Ultravac® 2100

Vacuum Chamber Packaging Machine

Effective Serial # 5512+

860804 Revision AC
Date 7/2013
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

TABLE OF CONTENTS
General................................................III Maintenance Log............................... 4.13
Specifications........................................ IV Service Log........................................ 4.13
SAFETY SCHEMATICS
Personal Safety.....................................1.1 Designation and Function of Controls.....5.1
Food Safety.........................................1.2 230 Volt, Single Phase, Analog Panel.... 5.2
General Safety Guidelines.....................1.2 230 Volt, 3 Phase, Analog Panel........... 5.3
Safety Decal Locations......................... 1.3 380 Volt, 50 Hz, Analog Panel............. 5.4
Machine Conformity.............................1.4 460 Volt, 3 Phase, Analog Panel........... 5.5
STARTUP 575 Volt, 3 Phase, Analog Panel........... 5.6
Unpacking...........................................2.1 230 Volt, Single Phase, Digital Panel..... 5.7
Power Requirements..............................2.1 230 Volt, 3 Phase, Digital Panel............ 5.8
Grounding Instructions......................... 2.2 380 Volt, 50 Hz, Digital Panel.............. 5.9
Vacuum Pump..................................... 2.3 460 Volt, 3 Phase, Digital Panel...........5.10
Checking Vacuum Pump Rotation......... 2.3 575 Volt, 3 Phase, Digital Panel........... 5.11
Gas Flush Connection......................... 2.3 Pneumatic Diagram............................ 5.12
Air-Assist Connection........................... 2.3 PARTS
Installation of Perforating Knives........... 2.4 Recommended Spare Parts....................6.1
Installation of Precut Knives.................. 2.4 Miscellaneous Machine Parts................ 6.2
OPERATION Lid, External........................................ 6.3
Placement of Product............................3.1 Lid, Internal......................................... 6.4
Operation with Analog Control Panel.... 3.2 Legs and Pump................................... 6.6
Operation with Digital Control Panel..... 3.3 Double Seam Seal Bar......................... 6.8
Operator Menu on Digital Panel........... 3.4 10mm Wide Seal Bar.......................... 6.9
Selecting a New Program..................... 3.6 Single Seam Seal Bar..........................6.10
Sealing with Air-Assist.......................... 3.7 Vacuum Manifold............................... 6.11
Gas Flush Option................................ 3.7 Main Electrical Components................6.12
Double Seam Seal Option................... 3.7 Base.................................................6.14
10mm Wide Seam Seal Option............ 3.7 Gas Flush..........................................6.16
Perforating Knife Option...................... 3.8 Swing Arm Assembly...........................6.18
Precut Option..................................... 3.8 Analog Control Panel........................ 6.20
Digital Control Panel......................... 6.22
MAINTENANCE
Inline Filter........................................ 6.23
Prior to Cleaning..................................4.1
Cleaning Recommendations..................4.1 REFERENCE MANUALS
Vacuum Pump Maintenance................. 4.2 R5 Series Vacuum Pumps...................... 7.1
Seal Bar Maintenance.......................... 4.2 INDEX............................................... 8.1
Reading the Indicators......................... 4.4 INDEX............................................... 8.2
Troubleshooting.................................. 4.5
Supervisor Menu on Digital Panel......... 4.7
Changing Vacuum Pump Oil and Filter.4.12
Replacing Potentiometer...................... 4.13

8 6 0 8 0 4 • A A
I N T R O D U C T I O N • P A G E I
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Ultravac® 2100
Vacuum Chamber Packaging Machine

Congratulations on your Ultravac® 2100 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 owner’s 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) 777-5624

For Technical Support, Call:

Phone (816) 753-2150 • Fax (816) 753-4976
Toll-Free (800) 777-5624

©Copyright 2012 UltraSource LLC

8 6 0 8 0 4 • A C
I N T R O D U C T I O N • P A G E II
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

General
This owner’s manual contains information pertinent to your Ultravac® 2100. 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® 2100 (check one):

208 Volt, 3 phase, 60 Hz

230 Volt, 3 phase, 60 Hz
230 Volt, Single phase, 60 Hz
380 Volt, 3 phase, 50 Hz
460 Volt, 3 phase, 60 Hz
575 Volt, 3 phase, 60 Hz

Pump horsepower size for your Ultravac® 2100 (check one):

5-horsepower
7.5-horsepower
10-horsepower
12-horsepower

Please fill in the serial numbers from the pump identification tags:

Serial No.

8 6 0 8 0 4 • A C
I N T R O D U C T I O N • P A G E III
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Specifications

H F
E
G

Figure 0.1

8-in. Model 12-in. Model

Length (A): 1638mm (64.5-in.) 64.5-in. (1638.3mm)
Width (B): 1067mm (42-in.) 1067mm (42-in.)
Maximum Height (C): 1194mm (47-in.) 1295mm (51-in.)
Working Height (D): 874mm (34.4-in.) 874mm (34.4-in.)
Chamber Width (E): 785mm (30.9-in.) 785mm (30.9-in.)
Chamber Length (F): 676mm (26.6-in.) 676mm (26.6-in.)
Chamber Depth (G): 203mm (8-in.) 305mm (12-in.)
Between Seal Bars (H): 813mm (32-in.) 813mm (32-in.)
Seal Bar Length: 673mm (26.5-in.) 673mm (26.5-in.)
200 m /h, (117 cfm) 5.6 kW (7½ hp) [8-in. Model Only]
3

Vacuum Pump: 306 m3/h, (180 cfm) 7.5 kW (10 hp)

360 m3/h, (212 cfm) 8.9 kW (12 hp)
Cycle Time: 15-25 seconds 15-25 seconds
Net Weight: 500kg (1104-lbs.) 559kg (1232-lbs.)
USDA Acceptable for use in
federally-inspected meat/poultry plants
Construction:
ETL-approved
Cast Aluminum

8 6 0 8 0 4 • A C
I N T R O D U C T I O N • P A G E IV
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

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 Ultravac 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 and locked out at risk of electric shock hazard.

DANGER Hot oil.

Hot oil poses scalding risk. Take necessary precautions while draining warm oil.

WARNING
Read and understand owner’s 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.
8 6 0 8 0 4 • A C
S A F E T Y • P A G E 1.1
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

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.

 Use a certified electrician to install permanent electrical connection for your packaging
machine. Failure to do so may result in death or serious injury and/or permanent
damage to the machine.

 Be sure to turn off power to your packaging machine before any maintenance work is
performed.

 Disconnect and lockout power to your packaging machine before any maintenance work
is performed.

 Place machine on a flat, stable surface.

 Do not place tools, parts, or other objects on or inside machine while operating.

8 6 0 8 0 4 • A C
S A F E T Y • P A G E 1.2
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Safety Decal Locations

Part # 861196 Qty. 1
(attached to power cord) Part # 860988 (Qty. 1)

Part # 860360 Qty. 1

(attached to power cord)

Part # 889599 (Qty. 1)

Factory Tested / Oil Filled

(Hanging Tag)

8 6 0 8 0 4 • A C
S A F E T Y • P A G E 1.3
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Machine Conformity
This machine has been manufactured to conform to the following safety standards:
UL 73, Motor Operated Appliances, USA
The Ultravac 2100 is manufactured to conform to the relevant provisions of ANSI/UL-73,
Tenth Edition dated 03/2011, Revised 01/2012.

