Instruction Manual PUMA WPA 040-095 A_EN_en.pdf

Installation and Operating Instructions

Vacuum pumps WPA 040/ 055/

075/ 080/ 095 A

0870544564/-0001 20.10.2021/ Original instructions 20000 48003 robert.babic Texte tapé à la machine

Table of Contents Introduction

Product description Use Principle of operation Cooling On/Off switch

Safety Intended use Safety notes Sound Emissions

Transport Transport in Packaging Transport without packaging

Storage Short-term Storage Removal of the pump Conservation

Commissioning after conservation

Installation and Commissioning Installation Prerequisites

Local installation Suction Connection Discharge connection Drive/ Coupling

Coupling alignment Electrical connection/ Controls

Installation Fitting Electrical connection Operation with frequency converter With pole-changing motor Connecting lines/ piping Filling up with Oil Saving the Operating Parameters

Water-cooled seal ring housing Preconditions to water-cooling:

Water quantities:

Recommendation:

Recommendations on operation Application New start after shut-down under working pressure

(high end pressure):

Heatable Roots vacuum pump WPA Limitations of use

Maintenance Maintenance Schedule

Weekly Monthly:

After the first 500 operating hours After each 4000 operating hours, latest every year Every 20000 operating hours, at the latest after 3 Years . . 10

Checking the oil Checking the oil level at the gears and bearing housings . . . 10

Oil level with mineral oil:

Oil level with Fomblin oil:

Checking the oil level in the seal housing Topping up with oil Checking the colour of the oil

Life span of the oil at the gears and the bearings Life span of the oil in the seal housing Oil Change

Draining used oil from the gears and the bearings Draining used oil from the seal housing Filling in fresh oil for the gears and the bearings Filling in fresh oil for the seal housing

Overhaul

Removal from Service Temporary preservation Recommissioning Dismantling and Disposal

Exploded view

Full service kit

Oil

Introduction

Introduction Congratulations on your purchase of the Busch vacuum pump/ compressor/ vacuum and pressure pump/ blower. With careful obser-vation of the field’s requirements, innovation and continuous develop-ment, Busch delivers modern vacuum and pressure solutions worldwide.

These operating instructions contain information on

– product description,

– security,

– transport,

– storage,

– installation and commissioning

– maintenance,

– overhaul,

– troubleshooting of the vacuum pump.

For the purpose of these instructions, “handling” the vacuum system means the transport, storage, installation, commissioning, influence on operating conditions, maintenance, troubleshooting and overhaul of the vacuum system.

Prior to handling the vacuum system, these operating instructions must be read and understood. If anything remains to be clarified please contact your Busch representative!

Keep these operating instructions and, if applicable, other relevant operating instructions available and accessible on site.

EU-Declaration of Conformity UK-Declaration of Conformity

Product description Use The vacuum pump is intended for

– the suction of

– air and other dry, non-aggressive, non-toxic and non-explosive ga-ses.

The Roots vacuum pumps are usually used as backing pumps in conjunction with other types of vacuum pumps in vacuum systems.

Conveying media with a higher density than air leads to an increased thermal and mechanical load on the vacuum pump and is permissible only after consultation with a Busch company.

Max. allowed temperature of the drawn gases:

See “Oil, Ambient temperature range”

Make sure that the oil level of both housings is in the upper third of the oil sight glasses (Fomblin oil) when the vacuum pump is at stand-still.

Make sure that the oil level in both housings is in the middle of the oil sight glasses (mineral oil) after the vacuum pump is at standstill.

Make sure that the oil filling level of the drop oiler (b) is in the middle of the oil sight glass.

The vacuum pump is intended for installation in a potentially non-ex-plosive environment (ATEX).

Max. permissible number of startings per hour: 6.

The vacuum pump is thermally suitable for continuous operation.

The vacuum pump is capable of holding end pressure.

Principle of operation The Roots vacuum pumps operate according to the approved principle of the Roots type machine. Operation is both simple and effective.

Two rotors with identical profiles rotate in opposite directions within a casing. As they rotate, gas is drawn into the space between each rotor and the casing where it is trapped and pushed out at the discharge through the rotation of the lobes. This action is repeated twice for each revolution of each rotor and therefore four times for each revolution of the drive shaft. There is no mechanical contact between rotors and cy-linder, therefore no oil lubrication in the process chamber is required.

Cooling All versions are air-cooled.

On/Off switch The vacuum pump comes without on/off switch. The control of the vacuum pump must be provided in the course of the installation.

Safety Intended use DEFINITION: For the purpose of these instructions, “handling” the va-cuum pump means the transport, storage, installation, commissioning, influence on operating conditions, maintenance, troubleshooting and overhaul of the vacuum pump.

The vacuum pump is intended for industrial use. It must be handled by qualified personnel only.

The different applications for use and operational limits of the va-cuum pump as laid out in the “Product Description” and the “Instal-lation Prerequisites” of the vacuum pump must be observed both by the manufacturer of the machinery into which the vacuum pump is to be incorporated and by the end user.

The maintenance instructions must be observed.

Non-observance of the technical application limits and safety regula-tions releases Ateliers Busch from warranty and liability regarding repla-cement for consequential damages. The same applies for defects caused by inspections carried out improperly or outside the given maintenance intervals.

Prior to handling the vacuum pump these operating instructions must be read and understood. If anything remains to be clarified please contact your Busch representative!

