BUSCH COBRA ATEX NC 2500 B User manual

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Instruction Manual
COBRA ATEX
Dry Screw Vacuum Pumps
NC 2500 B (water-cooled version)
0870569470/-0003_en / Original instructions / Modifications reserved 07/07/2020
Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland

Table of Contents
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Table of Contents
1 Safety .......................................................................................................................................4
2 Product Description ..................................................................................................................5
2.1 Operating Principle .......................................................................................................... 6
2.2 Application....................................................................................................................... 6
2.3 Start Controls ................................................................................................................... 6
2.4 Standard Features ............................................................................................................ 7
2.4.1 Water Cooling.......................................................................................................7
2.4.2 Cooling Gas Recirculation......................................................................................7
2.4.3 Resistance Thermometer (Cooling Liquid).............................................................. 7
2.4.4 Resistance Thermometer (Exhaust Gas) ................................................................. 7
2.4.5 Pressure Transmitter ..............................................................................................7
2.4.6 Vibration Diagnostic Unit ...................................................................................... 7
2.4.7 Sealing Systems .....................................................................................................7
2.5 Optional Accessories ........................................................................................................ 8
2.5.1 Silencer.................................................................................................................. 8
2.5.2 Mechanical Seals ...................................................................................................8
2.5.3 Terminal Box .........................................................................................................8
2.6 Explanation of ATEX Classification.................................................................................... 8
2.6.1 ATEX Nameplate ...................................................................................................8
2.7 Safety concept ................................................................................................................. 8
2.7.1 List of Mandatory ATEX Accessories ...................................................................... 9
2.7.2 P&ID "Piping and Instrumentation Diagram" ........................................................9
3 Transport ..................................................................................................................................10
4 Storage .....................................................................................................................................11
5 Installation................................................................................................................................12
5.1 Installation Conditions...................................................................................................... 12
5.2 Connecting Lines / Pipes .................................................................................................. 13
5.2.1 Suction Connection ...............................................................................................13
5.2.2 Discharge Connection ...........................................................................................14
5.2.3 Cooling Water Connection ....................................................................................14
5.2.4 Cooling Gas Recirculation......................................................................................15
5.2.5 Barrier Gas System Connection..............................................................................16
5.3 Filling Oil.......................................................................................................................... 17
5.4 Filling Cooling Liquid........................................................................................................ 19
5.5 Fitting the Coupling ......................................................................................................... 20
5.6 Electrical Connection ........................................................................................................ 20
5.6.1 Wiring Diagram Three-Phase Motor (Pump Drive) ................................................ 21
5.7 Electrical Connection of the Cooling Liquid Pump ............................................................ 22
5.7.1 Wiring Diagram Cooling Liquid Pump ................................................................... 22
5.8 Electrical Connection of the Monitoring Devices............................................................... 23
5.8.1 Wiring Diagram Resistance Thermometer.............................................................. 23
5.8.2 Wiring Diagram Pressure Transmitter..................................................................... 24
5.8.3 Wiring Diagram Vibration Diagnostic Unit............................................................. 24
5.9 Flowchart ......................................................................................................................... 26
6 Commissioning.........................................................................................................................27
6.1 Recommendations on Operation...................................................................................... 28
6.1.1 Operating frequency .............................................................................................28
6.1.2 Stop & Start........................................................................................................... 28
6.2 Conveying Condensable Vapours..................................................................................... 28
6.3 Trip Procedure.................................................................................................................. 29

