Busch MINK MM 1202–1322 AP Compressor Instruction Manual

Installation and
Operating Instructions
Compressors
Mink MM 1202, 1252, 1322 AP
ATEX-Version, Gas Tight
Busch Produktions GmbH
Schauinslandstr. 1
79689 Maulburg
Germany
0870142930 /
190705 / Original instructions / Modifications reserved
Table of Contents
Preface
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . 3
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Concept . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operational Options / Use of Optionally Available Equipment . . 5
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . 5
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Start Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transport in Packaging . . . . . . . . . . . . . . . . . . . . . . 6
Transport without Packaging . . . . . . . . . . . . . . . . . . . 6
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Short-term Storage . . . . . . . . . . . . . . . . . . . . . . . . 6
Conservation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation and Commissioning . . . . . . . . . . . . . . . . . . 6
Installation Prerequisites . . . . . . . . . . . . . . . . . . . . . 6
Mounting Position and Space . . . . . . . . . . . . . . . . . 6
Gas Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Connection . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Connection / Controls . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking Synchronising Gear Oil . . . . . . . . . . . . . . . 8
Connecting Electrically . . . . . . . . . . . . . . . . . . . . . 8
Connecting Lines/Pipes . . . . . . . . . . . . . . . . . . . . 9
Checking the Function of the Measurement and Safety Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recording of Operational Parameters . . . . . . . . . . . . . 9
Operation Notes . . . . . . . . . . . . . . . . . . . . . . . . 10
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conveying Condensable Vapours. . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 12
Monthly: . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Every 3 Months: . . . . . . . . . . . . . . . . . . . . . . 12
Every 6 Months: . . . . . . . . . . . . . . . . . . . . . . 12
Every Year: . . . . . . . . . . . . . . . . . . . . . . . . . 13
Every 5000 Operating Hours, At the Latest after 2 Years: . 13
Every 10000 Operating Hours, At the Latest after 2 Years:. 13
Every 20000 Operating Hours, At the Latest after 6 Years:. 13
Functional Check of the Measurement and Safety Instrumentation . 14
Congratulations on your purchase of the Busch compressor. With
watchful observation of the field’s requirements, innovation and steady
development Busch delivers modern vacuum and pressure solutions
worldwide.
These operating instructions contain information for
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product description,
safety,
transport,
storage,
installation and commissioning,
maintenance,
overhaul,
troubleshooting and
spare parts
of the compressor.
The ATEX-drive motor is subject to a separate instruction manual.
For the purpose of these instructions, “handling” the compressor
means the transport, storage, installation, commissioning, influence on
operating conditions, maintenance, troubleshooting and overhaul of
the compressor.
Prior to handling the compressor these operating instructions shall be
read and understood. If anything remains to be clarified please contact your Busch representative!
Keep these operating instructions and, if applicable, other pertinent
operating instructions available on site.
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal from Service . . . . . . . . . . . . . . . . . . . . . . . 14
Temporary Removal from Service . . . . . . . . . . . . . . . . 14
Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . 14
Dismantling and Disposal . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . 20
Equipment Documentation Measurement and Safety Instrumentation .21
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Version with Resistance Thermometer, without Transmitter . 21
Version with Resistance Thermometer and Transmitter . . . . 21
Pressure Switch/Indicator . . . . . . . . . . . . . . . . . . . 22
Excerpt from Operating Instructions Resistance Thermometers and
Thermocouples TR40 Pt100/B/3 . . . . . . . . . . . . . . . . . 23
Excerpt from Operating Instructions Temperature Transmitter
Type TMT181-B . . . . . . . . . . . . . . . . . . . . . . . . . 45
Excerpt from Operating Instructions BA0607 Precont S10 . . . . . 55
Excerpt from operating-/assembly instructions ROTEX coupling . . 62
Excerpt from operating-/assembly instructions BoWex-ELASTIC
coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Busch – All over the World in Industry . . . . . . . . . . . . . . 68
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Preface
page 2
a
b
c
Pressure relief lines with collecting line
Gas inlet
Terminal box
d
e
Nameplate, compressor
Inspection port, cooling air
duct
f
g
Terminal box, temperature
measurement system
Oil sight glass
h
i
j
Cover
Eye bolt
Equipotential bonding rail
k Pressure switch/indicator
l
Nameplate, drive motor
m Connection for equipotential
bonding, inlet air filter
n
o
Inlet air filter (depending on
version)
Cooling air outlet
p
q
Cooling air inlet
Position of condensate drain
cock (optional for version
“Aqua”)
r
s
t
u
v
w
x
y
Directional arrow
Safety valve
Gas recirculation line
Gas discharge
Acoustic enclosure
Cylinder
Rotors
Non-return valve
Product Description
the data given on the nameplate of the compressor and on the data
given on the nameplate of the drive motor.
Use
This requires a separate consideration of the conveyed gas/air or
dust/air mixtures on the one side and the environment of the
compressor on the other. On the nameplate of the compressor the
classification with regard to the conveyed gas/air or dust/air mixtures is
marked with an “(i)” (for “inside”), while the classification with regard
to the environment is marked with an “(o)” (for “outside”). The classification of the motor always refers to the environment.
The compressor is intended for
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the compression
of
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mixtures of dry non-aggressive and non-toxic gases and/or dust
according to the identification on the nameplate of the compressor
(explanation see below)
Conveying media with a lower or higher density than air leads to an increased thermal and/or mechanical load on the compressor and is permissible only after prior consultation with Busch.
Max. allowed temperature of the inlet gas: 40 °C
According to the directive 2014/34/EU (“ATEX 2014”) the
compressor is made for the intended use in potentially explosive
areas according to
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
In case Busch delivered the compressor without drive motor or a replacement motor is to be mounted or for economic reasons the
compressor was equipped with a simpler motor, the following must be
observed:
In case the classifications of the compressor and of the drive motor
are different the inferior classification is relevant. This means also
that the compressor is suitable for the placement in a potentially explosive environment only if both the compressor, the coupling a n d
the drive motor are approved to the required extent for use in potentially explosive areas.
Product Description
page 3
Depending on the version the approval is valid only together with
certain standard or optional components, or is limited by the use of
certain optional components, as described below and in the chapter
Operational Options / Use of Optionally Available Equipment
(Ú page 5).
The classification on the compressor is to be read as follows (interpretations of equipment categories and zones for information only; the
relevant laws, directives and standards are literally binding; for temperature classes and explosion groups see E. Brandes, W. Möller
“Sicherheitstechnische Kenngrößen, Band 1: Brennbare Flüssigkeiten
und Gase”, ISBN 3-89701-745-8 (or equivalent source)):
The compressor is equipped with pressure relief lines between the
pump stage and the gas inlet (b). The pressure relief lines and shaft seal
rings safeguard that no process gases will escape into the environ-ment
of the compressor.
The proper function of the compressor requires ambient pressure
±200* hPa (=mbar) to be present at the gas inlet (b) at any operating
point.
*unless specified otherwise on the nameplate of the compressor
The pressure switch/indicator (k) (for version with temperature monitoring in standard scope of delivery, for version without temperature
monitoring optional) is to be integrated into the system control such
that the maintenance of the permitted pressure range will be monitored. If the pressure gets outside this range the system control must
automatically shut down the compressor.
Standard-version:
The gas shall be free from vapours that would condensate under
the temperature and pressure conditions inside the compressor.
= Execution according to directive 2014/34/EU
inside = in this line classification for explosive atmosphere
inside the compressor
II 2G IIB3 TX = in the process gas explosive atmosphere
consisting of a mixture with air of flammable substances in the form
of gas likely to occur in normal operation occasionally;
if the process gas contains dust, also if the dust is not combustible,
the use of a special ATEX-inlet air filter (with equipotential bonding)
is required; temperature monitoring is required (resistance
thermometer and temperature-transmitter in standard scope of
delivery);
II 3G IIB3 TX = in the process gas explosive atmosphere consisting
of a mixture with air of flammable substances in the form of gas not
likely to occur in normal operation but, if it does occur, will persist for
a short period only;
if the process gas contains dust, also if the dust is not combustible,
the use of a special ATEX-inlet air filter (with equipotential bonding)
is required; temperature monitoring is required (resistance
thermometer and temperature-transmitter in standard scope of
delivery);
II 3D TX °C = in the process gas explosive atmosphere in the
form of a cloud of combustible dust in air not likely to occur in normal
operation but, if it does occur, will persist for a short period only;
the use of the special ATEX-inlet air filter (with equipotential
bonding) is required;
outside = in this line classification for explosive atmosphere in
the environment of the compressor
II 2G IIB3 TX = in the environment explosive atmosphere
consisting of a mixture with air of flammable substances in the form
of gas, vapour or mist likely to occur in normal operation
occasionally; temperature monitoring is required (resistance
thermometer and temperature-transmitter in standard scope of
delivery); sufficiently qualified ATEX-drive motor is required;
II 3G IIB3 TX °C = in the environment explosive atmosphere
consisting of a mixture with air of flammable substances in the form
of gas, vapour or mist not likely to occur in normal operation but, if it
does occur, will persist for a short period only; temperature
monitoring is required (resistance thermometer and temperaturetransmitter in standard scope of delivery); sufficiently qualified
ATEX-drive motor is required
Version “Aqua”:
The compressor features the corrosion protection coating CPC and
is capable of conveying water vapour (Ú page 11: Conveying
Condensable Vapours). Conveyance of other vapours shall be
agreed upon with Busch. Conveyance of water or other liquids in
liquid phase increases the power consumption and shall therefore
be avoided (risk of drive overload).
The compressor is thermally suitable for continuous operation
(100 percent duty).
Max. permissible number of startings per hour: 12
The maximum allowed pressure on the pressure connection (u) is
0.7 ... 2.0 barg (the nameplate of the compressor indicates the valid
pressure). By means of process control it must be made sure that the
maximum allowed pressure will not be exceeded.
The safety valve (s) on the compressor protects the compressor against
overload only. It is n o pressure limiting device in terms of EN 1012-1
for the pressure system. It is not designed for frequent use and must
therefore not be used as a system pressure regulating valve.
Note: The safety valve (s) routes compressed product gas back to the
gas inlet (b). This will increase the gas inlet temperature. In case of
continuous operation of the safety valve the temperature monitoring
will therefore shut down the compressor.
The compressor is not absolutely gas tight. In case of conveying air in
new conditions of the compressor the leakage rate amounts to
1.5 hPa l/s (=mbar l/s) at 2 barg. Due to illegal pressures at the gas
connections, worn shaft seal rings or clogged pressure relief lines this
leakage rate can rise considerably. Make sure that the installation space
or location is vented such that in case of conveying media which are
dangerous to health no impermissible accumulation of conveyed media
in the environment of the compressor will occur. The installation space
or location must be vented sufficiently.
The approval for use in potentially explosive atmospheres is valid for
the compressor together with the described measurement and safety
equipment. The approval is void if the system is altered or if the
scheduled maintenance is not complied with. Maintenance must be
performed by specifically instructed personnel only.
II 2D TX °C = in the environment explosive atmosphere in the
form of a cloud of combustible dust in air likely to occur in normal
operation occasionally; temperature monitoring is required
(resistance thermometer and temperature-transmitter in standard
scope of delivery); sufficiently qualified ATEX-drive motor is
required;
II 3D TX °C = in the environment explosive atmosphere in the form
of a cloud of combustible dust in air not likely to occur in normal
operation but, if it does occur, will persist for a short period only;
temperature monitoring is required (resistance thermometer and
temperature-transmitter in standard scope of delivery); sufficiently
qualified ATEX-drive motor is required
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Product Description
page 4
Safety Concept
Start Controls
Version with temperature monitoring:
The compressor comes without start controls. The control of the
compressor is to be provided in the course of installation.
The safety concept is based on the prevention of excessive temperatures by means of a gas temperature sensor in the vicinity of the
stage gas outlet (=zone of highest temperature) together with various other measures to prevent sparks. The temperature sensor
must be integrated into the system control such that operation of
the compressor will safely be inhibited if the shutdown temperature (see nameplate) is exceeded.
Version with pressure monitoring (k) at the gas inlet (for version with
temperature monitoring in standard scope of delivery, for version without temperature monitoring optional):
In order to ensure the gas tightness the pressure at the gas inlet is
monitored. The pressure switch/indicator (k) (in standard scope of
delivery) must be integrated into the system control such that the
compressor will be switched off if the pressure gets outside the
range from -200 mbarg* to +200 mbarg.
*unless specified otherwise on the nameplate of the compressor
Operational Options / Use of
Optionally Available Equipment
Operation with varying speed, i.e. with a frequency inverter is permitted, provided that the drive motor is approved for frequency inverter
operation and the allowed speed range is given on the nameplate of
the compressor.
Safety
Intended Use
Definition: For the purpose of these instructions, “handling” the
compressor means the transport, storage, installation, commissioning,
influence on operating conditions, maintenance, troubleshooting and
overhaul of the compressor.
The compressor is intended for industrial use. It shall be handled only
by qualified personnel.
The allowed media and operational limits (Ú page 3: Product Description) and the installation prerequisites (Ú page 6: Installation
Prerequisites) of the compressor shall be observed both by the manufacturer of the machinery into which the compressor is to be incorporated and by the operator.
In particular the intended use in potentially explosive areas, i.e. either
inside the compressor or in its adjacency potentially explosive atmosphere can occur, requires that the compressor is equipped accordingly
and carries the Ex-mark and that the associated documentation acc. to
the directive 2014/34/EU is available.
The maintenance instructions shall be observed.
The system control must be designed such that no speed outside the
permissible range can be set.
Prior to handling the compressor these installation and operating instructions shall be read and understood. If anything remains to be
clarified please contact your Busch representative!
For the version “Aqua” it can be necessary to dry the compressor after
process end by means of conveying ambient air (Ú page 11: Conveying Condensable Vapours).
Safety Notes
Aspiration of ambient air from a zone 2 (potentially explosive gas atmospheres) is permitted only if the compressor is approved for the
conveyance of these gases. An ATEX-air filter (with equipotential
bonding) must be installed upstream the ambient air valve.
