BUSCH PUMA User manual

Get technical data, instruction manuals, service kits
PUMA
Vacuum Boosters
WY 3600 A
Instruction Manual
0870242399 | -0001_en-US | Original instructions 7/4/2022

Table of Contents
2 | 36 Instruction Manual PUMA WY 3600 A_EN_en
Table of Contents
1 Safety..................................................................................................................................................................... 3
2 Product Description............................................................................................................................................. 4
2.1 Operating Principle ............................................................................................................................................. 5
2.2 Intended Use ....................................................................................................................................................... 5
2.3 Standard Features............................................................................................................................................... 6
2.3.1 Water Cooling........................................................................................................................................ 6
2.3.2 Temperature Switch ............................................................................................................................. 6
3 Transport .............................................................................................................................................................. 7
4 Storage .................................................................................................................................................................. 8
5 Installation ........................................................................................................................................................... 9
5.1 Installation Conditions........................................................................................................................................ 9
5.2 Connecting Lines / Pipes .................................................................................................................................... 9
5.2.1 Suction Connection............................................................................................................................... 10
5.2.2 Discharge Connection .......................................................................................................................... 10
5.2.3 Cooling Water Connection................................................................................................................... 11
5.3 Filling Oil............................................................................................................................................................... 12
6 Electrical Connection........................................................................................................................................... 14
6.1 Machine delivered without Control Box or Variable Speed Drive (VSD)....................................................... 14
6.2 Wiring Diagram Three-Phase Motor................................................................................................................. 15
6.3 Electrical Connection of the Monitoring Devices ............................................................................................ 16
6.3.1 Wiring Diagram Temperature Switch................................................................................................. 16
7 Commissioning..................................................................................................................................................... 17
7.1 Pump Down Cycle ............................................................................................................................................... 18
7.2 Compression Chamber Flushing....................................................................................................................... 18
8 Maintenance......................................................................................................................................................... 20
8.1 Maintenance Schedule ....................................................................................................................................... 21
8.2 Oil Level Inspection............................................................................................................................................. 21
8.3 Oil Color Inspection ............................................................................................................................................ 21
8.4 Oil Change............................................................................................................................................................ 22
9 Overhaul................................................................................................................................................................ 25
10 Decommissioning................................................................................................................................................. 26
10.1 Dismantling and Disposal .................................................................................................................................. 26
11 Spare Parts............................................................................................................................................................ 27
12 Troubleshooting................................................................................................................................................... 28
13 Technical Data...................................................................................................................................................... 30
14 Maximum Permissible Differential Pressures.................................................................................................. 31
15 Oil........................................................................................................................................................................... 32
16 EU Declaration of Conformity............................................................................................................................. 33
17 UK Declaration of Conformity ............................................................................................................................ 34

Safety | 1
Instruction Manual PUMA WY 3600 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. Never-
theless, residual risks may remain, as described in the following chapters and in accordance with the
chapter Intended Use [➔5]. This instruction manual highlights potential hazards where appropri-
ate. 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 trou-
ble-free operation.

2 | Product Description
4 | 36 Instruction Manual PUMA WY 3600 A_EN_en
2 Product Description
OFP IN
OSG
CWO
ODP, MP
OFP
NP ODP, MP
OSG
CWI
BGC
BGC TS MTB
OUT
EB
EB
MP
CWC CWC
CWCCWC
BGC
BGC
Description
BGC Barrier gas connection CWO Cooling water outlet
CWI Cooling water inlet EB Eyebolt
CWC Cooling water connection MP Magnetic plug
IN Suction connection NP Nameplate
MTB Motor terminal box OFP Oil fill plug
ODP Oil drain plug OUT Discharge connection
OSG Oil sight glass TS Temperature switch
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum booster’.

Product Description | 2
Instruction Manual PUMA WY 3600 A_EN_en 5 | 36
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.
2.2 Intended Use
WARNING
In case of foreseeable misuse outside the intended use of the machine.
Risk of injuries!
Risk of damages to the machine!
Risk of damages to the environment!
●Make sure to follow all instructions described in this manual.
The machine is intended for the suction of air and other dry, non-aggressive, non-toxic and non-ex-
plosive 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 machine is used in combination with a backing pump in vacuum system.
Permitted environmental conditions, see Technical Data [➔30].
NOTICE
Start the backing pump first up to the allowed inlet pressure of the vacuum booster, see Maxi-
mum Permissible Differential Pressures [➔31] or call Busch representative.
Risk of damage to the machine!

2 | Product Description
6 | 36 Instruction Manual PUMA WY 3600 A_EN_en
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 life-
time!
●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.
2.3 Standard Features
2.3.1 Water Cooling
The machine is driven by a water-cooled motor.
When operated with Variable Speed Drive (VSD), pump water cooling is mandatory, see Cooling Wa-
ter Connection [➔11].
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).

Transport | 3
Instruction Manual PUMA WY 3600 A_EN_en 7 | 36
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 name-
plate (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
8 | 36 Instruction Manual PUMA WY 3600 A_EN_en
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.

