BUSCH PUMA WP 0250 D4 User manual

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PUMA
Vacuum Boosters
WP 0250 D4, WP 0500 D2/D4, WP 0700 D2,
WP 1000 D2/D4, WP 1250 D2, WP 2000 D2
Instruction Manual
0870571055 | -0007_en-US | Original instructions 5/24/2022

Table of Contents
2 | 36 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 Intended Use ....................................................................................................................................................... 5
2.3 Variants................................................................................................................................................................. 6
2.3.1 D2 Versions............................................................................................................................................ 6
2.3.2 D4 Versions............................................................................................................................................ 6
2.3.3 Water Cooling........................................................................................................................................ 6
3 Transport .............................................................................................................................................................. 7
4 Storage .................................................................................................................................................................. 8
5 Installation ........................................................................................................................................................... 9
5.1 Installation Conditions........................................................................................................................................ 9
5.2 Connecting Lines / Pipes .................................................................................................................................... 9
5.2.1 Gas Flow Variants.................................................................................................................................. 10
5.2.2 Suction Connection............................................................................................................................... 10
5.2.3 Discharge Connection .......................................................................................................................... 11
5.2.4 Cooling Water Connection................................................................................................................... 11
5.3 Filling Oil............................................................................................................................................................... 12
6 Electrical Connection........................................................................................................................................... 15
6.1 Machine delivered without Control Box or Variable Speed Drive (VSD)....................................................... 15
6.2 Wiring Diagram Three-Phase Motor................................................................................................................. 16
7 Commissioning..................................................................................................................................................... 18
8 Maintenance......................................................................................................................................................... 19
8.1 Maintenance Schedule ....................................................................................................................................... 20
8.2 Oil Level Inspection............................................................................................................................................. 20
8.3 Oil Color Inspection ............................................................................................................................................ 20
8.4 Oil Change............................................................................................................................................................ 21
9 Overhaul................................................................................................................................................................ 24
10 Decommissioning................................................................................................................................................. 25
10.1 Dismantling and Disposal .................................................................................................................................. 25
11 Spare Parts............................................................................................................................................................ 26
12 Troubleshooting................................................................................................................................................... 27
13 Technical Data...................................................................................................................................................... 29
14 Oil........................................................................................................................................................................... 30
15 EU Declaration of Conformity............................................................................................................................. 31
16 UK Declaration of Conformity ............................................................................................................................ 32

Safety | 1
Instruction Manual PUMA WP 0250-2000 D_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, as described in the following chapters and in accordance
with the chapter Intended Use [➔5]. 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 PUMA WP 0250-2000 D_EN_en
2 Product Description
IN
ODP, MP
NP
MTB
OSG
OFP
OR
OUT
ODP, MP
CWC
WP 1000 D4 / WP 2000 D2
CWC
OSG
OR
Description
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 | 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, bearings and in certain
versions the oil lubricated mechanical seals.
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-
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 machine is used in combination with a backing pump in vacuum system.
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [➔29].

2 | Product Description
6 | 36 Instruction Manual PUMA WP 0250-2000 D_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
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 maximum 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 characterized 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.
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.

Transport | 3
Instruction Manual PUMA WP 0250-2000 D_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 [➔29] 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.

4 | Storage
8 | 36 Instruction Manual PUMA WP 0250-2000 D_EN_en
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.

Installation | 5
Instruction Manual PUMA WP 0250-2000 D_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 [➔29].
●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 elements.
●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 [➔20].
●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
[➔11].
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 | Installation
10 | 36 Instruction Manual PUMA WP 0250-2000 D_EN_en
5.2.1 Gas Flow Variants
The machine can be installed in different ways:
12
Description
1 Vertical gas flow 2 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 configuration ordered, other connection dimensions may apply.

Installation | 5
Instruction Manual PUMA WP 0250-2000 D_EN_en 11 | 36
5.2.3 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):
– 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 configuration ordered, other connection dimensions may apply.
5.2.4 Cooling Water Connection
Only required for PUMA WP 1000 D4 and WP 2000 D2 versions.
2 x CWC 2 x CWC
Description
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)

5 | Installation
12 | 36 Instruction Manual PUMA WP 0250-2000 D_EN_en
●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)
5.3 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 [➔29] and Oil [➔30].

Installation | 5
Instruction Manual PUMA WP 0250-2000 D_EN_en 13 | 36
●Fill up until the oiler (OR) is at least two thirds full (with lip seals only).
OR

5 | Installation
14 | 36 Instruction Manual PUMA WP 0250-2000 D_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.

Electrical Connection | 6
Instruction Manual PUMA WP 0250-2000 D_EN_en 15 | 36
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
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 [➔31] or UK Declaration of Conformity [➔32]).
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
allowed as long as the motor is capable and the permitted motor speed range is respected
(see Technical Data [➔29]).
Seek advice from your Busch representative.

6 | Electrical Connection
16 | 36 Instruction Manual PUMA WP 0250-2000 D_EN_en
●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.
6.2 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):

Electrical Connection | 6
Instruction Manual PUMA WP 0250-2000 D_EN_en 17 | 36
Double star connection, multi-voltage motor
with 9 pins (low voltage):
Star connection, multi-voltage motor with 9
pins (high voltage):
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

7 | Commissioning
18 | 36 Instruction Manual PUMA WP 0250-2000 D_EN_en
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.
●Make sure that the installation conditions (see Installation Conditions [➔9]) 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 [➔29].
●After a few minutes of operation, perform an Oil Level Inspection [➔20].
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.

Maintenance | 8
Instruction Manual PUMA WP 0250-2000 D_EN_en 19 | 36
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.
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.

8 | Maintenance
20 | 36 Instruction Manual PUMA WP 0250-2000 D_EN_en
8.1 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.
Interval Maintenance work
Monthly ●Check the oil level, see Oil Level Inspection [➔20].
●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 [➔21].
Every 6 months ●Perform an oil inspection; change it if the oil has changed
its initial color, see Oil Color Inspection [➔20].
Every 5000 hours or after 1 year ●Change the oil of the gear and bearing housings (both
sides)
●Clean the magnetic plugs (MP)
Every 16000 hours or after 4
years
●Have a major overhaul on the machine (contact Busch).
8.2 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 [➔12].
8.3 Oil Color Inspection
●Make sure that the oil is either light or transparent.
If the oil becomes dark or looks different from the initial color:
●Change the oil immediately, see Oil Change [➔21].
You can consult your Busch representative in order to find out why this color change has occurred.