BUSCH COBRA BA 0100 C User manual

Instruction Manual
COBRA
Dry Screw Vacuum Pumps
BA 0100 C
2020/05/19
Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland
0870211637/-0003_en / Original instructions / Modifications reserved

Table of Contents
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Table of Contents
1 Safety.......................................................................................................................... 3
2 Product Description .................................................................................................. 4
2.1 Operating Principle .............................................................................................. 5
2.2 Application...........................................................................................................5
2.3 Drive Variants ...................................................................................................... 5
2.4 Standard Features...............................................................................................5
2.4.1 Wheels......................................................................................................5
2.4.2 Emergency Stop Switch............................................................................5
2.4.3 I/O and Communication Port (With VFD Only) .........................................5
2.4.4 Silencer.....................................................................................................6
2.5 Optional Accessories........................................................................................... 6
2.5.1 Nitrogen System .......................................................................................6
3 Transport.................................................................................................................... 6
4 Storage ....................................................................................................................... 7
5 Installation ................................................................................................................. 7
5.1 Installation Conditions ......................................................................................... 7
5.2 Connecting Lines / Pipes.....................................................................................8
5.2.1 Suction Connection...................................................................................8
5.2.2 Discharge Connection ..............................................................................8
5.2.3 Nitrogen System Connection (Optional) ...................................................9
5.3 Earth Connection.................................................................................................10
5.4 Filling Oil..............................................................................................................10
5.5 Electrical Connection........................................................................................... 12
5.5.1 Voltage Switch 208 - 400 V ......................................................................13
5.5.2 Rotation sense of fan wheel .....................................................................13
5.6 I/O and Communication Port Schematic (With VFD Only) .................................. 14
6 Commissioning ......................................................................................................... 14
6.1 Conveying Condensable Vapours ....................................................................... 15
6.2 Restart Procedure ............................................................................................... 15
7 Maintenance............................................................................................................... 16
7.1 Maintenance Schedule ........................................................................................ 16
7.2 Oil Level Inspection ............................................................................................. 17
7.3 Oil Colour Inspection ........................................................................................... 17
7.4 Oil Change........................................................................................................... 18
8 Overhaul..................................................................................................................... 19
9 Decommissioning ..................................................................................................... 20
9.1 Dismantling and Disposal .................................................................................... 20
10 Spare Parts ................................................................................................................ 20
11 Troubleshooting ........................................................................................................ 21
12 Technical Data ........................................................................................................... 22
13 Oil................................................................................................................................ 22
14 EU Declaration of Conformity .................................................................................. 23

Safety | 1
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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 any-
thing 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 po-
tential 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 injur-
ies.
CAUTION
... indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
... indicates a potentially dangerous situation that could result in damage to property.
NOTE
... indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.

2 | Product Description
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2 Product Description
COM
4x WHL
OFP EB IN NP
OUT ECPNC
AF
ESS, MSH MC
EDPSI
VFDOSGDGVMSS VSODP
AF Axial fan COM I/O and communication port (with VFD
only)
DGV Dilution gas valve (Optional) EB Eye bolt
ECP Earth connection (machine) EDP Electrical data plate
ESS Emergency stop switch IN Inlet connection
MC Mains connection MSH Main switch
MSS Motor safety switch NC Nitrogen connection (Optional)
NP Nameplate OFP Oil fill plug
ODP Oil drain plug OSG Oil sight glass
OUT Discharge connection SI Silencer
VFD Variable-frequency drive (Optional) VS Voltage switch (with VFD only)
WHL Wheels
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
pump’.

Product Description | 2
0870211637_BA0100C_-0003_IM_en 5 / 24
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
outlet. 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.
The COBRA BA is fully air-cooled thanks to an integrated fan in the protective hood.
2.2 Application
The machine is intended for the suction of air and other dry, toxic, non-aggressive and
non-explosive gases.
Conveying of other media leads to an increased thermal and/or mechanical load on
the machine and is permissible only after a consultation with Busch.
The machine is intended for the placement in a non-potentially explosive environment.
The machine is suitable for continuous operation but limited to a suction pressure of
150 hPa (mbar). The machine is allowed to operate at atmospheric pressure for up to
5 minutes.
Permitted environmental conditions, see Technical Data [►22].
2.3 Drive Variants
The machine can be equipped with either a direct drive or a variable-frequency drive
(VFD).
2.4 Standard Features
2.4.1 Wheels
Four wheels are fitted to the bottom of the machine to facilitate transportation and in-
stallation.
2.4.2 Emergency Stop Switch
The machine is equipped in standard with an emergency stop switch (ESS).
2.4.3 I/O and Communication Port (With VFD Only)
The D-Sub 15 supports maintained dry contact remote control and monitoring of the
machine.