Safety notes The vacuum pump has been designed and manufactured in accordance with the latest technical and safety standards. Nevertheless, residual

Product description b Drop oiler c Oil filler plug d Inlet f Oil sight glass g Oil drain plug (under the pump) h Drain plug, seal ring housing i Outlet j Vent plug, seal ring housing risks may remain. These operating instructions and the pump itself in-form about potential hazards where appropriate. Safety instructions can be detected through the keywords, DANGER, WARNING and CAUTION as follows:

DANGER

Disregard of this safety instruction will always lead to accidents with fatal or serious injuries.

WARNING

Disregard of this safety instruction may lead to accidents with fatal or serious injuries.

CAUTION

Disregard of this safety instruction may lead to accidents with minor injuries or property damage.

Sound Emissions Refer to the table “Technical Properties” for the permissible sound le-vels in free field conditions according to EN ISO 2151.

CAUTION

The vacuum pump emits sounds of high intensity.

Risk of hearing damage.

Users spending a longer period of time in the vicinity of a non-insu-lated vacuum pump must wear suitable hearing protection.

Transport Roots vacuum pumps undergo a rigorous operating test in the factory and are packed carefully to avoid transport damage.

The inlet and outlet flange are sealed with plugs so that no dirt can en-ter the pump during transport. These covers must be removed before connecting up the pump.

Please check packaging for transport damage on delivery.

The pump can be lifted from its packaging using the lifting brackets on the pump and a suitable lifting gear or by using belts.

The packaging materials must be disposed of in accordance with appli-cable environmental protection regulations, or re-used.

These operating instructions are part of the delivery packaging consignment.

Pumps are generally shipped without oil.

Operating the vacuum pump without oil will destroy the pump!

Transport in Packaging When packed onto a pallet, the vacuum pump can be moved with sui-table transport equipment.

Transport without packaging

CAUTION

Please check out the weight of the vacuum pump before lifting it up (see "Technical Data").

Use adequate lifting gear for this.

In case the vacuum pump is bolted to a pallet or a base plate :

u Remove the fixing bolts between the vacuum pump and the pallet/base plate

CAUTION

Do not walk, work or stand under suspended loads.

l Attach lifting gear to a crane hook equipped with a safety latch l Lift the vacuum pump with a crane hook

CAUTION

Tilting a vacuum pump that is already filled with oil can cause large quantities of oil to flow into the cylinder.

Starting the vacuum pump with excessive quantities of oil in the cy-linder will immediately break the lobes and destroy the vacuum pump.

Once the vacuum pump is filled with oil it must not be lifted any more.

l Prior to every transport make sure that the oil has been drained (unless recommended otherwise)

Storage Short-term Storage l Make sure that the suction connection/gas inlet and the discharge connection /gas outlet are closed (fit the provided plugs) l Store the vacuum pump

– if possible in its original packaging,

– indoors,

– dry,

– dust free

– vibration free

Switching off and conservation of the pump

Please note TN01175

Removal of the pump Before starting up a vacuum pump that has been stored outside the building for a while, the vacuum pump must be moved to a room with ambient temperature, where it should rest for a day.

Conservation In case of adverse ambient conditions (e.g. aggressive atmosphere, fre-quent temperature changes) the vacuum pump must be preserved af-ter one week using a conservation agent inside the cylinder. In case of favourable ambient conditions, the pump must be preserved using a conservation agent inside the cylinder if the pump is to be stored for more than 3 months.

CAUTION

Using the pump with the gas discharge connection closed will da-mage the vacuum pump.

Make sure that the gas discharge connection is open.

CAUTION

During operation the surface of the vacuum pump may exceed tem-peratures of 70°C.

Risk of burns!

Do not touch the hot housing.

l Electrically connect the vacuum pump (see “Installation and Com-missioning, Installation, Connect Electrically”)

Transport l Dispose of the used oil in compliance with applicable regulations l Switch off the vacuum pump l Make sure that the oil level at the gears and bearings is between the MIN and MAX markings of the oil sight glasses l Make sure that oil level of the drop oiler (b) is in the middle of the oil sight glass.

l Make sure that all openings are firmly closed; seal all openings that are not closed with PTFE-tape, gaskets or o-rings, with adhesive tape.

l Wrap the vacuum pump in VCI film

NOTE: VCI stands for “Volatile Corrosion Inhibitor”. VCI-products (film, paper, cardboard, foam) evaporate a substance that condenses in molecular thickness on the packed good and by its electrochemical properties effectively suppresses corrosion on metallic surfaces. Howe-ver, VCI-products may attack the surfaces of plastics and elastomers.

Seek advice from your local packaging dealer! VCI packaging ensures good protection against corrosion for a few years, even in the most ex-treme of conditions such as see transport and prolonged storage.

l Store the vacuum pump

– if possible in its original packaging,

– indoors,

– dry,

– dust free and

– vibration free

Repeat the conservation process after 12 months of standstill.

CAUTION

Before a new conservation process or re-installation of the vacuum pump, make sure that the gasket, plug or adhesive tape from the discharge connection are removed.

Commissioning after conservation l Make sure that all gaskets, plugs or adhesive tape are removed from the openings l Make sure that the oil level at the gears and bearings is between the MIN and MAX markings of the oil sight glasses l Make sure that oil level of the drop oiler (b) is in the middle of the oil sight glass.

l Commission the vacuum pump as described in the chapter “Instal-lation and Commissioning”

Installation and Commissioning Installation Prerequisites

CAUTION

In case of non-compliance with the installation prerequisites, parti-cularly in case of insufficient cooling :

Risk of damage or destruction of the vacuum pump and adjoining system components!

Risk of injury!

The installation prerequisites must be complied with.

l Make sure that the integration of the vacuum pump is carried out in such a way that the essential safety requirements of the Ma-chine Directive 2006/42/EC are complied with (regarding the res-ponsibility of the designer of the machinery into which the vacuum pump is to be incorporated; see also the note in the EC-Declaration of Conformity)

WARNING

Please take into account that the running blower may induce vibra-tions and sound emission in the pipework and foundations.

