BUSCH PUMA WP 0250 D4 User manual

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Instruction Manual
PUMA
Vacuum Booster
WP 0250 D4, WP 0500 D2/D4, WP 0700 D2,
WP 1000 D2/D4, WP 1250 D2, WP 2000 D2
0870571055/-0006_en / Original instructions / Modifications reserved 15/09/2021

Table of Contents
2 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
Table of Contents
1 Safety .......................................................................................................................................3
2 Product Description ..................................................................................................................4
2.1 Operating Principle .......................................................................................................... 5
2.2 Application....................................................................................................................... 5
2.3 Variants............................................................................................................................ 5
2.3.1 D2 Versions...........................................................................................................5
2.3.2 D4 Versions...........................................................................................................5
2.3.3 Water Cooling.......................................................................................................6
3 Transport ..................................................................................................................................6
4 Storage .....................................................................................................................................7
5 Installation................................................................................................................................7
5.1 Installation Conditions...................................................................................................... 7
5.2 Connecting Lines / Pipes .................................................................................................. 7
5.2.1 Gas Flow Variants.................................................................................................. 8
5.2.2 Suction Connection ............................................................................................... 8
5.2.3 Discharge Connection ........................................................................................... 8
5.2.4 Cooling Water Connection ....................................................................................9
5.3 Filling Oil.......................................................................................................................... 10
5.4 Electrical Connection ........................................................................................................ 11
5.4.1 Wiring Diagram Three-Phase Motor...................................................................... 12
6 Commissioning.........................................................................................................................13
7 Maintenance.............................................................................................................................14
7.1 Maintenance Schedule ..................................................................................................... 15
7.2 Oil Level Inspection.......................................................................................................... 15
7.3 Oil Colour Inspection ....................................................................................................... 16
7.4 Oil Change....................................................................................................................... 16
8 Overhaul...................................................................................................................................18
9 Decommissioning.....................................................................................................................19
9.1 Dismantling and Disposal ................................................................................................. 19
10 Spare Parts................................................................................................................................19
11 Troubleshooting .......................................................................................................................20
12 Technical Data..........................................................................................................................22
13 Oil ............................................................................................................................................22
14 EU Declaration of Conformity...................................................................................................23

Safety | 1
Instruction Manual PUMA WP 0250-2000 D_EN_en 3 / 24
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.

2 | Product Description
4 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
2 Product Description
IN
ODP, MP
OSGNP
MTBOSGOFP
OR
OUTODP, MP
CWC
WP 1000 D4 / WP 2000 D2
IN Suction connection MTB Motor terminal box
OUT Discharge connection MP Magnetic plug
NP Nameplate OFP Oil fill plug
ODP Oil drain plug OSG Oil sight glass
OR Oiler (with lip seals only)
CWC Cooling water connection (WP 1000 D4 / WP 2000 D2 only)
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
booster’.

Product Description | 2
Instruction Manual PUMA WP 0250-2000 D_EN_en 5 / 24
NOTE
Illustrations
In this instruction manual the illustrations may differ from the machine appearance.
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 in
certain versions the oil lubricated mechanical seals.
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 [►22].
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.
2.3 Variants
2.3.1 D2 Versions
The D2 versions (ex: WP 0500 D2) have a differential pressure of 50 hPa with a maxi-
mum motor speed of 3600 min-1 at 60 Hz.
Refer to the nameplate (NP) in order to know what the machine version is.
2.3.2 D4 Versions
The D4 versions (ex: WP 0500 D4) are characterised by a particularly high differential
pressure of 80 hPa with a maximum motor speed of 1800 min-1 at 60 Hz.
Refer to the nameplate (NP) in order to know what the machine version is.

3 | Transport
6 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
2.3.3 Water Cooling
The versions WP 1000 D4 and WP 2000 D2 must be cooled by water. There are four
cooling water connections (CWC), two on each side, intended for the water inlet and
outlet.
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 in-
gress into the cylinder.
• Drain the oil prior to every transport or always horizontally transport the machine.
Machine weight:
see the technical data or the nameplate (NP)
Use appropriate slings
• 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 PUMA WP 0250-2000 D_EN_en 7 / 24
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.
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 [►22].
• 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 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 +/-
0.5° 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 [►15].
• Make sure that all provided covers, guards, hoods, etc. are mounted.
For versions WP 1000 D4 and WP 2000 D2:
• Make sure that the cooling water complies with the requirements, see Cooling
Water Connection [►9].
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.

5 | Installation
8 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
• 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 Gas Flow Variants
The machine can be installed in different ways:
Vertical gas flow Horizontal gas flow (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):
– DN63, DIN 28404 for WP 0250-0500 D
– DN100, DIN 28404 for WP 0700 D
– DN160, DIN 28404 for WP 1000-2000 D
Depending on the specific order, other connection dimensions may apply.
5.2.3 Discharge Connection
Connection size(s):
– DN63, DIN 28404 for WP 0250-0500 D
– DN100, DIN 28404 for WP 0700 D
– DN160, DIN 28404 for WP 1000-2000 D
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.

Installation | 5
Instruction Manual PUMA WP 0250-2000 D_EN_en 9 / 24
5.2.4 Cooling Water Connection
Only requier for the Puma versions WP 1000 D4 and WP 2000 D2
Suggestion of connection
2x CWC 2x CWC
CWC Cooling water connections
2 connections on each side (cooling water inlet and outlet)
• Connect the cooling water connections (CWI / CWO) to the water supply.
Connection size:
– G1/4 (CWC)
• Make sure that the cooling water complies with the following requirements:
Min. supply capacity l/min 2
Water pressure bar 2 ... 5
Supply temperature °C +10 ... +25
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 | Installation
10 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
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 [►22] and Oil [►22].
1
3
3
Busch Oil
2
Fill up until the oiler (OR)
is at least two thirds full
Oil filling at the motor side
(with lip seals only)