Installation | 5
Instruction Manual PUMA WY 3600 A_EN_en 9 | 36
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 representa-
tive
●Make sure that the environmental conditions comply with the protection class of the motor and
the electrical elements.
●Make sure that the installation space or location is protected from weather and lightning.
●Make sure that the installation space or location is vented such that sufficient cooling of the ma-
chine 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
[➔11].
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 effi-
ciency. Seek advice from your Busch representative.

5 | Installation
10 | 36 Instruction Manual PUMA WY 3600 A_EN_en
5.2.1 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
Depending on the specific configuration ordered, other connection dimensions may apply.
5.2.2 Discharge Connection
NOTICE
Discharge gas flow obstructed.
Risk of damage to the machine!
●Make sure that the discharged gas will flow without obstruction. Do not shut off or throttle the
discharge line or use it as a pressurized air source.
Connection size(s):
– DN160, DIN 28404
Depending on the specific configuration ordered, other connection dimensions may apply.

Installation | 5
Instruction Manual PUMA WY 3600 A_EN_en 11 | 36
5.2.3 Cooling Water Connection
Motor + Booster cooling (Mandatory for operation with Variable Speed Drive (VSD))
CWI
CWO
Description
CWI Cooling water inlet CWO Cooling water outlet
The cooling connection type depends on the application. Seek advice from your Busch representa-
tive.
●Connect the cooling water connections (CWI / CWO) to the water supply.
Connection size:
– G1/2 for the cooling water inlet and outlet on the motor (CWI / CWO)
– G1/2 for the cooling water connections on the covers (CWC)
●Make sure that the cooling water complies with the following requirements:
Min. supply capacity l/min 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 follow-
ing cooling water quality:
Hardness mg/l (ppm) < 90
Properties Clean & clear
PH value 7 ... 8
Particle size µm < 200
Chloride mg/l < 100

5 | Installation
12 | 36 Instruction Manual PUMA WY 3600 A_EN_en
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 PUMA WY 3600 A_EN_en 13 | 36
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.

6 | Electrical Connection
14 | 36 Instruction Manual PUMA WY 3600 A_EN_en
6 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 must be insured by the customer on its installation.
●The electrical installation must comply with the 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 dis-
turbance 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 net-
work system, if necessary provide further interference suppression (EMC of the machine, see EU
Declaration of Conformity [➔33] or UK Declaration of Conformity [➔34]).
6.1 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 al-
lowed 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.

Electrical Connection | 6
Instruction Manual PUMA WY 3600 A_EN_en 15 | 36
●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 suitable for the electrical in-
stallation.
●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 con-
nection instructions/diagrams.
6.2 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.

6 | Electrical Connection
16 | 36 Instruction Manual PUMA WY 3600 A_EN_en
Motor connectors:
U1
V1
W1
U2V2
W2
U3
V3
W3
P1
P2
P3
P4
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)
Double star connection (low voltage): Star connection (high voltage):
6.3 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.
6.3.1 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®

Commissioning | 7
Instruction Manual PUMA WY 3600 A_EN_en 17 | 36
7 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.
NOTICE
The machine is running at 90 Hz when starting a pump down cycle.
Risk of damage to the machine!
●Ensure no sudden ambient pressure while pump is running at 90 Hz.
●Ensure progressive transition to ambient pressure.
●Make sure that the installation conditions (see Installation Conditions [➔9]) 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].

7 | Commissioning
18 | 36 Instruction Manual PUMA WY 3600 A_EN_en
As soon as the machine is operated under normal operating conditions:
●Measure the motor current and record it as reference for future maintenance and trouble-
shooting work.
7.1 Pump Down Cycle
Below the graph and the procedure to operate the machine for a pump down cycle.
90
60
40
30
Open isolation valve
Close isolation valve
1 cycle
Time
Hz
Backing pump
Booster
●The machine must operate at a motor frequency of 30 Hz when opening the isolation valve.
●Gradually increase the motor frequency up to 90 Hz.
●As soon as the target pressure is reached, close the isolation and decrease the motor frequency
to 30 Hz.
7.2 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 representa-
tive.
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.

Commissioning | 7
Instruction Manual PUMA WY 3600 A_EN_en 19 | 36
Beforehand, a barrier gas must be connected according to the following illustration and recommen-
dations:
1
2
3
4
Description
1 Process flow inlet (IN) 2 Process flow oulet (OUT)
3 Barrier gas connections (BGC) 4 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 liter 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 af-
fect the ultimate pressure and the suction capacity.

8 | Maintenance
20 | 36 Instruction Manual PUMA WY 3600 A_EN_en
8 Maintenance
DANGER
Live wires.
Risk of electrical shock.
●Electrical installation work must only be executed by qualified personnel.
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.
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.
NOTICE
Using inappropriate cleaners.
Risk of removing safety stickers and protective paint!
●Do not use incompatible solvents to clean the machine.
●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.