vicinity of a non noise insulated machine over extended pe-riods:

• Make sure that ear protection is being used.

6.1 System Activation

WARNINGThe machines may start without notice.


As soon as the “PLUS Master regulation” button is switched to “Run”:

• Make sure that the machines are fully operational.

In Operation | 6


The “PLUS Master Control” is an automatic system. It controls the PLUS pumps inte-grated to the system according to a user-defined target pressure and the actual pressuremeasured in the system.




17.0 kW

20 mbar< 5 mbar

Run


Running70%


Running70%

Auto0%

Auto0%

N/ARunning70%

To set the target pressure:

• Go to “HOME”

• Enter the target pressure that the system should regulate, password required ► Role 2,see Role and User [► 6]. The value must be between 0 and 400 mbar(a).

To start the system and activate the PLUS Master Control, switch the “PLUS Master reg-ulation” button to Run.

NOTE- When the PLUS Master regulation is activated, the system automatically controls thepumps and starts/stops them according to the vacuum demand from the process. Acti-vating the function will therefore only cause one or more pumps to start if the pressurein the system is higher than the target pressure.

- The PLUS Master Control optimizes power consumption and overall operating hours ofsystem. It also controls the running hours of each pump individually. Therefore, the firstpump to start will not necessarily be the Master pump and will not always be the sameat each system restart.

- When a vacuum pump is in “Auto” mode in the PLUS Master Control interface, it isnot possible to start it or stop it locally by pressing the Start/Stop button located next tothe touchscreen on the pump. The pump is configured to be automatically started andstopped by the PLUS Master Control only.

6 | In Operation


6.2 Week PlannerThe "week planner" function is only available for “Role 2” people, password required ►see Role and User [► 6]. It allows definition of a weekly schedule for starting or stop-ping the PLUS system automatically. A single start and stop a day is possible.

To configure the weekly schedule:

• Go to “OPERATIONS” > “WEEK PLANNER”.

• Press on the days when automatic start and stop are required.

• Set up the starting and stopping times.

To activate the week planner:

• Switch on the “Week-planner” button.



MondayTuesdayWednesdayThursdayFridaySaturdaySunday

Day

00 :6 : 508 : 157 : 308 : 0Start at Stop at

17 : 150:17

17 : 1559:23

16 : 0

OnWeek-planner

↴↳

NOTETo allow the system to operate non-stop from one day to the next one, select 23:59 asthe stop time on the first day and 00:00 as the start time on the second day. Arrows ap-pear in the weekly schedule table to show that the system will continuously run betweenthe two days.

NOTEThe Week planner does not define time periods in which the system will operate contin-uously, but the time periods in which it will operate if the pressure value is higher thanthe Target pressure. Outside these time periods, the system will be automatically deacti-vated and will not start, regardless of the pressure value.

In Operation | 6


6.3 EcomodeThe Ecomode stops the system when the inlet pressure has reached the preset "Ecomodepressure" within a defined time delay and will restart once the inlet pressure exceeds the"Restart pressure".

This mode is only available for “Role 2” people, password required ► see Role and User[► 6].To active and set the Ecomode:

• Go to “OPERATIONS” > “ECOMODE”.

• Press on the Ecomode switch button (password required).




NEXTPREVIOUS

Ecomode

Ecomode pressure

20 mbar

On

Time delay

10 s

Restart pressure

100 mbar

• Press a value to change it.

Parameter Default value Adjustment range

Ecomode pressure 20 mbar 5 … 400 mbar

Restart pressure 100 mbar 100 … 1000 mbar

Time delay 10 s 1 … 999 s

6 | In Operation


6.4 Warm-up / Cool-down ModesThe warm-up mode allows the machines to obtain a suitable operating temperature forthe process.

The cool-down mode allows the evacuation of any condensable vapours, refer to the in-struction manual(s) of the respective pump(s) for more information.

During these phases, the pumps operate at maximum speed, with the gas ballast valveopen, in order to warm up and evacuate a maximum of humidity.