Aspiration of ambient air from areas not classified as potentially explosive is permitted. It is recommended to install an air filter upstream the
ambient air valve.
Principle of Operation
The compressor has been designed and manufactured according to
state-of-the-art methods. Nevertheless, residual risks may remain.
These operating instructions highlight potential hazards where appropriate. Safety notes are tagged with one of the keywords DANGER,
WARNING and CAUTION as follows:
DANGER_a
Disregard of this safety note will always lead to accidents with fatal or serious injuries.
The compressor works on the claw principle.
The components are dimensioned such, that on the one hand there is
never contact between the two claws or between a claw and the cylinder, on the other hand the gaps are small enough to keep the clearance loss between the chambers low.
In order to avoid the suction of dust, the compressor is equipped with
an air filter (n) on the gas inlet.
In order to avoid the suction of solids, the compressor is equipped with
a screen in the gas inlet.
In order to avoid reverse rotation after switching off, the compressor is
equipped with a non-return valve (y).
The compressor compresses the inlet gas absolutely oil-free. A lubrication of the pump chamber is neither necessary nor allowed.
Cooling
The compressor is cooled by
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WARNING_a
Disregard of this safety note may lead to accidents with fatal or serious injuries.
CAUTION_a
Disregard of this safety note may lead to accidents with minor injuries or property damage.
Noise Emission
For the sound pressure level in free field according to EN ISO 2151
Ú page 65: Technical Data.
CAUTION_a4
radiation of heat from the surface of the compressor
the air flow from the fan wheel of the drive motor
the process gas
the air flow from the fan wheel on the shaft of the compressor
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
The compressor emits noise of high intensity in a narrow band.
Risk of damage to the hearing.
Persons staying in the vicinity of a non noise insulated compressor
over extended periods shall wear ear protection.
Safety
page 5
Transport
Transport in Packaging
Packed on a pallet the compressor is to be transported with a forklift.
Transport without Packaging
In case the compressor is packed in a cardboard box with inflated
cushions:
◆ Remove the inflated cushions from the box
In case the compressor is in a cardboard box cushioned with rolled corrugated cardboard:
◆ Remove the corrugated cardboard from the box
In case the compressor is laid in foam:
◆ Remove the foam
In case the compressor is bolted to a pallet or a base plate:
◆ Remove the bolting between the compressor and the pallet/base plate
In case the compressor is fastened to the pallet by means of tightening
straps:
◆ Remove the tightening straps
CAUTION_af
Do not walk, stand or work under suspended loads.
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 electro-chemical properties effectively suppresses corrosion on metallic surfaces. However,
VCI-products may attack the surfaces of plastics and elastomers. Seek
advice from your local packaging dealer! Busch uses CORTEC
VCI 126 R film for the overseas packaging of large equipment.
● Wrap the compressor in VCI film
● Store the compressor
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–
–
–
–
if possible in original packing,
indoors,
dry,
dust free and
vibration free.
For commissioning after conservation:
● Make sure that all remains of adhesive tape are removed from the
ports
● Commission the compressor as described in the chapter Installation
and Commissioning (Ú page 6)
Installation and
Commissioning
Installation Prerequisites
● Make sure that the eyebolts are in faultless condition (replace
damaged, e.g. bent eyebolts with a new ones)
CAUTION_a
● Make sure that the eyebolts are fully screwed in and tightened by
hand
In case of non-compliance with the installation prerequisites, particularly in case of insufficient cooling:
● Attach lifting gear securely to the eyebolts on the synchronising
gear (i, 615) and on the drive motor
Risk of damage or destruction of the compressor and adjoining plant
components!
In case the drive motor comes without an eyebolt or the eyebolt on the
drive motor is located at an unfavourable position:
Risk of injury!
◆ Loop a belt/rope with suitable length and strength around the
flange of the drive motor
● Attach the lifting gear to a crane hook with safety latch
● Lift the compressor with a crane
In case the compressor was bolted to a pallet or a base plate:
◆ Remove the stud bolts from the rubber feet
Storage
Short-term Storage
The installation prerequisites must be complied with.
● Make sure that the integration of the compressor is carried out
such that the essential safety requirements of the Machine Directive 2006/42/EC are complied with (in the responsibility of the
de-signer of the machinery into which the compressor is to be
incorporated; Ú page 20: note in the EU Declaration of Conformity)
Mounting Position and Space
● Make sure that the following ambient conditions will be complied
with:
● Make sure that the gas inlet and the pressure connection are
closed (leave the provided plugs in)
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dry and free from corrosion-promoting gases, vapours, mists and
dusts
● Store the compressor
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–
–
ambient temperature: 0 ... 40 °C
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–
–
–
–
if possible in original packaging,
indoors,
dry,
dust free and
vibration free
Conservation
ambient pressure: atmospheric
altitude of location: up to 1000 m above sea level
● Make sure that the environmental conditions comply with the protection class of the drive motor (according to the nameplate)
● Make sure that the compressor can neither inadvertently nor intentionally be stepped on and cannot be used as a support for heavy
objects
● Make sure that the compressor cannot be hit by falling objects
In case of adverse ambient conditions (e.g. aggressive atmosphere, frequent temperature changes) conserve the compressor immediately. In
case of favourable ambient conditions conserve the compressor if a
storage of more than 3 months is scheduled.
● Make sure that the compressor will be placed or mounted horizontally
● Make sure that all ports are firmly closed; seal all ports that are not
sealed with PTFE-tape, gaskets or o-rings with adhesive tape
● Make sure that in order to warrant a sufficient cooling there will be
a clearance of minimum 1 m between the compressor and nearby
walls
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
● Make sure that the base for placement / mounting base is even
Transport
page 6
● Make sure that no heat sensitive parts (plastics, wood, cardboard,
paper, electronics) will touch the surface of the compressor
● Make sure that the installation space or location is vented such
that a sufficient cooling of the compressor is warranted
CAUTION_ad
The compressor is not absolutely gas tight.
Risk of damage to health!
Make sure that the installation space or location is vented such that
in case of conveying media which are dangerous to health no impermissible accumulation of conveyed media in the environment of
the compressor will occur.
● Make sure that the installation space or location is vented such
that even in the case of an impaired gas tightness of the
compressor (e.g. due to illegal pressures at the gas inlet, worn
shaft seal rings or clogged pressure relief lines) no impermissible
accumulation of process gas in the environment of the compressor
will occur. Closed cooling air circuits are not permitted.
CAUTION_ac
During operation the surface of the compressor may reach temperatures of more than 70 °C.
Risk of burns!
● Make sure that the compressor will not be touched inadvertently
during operation, provide a guard if appropriate
● Make sure that the sight glass (g) of the synchronising gear will remain accessible
Gas Inlet
CAUTION_a
Version “Aqua”, if very humid process gases and/or adverse operating
cycles bear the risk, that condensates remain in the compressor:
◆ Provide a shut-off valve, a drip-leg and a drain cock in the suction line, so that condensates can be drained from the suction
line
◆ Make sure that the anti-pulsation chamber is equipped with a
condensate drain cock (q) (optional; if the condensate drain
cock is missing contact the Busch service)
● Make sure that the suction line does not contain foreign objects,
e.g. welding scales
Pressure Connection
● Make sure that the pressure line fits to the pressure connection (u)
of the compressor
● Make sure that the pressure line is designed for 2.0 barg and
250 °C
Version for the conveyance of explosive atmospheres consisting of a
mixture with air of flammable substances in the form of gas:
◆ Make sure that the pipe is made from electrically conductive
material and equipped with an equipotential bonding connection (execution according to EN 60079-14 or equivalent national or local regulations)
● Make sure that the pipe will cause no stress on the compressor’s
connection, if necessary use an expansion joint
● Make sure that the line size of the pressure line over the entire
length is at least as large as the pressure connection (u) of the
compressor
In case the length of the pressure line exceeds 2 m it is prudent to use
larger line sizes in order to avoid a loss of efficiency and an overload of
the compressor. Seek advice from your Busch representative!
● Make sure that the pressure line either slopes away from the
compressor or provide a liquid separator or a drip leg with a drain
cock, so that no liquids can back up into the compressor
Electrical Connection / Controls
Version with ATEX-drive motor:
Intruding foreign objects or liquids can destroy the compressor.
In case the inlet gas can contain dust or other foreign solid particles:
◆ Make sure that a suitable filter (5 micron or less) is installed
upstream the compressor (included in scope of delivery)
◆ Make sure that the filter is sufficiently ATEX-qualified (electrically conductive, with equipotential bonding etc.; also for
non-combustible dusts!)
● Make sure that the suction line fits to the gas inlet (b) of the
compressor
Version for the conveyance of explosive atmospheres consisting of a
mixture with air of flammable substances in the form of gas:
◆ Make sure that the pipe is made from electrically conductive
material and equipped with an equipotential bonding connection (execution according to EN 60079-14 or equivalent national or local regulations)
Version for the conveyance of explosive atmospheres in the form of a
cloud of combustible dust in air:
◆ Make sure that the pipe is made from electrically conductive
material and equipped with an equipotential bonding connection (execution according to EN 61241-14 or equivalent national or local regulations)
● Make sure that the pipe will cause no stress on the compressor’s
connection, if necessary use an expansion joint
● Make sure that ambient pressure ±200* hPa (=mbar) will be present at the gas inlet (b) at any operating point
*unless specified otherwise on the nameplate of the compressor
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
◆ Make sure that installation instructions for the ATEX-drive motor (separate leaflet) are available
◆ Observe the instructions given in the installation instructions
manual for the ATEX-drive motor
● Make sure that the stipulations acc. to the EMC-Directive
2004/108/EC and Low-Voltage-Directive 2006/95/EC as well as
the EN-standards, electrical and occupational safety directives and
the local or national regulations, respectively, are complied with
(this is the responsibility of the designer of the machinery into
which the compressor is to be incorporated; Ú page 20: note in
the EU Declaration of Conformity).
● Make sure that the power supply for the drive motor is compatible
with the data on the nameplate of the drive motor
● Make sure that an overload protection according to EN 60204-1 is
provided for the drive motor
● Make sure that the drive of the compressor will not be affected by
electric or electromagnetic disturbance from the mains; if necessary
seek advice from the Busch service
In case of mobile installation:
◆ Provide the electrical connection with grommets that serve as
strain-relief
Version with temperature monitoring:
◆ Execute the interface for the temperature measurement system
in the system control according to the safety concept
(Ú page 5: Safety Concept) and according to the instructions
of the manufacturer (Ú page 21: Equipment Documentation
Measurement and Safety Instrumentation); applicable shutdown temperature Ú nameplate of the compressor)
Installation and Commissioning
page 7
Version with pressure monitoring (k) at the gas inlet (for version with
temperature monitoring in standard scope of delivery, for version without temperature monitoring optional):
Delta connection (low voltage):
◆ Execute the interface for the pressure switch/indicator (k) in
the system control according to the safety concept (Ú page 5:
Safety Concept) and according to the instructions of the manufacturer (Ú page 21: Equipment Documentation Measurement and Safety Instrumentation)
● Make sure that an earth point is available for connection to the
equipotential bonding rail or the ATEX-inlet air filter resp.
Electrical circuits in zone 1 (outside) shall be executed intrinsically safe
in protection class ib acc. to EN 60079-11.
All signal lines shall be executed with shielded cables according to
EN 60079-14 or EN 61241-14 or the equivalent national or local
regulations.
Star connection (high voltage):
Installation
Mounting
● Make sure that the installation prerequisites (Ú page 6) are complied with
● Set down or mount the compressor at its location
Checking Synchronising Gear Oil
The compressor is delivered with oil filled synchronising gear.
Double star connection, multi-voltage motor (low voltage):
The level shall be slightly above the middle of the sight glass (g).
● Check on the sight glass (g) that the proper amount of oil is filled
Connecting Electrically
WARNING_ab
Risk of electrical shock, risk of damage to equipment.
Electrical installation work must only be executed by qualified personnel 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
regulation.
Star connection, multi-voltage motor (high voltage):
Version with ATEX-driver motor:
◆ Connect the drive motor according to the installation instructions for the drive motor (separate leaflet)
Version with non-ATEX-drive motor:
◆ Connect the drive motor according to the installation instructions given below
CAUTION_ad
Operation in the wrong direction of rotation can destroy the
compressor in short time.
CAUTION_a
Risk of explosion!
The connection schemes given below are typical. Depending on the
specific order or for certain markets deviating connection schemes
may apply.
Prior to starting-up it must be made sure that the compressor is operated in the proper direction (clockwise rotating field).
Risk of damage to the drive motor!
● Determine the intended direction of rotation with the arrow (r)
(stuck on or cast)
The inside of the terminal box shall be checked for drive motor connection instructions/schemes.
● “Bump” the drive motor
● Electrically connect the drive motor
● Watch the fan wheel of the drive motor and determine the direction of rotation just before the fan wheel stops
● Connect the protective earth conductor
If the rotation must be changed:
◆ Switch any two of the drive motor wires
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Installation and Commissioning
page 8
WARNING_ad
The proper integration of measurement and safety equipment into
the system control is decisive for the explosion safety of the
compressor.
● Connect the variable ohmic resistance with 3 identical cables to the
pins 1, 2 and 3 of the temperature transmitter as shown in the
sketch (the cable connected to pin 2 compensates the cable resistance)
Risk of explosion!
The compressor may be operated in areas with potentially explosive atmosphere only with completely installed and checked measurement and safety equipment.