Table of Contents
0870569470_NC2500B_Ex_WCV_-0003_IM_en 3
6.4 Restart Procedure............................................................................................................. 29
7 Maintenance.............................................................................................................................30
7.1 Maintenance Schedule ..................................................................................................... 31
7.2 Oil Level Inspection.......................................................................................................... 31
7.3 Cooling Liquid Level Inspection ........................................................................................ 32
7.4 Oil Change....................................................................................................................... 32
7.5 Cooling Liquid Change..................................................................................................... 35
7.6 Calibration Procedure of the Electrical Devices ................................................................. 39
7.6.1 Procedure A ..........................................................................................................39
7.6.2 Procedure C ..........................................................................................................39
7.6.3 Procedure D ..........................................................................................................39
8 Overhaul...................................................................................................................................40
9 Decommissioning.....................................................................................................................40
9.1 Dismantling and Disposal ................................................................................................. 40
10 Spare Parts................................................................................................................................41
11 Troubleshooting .......................................................................................................................42
12 Technical Data..........................................................................................................................44
13 Cooling Liquid..........................................................................................................................44
14 Oil ............................................................................................................................................44
15 EU Declaration of Conformity...................................................................................................45

1 | Safety
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1 Safety
Prior to handling the machine, this instruction manual should be read and understood. If
anything needs to be clarified, please contact your Busch representative.
Read this manual carefully before use and keep for future reference.
This instruction manual remains valid as long as the customer does not change anything
on the product.
The machine is intended for industrial use. It must be handled only by technically trained
personnel.
Always wear appropriate personal protective equipment in accordance with the local
regulations.
The machine has been designed and manufactured according to state-of-the-art meth-
ods. Nevertheless, residual risks may remain. This instruction manual highlights potential
hazards where appropriate. Safety notes and warning messages are tagged with one of
the keywords DANGER, WARNING, CAUTION, NOTICE and NOTE as follows:
DANGER
... indicates an imminent dangerous situation that will result in death or serious injuries if
not prevented.
WARNING
... indicates a potentially dangerous situation that could result in death or serious injuries.
CAUTION
... indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
... indicates a potentially dangerous situation that could result in damage to property.
NOTE
... indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.

Product Description | 2
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2 Product Description
MP OSGODV
TSA+/0102
FIL
CWIPHECWO
CWOGC
IN
NP2
CLV2
MTB
CLV1
TM
OUT
EB
EB
NP1
OFP
CWIGC
TSA+/0101 CLG MV
ODV
BGS
TV CLD
CLF
GCSA
PSA+/0301
OSG MP
CLP
OFP
ECP
CWV
CWD
PCD
BGS Barrier gas system CLD Cooling liquid drain plug*
CLF Cooling liquid fill plug CLG Cooling liquid sight glass
CLP Cooling liquid pump CLV1 Cooling liquid vent plug (cooling liquid
pump)
CLV2 Cooling liquid vent plug (machine) CWD Cooling water drain plug
CWI Cooling water inlet CWIGC Cooling water inlet gas cooler
CWO Cooling water outlet CWOGC Cooling water outlet gas cooler
CWV Cooling water vent plug EB Eye bolt
ECP Earth connection FIL Air filter (option)
GC Gas Cooler IN Suction connection with mesh screen
MP Magnetic plug MTB Motor terminal box
MV Solenoid valve (option) NP Nameplate (NP1 + NP2)
ODV Oil drain valve OFP Oil fill plug
OSG Oil sight glass OUT Discharge connection
PCD Process condensate drain PHE Plate heat exchanger
PSA Pressure transmitter SA Vibration transmitter
TM Thermometer TSA Resistance thermometer
TV Thermostatic valve
*For additional cooling liquid drain plugs (CLD), see Cooling Liquid Change [►35].

2 | Product Description
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NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
pump’.
NOTE
Illustrations
In this instruction manual the illustrations may differ from the machine appearance.
2.1 Operating Principle
The machine works on the one-stage, twin-screw pump principle.
Two screw rotors are rotating inside the cylinder. The pumped medium is trapped
between the cylinder and screw chambers, compressed, and transported to the gas out-
let. During the compression process, the two screw rotors do not come into contact with
each other nor with the cylinder. There is no need for a lubrication or an operating fluid
in the compression chamber.
2.2 Application
Explosive gases and vapour mixtures can be drawn according to the scope of the Direct-
ive ATEX 2014/34/EU.
The machine is intended for the suction of explosive gases and for the placement in a
non-explosive environment according to the nameplate.
The ATEX classification:
Inside (i)
Outside (o)
2G Ex h IIC T2 Gb X
No ATEX zone
II
Conveying of other media leads to an increased thermal and/or mechanical load on the
machine and is permissible only after a consultation with Busch.
The machine is capable of maintaining ultimate pressure, see Technical Data [►44].
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [►44].
2.3 Start Controls
The machine comes without start controls. The control of the machine is to be provided
in the course of installation.
The machine must be equipped with a variable-frequency drive.