• The warm-up and cool down modes must be set with a target time. They are onlyavailable for “Role 2“ people, password required ► see Role and User [► 6].

To activate these two modes:

• Go to “OPERATIONS” > “PARAMETERS”.

• Access to the first screen.

• Press on warm-up and/or cool-down switch button (password required).



NEXTPREVIOUS

Warm-up Enable Time

On 30 min

Cool down Enable Time

On 30 min

• Press a value to change it.

Parameter Default value

Warm-up time 30 min

Cool-down time 30 min

The Warm-up mode requires the activation of the Week-planner, see Week Planner[► 18]. When the Warm-up mode is activated, all pumps in the system will perform awarm-up cycle for the time defined by the user at each system start time defined in thecalendar.

The Cool-down mode does not require the activation of the Week-planner. When theCool-down mode is activated, each pump will perform a cool-down cycle before beingswitched off by the PLUS Master control. If the vacuum demand increases before theend of the cool-down cycle and the pump is required again in the system, the cool downphase will be stopped and the pump will be activated again in the system.

In Operation | 6


NOTEWarm-up and Cool-down modes.

The warm-up and cool-down modes require the installation of isolation valves at thesuction side of the pumps and an external pressure sensor connected to the Masterpump.

• The isolation valve will be automatically controlled by the PLUS Master Control duringthe warm-up and cool-down phases, see Vacuum Pumps Installation [► 7] (IsolationValves) and Optional Inlet Valve Control [► 22].







6 | In Operation


6.5 Optional Inlet Valve ControlThe control of optional isolation valves is activated on the Master Control by default. Ifvalves are installed, the system will automatically pilot them.

3 time delays are involved in the control of the function and must be set if inlet valvesare installed. These time delays apply when each PLUS pump in the system is started orstopped individually.

To set time delays (only available for “Role 2“ people, password required ► see Roleand User [► 6]):• Go to “OPERATIONS” > “PARAMETERS”.

• Access to the second screen.



NEXTPREVIOUS

Optional inlet valve control

0 s

Time delay beforeopening valve

0 s

0 s

Time delay beforeclosing valve

Additional time delay2VP -> 1VP

– Time delay before opening valve:

This time delay applies between the time a PLUS pump starts in the system (when onemore pump is needed to reach the Target pressure) and the time the isolation valve in-stalled upstream of this vacuum pump opens.

*if optional isolation valve installed (not included in the scope of delivery)

Open the inlet valve*and perform the processSTART

Time delaybefore opening valve*Start signal sent by

PLUS Master Control

– Time delay before closing valve:

This time delay applies between the time the PLUS Master Control sends a signal to takea PLUS pump out of the system (when it is no longer needed to reach the Target pres-sure) and the time the isolation valve installed upstream of this vacuum pump closes.

– Additional time delay 2VP -> 1 VP:

This time delay comes in addition to the "Time delay before closing valve". It only ap-plies when just two PLUS pumps are in operation in the system, to avoid untimely stop /restart of the second pump in the event that the vacuum requirement is slightly higherthan 100% of the capacity of one vacuum pump alone.

In Operation | 6


*if optional isolation valve installed (not included in the scope of delivery)*applies only when just two vacuum pumps are in operation in the system

Close the inlet valve* STOPTime delay

before closing valve*Stop signal sent byPLUS Master Control + Additional time delay

2VP -> 1 VP**

Recommended settings:

Main operating criteria Stability andenergy sav-

ings*

Reactivity andperformance

Stability andenergy sav-

ings


Inlet valves installed atPLUS pumps inlets

No Yes

Time delay before open-ing valve 0 sec. 0 sec. 5 sec. 0 sec.

Time delay before clos-ing valve 0 sec. 0 sec. 2 sec. 0 sec.

Additional time delay2VP -> 1 VP

30 sec. 5 sec. 30 sec. 5 sec.

* Default factory setting






6 | In Operation


6.6 Vacuum pumps controlFour parameters allow fine-tuning of the control of the PLUS vacuum pumps start-upand shut-down command by the PLUS Master Control: 2 time delays and two perfor-mance factors.

