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)

Installation | 5
Instruction Manual PUMA WP 0250-2000 D_EN_en 11 / 24
1
MAX
MIN
3
4
2
Busch Oil
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 (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.
• Make sure that the power supply for the motor is compatible with the data on the
nameplate of the motor.
• The electrical installation must comply with applicable national and international
standards.
• Provide a lockable disconnect switch on the power line so that the machine is com-
pletely secured during maintenance tasks.

5 | Installation
12 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
• Provide an 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
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.
Delta connection (low voltage): Star connection (high voltage):
Double star connection, multi-voltage
motor with 9 pins (low voltage):
Star connection, multi-voltage motor
with 9 pins (high voltage):

Commissioning | 6
Instruction Manual PUMA WP 0250-2000 D_EN_en 13 / 24
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
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 pe-
riods:
• 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 [►10].

7 | Maintenance
14 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
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 [►7]) are met.
For versions WP 1000 D4 and WP 2000 D2:
• 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 [►22].
• After a few minutes of operation, perform an Oil Level Inspection [►15].
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.
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!
• Respect the maintenance intervals or ask your Busch representative for service.
• Shut down the machine and lock against inadvertent start up.

Maintenance | 7
Instruction Manual PUMA WP 0250-2000 D_EN_en 15 / 24
For versions WP 1000 D4 and WP 2000 D2:
• 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 ex-
tended 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 signifi-
cantly.
Interval Maintenance work
Monthly • Check the oil level, see Oil Level Inspection [►15].
• 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 [►16].
Every 6 months • Perform an oil inspection; change it if the oil has
changed its initial colour, see Oil Colour Inspection
[►16].
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 16000 hours, at the least
after 4 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 [►10].

7 | Maintenance
16 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
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 [►16].
• See Oil Change [►16].
You can consult your Busch representative in order to find out why this colour change
has occurred.
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.
2
1
3
Drain pan
Cleaning cloth
Oil draining at the motor side

Maintenance | 7
Instruction Manual PUMA WP 0250-2000 D_EN_en 17 / 24
1
3
2
Drain panCleaning cloth
Oil draining at the gear side
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)

8 | Overhaul
18 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
1
MAX
MIN
3
4
2
Busch Oil
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 (part no. 0565 568 959) on the machine:
• Order it from your Busch representative.
8 Overhaul
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.

Decommissioning | 9
Instruction Manual PUMA WP 0250-2000 D_EN_en 19 / 24
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.
In case of the machine having conveyed gas that was contaminated with foreign materi-
als which are dangerous to health:
• Decontaminate the machine as much as possible and state the contamination sta-
tus 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.
For versions WP 1000 D4 and WP 2000 D2:
• Turn off the water supply.
• Disconnect the water supply.
• Blow through the water cooling inlet with compressed air.
• Disconnect all connections.
If the machine is going to be stored:
• See Storage [►7].
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 correct functioning of the machine and to validate the 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.

11 | Troubleshooting
20 / 24 Instruction Manual PUMA WP 0250-2000 D_EN_en
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 en-
tered 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 lo-
cal Busch representative.
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
[►12].
Internal parts are worn or
damaged.
• Repair the machine (con-
tact Busch).
The machine runs very noisi-
ly.
Wrong oil quantity or un-
suitable oil type.
• Use one of the recom-
mended oils in the correct
quantity, see Oil [►22].
Defective gears, bearings or
coupling element.
• Repair machine (contact
Busch).