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2.4 Standard Features
2.4.1 Water Cooling
The machine is cooled by a cooling liquid circuit in the cylinder cover and cylinder.
The cooling liquid pump (CLP) allows a recirculating flow in the cooling liquid chamber.
The motor of the cooling liquid pump must be electrically connected, see Electrical Con-
nection of the Cooling Liquid Pump [►22]
The cooling liquid is cooled by a plate heat exchanger (PHE) which must be connected to
the water main.
2.4.2 Cooling Gas Recirculation
The cooling gas is sucked in from the pump exhaust and cooled as it passes through an
air/water heat exchanger.
2.4.3 Resistance Thermometer (Cooling Liquid)
The resistance thermometer monitors the cooling liquid temperature of the machine.
Warning and trip signals must be set, see Wiring Diagram Resistance Thermometer
[►23].
2.4.4 Resistance Thermometer (Exhaust Gas)
The resistance thermometer monitors the exhaust gas temperature at the machine dis-
charge.
Warning and trip signals must be set, see Wiring Diagram Resistance Thermometer
[►23].
2.4.5 Pressure Transmitter
The pressure transmitter monitors the gas pressure at the discharge connection (OUT).
Warning and trip signals must be set, see Wiring Diagram Pressure Transmitter [►24].
2.4.6 Vibration Diagnostic Unit
The vibration diagnostic unit monitors the correct mechanical operation of the machine.
This unit is composed of a vibration sensor (SA) and a diagnostic electronics VSE100 (de-
livered loose).
The machine must be stopped when the vibration limit value (preset at the factory) is
reached, see Wiring Diagram Vibration Diagnostic Unit [►24].
2.4.7 Sealing Systems
The machine is equipped with labyrinth seals on the motor side and suction side.
Other sealing systems are optionally available, see Mechanical Seals [►8].
Sealing systems prevent the process gas going to the bearings chambers.
The sealing systems include a barrier gas system, see Barrier Gas System Connection
[►16].

2 | Product Description
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2.5 Optional Accessories
2.5.1 Silencer
A silencer at the discharge connection (OUT) can be provided to reduce the exhaust gas
noise.
2.5.2 Mechanical Seals
The sealing systems can be equipped with mechanical seals. The following variants are
possible:
– Oil lubricated single mechanical seals on the motor side and labyrinth seals on the
suction side.
– Oil lubricated single mechanical seals on the motor side and suction side.
2.5.3 Terminal Box
The machine can be optionally equipped with one or two terminal boxes. All electrical
devices, except the motor, are wired to the terminal box.
2.6 Explanation of ATEX Classification
The ATEX classification is written on the nameplate of the machine (NP), see below a
marking example:
Inside (i)
Outside (o)
II 2G Ex h IIB T2 Gb X
No ATEX zone
Explosion group inside the machine
Equipment category for explosive gases inside the machine
Equipment group II (not for mining application)
Explosion protection inside the machine
Design approved according to ATEX Directive
Temperature class inside the machine
Equipment protection level
(T2=300°C) ; (T3=200°C) ; (T4=135°C)
Type of protection
Special conditions for operation*
* The specific operating conditions are determined in this instruction manual.
2.6.1 ATEX Nameplate
The machine has two different nameplates:
– A nameplate (NP1) is fixed on the base frame of the machine with the ATEX marking
inscription.
– A second nameplate (NP2) is fixed on the machine stage (module) identifying that
the stage is suitable for ATEX certified machine.
This allows the preservation of the machine ATEX certification if the machine stage
should be replaced.
2.7 Safety concept
The safety concept is based on the prevention of sparks and excessive temperatures by
means of various accessories.
The monitoring devices must be integrated into the system control such that operation
of the machine will be inhibited if the safety limit values are exceeded.

