BUSCH PANDA WZ 1200 A User manual

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PANDA
Vacuum Booster
WZ 1200 A, WZ 2400 A
Instruction Manual
0870203784 | -0002_en | Original instructions 07/03/2022

Table of Contents
2 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
Table of Contents
1 Safety..................................................................................................................................................................... 3
2 Product Description............................................................................................................................................. 4
2.1 Operating Principle ............................................................................................................................................. 6
2.2 Application ........................................................................................................................................................... 6
2.3 Standard Features............................................................................................................................................... 7
2.3.1 Water Cooling........................................................................................................................................ 7
2.3.2 Temperature Switch ............................................................................................................................. 7
3 Transport .............................................................................................................................................................. 8
4 Storage .................................................................................................................................................................. 9
5 Installation ........................................................................................................................................................... 10
5.1 Installation Conditions........................................................................................................................................ 10
5.2 Connecting Lines / Pipes .................................................................................................................................... 10
5.2.1 Gas Flow Variants.................................................................................................................................. 10
5.2.2 Suction Connection............................................................................................................................... 11
5.2.3 Discharge Connection .......................................................................................................................... 11
5.2.4 Cooling Water Connection................................................................................................................... 12
5.3 Filling Oil............................................................................................................................................................... 12
5.4 Electrical Connection .......................................................................................................................................... 14
5.4.1 Machine delivered without Control Box or Variable Speed Drive (VSD) ........................................ 15
5.4.2 Wiring Diagram Three-Phase Motor .................................................................................................. 16
5.5 Electrical Connection of the Monitoring Devices ............................................................................................ 17
5.5.1 Wiring Diagram Temperature Switch................................................................................................. 17
6 Commissioning..................................................................................................................................................... 18
6.1 Compression Chamber Flushing....................................................................................................................... 18
7 Maintenance......................................................................................................................................................... 20
7.1 Maintenance Schedule ....................................................................................................................................... 20
7.2 Oil Level Inspection............................................................................................................................................. 21
7.3 Oil Colour Inspection .......................................................................................................................................... 21
7.4 Oil Change............................................................................................................................................................ 22
8 Overhaul................................................................................................................................................................ 25
9 Decommissioning................................................................................................................................................. 26
9.1 Dismantling and Disposal .................................................................................................................................. 26
10 Spare Parts............................................................................................................................................................ 27
11 Troubleshooting................................................................................................................................................... 28
12 Technical Data...................................................................................................................................................... 30
13 Maximum Permissible Differential Pressures.................................................................................................. 31
14 Oil........................................................................................................................................................................... 32
15 EU Declaration of Conformity............................................................................................................................. 33
16 UK Declaration of Conformity ............................................................................................................................ 34

Safety | 1
Instruction Manual PANDA WZ 1200-2400 A_EN_en 3 | 36
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
methods. 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.

2 | Product Description
4 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
2 Product Description
OFP BPV IN
OSGCWO ODP, MP
OFP
NP
ODP, MPOSG
CWI
OUT
BGC
BGC TS MTB
OUT2
EBEB MP
WZ 1200 A
Description
BGC Barrier gas connection BPV Bypass valve
CWI Cooling water inlet CWO Cooling water outlet
EB Eye bolt IN Suction connection
MP Magnetic plug MTB Motor terminal box
NP Nameplate ODP Oil drain plug
OFP Oil fill plug OSG Oil sight glass
OUT Discharge connection OUT2 Lateral discharge connection (Optional)
TS Temperature switch

Product Description | 2
Instruction Manual PANDA WZ 1200-2400 A_EN_en 5 | 36
OFP BPV IN
OSGCWO ODP, MP
OFP
NP
ODP, MPOSG
CWI
OUT
BGC
BGC TS MTB
OUT2
EBEB MP
WZ 2400 A
Description
BGC Barrier gas connection BPV Bypass valve
CWI Cooling water inlet CWO Cooling water outlet
EB Eye bolt IN Suction connection
MP Magnetic plug MTB Motor terminal box
NP Nameplate ODP Oil drain plug
OFP Oil fill plug OSG Oil sight glass
OUT Discharge connection OUT2 Lateral discharge connection (Optional)
TS Temperature switch
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum booster’.

2 | Product Description
6 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
NOTE
Illustrations
In this instruction manual the illustrations may differ from the machine appearance.
2.1 Operating Principle
The machine works on the Booster blower principle.
The two oil housings (on each side) allow the lubrication of the gears and bearings.
A bypass valve (BPV) limits automatically the differential pressure between inlet and outlet.
2.2 Application
The machine is intended for the suction of air and other dry, non-aggressive, non-toxic and non-
explosive gases.
Conveying of other media leads to an increased thermal and/or mechanical load on the machine
and is permissible only after a consultation with Busch.
The machine is intended for the placement in a non-potentially explosive environment.
The vacuum booster is used in combination with a backing pump in vacuum system.
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [➔30].
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
- Epoxy resin
- Fluoroelastomer (FKM/FPM)
●In doubt, please contact your Busch representative.