Therefore isolation- and sound protection measures must be consi-dered in the planning stage already.

Safety precautions and technical documents of your component suppliers must be observed, if you carry out the planning of a sys-tem and/ or installation of the blower stage on your own!

Local installation l Make sure that the vacuum pump is switched off and cannot acci-dentally be switched on again l Make sure that the following ambient conditions are adhered to:

– Ambient temperature : see “Oil”

– Ambient pressure: atmospheric l Make sure that the environmental conditions comply with the pro-tection class of the drive motor (according to the nameplate) l Make sure that the vacuum pump is placed on or fastened to a horizontal surface l Make sure that the vacuum pump is level and even l Make sure that the vacuum pump cannot inadvertently or intentio-nally be used as a support for heavy objects l Make sure that the vacuum pump cannot be hit by falling objects l Make sure that the vacuum pump is at least 0,5m away from any wall to ensure sufficient cooling l Make sure that no temperature-sensitive components (plastics, wood, cardboard, paper, electronics) come into direct contact with the hot surface of the vacuum pump l Make sure that the installation site or assembly area is ventilated in such a way that adequate cooling of the vacuum pump is guaranteed

CAUTION

During operation the surface of the vacuum pump can exceed tem-peratures of 70°C.

Risk of burns!

l Make sure that the vacuum pump cannot be touched inadvertently during operation, provide a guard if necessary l Make sure that the oil sight glasses (f,80) remain easily accessible

If the oil change is meant to be performed on site:

u Make sure that the oil drain plugs (g) and the oil filler plugs (c) remain easily accessible

Suction Connection

CAUTION

Do not put hands into the inlet aperture.

Risk of body damage!

CAUTION

The ingress of foreign particles or liquids can destroy the vacuum pump.

In case the inlet gas contains dust or other foreign solid particles :

u Make sure that a suitable filter is installed upstream of the va-cuum pump

Installation and Commissioning l Make sure that the suction line fits the suction flange/gas inlet of the vacuum pump l Make sure that the vacuum pump is switched off and cannot acci-dentally be switched on again

When using pipes :

u Make sure that the pipe does not exercise any pressure on the vacuum pump’s connection, use bellows if necessary u Make sure that distance on the sealing surfaces on each side does not exceed 0,05 mm l Make sure that the suction line’s diameter on its entire length is at least as large as the diameter of the suction connection/gas inlet(d) of the vacuum pump

If two or more vacuum pumps work on the same suction line, if the volume of the vacuum system is large enough to draw back oil after having been switched off, or if the vacuum must be maintained after switching off the vacuum pump :

u Provide a manually or automatically operated valve (=non-re-turn valve) in the suction line

(the non-return valve installed as standard inside the suction connec-tion is not meant to be used for this purpose!)

If the vacuum pump is intended to be used for the drawing of gases that contain limited quantities of condensable vapour :

u Provide a shut-off valve, a drain line and a drain tap in the suc-tion line, so that condensates can be drained from the suction line l Make sure that the suction line does not contain foreign matter, e.g. welding slag

Discharge connection

CAUTION

Do not put hands into the outlet aperture.

Risk of body damage!

The following guidelines for the discharge line do not apply if the drawn air is discharged into the environment directly at the vacuum pump.

l Make sure that the discharge line fits the gas discharge of the va-cuum pump

When using pipes:

u Make sure that the pipe does not exercise any pressure on the discharge connection, use bellows if necessary l Make sure that the discharge line’s diameter over its entire length is at least as large as the diameter of the gas discharge of the va-cuum pump

In case of very long discharge lines, it is advisable to use a larger dia-meter piping in order to avoid a loss in efficiency and an overload on the vacuum pump. For advice please contact your local Busch repre-sentative!

l Make sure that the discharge line either slopes away downwards from the vacuum pump or provide a liquid separator or a drain line with a drain tap, so that no liquids can be drawn back into the va-cuum pump

WARNING

Discharge lines made from non-conducting material can build up electrostatic charge.

Electrostatic discharge can lead to explosion of potentially present oil mist.

The discharge line must be made of conducting material or provi-sions must be made against electrostatic discharge.

Drive/ Coupling l The shaft end must be cleaned from conservation oil prior to as-sembly l Sharp edges on shaft or coupling must be broken / deburred.

l Couplings must be slipped onto the shaft end with the help of a mounting device and a threaded rod.

l The mounting device / threaded rod is to be screwed into the me-tric centering thread of the driving shaft.

CAUTION

Do not install with hammer blows! Risk of bearing damage!

Coupling must be secured against axial displacement after assembly.

Coupling alignment

Concentric running of the coupling must be checked axially and radial-ly using measuring gauges. Install coupling and spacers up to the stop.

Check alignment to the driving coupling half by means of measuring gauges or an edge.

Concentricity tolerances:

l Radial: max. 0,05 mm on the shaft (0,1 mm on pul-ley radius) l Axial: max. 0,05 mm on pulley radius u At a distance r=100 mm from shaft centre.

u Concerning other distances the tolerances must be converted proportionally.