Product Description | 2
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The limit values of each accessory are defined in the wiring diagram chapters, see Elec-
trical Connection of the Monitoring Devices [►23].
To have more details about the monitoring procedure, see Flowchart [►26].
2.7.1 List of Mandatory ATEX Accessories
The following list indicates the mandatory accessories according to the ATEX classifica-
tion of the machine.
TSA+
/0101 ECP
TTSA+
/0102
PSA+
/0301
(i) II 2G Ex h IIB T2 Gb X
(o) No ATEX zone
SA+
/0701
ECP Pump earth connection PSA Pressure transmitter
SA Vibration transmitter TSA Resistance thermometer
2.7.2 P&ID "Piping and Instrumentation Diagram"
FIL
CLP
GC
IS
TCV
BGC Barrier gas connection CLP Cooling liquid pump
CPL Coupling FIL Air filter (option)
FME Flow meter FS Flow switch (option)
GC Gas cooler IN Suction connection
IS Inlet screen MAN Manometer
MOT Motor MV Solenoid valve (option)
NRV Non-return valve PHE Plate heat exchanger
PRV Pressure regulating valve PSA Pressure transmitter
SA Vibration transmitter TCV Temperature control valve
TSA Resistance thermometer

3 | Transport
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3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
WARNING
Lifting the machine using the motor eye bolt.
Risk of severe injury!
• Do not lift the machine using the eye bolt fitted to the motor. Only lift the machine as
shown.
NOTICE
In case the machine is already filled with oil.
Tilting a machine that is already filled with oil can cause large quantities of oil to in-
gress into the cylinder.
• Drain the oil prior to every transport or always horizontally transport the machine.
• Make sure that the eyebolt(s) (EB) is/are in faultless condition, fully screwed in and
tightened by hand.
Machine weight:
see the technical data or the nameplate (NP)
Transport with a lifting hook
l1 = ~430 mm
l2 & l3 = ~650 mm

Storage | 4
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Transport with a Forklift
Handling access must be from the
underneath of the base frame
• Check the machine for transport damage.
If the machine is secured to a base plate:
• Remove the machine from the base plate.
4 Storage
• Seal all apertures with adhesive tape or reuse provided caps.
If the machine is to be stored for more than 3 months:
• Wrap the machine in a corrosion inhibiting film.
• Store the machine indoors, dry, dust free and if possible in original packaging
preferably at temperatures between 5 ... 55 °C.
NOTICE
Long storage time.
Risk of damage to the machine!
• If the machine is equipped with oil lubricated mechanical seals, we recommend to
completely fill the oil chamber before a long storage, see “Oil filling” in chapter Oil
Change [►32]. This protects the mechanical seals during a long storage. Use the
standard pump oil, see chapter Oil [►44].
• Before restarting the machine, drain the oil to the normal oil level, see “Oil draining”
in chapter Oil Change [►32].

5 | Installation
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5 Installation
5.1 Installation Conditions
WARNING
The installation conditions are not respected in an ATEX environment.
Risk of severe injury!
Risk of explosion!
• Take care that the installation conditions are met.
NOTICE
Use of the machine outside of the permitted installation conditions.
Risk of premature failure!
Loss of efficiency!
• Take care that the installation conditions are fully complied with.
• Make sure that the environment of the machine complies with the ATEX classification
of the machine according to the data given on the nameplate of the motor and the
nameplate of the machine (NP).
• Make sure that the ambient conditions comply with the Technical Data [►44].
• Make sure that the environmental conditions comply with the protection class of the
motor and the electrical instruments.
• Make sure that the installation space or location is vented such that sufficient cooling
of the machine is provided.
• Make sure that cooling air inlets and outlets of the motor fan are not covered or ob-
structed and that the cooling air flow is not affected adversely in any other way.
• Make sure that the oil sight glass (OSG) remains easily visible.
• Make sure that enough space remains for maintenance work.
• Make sure that the machine is placed or mounted horizontally, a maximum of 1° in
any direction is acceptable.
• Check the oil level, see Oil Level Inspection [►31].
• Check the cooling liquid level, see Cooling Liquid Level Inspection [►32].
If the machine is installed at an altitude greater than 1000 meters above sea level:
• Contact your Busch representative, the motor should be derated or the ambient
temperature limited.
If additional electrical components not included in scope of delivery should be added:
• Make sure that they have a better or equal ATEX classification than that of the
machine, see the ATEX marking on the nameplate (NP).

