Bush WV 1200 A User manual

Get technical data, instruction manuals, service kits
Instruction Manual
Panda ATEX
Vacuum Booster
WV 1200 A, WV 1800 A, WV 2400 A
0870206364/-0004_en / Original instructions / Modifications reserved 04/12/2020
Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland

Table of Contents
2 / 36 0870206364_WV1200-2400A_Ex_-0004_IM_en
Table of Contents
1 Safety .......................................................................................................................................4
2 Product Description ..................................................................................................................5
2.1 Operating Principle .......................................................................................................... 6
2.2 Application....................................................................................................................... 6
2.3 Shaft Sealing Variants....................................................................................................... 6
2.3.1 Mechanical Seal..................................................................................................... 7
2.3.2 Lip Seals (Optional) ............................................................................................... 7
2.4 Accessories....................................................................................................................... 7
2.4.1 Resistance Thermometer ....................................................................................... 7
2.4.2 Active Bypass Valve...............................................................................................7
2.5 Explanation of ATEX Classification.................................................................................... 8
2.6 Safety concept ................................................................................................................. 8
2.6.1 ATEX Classifications and Associated Accessories .................................................... 9
2.6.2 P&ID "Piping and Instrumentation Diagram" ........................................................ 9
3 Transport ..................................................................................................................................10
4 Storage .....................................................................................................................................10
5 Installation................................................................................................................................11
5.1 Installation Conditions...................................................................................................... 11
5.2 Connecting Lines / Pipes .................................................................................................. 12
5.2.1 Gas Flow Variants.................................................................................................. 12
5.2.2 Suction Connection ............................................................................................... 12
5.2.3 Discharge Connection ........................................................................................... 13
5.2.4 Pneumatic Connection (with Active Bypass Valve only) ......................................... 13
5.3 Earth Connection ............................................................................................................. 14
5.4 Filling Oil.......................................................................................................................... 14
5.5 Fitting the Coupling ......................................................................................................... 16
5.6 Electrical Connection ........................................................................................................ 17
5.6.1 Wiring Diagram Three-Phase Motor...................................................................... 17
5.7 Electrical Connection of the Monitoring Devices............................................................... 19
5.7.1 Wiring Diagram Resistance Thermometer.............................................................. 19
5.7.2 Wiring Diagram Limit Switch ................................................................................. 20
5.8 Flowchart ......................................................................................................................... 22
6 Commissioning.........................................................................................................................23
6.1 Compression Chamber Flushing ....................................................................................... 24
7 Maintenance.............................................................................................................................25
7.1 Maintenance Schedule ..................................................................................................... 25
7.2 Oil Level Inspection.......................................................................................................... 26
7.3 Oil Colour Inspection ....................................................................................................... 26
7.4 Oil Change....................................................................................................................... 27
7.5 Coupling Maintenance ..................................................................................................... 30
7.6 Calibration Procedure of the Electrical Devices ................................................................. 30
7.6.1 Procedure A ..........................................................................................................30
7.6.2 Procedure I............................................................................................................30
8 Overhaul...................................................................................................................................31
9 Decommissioning.....................................................................................................................31
9.1 Dismantling and Disposal ................................................................................................. 31
10 Spare Parts................................................................................................................................32

Table of Contents
0870206364_WV1200-2400A_Ex_-0004_IM_en 3
11 Troubleshooting .......................................................................................................................32
12 Technical Data..........................................................................................................................34
13 Oil ............................................................................................................................................34
14 EU Declaration of Conformity...................................................................................................35

1 | Safety
4 / 36 0870206364_WV1200-2400A_Ex_-0004_IM_en
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.

Product Description | 2
0870206364_WV1200-2400A_Ex_-0004_IM_en 5 / 36
2 Product Description
OFP
BPV IN
OSG ODP, MP
OFP
ODP, MP MTB
OSG
OUT1
BGC
BGCBGC
OR
OUT2
BGC
NP
EB
WV 2400 A
WV 2400 A
WV 2400 A with lip seals variant
(Optional)
TSA+/0101
GS/0601
PMC
ECP
PCY
BGC Barrier gas connection BPV Bypass valve or active bypass valve
EB Eye bolt ECP Earth connection (machine)
GS Limit switch (with active bypass valve only) IN Suction connection
MP Magnetic plug MTB Motor terminal box
NP Nameplate ODP Oil drain plug
OFP Oil fill plug OR Oiler (Optional)
OSG Oil sight glass OUT Discharge connection
OUT2 Lateral discharge connection (optional) PCY Pneumatic cylinder (with active bypass
valve only)
PMC Pneumatic connection (with active bypass
valve only)
TSA Resistance thermometer
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum booster’.
NOTE
Illustrations
In this instruction manual the illustrations may differ from the machine appearance.

2 | Product Description
6 / 36 0870206364_WV1200-2400A_Ex_-0004_IM_en
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.
A bypass valve (BPV) limits automatically the differential pressure between inlet and out-
let.
2.2 Application
The machine is intended for the suction of air and other dry, non-aggressive and non-
toxic gases.
Explosive gases and vapour mixtures can be drawn according to the scope of the Direct-
ive ATEX 2014/34/EU.
Depending on the equipment, the machine is intended for suction of explosive gases ac-
cording to the data given on the nameplate of the machine (NP), see Explanation of
ATEX Classification [►8].
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 potentially explosive environment ac-
cording to the data given on the nameplate of the motor and the nameplate of the ma-
chine (NP), see Explanation of ATEX Classification [►8].
In case Busch delivered the machine without motor and coupling, the following must be
observed:
• In regards to its explosive atmosphere protection class, the motor and the coup-
ling must have at least the same ATEX classification as the machine for the outside
area “Outside (o)”.
• The motor and the coupling do not require an ATEX certification when the ma-
chine ATEX classification corresponds to “Outside (o) No ATEX zone”.
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 [►34].

