BUSCH Panda WV 4500 B User manual

Instruction Manual
Panda
Vacuum Booster
WV 4500 B
0870559397/A0001_en / Original instructions / Modifications reserved 17/10/2017
Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland
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Table of Contents
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Table of Contents
1 Safety........................................................................................................................... 3
2 Product Description ..................................................................................................... 4
2.1 Operating Principle............................................................................................... 5
2.2 Application ........................................................................................................... 5
3 Transport ..................................................................................................................... 5
4 Storage......................................................................................................................... 6
5 Installation................................................................................................................... 7
5.1 Installation Conditions ..........................................................................................7
5.2 Connecting Lines / Pipes ......................................................................................7
5.2.1 Suction Connection....................................................................................7
5.2.2 Discharge Connection................................................................................8
5.3 Filling Oil..............................................................................................................8
5.4 Electrical Connection ............................................................................................10
5.4.1 Wiring Diagram Three-Phase Motor ..........................................................10
6 Commissioning............................................................................................................ 11
6.1 Process Chamber Flushing .................................................................................... 12
7 Maintenance................................................................................................................ 13
7.1 Maintenance Schedule.......................................................................................... 14
7.2 Oil Level Inspection .............................................................................................. 14
7.3 Oil Colour Inspection............................................................................................ 14
7.4 Oil Change...........................................................................................................15
8 Overhaul...................................................................................................................... 17
9 Decommissioning ........................................................................................................ 18
9.1 Dismantling and Disposal...................................................................................... 18
10 Spare Parts................................................................................................................... 18
11 Troubleshooting........................................................................................................... 19
12 Technical Data ............................................................................................................. 21
13 Oil ............................................................................................................................... 21
14 EU Declaration of Conformity ...................................................................................... 22
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Safety | 1
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1 Safety
Prior to handling the machine, this instruction manual should be read and understood. If
anything needs to be clarified, please contact your Busch representative.
Read this manual carefully before use and keep for future reference.
This instruction manual remains valid as long as the customer does not change anything
on the product.
The machine is intended for industrial use. It must be handled only by technically trained
personnel.
Always wear appropriate personal protective equipment in accordance with the local
regulations.
The machine has been designed and manufactured according to state-of-the-art meth-
ods. Nevertheless, residual risks may remain. This instruction manual highlights potential
hazards where appropriate. Safety notes and warning messages are tagged with one of
the keywords DANGER, WARNING, CAUTION, NOTICE and NOTE as follows:
DANGER
... indicates an imminent dangerous situation that will result in death or serious injuries if
not prevented.
WARNING
... indicates a potentially dangerous situation that could result in death or serious injuries.
CAUTION
... indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
... indicates a potentially dangerous situation that could result in damage to property.
NOTE
... indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.
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2 | Product Description
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2 Product Description
BPV IN
OSGODP
OFP
NP
ODP MTBOSGMP
BGC
BGC BGC
BGC MP
OUT OFP
EBEB
IN Suction connection MTB Motor terminal box
OUT Discharge connection OFP Oil fill plug
MP Magnetic plug OSG Oil sight glass
NP Nameplate ODP Oil drain plug
BPV Bypass valve BGC Barrier gas connection
EB Eyebolt
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
booster’.
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Transport | 3
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2.1 Operating Principle
The machine works on the Roots blower principle.
The two oil housings (on each side) allow the lubrication of the gears, bearings and the
oil lubricated mechanical seal.
A bypass valve (BPV) limits automatically the differential pressure between inlet and out-
let.
2.2 Application
The machine is intended for the suction of air and other dry, non-aggressive, non-toxic
and non-explosive gases.
Conveying of other media leads to an increased thermal and/or mechanical load on the
machine and is permissible only after a consultation with Busch.
The machine is intended for the placement in a non-potentially explosive environment.
The vacuum booster is used in combination with a backing pump in vacuum system.
Permitted environmental conditions see Technical Data [►21].
NOTICE
Chemical compatibility of the process gases with the machine component materials.
Risk of corrosion inside the compression chamber which can reduce performance and
its lifetime!
• Check if the process gases are compatible with those following materials:
- Cast iron
- Steel
- Aluminium
- Fluoroelastomer (FKM/FPM)
• In doubt, please contact your Busch representative.
3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
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4 | Storage
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WARNING
Lifting the machine using the motor eye bolt.
Risk of severe injury!
• Do not lift the machine using the eye bolt fitted to the motor. Only lift the machine as
previously shown.
NOTICE
In case the machine is already filled with oil.
Tilting a machine that is already filled with oil can cause large quantities of oil to in-
gress into the cylinder.