Product Description | 2
Instruction Manual PANDA WZ 1200-2400 A_EN_en 7 | 36
2.3 Standard Features
2.3.1 Water Cooling
The machine is driven by a water-cooled motor.
2.3.2 Temperature Switch
The temperature switch monitors the oil temperature of the machine.
The machine must be stopped when the temperature switch trips (140 °C).

3 | Transport
8 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
3 Transport
WARNING
Suspended load.
Risk of severe injury!
●Do not walk, stand or work under suspended loads.
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 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 ingress into
the cylinder.
●Drain the oil prior to every transport or always horizontally transport the machine.
●To find out the weight of the machine, refer to the chapter Technical Data [➔30] 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.

Storage | 4
Instruction Manual PANDA WZ 1200-2400 A_EN_en 9 | 36
4 Storage
●Seal all apertures with adhesive tape or reuse provided caps.
●Make sure that the cooling water has been completely removed, see Decommissioning [➔26].
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.

5 | Installation
10 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
5 Installation
5.1 Installation Conditions
NOTICE
Use of the machine outside of the permitted installation conditions.
Risk of premature failure!
Loss of efficiency!
●Take care that the installation conditions are fully complied with.
●Make sure that the environment of the machine is not potentially explosive.
●Make sure that the ambient conditions comply with the Technical Data [➔30].
●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 and
the electrical instruments.
●Make sure that the installation space or location is vented such that sufficient cooling of the
machine is provided.
●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
is acceptable.
●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 [➔21].
●Make sure that all provided covers, guards, hoods, etc. are mounted.
●Make sure that the cooling water complies with the requirements, see Cooling Water Connection
[➔12].
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 covers 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 long connection lines it is advisable to use larger line sizes in order to avoid a loss of
efficiency. Seek advice from your Busch representative.
5.2.1 Gas Flow Variants
The machine can be installed in different ways:

Installation | 5
Instruction Manual PANDA WZ 1200-2400 A_EN_en 11 | 36
12
Description
1 Vertical gas flow 2 Lateral discharge (Optional)
5.2.2 Suction Connection
WARNING
Unprotected suction connection.
Risk of severe injury!
●Do not put hand or fingers in the suction connection.
NOTICE
Ingress of 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(s):
– DN160, DIN 28404 for WZ 1200 A & WZ 2400 A
Depending on the specific order, other connection dimensions may apply.
5.2.3 Discharge Connection
Connection size(s):
– DN100, DIN 28404 for WZ 1200 A
– DN160, DIN 28404 for WZ 2400 A
Connection size for lateral discharge (OUT2):
– DN100, DIN 28404 for WZ 1200 A
– DN160, DIN 28404 for WZ 2400 A
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 | Installation
12 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
5.2.4 Cooling Water Connection
●Connect the cooling water connections (CWI / CWO) to the water supply.
Connection size:
– G1/4 for the cooling water inlet and outlet on the motor (CWI / CWO)
●Make sure that the cooling water complies with the following requirements:
Min. supply capacity l/min WZ1200A: 2 / WZ2400A: 4
Water pressure bar 2 ... 5
Supply temperature °C +5... +30
Required pressure differential across supply
and return
bar ≥ 1
●To reduce the maintenance effort and ensure a long product lifetime we recommend the
following cooling water quality:
Hardness mg/l (ppm) < 90
Properties Clean & clear
PH value 7 ... 8
Particle size µm < 200
Chloride mg/l < 100
Electrical conductivity µS/cm ≤ 100
Free chloride mg/l < 0.3
Materials in contact with the cooling water Stainless steel, copper and cast iron
NOTE
Water hardness unit conversion.
1 mg/l (ppm) = 0.056 °dh (german degree) = 0.07 °e (english degree) = 0.1 °fH (french degree)
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.
For oil type and oil capacity see Technical Data [➔30] and Oil [➔32].

Installation | 5
Instruction Manual PANDA WZ 1200-2400 A_EN_en 13 | 36

5 | Installation
14 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
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 (part no. 0565 568 959) on the machine:
●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.
CURRENT PROTECTION OF THE CUSTOMER INSTALLATION:
DANGER
Missing current protection.
Risk of electrical shock.
●Current protection according to EN 60204-1 has to be insured by customer on its installation.
●The electrical installation must comply with applicable national and international standards.
NOTICE
Electromagnetic compatibility.
●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.
●Make sure that the EMC of the machine is compliant with the requirements of your supply
network system, if necessary provide further interference suppression (EMC of the machine, see
EU Declaration of Conformity or UK Declaration of Conformity).

