BUSCH COBRA BA 0100 C User manual

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COBRA
Dry Screw Vacuum Pumps
BA 0100 C
Instruction Manual
0870211637 | -0006_en-US | Original instructions 11/3/2022

Table of Contents
2 | 36 Instruction Manual COBRA BA 0100 C_EN_en
Table of Contents
1 Safety..................................................................................................................................................................... 3
2 Product Description............................................................................................................................................. 4
2.1 Operating Principle ............................................................................................................................................. 5
2.2 Intended Use ....................................................................................................................................................... 5
2.3 Drive Variants ...................................................................................................................................................... 6
2.4 Standard Features............................................................................................................................................... 6
2.4.1 Wheels .................................................................................................................................................... 6
2.4.2 Emergency Stop Switch........................................................................................................................ 6
2.4.3 I/O and Communication Port (only with VSD) ................................................................................... 6
2.4.4 Silencer................................................................................................................................................... 6
2.5 Optional Accessories........................................................................................................................................... 6
2.5.1 Nitrogen System ................................................................................................................................... 6
3 Transport .............................................................................................................................................................. 7
4 Storage .................................................................................................................................................................. 8
5 Installation ........................................................................................................................................................... 9
5.1 Installation Conditions........................................................................................................................................ 9
5.2 Connecting Lines / Pipes .................................................................................................................................... 10
5.2.1 Suction Connection............................................................................................................................... 10
5.2.2 Discharge Connection .......................................................................................................................... 10
5.2.3 Nitrogen System Connection (Optional) ............................................................................................ 11
5.3 Earth Connection................................................................................................................................................. 12
5.4 Filling Oil............................................................................................................................................................... 13
6 Electrical Connection........................................................................................................................................... 15
6.1 Machine delivered without Variable Speed Drive ........................................................................................... 16
6.2 Machine delivered with a Variable Speed Drive (Option)............................................................................... 17
6.3 Voltage Switch 208 - 400 V (only with VSD) ...................................................................................................... 18
6.4 Direction of Rotation of the Fan Wheel ............................................................................................................ 18
6.5 I/O and Communication Port Schematic (only with VSD)............................................................................... 19
7 Commissioning..................................................................................................................................................... 20
7.1 Conveying Condensable Vapors........................................................................................................................ 21
7.2 Restart Procedure ............................................................................................................................................... 21
8 Maintenance......................................................................................................................................................... 22
8.1 Maintenance Schedule ....................................................................................................................................... 23
8.2 Oil Level Inspection............................................................................................................................................. 23
8.3 Oil Color Inspection ............................................................................................................................................ 24
8.4 Oil Change............................................................................................................................................................ 24
9 Overhaul................................................................................................................................................................ 27
10 Decommissioning................................................................................................................................................. 28
10.1 Dismantling and Disposal .................................................................................................................................. 28
11 Spare Parts............................................................................................................................................................ 29
12 Troubleshooting................................................................................................................................................... 30
13 Technical Data...................................................................................................................................................... 31
14 Oil........................................................................................................................................................................... 32
15 EU Declaration of Conformity............................................................................................................................. 33
16 UK Declaration of Conformity ............................................................................................................................ 34

Safety | 1
Instruction Manual COBRA BA 0100 C_EN_en 3 | 36
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 methods. Never-
theless, residual risks may remain, as described in the following chapters and in accordance with the
chapter Intended Use [➔5]. This instruction manual highlights potential hazards where appropri-
ate. 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 trou-
ble-free operation.

2 | Product Description
4 | 36 Instruction Manual COBRA BA 0100 C_EN_en
2 Product Description
COM
WHL
OFP EB INNP
OUT ECPNC
AF
ESS, MSH MC
EDPSI
VSDOSGDGVMSS VSODP
CD
PMR
Description
IN Suction connection (Inlet) OUT Discharge connection (Outlet)
AF Axial fan CD Condensate drain
COM I/O and communication port (with VSD only) DGV Dilution gas valve (Optional)
EB Eye bolt ECP Earth connection (machine)
EDP Electrical data plate ESS Emergency stop switch
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
PMR Plug for manual rotation of rotors SI Silencer
VSD Variable speed drive (Optional) VS Voltage switch (with VSD only)
WHL Wheels

Product Description | 2
Instruction Manual COBRA BA 0100 C_EN_en 5 | 36
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 rotate inside the cylinder. The pumped medium is trapped between the cylinder
and screw chambers, compressed, and transported to the gas outlet. During the compression pro-
cess, the two screw rotors do not come into contact with each other or 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 Intended Use
WARNING
In case of foreseeable misuse outside the intended use of the machine.
Risk of injuries!
Risk of damages to the machine!
Risk of damages to the environment!
●Make sure to follow all instructions described in this manual.
The machine is intended for the suction of air and other dry, toxic, non-aggressive and non-explo-
sive 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 abs.
(mbar abs.).