Version with temperature monitoring:
◆ Connect the temperature measurement system (part of standard scope of delivery) to the system control
Version with pressure monitoring (k) at the gas inlet (for version with
temperature monitoring in standard scope of delivery, for version without temperature monitoring optional):
◆ Connect the pressure switch/indicator to the system control
Version with equipotential bonding rail:
◆ Connect the equipotential bonding rail to the earth point with
an earth cable
Version with ATEX-inlet air filter, without equipotential bonding rail:
◆ Connect the housing of the ATEX-inlet air filter to the earth
point with an earth cable
Connecting Lines/Pipes
● Switch on the compressor
● Increase the ohmic resistance to the resistance at shutdown temperature according to the Equipment Documentation Measurement and Safety Instrumentation (Ú page 21)
● Make sure that an alarm is released in the system control and the
compressor is shut down automatically
● Decrease the ohmic resistance to a value less than the shutdown
point
● Make sure that the alarm persists
● Make sure that the compressor does not start self-acting
● Switch on the compressor again
● Interrupt the ohmic resistance
● Connect the suction line
● Make sure that a fault indication is released in the system control
and the compressor is shut down automatically
● Connect the pressure line
● Reconnect the variable ohmic resistance
Version with equipotential bonding rail:
● Switch on the compressor again
◆ Connect the equipotential bonding connectors of the pipes to
the equipotential bonding rail
Version with ATEX-inlet air filter, without equipotential bonding rail:
◆ Connect the equipotential bonding connector of the suction
line to the earth point
● Make sure that all provided covers, guards, hoods etc. are
mounted
● 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
● Short circuit the variable ohmic resistance
● Make sure that a fault indication is released in the system control
and the compressor is shut down automatically
● Remove the short circuit
● Remove the variable ohmic resistance
● Reconnect the resistance thermometer Pt100 to the temperature
transmitter (white cable to pin 1, first red cable to pin 2, second
red cable to pin 3, Ú sketch)
Checking the Function of the Measurement
and Safety Instrumentation
(version with temperature monitoring only)
WARNING_ab
Risk of electrical shock, risk of damage to equipment.
Electrical installation work must only be executed by qualified personnel 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
regulation.
● Firmly close the temperature measurement system (f) with the lid
Recording of Operational Parameters
As soon as the compressor is operated under normal operating
conditions:
● Measure the drive motor current and record it as reference for future maintenance and troubleshooting work
● Make sure that the compressor aspirates inert gases and that there
are no potentially explosive atmospheres in the environment
● Open the lid of the temperature measurement system (f)
● Disconnect the white cable from pin 1, the first red cable from
pin 2 and the second red cable from pin 3
● In order to simulate the resistance thermometer Pt100 set a variable ohmic resistance to approx. 100 Ω
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Installation and Commissioning
page 9
Operation Notes
Use
WARNING_ad
The compressor is designed for operation under the conditions described below.
In case of disregard risk of explosion!
The compressor must only be operated under the conditions described below.
WARNING_ad
Operating a faulty compressor puts the explosion safety at risk.
Risk of explosion!
The compressor must only be operated in faultless condition.
A faulty compressor must immediately be removed from service.
The compressor is intended for
–
the compression
of
–
mixtures of dry non-aggressive and non-toxic gases and/or dust
according to the identification on the nameplate of the compressor
(explanation see below)
Conveying media with a lower or higher density than air leads to an increased thermal and/or mechanical load on the compressor and is permissible only after prior consultation with Busch.
Max. allowed temperature of the inlet gas: 40 °C
According to the directive 2014/34/EU (“ATEX 2014”) the compressor
is made for the intended use in potentially explosive areas according
to the data given on the nameplate of the compressor and on the data
given on the nameplate of the drive motor.
This requires a separate consideration of the conveyed gas/air or
dust/air mixtures on the one side and the environment of the
compressor on the other. On the nameplate of the compressor the
classification with regard to the conveyed gas/air or dust/air mixtures is
marked with an “(i)” (for “inside”), while the classification with regard
to the environment is marked with an “(o)” (for “outside”). The classification of the motor always refers to the environment.
In case Busch delivered the compressor without drive motor or a replacement motor is to be mounted or for economic reasons the
compressor was equipped with a simpler motor, the following must be
observed:
In case the classifications of the compressor and of the drive motor
are different the inferior classification is relevant. This means also
that the compressor is suitable for the placement in a potentially explosive environment only if both the compressor, the coupling a n d
the drive motor are approved to the required extent for use in potentially explosive areas.
Depending on the version the approval is valid only together with
certain standard or optional components, or is limited by the use of
certain optional components, as described below and in the chapter
Operational Options / Use of Optionally Available Equipment
(Ú page 5).
The classification on the compressor is to be read as follows (interpretations of equipment categories and zones for information only; the
relevant laws, directives and standards are literally binding; for temperature classes and explosion groups see E. Brandes, W. Möller
“Sicherheitstechnische Kenngrößen, Band 1: Brennbare Flüssigkeiten
und Gase”, ISBN 3-89701-745-8 (or equivalent source)):
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
= Execution according to directive 2014/34/EU
inside = in this line classification for explosive atmosphere
inside the compressor
II 2G IIB3 TX = in the process gas explosive atmosphere
consisting of a mixture with air of flammable substances in the form
of gas likely to occur in normal operation occasionally;
if the process gas contains dust, also if the dust is not combustible,
the use of a special ATEX-inlet air filter (with equipotential bonding)
is required; temperature monitoring is required (resistance
thermometer and temperature-transmitter in standard scope of
delivery);
II 3G IIB3 TX = in the process gas explosive atmosphere consisting
of a mixture with air of flammable substances in the form of gas not
likely to occur in normal operation but, if it does occur, will persist for
a short period only;
if the process gas contains dust, also if the dust is not combustible,
the use of a special ATEX-inlet air filter (with equipotential bonding)
is required; temperature monitoring is required (resistance
thermometer and temperature-transmitter in standard scope of
delivery);
II 3D TX °C = in the process gas explosive atmosphere in the
form of a cloud of combustible dust in air not likely to occur in normal
operation but, if it does occur, will persist for a short period only;
the use of the special ATEX-inlet air filter (with equipotential
bonding) is required;
outside = in this line classification for explosive atmosphere in
the environment of the compressor
II 2G IIB3 TX = in the environment explosive atmosphere
consisting of a mixture with air of flammable substances in the form
of gas, vapour or mist likely to occur in normal operation
occasionally; temperature monitoring is required (resistance
thermometer and temperature-transmitter in standard scope of
delivery); sufficiently qualified ATEX-drive motor is required;
II 3G IIB3 TX °C = in the environment explosive atmosphere
consisting of a mixture with air of flammable substances in the form
of gas, vapour or mist not likely to occur in normal operation but, if it
does occur, will persist for a short period only; temperature
monitoring is required (resistance thermometer and temperaturetransmitter in standard scope of delivery); sufficiently qualified
ATEX-drive motor is required
II 2D TX °C = in the environment explosive atmosphere in the
form of a cloud of combustible dust in air likely to occur in normal
operation occasionally; temperature monitoring is required
(resistance thermometer and temperature-transmitter in standard
scope of delivery); sufficiently qualified ATEX-drive motor is
required;
II 3D TX °C = in the environment explosive atmosphere in the form
of a cloud of combustible dust in air not likely to occur in normal
operation but, if it does occur, will persist for a short period only;
temperature monitoring is required (resistance thermometer and
temperature-transmitter in standard scope of delivery); sufficiently
qualified ATEX-drive motor is required
The compressor is equipped with pressure relief lines between the
pump stage and the gas inlet (b). The pressure relief lines and shaft seal
rings safeguard that no process gases will escape into the environ-ment
of the compressor.
The proper function of the compressor requires ambient pressure
±200* hPa (=mbar) to be present at the gas inlet (b) at any operating
point.
*unless specified otherwise on the nameplate of the compressor
The pressure switch/indicator (k) (for version with temperature monitoring in standard scope of delivery, for version without temperature
monitoring optional) is to be integrated into the system control such
that the maintenance of the permitted pressure range will be monitored. If the pressure gets outside this range the system control must
automatically shut down the compressor.
Installation and Commissioning
page 10
Standard-version:
The gas shall be free from vapours that would condensate under
the temperature and pressure conditions inside the compressor.
Version “Aqua”:
The compressor features the corrosion protection coating CPC and
is capable of conveying water vapour (Ú page 11: Conveying
Condensable Vapours). Conveyance of other vapours shall be
agreed upon with Busch. Conveyance of water or other liquids in
liquid phase increases the power consumption and shall therefore
be avoided (risk of drive overload).
The compressor is thermally suitable for continuous operation
(100 percent duty).
● Make sure that all provided covers, guards, hoods etc. remain
mounted
● Make sure that protective devices will not be disabled
● Make sure that cooling air inlets and outlets will not be covered or
obstructed and that the cooling air flow will not be affected adversely in any other way
● Make sure that the installation prerequisites (Ú page 6: Installation
Prerequisites) are complied with and will remain complied with,
particularly that a sufficient cooling will be ensured
Conveying Condensable Vapours
Version “Aqua”:
Max. permissible number of startings per hour: 12
The maximum allowed pressure on the pressure connection (u) is
0.7 ... 2.0 barg (the nameplate of the compressor indicates the valid
pressure). By means of process control it must be made sure that the
maximum allowed pressure will not be exceeded.
The safety valve (s) on the compressor protects the compressor against
overload only. It is no pressure limiting device in terms of EN 1012-1
for the pressure system. It is not designed for frequent use and must
therefore not be used as a system pressure regulating valve.
Note: The safety valve (s) routes compressed product gas back to the
gas inlet (b). This will increase the gas inlet temperature. In case of
continuous operation of the safety valve the temperature monitoring
will therefore shut down the compressor.
The compressor is not absolutely gas tight. In case of conveying air in
new conditions of the compressor the leakage rate amounts to
1.5 hPa l/s (=mbar l/s) at 2 barg. Due to illegal pressures at the gas
connections, worn shaft seal rings or clogged pressure relief lines this
leakage rate can rise considerably. Make sure that the installation space
or location is vented such that in case of conveying media which are
dangerous to health no impermissible accumulation of conveyed media
in the environment of the compressor will occur. The installation space
or location must be vented sufficiently.
The approval for use in potentially explosive atmospheres is valid for
the compressor together with the described measurement and safety
equipment. The approval is void if the system is altered or if the
scheduled maintenance is not complied with. Maintenance must be
performed by specifically instructed personnel only.
CAUTION_a
Due to the corrosion protection coating CPC the compressor is capable of conveying water vapour.
Very humid process gases and/or adverse operating cycles can lead
to residual condensates, though, which cause corrosion.
If this is the case, it is necessary to counteract residual condensates
by warming up the compressor, conveyance of ambient air after
process end and regular draining of the anti-pulsation chamber (q).
◆ Close the shut-off valve in the suction line
◆ Warm up the compressor for approx. 10 minutes
At process start:
◆ Open the shut-off valve in the suction line
At the process end:
◆ Close the shut-off valve in the suction line
◆ Open the ambient air valve
◆ Operate the compressor for another approx. 10 minutes
◆ Close the ambient air valve
CAUTION_a
During operation of the compressor the anti-pulsation chamber is
under pressure.
CAUTION_ac
During operation the surface of the compressor may reach temperatures of more than 70 °C.
Risk of burns!
The compressor shall be protected against contact during operation,
it shall cool down prior to a required contact or heat protection
gloves shall be worn.
Risk of injury when the condensate drain cock is opened!
Drain condensate only when the compressor is shut down and the
pressure connection (u) is vented to atmospheric pressure.
◆ Regularly drain condensate from the anti-pulsation chamber
(q)
CAUTION_a4
The compressor emits noise of high intensity in a narrow band.
Risk of damage to the hearing.
Persons staying in the vicinity of a non noise insulated compressor
over extended periods shall wear ear protection.
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Installation and Commissioning
page 11
The level of the synchronising gear should stay constant over the lifetime of the oil. If the level does fall, the gear is leaky and the
compressor requires repair (Busch service).
Maintenance
Every 6 Months:
WARNING_ad
The approval of the compressor for use in potentially explosive areas remains valid only if the maintenance is conducted regularly
according to the maintenance schedule below and genuine spare
parts and consumables, approved for use in potentially explosive
areas by Busch, are used exclusively.
Maintenance work must be executed by qualified personnel, specially instructed in the maintenance of this type of compressor by
Busch.
● Make sure that the housing is free from dust and dirt, clean if necessary
● Make sure that the compressor is shut down and locked against inadvertent start up
● Remove the acoustic enclosure
Note: Any kind of deposit on the compressor compromises the explosion safety of the compressor.
Deposits on a fan wheel deteriorate the balancing quality of the fan
wheel, which compromises the explosion safety further.
● Remove the protective grid (e) from the cooling air outlet
WARNING_ad
Do not open the compressor in potentially explosive atmosphere.
● Open the inspection port (e) on the cooling air duct
● Clean the cooling air duct (compressed air)
Risk of explosion!
Note: Make sure that the foam mats do n o t get soaked with water
DANGER_age32
In case the compressor conveyed gas that was contaminated with
foreign materials which are dangerous to health, harmful material
can reside in filters.
● Clean the fan cowlings, fan wheels, the ventilation grilles and cooling fins
● Undo the screws of the drive motor
● Remove the drive motor
Version with ROTEX coupling:
Danger to health during inspection, cleaning or replacement of filters.
Danger to the environment.
Personal protective equipment must be worn during the handling
of contaminated filters.
Contaminated filters are special waste and must be disposed of
separately in compliance with applicable regulations.
CAUTION_ac
During operation the surface of the compressor may reach temperatures of more than 70 °C.
◆ Check the wear of the coupling element (Ú page 62: excerpt
from operating- / assembly instructions of the ROTEX
coupling)
Risk of burns!
If the measured value X < 8 mm:
● Prior to disconnecting connections make sure that the connected
pipes/lines are vented to atmospheric pressure
Maintenance Schedule
Note: The maintenance intervals depend very much on the individual
operating conditions. The intervals given below are upper limits that
must not be exceeded.
Particularly heavy duty operation, such like high dust loads in the environment or in the process gas, other contaminations or ingress of process material, can make it necessary to shorten the maintenance
intervals significantly.