To set time delays and performance factors (only available for “Role 2“ people, pass-word required ► see Role and User [► 6]):• Go to “OPERATIONS” > “PARAMETERS”.




NEXTPREVIOUS

Vacuum pumps control

2 s

Time delay beforepump start-up

5 s

30 s

Time delay beforepump shut-down

Performance factorpump shut-down

Performance factorpump start-up

10 s

– Time delay before pump start-up:

This delay occurs between the time the control system sends a start signal to an addi-tional pump in the system (in case the pumps already in operation are not sufficient) andthe time this pump actually starts.

*if optional isolation valve installed (not included in the scope of delivery)**if Warm-up mode activated and first start-up in the day

Open the inlet valveand perform the process*START

Time delaybefore opening valve*Start signal sent by

PLUS Master Control

Time delaybefore pump start-up

+ Warm-up time**

– Time delay before pump shutdown:

This delay occurs between the time the PLUS Master Control sends a signal to stop avacuum pump in the system (in case no isolation valves are installed at the vacuumpumps inlets), or between the time the inlet valve closes (in case isolation valves are in-stalled at the vacuum pumps inlets) and the time this pump actually stops.

Close the inlet valve* STOPTime delay

before closing valve*Stop signal sent byPLUS Master Control + Additional time delay

2VP -> 1 VP*

*if optional isolation valve installed (not included in the scope of delivery)**if Cool-down mode activated

Time delay beforepump shutdown

+ Cool-down time**

In Operation | 6


– Performance factor pump start-up / Performance factor pump shut-down:

These performance factors affect the responsiveness of the system when starting andstopping an additional pump. The higher these factors are, the more precise the systemwill be and the more the control will tend to approach the pressure set point from below.The smaller these factors are, the more energy efficient the system will be and the morethe system will tend to approach the pressure set point from the top.

Target pressure

Pressure

Time

High performance factors

Low performance factors

Recommended settings:

Main operating criteria Best compromisestability / reactiv-

ity*

Stability and en-ergy savings


Time delay before pump start-up 2 sec. 2 sec. 0 sec.

Time delay before pump shut-down 5 sec. 0 sec. 10 sec.

Performance factor pumpstart-up 10 sec. 2 sec. 30 sec.

Performance factor pumpshutdown

30 sec. 2 sec. 200 sec.

* Default factory setting

6 | In Operation


6.7 TrendThe menu “TREND” shows the trend curve of the Power consumption and Inlet pressureof the system over the time.

It is possible to choose between two different time intervals (1 hour or 24 hours).

To change the time interval:

• Press on “1h” or “24h” button.

2200

1760

1320

880

440

011:05:00-30min-45min-1h

200

1410

-15min


Power consumption Inlet pressure

1000<=>

10kW1000<=>

1000mbar

24h

In Operation | 6


6.8 Dysfunction

6.8.1 Warnings / AlarmsThe PLUS Master Control centralizes and reports warnings and alarms for all vacuumpumps in the system.

In case of a warning or alarm on one of the PLUS pumps, a message appears in the sta-tus bar of the PLUS Master Control interface (see Bottom Bar [► 4]). The icon of theconcerned pump is displayed in orange (in case of a warning) or red (in case of an alarm)in the main screen (HOME) and in the screen of this specific pump (OPERATIONS >PUMPS).

?01.08.2020 - 15:00




17.0 kW

20 mbar< 5 mbar

Run


Running70%


Running70%

Running70%

Auto0%

Auto0%

N/A

RUNNING WARNING

– Warnings are an indication that an operating parameter has exceeded the normalthreshold, but do not affect the operation of the vacuum pumps and the PLUS sys-tem.

– Alarms are an indication that an operating parameter has exceeded the maximumpermissible threshold. In case of an alarm, the vacuum pump affected is automatical-ly shut down by its local control system. However the PLUS system continues to op-erate with the other PLUS pumps still in operation.

