BUSCH COBRA NC 1500 B User manual

Installation and
Maintenance Instructions
Screw Vacuum Pumps
COBRA NC 1500 B
VR - Vapour Recovery
Ateliers Busch S.A.
Zone industrielle
2906 Chevenez
Switzerland
0870573045/ 170918 / Original instructions / Modifications reserved

Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . 4
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Principle of operation. . . . . . . . . . . . . . . . . . . . . . . 4
Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Process diagram . . . . . . . . . . . . . . . . . . . . . . . . 4
Sealing systems. . . . . . . . . . . . . . . . . . . . . . . . . . 4
Condensate return . . . . . . . . . . . . . . . . . . . . . . . 4
On/ Off switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety information . . . . . . . . . . . . . . . . . . . . . . . . 5
Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stopping procedure for maintenance. . . . . . . . . . . . . . 6
Start-up procedure after maintenance . . . . . . . . . . . . . 6
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transportation of packaged pump . . . . . . . . . . . . . . . . 6
Transport in unpacked state . . . . . . . . . . . . . . . . . . . 6
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Short-term Storage . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal from storage . . . . . . . . . . . . . . . . . . . . . . 6
Conservation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Starting-up of the vacuum pump after storage. . . . . . . . . 7
Installation and Commissioning . . . . . . . . . . . . . . . . . . 7
Installation prerequisites . . . . . . . . . . . . . . . . . . . . . 7
Local installation . . . . . . . . . . . . . . . . . . . . . . . . 7
Suction Connection . . . . . . . . . . . . . . . . . . . . . . 7
Discharge connection . . . . . . . . . . . . . . . . . . . . . 8
Cooling liquid connections (CLI, CLO) . . . . . . . . . . . . . 8
Connection of cooling liquid in cylinder (INJ). . . . . . . . . . 8
Electrical connection/ Checks . . . . . . . . . . . . . . . . . 8
Fitting the drive motor . . . . . . . . . . . . . . . . . . . . . 8
Fitting the coupling . . . . . . . . . . . . . . . . . . . . . 8
Axial displacement. . . . . . . . . . . . . . . . . . . . . . 8
Coupling alignment . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical connection . . . . . . . . . . . . . . . . . . . . . . 9
Technical data of the level switch condensate (LSC) . . . . . . 9
Technical data of the solenoid valve condensate (SVC) . . . . 10
Connecting up of lines/ pipes. . . . . . . . . . . . . . . . . 10
Control condensate return . . . . . . . . . . . . . . . . . . 10
Filling up with oil . . . . . . . . . . . . . . . . . . . . . . . 10
Filling in cooling liquid (CLI, CLO) . . . . . . . . . . . . . . 11
Filling in cooling liquid in cylinder (INJ) . . . . . . . . . . . . 11
Saving the operating parameters . . . . . . . . . . . . . . . 11
Recommendations on operation. . . . . . . . . . . . . . . . . 11
Application . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Switching the vacuum pump on/ off . . . . . . . . . . . . . 12
First start-up of the system. . . . . . . . . . . . . . . . . 12
Switching off the system . . . . . . . . . . . . . . . . . . 12
Re start procedure following an Emergency Shut Down of
the system . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance program. . . . . . . . . . . . . . . . . . . . . . 13
Monthly: . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Yearly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Every 5000 operating hours: . . . . . . . . . . . . . . . . . 13
Every 10’000 operating hours: . . . . . . . . . . . . . . . . 13
Every 16’000 operating hours, at the latest after 4 Years:. . . 13
Stopping procedure for maintenance . . . . . . . . . . . . . 13
Start-up after maintenance . . . . . . . . . . . . . . . . . . 13
Checking the oil. . . . . . . . . . . . . . . . . . . . . . . . . 14
Checking the oil level . . . . . . . . . . . . . . . . . . . . . 14
Topping up with oil. . . . . . . . . . . . . . . . . . . . . . 14
Checking the colour of the oil . . . . . . . . . . . . . . . . 14
Life-span of the Oil . . . . . . . . . . . . . . . . . . . . . . . 14
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Draining used oil . . . . . . . . . . . . . . . . . . . . . . . 14
Filling in new oil . . . . . . . . . . . . . . . . . . . . . . . 14
Cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drain the cooling liquid . . . . . . . . . . . . . . . . . . . . 15
Checking the current consumption . . . . . . . . . . . . . . . 15
Checking the motor hood . . . . . . . . . . . . . . . . . . . . 15
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal from service . . . . . . . . . . . . . . . . . . . . . . . 15
Temporary removal from service . . . . . . . . . . . . . . . . 15
Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . 15
Dismantling and Disposal of the vacuum pump . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spare parts kit. . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil type/ quantity . . . . . . . . . . . . . . . . . . . . . . . . . 21
Oil type. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Oil quantity . . . . . . . . . . . . . . . . . . . . . . . . . 21
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
EU-Declaration of Conformity . . . . . . . . . . . . . . . . . . . 23
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operating, Assembly instructions coupling SAMIFLEX . . . . 24
Introduction
Page 2
Introduction
Congratulations on your purchase of the Busch vacuum pump. 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
–product description,
–security,
–transport,
–storage,
–installation and commissioning,
–maintenance,
–overhaul,
–troubleshooting
of the vacuum pump.
For the purpose of these instructions, “handling” the vacuum system
means the transport, storage, installation, commissioning, influence on
operating conditions, maintenance, troubleshooting and overhaul of
the vacuum system.
Prior to handling the vacuum system, these operating instructions
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.