CSA 22.2, No. 68, Motor Operated Appliances, Canada

The Ultravac 2100 is manufactured to conform to the relevant provisions of CSA C22.2 No.
68-09, Seventh Edition, Update #2 dated 09/2010.

CE Low Voltage Directive (LVD) 2006/95/EC

The Ultravac 2100 is manufactured to conform to the relevant provisions of
• EN 60335-1-2012 relating to “Safety of household and similar electrical appliances,”
• EN 60335-2-64:2000 relating to “Particular requirements for commercial electric kitchen
machines.”
and overall the provisions of Low Voltage Directive (LVD) 2006/95/EC relating to
“Equipment designed for use within certain voltage limits of 12 December 2006.”

CE Electromagnetic Compatibility (EMC) Directive 89/336/EEC

The Ultravac 2100 is manufactured to conform to the relevant provisions of
• EN 61000-6-4 relating to “Emissions, Radiated, 30Mhz - 1Ghz”
• EN 61000-6-2 relating to “Emissions, Conducted, 150kHz - 30Mhz”
• EN 61000-4-2 relating to “Immunity ESD ± 4kV Contact/ ±8kV air discharge “
• EN 61000-4-3 relating to “Immunity Radiated RF, 10V/m, 80Mhz - 2.7Ghz”
• EN 61000-4-4 relating to “Immunity EFT (Mains) ±1kV”
• EN 61000-4-5 relating to “Immunity Surge AC, ±2kV”
• EN 61000-4-6 relating to “Immunity Conducted RF (Mains), 10Vrms.”
and overall the provisions of “Electromagnetic Compatibility (EMC) Directive 89/336/EEC of
15 December 2004.”

USDA / AMI Sanitary Design Standards

The Ultravac 2100 is designed for sanitary conditions in USDA inspected facilities. All
UltraSource equipment is manufactured with respect to AMI Sanitary Design Standards. All
materials that are in food contact areas meet relevant USDA standards.

The Design and Technical Construction files for this machine are maintained at:

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

8 6 0 8 0 4 • A C
S A F E T Y • P A G E 1.4
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

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 a 7½ horsepower vacuum pump for the 200mm (8-in.) model
and a 10 horsepower vacuum pump for the 300mm (12-in.) model. The standard machine
is rated 220 volt, 60 Hertz, 3 phase and is supplied with a 30 amp, 250 volt, 3 phase plug.

The owner must supply the correct 3 phase or single phase power source in accordance
with the National Electric Code. The table below is based on the National Electric Code and
is to be used as a guide in wire size selection and short circuit protection. The requirements
noted in the table may change. Please consult an electrician prior to installation.

Pump Motor Full Load

Customer Voltage Amps
7.5 HP 10 HP 12 HP
Supply conductor shall
208, 60 Hz 3 Phase 21 26.5 32 have an ampacity not
230, 60 Hz 3 Phase 20.5 26 30 less than 125% of the
380, 50 Hz 3 Phase 12 14 15 Pump Motor Full Load
460, 60 Hz 3 Phase 10.5 13 15 Amps
575, 60 Hz 3 Phase 9 10.5 12.5
230, 60 Hz Single Phase - - -

Fused Disconnect
Inverse Time Circuit
Dual Element (Time
Customer Voltage Breaker
Delay)
7.5 HP 10 HP 12 HP 7.5 HP 10 HP 12 HP
208, 60 Hz 3 Phase 50 60 70 35 45 50
230, 60 Hz 3 Phase 50 60 60 35 45 50
380, 50 Hz 3 Phase 25 30 35 20 20 25
460, 60 Hz 3 Phase 25 30 35 15 20 25
575, 60 Hz 3 Phase 20 25 30 15 15 20
230, 60 Hz Single Phase - - - - - -

8 6 0 8 0 4 • A C
S T A R T U P • P A G E 2.1
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Grounding Instructions
The Ultravac® 2100 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. The unit is equipped with an equipment-grounding conductor cord and a grounding
plug. The plug must be plugged into an appropriate outlet that is properly installed and
grounded in accordance with all local codes and ordinances.

DANGER Hazardous voltage.

Improper connection of the equipment-grounding conductor can result in a risk of electric
shock.

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

stripes. If repair or replacement of the cord or plug is necessary, do not connect the
equipment-grounding conductor to a live terminal. Check with a qualified electrician
or Ultravac 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.

DANGER OXYGEN ENRICHED USE

ULTRASOURCE TRAY SEALING AND VACUUM CHAMBER MACHINES ARE NOT DESIGNED
FOR USE WITH OXYGEN ENRICHED PROCESS GASES. ANY APPLICATION THAT REQUIRES
A PROCESS GAS CONTAINING 25% OR MORE OXYGEN SHOULD CONTACT ULTRAVAC
SERVICES AT (800) 777-5624 AS RETROFIT OPTIONS ARE REQUIRED.

RUNNING THIS MACHINE WITH AN OXYGEN ENRICHED PROCESS GAS, WITHOUT THE
NECESSARY RETROFIT KIT COULD CAUSE SEVERE INJURY, DAMAGE OR DEATH.

ULTRASOURCE 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 MACHINE’S READINESS TO RUN OXYGEN ENRICHED
PROCESS GASES.

8 6 0 8 0 4 • A C
S T A R T U P • P A G E 2.2
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

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 below. Refer to page 4.12 for details on changing the oil.

NOTE: ALL ULTRAVAC 2100 CHAMBER MACHINES ARE SHIPPED WITH OIL IN THE PUMP.
ALTHOUGH THE FACTORY RECOMMENDS CHECKING THE OIL LEVEL PRIOR TO FIRST
USE!

Figure 2.1

MAX
MIN

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.

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 55 p.s.i.

Air-Assist Connection
The machine is equipped with a regulator for air-assisted sealing. The hose barb will
accept 1/4-in. I.D. hose. The recommended air supply is 75 p.s.i. at 6 c.f.m. The maximum
regulator setting is 40 p.s.i.

8 6 0 8 0 4 • A C
S T A R T U P • P A G E 2.3
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Installation of Perforating Knives

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

Remove standard seal bars. Install perforating bars with the cutting blade facing toward
the outside of the lid. The use of air-assist is required for proper operation. The air-assist
regulator should be set at 20 to 30 p.s.i.

As the backup strip wears, it can be removed and changed end for end for a better surface.
The strip may also be turned upside down when one side is worn.

Installation of Precut Knives

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

Remove standard seal bars. Install precut seal bars with the blade facing toward the outside
of the lid. The use of air-assist is required for proper operation. The air-assist regulator
should be set at 20 to 30 p.s.i.

As the backup strip wears, it can be removed and changed end for end for a better surface.
The strip may also be turned upside down when one side is worn.

Precut Knife
this side

Excess Pouch

Figure 2.2

8 6 0 8 0 4 • A C
S T A R T U P • P A G E 2.4
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

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
below on use of filler plates).
• 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.