In the event of a warning or alarm, refer to the “WARNING/ALARM” menu in the con-trol interface of the relevant pump and to the instruction manual of this pump for trou-bleshooting and acknowledgement.

It is possible to de-prioritize vacuum pumps with active warnings in the PLUS system toavoid the risk of an alarm or a failure, see Settings [► 31].On the opposite, it is also possible to automatically acknowledge warnings directly fromthe control interface of the PLUS Master Control by activating the "Auto warning ac-knowledgement" button, see Settings [► 31].

6 | In Operation


6.8.2 Warnings / Alarms ThresholdsThe thresholds that trigger warnings and alarms can be set by Busch for particular appli-cations, in the control interface of each individual PLUS pump that is part of the PLUSsystem. Contact Busch for more information.

6.8.3 Modbus Communication LossIf for any reason the Modbus communication (Ethernet network) is lost between thePLUS Master Control system and one of the vacuum pumps during operation, the sys-tem will continue to operate without the concerned pump. This vacuum pump will auto-matically shut down for safety reasons. It will be automatically reintegrated into the sys-tem when communication is re-established.

NOTEThis setting can be changed in the control interface of each of the PLUS pumps, so thatthe vacuum pumps will continue to operate with the last parameters received instead ofstopping in case of Modbus communication loss.

To allow the vacuum pumps to operate with the last received parameters in case ofModbus communication loss:

• In the control interface of each PLUS vacuum pump in the system, switch off the"Modbus Ethernet port 1 disconnected, Stop in case of alarm" parameter (availablefor “Role 3“ people, password required ► see Role and User [► 6]).

ð

HOME

SETTINGS

OPERATIONS

CONTACT

MAINTENANCE SYSTEM

MODEL

Inlet pressure sensor disconnected

Stop in case of alarm

ETHERNET

Oil level

On

On

PREVIOUS


Analog inputs disconnected

Stop in case of alarm On

Modbus Ethernet port 1 disconnected

Stop in case of alarm On


External inlet pressure sensor disconnected Inlet filter pressuredifferential

On 60 mbar

Warning

ð Refer to the chapters “Warnings and Alarms Thresholds”, available in the instructionmanual(s) of the respective pump(s) and in the specific document “Pump Control In-structions, art.0870213261”.

DANGERDisabling the automatic switch-off of the pumps.

Disabling the automatic switch-off of the pumps in case of Modbus communicationloss will result in the loss of the central emergency stop function.

• A physical emergency stop line connecting all pumps is then required.

In Operation | 6


6.9 Stop the SystemTo stop the complete system:

• Go to the main screen (“HOME”) of the Master Control, password required ► Role 2,see Role and User [► 6].

• Switch the "PLUS Master regulation" button to Stop.

?01.08.2020 - 15:00




17.0 kW

50 mbar49 mbar



Auto0%

Auto0%

N/A

RUNNING

Stop

Auto0%

Auto0%

Auto0%

ð The system is then disabled and no vacuum pump will start, even if they are in “Au-to” mode.

To stop one or several pumps and let the other pumps of the system run:


• In the page specific to each of the PLUS pumps in the system (VP1, VP2,...), removethe pump(s) from the system by switching it (them) to the “Disabled” mode, pass-word required ► Role 2, see Role and User [► 6].


Running hours

15632 hRA 0760 A PLUS

Controlled


VP2

Next service

2400 h

Serial number


Auto


NEXTPREVIOUS

N/A

ð This pump is then taken out of the PLUS system. Its status becomes "N/A" on themain screen of the PLUS Master Control interface. It will no longer be controlled bythe PLUS Master Control until it is switched to “Auto” mode.

6 | In Operation


NOTE- When a vacuum pump is in “Auto” mode in the PLUS Master Control interface, it isnot possible to start it or stop it locally by pressing the Start/Stop button located next tothe touchscreen on the pump. The pump is configured to be automatically started andstopped by the PLUS Master Control only.