Electrical connection/ Controls l Make sure that the regulations acc. to the EMC-Directive

2014/30/EU as well as the EN-standards, electrical and occupa-tional safety directives and the local or national regulations, respec-tively, are complied with (this is in the responsibility of the designer of the machinery into which the vacuum pump is to be incorpora-ted; see also the note in the EC-Declaration of Conformity) l Make sure that the power supply is compatible with the specifica-tion on the nameplate of the drive motor l Make sure that an overload protection according to EN 60204-1 is provided for the drive motor l Make sure that the drive of the vacuum pump will not be affected by electric or electromagnetic disturbance from the mains; if neces-sary contact the Busch service for advice

In case of mobile installation :

u Make sure that the vacuum pump is switched off and cannot accidentally be switched on again l If the Roots blower is used in a vacuum system where a vacuum pump is connected upstream, the vacuum pump can only be star-ted up after the primary pump has gone into operation.

Installation

Fitting l Make sure that the “Installation Prerequisites” are complied with l Fit or mount the vacuum pump at its final location

Electrical connection

WARNING

Risk of electrical shock, risk of damage to equipment.

Electrical installation work must only be executed by qualified per-sonnel that knows and observes the following regulations:

- IEC 364 or CENELEC HD 384 or DIN VDE 0100, respectively,

- IEC-Report 664 or DIN VDE 0110,

- BGV A2 (VBG 4) or corresponding national accident prevention regulations.

CAUTION

The wiring diagrams given below are typical. Depending on specific purchase orders or certain markets different wiring diagrams may apply

Risk of damage to the drive motor!

The inside of the terminal box must be checked for correct drive motor wiring diagrams/instructions.

l Electrically connect the drive motor l Connect the earth

Triangle connection (low voltage):

Star connection (high voltage):

CAUTION

Operation in the wrong direction of rotation of the motor will des-troy the vacuum pump within a very short period of time.

Risk of explosion of the drive motor!

Prior to starting-up make sure that the vacuum pump is to be opera-ted in the right direction.

l Make sure that the vacuum pump is switched off and cannot acci-dentally be switched on again l Switch on the drive motor for a fraction of a second only l Watch the fan of the drive motor and determine the direction of rotation just before the fan stops

If the direction of rotation of the fan must be changed:

u Switch around any two of the drive motor wires in the terminal box

Operation with frequency converter l In case a frequency converter is provided, the electrical and mecha-nical characteristics of the drive motor must be taken into account.

l The minimum frequency must always be set to a specified value.

This frequency must not be undercut during operation .

l The maximum frequency must be set, taking into account the maximum motor speed and the maximum rotational speed of the vacuum pump.

l The acceleration time of the drive motor from standstill up to mini-mum speed may be 3 to 6 seconds.

l The frequency converter must be designed for operation with a machine with constant torque.

Min.- or max. rotational speeds must not be exceeded or undercut.

l The highest admissible rate of voltage increase for the motor converter is 1200 V/ms. When exceeding this value, e.g. due to ex-cessively long cables, the frequency converter type etc., a motor throttle / motor filter coil compatible with the frequency converter must be fitted.

Leaving out any of these components may lead to damage of the motor insulation and to a motor breakdown.

l The max. rotational speed alteration rate for vacuum pumps after acceleration to min. speed for upward and downward regulation time is 1 Hz per second.

Min. frequency = 20Hz Max. frequency = 50Hz results in a regulation time of 30 seconds from min. to max. frequency.

l The max. current limit of the motor must not be exceeded.

Follow the information on the motor nameplate.

l In order to avoid any problems during operation, the function “in-terception circuit” must not be parametrised in the supervision of the frequency converter. When switching off the frequency converter, a re-start is only permitted after a complete standstill of the vacuum pump.

With pole-changing motor Between every change of motor speed:

l From high to low rotational speed the motor must have reached zero speed every time l Switching from low to high rotational speed switching can be done directly and instantaneously.

Connecting lines/ piping In case the suction line is equipped with a shut-off valve :

u Connect the suction line l Connect the discharge line l Make sure that cooling air inlets and outlets are not covered or obstructed and that the cooling air flow can circulate without obstruction

Filling up with Oil The gears and the bearings are oil-lubricated.

In case the pump has been preserved with conservation oil:

u Drain any remaining conservation liquids (see “Maintenance, Draining the Oil”)

CAUTION

The vacuum pump is always shipped without oil.

Operation without oil will destroy the vacuum pump within a veryshort period of time.

Prior to commissioning the vacuum pump, make sure that oil is filled in.

The vacuum pump is delivered without oil (oil specification see “Oil”).

The application of the vacuum pump will determine the oil to be used.

CAUTION

In case of a change-over from mineral to a fully synthetic oil an oil change has to be carried out after 50 operating hours.

This even applies for initial filling with synthetic oil as the machines are tested with a mineral oil.

Dispose of the used oil according to applicable environmental protec-tion regulations.

NOTE: The quantity of oil given in these operating instructions serves as a guideline only. Check the oil level with the help of the oil sight glasses (f,80) on he vacuum pump.

CAUTION

Before changing the oil type, compatibility must be checked and, if necessary, the pump must be flushed.

CAUTION

In case the vacuum pump has been treated with conservation oil:

Synthetic oils (except for oils based on poly-olefin) are incompatible with mineral oils and conservation oils.

Risk of foam building leading to the destruction of the vacuum pump.

CAUTION

Oil may only be filled in through oil filler holes (c).

Remove oil filler plugs (c) only if the vacuum pump and the primary pump are at a complete standstill.

The vacuum pump must only be operated with the oil filler plugs (c) firmly tightened up.

l Make sure that the oil drain plugs (g) are closed l Remove oil filler plugs (c) l Fill in the relevant quantity of oil as detailed in the table “Oil Quantity” l When using mineral oil, make sure that the oil level at the gears and bearings is in the middle of the oil sight glasses. When using

Fomblin oil, make sure that the oil level stands at 2/3 in the oil sight glasses.

l Make sure that the oil level of the drop oiler (b) is in the middle of the reservoir

CAUTION

Depending on the model, the drop oiler is also supplied as an “op-tional accessory” and must be fitted prior to filling up.