3 | Transport
6 / 24 0870211637_BA0100C_-0003_IM_en
2.4.4 Silencer
A silencer at the discharge connection (OUT) is provided as standard to reduce the
exhaust gas noise.
2.5 Optional Accessories
2.5.1 Nitrogen System
The nitrogen connection (NC) supplies nitrogen or clean dry compressed air for:
– The barrier gas system (gas sealing between the compression chamber and
gears/bearing housing).
– The dilution gas system.
3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
• 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)
• Check the machine for transport damage.
If the machine is secured to a base plate:
• Remove the machine from the base plate.

Storage | 4
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4 Storage
• Seal all apertures with adhesive tape or reuse provided caps.
NOTICE
Long storage time.
Risk of damage to the machine!
• Due to a long storage time the capacitors of the variable-frequency drive can lose
efficiency because of electrochemical processes. In the worst case, it can lead to a
short-circuit and therefore to a damage to the variable-frequency drive of the ma-
chine.
• Connect the machine every 18 months for 30 minutes to the mains.
If the machine is to be stored for more than 3 months:
• Wrap the machine in a corrosion inhibiting film.
• Store the machine indoors, dry, dust free and if possible in original packaging
preferably at temperatures between -20 ... 60 °C.
5 Installation
5.1 Installation Conditions
NOTICE
Use of the machine outside of the permitted installation conditions.
Risk of premature failure!
Loss of efficiency!
• Take care that the installation conditions are fully complied with.
~50 cm
~20 cm
~20 cm
~20 cm
• Make sure that the environment of the machine is not potentially explosive.
• Make sure that the ambient conditions comply with the Technical Data [►22].
• Make sure that the installation space or location is vented such that sufficient cool-
ing of the machine is provided.
• Make sure that cooling air inlets and outlets are not covered or obstructed and that
the cooling air flow is not affected adversely in any other way.

5 | Installation
8 / 24 0870211637_BA0100C_-0003_IM_en
• 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 [►17].
• Make sure that all provided covers, guards, hoods, etc. are mounted.
If the machine is installed at an altitude greater than 1000 meters above sea level:
• Contact your Busch representative, the motor should be derated or the ambient
temperature limited.
5.2 Connecting Lines / Pipes
• Remove all protective covers before installation.
• Make sure that the connection lines cause no stress on the machine‘s connection; if
necessary use flexible joints.
• Make sure that the line size of the connection lines over the entire length is at least
as large as the connections of the machine.
In case of 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!
• Keep long hair, loose articles of clothing, etc. away from 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):
– ISO-KF 50
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.
5.2.2 Discharge Connection
Connection size(s):
– ISO-KF 40
• 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
connection (OUT) does not exceed the maximum allowable discharge pressure,
see Technical Data [►22].

Installation | 5
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5.2.3 Nitrogen System Connection (Optional)
DGVNC
DGV Dilution gas valve NC Nitrogen connection
• Connect the nitrogen connection (NC) to the gas supply.
Connection size:
– G1/4, NPT (NC) + 2 adapters for pipe d6,15 and 6,5mm are supplied loose.
To access the dilution gas valve (DGV):
• Remove the two cruciform head screws at the top corners of the side cover.
• Lift the side cover to remove it from the frame.
• Make sure that the gas complies with the following requirements:
Gas type Dry nitrogen or air
Gas temperature °C 0 ... 60
Maximum gas supply pressure bar 6
Minimum gas supply pressure bar 2.7
Filtration µm 5
Air quality (only for air) Acc. To ISO 8573-1 Class 5.4.4.
Flow rate of barrier gas
(with DGV closed):
SLM* 19 ... 33
Flow rate of barrier and dilution
gas (with DGV open):
SLM* 25 ... 51
* standard litre per minute

5 | Installation
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Dilution gas system
DGV
NC
Barrier gas system
5.3 Earth Connection
• Connect the earth connection of the machine (ECP).
ECP
5.4 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.