- When a vacuum pump is in “Disabled” mode in the PLUS Master Control interface, itis no longer controlled by the PLUS Master Control. To start and stop it locally from theStart/Stop button located on the pump, it is necessary to first switch it back to the "LO-CAL / MANUAL" mode in the control interface of the pump, refer to the instructionmanual(s) of the respective pump(s).

In case of emergency stop:

• Push the emergency stop switch (ESS) of any of the vacuum pumps in the system.

As long as the power indicator light (PIL) is green, the machine(s) is (are) still powered.

NOTEThe PLUS Master Control supports a centralized emergency stop function via the Ether-net network which connects all the vacuum pumps in the system. If the emergency stopbutton on any of them is pushed, the entire system will automatically shut down.

The system will then automatically restart when the emergency stop button has beendisengaged and the alarm related to its activation has been acknowledged on the con-cerned pump(s).

Settings | 7


7 Settings

7.1 PLUS Master Control Settings

7.1.1 Settings Screen 1


Running hours difference target:

NEXT

Unequal running hours between vacuum pumps

On

PREVIOUS

VP1 +500h

VP2

VP3 VP6

VP5

VP4

+ 0 h

+500h

+ 0 h

N/A

+ 0 h

This menu is used to set the operating hours target for the vacuum pumps integrated inthe system.

By default (“Unequal running hours between vacuum pumps” set to "off"), the systemcontrols the PLUS pumps so that they all have the closest possible number of operatinghours. This makes it possible to group the maintenance of all the pumps together andthus limit the number of maintenance operations required.

When the function “Unequal running hours between vacuum pumps” is activated (setto “on”), it is possible to individually define a different running hours target for eachPLUS pump, and thus to shift the maintenance. This allows maintenance operations tobe carried out on one part of the pumps while the system is running with the rest of thepumps, thus avoiding production downtime.

To activate the function:

• Switch on the “Unequal running hours between vacuum pumps” button, passwordrequired ► Role 2, see Role and User [► 6].

NOTEAuto pump change in case of warning.

If the option "Auto pump change in case of warning" is activated (Settings Screen 2[► 32]), it will have priority over the control of the vacuum pumps operating hoursby the PLUS Master Control system.

In case of active warnings on some vacuum pumps that would not be acknowledged byusers, an offset may therefore occur in the planning of the operating hours of thesepumps.

7 | Settings




NEXT

Auto pump change in case ofwarning

On

PREVIOUS

Auto warning acknowledgment

Off

The function “Auto pump change in case of warning” allows the PLUS Master Controlsystem to automatically de-prioritize vacuum pumps with active warnings to avoid therisk of an alarm or a failure.

When the function is activated, all vacuum pumps in the system with an active warningwill be de-prioritized: the system will use these pumps only if all the other pumps are al-ready in operation and additional pumps are required to reach the vacuum target. Assoon as a vacuum pump can be stopped by the PLUS Master Control, pumps with activewarning will be stopped first.

To activate the function:

• Switch on the “Auto pump change in case of warning” button, password required ►Role 2, see Role and User [► 6].

NOTEAuto pump change in case of warning.

If the option "Auto pump change in case of warning" is activated (Settings Screen 2[► 32]), it will have priority over the control of the vacuum pumps operating hoursby the PLUS Master Control system.

In case of active warnings on some vacuum pumps that would not be acknowledged byusers, an offset may therefore occur in the planning of the operating hours of thesepumps.

To overcome this, it is also possible to automatically acknowledge warnings directly fromthe control interface of the PLUS Master Control. This option is useful if the user prior-itizes the planning of the operating hours of the vacuum pump by the PLUS Master Con-trol system.

After a warning appears on a vacuum pump, and as soon as it is no longer active, it willbe automatically acknowledged by the system. The pump will no longer be de-prioritizedand can be used by the PLUS Master Control according to the parameters defined by theuser in the screen “Unequal running hours between vacuum pumps” (Settings Screen 1[► 31]).To activate the function:

Settings | 7


• Switch on the “Auto warning acknowledgement” button, password required ► Role 2,see Role and User [► 6].