Prior to fitting, remove the plug of the connection pipe and screw in the drop oiler together with a corresponding seal.

l Make sure that the seals of the oil drain plugs (g) are not dama-ged and positioned correctly. Replace seals if damaged.

l Refit the oil filler plugs (c) together with the seals l Switch on the vacuum pump

In case the suction line is equipped with a shut-off valve:

u Close the shut-off valve

In case the suction line is not equipped with a shut-off valve:

u Cover the suction flange with a rubber mat (d) l Let the vacuum pump run for a few minutes l Switch off the vacuum pump and wait for a few minutes l When using mineral oil, make sure that the oil level at the gears and bearings is in the middle of the oil sight glasses. When using Fomblin oil, make sure that the oil level stands at 2/3 in the oil sight glasses.

l Make sure that the oil level of the drop oiler (b) is in the middle of the reservoir

CAUTION

The oil level in the transparent reservoir may increase due to the in-fluence of heat.

If the oil level has dropped below the MIN- marking of the oil sight glass.

u Top-up with oil

In case the suction line is equipped with a shut-off valve:

u Open the shut-off valve

In case the suction line is not equipped with a shut-off valve:

u Remove the rubber mat from suction flange and connect the suction line

Saving the Operating Parameters Make sure that the vacuum pump and the primary pump are switched off and cannot accidentally be switched on again.

l Measure the working current of the drive motor and keep it as re-ference value for all future maintenance and repair work

Water-cooled seal ring housing On vacuum pumps with water-cooed seal housing the cooling water supply is to be connected prior to commissioning.

Preconditions to water-cooling:

l Water pressure max. 6 bar l water inlet temperature max. 35°C l water outlet temperature max. 50°C l DT to be set between inlet and outlet: min. 4K l Any cooling water flow reduction must be on the outlet side l water quality: as per works standard TN01153 l Electrical conductivity: 100-150 µ s/cm u pH-values (25°C): 8-9 u Hardness (°d): 2-3 u Chlorides: 1 mg/l (<100mg/l no flocks contained) u Mineral shares (salt content): <0,02 mg/l (silicic acid, iron, al-kaline earths) u Oxygen (O2): <0,5 mg/l, (on open reservoirs not possible; 7,8 mg/l saturation) Alternatives: e.g. heat up to 90° then cool down or evacuate.

u Filter fineness: 10 µm u Coating material: chromium oxide l Provide corrosion protection inhibitors in cooling water

Water quantities:

Profile 10-20: approx. 5 l/min

Recommendation:

Concerning danger of frost the cooling water should be provided in addition with an antifreezing compound

Recommendations on operation

Application

CAUTION

The vacuum pump is designed for operation under the conditions described below.

In case of disrespect of the above, risk of damage or destruction of the vacuum pump and adjacent system components!

Risk of Injury!

The vacuum pump must only be operated under the conditions described below.

The vacuum pump has been designed for

– the suction of

– air and other dry, non-aggressive, non-toxic and non-explosive ga-ses.

The Roots vacuum pumps are usually used in conjunction with other types of primary pumps in vacuum systems.

Drawing substances with a higher density than air leads to an increased thermal and mechanical load on the vacuum pump and is permissible only after consultation with Busch.

Max. allowed temperature of the drawn gas:

See “Oil, Ambient temperature range”

Dispose of the used oil according to applicable environmental protec-tion regulations.

Max. permissible number of startings per hour: 6.

The vacuum pump is thermally suitable for continuous operation.

The vacuum pump is ultimate pressure- proof.

The pumping of other vapours must be previously approved by the Busch Company.

CAUTION

During operation the surface of the vacuum pump may exceed tem-peratures of 70°C.

Risk of burns!

The vacuum pump must be protected against contact during opera-tion, provide a guard if necessary

CAUTION

The vacuum pump emits sound of high intensity.

Risk of hearing damage.

Users spending a longer period of time in the vicinity of a non-insu-lated vacuum pump must wear suitable hearing protection.

l Make sure that the vacuum pump and the primary pump are swit-ched off and cannot accidentally be switched on again.

l Make sure that protective devices will not be disconnected l Make sure that cooling air inlets and outlets are not covered or obstructed and that the cooling air flow can circulate without obstruction l Make sure that the “Installation Prerequisites” (see “Installation Prerequisites and Commissioning”) are followed, particularly follow those instructions that ensure sufficient cooling

New start after shut-down under working pressure (high end pressure):

After a shut-down under working pressure the WPA Vacuum Pump should be started anew only after previous ventilation of the installa-tion.

Otherwise there is a risk that the internal shaft seal will be damaged.

During shut-down under working pressure, the supporting lubricating film under the lip seal collapses due to the high force between the sea-ling lip and the shaft sleeve. Therefore, when starting anew under wor-king pressure, there will be insufficient lubrication at the sealing lip for a little while. Therefore, prior to each new start under working pres-sure, Ateliers Busch recommends to ventilate the installation until there is almost atmospheric pressure within the oil chambers. This procedure guarantees that the pressure drop and consequently the force between the sealing lip and the shaft sleeve of the internal shaft seal is kept to a minimum.

If, nevertheless, there has to be a start under working pressure, increa-sed wear of the internal shaft seal has to be taken into account. The changing intervals of the shaft seals are likely to be shortened. After having reached the working pressure, it is therefore recommended to maintain a certain minimum rotational speed. This will ensure a suffi-cient oil supply to the gears and bearings without shut-down of the installation. The minimum rotational speeds below are applicable for the following operational cases :

l Short-time high-vacuum operation for max. 30 min. (e.g. frequen-cy converter operation)

CAUTION

Continuous operation not permissible.