• Drain the oil prior to every transport or always horizontally transport the machine.
• Make sure that the eyebolt (EB) is in faultless condition, fully screwed in and tightened
by hand.
Machine weight:
see the technical data or the nameplate (NP)
• Check the machine for transport damage.
If the machine is secured to a base plate:
• Remove the machine from the base plate.
4 Storage
• Seal all apertures with adhesive tape or reuse provided caps.
If the machine is to be stored for more than 3 months:
• Wrap the machine in a corrosion inhibiting film.
• Store the machine indoors, dry, dust free and if possible in original packaging
preferably at temperatures between -20 ... 55 °C.
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Installation | 5
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5 Installation
5.1 Installation Conditions
• Make sure that the environment of the machine is not potentially explosive.
• Make sure that the ambient conditions comply with the Technical Data [►21].
• Make sure to use a suitable backing pump, if necessary seek advice from your Busch
representative
• Make sure that the environmental conditions comply with the protection class of the
motor.
• Make sure that the installation space or location is vented such that sufficient cooling
of the machine is provided.
• Make sure that cooling air inlets and outlets are not covered or obstructed and that
the cooling air flow is not affected adversely in any other way.
• Make sure that the oil sight glass (OSG) remains easily visible.
• Make sure that enough space remains for maintenance work.
• Make sure that the machine is placed or mounted horizontally, a maximum of 1° in
any direction.
• Make sure that the machine is secured either from the four feet or from the discharge
flange.
• Check the oil level, see Oil Level Inspection [►14].
• Make sure that all provided covers, guards, hoods, etc. are mounted.
If the machine is installed at an altitude greater than 1000 meters above sea level:
• Contact your Busch representative, the motor should be derated or the ambient
temperature limited.
5.2 Connecting Lines / Pipes
• Remove all protective caps before installation.
• Make sure that the connection lines cause no stress on the machine‘s connection; if
necessary use flexible joints.
• Make sure that the line size of the connection lines over the entire length is at least as
large as the connections of the machine.
In case of very long connection lines it is advisable to use larger line sizes in order to
avoid a loss of efficiency. Seek advice from your Busch representative.
5.2.1 Suction Connection
WARNING
Unprotected suction connection.
Risk of severe injury!
• Do not put hand or fingers in the suction connection.
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5 | Installation
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NOTICE
Intruding foreign objects or liquids.
Risk of damage to the machine!
If the inlet gas contains dust or other foreign solid particles:
• Install a suitable filter (5micron or less) upstream from the machine.
Connection size:
– DN250 ISO
Depending on the specific order, other connection dimensions may apply.
5.2.2 Discharge Connection
Connection size:
– DN160 ISO
Depending on the specific order, other connection dimensions may apply.
• Make sure that the discharged gas will flow without obstruction. Do not shut off or
throttle the discharge line or use it as a pressurised air source.
5.3 Filling Oil
NOTICE
Use of an inappropriate oil.
Risk of premature failure!
Loss of efficiency!
• Only use an oil type which has previously been approved and recommended by
Busch.
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Installation | 5
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For oil type and oil capacity see Technical Data [►21] and Oil [►21].
21
4
3
MAX
MIN
Busch Oil
Check oil level
Oil filling at the motor side
1
Busch Oil
4
Busch Oil
Busch Oil
2
3
MAX
MIN
Check oil level
Oil filling at the gear side
When the oil filling is achieved:
• Write down the oil change date on the sticker.
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5 | Installation
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Last oil change
__ / __ / ____
Oil type see nameplate
Change interval see
instruction manual
If there is no sticker on the pump:
• Order it from your Busch representative.
5.4 Electrical Connection
DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
• Make sure that the power supply for the motor is compatible with the data on the
nameplate of the motor.
• Provide overload protection according to EN 60204-1 for the motor.
• Make sure that the motor of the machine will not be affected by electric or electro-
magnetic disturbance from the mains; if necessary seek advice from Busch.
• Connect the protective earth conductor.
• Electrically connect the motor.
NOTICE
Incorrect connection.
Risk of damage to the motor!
• The wiring diagrams given below are typical. Check the inside of the terminal box for
motor connection instructions/diagrams.
5.4.1 Wiring Diagram Three-Phase Motor
Delta connection (low voltage): Star connection (high voltage):
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Commissioning | 6
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Double star connection, multi-voltage
motor with 12 pins (low voltage):
4
4
4
Star connection, multi-voltage motor
with 12 pins (high voltage):
4
4
4
Delta connection, multi-voltage motor
with 12 pins (middle voltage):
4
4
4
NOTICE
Incorrect direction of rotation.