Product Description | 2
0870206364_WV1200-2400A_Ex_-0004_IM_en 7 / 36
2.3 Shaft Sealing Variants
2.3.1 Mechanical Seal
The shaft sealing consists, in standard execution, of a mechanical seal.
2.3.2 Lip Seals (Optional)
Optionally, the shaft sealing may consist of three lip seals. This variant requires an oiler
(OR) in order to continuously lubricate the sealing system.
2.4 Accessories
NOTE
Depending on the ATEX classification of the machine, some of the following accessories
may be mandatory, see ATEX Classifications and Associated Accessories [►9].
2.4.1 Resistance Thermometer
The resistance thermometer monitors the exhaust gas temperature.
Warning and trip signals must be set, see Wiring Diagram Resistance Thermometer [►19].
2.4.2 Active Bypass Valve
The active bypass valve allows the gas to flow (forced bypass) when the absolute inlet
pressure (P1) is above 100 hPa (abs.).
The active bypass valve is controlled mechanically by a double activated pneumatic cylin-
der.
A pressure switch/transmitter and a directional control valve (not delivered) must be installed to
control the active bypass valve, see Pneumatic Connection (with Active Bypass Valve only)
[►13].
The limit switch (GS/0601) detects the position of the active bypass valve. See Wiring
Diagram Limit Switch [►20].
X
P1
P1
GS/0601
GS/0601
P1 <100 hPa = free bypassP1 >100 hPa = forced bypass
- the active bypass valve is released
- the limit switch signal can be ignored
- the vacuum booster is running
- the active bypass valve is forced in high position
- the limit switch (GS/0601) validates the high
position of the bypass
- the gas flow goes through the bypass channel
- the vacuum booster does not operate
NOTE
The active bypass valve can be substituted by an external bypass (not delivered), see
P&ID "Piping and Instrumentation Diagram" [►9].

2 | Product Description
8 / 36 0870206364_WV1200-2400A_Ex_-0004_IM_en
2.5 Explanation of ATEX Classification
2.6 Safety concept
WARNING
Misinterpretation of the ATEX instructions.
Risk of severe injury!
Risk of explosion!
• Make sure that the recommendations described in this manual correspond to the
ATEX marking written on the nameplate (NP).
• If anything needs to be clarified, please contact your Busch representative.
The safety concept is based on the prevention of sparks and excessive temperatures by
means of various accessories.
The monitoring devices must be integrated into the system control such that operation
of the machine will be inhibited if the safety limit values are exceeded.
The limit values of each accessory are defined in the wiring diagram chapters, see Elec-
trical Connection of the Monitoring Devices [►19].
To have more details about the monitoring procedure, see Flowchart [►22].

Product Description | 2
0870206364_WV1200-2400A_Ex_-0004_IM_en 9 / 36
2.6.1 ATEX Classifications and Associated Accessories
The following table defines the obligatory accessories depending on the ATEX classifica-
tion.
(i) No ATEX zone
(o) II 3G Ex h IIC T4 Gc X
TSA+
/0101
ATEX
MOT IIC
ATEX
CPL ECP
X
A
B
C
D
ATEX
MOT IIB
(i) II 3G Ex h IIC T3, T4 Gc X
(o) II 3G Ex h IIC T4 Gc X
(i) No ATEX zone
(o) II 2G Ex h IIB (or IIC) T4 Gb X
(i) II 2G Ex h IIB T3, T4 Gb X
(o) II 2G Ex h IIB (or IIC) T4 Gb X
X
X
BPV
E
(i) II 2G Ex h IIB T3, T4 Gb X
(o)
No ATEX zone X
X*
X*
X*
X
X
X
X
X
X
X
X
X
X
X
X
X
X
(X)
(X)
ATEX classification
* can be substituted by an external bypass
Active
BPV Active bypass valve or external bypass CPL Coupling
ECP Pump earth connection MOT Motor (IIB or IIC)
TSA Resistance thermometer
2.6.2 P&ID "Piping and Instrumentation Diagram"
TSA+
0101
IN
OUT
M
CPL
MOT
BPV
TSA+
0101
IN
OUT
M
CPL
MOT
BPV
PS/PSA
GS
0601
TSA+
0101
IN
OUT
M
CPL
MOT
BPV
PS/PSA
MV
MV
MV
P1
P1
P&ID - standard execution P&ID - with active bypass P&ID - with external bypass
P1 >100 hPa = active bypass forced open
P1 <100 hPa = active bypass free
P1 >100 hPa = external bypass open
P1 <100 hPa = external bypass closed
(not included in the scope of delivery)
(Optional)
External bypass open when P1 >100 hPa
(Normally open)
(Normally closed)
(Normally closed)
P1 >100 hPa = MOT state "OFF"
P1 <100 hPa = MOT state "ON"
P1 >100 hPa = MOT state "OFF"
P1 <100 hPa = MOT state "ON"
BPV Bypass valve CPL Coupling
GS Limit switch IN Suction connection
MOT Motor MV Solenoid valve (not included)
OUT Discharge connection PS/PSA Pressure switch/transmitter
(not included)
TSA Resistance thermometer

3 | Transport
10 / 36 0870206364_WV1200-2400A_Ex_-0004_IM_en
3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
WARNING
Lifting the machine using the motor eye bolt.
Risk of severe injury!
• Do not lift the machine using the eye bolt fitted to the motor. Only lift the machine as
shown.
NOTICE
In case the machine is already filled with oil.
Tilting a machine that is already filled with oil can cause large quantities of oil to 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)
• Check the machine for transport damage.
If the machine is secured to a base plate:
• Remove the machine from the base plate.
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.