Figure 3.1

Products containing liquid or loose particles can be packaged by slightly loosening the nuts
on each end of the machine and tilting the machine to the desired angle. Retighten the nuts
to secure the machine.

Figure 3.2

8 6 0 8 0 4 • A C
O P E R A T I O N • P A G E 3.1
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Operation with Analog Control Panel

The analog control panel is shown below in Figure 3.3. The range for timed vacuum is 0 to
45 seconds and is controlled by the Vacuum Potentiometer. An initial setting of 3 on the dial
is suggested. To use the gas flush option, turn the Gas Flush Switch to “ON.” The range for
timed gas flush is 0 to 30 seconds and is adjusted by the Gas Flush Potentiometer. An initial
setting of 3 on the potentiometer and an initial pressure regulator setting of 30 p.s.i. is
recommended. Increasing the gas flush time will allow more gas into the pouch. Increasing
the pressure (up to a maximum of 55 p.s.i.) will allow gas to enter the pouch at a faster rate
providing a shorter cycle time.

WARNING Explosion hazard.

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

Experiment with both settings to achieve the best results. 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. An initial setting of 4 is recommended 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.

GAS FLUSH
POWER LIGHT VACUUM POTENTIOMETER SEAL
(GREEN) POTENTIOMETER (OPTIONAL) POTENTIOMETER

VACUUM POWER GAS FLUSH SEAL LIGHT

INDICATOR SWITCH SWITCH (RED)
(OPTIONAL)

Figure 3.3

8 6 0 8 0 4 • A C
O P E R A T I O N • P A G E 3.2
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

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 3.4
8 6 0 8 0 4 • A C
O P E R A T I O N • P A G E 3.3
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Operator Menu on Digital Panel

NOTE: if the supervisor has set security on, these settings cannot be changed.

+
PROGRAM
YES
This is the Main Menu screen. When
the machine starts up, the last program
RUNNING PROG: 1 that was run will be the current program
shown in the window. To set the operating
- NO parameters for the program shown press
the MENU Key.

+
PROGRAM
YES VACUUM is set to % vacuum using the UP
and DOWN arrow keys. The range is 30%
to 99%.
VACUUM: 98
Press the MENU Key.
- NO

+ YES
VACPLUS may be set greater than zero
to allow the pump to continue evacuating
PROGRAM

the chamber (for the specified number

VACPLUS: 4.0 of seconds) after the pressure in the
chamber has reached the % vacuum set
- NO
in the vacuum menu. The range is 0 to 20
seconds.
Press the MENU Key.

+
PROGRAM
YES
The SEAL setting is in seconds.
Use the UP and DOWN arrow keys to
SEAL: 1.2 change the seal time. The range is 0 to 2
seconds.
- NO Press the MENU Key.

Figure 3.5

8 6 0 8 0 4 • A C
O P E R A T I O N • P A G E 3.4
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Operator Menu on Digital Panel (continued)

If the machine is equipped with the gas
+
PROGRAM
YES
option, it can be turned ON or OFF by
pressing the UP or DOWN arrow keys.
GAS: YES Press the MENU Key.

- NO

GAS is set to % gas using the UP and

+
PROGRAM
YES DOWN arrow keys. This value also
corresponds to the vacuum reading inside
the chamber. It is recommended to use
GAS: 65
Pulse Vent when gas flushing to a low %
vacuum. The range is 98% to 30%.
Press the MENU Key.
- NO

If the machine is equipped with the

YES
PROGRAM

PRECUT option, it can be turned ON or

PRECUT: YES OFF by pressing the UP or DOWN arrow
keys.
- NO Press the MENU Key.

Figure 3.5

WARNING Explosion hazard.

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

8 6 0 8 0 4 • A C
O P E R A T I O N • P A G E 3.5
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Selecting a New Program

From the Main Menu, use the UP and
+ YES
PROGRAM

DOWN arrow keys to select a new

RUNNING PROG: 1 program.

- NO

Press the UP arrow to switch to Program 2

(or any of the 10 programs).

+
PROGRAM
YES New parameters may be set for Vacuum,
Seal Time, and Gas for Program 2
(following the procedures described in the
ENTER PROGAM: 2
previous example) or simply close the lid
on the machine and run Program 2.
- NO

Figure 3.6

8 6 0 8 0 4 • A C
O P E R A T I O N • P A G E 3.6
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

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.
• Always use air-assist when using the Perforating Knife Option.
• Always use air-assist when using the Precut 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.

WARNING Explosion hazard.

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

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.

10mm Wide Seam Seal Option

All machines are equipped with standard seal bars having a single seal element per seal
bar. The 10mm Wide Seam seal bars have a wide seal element. It is recommended to use
air-assisted sealing with this option to achieve best results.

8 6 0 8 0 4 • A C
O P E R A T I O N • P A G E 3.7
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Perforating Knife Option

Perforating knives are used to facilitate the removal of excess pouch material. Perforating
knives are not intended to cut pouches off completely, only to perforate so that excess
material can be easily removed by hand.

Precut Option
The precut option is a patented system designed by UltraSource to increase the versatility
of the Ultravac® 2100. This option increases the speed in which this machine can be loaded
with product. The user simply places the pouch full of product into the machine and pulls
it close to the seal bar allowing the excess material to hang on the outside of the machine.
Not only does this increase the loading speed, but it also improves the appearance of the
final product. The precut option also allows the end user to stock fewer sizes of pouches
because excess pouch material is trimmed away.

When using this option, the bag or pouch containing product is placed inside the machine
as usual. However, rather than having to carefully tuck the bag inside the slot in the
machine before closing the lid, the open end of the bag is placed outside the machine by
simply draping the bag over the side of the machine. When the lid is closed, the seal bar is
brought down and the special precut blade cuts evacuation slits in the bag or pouch, which
allow the air inside the bag to escape during the normal evacuation process.

Start by making sure the Precut menu is set to the “ON” position. With precut, air-assisted
sealing is required. Place the bag containing product inside the chamber. Drape the open
end of the bag over the side of the machine and close the lid. When the evacuation process
is finished, the bag will have “slits” pierced in it by the precut knife. The slits allow the air to
be evacuated from the bag. The slits also facilitate the removal of excess bag material after
the completion of the cycle.

8 6 0 8 0 4 • A C
O P E R A T I O N • P A G E 3.8
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

MAINTENANCE
Prior to Cleaning
Every environment and application is different; therefore, UltraSource LLC cannot provide
cleaning instructions to guarantee microbiological sanitation. UltraSource 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.

DANGER Hazardous voltage.

Disconnect and lockout power before servicing machine or cleaning. Do not remove panels
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, Chamber, and Base: These components are made of aluminum. Clean the lid,
chamber, base, and silicone seal backup strip with a non-ionic cleaning solution such
as Crystal Simple Green.
3. Seal Bars: Remove the seal bars. The seal bars are made of phenolic. Clean, sanitize,
and dry. Also clean under the seal bar bladder in the lid, which is not removable.
4. Clean under the machine.
5. Reinstall the seal bars.
6. Use bacteriological testing to insure cleaning process.

WARNING Electrical Supply Cord.