Page 3
IN Inlet
OUT Discharge
ECP Earth connection (Pump)
OFP Oil filler plug
OSG Oil sight glass
ODV Oil drain ball valve
CLI Cooling liquid inlet connection
CLO Cooling liquid outlet connection
CLD Cooling liquid drain plug
INJ Injection point for injected liquid
LSC Level switch condensate drain
OIL Oil
CL Cooling liquid
RT Screw rotors
SVC Solenoid valve condensate drain
OSG
INJ
OUT
ODV
OFP
CLO
ODV
IN
OSG
OFP
CLD CLD
CLD
MP
LSC
SVC
CLI
ECP
ECP
IN OUT
OIL OILCL CL RT

Product Description
Use
The COBRA vacuum pumps are designed for use in the field of indus-
trial applications and similar industries.
They can be used to draw gases, gas mixtures and hydrocarbon gases.
WARNING
When using toxic, inflammable and/ or explosive gases, make sure
that the system corresponds in design to applicable local and na-
tional safety regulations and that all applicable safety measures are
followed.
All product-specific safety regulations must be observed.
Solid particles must not get into the vacuum pump.
The maximum admissible temperature of drawn gas depends on the
inlet pressure and the nature of the gases. The lower the inlet pressure
(Pa), the higher can be the drawn gas temperature (TGas). We can
consider as air the following indications:
–Pa < 50 mbar, TGas < 200°C
–Pa > 50 mbar, TGas < 70°C
The vacuum pump is thermally suitable for continuous operation at any
pressure between atmospheric pressure and ultimate pressure.
Max. permissible number of startings per hour: 6.
Principle of operation
The COBRA vacuum pumps are screw vacuum pumps with cooling li-
quid circuit. The screw rotors cooling must be made with cooling liquid
injection in the cylinder.
The COBRA vacuum pumps the principle of screw pumps. Two parallel
screws (RT) rotate in opposite directions in the pump body. Entering
gases are trapped between the pitches of the screws and the pump
body. The gases are conveyed by the rotation of the screws to the ex-
haust side where they are discharged.
The COBRA vacuum pump is driven by an air-cooled motor.
Cooling
The vacuum pump is cooled by
–a cooling liquid (for example: water) inside the water chambers
(CL) of the cylinder and the motor side endplate of cylinder as well
as the inlet side end plate.
The cooling liquid circuit allows to stabilise the temperature of the
vacuum pump.
The cooling liquid flow rate must be adjusted to 12 l/ min.
The operating temperature must be adapted to the application, this
in order to avoid internal damage such as for example condensa-
tion inside the pump.
–The screws (RT) are cooled by injection of cooling liquid in cylin-
der. The cooling liquid flow rate in cylinder must be adjusted to
3-6 l/ min after the vacuum pump start.
NOTE:
The COBRA vacuum pumps are always shipped without oil and co-
oling liquid. Operation without any of these lubricants will destroy
the vacuum pump within a short period of time.
Process diagram
Sealing systems
The COBRA vacuum pumps are equipped with oil lubricated single me-
chanical seal with labyrinth seal on the motor side (A-side) and oil lu-
bricated single mechanical seal with lip seal on the inlet side (B-side) as
standard.
Condensate return
Condensates are automatically fed back from the seal area to the inlet
flange of the vacuum pump.
On/ Off switch
The vacuum pump is delivered without on/ off switch. The control of
the vacuum pump must be provided in the course of the installation.
Product Description
Page 4
CLI
CLO
NC 1500 B
VR
IN
OUT
INJ
LSC
SVC