Risk of damage to the machine!
• Operation in the wrong direction of rotation can destroy the machine in a short time!
Prior to start-up, ensure that the machine is operated in the right direction.
The intended rotation direction of the motor is defined by the specific instruction label
stuck on the machine.
• Jog the motor briefly.
• Watch the fan wheel of the motor and determine the direction of rotation just before
the fan wheel stops.
If the rotation of the motor must be changed:
• Switch any two of the motor phase wires.
6 Commissioning
NOTICE
The machine is shipped without oil.
Operation without oil will ruin the machine in short time!
• Prior to commissioning, the machine must be filled with oil, see Filling Oil [►8].
NOTICE
Lubricating a dry running machine (process chamber).
Risk of damage to the machine!
• Do not lubricate the process chamber of the machine with oil or grease.
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6 | Commissioning
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CAUTION
During operation the surface of the machine may reach temperatures of more than
70°C.
Risk of burns!
• Avoid contact with the machine during and directly after operation.
CAUTION
Noise of running machine.
Risk of damage to hearing!
If persons are present in the vicinity of a non noise insulated machine over extended
periods:
• Make sure that ear protection is being used.
• Make sure that the installation conditions (see Installation Conditions [►7]) are com-
plied with.
• Switch on the machine.
• Make sure that the maximum permissible number of starts does not exceed 6 starts
per hour.
• After few minutes of operation, perform an Oil Level Inspection [►14].
As soon as the machine is operated under normal operating conditions:
• Measure the motor current and record it as reference for future maintenance and
troubleshooting work.
6.1 Process Chamber Flushing
Depending on the process type (very demanding application), flushing through the pro-
cess chamber (cylinder + lobes) might need to be performed. Seek advice from your
Busch representative.
NOTICE
Flushing without barrier gas.
Risk of damage to the machine!
• The flushing process can pass over into the bearings and the oil chambers!
Do not perform flushing without using the barrier gas.
Beforehand, a barrier gas must be connected according to the following illustration and
recommendations:
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Maintenance | 7
0870559397_WV4500B_A0001_IM_en 13 / 24
Process flow inlet (IN)
Process flow outlet (OUT)
Barrier gas
connection (BGC)
Barrier gas
connection (BGC)
Connection size:
– 4 x G3/8 (BGC)
Barrier gas requirements:
Gas type Dry nitrogen, air or other suitable gas
Gas temperature °C 0 ... 60
Filtration µm ≤ 5
Gas pressure bar ≥ Pressure of flushing fluid + 1 bar
Recommended flow rate SLM* 30
* standard litre per minute
• Stop the machine.
• Open the gas supply.
• Flush the machine.
When the flushing is finished:
• Close the gas supply.
• Dry the machine of flushing fluid.
Do not operate the machine in normal operating conditions with the barrier gas opened.
It might affect the ultimate pressure and the suction capacity.
7 Maintenance
WARNING
Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:
• Wear appropriate personal protective equipment.
CAUTION
Hot surface.
Risk of burns!
• Prior to any action requiring touching the machine, let the machine cool down first.
• Shut down the machine and lock against inadvertent start up.
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7 | Maintenance
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• Vent the connected lines to atmospheric pressure.
If necessary:
• Disconnect all connections.
7.1 Maintenance Schedule
The maintenance intervals depend very much on the individual operating conditions. The
intervals given below are desired to be considered as starting values which should be
shortened or extended as appropriate. Particularly heavy duty operation, such as high
dust loads in the environment or in the process gas, other contamination or ingress of
process material, can make it necessary to shorten the maintenance intervals significant-
ly.
Interval Maintenance work
Monthly • Check the oil level, see Oil Level Inspection [►14].
• Check the machine for oil leaks - in case of leaks have
the machine repaired (contact Busch).
After the first 500 hours • Change the oil of the gear and bearing housings
(both sides), see Oil Change [►15].
Every 6 months • Perform an oil inspection; change it if the oil has
changed its initial colour, see Oil Colour Inspection
[►14].
Every 5000 hours, at the latest
after 1 year
• Change the oil of the gear and bearing housings
(both sides)
• Clean the magnetic plugs (MP)
Every 8 years • Have a major overhaul on the machine (contact
Busch).
7.2 Oil Level Inspection
• Shut down the machine.
• When the machine is stopped, wait 1 minute before checking the oil level.
MAX
MIN MAX
MIN MAX
MIN
• Fill up if necessary, see Oil Filling [►8].
7.3 Oil Colour Inspection
• Make sure that the oil is either light or transparent.
If the oil becomes dark or looks different from the initial colour:
• Change the oil immediately, see Oil Change [►15].