The supply cord must be replaced by an Ultravac Services Service Technician or similarly
qualified person in order to avoid hazard.

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.1
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Vacuum Pump Maintenance

Consult the pump manufacturer’s 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.

Teflon® tape
Clamping
Seal
Screw
Element
Spring
Retainer

Figure 4.1
Brass
Contact
Tightening
Tool
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.

1/8-in.

Spring
Figure 4.3
Retainer
Set
Screw

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.2
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Seal Bar Maintenance (continued)

Step 4.
Insert the new seal element through the hole in the brass contact. Leave about 3/4-in.
of excess seal element extending past the brass contact and tighten the clamping screw.
Insert the other end of the element through brass contact on the opposite end of the seal
bar. Place a slotted tip screwdriver on top of the seal element and against the brass contact
where the seal element exits. Using the tightening tool provided (or needle nose pliers),
tighten the seal element as shown.

Step 5.
While maintaining tension on the tightening tool, use the slotted tip screwdriver to tighten
the clamping screw.

NOTE: A 1.5mm Allen wrench will be needed to tighten the clamping screws on a Double
Seam seal bar.

Figure 4.4

Step 6.
Check the tension of the seal element by pulling it up at the middle of the bar. The seal
element should not pull beyond 3/16-in. of the seal bar. If there is not enough tension,
tighten as necessary. Elements may break in the middle of the bar if tension is not set
properly. Install the new Teflon® tape strip over the bar.

3/16-in. maximum

Figure 4.5

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.3
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Reading the Indicators

All machines are controlled by an analog control module (with knobs) or a digital control
module (with touch pad) designed to aid in troubleshooting. The analog control module,
mounted behind the front control panel, has five red indicator lights (LEDs) mounted to it.
To view the indicator lights on the analog control module during operation remove the six
screws on the front of the control panel and pull the control panel out. 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 VALVE
Valve [SOL-1]
[SOL-1]
2.
2. GASFlush
Gas FLUSH
ValveVALVE
[SOL-2][SOL-2] (OPTIONAL)
(Optional)
3.
3. Seal
SEALBladder
BLADDER ValveVALVE
[SOL-3][SOL-3]
(Stays
(STAYSon ON
until completion of cycle)
UNTIL COMPLETION OF CYCLE)
4.
4. Seal Impulse Contractor
SEAL IMPULSE CONTACTOR [C-2][C-2]
5.
5. Ventilation
VANTILATION Valve [SOL-4]
VALVE [SOL-4]
The device should be operating when the LED is illuminated. If the LEDs illuminate in the
proper sequence, but there is still a problem, look for the problem in the operating device
itself. If the LEDs do not sequence properly, look for a problem in the related potentiometer
or the control module.

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.4
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

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-3; replace if blown.
Vacuum pump does not run Make sure that the power
requirements match those given
on the nameplate. Also, check the
overload OL-1; reset if necessary.
No vacuum When lid is closed, indicator Check lid switches LS-1 and LS-2
light (VAC) is “OFF” on the for proper adjustment
control module
Vacuum not pulling lid down Check intake screen in vacuum
on both sides 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
If indicator light (GAS) is not Check for proper operation of gas
lit flush valve (SOL-2)
Check gas flush potentiometer,
POT-2 or possible defective
control module
Gas flushes to one chamber Check gas flush selector valve
side only (V-1) for proper adjust
Chamber not venting Lid will not open and red Check ventilation valve SOL-4 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 POT-3 for possible defective
NOTE: Lid can be released by pulling the hose off of control module
the vacuum gauge to remove product.

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.5
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Troubleshooting
Problem Indications Remedy
Improper or no 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 come down clockwise, or, if air-assist is used,
set to the recommended pressure
Check seal bladder valve SOL-3
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 for front
light for the proper length seal bar and F-2 for rear seal bar*
of time (1/2 to 1 second) or Make sure the seal impulse
does not light at all potentiometer POT-3 is set high
enough or check for defective
control module
Front or rear seal bar Check seal bar fuse F-1 for front
heating, but not both seal bar and F-2 for rear seal bar*

* Fuses F-1 and F-2 only apply to machines shipped before 1/1/2006.

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.”

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.6
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Supervisor Menu on Digital Panel

Untrained personnel should not alter any setting in the supervisor menu.
This is the main menu screen. When
+
PROGRAM
YES
the machine starts up, the last program
that was run will be the current program
shown in the window.
RUNNING PROG: 1

- NO
Press and hold down both arrow keys for
at least 3 seconds to enter the supervisor
menu.
The following are parameters that can
only be set in the supervisor menu.
NOTE: If your machine is not installed
with the precut option, disregard the
PREVAC, CUTTIME, and WAITTIME
parameters.

PREVAC is the % vacuum that you wish to

reach before activating the knife, which
+ YES
makes slits in the bag for precut. Use the
up or down arrow keys to change the
PROGRAM

current setting.
PREVAC: 25 The range is from 5% to 20% vacuum.
Press the MENU key.
- NO

CUTTIME is the number of seconds that

the seal valve is activated. This is the
time when the knife actually makes the
evacuation slits in the bag/pouch for
precut. The range is from 0 to 3 seconds.
+

Press the MENU key.

YES
PROGRAM

CUTTIME: 1.5

- NO
WAITTIME is the number of seconds the
machine waits for the knife to retract
before resuming the vacuum cycle. The
range is from 0 to 6 seconds.
Press the MENU key.

Figure 4.6 + YES

PROGRAM

WAITTIME: 4
8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.7
- NO
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Supervisor Menu on Digital Panel

+
PROGRAM
YES
COOLDOWN is the time that the machine
waits after sealing the bag/pouch before
COOLDOWN: 4.0 the seal bars retract. This allows time for
- NO
the actual seal to cool down and take a set.
The range is from 1 to 8 seconds.
Press the MENU key.

+ YES
PROGRAM

SECURITY: NO
SECURITY can be turned on by selecting
- NO
yes. If security is on, the operator menu will
be read only and the operator will not be
able to change any settings.
Press the MENU key.
+ YES
PROGRAM

# PROGRAMS: 10

- NO

This is how you specify the maximum

number of programs that may be saved in
memory. Each program may have its own
set of unique parameters.
+
PROGRAM
YES
This range is from 1 to 10.
Press the MENU key.
TEST: YES

- NO

If TEST is set to YES (using the up arrow

key), the vacuum valve and vent valve may
be operated manually. The up arrow key
activates the vacuum valve, the down arrow
key activates the vent valve, and pressing
both at the same time turns them both off.
As you activate either valve, the vacuum
pressure is displayed.
Press the MENU key.
Figure 4.7

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.8
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Supervisor Menu on Digital Panel

+ YES
PULSE VENT allows for a more controlled
venting process. Rather than simply
PROGRAM

opening up the vent valve for a continuous

PULSE VENT: YES vent, the vent valve is opened and closed
repeatedly until the chamber vents back to
- NO
atmospheric pressure.
Press the MENU Key.

This is the % vacuum reached by pulsing

+ YES
PROGRAM

the vent valve before the vent valve opens

PULSE TO: 50 completely to fully vent the chamber.
The range is 90% to 30%.
- NO Press the MENU Key.