Risk of contact problems of the rotary lobes due to overheating !

l Operation without motor, rotary lobes rotate due to the drawn vo-lume flow.

Minimum rotational speeds (1/min.)

WPA 040 A (Profile 14) 500

WPA 055 A / WPA 075 A (Profile 15) 500

WPA 095 (Profile 16) 500

Heatable Roots vacuum pump WPA When using Roots pump versions with double-walled side plates, these plates are filled with the heating agent. Permissible heating media are steam, oil or recycled water.

Max. admissible heating agent temperature: 110°C.

Max. admissible heating agent pressure: 2,0 mbar(g).

CAUTION

Risk of burns!

Limitations of use

DP=differential pressure between the outlet and the inlet of the va-cuum pump. See table “Technical Characteristics”. Do not exceed the values given in the table.

Maintenance

DANGER

When the vacuum pump has been drawing toxic gases or gases contaminated with toxic substances, the pump itself may be conta-minated with toxic substances.

These foreign materials can infiltrate the pores, recesses and other internal spaces of the vacuum pump.

Danger to health when checking or cleaning the vacuum pump, or when individual components are changed on or within the vacuum pump.

Danger to the environment.

Always wear protective clothing when carrying out maintenance work.

Contaminated vacuum pumps are spezial waste and must be dis-posed of in accordance with current and local environmental laws.

For all maintenance work, the vacuum pump or the vacuum system must be switched off and it must be ensured that it cannot accidentally be switched on again.

Any dismantling of the pump must be executed by qualified personnel only. Before dismantling, the end user of the vacuum pump must fill in a “Declaration of Contamination of Vacuum Equipment and Compo-nents” which will inform about possible risks and dangers and corres-ponding measures.

Without this document duly filled in and signed by an authorised person, the pump cannot be dismantled.

CAUTION

During operation, the surface of the vacuum pump may exceed temperatures of 70°C.

Risk of burns!

l Prior to any work that requires touching the vacuum pump, let the vacuum pump cool down

When draining the oil:

u Let the vacuum pump cool down for no more than 20 minutes l Prior to disconnecting the inlet or discharge lines, make sure that these pipes/lines have been vented to atmospheric pressure

When contacting the Ateliers Busch After Sales Service concerning maintenance, servicing or overhaul of a Roots WPA vacuum pump, please keep the following information to hand:

l Purchase order- and serial numbers l Describe any failures / malfunctions as detailed as possible l Describe the steps taken so far to remove the failure

Maintenance Schedule NOTE: The maintenance intervals depend very much on the individual operating conditions. The intervals given below must be considered as starting values which should be shortened or extended as appropriate.

Particularly heavy duty operation, e.g. high dust loads in the environ-ment or in the process gases, other contaminations or ingress of pro-cess material, can make it necessary to shorten the maintenance intervals significantly.

Weekly l Check the oil level (see “Checking the oil”)

Monthly:

l Make sure that the vacuum pump and the primary pump are swit-ched off and cannot be accidentally be switched on again l Check the vacuum pump for oil leaks - in case of leaks have the vacuum pump repaired (Busch service)

In case of operation in a dusty environment:

u Make sure that the working area is free from dust and dirt, clean if necessary u Check and clean the motor fan if necessary

After the first 500 operating hours l Drain the oil of the gears and the bearing housings (see “Draining the Oil”)

After each 4000 operating hours, latest every year l Drain the oil of the gears and the bearing housings (see “Draining the Oil”) l Drain the oil of the seal housing (see “Draining the Oil”)

Every 20000 operating hours, at the latest after 3 Years l Have a major overhaul done on the vacuum pump (Busch service)

Checking the oil

Checking the oil level at the gears and bearing housings Oil level with mineral oil:

l Make sure that the vacuum pump and the primary pump are swit-ched off and cannot accidentally be switched on again l Read the level on the oil sight glasses (f,80)

In case the level is above the MAX-marking:

u Change the oil (see “Change the oil”)

Dispose of the used oil in compliance with applicable environmental protection regulations.

Maintenance

Oil level with Fomblin oil:

l Make sure that the vacuum pump and the primary pump are swit-ched off and cannot accidentally be switched on again l Read the level on the oil sight glasses (f,80) l Make sure that the oil level at the gears and bearing housings stands at 2/3 in the oil sight glasses

Dispose of the used oil in compliance with applicable regulations.

Checking the oil level in the seal housing l Make sure that the vacuum pump is switched off and cannot acci-dentally be switched on again l Check the oil level of the drop oiler (b)

If either an excessive rise or drop in the oil level of the drop oiler is no-ticed, please check for possible causes under chapter “Troubleshoo-ting”.

Dispose of the used oil in compliance with applicable regulations.

Topping up with oil NOTE: Under normal conditions, there should be no need to top up with oil during the recommended oil change intervals. A significant le-vel drop indicates a malfunction (see “Troubleshooting”).

CAUTION

Make sure that the vacuum pump is switched off and cannot acci-dentally be switched on again.

Please fill in the oil after removing the oil filler plugs on the cylinder covers.

l Remove oil filler plugs l Top up with oil until the oil level is in the middle of the oil sight glasses (Mineral oil) l When using mineral oil, make sure that the oil level at the gears and bearings is in the middle of the oil sight glasses. When using Fomblin oil, make sure that the oil level stands at 2/3 in the oil sight glasses.

l Make sure that oil level of the drop oiler (b) is in the middle of the oil sight glass l Refit the oil filler plugs (c) l Make sure that the oil filler plugs have been correctly fitted after filling in the oil, so that no air can enter the pump. Too high an oil level must be avoided as well as this could lead to overheating of the gears.

l Please always use a new seal

CAUTION

We recommend submitting the pump to leakage rate test in order to ensure the pump is leak tight.