You can consult your Busch representative in order to find out why this colour change
has occurred.
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Maintenance | 7
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7.4 Oil Change
NOTICE
Use of an inappropriate oil.
Risk of premature failure!
Loss of efficiency!
• Only use an oil type which has previously been approved and recommended by
Busch.
1
7
32
4
6
5
Drain pan
Cleaning cloth
Oil draining at the motor side
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7 | Maintenance
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1
7
2
4
3
56
Drain pan
Cleaning cloth
Oil draining at the gear side
For oil type and oil capacity see Technical Data [►21] and Oil [►21].
21
4
3
MAX
MIN
Busch Oil
Check oil level
Oil filling at the motor side
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Overhaul | 8
0870559397_WV4500B_A0001_IM_en 17 / 24
1
Busch Oil
4
Busch Oil
Busch Oil
2
3
MAX
MIN
Check oil level
Oil filling at the gear side
When the oil filling is achieved:
• Write down the oil change date on the sticker.
Last oil change
__ / __ / ____
Oil type see nameplate
Change interval see
instruction manual
If there is no sticker on the pump:
• Order it from your Busch representative.
8 Overhaul
NOTICE
Improper assembly.
Risk of premature failure!
Loss of efficiency!
• It is highly recommended that any dismantling of the machine that goes beyond any-
thing that is described in this manual should be done through Busch.
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9 | Decommissioning
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WARNING
Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:
• Wear appropriate personal protective equipment.
In case of the machine having conveyed gas that was contaminated with foreign materi-
als which are dangerous to health:
• Decontaminate the machine as well as possible and state the contamination status
in a ‘Declaration of Contamination’.
Busch will only accept machines that come with a completely filled in and legally binding
signed ‘Declaration of Contamination’.
(Form downloadable from www.buschvacuum.com)
9 Decommissioning
• Shut down the machine and lock against inadvertent start up.
• Vent the connected lines to atmospheric pressure.
• Disconnect all connections.
If the machine is going to be stored:
• See Storage [►6].
9.1 Dismantling and Disposal
• Drain the oil.
• Separate special waste from the machine.
• Dispose of special waste in compliance with applicable regulations.
• Dispose of the machine as scrap metal.
10 Spare Parts
NOTICE
Use of non-Busch genuine spare parts.
Risk of premature failure!
Loss of efficiency!
• The exclusive use of Busch genuine spare parts and consumables is recommended for
the proper function of the machine and for granting of warranty.
There is no standard spare parts kits available for this product, if you require Busch gen-
uine parts:
• Contact your Busch representative for the detailed spare parts list.
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Troubleshooting | 11
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11 Troubleshooting
DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
CAUTION
Hot surface.
Risk of burns!
• Prior to any action requiring touching the machine, let the machine cool down first.
Problem Possible Cause Remedy
The machine does not start. The motor is not supplied
with the correct voltage.
• Check the power supply.
The lobes are jammed or
seized.
• Lobes inspection or repair
the machine (contact
Busch).
Solid foreign matter has
entered the machine.
• Remove the solid foreign
matter or repair the ma-
chine (contact Busch).
• Equip the machine with a
mesh screen at the suc-
tion connection.
The motor is defective. • Replace the motor.
The machine does not reach
the usual pressure.
Suction or discharge lines
too long or section diameter
too small.
• Use larger diameter or
shorter lines.
• Seek advice from your
local Busch representa-
tive.
The backing pump is not
correctly defined.
• Contact Busch.
The machine runs in the
wrong direction.
• Check the direction of ro-
tation, see Wiring Dia-
gram Three-Phase Motor
[►10].
Internal parts are worn or
damaged.
• Repair the machine (con-
tact Busch).
The machine runs very nois-
ily.
Wrong oil quantity or un-
suitable oil type.
• Use one of the recom-
mended oils in the correct
quantity, see Oil [►21].
Defective gears, bearings or
coupling element.
• Repair machine (contact
Busch).
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11 | Troubleshooting
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The machine runs too hot. Ambient temperature too
high.
• Observe the permitted
ambient temperature, see
Technical Data [►21].
Temperature of the process
gases at the inlet too high.
• Observe the permitted
gas inlet temperature, see
Technical Data [►21].
Oil level too low. • Top up oil.
The backing pump is not
correctly defined.
• Contact Busch.
The oil is black. Oil change intervals are too
long.
• Drain the oil and fill in
new oil, see Oil Change
[►15].
The machine runs too hot. • See problem "The ma-
chine runs too hot".
For the solution of problems not mentioned in the troubleshooting chart contact your
Busch representative.
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