+ YES
PROGRAM

This is how long the vent valve is turned on

PULSE ON: 1.2 during the vent cycle.
The range is 0 to 3 seconds.
- NO
Press the MENU Key.

+ YES
PROGRAM

This is how long the vent valve is turned

off during the vent cycle.
PULSE OFF: 1.0 The range is 0 to 3 seconds.
Press the MENU Key.
- NO

Figure 4.8

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.9
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Supervisor Menu on Digital Panel

+ YES
PULSE VAC allows for a more controlled
vacuum process. Rather than simply
PROGRAM

opening up the vacuum valve for a

PULSE VAC YES
PULSE VENT: continuous vacuum, the vacuum valve is
opened and closed repeatedly until the
- NO
chamber reaches the desired vacuum.
Press the MENU Key.

+
PROGRAM
YES
This is the % vacuum reached by pulsing
the vac valve.
PULSE TO: 50 The range is 90% to 30%.
Press the MENU Key.
- NO

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

+ YES
This is how long the vacuum valve is
turned off during the vacuum cycle.
PROGRAM

The range is 0 to 3 seconds.

PULSE OFF: 1.0 Press the MENU Key.
- NO

Figure 4.9

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.10
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Supervisor Menu on Digital Panel

+ YES
If the machine is equipped with the LOOP
option, this is the number of vacuum/gas
PROGRAM

cycles the control will perform prior to the

LOOP #: 1 seal and vent.
The range is 1 to 5 cycles.
- NO
The default value is 1 cycle.
Press the MENU Key.

If the Loop # is set greater than 1, the

control can be set to exit this loop on either
+ YES
PROGRAM

the last gas cycle or the last vacuum cycle

EXIT GAS: YES prior to sealing.
The DOWN arrow key indicates NO.
- NO The UP arrow key indicates YES.
Press the MENU Key.

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
reached in 30 seconds, and the machine
VAC ERROR: ON with complete the cycle. If set ON and the
machine does not reach the preset vacuum
in 30 seconds, then the panels will display
- NO

VAC ERROR and vent the chamber without

sealing.
Figure 4.10

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.11
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Changing Vacuum Pump Oil and Filter

NOTE: The pump should have been running for at least 15 minutes to warm the pump oil.

1. Turn the power switch to the “OFF” position and disconnect the power.

DANGER Hot oil.

Hot oil poses scalding risk. Take necessary precautions while draining warm oil.

DANGER Hazardous voltage.

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

2. Position an oil collection pan underneath the Oil Drain Plug.

3. Loosen and remove the Oil Fill Plug with a 1¼-in. open end wrench.

4. Loosen the Oil Drain Plug located to the front and lower middle on the pump with a
1¼-in. open end wrench. Remove the plug slowly to control the flow of oil.

5. Replace auto-type oil filter with a filter wrench (strap wrench.) Coat face of gasket on
new filter with oil and hand tighten until gasket contacts base, then tighten two-thirds
turn more. DO NOT OVER TIGHTEN.

6. With the oil drained, replace the Oil Drain Plug and wipe any excess oil off of the pump.

7. Fill the pump with oil until the level is at the maximum lines on the Oil Sight Glass.
Replace the Oil Filler Cap.

8. Reconnect the power cord back into the wall receptacle.

9. Cycle the machine a couple of times, unplug, and check the Oil Level. Add oil to the
maximum line. DO NOT OVER FILL.

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.12
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

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 4.11

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 4.14, please create a
copy and store in the back of this owner’s 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 4.15, please create a copy and store in the back of this
owner’s manual.

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.13
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Maintenance Log
Date Maintenance Performed Technician

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.14
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Service Log
Date Service Provided Technician

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.15
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

THIS PAGE LEFT BLANK INTENTIONALLY.

8 6 0 8 0 4 • A C
M A I N T E N A N C E • P A G E 4.16
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

SCHEMATICS
Designation and Function of Controls
The following designations are found on the Electrical Diagrams:
Manually Activated Switches and Buttons: Potentiometers:
SW-1 On/off control power POT-1 Vacuum time
SW-3 On/off gas flush POT-2 Gas flush time
SW-4 Quick seal (Optional) POT-3 Sealing impulse and
cool down
Limit Switches:
LS-1 Left chamber cycle start Solenoid Valves:
LS-2 Right chamber cycle start SOL-1 Vacuum flush solenoid
SOL-2 Gas flush solenoid
Contactors: SOL-3 Seal bladder solenoid
C-1 Vacuum pump SOL-4 Ventilation solenoid
C-2 Seal impulse
C-3 Redundant seal impluse Mechanically Activated Switches
(Pneumatic Diagram only):
Overloads and Fusing: V-1 Gas selector valve
OL-1 Vacuum pump motor
F-3 Control power fuse

Control Modules:
MCM Master control module
R-1 Redundant seal impluse
contactor timer

Control Lights:
LT-1 On/off control power
light (green)
LT-2 Seal impulse on light
(red)

Transformers:
T-1 Seal impulse, front
T-2 Seal impulse, rear
T-3 Control power

Motors:
M-1 Vacuum pump

8 6 0 8 0 4 • A C
S C H E M A T I C S • P A G E 5.1
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

230 Volt, Single Phase, Analog Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.2
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

230 Volt, 3 Phase, Analog Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.3
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

380 Volt, 50 Hz, Analog Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.4
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

460 Volt, 3 Phase, Analog Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.5
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

575 Volt, 3 Phase, Analog Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.6
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

230 Volt, Single Phase, Digital Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.7
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

230 Volt, 3 Phase, Digital Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.8
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

230 Volt, 3 Phase, Digital Panel [ES0109]

(Serial Number Range: 5086-5105)

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.9
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

380 Volt, 50 Hz, Digital Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.10
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

380 Volt, 50 Hz, W/O Neutral Digital Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.11
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

460 Volt, 3 Phase, Digital Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.12
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

575 Volt, 3 Phase, Digital Panel

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.13
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Pneumatic Diagram

8 6 0 8 0 4 • A B
S C H E M A T I C S • P A G E 5.14
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

PARTS
Recommended Spare Parts
UltraSource
Qty. Description
Part No.
1 ea 861001 Seal Bar Assembly
10 ft 880431 Back Up Strip
4 ea 880443 Back Up Strip Textured
12 ft 880432 Lid Gasket
1 ea 880746 Seal Element
3 ft 885507 Teflon® Tape
1 ea 860908 DIN Coil
1 ea 860906 Vacuum Valve Diaphragm
1 ea 860907 Vent Valve Diaphragm
2 gal Specify pump Vacuum Pump Oil
1 ea Specify pump Vacuum Pump Oil Filter
1 ea 861002 Bladder Assembly
Select your machine’s configuration:
1 ea 860250 Double Seam Seal Bar Contact Kit
1 ea 863016 10mm Wide Seal Bar Contact Kit
1 ea 861013 Single Seam Seal Bar 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) 777-5624

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.1
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Miscellaneous Machine Parts