Installation | 5
Instruction Manual PANDA WZ 1200-2400 A_EN_en 15 | 36
5.4.1 Machine delivered without Control Box or Variable Speed
Drive (VSD)
DANGER
Live wires.
Risk of electrical shock.
●Electrical installation work must only be executed by qualified personnel.
NOTE
The operation with variable speed, i.e. with a variable speed drive or a soft starter unit, is
allowed as long as the motor is capable and the permitted motor speed range is respected
(see Technical Data [➔30]).
Seek advice from your Busch representative.
●Make sure that the power supply for the motor is compatible with the data on the nameplate of
the motor.
●If the machine is equipped with a power connector, install a residual current protective device to
protect persons in case of isolation default.
●Busch recommends installing a type B residual protective device and adapted to the electrical
installation.
●Provide a lockable disconnect switch or an emergency stop switch on the power line so that the
machine is completely secured in case of an emergency situation.
●Provide a lockable disconnect switch on the power line so that the machine is completely secured
during maintenance tasks.
●Provide an overload protection according to EN 60204-1 for the motor.
●Busch recommends installing a D-curve circuit breaker.
●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 | Installation
16 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
5.4.2 Wiring Diagram Three-Phase Motor
NOTICE
The tightening torque does not comply with the recommendation.
Risk of damage the connector threads!
●When connecting up the wires into the terminal box, make sure the tightening torque of 3 Nm is
applied and checked with a calibrated torque wrench.
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.
●With a phase rotation tester, check if the wiring corresponds to the correct direction of rotation.
If the rotation of the motor must be changed:
●Switch any two of the motor phase wires.
Motor connectors:
P1
P2
U1
V1
W1
V2
U2
W2
Connection of motor temperature switches
(recommended):
P1 P2
MTS1 MTS2 MTS3
Control voltage: ≤ 250 V
Max current: 1.6 A
MTS = Motor temperature switch (in motor coil)
Delta connection (low voltage): Star connection (high voltage):

Installation | 5
Instruction Manual PANDA WZ 1200-2400 A_EN_en 17 | 36
5.5 Electrical Connection of the Monitoring Devices
NOTE
In order to prevent potential nuisance alarms, Busch recommends that the control system is
configured with a time delay of at least 20 seconds.
5.5.1 Wiring Diagram Temperature Switch
AC (cosφ=1): U = 250 V ; I = 2.5 A
AC (cosφ=0.6): U = 250 V ; 1.6 A
DC: U = 24 V ; I = 1.6 A
DC: U = 48 V ; I = 1.25 A
Contact: Normally closed
Switch point (T): pin 1 + 2 = 140 °C
2
1
T
Connector: WAGO CAGE CLAMP®

6 | Commissioning
18 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
6 Commissioning
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.
NOTICE
The machine can be 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 [➔12].
NOTICE
Lubricating a dry running machine (compression chamber).
Risk of damage to the machine!
●Do not lubricate the compression chamber of the machine with oil or grease.
●Make sure that the installation conditions (see Installation Conditions [➔10]) are met.
●Turn on the water supply.
●Switch on the machine.
●Make sure that the maximum permissible number of starts does not exceed 6 starts per hour.
Those starts should be spread within the hour.
●Make sure that the operating conditions comply with the Technical Data [➔30].
●After a few minutes of operation, perform an Oil Level Inspection [➔21].
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 Compression Chamber Flushing
Depending on the process type (very demanding application), flushing through the compression
chamber (cylinder + lobes) might need to be performed. Seek advice from your Busch
representative.

Commissioning | 6
Instruction Manual PANDA WZ 1200-2400 A_EN_en 19 | 36
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:
IN
OUT
BGC
1
BGC
2
3
4
Description
1 Process flow inlet (IN) 2 Porcess flow outlet (OUT)
3 2 x Barrier gas connections (BGC) 4 2 x Barrier gas connections (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
20 | 36 Instruction Manual PANDA WZ 1200-2400 A_EN_en
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.
NOTICE
Using inappropriate cleaners.
Risk of removing safety stickers and protective paint!
●Do not use incompatible solvents to clean the machine.
CAUTION
Failing to properly maintain the machine.
Risk of injuries!
Risk of premature failure and loss of efficiency!
●Maintenance work must only be executed by qualified personnel.
●Respect the maintenance intervals or ask your Busch representative for service.
●Shut down the machine and lock against inadvertent start up.
●Turn off the water supply.
●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 considered as starting values which should be shortened or extended as
appropriate. Particularly harsh applications or 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 significantly.