Installation | 5
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5.2 Connecting Lines / Pipes
WARNING
The connection lines can build up an electrostatic charge.
Risk of severe injury!
Risk of explosion!
• The connection lines must be made out of conductive material or provisions must be
made against creating an electrostatic charge.
WARNING
Rotating Parts.
Risk of severe injury!
• Do not operate the machine without suction / discharge connection installed.
• Remove all protective covers before installation.
• Make sure that the connections are gas tight.
• Make sure that the connection lines cause no stress on the machine‘s connection; if
necessary use flexible joints.
• Make sure that the line size of the connection lines over the entire length is at least as
large as the connections of the machine.
In case of very long connection lines it is advisable to use larger line sizes in order to
avoid a loss of efficiency. Seek advice from your Busch representative.
5.2.1 Suction Connection
WARNING
Unprotected suction connection.
Risk of severe injury!
• Do not put hand or fingers in the suction connection.
NOTICE
Ingress of foreign objects or liquids.
Risk of damage to the machine!
If the inlet gas contains dust or other foreign solid particles:
• Install a suitable filter (5micron or less) upstream from the machine.
Connection size(s):
– DN150 PN16 or 6’’ ASME B16.5 Class 150
If the machine is used as part of a vacuum system:
• Busch recommends the installation of an isolation valve in order to prevent the
machine from turning backwards.

5 | Installation
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5.2.2 Discharge Connection
Connection size(s):
At the machine discharge connection:
– DN100 PN16 or 4’’ ASME B16.5 Class 150
At the silencer (SI) discharge connection:
– DN100 ISO-K, DIN 28404
• Make sure that the discharged gas will flow without obstruction. Do not shut off or
throttle the discharge line or use it as a pressurised air source.
• Make sure that the counter pressure (also termed back pressure) at the discharge con-
nection (OUT) does not exceed the maximum allowable discharge pressure, see Tech-
nical Data [►44].
5.2.3 Cooling Water Connection
CWO CWI PHE
CWI Cooling water inlet CWO Cooling water outlet
PHE Plate heat exchanger
• Connect the cooling water connections (CWI / CWO) to the water supply.
Connection size:
– G1/2, ISO 228-1 (CWI / CWO)
• Make sure that the cooling water complies with the following requirements:
Supply capacity l/min 18
Water pressure bar 1 ... 6
Supply temperature °C +10 ... +30
Required pressure differential across supply
and return
bar ≥ 1
• To reduce the maintenance effort and ensure a long product lifetime we recommend
the following cooling water quality:
Hardness mg/l (ppm) < 90
Properties Clean & clear
PH value 7 ... 8
Particle size µm < 200
Chloride mg/l < 100
Electrical conductivity µS/cm ≤ 100

Installation | 5
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Free chloride mg/l < 0.3
Materials in contact with the cooling water Stainless steel
NOTE
Water hardness unit conversion.
1 mg/l (ppm) = 0.056 °dh (german degree) = 0.07 °e (english degree) = 0.1 °fH (french
degree)
5.2.4 Cooling Gas Recirculation
CWOGC CWIGC
GC
CWIGC Cooling water inlet gas cooler CWOGC Cooling water outlet gas cooler
GC Gas cooler
• Connect the cooling water connections (CWIGC / CWOGC) to the water supply.
Connection size:
• DN20 PN40, EN 1092-1 (CWIGC / CWOGC)
• Make sure that the cooling water complies with the following requirements:
Supply capacity l/min ≥ 18
Water pressure bar 1 ... 6
Supply temperature °C +10 ... +30
Required pressure differential across supply
and return
bar ≥ 1
• To reduce the maintenance effort and ensure a long product lifetime we recommend
the following cooling water quality:
Hardness mg/l (ppm) < 90
Properties Clean & clear
PH value 7 ... 8
Particle size µm < 200
Chloride mg/l < 100
Electrical conductivity µS/cm ≤ 100
Free chloride mg/l < 0.3
Materials in contact with the cooling water Stainless steel