Parts List and Diagram
Item
Description
No.
1 860402 Filler Plate Set (two sets per machine)
2 860899 Plug, Black Nylon (standard on machines without gas flush)
3 880431 Chamber Gasket (10-ft. required)
Chamber Gasket, Grey (10-ft. required)
860950
(for precut and perforating knife options)
880443 Chamber Gasket - 4 pcs. - Textured
4 860844 Cover Panel with Latches
5 860409 Latch
861228 Coiled Lanyard (between chassis and cover)

4
5
8 6 0 8 0 4 • A C
P A R T S • P A G E 6.2
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Lid, External
Parts List
Item
Description
No.
861076 Lid Assembly, 8-in.
861077 Lid Assembly, 12-in.
1 880432 Lid Gasket (12-ft. required)
2 860954 Hose, 1/4-in. Reinforced (35-in. required)
3 860110 Hose Clamp for 1/4-in. Reinforced Hose
4 860109 Brass Hose Barb
5 863031 Wire Harness, Complete
6 861130 Cord Grip
7 860113 Lid Handle
8 860269 Nut, M10 Nylon Lock
NOTE:
• For Internal Lid Parts see pages 6.4-6.5
• For Seal Bar Parts see pages 6.8-6.10

8
6
5 4
3
2

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.3
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Lid, Internal
Parts List
Item UltraSource
Description
No. Part No.
1 863017 Double Seam Seal Bar Complete (refer to page 6.8)
903032 Double Seam Seal Bar with Knife (one complete assembly)
861071 10mm Wide Seal Bar Complete (refer to page 6.9)
903032-10 10mm Wide Seal Bar with Knife (one complete assembly)
861001 Single Seam Seal Bar Complete (refer to page 6.11)
860001 Single Seam Seal Bar with Knife (one complete assembly)
2 860102 Seal Bar Support
3 860226 Seal Bar Support Washer
4 860273 Screw, M5x25 Slotted Flat Head
5 860261 Nut, 5mm Nylon Lock
6 860258 Screw, M5x8 SHCS
7 860257 Screw, M5x20 Slotted Pan Head
8 860005 Electrical Contact
9 866832 Screw, M5x35 SHCS
10 860260 Washer, 5mm Lock
11 866764 Nut, 5mm Hex
12 860954 1/4-in. Hose (specify length)
13 860107 1/4-in. Hose “T”
14 860110 Hose Clamp
15 860307 Bladder Return Spring
16 860030 Bladder Backup Plate
17 861002 Bladder Assembly
18 861232 Swing Arm
19 860202 Swing Arm Tie Block

Kit to add on knife blade (903055) includes:

20 860018 Knife Only
21 860991 Shim
Screw, M5x20 Slotted Pan Head
Seal Bar Support Washer
Nut, 5mm Hex
Screw, M5x25 Slotted Flat Head
Nut, 5mm Nylon Lock

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.4
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Lid, Internal
Diagram
17

16
19
18

10

6
12
15 13
5

11
14
10
9
8

21 4

3 6

20 1

WITH PERFORATION KNIFE

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.5
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Legs and Pump

Parts List
Item UltraSource
Description
No. Part No.
1 860705 Leg
2 860767 Pump Plate Brace
3 900038 Pump, 5-hp for 230V, 3-phase
900039 Pump, 5-hp for 230V, Single-phase
900165 Pump, 7-½-hp for 230/380/460V, 3-phase
900166 Pump, 7-½-hp for 575V, 3-phase
900253 Pump, 10-hp for 200V, 3-phase
900255 Pump, 10-hp for 230/380/460V, 3-phase
900257 Pump, 10-hp for 575V, 3-phase
900305-200 Pump, 12-hp for 200V, 3-phase
900305-230 Pump, 12-hp for 230/380/460V, 3-phase
900305-575 Pump, 12-hp for 575V, 3-phase
4 860613 Hose Barb, 2-in.
5 860759 Pump Mounting Plate
6 810109 Bolt, M10x25 Hex Head
7 860268 Washer, 10mm Flat
8 860269 Nut, 10mm Lock
9 861164 Bolt, 3/4-10 Thread x 3-3/4-in., Hex Head
10 860733 Nut, 3/4-in. Jam
11 860730 Leg Spacer
12 860732 Washer, 3/4-in. Flat
13 860714 Nut, 3/4-in. Acorn
14 860736 Washer, 3/4-in. Lock
15 863080 Kit, Support Pads with M10x35 SHCS
16 903010 Kit, Caster (optional)

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.6
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Legs and Pump

Diagram

4
3

9
10
11
6
12

13
7
2
1
5

9 14

12

13
15
16

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.7
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Double Seam Seal Bar

Parts List and Diagram
Item
Description
No.
863017 Double Seam Seal Bar Complete
1 880746 Seal Element
2 885507 Teflon® Tape, (3-ft. required per seal bar) (not shown)
3 860250 Double Seam Seal Contact Kit
Kit (860250) includes:
Element Spring
Element Clip
Double Seam Contact
Screw, M3x12 Slotted Flat Head
Set screw, M4x6 Socket

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.8
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

10mm Wide Seal Bar

Parts List and Diagram
Item
Description
No.
861071 10mm Wide Seal Bar Complete
1 860512 Seal Element
2 885507 Teflon® Tape, (3-ft. required per seal bar) (not shown)
3 860174 Screw, M4x12 Slotted Flat Head
4 860251 Screw, M5x10 Slotted Flat Head
5 863016 10mm Wide Seal Contact Kit
Kit (863016) includes:
Element Spring
Element Clip
10mm Wide Seam Contact
Set Screw, M5x6 Socket Head
Screw, M3x6 Slotted Flat Head

4
3
5

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.9
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Single Seam Seal Bar

Parts List and Diagram
Item
Description
No.
861001 Single Seam Seal Bar Complete
1 880746 Seal Element
2 885507 Teflon® Tape, (3-ft. required per seal bar) (not shown)
3 861013 Single Seam Seal Contact Kit
Kit (861013) includes:
Element Spring
Element Clip
Single Seam Contact
Screw, M3x5 Slotted Panhead
Set Screw, M3x5 Socket

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.10
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Vacuum Manifold
Parts List and Diagram
Item
Description
No.
1 861152 Manifold Assembly
Assembly (861152) includes:
Valve Manifold Plate
Valve, Mebner Vacuum and Vent
Fitting, 2-in. Close Nipple
Fitting, 2-in. Hose Barb
NOTE: New manifold o-ring (860603) recommended.

2 860618 Hose Clamp, 2-in.

3 860617 Vacuum Hose (to vacuum pump), (5-ft. required)
4 860603 Manifold O-Ring
5 860954 Braided Hose, 1/4-in.
6 861020 Electrical Switch Cable
7 860908 DIN Coil, [SOL-1] [SOL-4]
8 860906 Replacement Vacuum Valve Diaphragm (not shown)
9 860907 Replacement Vent Valve Diaphragm (not shown)

NOTE: Epoxy is applied to fittings at 3

valve inlets for vacuum integrity.