NEXTPREVIOUS


192 . 168 . 0 . 22

MasterIP address


192 . 168 . 0 . 24

MasterIP address


192 . 168 . 0 . 26

MasterIP address


192 . 168 . 0 . 25

MasterIP address


192 . 168 . 0 . 23

MasterIP address


000 . 000 . 0 . 00

MasterIP address

See chapter Setting of the PLUS Master Control [► 14].

7.1.4 Settings Screen 4Enter the password ► Role 3 for visualization and/or modification, see Role and User[► 6].


Pressure control settings

NEXT

Inlet pressure

PREVIOUS

Target pressure

0 - 125 mbar

Kp : 0.40

Tn : 6.00

Tv : 0.00

20 mbar< 5 mbar

0.00

3.00

0.10

125 - 400 mbar

Factory settings

Kp :

Tn :

Tv :

First set of parameters Second set of parameters

Pressurerange

Pressurerange

PID Control

This menu gives access to the parameters of the pressure regulation (used to control thePLUS system):

7 | Settings


• P = Proportional gain (Kp)

• I = Integral time (Tn)

• D = Derivate time (Tv)

By default, two sets of parameters are programmed in the control unit(s) of the ma-chine(s):

End vacuum ≤ inlet pressure < 125 mbar 125 mbar ≤ inlet pressure < 400 mbar

P (Kp) I (Tn) D (Tv) P (Kp) I (Tn) D (Tv)

0.4 6 0 0.1 3 0

The modification of the PID parameters is possible, in order to adjust the reactivity / sta-bility of the machine(s) and fine tune the pressure control to each application and eachprocess requirement.

• To change the PID settings:

– Set the required target pressure.

– Turn on the PLUS Master regulation (see System Activation [► 16]).– Click on the value(s) to be modified (PID, switching pressure between the two sets of

parameters) and type the new value(s).

– The system will dynamically use the new parameters. Test and adjust the settings un-til the system achieves the required performance.

• To restore the factory settings:

– Press the “Factory settings” button.

NOTICEWrong PID settings

Risk of loss of performance!

Selecting inappropriate PID settings can affect system performance.

• Make sure that the pressure control is effective at each step of the process and restorefactory settings if necessary.

7.2 Local Settings of the PLUS PumpsThe parameters and settings of the PLUS Master Control have priority over the localparameters and settings of each PLUS vacuum pump in the system.

Therefore, all parameters described in this manual and set through the PLUS MasterControl interface apply to all pumps instead of their local settings (Ecomode, Week-plan-ner, Warm-up and cool-down,…).

However, some parameters are not controlled by the PLUS Master Control. In this casethe local parameters defined in the control interface of each PLUS pump apply. This isparticularly the case for the following functions:

• gas ballast control,

• warnings and alarms,

• advanced pumps settings.

In addition, the basic settings of the PLUS Master interface (language, time and date,units) follow the basic settings of the Master pump. These settings must therefore bechanged in the control interface of the Master pump.

For further information, refer to the specific document “Pump Control Instructions,art.0870213261” and to the instruction manual(s) of the respective pump(s).

Maintenance | 8


8 Maintenance

WARNINGThe machine may start without notice.


• Make sure that the lockable disconnect switch is activated and protects the machineagainst inadvertent start up.

• The power indicator light (PIL) must be turned off.

The PLUS Master interface allows the monitoring and planning of maintenance opera-tions to be carried out on the PLUS vacuum pumps that are part of the system.

– The remaining hours until the next maintenance, as well as the total operating hoursof the pump, can be visualized on the information page of each vacuum pump in thePLUS Master Control interface.

To visualize the remaining hours until the next maintenance:


• The information about running hours is available in the page specific to each of thePLUS pumps in the system (VP1, VP2,...).


Running hours

15792 hRA 0760 A PLUS

MasterRunning

70%


VP1

Next service

2340 h

Serial number


Auto


NEXTPREVIOUS


Running hours

15632 hRA 0760 A PLUS

ControlledRunning

70%


VP2

Next service

2400 h

Serial number


Auto


NEXTPREVIOUS

8 | Maintenance


– Details on the type of maintenance to come and the consultation / modification ofmaintenance intervals are done directly on the interface of each of the pumps in thesystem, refer to the instruction manual(s) of the respective pump(s).