◆ Replace the coupling element (the proper function of the fan
wheel requires the precise adjustment of the coupling on the
motor shaft and on the pump shaft; therefore the coupling element can be replaced by the Busch service only)
Version with BoWex-ELASTIC coupling:
◆ Check the wear of the coupling element (Ú page 63: excerpt
from operating- / assembly instructions of the BoWexELASTIC coupling)
● Mount the drive motor on the compressor
● Mount the protective grid (e) on the cooling air outlet
Monthly:
● Close the inspection port (e) on the cooling air duct
● Make sure that the compressor is shut down and locked against inadvertent start up
● Mount the acoustic enclosure
● Check the inlet air filter (n), if necessary replace
● Make sure that the electrical connection of the temperature monitoring is undamaged
In case of operation in a dusty environment:
◆ Clean as described under Ú page 12: Every 6 Months:
Every 3 Months:
● Make sure that the compressor is shut down
● Check the level of the synchronising gear oil
The level shall be slightly above the middle of the sight glass (g).
● Check the electrical connection
● Make sure that the electrical connection of the pressure monitoring
is undamaged
Version with equipotential bonding of the fan cover:
◆ Make sure that the earth cable on the fan cover is undamaged
(resistance check)
Version with ATEX-inlet air filter (with equipotential bonding):
◆ Make sure that the earthing cable on the inlet air filter housing
is undamaged (resistance check)
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Maintenance
page 12
Every Year:
615
● Make sure that the compressor is shut down and locked against inadvertent start up
● Replace the inlet air filter (n)
424
● Check the inlet screen, clean if necessary
Note: As there is an inlet air filter upstream the inlet screen, the inlet
screen should not show soiling. A soiled inlet screen indicates that the
filter is either broken through or improperly inserted.
WARNING_ad
A soiled screen indicates the improper function of the filter. The
pump chamber contains material that can compromise the explosion safety of the compressor.
Risk of explosion!
If the inlet screen is soiled, the compressor must be cleaned by
Busch service.
Version with vacuum relief valve with inlet air filter:
◆ Replace the inlet air filter of the vacuum relief valve
● Check the function of the measurement and safety instrumentation (Ú page 14: Functional Check of the Measurement and
Safety Instrumentation)
Every 5000 Operating Hours, At the Latest after
2 Years:
● Remove the eyebolt (i, 615)
● Remove the lid (h, 424)
CAUTION_a
Pressurised air supply systems supply a too high pressure.
In case of higher requirements in terms of gas tightness:
◆ Replace the shaft seal rings (Busch service)
Every 10000 Operating Hours, At the Latest after
2 Years:
DANGER_age32
Risk of damage to the compressor.
Adjust the pressurised air to 0.2 barg by means of a pressure regulator.
● Remove the screw plugs of the pressure relief lines and connect
the pressurised air lines (Ú illustration)
In case the compressor conveyed gas that was contaminated with
foreign materials which are dangerous to health, harmful material
can reside in the pressure relief lines (a).
Danger to health during blowing out the pressure relief lines.
Danger to the environment.
Wear personal protective equipment while handling contaminated
pressure relief lines.
Collect deposits from the pressure relief lines and dispose of them
in compliance with applicable regulations.
In order to check the pressure relief lines (a):
● Undo the fittings between the pressure relief lines and the collecting line (Ú illustration)
● Apply 0.2 barg to the pressure relief lines (a)
● Check that both pressure relief lines (a) pass the pressurised air
In case one or both pressure relief line(s) (a) is/are clogged:
◆ Remove the compressor from service and have it repaired
(Busch service)
● Reconnect the collecting line to the gas inlet (b) and to the pressure relief lines
● Reinsert the screw plugs, remount the lid (h, 424) and the eyebolt
(i, 615)
● Undo the fitting between the the collecting line and the gas inlet
(b) and remove the collecting line
● Blow out the collecting line with pressurised air
Every 20000 Operating Hours, At the Latest after
6 Years:
● Have a major overhaul on the compressor (Busch service)
● Pierce the connection for the collection line at the gas inlet (b)
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Maintenance
page 13
Functional Check of the Measurement
and Safety Instrumentation
● Reconnect the resistance thermometer Pt100 to the temperature
transmitter (white cable to pin 1, first red cable to pin 2, second
red cable to pin 3, Ú sketch)
(version with temperature monitoring only)
WARNING_ab
Risk of electrical shock, risk of damage to equipment.
Electrical installation work must only be executed by qualified personnel 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
regulation.
● Make sure that the compressor aspirates inert gases and that there
are no potentially explosive atmospheres in the environment
● Open the lid of the temperature measurement system (f)
● Firmly close the temperature measurement system (f) with the lid
Overhaul
WARNING_ad
● Disconnect the white cable from pin 1, the first red cable from
pin 2 and the second red cable from pin 3
Improper work on the compressor puts the operating safety at risk.
● In order to simulate the resistance thermometer Pt100 set a variable ohmic resistance to approx. 100 Ω
Risk of explosion!
● Connect the variable ohmic resistance with 3 identical cables to the
pins 1, 2 and 3 of the temperature transmitter as shown in the
sketch (the cable connected to pin 2 compensates the cable resistance)
Approval for operation will be void!
Any dismantling of the compressor that is beyond of what is described in this manual must be done by specially trained Busch service personnel only.
DANGER_age32
In case the compressor conveyed gas that was contaminated with
foreign materials which are dangerous to health, harmful material
can reside in pores, gaps and internal spaces of the compressor.
Danger to health during dismantling of the compressor.
● Switch on the compressor
● Increase the ohmic resistance to the resistance at shutdown temperature according to the Equipment Documentation Measurement and Safety Instrumentation (Ú page 21)
● Make sure that an alarm is released in the system control and the
compressor is shut down automatically
● Decrease the ohmic resistance to a value less than the shutdown
point
● Make sure that the alarm persists
● Make sure that the compressor does not start self-acting
Danger to the environment.
Prior to shipping the compressor shall be decontaminated as good
as possible and the contamination status shall be stated in a “Declaration of Contamination” (form downloadable from
www.buschvacuum.com).
Busch service will only accept compressors that come with a completely
filled in and legally binding signed “Declaration of Contamination”
(form downloadable from www.buschvacuum.com).
Removal from Service
● Switch on the compressor again
Temporary Removal from Service
● Interrupt the ohmic resistance
● Prior to disconnecting pipes/lines make sure that all pipes/lines are
vented to atmospheric pressure
● Make sure that a fault indication is released in the system control
and the compressor is shut down automatically
● Reconnect the variable ohmic resistance
● Switch on the compressor again
Recommissioning
● Observe the chapter Installation and Commissioning (Ú page 6)
● Short circuit the variable ohmic resistance
● Make sure that a fault indication is released in the system control
and the compressor is shut down automatically
● Remove the short circuit
● Remove the variable ohmic resistance
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Maintenance
page 14
Dismantling and Disposal
DANGER_age32
In case the compressor conveyed gas that was contaminated with
foreign materials which are dangerous to health, harmful material
can reside in pores, gaps and internal spaces of the compressor.
Danger to health during dismantling of the compressor.
Danger to the environment.
During dismantling of the compressor personal protective equipment must be worn.
The compressor must be decontaminated prior to disposal.
● Drain the oil
● Make sure that materials and components to be treated as special
waste have been separated from the compressor
● Make sure that the compressor is not contaminated with harmful
foreign material
According to the best knowledge at the time of printing of this manual
the materials used for the manufacture of the compressor involve no
risk.
● Dispose of the used oil in compliance with applicable regulations
● Dispose of the compressor as scrap metal
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Removal from Service
page 15
Troubleshooting
WARNING_ad
Vacuum pump/ Compressor/ Vacuum and pressure pump/ Blower for use in potentially explosive atmospheres.
The compressor must only be operated in faultless condition.
Risk of explosion in case of operation of faulty equipment!
A faulty compressor must immediately be removed from service.
In case of faults the cause of which cannot be determined the Busch service must be contacted.
WARNING_ab
Risk of electrical shock, risk of damage to equipment.
Electrical installation work must only be executed by qualified personnel 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 equivalent national accident prevention regulation.
CAUTION_ac
During operation the surface of the compressor may reach temperatures of more than 70 °C.
Risk of burns!
Let the compressor cool down prior to a required contact or wear heat protection gloves.
Problem
Possible Cause
Remedy
The compressor does not reach the usual pressure
The pressure system or pressure line is not
leak-tight
Check the hose or pipe connections for possible leak
The pressure relief valve/regulating system is
misadjusted or defective
Adjust, repair or replace, respectively
The screen in the gas inlet (b) is partially
clogged
Clean the screen
The filter (n) on the gas inlet (b) is partially
clogged
Clean or replace the inlet air filter (n), respectively
Partial clogging in the suction, discharge or
pressure line
Remove the clogging
Long suction, discharge or pressure line with
too small diameter
Use larger diameter
The valve disk of the inlet non-return valve is
stuck in closed or partially open position
Disassemble the inlet, clean the screen and the
valve (y) as required and reassemble
Internal parts are worn or damaged
Repair the compressor (Busch service)
Partial clogging in the suction line
Remove the clogging
The upstream process stage delivers to little or
too much process gas
Make sure that the upstream process stage
delivers the right amount of process gas
The drive motor is not supplied with the correct voltage or is overloaded
Supply the drive motor with the correct voltage
The drive motor draws a too high current
(compare with initial value after commissioning)
Filling the system takes too long
Building up pressure in the system takes too
long
There is an indication on the control panel / in
the control room that the pressure switch/indicator (k) measured a pressure outside the
range from -200 mbarg to +200 mbarg
The compressor does not start
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
If cleaning is required too frequently install a
filter upstream
Troubleshooting
page 16
The drive motor starter overload protection is
too small or trip level is too low
Compare the trip level of the drive motor
starter overload protection with the data on
the nameplate, correct if necessary
One of the fuses has blown
Check the fuses
The connection cable is too small or too long
causing a voltage drop at the compressor
Use sufficiently dimensioned cable
The compressor or the drive motor is blocked
Make sure the drive motor is disconnected
from the power supply
Remove the fan cover
Try to turn the drive motor with the
compressor by hand
If the compressor is blocked:
Repair the compressor (Busch service)
The drive motor is defective
Replace the drive motor (Busch service)
(in order not to compromise the explosion
safety of the compressor the coupling must be
adjusted and measured according to a precisely defined procedure; therefore the motor
must be mounted by the Busch service only)
The compressor is blocked
Solid foreign matter has entered the
compressor
Repair the compressor (Busch service)
Make sure the suction line is equipped with a
screen
If necessary additionally provide a filter
Corrosion in the compressor from remaining
condensate
Repair the compressor (Busch service)
Check the process
Observe the chapter Conveying Condensable
Vapours (Ú page 11)
The compressor was run in the wrong direction
Repair the compressor (Busch service)
The drive motor is running, but the
compressor stands still
The coupling between the drive motor and
the compressor is defective
Replace the coupling element
The compressor starts, but labours or runs
noisily or rattles
Loose connection(s) in the drive motor terminal box
Check the proper connection of the wires
against the connection diagram
The drive motor draws a too high current
(compare with initial value after commissioning)
Not all drive motor coils are properly connected
(particularly on motors with six coils)
When connecting the compressor make sure
the compressor will run in the correct direction
(Ú page 8: Installation)
(in order not to compromise the explosion
safety of the compressor the coupling must be
adjusted and measured according to a precisely defined procedure; therefore the coupling element must be replaced by the Busch
service only)
Tighten or replace loose connections
The drive motor operates on two phases only
The compressor runs in the wrong direction
Verification and rectification Ú page 6: Installation and Commissioning
Foreign objects in the compressor
Repair the compressor (Busch service)
Stuck bearings
The compressor runs very noisily
Defective bearings
Repair the compressor (Busch service)
Worn coupling element
Replace the coupling element
(in order not to compromise the explosion
safety of the compressor the coupling must be
adjusted and measured according to a precisely defined procedure. Therefore the coupling element must be replaced by Busch
service only)
Low oil level in the synchronising gear
The synchronising gear is leaky
Repair the compressor (Busch service)
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Troubleshooting
page 17
There is an indication on the control panel / in
the control room that the temperature monitoring has tripped (permissible temperature at
the outlet of the stage has been exceeded)
Synchronising gear damaged due to operation
with low oil level
Repair the compressor (Busch service)
Insufficient air ventilation
Make sure that the cooling of the compressor
is not impeded by dust/dirt
Clean the fan cowlings, the fan wheels, the
ventilation grilles and the cooling fins
The compressor is shut down
Install the compressor in a narrow space only
if sufficient ventilation is ensured
Ambient temperature too high
Observe the permitted ambient temperatures
Temperature of the inlet gas too high
Observe the permitted temperatures for the
inlet gas
Insufficient gas transfer
Check the process conditions
Mains frequency or voltage outside tolerance
range
Provide a more stable power supply
In case a pressure relief valve/regulating system
is installed:
Adjust, repair or replace, respectively
The pressure relief valve/regulating system is
misadjusted or defective
Partial clogging of filters or screens
Remove the clogging
Partial clogging in the suction, discharge or
pressure line
Long suction, discharge or pressure line with
too small diameter
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Use larger diameter
Troubleshooting
page 18
Spare Parts
Note: When ordering spare parts or accessories acc. to the table below
please always quote the type (“Type”) and the serial no. (“No”) of the
compressor. This will allow Busch service to check if the compressor is
compatible with a modified or improved part.
The approval of the compressor for use in potentially explosive areas
remains valid only if genuine spare parts and consumables, which are
approved for use in potentially explosive areas by Busch, are used exclusively.
Your point of contact for service and spare parts in the United
Kingdom:
Busch (UK) Ltd.
Hortonwood 30-35
Telford
Shropshire
TF1 7YB
Tel:
01952 677 432
Fax:
01952 677 423
Your point of contact for service and spare parts in Ireland:
Busch Ireland Ltd.
A10-11 Howth Junction Business Centre
Kilbarrack, Dublin 5
Tel:
+353 (0)1 8321466
Fax:
+353 (0)1 8321470
Your point of contact for service and spare parts in the USA:
Busch lnc.
516-B Viking Drive
Virginia Beach, VA 23452
Tel:
1-800-USA-PUMP (872-7867)
Your point of contact for service and spare parts in Canada:
Busch Vacuum Technics Inc.