2
6

1 7

6 5
4

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.11
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Main Electrical Components

Parts List
Item
Description
No.
1 860311 Transformer, Control, 50VA, 460, 230/115 VAC
860394 Transformer, Control, 50VA, 208/115 VAC
2 860255 Screw, M5x6 Slotted Pan Head
3 860312 Transformer, Seal, 300KVA, 460, 230, 208/115 VAC
Transformer, Seal, 600VA, 460/230, 48 VAC Sec. (double seam
860059
option)
4 860703 Relay, Interval 4 sec. for Sealing
5 860793 Contactor, Sealing
6 860341 Terminal, End Cap
7 861179 Contactor, Pump, 32A, 600V, 110 Volt Coil
8 860339 Fuse Holder, Control
860337 Fuse, 1A (not shown)
9 860340 Terminal Block
10 860342 Terminal, Ground Block
11 See Overload Table below

Pump Overload Pump Overload

Voltage Voltage
Size Part No. Size Part No.
208V 860797 208V
860796
230V/1PH 860796 230V
5 HP 230V/3PH 861214 10 HP 380V 860797
380V 860798 460V
861214
460V 861215 575V

208V 208V
860795 860796
230V 230V
7 ½ HP 380V 12 HP 380V
460V 861214 460V 860797
575V 575V

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.12
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Main Electrical Components

Diagram

6
10
5
8 9

1
7 2
4
11 5

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.13
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Base
Parts List
Item UltraSource
Description
No. Part No.
1 863012 Wire Harness, Complete
2 860954 1/4-in. Reinforced Hose (34-in. required)
3 861018 Cycle Switch Assembly Complete with Harness
860309 Cycle Switch [LS-1] [LS-2]
4 861020 Harness for Valve, Complete with DIN Plug
5 861023 Valve Assembly, Seal Pilot with Fittings [SOL-3]
Valve Assembly (861023) includes:
Valve, 3-Way, NC, 1/4 NPT Ports, 120 Volt
Hose Barb, 1/4-in. - 1/4-in. Elbow
Hose Barb, 1/4-in. - 1/8-in. Elbow

6 860404 Brass Fitting

7 860775 Air Pressure Regulator and Gauge Assembly
8 860514 Hose Barb, 1/4-in. - 1/4-in. Elbow
9 861178 Electrical Compression Fitting, 230/460 Volt
861131 Electrical Compression Fitting, 380 Volt
Pump Harness, 208/230/460V, 5- and 7-½-hp
10 861045
Pump Harness, 460V, 10- and 12-hp
861046 Pump Harness, 380V, 5-, 7-½-, 10-, and 12-hp
861288 Pump Harness, 380V w/o Neutral (Special Option)
861176 Pump Harness, 208/230V, 10- and 12-hp
11 861035 Power Harness, 208/230V, 5- and 7-½-hp
861036 Power Harness, 380V, 5-, 7-½-, 10-, and 12-hp
861287 Power Harness, 380V w/o Neutral (Special Option)
861037 Power Harness, 460V, 5-, 7-½-, 10-, and 12-hp
861177 Power Harness, 208/230V, 10- and 12-hp Pump

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.14
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Base
Diagram

10
3
8
9 11
6
7
5
9

1 3
2

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.15
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Gas Flush
Parts List
Item
Description
No.
1 860352 Electrical Switch Cable
2 861024 Valve Assembly, Gas Pilot with Fitting
Valve Assembly (861024) includes:
Two-way Pilot Valve for Gas [SOL-2]
Hose Barb, 1/4-in. - 1/4-in. Elbow

3 860404 Brass Fitting

4 860513 Gas Inlet Barb, 1/4-in.
5 860514 Hose Barb, 1/4-in. - 1/4-in. Elbow
6 861025 Valve Assembly, Gas Switching with Plate
Valve Assembly (861025) includes:
Gas Flush Selector Valve [V-1] (Serial #2090-Current)
Hose Barb, 1/4-in. - 1/4-in. Elbow
Valve Plate
Nut, 6mm Nylon Lock
Screw, M6x40 SHCS

861010 Assembly, Gas Flush Hose [Items 7, 8, 9]

NOTE: Shown is 1/2 of the gas flush hose assembly (861010). One assembly required per
chamber side.
7 860954 Reinforced Hose, 1/4-in. (specify length)
8 860107 Hose Barb, ‘T’, 1/4-in.
9 860507 Gas Nozzle
10 863024 Bag Holder with Foam Padding (in machine lid)
860203 Replacement Foam Padding Only

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.16
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Gas Flush
Diagram

10

8 6

7 4
5
5 3

2
1

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.17
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Swing Arm Assembly

Parts List
Item
Description
No.
861158 Lid Lever Shaft and Cam with Dowel Assembly [Items 1, 2, 3, 4]
1 861155 Lid Lever Shaft
2 860403 Connecting Shaft
3 861156 Dowel, M10x25mm long, Stainless Steel (Serial #4606 - Current)
4 861157 Cam Lever Complete Assembly
Assembly (861157) includes:
Cam Lever
Cam Bushing
Screw, M8x30 Socket Head

5 866766 Nut, M8
6 860424 Spring Retainer
7 866742 Screw, M10x35 Socket Head
8 860244 Lid Spring
9 861008 Bearing Hub Assembly
Assembly (861008) includes:
Bearing Retainer
Shaft Bearing
Bearing Hub

10 866739 Screw, M8x25 Socket Head

11 860114 Lid Lever
860111 Lid Lever for Utilities Clamp (backside of machine)
12 860749 Utilities Clamp
13 860754 Button, Cable Clamp
14 866729 Screw, M5x20 Socket Head
15 860414 Bushing Spacer
16 860401 Lid Lever Bushing

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.18
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Swing Arm Assembly

Diagram

1
15
16

13

5
12
3 6
14 4 8
9
7 10
11 7

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.19
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Analog Control Panel

Parts List
Item UltraSource
Description
No. Part No.
861056Complete Front Panel without Gas Flush (not shown)
861057Complete Front Panel with Gas Flush
1 860610Standard Vacuum Gauge
2 860319Green Lens and Switch Body Assembly
3 860316Switch, Main Power On/Off [SW-1] or Selector Lever
4 860320Red Seal Light Lens
5 860302Blue Cap for Potentiometer Knob
860315Potentiometer Knob Only
6 860303Yellow Cap for Potentiometer Knob (optional with gas flush)
860315Potentiometer Knob Only
7 860301Red Cap for Potentiometer Knob
860315Potentiometer Knob Only
Potentiometer for Vacuum [POT-1] and Gas [POT-2]
8 860313
(optional with gas flush)
860450 Vacuum Potentiometer [POT-1] for Special Produce Product
9 860314 Sealing Potentiometer [POT-3], Standard for Extended Seal Time
10 861327 Main Control Module Assembly
Assembly (861327) includes:
11 860328 Connector, 4-pin
12 860329 Connector, 5-pin
13 860330 Connector, 8-pin
14 860331 Connector, 9-pin
15 860332 Connector Retainer
16 860327 Main Control Module, Analog [MCM]
NOTE: Hardware (items 17, 18, and 19) are not included in assembly (861327).

17 866772 Washer, 4mm Flat

18 866714 Screw, M4x10 Slotted Panhead
19 860231 Main Control Module Standoff, 1-in.
20 860322 Bulb, 120 Volt (not shown)
21 866728 Screw, M5x16 SHCS, SS
22 866773 Washer, M5 Flat

NOTE: Torque specification for 866728 (item 21) is 20 inch-pound.