5 | Installation
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NOTE
Water hardness unit conversion.
1 mg/l (ppm) = 0.056 °dh (german degree) = 0.07 °e (english degree) = 0.1 °fH (french
degree)
5.2.5 Barrier Gas System Connection
Without nitrogen panel
PRV FRBGC MAN FME
BGC Barrier gas connection FME Flow meter
FR Flow regulator MAN Manometer
PRV Pressure regulating valve
• Connect the barrier gas connection (BGC) to the gas supply.
Connection size:
– G1/4, ISO 228-1
• Make sure that the gas complies with the following requirements:
Gas type Dry nitrogen or air
Gas temperature °C 0 ... 60
Maximum gas pressure bar 13
Recommended pressure setting at the
pressure regulating valve (PRV)
bar 3
Filtration µm 5
Recommended flow rate SLM* 30
Air quality (only for air) Acc. to ISO
8573-1
Class 5.4.4.
* standard litre per minute

Installation | 5
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5.3 Filling Oil
NOTICE
Use of an inappropriate oil.
Risk of premature failure!
Loss of efficiency!
• Only use an oil type which has previously been approved and recommended by
Busch.
For oil type and oil capacity see Technical Data [►44] and Oil [►44].
1
2
Busch Oil
3
MAX
MIN
3 mm
4
Check oil level
Oil filling at the motor side

5 | Installation
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1
2
Busch Oil
3
MAX
MIN
3 mm
4
Check oil level
Oil filling at the suction side
When the oil filling is achieved:
• Write down the oil change date on the sticker.
Last oil change
__ / __ / ____
Oil type see nameplate
Change interval see
instruction manual
If there is no sticker (part no. 0565 568 959) on the machine:
• Order it from your Busch representative.

Installation | 5
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5.4 Filling Cooling Liquid
For cooling liquid type and cooling liquid capacity see Technical Data [►44] and
Cooling Liquid [►44].
1
2
Cooling
liquid
Zitrec M-25
3
4
5
Cooling liquid filling Cooling liquid vent plug (CLV1)
Fill up to the top of the
vent orifice (CLV1)
3
2
MAX
MIN
Cooling
liquid
Zitrec M-25
1
Resume cooling liquid filling

5 | Installation
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5.5 Fitting the Coupling
2
3
E
1
Coupling hub (machine side)
Coupling hub (motor side)
Elastic insert
Radial screw
Max. admissible
torque: 10 Nm
Ring
Machine type Coupling size Value “E” (mm)
NC 2500 B Samiflex® A45 3,5 (0/+1)
In case of a machine delivery without motor:
• Fit the second coupling hub on the motor shaft (separately delivered).
• Axially adjust the hub in such a way until value "E" is reached.
• When the coupling adjustment is done, lock the coupling hub by tightening the
radial screw.
For further coupling information, go to www.samiflex.se and download the instruction
manual of the Samiflex® coupling.
5.6 Electrical Connection
DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
• Make sure that the power supply for the motor is compatible with the data on the
nameplate of the motor.
• The electrical installation must comply with applicable national and international
standards.
• Provide a lockable disconnect switch on the power line so that the machine is com-
pletely secured during maintenance tasks.
• Provide an overload protection according to EN 60204-1 for the motor.
• Make sure that the motor of the machine will not be affected by electric or electro-
magnetic disturbance from the mains; if necessary seek advice from Busch.
• Connect the protective earth conductor.
• Electrically connect the motor.
• Make sure that the machine is started by a variable-frequency drive.