1740, Boulevard Lionel Bertrand
Boisbriand (Montréal)
Québec J7H 1N7
Tel:
450 435 6899
Fax:
450 430 5132
Your point of contact for service and spare parts in Australia:
Busch Australia Pty. Ltd.
30 Lakeside Drive
Broadmeadows, Vic. 3047
Tel:
(03) 93 55 06 00
Fax:
(03) 93 55 06 99
Your point of contact for service and spare parts in New Zealand:
Busch New Zealand Ltd.
Unit D, Arrenway Drive
Albany, Auckland 1311
P O Box 302696
North Harbour, Auckland 1330
Tel:
0-9-414 7782
Fax:
0-9-414 7783
Find the list of Busch companies all over the world (by the time of the
publication of these installation and operating instructions) on
Ú page 68 (rear cover page).
Find the up-to-date list of Busch companies and agencies all over the
world on the internet at www.buschvacuum.com.
Pos.
Part
Qty
Part no.
—
Filter cartridge, paper, for inlet
filter
1
0532 134 779
—
Filter cartridge, polyester, for
inlet filter
1
0532 137 989
—
Safety valve (quote in your
order also the ultimate working
pressure of the compressor)
1
on request
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Spare Parts
page 19
EU Declaration of Conformity
Note: This Declaration of Conformity and the CE-mark affixed to the nameplate are valid for the machine within the Busch scope of delivery. This
Declaration of Conformity is issued under the sole responsibility of the manufacturer.
When this machine is integrated into a superordinate machinery the manufacturer of the superordinate machinery (this can be the operating
company, too) must conduct the conformity assessment process for the superordinate machine or plant, issue the Declaration of Conformity for it
and affix the CE-mark.
We
Busch Produktions GmbH
Schauinslandstr. 1
79689 Maulburg
Germany
Declare that the vacuum pumps MM ‘ATEX’ 1324, 1202, 1252, 1322 AP, Gas Tight
with a serial number from DEM11917… to DEM12252…
Documentation No.: T611141618
has (have) been manufactured in accordance with the European Directives:
•
‘Machinery’ 2006/42/EC
•
‘ATEX Directive’ 2014/34/EU
for use in potentially explosive areas according to classification written on the machine nameplate
•
‘Electromagnetic Compatibility’ 2014/30/EU
•
‘RoHS’ 2011/65/EU + Commission Delegated Directive (EU) 2015/863, restriction of the use of certain hazardous substances in
electrical and electronic equipment
and following the standards.
Standard
Title of the Standard
EN ISO 12100: 2010
Safety of machinery – Basic concepts, General principles for design –Risk assessment and risk reduction
EN ISO 13857: 2008
Safety of machinery - Safety distances to prevent hazard zones being reached by the upper and lower limbs
EN 1012-1: 2010
EN 1012-2: 1996 + A1: 2009
Compressors and vacuum pumps - Safety requirements - Part 1 and Part 2
EN ISO 2151: 2008
Acoustics - Noise test code for compressors and vacuum pumps - Engineering method (grade 2)
EN 60204-1: 2006
Safety of machinery - Electrical equipment of machines - Part 1: General requirements
EN 61000-6-2: 2005
Electromagnetic compatibility (EMC) - Generic immunity standards. Immunity for industrial environments
EN 61000-6-4: 2007 + A1: 2011
Electromagnetic compatibility (EMC) - Generic immunity standards. Emission standard for industrial
environments
EN ISO 13849-1: 2015 (1)
Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design
EN ISO 13463-1: 2009
Non-electrical equipment for potentially explosive atmospheres - Part 1:
Basic methodology and requirements
EN ISO 1127-1: 2011
Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and methodology
Manufacturer
Dr. Martin Gutmann, General Manager
Person authorized to compile
the technical file
Gerd Rohweder
Busch Dienste GmbH
Schauinslandstr. 1
DE-79689 Maulburg
Maulburg, 23.04.2019
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
EU Declaration of Conformity
page 20
Equipment Documentation
Measurement and Safety
Instrumentation
Temperatures - currents (presets)
Temperature
Resistance
Current
Under measurement
range
(= sensor short circuit)
-
-
3.6 mA
Version with Resistance Thermometer,
without Transmitter
Lower measurement
range limit
-20 °C
92.160 Ω
4.0 mA
In case the transmitter is furnished by the system supplier or operator.
Shutdown temperature
125 °C
147.944 Ω
10.270 mA
130 °C
149.824 Ω
10.486 mA
150 °C
157.315 Ω
11.351 mA
160 °C
161.043 Ω
11.784 mA
165 °C
162.903 Ω
12.000 mA
170 °C
164.760 Ω
12.216 mA
180 °C
168.465 Ω
12.649 mA
190 °C
172.158 Ω
13.081 mA
220 °C
183.168 Ω
14.378 mA
225 °C
184.993 Ω
14.595 mA
230 °C
186.815 Ω
14.811 mA
240 °C
190.451 Ω
15.243 mA
250 °C
194.074 Ω
15.676 mA
270 °C
201.287 Ω
16.541 mA
280 °C
204.876 Ω
16.973 mA
290 °C
208.453 Ω
17.405 mA
300 °C
212.019 Ω
17.838 mA
310 °C
215.573 Ω
18.270 mA
340 °C
226.166 Ω
19.568 mA
350 °C
229.673 Ω
20.000 mA
Upper measurement
range limit
350 °C
229.673 Ω
20.0 mA
Connection of supply voltage to pins + (positive pole) and - (negative pole).
Sensor breakage
-
-
21.0 mA
Upper limiting values in supply circuit (certified intrinsically safe
electric circuit):
More installation
notes:
After connection of the cables to the
switchboard/system control make sure
that the housing is firmly closed and the
cable glands are tightened.
Overview
Scope of delivery
Resistance thermometer with connecting
cable
Type/Marking
TR40 Pt100/B/3
Documentation
(applicable shutdown
temperature see
nameplate of the
compressor)
Operating instructions resistance thermometers and thermocouples (on the
following pages)
Version with Resistance Thermometer and
Transmitter
Standard scope of delivery for version with temperature monitoring
Scope of delivery
Thermometer system, consisting of:
Resistance thermometer with connecting
cable, transmitter, junction box
Type/Marking
Resistance thermometer:
TR40 Pt100/B/3
Transmitter: TMT181-B
Junction box: 15060603
Brief description:
Resistance thermometer with connected temperature transmitter
Temperature resistor with 3-wire connection.
Temperature transmitter with 3-wire electronics for signal
4 ... 20 mA.
Ui = 30 V; Pi = 800 mW; Ii = 120 mA
Documentation
Operating instructions resistance thermometers and thermocouples (on the
following pages)
Operating Instructions Temperature
Transmitter (on the following pages)
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 21
Pressure Switch/Indicator
Fast adjustment
on
(for version with temperature monitoring in standard scope of delivery, for version without temperature monitoring optional)
Behaviour of signal output
oFF
More installation notes:
Type/Marking
ExS10-0AVA1710R2SB4
Brief description:
The device is fed with a voltage between 14.5 and 45 V DC (between 14.5 and 27.3 V DC in intrinsically safe circuits). The positive
pole of the supply is connected to pin 1, the negative pole to pin 3.
Depending on the pressure signal the current between pin 3 and the
negative pole of the supply varies between 4 mA (corresponding to
-1 barg in factory setting) and 20 mA (corresponding to +1 barg in
factory setting).
If required two switching points can be evaluated by means of the
pins 4 and 2 and the state of the switches be read on the LEDs S1
and S2.
Technical data
excerpt from Installation and
Oper-ating Instructions BA0607
Interface
A mating coupling is in the scope of
delivery. Cable connection with screw
clamps max. 0.75 mm².
The pressure switch/indicator (k) is to be integrated into the system
control such that the maintenance of the permitted pressure range*
will be monitored. If the pressure gets outside this range the system
control must automatically shut down the compressor.
*ambient pressure ±200 hPa (=mbar), unless specified otherwise on
the nameplate of the compressor
Observe the excerpt from Installation and Operating Instructions
BA0607; the complete documentation is available from www.acscontrolsystem.de.
A matching coupling for the connection of a cable to the pressure
switch/indicator (k) is included in the scope of delivery of the
compressor.
Pin 1 transmits the sum of the currents of the pins 2, 3 and 4. The
monitoring circuitry shall be designed such that the current and the
voltage allowed for intrinsically safe circuits will not be exceeded on
any wire at any time.
Switching options (examples):
Upon delivery the pressure switch/indicator is set to “factory values”, except for the limit values of the switch points 1 and 2 and
the operating mode of switch point 2. Restoration in case of
inad-vertent misadjustment.
Lower pressure signal with
signal applied (liquid adjustment)
not to be set
Zero signal without applied signal (dry adjustment)
-.999
(achieves sufficient accuracy, can be
retained)
Upper pressure signal with
signal applied (liquid adjustment)
not to be set
Span signal without applied signal (dry adjustment)
1.000
(achieves sufficient accuracy, can be
retained)
Decimal places
dp3
(corresponds to indication 8.888)
Zero scaling
-.999
Endpoint-scaling
1.000
Damping
1
(corresponds to 0.3 seconds delay)
Limit value switch point 1
-.200
(“customer specific adjustment”)
Hysteresis switch point 1
0.003
Operating mode switch
point 1
n.o.
(working principle)
Function switch point 1
norF
Limit value switch point 2
0.200
(“customer specific adjustment”)
Hysteresis switch point 2
0.003
Operating mode switch
point 2
n.c.
(quiescent principle, “customer specific adjustment”)
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
1. Use of isolation switch amplifiers (e.g. Pepperl+Fuchs
KF__-SR2-Ex1.W; not in the Busch scope of delivery) switched between the pins 1, 2 and 4 of the pressure switch/indicator (k) on the
one side and the switching relays on the other.
2. Evaluation of the 4 ... 20 mA signal of the pressure switch/indicator (k) alone, by means of a suitable transmitter supply (e.g.
Pepperl+Fuchs KF__-CRG-Ex1.D; not in the Busch scope of delivery).
3. Evaluation of the 4 ... 20 mA signal of the pressure switch/indicator (k) alone, after isolation by means of a suitable transmitter supply (e.g. ACS ExTVA500, Pepperl+Fuchs KFD2-STC4-Ex1; not in the
Busch scope of delivery), by means of a non-Ex-system control or
SPS respectively.
The pressure switch/indicator (k) is to be integrated into the system
control such that the maintenance of the pressure range from
-200 mbarg to +200 mbarg (corresponding to a current between
10.4 and 13.6 mA, if the factory set measurement range is retained)
will be monitored. If the pressure gets outside this range the system
control must automatically shut down the compressor. The restart
of the compressor is permitted only by action from the operating
personnel after remedy of the cause of the excessive pressure.
Equipment Documentation Measurement and Safety Instrumentation
page 22
Documentation Resistance Thermometer
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 23
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 24
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 25
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 26
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 27
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 28
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 29
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 30
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 31
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 32
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 33
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 34
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 35
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 36
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 37
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 38
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 39
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 40
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 41
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 42
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 43
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 44
Documentation Temperature Transmitter
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 45
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 46
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 47
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 48
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 49
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 50
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 51
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 52
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 53
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 54
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 55
BA 0607
Pressure
Lauterbachstr. 57 – 84307 Eggenfelden – Germany
Tel: +49 8721/9668-0 – Fax: +49 8721/9668-30
[email protected] – www.acs-controlsystem.de
Password function for protection of the settings against alternation
Programmable evaluation electronic with high brightness LED-display
- in 2-wire-technology with current signal 4...20 mA or
- in 3-wire-technology with voltage signal 0...10 V
- with two PNP switching outputs
Excellent accuracy up to ≤ 0,1%
ATEX II 1/2 G D EEx ia IIC T4
Certification for the use in explosion hazardous areas
Humidity resistant variant for climatic extreme conditions
like high air humidity or also at condensed water formation
Various usability, especially for hygienic applications
Suitable for wide process temperature range from – 40 °C to +370 °C
Ceramic or metallic membrane with various process connections
Pressure ranges 0...0,1 bar to 0...1000 bar / -0,1...0/+0,1 bar / -1...0/+1 bar
for continuous measuring and supervision of pressures
in gases, steam, liquids and dusts
Pressure transmitter
Precont S – Precont D40
Technical manual
........................................................................................................... 7
........................................................................................................ 7
...................................................................................................... 7
Installation notes
Maintenance notes
Electrical connection
...................................................... 10
................................. 9
.............................................................................. 21
............................................................................... 22
.............................................................................. 23
............................................................................... 24
.............................................................................. 25
............................................................................... 26
.............................................................................. 27
............................................................................... 28
Dimension drawings Precont S40
Order code overview Precont S40
Dimension drawings Precont D40
Order code overview Precont D40
Dimension drawings Precont S60
Order code overview Precont S60
Dimension drawings Precont S70
Order code overview Precont S70
page 2 of 28
............................................................................... 20
Order code overview Precont S30
.............................................................................. 19
.............................................................................. 18
Order code overview Precont S20
Dimension drawings Precont S30
.............................................................................. 17
............................................................................... 16
Dimension drawings Precont S20
Order code overview Precont S10
.............................................................................. 15
............................................................................................... 12 / 13 / 14
........................................................................................................ 11
Dimension drawings Precont S10
Technical data
Adjustment menu
Operation and display elements / Function modes
Electrical connection – connection in explosive hazardous areas
......................... 8
........................................................................................................... 6
Assignment – electrical connection in non-explosive hazardous areas
................................................................................................................... 6
Safety notes
........................ 5
Safety notes
Available pressure ranges – permissible overload resp. burst pressure
.......................................................................... 4
...................................................................................................... 3
................................................................................................... 3
Variant differences – application range
Function description
Application description
Index
Precont S – Precont D40
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 56
page 3 of 28
By 3 keys and the four digit LED display all settings for the display, the analogue output as well as the
PNP switching outputs can be set resp. adjusted.
A transmitter fast adjustment per key combinations is also possible.
According to the resp. settings the PNP switching outputs are driven.
The switching state of the two PNP switching output are indicated by each an LED.