Installation | 5
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For oil type and oil capacity see Technical Data [►22] and Oil [►22].
4x
2x
Use a crussiform screwdriver
Use a crussiform screwdriver
Remove side cover
Remove top cover
1
2
Busch Oil
3
MAX
MIN
4
Check oil level
Oil sight glass

5 | Installation
12 / 24 0870211637_BA0100C_-0003_IM_en
When the oil filling is achieved:
• Write down the oil change date on the sticker.
Last oil change
__ / __ / ____
Oil type see nameplate
Change interval see
instruction manual
If there is no sticker (part no. 0565 568 959) on the machine:
• Order it from your Busch representative.
5.5 Electrical Connection
• Wire the mating connector (delivered loose) in accordance with the scheme below:
Mains connection (MC) 4-pin connector
1 2
3
1 = Phase 1 (L1)
2 = Phase 2 (L2)
3 = Phase 3 (L3)
(4) = Earth
• Electrically connect the machine directly to the mains connection (MC).
NOTICE
Incorrect direction of rotation.
Risk of damage to the machine!
• Operation in the wrong direction of rotation can destroy the machine in a short time!
Prior to start-up, ensure that the machine is operated in the right direction.
• With a phase rotation tester, check if the wiring corresponds to the correct direction
of rotation.
• Jog the motor briefly.
Make sure that the machine draws in air.
If the rotation of the motor must be changed:
• Switch any two of the motor phase wires.

Installation | 5
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5.5.1 Voltage Switch 208 - 400 V
• Make sure that the main switch (MSH) is in “OFF” position.
• Select the needed voltage from the voltage switch (VS)
(factory default setting ► 400 V).
The 208 V setting is used for 200-240 VAC and the 400 V switch position is used for
380-480 VAC.
2x
400 V
208 V
Use a crussiform
screwdriver
Remove side cover
5.5.2 Rotation sense of fan wheel
Watch the fan wheel rotation and determine the intended direction of rotation with the
arrow (stuck on).
• Jog the motor briefly.
Make sure that the fan wheel draws air inside and through the whole machine.
If the rotation must be changed:
• Switch any two of the phase wires.

6 | Commissioning
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5.6 I/O and Communication Port Schematic (With
VFD Only)
Connector: D-Sub15, 15-pin, female
81
915
Pin No. Description
1N/A
2 Digital Input 2 Start pump
Open: Stop
Closed: Start
3 … 4 N/A
5 24 V OUT
6 Digital Input 1 Preset speed
DI1 = 0 ►50 Hz
DI1 = 1 ►60 Hz
7 Fault relay IN
8 Fault relay OUT
9 … 14 N/A
15
24 V OUT
Power supply (max. 10 mA)
Power supply (max. 10 mA)
N/A
N/A
Signal
Contact NC (normally closed)
Umax = 250 VDC / Imax = 2 A
N/A
Relay
of VFD
User side
Male connector
Included in standard scope of delivery:
Male connector with bridge for Pin No. 2-15 and Pin No. 5-6 (automatic start at 60 Hz).
6 Commissioning
NOTICE
Lubricating a dry running machine (compression chamber).
Risk of damage to the machine!
• Do not lubricate the compression chamber of the machine with oil or grease.
NOTICE
Running without air-cooled system.
Risk of damage to the machine!
• Make sure that the fan (AF) is running whenever the machine is running.
CAUTION
During operation the surface of the machine may reach temperatures of more than
70°C.
Risk of burns!
• Avoid contact with the machine during and directly after operation.
CAUTION
Noise of running machine.
Risk of damage to hearing!
If persons are present in the vicinity of a non noise insulated machine over extended
periods:
• Make sure that ear protection is being used.

Commissioning | 6
0870211637_BA0100C_-0003_IM_en 15 / 24
• Make sure that the installation conditions (see Installation Conditions [►7]) are
met.
If the machine is equipped with a nitrogen system:
• Turn on the nitrogen supply.
• Switch on the machine.
• Make sure that the maximum permissible number of starts does not exceed 6 starts
per hour. Those starts should be spread within the hour.
• Make sure that the operating conditions comply with the Technical Data [►22].
• After a few minutes of operation, perform an Oil Level Inspection [►17].
As soon as the machine is operated under normal operating conditions:
• Measure the motor current and record it as reference for future maintenance
and troubleshooting work.
6.1 Conveying Condensable Vapours
The machine, equipped with a dilution gas sytem, is suitable for the conveyance of
condensable vapour within the gas flow.
START
Open the dilution
gas valve (DGV)
Start the
machine
to warm it up
30 minutes 30 minutes
• Open the inlet valve
• Perform the process
• Close the inlet valve
Stop the nitrogen
supply
Stop the machine
END
6.2 Restart Procedure
If the machine has stopped unintentionally:
• Find out why the machine has stopped and solve the problem, see
Troubleshooting [►21].
• Let the machine cool down (approx. 1 hour).
• Switch on the motor safety switch (MSS).
• Start up the machine again with the main switch (MSH).
* accessories in option