2 | Product Description
6 | 36 Instruction Manual COBRA BA 0100 C_EN_en
The machine is allowed to operate at ≥150 mbar abs. for up to 5 minutes.
Guideline for maximum recommended chamber size to be evacuated from atmospheric pressure to
<100 mbar:
Pump drive Maximum chamber size (liters)
Direct drive 50 or 60Hz - Machine without VSD (Variable
Speed Drive)
300
Machine with VSD, voltage supply 200-240V 1000
Machine with VSD, voltage supply 380-480V 3000
How to identify a machine with VSD?
●Check if the machine is equipped with a Communication port (COM) or a Variable Speed Drive
(VSD), see Product Description [➔4].
The machine is intended for indoor placement in a non-potentially explosive environment.
Permitted environmental conditions, see Technical Data.
2.3 Drive Variants
The machine can be equipped with either a direct drive or a variable speed drive (option).
2.4 Standard Features
2.4.1 Wheels
Four wheels are fitted to the bottom of the machine to facilitate transportation and installation.
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 (only with VSD)
The D-Sub 15 supports maintained dry contact remote control and monitoring of the machine.
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.

Transport | 3
Instruction Manual COBRA BA 0100 C_EN_en 7 | 36
3 Transport
WARNING
Suspended load.
Risk of severe injury!
●Do not walk, stand or work under suspended loads.
●To find out the weight of the machine, refer to the chapter Technical Data or the nameplate (NP).
●Make sure that the eye bolt(s) (EB) is/are in faultless condition, fully screwed in and tightened by
hand.
●Check the machine for transport damage.
If the machine is secured to a base plate:
●Remove the machine from the base plate.

4 | Storage
8 | 36 Instruction Manual COBRA BA 0100 C_EN_en
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 speed 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 speed drive of the machine.
●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.

Installation | 5
Instruction Manual COBRA BA 0100 C_EN_en 9 | 36
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.
●Make sure that the installation space or location is vented such that sufficient cooling of the ma-
chine 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.
●Make sure that enough space remains for maintenance work.
●Make sure that the machine is placed or mounted horizontally, a maximum deviation of 1° in any
direction is acceptable.
●Check the oil level, see Oil Level Inspection [➔23].
●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 | Installation
10 | 36 Instruction Manual COBRA BA 0100 C_EN_en
5.2 Connecting Lines / Pipes
●Remove all protective covers before installation.
●Make sure that the connection lines cause no stress on the connection of the machine; if neces-
sary 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 long connection lines, it is advisable to use larger line sizes in order to avoid a loss of effi-
ciency. 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
NOTICE
Discharge gas flow obstructed.
Risk of damage to the machine!
●Make sure that the discharged gas will flow without obstruction. Do not shut off or throttle the
discharge line or use it as a pressurized air source.
Connection size(s):
– ISO-KF 40
●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.

Installation | 5
Instruction Manual COBRA BA 0100 C_EN_en 11 | 36
5.2.3 Nitrogen System Connection (Optional)
DGVNC
Description
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):
Standard liter per min-
ute
19 ... 33
Flow rate of barrier and dilution gas
(with DGV open):
Standard liter per min-
ute
25 ... 51

5 | Installation
12 | 36 Instruction Manual COBRA BA 0100 C_EN_en
2
4
1
3
Description
1 Nitrogen connection (NC) 2 Barrier gas system
3 Dilution gas valve (DGV) 4 Dilution gas system
5.3 Earth Connection
●Connect the earth connection of the machine (ECP).
ECP

Installation | 5
Instruction Manual COBRA BA 0100 C_EN_en 13 | 36
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.
For oil type and oil capacity see Technical Data and Oil [➔32].
1
3
2
4
Description
1 Use a cruciform screwdriver 2 Remove top cover
3 Use a cruciform screwdriver 4 Remove side cover

5 | Installation
14 | 36 Instruction Manual COBRA BA 0100 C_EN_en
1
Description
1 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.