Signal processing
The pressure dependent variation of capacity resp. the variation of the strain gauge output voltage is
recorded in high resolution by a processor, adjusted acc. to the settings and converted in high
resolution into an output signal of 4...20mA or 0...10V.
Characteristics of the process diaphragm seal – Precont S60 / S70
The system pressure is applied to the metallic membrane of the process diaphragm seal and is
transmitted by a pressure transmitting liquid to the respective ceramic or metallic measuring
membrane that is placed behind.
This leads among others to a extension of the permissible medium temperature up to +370°C and to
an essential increase of the temperature stability of the device.
The metallic membrane offers excellent characteristics like high pressure and pressure blow strength
up to six times the nominal pressure, vacuum resistance, good reproducibility and hysteresis and also
good long term stability and a low temperature influence.
Characteristics of the metallic measuring membrane – Precont S20 / S30 / S70
The system pressure is applied to the metallic membrane and causes there a deflection of the strain
gauge at the back side of the membrane.
A pressure transmitting liquid is only used at pressure ranges lower than 0...25 bar.
The ceramic membrane offers excellent characteristics like highest pressure and pressure blow
strength up to forty times the nominal pressure, vacuum resistance, very high resistance against
chemicals, corrosion and abrasion as well as very good insensitiveness against temperature shocks,
highest accuracy and reproducibility, good long term stability and a very low temperature influence.
Characteristics of the ceramic measuring membrane – Precont S10 / S40 / D40 / S60 / S70
The system pressure is applied to the ceramic membrane and causes there a variation of the capacity
at the back side of the membrane.
A pressure transmitting liquid is not used.
The pressure transmitter Precont S – Precont D40 is mounted in the wall of the pressure container or
of the pipe.
Function description
The device variant Precont D40 is especially suitable for the use in areas with high air humidity and
condensed water formation, where conventional devices can not or can only be operated with a
expensive installed pressure compensation capillary.
The use of a capacitive measuring sensor with ceramic membrane or of a strain gauge with metallic
membrane, by use of various, also front flush process connections resp. process diaphragm seals,
allows the use in nearly all fields of industry, especially also in hygienic applications.
The devices of the series Precont S – Precont D40 with integrated digital evaluation electronic are
compact pressure transmitter for continuous measuring and supervision of pressures from
–1 up to 1000 bar in gases, steams, liquids and dusts within closed container or pipes, also in
explosive hazardous areas, at process temperatures from – 40°C to +370°C.
Application description
Precont S – Precont D40
0032
page 6 of 28
The devices are conceived for measuring of pressures in explosive hazardous areas.
The measured medium may also be combustible liquids, gases, fogs or steams.
The permitted operating temperatures and pressures are type and variant dependent and can be
found in this technical manual.
For applications, which require devices of category 1/2 or category 1, the process pressure and
temperature range of the media has to be between 0,8 bar and 1,1 bar and between -20 °C and
60 °C.
The permissible maximum values for Ui, Ii and Pi are equal for all variants. To this there must be paid
especially attention in the case of combining more intrinsically safe circuits at the variants with
voltage output 0...10V (variants E/F/G/H) and at the variants with PNP switching outputs (variants
A/E). The rules for combination of intrinsically safe circuits must be applied.
At variants of the devices with chargeable plastic parts (e.g. cable resp. connection housing), a
warning marking points out to the safety measures, that must be applied because of the electrostatic
charging in operation and especially in the case of maintenance activities.
avoid friction
no dry cleaning
no assembling in pneumatic conveying stream
If a device is installed and operated in explosive hazardous areas, the general
Ex construction standards (EN60079-14, VDE0165), this safety notes and the enclosed
EC conformity certificate must be observed.
The installation of explosive hazardous systems must be carried out principally by specialist staff.
The device meets the classification:
Ta medium
Ta housing
II 1/2 G D EEx ia IIC T4 IP65 T60°C / T102°C (T57°C)
-20... +60 °C
-20…+85 °C (+40 °C)
II 2 G D EEx ib IIC T4 IP65 T102°C
-20…+85 °C
-20…+85 °C
II 2 G D EEx ib IIC T4 IP65 T125°C
-20…+125 °C
-20…+50 °C
II 1/2 G EEx ia IIC T4
-20... +60 °C
-20…+85 °C
II 2 G EEx ib IIC T4
-20…+85 °C
-20…+85 °C
II 2 G EEx ib IIC T4
-20…+125 °C
-20…+50 °C
Safety notes for electrical operating supplies
for explosive hazardous areas
The device meets the legal requirements of all relevant EC directives.
This measuring device meets article 3 (3) of the EC directive 97/23/EC (pressure equipment device
directive) and is designed and produced in good engineer practice.
The sensors may not used as sole device for prevention of dangerous conditions in machines and
plants.
The materials for membrane, process connection and gaskets must be chosen according to the
respective application requirements (used medium, process temperature).
An unsuitable material can lead to damage, abnormal behavior or destruction of the device and to the
resulting dangers.
The device may only be used within the permitted operation limits that are listed in this technical
manual. Every use besides these limits as agreed can lead to serious dangers.
Installation, electrical connection, inauguration and operation of the device must be made by a
qualified employee according to the informations in this technical manual and the relevant standards
and rules.
Each person that is engaged with inauguration and operation of this device, must
have read and understood this technical manual and especially the safety notes.
Safety notes
Precont S – Precont D40
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 57
page 7 of 28
Inductive loads at the pnp switching outputs, e.g. relays or contactors may only be used with a freewheeling diode or a RC protection circuit to avoid high voltage peaks.
The voltage applied to the terminal contacts may not exceed 45 V to avoid damage of the
electronic. All connections are polarity protected.
At the housing variant with terminal box, the terminals for the connection of a cable are placed below
the electronic module. This is plugged and can be pushed easily. After the connection of the cable,
the module must be correctly inserted again.
The cable gland is suitable für cable diameter from 4,5 to 10 mm.
After the installation of the cable the cable gland must be firmly screwed to ensure the tightness of
the connection housing. The same is valid for the screw cap of the housing.
Use only shielded signal and measurement wires and install these wires separated from
power leading wires. Connect the cable shield only at one side to earth, ideally at the
installation place of the device. The metallic parts of the device with connection housing plug - type S
resp. cable - type K are electrically connected with the earthing connection screw. At the variant with
connection housing terminal box – type A all metallic parts are connected with terminal 1 - PE/shield.
The electrical connection of the device must be carried out according to the respective
country specific standards.
Incorrect installation or adjustment could cause applicationally conditioned risks.
Electrical connection
Special substances can lead to solid coatings on the membrane.
Such depositions can lead to faulty measurement results of the pressure transmitter.
In the case of coat forming liquids the membrane must be regularly cleaned.
Don’t use sharp tools or aggressive chemicals for cleaning.
The devices of the series Precont S – Precont D40 are free of maintenance.
Maintenance notes
The correct function of the device within the specific technical data can only be guaranteed, if the
permitted temperature in the area of the connection housing from – 40°C to +85°C will not be
exceeded.
This can be achieved by the using of the temperature decoupler or also by isolation of the medium
carrying part of the plant or by other constructive measures to reduce the transferring of an extreme
temperature to the connection housing.
Avoid the pollution of the pressure compensation vent. The hindrance of the pressure compensation
can lead to faulty measuring results.
The housing can be rotated every time, also at operation, by 330°.
The tightening of the process connection with screw-in thread may only be done at the hexagon by a
suitable spanner. The maximum permitted torque strength is 50 Nm.
The screw in of the process connection by using the housing tube is not permitted.
Drive the system pressure free prior installation resp. deinstallation of the sensor.
The installation of the device should be made if possible at temperature calmed places to get a
reliable measuring result. Large temperature steps, e.g. at filling of a hot medium into a cold system,
can produce a short-time higher measuring signal deviation at the variants with ceramic measuring
membrane. At a large amplification of the measuring signal this deviation will be also amplified
accordingly. The deviation will be completely neutralized after the adaptation of the measuring
membrane of the pressure transmitter to the temperature.
At a step from +20°C ...+80°C this neutralization can wile up to 3 minutes.
The use of a process diaphragm seal can cause an essential improvement.
The installation of the device at locations where high pressure blows can occur should be avoided.
Installation notes
Precont S – Precont D40
4
1
3(blau)
1(braun)
view to
plug socket
current shunt or
current meter
-VS
+VS
white
shortest
connection
PE / PA
connection K
current shunt or
current meter
-VS
+VS
4
1(brown)
-VS
S2
connection K
5
4
+VS
connection K
white
grey
S1
+VS
0...10V
-VS
5
4
-VS
S2
connection K
shortest
connection
S1
+VS
0...10V
PE / PA
3(blue)
4(black)
5(grey)
2(white)
1(brown)
view to
plug socket
shortest
connection
1
PE / PA
connection S
3
2
white
green
brown
grey
yellow
S1
+VS
0...10V
-VS
S2
1
+VS
PE
2
current shunt or
current meter
connection A
+VS
PE
1
3
4
-VS
connection A
1
PE
+VS
T. 1 PE/shield
T. 3 -VS
T. 5 SP1
PE
1
2
4
-VS
3
6
UOUT
0...10V
screw terminal
5
T. 2 +VS
T. 4 UOUT (0…10V)
T. 6 not connected
+VS
2
S2
6
-VS
S2
E
page 8 of 28
S1
screw terminal
5
UOUT
0...10V
4
T. 2 +VS
T. 4 UOUT (0…10V)
T. 6 SP2
3
A
F/G/H
S1
transmitter electronic
connection A
T. 1 PE/shield
T. 3 -VS
T. 5 not connected
6
screw terminal
5
T. 2 +VS
T. 4 not connected
T. 6 SP2
4...20mA
2
T. 1 PE/shield
T. 3 IOUT (4…20mA)
T. 5 SP1
-VS
screw terminal
4...20mA
3
transmitter electronic
connection A
T. 1 PE/shield
T. 2 +VS
T. 3 IOUT (4…20mA)
transmitter electronic
-VS
S2
+VS
3 – wire – technology / signal 0...10 V / 2x PNP switching output
shortest
connection
-VS
0...10V
white
green
brown
yellow
brown
PE / PA
3(blue)
5(grey)
1(brown)
shortest
connection
1
view to
plug socket
PE / PA
connection S
3
2
3 – wire – technology / signal 0...10 V
shortest
connection
S1
+VS
PE / PA
3(blue)
4(black)
2(white)
shortest
connection
1
view to
plug socket
PE / PA
connection S
3
2
connection type A
terminal box
transmitter electronic B / C / D
2 – wire – technology / signal 4...20 mA / 2x PNP switching output
shortest
connection
PE / PA
connection S
3
2
brown
connection type K
cable
2 – wire – technology / signal 4...20 mA
connection type S
plug M12x1
Assignment – connection in non-explosion hazardous areas
NAMUR
NAMUR
Precont S – Precont D40
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 58
+I
-I
+Vs
-Vs
L/+
N/-
auxiliary power
isolation amplifier
intrinsically safe
-O
+O
SP2
SP1
-I
+U
-Vs
Uout
-U
+I
+Vs
L/+
N/-
N/-
-O
N/-
N/-
N/-
isolation amplifier
intrinsically safe
L/+
auxiliary power
isolation amplifier
intrinsically safe
L/+
auxiliary power
-O
+O
-O
+O
isolation switch amplifier
intrinsically safe
L/+
auxiliary power
Precont S
transmitter electronic
variant E
SP2
SP1
in
out
in
out
-U
+U
-I
-Vs
Uout
+I
+Vs
N/-
N/-
N/-
-O
N/-
isolation switch amplifier
intrinsically safe
L/+
auxiliary power
-O
+O
+O
isolation switch amplifier
intrinsically safe
L/+
auxiliary power
isolation amplifier
intrinsically safe
L/+
auxiliary power
isolation amplifier
intrinsically safe
L/+
auxiliary power
si g n a l 4..20mA
relay output
relay output
mA
mA
si g n a l 4..20mA
si g n a l 4..20mA
relay output
relay output
mA
si g n a l 4..20mA
si g n a l 4..20mA
page 9 of 28
transmitter electronic E
mA
mA
transmitter electronic F / G / H
+O
isolation switch amplifier
intrinsically safe
L/+
auxiliary power
isolation amplifier
intrinsically safe
3 – wire – technology / signal 0...10 V / 2x PNP switching output
Precont S
transmitter electronic
variant F/G/H
in
out
in
out
-I
-Vs
3 – wire – technology / signal 0...10 V
Precont S
transmitter electronic
variant A
+I
+Vs
auxiliary power
si g n a l 4..20mA
transmitter electronic A
mA
transmitter electronic B / C / D
2 – wire – technology / signal 4...20 mA / 2x PNP switching output
Precont S
transmitter electronic
variant B/C/D
2 – wire – technology / signal 4...20 mA
Electrical connection – connection in explosive hazardous areas
Precont S – Precont D40
S1
S2
Control key „OK“
Control key „+ / -“
The counter advance sense is at first set to
„+“ Î increasing of the displayed value.
Press the control key „Change“ to change
the counter advance sense to „-“ Î
decreasing the displayed value
page 10 of 28
By pushing of key combinations in the run mode the transmitter can be operated without using the
adjustment menu.
Zero value adjustment with applied pressure signal:
Short pushing the key’s „Change“ and „OK“ in succession and hold approx. 6 seconds. The output
signal 4mA / 0V is generated that can be varied by „+ / -“ resp. „Change“ and „+ / -“. By pushing the
key „OK“, the current pressure value is captured as lower pressure reference value, assigned to the
previously adjusted output signal and the changed settings are stored loss protected (duration
approx. 3 s). A jump back to the run mode is carried out.
End value adjustment with applied pressure signal:
Short pushing the key’s „+ / -“ and „OK“ in succession and hold approx. 6 seconds. The output
signal 20mA / 10V is generated that can be varied by „+ / -“ resp. „Change“ and „+ / -“. By pushing the
key „OK“, the current pressure value is captured as upper pressure reference value, assigned to the
previously adjusted output signal and the changed settings are stored loss protected (duration
approx. 3 s). A jump back to the run mode is carried out.