– The PLUS Master Control integrates a function for planning the operating hours ofthe vacuum pumps integrated in the system, in order to schedule maintenance oper-ations. It is possible to group the maintenance on all pumps (which limits the numberof maintenance operations required) or to plan it individually (which avoids vacuumsystem downtime), see Settings Screen 1 [► 31].

– It is possible to let the system run during a maintenance operation on one or severalof the vacuum pumps. However, it is necessary to ensure that it is isolated from thesystem and cannot restart automatically.

Before starting a maintenance operation on a pump:


• In the page specific to each of the PLUS pumps in the system (VP1, VP2,...), removethe pump(s) from the system by switching it (them) to the “Disabled” mode, pass-word required ► Role 2, see Role and User [► 6].


Running hours

15632 hRA 0760 A PLUS

Controlled


VP2

Next service

2400 h

Serial number


Auto


NEXTPREVIOUS

N/A

• Switch off the power supply to the concerned pump(s).

• Isolate the vacuum pump(s) from the rest of the system by closing an isolation valveon the piping between the pump(s) and the rest of the system.

NOTE- When a vacuum pump is in “Auto” mode in the PLUS Master Control interface, it isnot possible to start it or stop it locally by pressing the Start/Stop button located next tothe touchscreen on the pump. The pump is configured to be automatically started andstopped by the PLUS Master Control only.

- When a vacuum pump is in “Disabled” mode in the PLUS Master Control interface, itis no longer controlled by the PLUS Master Control. To start and stop it locally from theStart/Stop button located on the pump, it is necessary to first switch it back to the "LO-CAL / MANUAL" mode in the control interface of the pump, refer to the instructionmanual(s) of the respective pump(s).

Troubleshooting | 9


NOTE- The Master pump can be put into “Disabled” mode like any other pump in the system,without affecting the operation of the system with the other pumps. However, operationof the PLUS Master Control system requires the Master pump to be electrically powered.In case of intervention on the Master pump requiring the power supply to be cut, it isnecessary to first set another pump as Master pump beforehand. The access to the sys-tem control interface will then be done on the new Master pump, see Installation andCommissioning [► 7].

9 Troubleshooting

DANGERCarry out any work on the control unit and motor.

Risk of electrical shock!

• Electrical installation work must only be executed by qualified personnel.

CAUTIONHot surface.

Risk of burns!

• Prior to any action requiring touching the machine, let the machine cool down first.

Problem Possible cause Remedy

The PLUS System does notstart.

The PLUS Master Regulationis not activated.

• Activate the PLUS Masterregulation in the menu"HOME".

The Target pressure is higherthan the pressure measuredby the PLUS Master Controlsystem.

• Check the connection ofthe controlled isolationvalves if any.

• Check the connection andsettings of the external in-let pressure sensor if any.

The week-planner is activat-ed.

• Check the Week-plannermenu in the PLUS MasterControl interface.

• Disable the function or setthe daily start-up andshut down times as de-sired.

9 | Troubleshooting



One of the machines doesnot start.

An Ethernet wire is cut ornot connected.

The Modbus connection isnot properly made.

Wrong settings between themachine and the PLUS Mas-ter Control.

• Check the wiring betweenthe machine and the net-work.

• Check the Ethernet con-nection.

• Check the Ethernet set-tings of the machine andof the PLUS Master Con-troller.

The machine sent an alarm. • Check the status of themachine in the PLUSMaster Control interface.

• Check the ALARM Menuin the control interface ofthe machine for more de-tailed information.

• Acknowledge the alarmonce the problem issolved and it is no moreactive.

The "Unequal running hoursbetween vacuum pumps"function is enabled and asignificant running hours dif-ference target between thismachine and the other ma-chines has been set in thesystem.