Checking the colour of the oil NOTE: The oil should have a light colour and can be transparent, a little foamy or a little clouded. A milky discolouration that does not va-nish after the oil has been left to rest indicates contamination with fo-reign material. Darkly coloured oil has either been contaminated with foreign material or burnt and must be changed (see “Oil Change”).

Life span of the oil at the gears and the bearings The oil life depends very much on the operating conditions. A clean and dry air stream and operating temperatures below 100°C are ideal.

Under these conditions the oil and the oil filter must be changed every 4000 operating hours, latest after 6 months.

Under very unfavourable operating conditions the oil life can be less than 500 operating hours. Extremely short life times indicate malfunc-tions (see “Troubleshooting”) or unsuitable operating conditions.

If there is no experience available regarding the oil life under the pre-vailing operation conditions, it is recommended to have an oil analysis carried out every 1000 operating hours and establish the oil change in-terval accordingly thereafter.

Life span of the oil in the seal housing The oil life depends very much on the operating conditions. A clean and dry air stream and operating temperatures below 100°C are ideal.

Under these conditions, the oil must be changed latest after 4000 ope-rating hours or one year.

Under very unfavourable operating conditions the oil life can be less than 500 operating hours. Extremely short life times indicate malfunc-tions (see “Troubleshooting”) or unsuitable operating conditions.

If there is no experience available regarding the oil life under the pre-vailing operation conditions, it is recommended to have an oil analysis carried out every 1000 operating hours and establish the change inter-val accordingly thereafter.

Oil Change

WARNING

When the vacuum pump has been drawing toxic gases or gases contaminated with toxic substances, the pump itself may be conta-minated with toxic substances.

Danger to health when checking or cleaning the vacuum pump, or when individual components are changed on or within the vacuum pump.

Danger to the environment.

When working on, or handling, a contaminated pump, suitable and appropriate safety clothing must be worn.

Contaminated vacuum pumps are special waste and must be dis-posed of in accordance with current and local environmental laws.

Draining used oil from the gears and the bearings NOTE: After switching off the vacuum pump at normal operating tem-perature, wait no more than 20 minutes before draining the oil.

CAUTION

When draining the oil, the oil temperature must not exceed 60°C.

Risk of burns!

l Make sure that the vacuum pump and the primary pump are swit-ched off and cannot accidentally be switched on again l Make sure that the vacuum pump is vented to atmospheric pres-sure l Put a drain tray underneath the oil drain plugs (g) l Remove the oil drain plugs (g) l Drain the oil

When the oil flow has stopped:

Make sure that all the used oil is drained l Make sure that the seal of the oil drain plug is not damaged and fits correctly. Please always use a new seal.

l Refit the oil drain plugs (g) l Dispose of the used oil in compliance with applicable regulations

Draining used oil from the seal housing NOTE: After switching off the vacuum pump at normal operating tem-perature, wait no more than 20 minutes before the oil is drained.

l Make sure that the vacuum pump and the primary pump are swit-ched off and cannot accidentally be switched on again

Maintenance l Check the oil level of the drop oiler (b) l Remove the oil drain plug (g) l Drain the oil

When the oil flow has stopped:

Make sure that all the used oil is drained l Refit the oil drain plug (g) l Dispose of the used oil in compliance with applicable regulations

Filling in fresh oil for the gears and the bearings

CAUTION

In case of a change-over from mineral to a fully synthetic oil, an oil change has to be carried out after 50 operating hours.

Replace the shaft seals at the driving shaft, if necessary.

In this case, the housing of the gears and bearing seals must be fil-led with the same oil and an oil change must be carried out after 50 operating hours.

l Prepare the necessary oil quantity (see table “Oil quantity”

NOTE: The quantity given in these operating instructions serves as a guideline only. Check the oil level with the help of the oil sight glasses (f,80) on the vacuum pump.

l Make sure that oil drain plugs (c) have been correctly fitted and are tight

CAUTION

Oil may be filled through oil filler holes only.

l Remove the oil filler plugs (c) l Fill in the new oil up to the middle of the oil sight glasses (f,80) (Mineral oil) l Fill in the new oil up to 2/3 of the oil sight glasses (f,80) (Fomblin oil) l Make sure that the seals have been fitted to the oil filler plugs (c) and are undamaged, replace if necessary.

l Refit the oil filler plugs (c) l Dispose of the used oil in compliance with applicable regulations

Filling in fresh oil for the seal housing

CAUTION

In case of a change-over from mineral to a fully synthetic oil, an oil change has to be carried out after 50 operating hours.

Replace the shaft seals at the driving shaft.

In this case, the housing of the gears and bearing seals must be fil-led with the same oil and an oil change must be carried out after 50 operating hours.

l Prepare the oil quantity needed (see table “Oil quantity”) l Remove the drop oiler (b) l Fill the seal housing with oil right up to the beginning of the threa-ding of the drop oiler

ATTENTION

Oil may be filled through oil filler hole only.

l Refit the drop oiler (b) l Remove the flap (b) of the drop oiler l Fill the drop oiler (b) reservoir up to the middle.

Overhaul

ATTENTION

In case of a change-over from mineral to a fully synthetic oil, an oil change has to be carried out after 50 operating hours.

CAUTION

In order to achieve the highest degree of efficiency and a long life span, the vacuum pump has been assembled and adjusted in accor-dance with precisely defined tolerances.

This adjustment will be lost during dismantling of the vacuum pump.