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.20
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Analog Control Panel

Diagram

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.21
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Digital Control Panel

Parts List and Diagram
Item UltraSource
Description
No. Part No.
1 860995 Front Panel Assembly
2 860673 Vacuum Sensor
3 860316 Main Power On/Off Switch [SW-1]
4 860683 Fitting 1/4 x 1/8 Reducer
5 866728 Screw, M5x16 SHCS, SS
6 866773 Washer, M5 Flat

NOTE: Torque specification for 866728 (item 5) is 20 inch-pound.

5 6

1
3

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.22
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Inline Filter
Parts List and Diagram
Item UltraSource
Description
No. Part No.
861153 Inline Filter Complete
1 835427 Tube, Inlet Filter
2 884250 Filter Screen
3 835429 Gasket, Inlet Filter
Hardware included in complete assembly (861153):
Screw, M8x120 Hex Head
Nut, 8mm Hex
Nut, 8mm Wing

NOTE: Epoxy is applied to fittings at filter and pump inlets for vacuum integrity.

Filter Inlet

Dir
e
of ctio
Flo n
w 3
Pump Inlet

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.23
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

THIS PAGE LEFT BLANK INTENTIONALLY.

8 6 0 8 0 4 • A C
P A R T S • P A G E 6.24
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

REFERENCE MANUALS
R5 Series Vacuum Pumps
Included within Ultravac® 2100 owner’s manual is an installation and operating manual for
the vacuum pump equipped with this vacuum chamber machine.

Refer to page 6.1 of the Ultravac® 2100 owner’s manual for oil and replacement filter part
numbers for this machine.

For Replacement Parts, Call:

Phone (816) 753-2150 • Fax (816) 561-2854
Toll-Free (800) 777-5624

8 6 0 8 0 4 • A C
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 manufacturer’s 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 customer’s 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 41°F, 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 90°F) 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. 3°F to 5°F 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 210°F 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. 210°F, 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
4.1.3 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.
4.1.5 Possible Cause
4.1.10 Possible Cause
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.
4.2.2 Possible Cause
4.1.12 Possible Cause
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 (41°F).
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.
4.3.2 Possible Cause
4.2 Trouble
Pump runs in the wrong direction.
Pump will not start.
Remedy:
4.2.1 Possible Cause
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.
4.3.5 Possible Cause
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.
4.5.1 Possible Cause
Remedy:
Coupling insert worn.
Change automotive oil filter.
Remedy:
4.6.3 Possible Cause
Replace coupling insert in motor/pump cou-
pling. Not enough oil in oil reservoir or badly burned
oil is used for pump lubrication.
4.5.2 Possible Cause
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.
4.5.3 Possible Cause
4.7 Trouble
Vanes stuck.
Pump is seized.
Remedy:
4.7.1 Possible Cause
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.
4.7.3 Possible Cause

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.

4.8.1 Possible Cause

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 80°F 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
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

THIS PAGE LEFT BLANK INTENTIONALLY.

8 6 0 8 0 4 • A C
R E F E R E N C E M A N U A L S • P A G E 7.27
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Index
Symbols G P
Gas 3.5 Perforating Knife 1.1, 2.4, 3.8
10mm Wide Seal Bar 3.7, 6.9
Gas Flush 1.2, 2.3, 3.3, 3.7, 4.4, Personal Safety 1.1
A 5.1, 6.14 Placement of Product 3.1
Gasket 6.7 Potentiometer 4.13
Air-Assist 2.4, 3.7 Gas selector valve 5.1 Power Requirements 2.1
Analog Control Panel 3.2, 6.20 Grounding Instructions 2.2 Precut Knife 1.1, 2.4
Auto Stop 3.3 Precut Option 3.5, 3.8
H PREVAC 4.7
B Prior to Cleaning 4.1
Hazardous voltage 1.1, 2.2, 4.1,
Back Up Strip 6.1 4.12 Proper Sealing 4.6
Base 4.1, 6.12 Hot oil 1.1, 4.12 Pulse Vent 4.9
Blade hazard 1.1 Pump 6.2
I Pump Motor Full Load Amps 2.1
C
Improper or no sealing 4.6 Q
Caution 1.1 Inverse Time Circuit Breaker 2.1
Chamber 4.1 Quick seal 5.1
Chamber not venting 4.5 L
Changing Vacuum Pump Oil and
R
Left chamber cycle start 5.1
Filter 4.12 Reading the Indicators 4.4
Legs 6.2
Circuit Breaker 2.1 Redundant seal impluse 5.1
Lid 4.1, 6.4, 6.6
Cleaning agents 1.1, 4.1 Replacing Potentiometer 4.13
Liquid 3.1
Cleaning Recommendations 4.1
Loop Option 3.3, 4.11 S
Control power 5.1
Loose Particles 3.1
Cooldown 4.8, 5.1
Safety Guidelines 1.2
CUTTIME 4.7 M Seal Bar 4.2, 6.1
Cycle Time IV
Machine will not start 4.5 Seal Bar Length IV
D Main Menu 3.4 Seal Bar Maintenance 4.2
Maintenance Log 4.13, 4.14 Seal Bars 4.1
Danger 1.1 Seal bladder solenoid 5.1
Master control module 5.1
Designation and Function of Seal Bladder Valve 4.4
Controls 5.1 N Seal Impulse 4.4, 5.1
Digital Control Panel 3.3 Security 4.8
Double Seam Seal Bar 3.7, 6.8 Net Weight IV Service Log 4.13, 4.15
No gas flush 4.5 Spare Parts 6.1
E No vacuum 4.5 Startup 2.3
Electrical Components 6.10 Supervisor Menu 4.7
O Swing Arm Assembly 6.18
Explosion hazard 1.1, 3.2, 3.5,
3.7 On/off control power 5.1
T
F Teflon® Tape 4.2, 4.13, 6.1
Filler Plates 4.1 Tension 4.3
Food Safety 1.2 Time Delay 2.1
Function of Controls 5.1
Fused Disconnect Dual Element
U
2.1 Unpacking 2.1

8 6 0 8 0 4 • A C
I N D E X • P A G E 8.1
 MAIN: 816-753-2150
TOLL FREE: 800-777-5624
WEB SITE: UltraSourceUSA.com
E-MAIL: info@UltraSourceUSA.com

Index
V
VAC ERROR 4.11
VACPLUS 3.3, 3.4
Vacuum 3.4
Vacuum Manifold 6.16
Vacuum Pump IV, 2.3, 4.12, 5.1
Vacuum Pump Maintenance 4.2
Vacuum Pump Motor 5.1
Vacuum Pump Rotation 2.3
Vacuum Time 5.1
Vacuum Valve 4.4
Ventilation Valve 4.4
Voltage, Hazardous 4.12

W
WAITTIME 4.7
Warning 1.1

8 6 0 8 0 4 • A C
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@UltraSourceUSA.com • UltraSourceUSA.com

Replacement Parts
Toll-Free (800) 777-5624
Fax (816) 561-2854

Technical Support
Toll-Free (800) 777-5624
Fax (816) 753-4976