Electrical Connection | 6
Instruction Manual COBRA BA 0100 C_EN_en 15 | 36
6 Electrical Connection
DANGER
Live wires.
Risk of electrical shock.
●Electrical installation work must only be executed by qualified personnel.
CURRENT PROTECTION OF THE CUSTOMER INSTALLATION:
DANGER
Missing current protection.
Risk of electrical shock.
●Current protection according to EN 60204-1 must be insured by the customer on its installation.
●The electrical installation must comply with the applicable national and international standards.
NOTICE
Electromagnetic compatibility.
●Make sure that the motor of the machine will not be affected by electric or electro- magnetic dis-
turbance from the mains, if necessary seek advice from Busch.
●Make sure that the EMC of the machine is compliant with the requirements of your supply net-
work system, if necessary provide further interference suppression (EMC of the machine, see EU
Declaration of Conformity [➔33] or UK Declaration of Conformity [➔34]).
●Wire the mating connector (delivered loose) in accordance with the scheme below:
Mains connection (MC) - 4-pin connector
1
2
3
4
Description
1 Phase 1 (L1) 2 Phase 2 (L2)
3 Phase 3 (L3) 4 Earth

6 | Electrical Connection
16 | 36 Instruction Manual COBRA BA 0100 C_EN_en
●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.
6.1 Machine delivered without Variable Speed Drive
DANGER
Live wires.
Risk of electrical shock.
●Electrical installation work must only be executed by qualified personnel.
NOTE
The operation with variable speed, i.e. with a variable speed drive, is allowed as long as the
motor is capable and the permitted motor speed range is respected (see Technical Data).
Seek advice from your Busch representative.
●Make sure that the power supply for the motor is compatible with the data on the nameplate of
the motor.
●If the machine is equipped with a power connector, install a residual current protective device to
protect persons in case of isolation default.
●Busch recommends installing a type B residual protective device suitable for the electrical in-
stallation.
●Provide a lockable disconnect switch or an emergency stop switch on the power line so that the
machine is completely secured in case of an emergency situation.
●Provide a lockable disconnect switch on the power line so that the machine is completely secured
during maintenance tasks.
●Provide an overload protection according to EN 60204-1 for the motor.
●Connect the protective earth conductor.
●Electrically connect the motor.

Electrical Connection | 6
Instruction Manual COBRA BA 0100 C_EN_en 17 | 36
NOTICE
Incorrect connection.
Risk of damage to the motor!
●The wiring diagrams given below are typical. Check the inside of the terminal box for motor con-
nection instructions/diagrams.
6.2 Machine delivered with a Variable Speed Drive
(Option)
DANGER
Live wires. Carry out any work on the variable speed drive and motor.
Risk of electrical shock!
●Electrical installation work must only be executed by qualified personnel.
DANGER
Maintenance work without disconnecting the variable speed drive.
Risk of electrical shock.
●Disconnect and isolate the variable speed drive before attempting any work on it.
High voltages are present at the terminals and within the variable speed drive for up to 10 min-
utes after disconnection of the electrical supply.
●Always ensure by using a suitable multimeter that no voltage is present on any drive power termi-
nals prior to commencing any work.
●Make sure that the power supply for the drive is compatible with the data on the nameplate of
the variable speed drive.
●If the machine is equipped with a power connector, install a residual current protective device to
protect persons in case of isolation default.
●Busch recommends installing a type B residual protective device suitable for the electrical in-
stallation.
●If the variable speed drive is not equipped with a lockable disconnect switch, provide it on the
power line so that the machine is completely secured during maintenance tasks.
●Provide an overload protection according to EN 60204-1.
●Busch recommends installing a C-curve circuit breaker.
●Connect the protective earth conductor.
●Electrically connect the Variable Speed Drive (VSD).
NOTICE
The admissible motor speed exceeds the recommendation.
Risk of damage to the machine!
●Check the admissible motor speed range, see Technical Data.

6 | Electrical Connection
18 | 36 Instruction Manual COBRA BA 0100 C_EN_en
NOTICE
Incorrect connection.
Risk of damage to the variable speed drive!
●The wiring diagrams given below are typical. Check the connection instructions/diagrams.
6.3 Voltage Switch 208 - 400 V (only with VSD)
●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.
1
2
Description
1 Use a cruciform screwdriver 2 Remove side cover
6.4 Direction of Rotation of the 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:

Electrical Connection | 6
Instruction Manual COBRA BA 0100 C_EN_en 19 | 36
●Switch any two of the phase wires.
1
2
Description
1 Minimum 0.5 meter 2 Cooling air
6.5 I/O and Communication Port Schematic (only with
VSD)
Connector: D-Sub15, 15-pin, female
81
915
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).

7 | Commissioning
20 | 36 Instruction Manual COBRA BA 0100 C_EN_en
7 Commissioning
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.
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.
●Make sure that the installation conditions (see Installation Conditions [➔9]) 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.
●After a few minutes of operation, perform an Oil Level Inspection [➔23].
As soon as the machine is operated under normal operating conditions:
●Measure the motor current and record it as reference for future maintenance and trouble-
shooting work.