7 | Maintenance
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7 Maintenance
WARNING
Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:
• Wear appropriate personal protective equipment.
CAUTION
Hot surface.
Risk of burns!
• Prior to any action requiring touching the machine, let the machine cool down first.
NOTICE
Using inappropriate cleaners.
Risk of removing safety stickers and protective paint!
• Do not use incompatible solvents to clean the machine.
CAUTION
Failing to properly maintain the machine.
Risk of injuries!
Risk of premature failure and loss of efficiency!
• Respect the maintenance intervals or ask your Busch representative for service.
• Shut down the machine and lock against inadvertent start up.
If the machine is equipped with a barrier gas system:
• Close the barrier gas supply.
• Vent the connected lines to atmospheric pressure.
If necessary:
• Disconnect all connections.
7.1 Maintenance Schedule
The maintenance intervals depend very much on the individual operating conditions.
The intervals given below are desired to be considered as starting values which
should be shortened or extended as appropriate. Particularly harsh applications or
heavy duty operation, such as high dust loads in the environment or in the process
gas, other contamination or ingress of process material, can make it necessary to
shorten the maintenance intervals significantly.

Maintenance | 7
0870211637_BA0100C_-0003_IM_en 17 / 24
Interval Maintenance work
Yearly • Check the oil level, see Oil Level Inspection
[►17].
• Check the oil colour, see Oil Colour Inspection
[►17].
• Carry out a visual inspection and clean the machine
from dust and dirt
• Check the electrical connections and the monitoring
devices.
Every 16000 hours, could be
shortened or extended de-
pending on the application
• Change the oil of the gear and bearings, see Oil
Change [►18].
• If necessary, have a major overhaul on the machine
(contact Busch).
7.2 Oil Level Inspection
• Shut down the machine.
• When the machine is stopped, wait 1 minute before checking the oil level.
MAX
MIN
MAX
MIN
MAX
MIN
• Fill up if necessary, see Oil Filling [►10].
7.3 Oil Colour Inspection
WARNING
Oil “YLC 250 B” contaminated chemically or by foreign bodies.
Risk of explosion!
If the oil becomes dark:
• Contact your Busch representative without delay.
• Make sure that the oil is always transparent.
If the oil becomes dark, white or looks different from the initial colour:
• Change the oil immediately, see Oil Change [►18].
You can consult your Busch representative in order to find out why this colour change
has occurred.

7 | Maintenance
18 / 24 0870211637_BA0100C_-0003_IM_en
7.4 Oil Change
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.
1
2
Drain pan
For oil type and oil capacity see Technical Data [►22] and Oil [►22].
4x
2x
Use a crussiform screwdriver
Use a crussiform screwdriver
Remove side cover
Remove top cover

Overhaul | 8
0870211637_BA0100C_-0003_IM_en 19 / 24
1
2
Busch Oil
3
MAX
MIN
4
Check oil level
Oil sight glass
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.
8 Overhaul
In case of the machine having conveyed gas that was contaminated with foreign ma-
terials which are dangerous to health:
• Decontaminate the machine as much as possible and state the contamination
status in a ‘Declaration of Contamination’.
Busch will only accept machines that come with a completely filled in and legally bind-
ing signed ‘Declaration of Contamination’.
(Form downloadable from www.buschvacuum.com)

9 | Decommissioning
20 / 24 0870211637_BA0100C_-0003_IM_en
NOTICE
Improper assembly.
Risk of premature failure!
Loss of efficiency!
• It is highly recommended that any dismantling of the machine that goes beyond
anything that is described in this manual should be done through Busch.
WARNING
Machines contaminated with hazardous material.
Risk of poisoning!
Risk of infection!
If the machine is contaminated with hazardous material:
• Wear appropriate personal protective equipment.
9 Decommissioning
• Shut down the machine and lock against inadvertent start up.
If the machine is equipped with a barrier gas system:
• Close the barrier gas supply.
• Vent the connected lines to atmospheric pressure.
• Disconnect all connections.
If the machine is going to be stored:
• See Storage [►7].
9.1 Dismantling and Disposal
• Separate special waste from the machine.
• Dispose of special waste in compliance with applicable regulations.
• Dispose of the machine as scrap metal.
10 Spare Parts
NOTICE
Use of non-Busch genuine spare parts.
Risk of premature failure!
Loss of efficiency!
• The exclusive use of Busch genuine spare parts and consumables is recommended
for the correct functioning of the machine and to validate the warranty.
There is no standard spare parts kits available for this product, if you require Busch
genuine parts:
• Contact your Busch representative for the detailed spare parts list.