• Check the Running hoursof all the machines andthe running hours differ-ence target in the PLUSMaster Control interface.

• Adjust the target as de-sired.

One of the machines doesnot start or does not reachthe running hours target.

The machine sent a warningand the "Auto pump changein case of warning" functionis switched on.

• Check the status of themachine in the PLUSMaster Control interface.

• Check the ALARM Menuin the control interface ofthe machine for more de-tailed information.

• Acknowledge the warningonce the problem issolved and it is no moreactive.

• Optionally switch on the"Auto warning acknowl-edgement" function sothat the warning is auto-matically acknowledgedas soon as the warning isno more active.

The system does not reachthe target pressure.

The system is undersized forthe application.

Leaks or pressure drops inthe pipework upstream thesuction connection.

• Check the system pipe-work.

• Ask Busch for advice.

Troubleshooting | 9



The PLUS System does notstop.

The Target pressure is lowerthan the pressure measuredby the PLUS Master Controlsystem.

• Deactivate the PLUS Mas-ter regulation in the menu"HOME" to force thecomplete system shut-down.

The week-planner is activat-ed.

• Check the Week-plannermenu in the PLUS MasterControl interface.

• Disable the function or setthe daily start-up andshut down times as de-sired.

NOTEOperating problems.

For troubleshooting of operating problems related to the vacuum pumps themselvesand for information on faults in the PLUS pumps control interfaces, refer to the instruc-tion manual(s) of the respective pump(s).

10 | Data Logger


10 Data LoggerThe PLUS Master Control has a built-in data logging function.

The following operating parameters are continuously recorded (one recording every min-ute) on a SD memory card in the programmable logic controller (PLC) located in the con-trol unit (CU) of the Master vacuum pump:

• Pressure in the system

• Rotational frequency of each of the vacuum pumps

• Power consumption of each of the vacuum pumps

• Position of optional isolation valves (open / closed)

In addition, the complete operational data specific to each vacuum pump are recordedlocally in the control system of the pumps. Refer to the instruction manual(s) of the cor-responding pump(s) for more information.

To access the logged data via a LAN connection:

• Connect an Ethernet cable to an available Ethernet port on the Ethernet switch con-necting all the vacuum pumps in the PLUS system.

• Connect the Ethernet cable to a computer. To connect the Ethernet cable to the com-puter, use a USB/LAN adapter or connect it directly to the Ethernet port of the com-puter and use the internal network card (administrator access required).

• Check the ethernet settings of the Master pump (or any other vacuum pump) in thethird screen of the SETTINGS menu of the PLUS Master Control interface (see Set-tings Screen 3 [► 33] and Setting of the PLUS Master Control [► 14]). By default,the Ethernet settings of the Master pump are:

– IP address: 192.168.0.22

– Subnet mask: 255.255.255.0

– Gateway: 192.168.0.1

• Check the ethernet settings of the computer network (Internet Protocol Version 4(TCP/IPv4) Properties). The Subnet mask and the first 3 bytes of the IP address mustbe the same as on the PLUS machine.

Data Logger | 10


• Use Filezilla Client (freeware) or an equivalent FTP client software.To configure Filezilla Client, open the freeware and use the following parameters:

– Host: IP address of the PLUS machine (192.168.0.22 by default)

– Username: “USER”

– Password: “USER”

– Port: not used, should remain empty

– Then press the “Quickconnect” button

• Once the connection between the computer and the PLUS machine established, type“/sd0” as Remote site to access to the SD card and drag / drop the desired files tocreate local copies in the computer.

To access the logged data via the SD card:

• Switch off the power supply of the machine.

• Open the door of the control unit cabinet and take the SD card out of the Programa-ble logic controller (PLC1).

10 | Data Logger


• Insert the SD card in a computer to download the .csv files and open them with aspreadsheet program.

NOTE

• Once the .csv files have been downloaded, the SD card must be inserted back into thePLC, so that the operating data of the machine can be saved once it has been restart-ed.

Note

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Documents

Instruction Manual PLUS Master Control R5 PLUS EN en