It is therefore highly recommended that any dismantling of the va-cuum pump going beyond the scope of description in this manual should be carried out by specially trained Busch service personnel only.

CAUTION

Risk for the operating safety after improper work on the vacuum pump.

Risk of explosion!

Approval for operation of the pump will be void!

Any dismantling of the vacuum pump going beyond the scope of what is described in this manual must be carried out by specially trained Busch service personnel only.

WARNING

Prior to shipping the vacuum pump, it must be decontaminated as thoroughly as possible and the contamination status must be docu-mented in a “Declaration of Contamination” (form downloadable from www.busch-vacuum.com).

Busch service will only accept vacuum pumps that come with a com-pletely filled in and legally binding signed “Declaration of Contamina-tion” (form downloadable from www.busch-vacuum.com).

Removal from Service Temporary preservation l Prior to disconnecting the inlet and discharge lines, make sure that all pipes have been vented to atmospheric pressure

Recommissioning After longer periods of standstill:

u Make sure that the vacuum pump and the primary pump are switched off and cannot accidentally be switched on again u Remove the fan cover of the drive motor u Slowly rotate the fan by hand a few times in the intended di-rection of rotation (see arrow sticker or cast arrow on the fan cover) u Refit the fan cover of the drive motor, in case it might have been removed previously during maintenance work or when removing the pump from service.

l Follow the instructions in chapter “Installation and Commissio-ning”

Overhaul

Dismantling and Disposal

WARNING

Prior to shipping the vacuum pump, it must be decontaminated as thoroughly as possible and the contamination status must be docu-mented in a “Declaration of Contamination” (form downloadable from (www.busch-vacuum.com).

l Drain the oil u Dispose of the used oil in compliance with applicable regula-tions l Make sure that all materials and components that must be treated as special waste have been removed from the vacuum pump l Make sure that the vacuum pump is not contaminated with any harmful foreign material

Based on what is known at the time of print of this manual, the mate-rials used for the manufacturing of the vacuum pump involve no risk.

l Please dispose of used parts and fluids in accordance with local applicable environmental laws and regulations l Dispose of the vacuum pump as scrap metal

Removal from Service

Exploded view

Exploded view

Full service kit These full service kits contain all relevant gasket kits as well as the wear and tear parts that need to be changed.

WPA 040 A 0993 561 987

WPA 055 A 0993 561 988

WPA 075 A 0993 561 989

WPA 080 A 0993 561 990

WPA 095 A 0993 564 801

Full service kit

Seite 15

Oil Oil for the gears and bearings Oils with the following characteristics must be used:

l Non-ageing mineral oils or fully synthetic oils with good, natural corrosion- and ageing protection l Lubrication oils which fulfill the minimum requirements according to: Type CL as per DIN 51 517 part 2 l The lubrication oils must not exceed a vapour pressure of 1x10-4 mbar at 100°C l In case of outdoor installation, make sure that the yield point (solidifying point) of the mineral oil used is below the lowest ambient temperature

Examples of oil types / Proven comparable qualities may also be used

Brand Oil type

ARAL Motanol HV 100

EXXON / MOBIL Nuto H 100

SHELL Corena V

CASTROL Tribol 800 / 100 *

* Fully synthetic oil (Polyglycol), see also lube oil conversion

Oil for seal housing l ARAL Motanol HV 100 / filled in at the factory l Oils which are listed in the above chart “Examples of oils”

Gear Housing and bearing seals housing / seal housing Total oil quantity (in Liter)

WPA 040 A 7

WPA 055 A 12

WPA 075 A 12

WPA 080 A 11

WPA 095 A 11

Oil

Technical Data

Technical Properties - WPA 040 A 3000 min-1 3600 min-1

Nominal displacement 50/ 60 Hz m3/h 3850 4700

Max. differential pressure (standard) 50/ 60 Hz hPa (mbar) 75 75

Nominal motor rating (standard) 50/ 60 Hz kW 11 11

Max. differential pressure (Heavy duty) 50/ 60 Hz hPa (mbar) 100 100

Nominal motor rating (Heavy duty) 50/ 60 Hz kW 15 15

Technical Properties - WPA 055 A 3000 min-1 3600 min-1

Nominal displacement 50/ 60 Hz m3/h 5500 6650

Max. differential pressure (standard) 50/ 60 Hz hPa (mbar) 80 80

Nominal motor rating (standard) 50/ 60 Hz kW 15 15

Max. differential pressure (Heavy duty) 50/ 60 Hz hPa (mbar) 100 53

Nominal motor rating (Heavy duty) 50/ 60 Hz kW 18.5 18.5

Technical Properties - WPA 075 A 3000 min-1 3600 min-1

Nominal displacement 50/ 60 Hz m3/h 7350 8950

Max. differential pressure (standard) 50/ 60 Hz hPa (mbar) 100 53

Nominal motor rating (standard) 50/ 60 Hz kW 18.5 18.5

Technical Properties - WPA 080 A 1500 min-1 1800 min-1

Nominal displacement 50/ 60 Hz m3/h 8000 9800

Max. differential pressure (standard) 50/ 60 Hz hPa (mbar) 75 75

Nominal motor rating (standard) 50/ 60 Hz kW 18.5 18.5

Max. differential pressure (Heavy duty) 50/ 60 Hz hPa (mbar) 80 80

Nominal motor rating (Heavy duty) 50/ 60 Hz kW 22 22

Technical Properties - WPA 095 A 1500 min-1 1800 min-1

Nominal displacement 50/ 60 Hz m3/h 9535 11675

Max. differential pressure (standard) 50/ 60 Hz hPa (mbar) 75 75

Nominal motor…