Damping adjustment:
Short pushing the key’s „Change“ and „+ / - “ in succession and hold approx. 6 seconds.
The damping value can now be varied. This value can be varied arbitrary by „+ / -“ resp. „Change“
and „+ / -“ from 0,3 to 30 seconds in 100 steps of each 0,3 seconds (variants C / G in 10 steps of
each 3 seconds). By pushing the key „OK“, the value is captured and stored loss protected (duration
approx. 3 s). A jump back to the run mode is carried out.
Reset to factory values:
At devices of variants C / G, a reset to factory values will be carried out by pushing the key „OK“ for
approx. 5 seconds at a restart after removing the supply voltage. All customer specific adjustment
values will be lost.
Attention:
If the lower pressure reference value (zero) is adjusted higher than the upper pressure reference
value (span), the output signal falls below 3,8mA resp. to 0V. The display shows EEEE as long as
the key „OK“ is pushed. A readjustment has to be done correctly (zero < span).
Fast adjustment mode
To access to the adjustment menu push the control key „OK“ and enter the password 3009.
Programming mode
The pressure transmitter records the applied system pressure and proceeds the chosen functions
according to the set parameter. The measuring value is displayed in the display window.
The analogue output and the switching outputs are driven, whereby an active switched-on switching
output is signaled by the come on of the respective red switching condition light-emitting diode.
The transgression of the frame specifications, abnormal behavior conditions or also device
malfunctions are displayed by the display values EEEE resp. -EEE.
By pushing the control key „+ / -“ the software version will be displayed
run mode
Function modes
Control key „Change“
Also used for switchover the function
of the control key „+/-“
Switching state indicator S1 and S2
Indication of the active switching output
by the respective red LED
Display window 4-digit
Operation and display elements
Precont S – Precont D40
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 59
OK
OK
OK
OK
OK
SP 1
SP 2
SAbG
ErrS
FrES
SPEi
Limit switch 1
Limit switch 2
Fast
adjustment
Behaviour
output signal
Reset to
factory values
Store
OK
OK
OK
OK
diSP
t_F
OK
OK
SPAn
2Ero
password 3009
Func
n.o.n.c.
OK
HYS1
OK
OK
OK
OK
SP_1
SPAn
OK
OK
FS22
oFF
25.12
OK
OK
oFF
FS3.8
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
on
ErrF
n.c.
norF
n.o.
0.005
0.250
1
1.000
0.000
dP3
3 seconds
1.000
3 seconds
20..00
3 seconds
0.000
3 seconds
4.00
run mode
OK
2Ero
oSig
OK
OK
dP-_
OK
OK
oSig
NSig
OK
Password wrong
pressed, the faster the value will increase or decrease.
Function direction (higher or lower) can be changed by
the key „Change“. Pressing this key in the run mode will
display the software version
Jump from menu to menu / changing the direction of the
„+/-„ key / changing between the different possibilities in
selection menu
Enter the respective submenu and
capturing the set values
+- Change the indicated values. The longer the key will be
OK
Î S1 switches on at transgression of the limit value
Î S1 switches on at underrun of the limit value
Func is not available.
Loss protected storage of all parameters (duration approx. 7 s)
Store
Reset of all parameters to factory values. Customer specific settings will be lost.
Factory-Reset
page 11 of 28
A signal besides these limits is not possible. The end values are kept at transgression.
A error current output at transgression or underrun is not generated.
oFF = The output signal operates linear in the range from 3,9...21,0 mA resp. 0...10,5 V.
At transgression of this range a constant signal of 22 mA / 11,25 V is generated.
FS22 = The output signal operates linear in the range from 4,0...20,0 mA resp. 0...10 V.
At transgression of this range a constant signal of 3,8 mA / 0 V is generated.
Behaviour of the output signal at signal range transgression
FS3.8 = The output signal operates linear in the range from 4,0...20,0 mA resp. 0...10 V.
Unlock or lock of fast adjustment for the lower and upper pressure reference value with applied signal as well as
setting the damping per key combinations.
Fast adjustment per key combinations
This menu is identical to the menu switch point 1 with the exception that the submenu
Limit switch 2
lower than 4mA/0V.
Function limit switch 1
norF = limit value function with hysteresis
ErrF = error indication function Î S1 switches, if the output signal become higher than 20mA/10V resp.
Operation mode limit switch 1
n.o. = normally open
= working current principle
n.c. = normally closed
= quiescent current principle
Switch point hysteresis of switch point S1 referring to the display value
Hysteresis limit switch 1
Display value, where the PNP switching output S1 will be activated.
Limit value limit switch 1
Setting the system damping for neutralization of short pressure blows or also for calming down cyclic fluctuating
pressure signals.
The adjustment range is 0,3...30 seconds, in 100 steps of each 0,3 seconds.
System damping
indication value at 20 mA / 10 V output signal. If the displayed value rises above 9999, EEEE is displayed.
Display end value scaling
indication value at 4 mA / 0 V output signal. If the displayed value falls below -999, -EEE is displayed.
Display zero value scaling
Decimal places
setting dP0 display 8888. / setting dP1 display 888.8
setting dP2 display 88.88 / setting dP3 display 8.888
adjust upper pressure reference signal, referring to the nominal sensor pressure, with „+“ resp. „-“ to the
value that should be assigned to the output signal of 20,00 mA or resp. 10V. Set with „OK“, cancel by pressing
„Change“ for 3 seconds.
Adjustment upper pressure reference value without applied signal
Current pressure signal is assigned as the upper pressure signal to the displayed and
by „+“ resp. „-“ adjustable output signal (output mA resp. V).
Set with „OK“, cancel by pressing „Change“ for 3 seconds. At the signal 0...10V the value of
4.00 equals a voltage of 0V and a value of 20.00 equals a voltage of 10V
Adjustment of upper pressure reference value with applied signal
adjust lower pressure reference signal, referring to the nominal sensor pressure, with „+“ resp. „-“ to the
value that should be assigned to the output signal of 4,00 mA or resp. 0V. Set with „OK“, cancel by pressing
„Change“ for 3 seconds.
Adjustment lower pressure reference value without applied signal
Current pressure signal is assigned as the lower pressure signal to the displayed and
by „+“ resp. „-“ adjustable output signal (output mA resp. V).
Set with „OK“, cancel by pressing „Change“ for 3 seconds. At the signal 0...10V the value of
4.00 equals a voltage of 0V and a value of 20.00 equals a voltage of 10V
Adjustment of lower pressure reference value with applied signal
Input password 3009
Entry to code-inquiry
Indication of current measurement value
run mode
NSig
NESS EEEE
OK
0000
System
damping
Display
Adjustment
upper
pressure
reference
signal
Adjustment
lower pressure
reference
signal
Passwort right
OK
OK
codE
OK
25.12
Adjustment menu
Precont S – Precont D40
at set system damping 1
2)
Referring to nominal measuring span resp. full scale (FS)
page 12 of 28
at set system damping 1
≥ 100.000.000
≤ 330 ms (typ. 280 ms)
Delay time:
Switching cycles:
≤ 700 μs
Rise up time:
current limited, short circuit protected
output load ≤ 3000 Ω resp. ≥ 4,5 mA
≤ 250 mA, min. 200 mA
VOUT ≥ +Vs – 2 V
at set system damping 1
Output current:
PNP switching to +Vs
Output voltage:
≤ ±0,02% FS 2) / 10V
≤ 310 ms (typ. 260 ms)
≤ 0,5 mV
RL ≥ 2000 Ω, results in 5 mA at signal 10 V, current limited
linear characteristic from ≤ 0,07...10,5 V, error ≤ 0,07 V / 11,25 V
inverted output characteristic 10...0 V only possible by
manufacturer on separate request
≤ ±0,02% FS 2) / 10V
Function:
PNP switching output
Influence of supply voltage:
Minimum delay time:
Resolution:
Permitted load:
Signal range:
Analogue output 0...10 V
Influence of supply voltage:
≤ 1 μA
≤ 310 ms (typ. 260 ms)
Minimum delay time:
linear characteristic from 3,9 mA resp. 21 mA, error 3,8 mA / 22 mA
inverted output characteristic 20...4 mA only possible by
manufacturer on separate request
RL max = (VS act - VS min) / 20mA
VS min = 10,5 / 12,5 / 14,5 / 16,5 V
2-wire 4...20 mA
3-wire 0...10 V
Resolution:
Permitted load:
Signal range:
Analogue output 4...20 mA
Supply current:
≤ 2 VPP
Ripple voltage:
condition: within the permitted
supply voltage range
≤ 22 mA
PNP switching outputs no load
≤ 10 mA
PNP switching outputs no load
reverse polarity protected
Precont S
Variant A/B/E/F/G/H 14,5..45 V DC / Ex 14,5..27,3V
Variant C/D
10,5..45 V DC / Ex 10,5..27,3V
Precont D40
Variant A/B/E/F/G/H 16,5..45 V DC
Variant C/D
12,5..45 V DC
Permitted supply voltage:
Auxiliary supply
Technical data
Precont S – Precont D40
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 60
7)
6)
5)
4)
3)
2)
not cumulative
2)
≤ ±0,2% FS 2) / 10 K
Tk4) Span
besides 0...+80°C with factor 2 for Tk
metallic membrane Tk4) Zero
≤ ±0,2% FS 2) / 10 K
(≤ 25 bar)
range 0..0,4 bar ≤ ±0,25% FS 2) / 10 K
range 0..0,25 bar ≤ ±0,4% FS 2) / 10 K
range 0..0,1 bar ≤ ±1,0% FS 2) / 10 K
4)
metallic membrane Tk Zero
≤ ±0,2% FS / 10 K
(≥ 40 bar)
Tk4) Span
≤ ±0,2% FS 2) / 10 K
besides -40...+100°C with factor 2 for Tk
≤ ±0,20% FS 2) / 10 K
Tk4) Span
max. ≤ ±1,0 % FS 2) (-20...+80°C)
besides -20...+80°C with factor 2 for Tk
ceramic membrane Tk4) Zero
≤ ±0,20% FS 2) / 10 K
Precont D40)
max. ≤ ±1,5 % FS 2) (-20...+80°C)
≤ ±0,10% FS 2) / 10 K
Tk4) Span
max. ≤ ±0,5 % FS 2) (-20...+80°C)
max. ≤ ±0,8 % FS 2) (-20...+80°C) ≤ 0..0,4 bar
besides -20...+80°C with factor 2 for Tk
ceramic membrane Tk4) Zero
≤ ±0,10% FS 2) / 10 K
(Precont S)
max. ≤ ±0,75 % FS 2) (-20...+80°C)
not cumulative
ceramic membrane ≤ ±0,1% FS 2) / year
metallic membrane ≤ ±0,15% FS 2) / year
metallic membrane ≤ ±0,1% FS 2)
metallic membrane ≤ ±0,6% FS 2) at pressure range 0..0,1 / 0,25 bar
ceramic membrane negligible
metallic membrane ≤ ±0,3% FS 2)
ceramic membrane ≤ ±0,1% / 0,2% FS
2)
metallic membrane ≤ ±1,0% FS 2) at pressure range 0..0,1 / 0,25 bar
metallic membrane ≤ ±0,5% FS 2)
ceramic membrane ≤ ±0,1% / 0,2% FS 2)
page 13 of 28
Referring to nominal measuring span resp. full scale (FS)
Nonlinearity + Hysteresis + Reproducibility
Tk = Temperature coefficient
At limit value adjustment
Specification valid, if adjusted measuring range = nominal measuring range, i.e. for TD 7) = 1
At TD 7) ≥ 1 (adjusted measuring range ≤ nominal measuring range):
Specification at adjusted measuring range = specification at nominal measuring range x TD 7)
Turn-Down TD = nominal measuring range (FS 2)) / adjusted measuring range)
Temperature deviation 6):
Long term drift 6):
Hysteresis 6):
Nonlinearity :
6)
Characteristic deviation 3) 5) 6):
Measuring accuracy
Technical data
Precont S – Precont D40
Reference conditions:
page 14 of 28
at process connections with screw-in thread
DIN EN 60592
IP65 at Ex variant
DIN EN 60721-3
5 - 100 Hz
DIN EN 61326
operation device class B
DIN EN 61326
appendix A (industrial range)
T = 15...35 °C, relative humidity 45...75 %,
environmental air pressure 860...1060 kPa
≤ 50 Nm
IP67
4K4H
4g
emission
immunity
DIN IEC 60770
Torque strength:
Protection classification:
Climatic classification:
Vibration classification:
EM – compatibility:
Weight:
Vacuum strength:
Overload strength:
Precont S20 synthetic oil
ranges ≤ 0...25 bar
Precont S30 synthetic oil
FDA listed
Precont S60 vegetable oil
food applications
Precont S70 silicone oil / high temperature oil
depends on membrane resp. measuring range,
see table overload / burst pressure
0 mbarabs
Ceramic membrane –0,1...0 bar resp. 0...0,1 bar Î 700mbarabs
Ceramic membrane –0,1...+0,1 bar / 0...0,2 bar Î 500mbarabs
depends on variant
Pressure transmitting liquid:
Î FPM – fluorelastomere (Viton®)
EPDM – etylene-propylene-dienmonomere
CR – chloroprene-rubber (Neopren®)
FFKM – perfluorelastomere (Kalrez®)
NBR – nitril-butadien-rubber
Î FPM – fluorelastomere (Viton®)
Silicone
– 40°C...+85°C, limitation at Ex variants
depends on variant, maximum – 40°C...+370°C
depends on variant, maximum – 1 bar...1000 bar, relative or absolute
others
medium contact
PC – polycarbonate (Makrolon®)
socket CrNi-steel, insert PUR, contacts gold-plated
PE – polyethylene
housing PA – polyamide, gasket CR / NBR
housing PA – polyamide, membrane ePTFE
PES – polyester
ceramic AL2O3 96% resp. 99,9%
steel V4A
steel 1.4404 (AISI 316L)
steel 1.4404 (AISI 316L) /
steel 1.4571 (AISI 316Ti)
Precont S20 / S30
steel V4A
Precont S60 / S70
steel 1.4404 / 1.4435 (AISI 316L)
CrNi-steel / PBT polybutyleneterephthalat / PP – polypropylene /
POM – polyoxymethylene (Delrin®)
Precont S10 / S40 / D40
Precont S20 / S30
Precont S60 / S70
Precont S10 / S40 / D40
Environmental temperature:
Process temperatures:
Process pressure ranges:
Environmental conditions
Gaskets:
Display window:
Device plug M12x1:
Connection cable:
Cable gland:
Pressure compens. element:
Membrane keyboard:
Connection housing:
Process connection:
(medium contact)
Membrane:
(medium contact)
Materials
Technical data
Precont S – Precont D40
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 61
Dimension drawings Precont S10
page 15 of 28
Precont S – Precont D40
signal 4...20 mA
signal 4...20 mA
signal 4...20 mA
signal 4...20 mA
signal 0...10 V
signal 0...10 V
signal 0...10 V
signal 0...10 V
manometer connection
inside drill 11,4 mm
manometer connection
only with material connection housing type C - steel
2x PNP switching output LED display, 3 key’s
LED display, 3 key’s
3 key’s
fix adjusted
2x PNP switching output LED display, 3 key’s
LED display, 3 key’s
3 key’s
fix adjusted
DIN EN 837-3
DIN EN 837-3
10
11
12
13
14
15
16
17
18
YY
-40°C to +100°C
-40°C to +125°C
with temperature decoupler
Precont _ _ _ V _ _ _ _ _ _ _
Electrical connection:
S Plug M12x1
K Cable 2m
A Terminal box
page 16 of 28
Accuracy measuring system – variant measuring membrane (medium contact):
2 0,2%
ceramic AL2O3
96%
1 0,2%
ceramic AL2O3
99,9% (highly clean)
0 0,1% Linearization protocol
ceramic AL2O3
96%
3 0,1% Linearization protocol
ceramic AL2O3
99,9% (highly clean)
Pressure type:
R Relative pressure
A Absolute pressure
Process temperature:
0 Standard
1 Extended
for gas applications
for food applications
0...10 bar
0...16 bar
0...20 bar
0...40 bar
0...60 bar
-0,1...0 bar
-1...0 bar
-1...+1 bar
-0,1...+0,1 bar
special measuring range separate spec. necessary
not for electrical connection type S / K
not for electrical connection type S / K
not for electrical connection type A
Gaskets (medium contact):
1 FPM
fluorelastomere (Viton®)
2 CR
chloroprene-rubber (Neopren®)
3 EPDM
etylene-propylene-dienmonomere
4 FFKM
perfluorelastomere (Kalrez®)
6 FFKM
perfluorelastomere high density
Measuring range:
01
0...0,1 bar
02
0...0,2 bar
03
0...0,4 bar
04
0...0,6 bar
05
0...1 bar
06
0...1,6 bar
07
0...2,5 bar
08
0...4 bar
09
0...6 bar
Material connection housing:
A PBT – polybutyleneterephthalat
C CrNi-steel
D PP – polypropylene
E POM – polyoxymethylene (Delrin®)
Material process connection (medium contact):
V Steel 1.4404 (AISI 316L) / 1.4571 (AISI 316Ti)
Electronic - output:
A 2-wire-technology
B 2-wire-technology
C 2-wire-technology
D 2-wire-technology
E 3-wire-technology
F 3-wire-technology
G 3-wire-technology
H 3-wire-technology
Process connection:
0 G ½“ A
DIN EN ISO288-1
6 G ½“ A
DIN EN ISO288-1
1 G ¼“ A
DIN EN ISO288-1
Standard
ATEX II 1/2 G EEx ia IIC T4
ATEX II 1/2 GD EEx ia IIC T4 IP65
Digital pressure transmitter with inside placed ceramic capacitive membrane from –1 to 60 bar
analogue output 4...20mA resp. 0...10V, 4-digit LED display, 2 switching outputs
Type:
S10
ExS10
XDS10
Precont S10
Order code overview Precont S10
Precont S – Precont D40
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 62
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 63
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Equipment Documentation Measurement and Safety Instrumentation
page 64
Technical Data
60
50
MM 1252 AP
60
50
MM 1322 AP
60
5.5
1.2
7.5
2.0
11
0.7
7.5
1.0
8.6
1.8
12.6
2.0
17.3
0.9
7.5
1.6
11
2.0
15
0.7
8.6
1.4
12.6
2.0
17.3
1.0
11
1.7
15
2.0
18.5
0.8
12.6
1.5
17.3
2.0
21.3
3000
200
80
3600
240
83
3000
250
81
~270
... 350
3600
300
84
3000
300
82
3600
360
85
b
ra ien
ng t t
e em
[°
p
Am C] era
tu
bi
re
en
tp
re
ss
ur
e
Am
atmospheric
MM 1202 AP
0.7
0 ... 40
50
Ul
tim
[b ate
ar
(g wo
)] rk
in
No
g
pr
m
es
[k ina
su
W lm
re
]
*
ot
or
No
ra
tin
m
g
[m ina
in -1 l sp
ee
]
d
No
m
[m ina
³/ l fl
h] ow
So
un
(E d p
N
re
m ISO ssu
ea 2 re
s
1
[d ure 51 leve
b( d ) w l
A) at
]
+0 ith s
W
.7 ile
eig
ba nc
[k ht
r g er,
g]
Type
Fr
eq
[H uen
z] cy
Ex-classification, permitted ultimate pressures, shut-off temperatures and motor connection parameters see nameplates
*valid ultimate working pressure see nameplate
**may vary depending on specific order
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
Technical Data
page 65
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
page 66
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
page 67
Busch – All over the World in Industry
Australia
Busch Australia Pty. Ltd.
30 Lakeside Drive
Broadmeadows, Vic. 3047
Tel: (03) 93 55 06 00
Fax: (03) 93 55 06 99
Austria
Busch Austria GmbH
Industriepark Nord
2100 Korneuburg
Tel: 02262 / 756 65-0
Fax: 02262 / 756 65-20
Belgium
Busch N.V./Busch SA
Kruinstraat 7
9160 Lokeren
Tel: (0)9 / 348 47 22
Fax: (0)9 / 348 65 35
Brazil
Busch do Brasil Ltda.
Rod. Edgard Máximo Zambotto, Km 64
13240-000 Jarinu-SP
Tel: (55) 11-4016 1400/5277
Fax: (55) 11-4016 5399
Canada
Busch Vacuum Technics Inc.
1740, Boulevard Lionel Bertrand
Boisbriand (Montréal)
Québec J7H 1N7
Tel: 450 435 6899
Fax: 450 430 5132
Chile
Busch Chile S. A.
Calle El Roble N° 375-G
Lampa - Santiago
Tel: (56-2) 7387092
Fax: (56-2) 7387092
China
Busch Vacuum (Shanghai) Co., Ltd
No.5, Lane 195 Xipu Road
Songjiang Industrial Estate East New Zone
Shanghai 201611 PRC
Tel: +86 (0)21 67600800
Fax: +86 (0)21 67600700
Czech Republic
Busch Vakuum s.r.o.
Pražákova 10
619 00 Horní Heršpice
Brno
Tel: +420 543 42 48 55
Fax: +420 543 42 48 56
Denmark
Busch Vakuumteknik A/S
Parallelvej 11
8680 Ry
Tel: +45 87 88 07 77
Fax: +45 87 88 07 88
Finland
Busch Vakuumteknik Oy
Sinikellontie 4
01300 VANTAA
Tel: 09 774 60 60
Fax: 09 774 60 666
France
Busch France S.A.
Parc Technologique
de Bois Chaland CE 2922
91029 Evry Cedex
Tel: 01 69 89 89 89
Fax: 01 60 86 16 74
Germany
Dr.-Ing. K. Busch GmbH
Schauinslandstr. 1
79689 Maulburg
Tel: (0 76 22) 6 81-0
Fax: (0 76 22) 6 81-194
e-mail: [email protected]
Dr.-Ing. K. Busch GmbH
Niederlassung Nord
Ernst-Abbe-Str. 1-3
25451 Quickborn
Tel: (0 41 06) 7 99 67-0
Fax: (0 41 06) 7 99 67-77
Dr.-Ing. K. Busch GmbH
Niederlassung West
Nordring 35
64807 Dieburg
Tel: (0 60 71) 92 82-0
Fax: (0 60 71) 14 71
Dr.-Ing. K. Busch GmbH
Außenstelle Neuenrade
Breslauer Str. 36
58809 Neuenrade
Tel: (0 23 92) 50 29 92
Fax: (0 23 92) 50 72 11
Dr.-Ing. K. Busch GmbH
Niederlassung Süd-Ost
Gewerbestraße 3
90579 Langenzenn
Tel: (0 91 01) 90 25-0
Fax: (0 91 01) 90 25-25
Dr.-Ing. K. Busch GmbH
Außenstelle Zella-Mehlis
Am Rain 11
98544 Zella-Mehlis
Tel: (0 36 82) 46 92 71
Fax: (0 36 82) 46 92 73
Dr.-Ing. K. Busch GmbH
Außenstelle Meitingen-Ostendorf
Grüntenweg 8
86405 Meitingen-Ostendorf
Tel: (0 82 71) 426-341
Fax: (0 82 71) 426-342
India
Busch Vacuum India Pvt Ltd.
Plot No. 110, Sector 7
PCNTDA, Bhosari
Pune 411026, Maharashtra
Tel: (0)206410 2886
Fax: (0)202711 2838
Ireland
Busch Ireland Ltd.
A10-11 Howth Junction Business Centre
Kilbarrack, Dublin 5
Tel: 00353 1 832 1466
Fax: 00353 1 832 1470
Israel
Busch Israel Ltd.
1 Mevo Sivan Street
Qiryat Gat 82022, Israel
Tel: +972 (0)8 6810485
Fax +972 (0)8 6810486
Italy
Busch Italia S.r.l.
Via Ettore Majorana, 16
20054 Nova Milanese
Tel: 0362 370 91
Fax: 0362 370 999
Japan
Nippon Busch K.K.
1-23-33, Megumigaoka
Hiratsuka City, Kanagawa
Japan 259-1220
Tel: 0463-50-4000
Fax: 0463-50-4004
Korea
Busch Korea Ltd.
392-1 Yangji-Ri, Yangji-Myun,
Yongin-si, Kyunggi-Do
Tel: 031) 321-8114
Fax: 031) 321 4330
Malaysia
Busch (Malaysia) Sdn Bhd.
6 Jalan Taboh 33/22
Shah Alam Technology Park
Section 33
40400 Shah Alam
Selangor D. E.
Tel: 03 5122 2128
Fax 03 5122 2108
Mexico
Busch Vacuum Mexico S de RL de CV
Tlaquepaque 4865, Los Altos
Monterrey, Nuevo Leon
Mexico 64370
Tel: (81) 8311-1385
Fax: (81) 8311-1386
Netherlands
Busch B.V.
Pompmolenlaan 2
3447 GK Woerden
Postbus 2091
3440 DB Woerden
Tel: (0)348 - 462300
Fax: (0)348 - 422939
New Zealand
Busch New Zealand Ltd.
Unit D, 41 Arrenway Drive
Albany 0632
Auckland
Tel: 09 414 7782
Fax: 09 414 7783
MM 1202, 1252, 1322 AP ATEX-Version, Gas Tight
0870142930 / 190705
www.buschvacuum.com
Norway
Busch Vakuumteknikk AS
Hestehagen 2
1440 Drøbak
Tel: 64 98 98 50
Fax: 64 93 66 21
Poland
Busch Polska Sp. z o.o.
Ul. Chopina 27
87800 W»oc»awek
Tel: (054) 2315400
Fax: (054) 2327076
Portugal
Busch lbérica S.A., Sucursal em Portugal
Zona Industrial Raso de Travassô, Fracção B, Armazém 2
3750-753 Agueda
Aveiro, Portugal
Tel: +351 234 648 070
Fax: +351 234 648 068
Russia
Busch Vacuum Russia OOO
Kotlyakovskaya str., 6/9
115201 Moscow
Tel: +7 495 6486726
Fax: +7 495 6486724
Singapore
Busch Vacuum Singapore Pte Ltd
20 Shaw Road
#01-03 Ching Shine Building
Singapore 36 79 56
Tel: (65) 6488 0866
Fax: (65) 6288 0877
Spain
Busch Ibérica S.A.
C/ Jaume Ferran, 6-8
Pol. Ind. Coll de la Manya
08403 Granollers
Tel: +34 93 861 61 60
Fax: +34 93 840 91 56
Sweden
Busch Vakuumteknik AB
Bråta Industriområde
435 33 Mölnlycke
Tel: 031 - 338 00 80
Fax: 031 - 338 00 89
Switzerland
Busch AG
Waldweg 22
4312 Magden
Tel: 061 / 845 90 90
Fax: 061 / 845 90 99
Taiwan
Busch Taiwan Corporation
1F. No. 69, Sec. 3, Beishen Rd.
Shenkeng Township,
Taipei Country,
Taiwan (222), R.O.C
Tel: (02) 2662 0775
Fax: (02) 2662 0796
Thailand
Busch Vacuum (Thailand) Co., Ltd.
888/30 Moo19, Soi Yingcharoen, Bangplee-Tamru Rd.,
Bangpleeyai, Bangplee, Samutprakarn 10540 Thailand
Tel: (66) 2-382-5428
Fax: (66) 2-382-5429
Turkey
VAKUTEK
Emlak Kredi Ishani No: 179
81130 Üsküdar-Istanbul
Tel: (216) 310 0573
Fax: (216) 343 5126
United Kingdom
Busch (UK) Ltd
Hortonwood 30-35
Telford Shropshire TF1 7YB
Tel: 01952 677 432
Fax: 01952 677 423
USA
Busch, Inc.
516-B Viking Drive
Virginia Beach, VA 23452
Tel: (757) 463-7800
Fax: (757) 463 7407
Semiconductor Vacuum Group Inc.
Morgan Hill, CA 95037
Tel: (408) 955 1900
Fax: (408) 955 0229
Busch – All over the World in Industry
page 68