Safety
Intended use
DEFINITION: For the purpose of correct understanding, the “handling”
of the vacuum pump implies the transport, storage, installation, com-
missioning, the influence on operating conditions, maintenance, trou-
bleshooting and overhaul of the vacuum pump.
The vacuum pump is intended for industrial use. It should only be han-
dled by qualified staff.
The differenty applications for use and operational limits of the vacuum
pump as laid out in the “Product Description” and the “Installation
Prerequisites” of the vacuum pump must be observed both by the ma-
nufacturer of the machinery into which the vacuum pump is to be in-
corporated and by the end user.
The need for personal safety regulations depends mainly on the appli-
cation the pump will be used in. The end user must provide the opera-
tors with all necessary means and tools and must inform his personnel
about any dangers emanating from the processed products.
The operator of the vacuum pump must observe the safety regulations
and must train and instruct his personnel accordingly.
Local regulations regarding the motors and electric control elements
must be observed when installing the pump in potentially explosive
environments.
The maintenance instructions must be observed and respected.
Is is vital that these installation and maintenance instructions are read
and understood before the vacuum pump is used. If you have any
doubts, please contact your local Busch representative.
Safety information
The vacuum pump has been designed and manufactured in accordance
with the latest technical and safety standards. Nevertheless, residual
risks may remain.
A lot of safety information is mentioned in these Installation and Ope-
rating Instructions as well as on the pump. The safety instructions must
be observed. The safety information can quickly be detected through
key words like DANGER, WARNING and CAUTION and is defined as
follows:
DANGER
Disregard of this safety note will always lead to accidents with po-
tentially fatal injuries and serious damages.
WARNING
Disregard of this safety note may lead to accidents with potentially
fatal injuries and serious damages.
CAUTION
Disregard of this safety note will always lead to accidents with minor
injuries and damages to property.
Safety
Page 5
Shell
T
ellus Oil 68
TT
Shell
T
ellus Oil 68
T
T

Noise emission
Refer to the table “Technical data” for permissible noise levels in free
field conditions according to EN ISO 2151.
CAUTION
The sound level of the vacuum pump within a certain perimeter of
the pump is high.
Risk of hearing damage.
Users who are spending a longer period of time in the vicinity of a
non-insulated vacuum pump must wear suitable ear protection.
Safety area
Before any maintenance action, ensure a safety perimeter of at least 1
[m] around the pump.
Stopping procedure for maintenance
lClose the injection of cooling liquid (INJ) in the cylinder
uLet the vacuum pump run for 1 minute
lStop the vacuum pump
lClose the cooling liquid supply (CL)
lSwitch off power supply (the vacuum pump must be fully discon-
nected from any power supply)
lPut up label or warning board “Maintenance in progress” on or
next to the pump.
Start-up procedure after maintenance
lRemove label or warning board “Maintenance in progress”
lCheck oil level according to the chapters “Checking the oil level”
lSwitch on power supply (the vacuum pump must be connected to
the power supply)
lMake sure that the "Installation Prerequisites" are followed
lOpen the cooling liquid supply (CL)
uAdjust the flow rate to 12 l/min
lStart the vacuum pump
lOpen the injection of cooling liquid in the cylinder (INJ)
uWith the pump operating at 60 Hz/3600 rpm and an inlet
pressure < 100 mbar. Adjust the cooling liquid flow rate to 3-6
l/min or a quantity sufficient to ensure an exhaust gas outlet
temperature <80°C
uCheck the exhaust gas outlet temperature <80°C
lIf the vacuum pump is equipped with a solenoid valve at the inlet:
uOpen the solenoid valve
lIf the vacuum pump is equipped with a shut-off valve at the inlet:
uOpen the shut-off valve
Transport
The COBRA vacuum pumps are tested and checked in our factory be-
fore careful packing. Check the packaging for transport damage when
the goods arrive. The pump can withstand temperatures between
-25°C and +55°C during transport.
Transportation of packaged pump
Packed on a pallet, the vacuum pump can be transported with a for-
klift.
Transport in unpacked state
The vacuum pump is bolted to a pallet or a base plate:
uRemove the bolts between the vacuum pump and the pallet or
base plate
CAUTION
Do not walk, work or stand under suspended loads.
CAUTION
Please check out the weight of the vacuum pump before lifting it up
(see “Technical Data”).
Use adequate lifting gear for this.
NOTE: The eyebolts are not used to lift the vacuum pump from the
packing. The vacuum pump must be lifted by the base frame (with a
forklift or belts).
lAttach belts securely to the base frame
lUse lifting gear with a crane hook equipped with safety latch.
lLift the vacuum pump
In case the vacuum pump was bolted to a pallet with fixing bolts:
uUnscrew the fixing bolts in the base frame
CAUTION
Once filled with oil, the vacuum pump cannot be lifted anymore.
Prior to every transport make sure that the oil has been drained from
the vacuum pump
The packaging material must be disposed of in accordance with local
and national regulations.
This operating instructions is part of the delivery package.
Storage
Short-term Storage
lMake sure that the inlet/ discharge connections are closed (leave
the provided plugs in the pump)
lStore the vacuum pump
–if possible in its original packaging,
–indoors,
–dry,
–in a dust free room and
–free from vibrations
Removal from storage
Before starting up a vacuum pump that has been stored outside the
building for a while, the vacuum pump must be moved to a room with
ambient temperature, where it should rest for a day.
Conservation
In case of adverse ambient conditions (e.g. aggressive atmosphere, fre-
quent temperature changes) conserve the vacuum pump immediately.
In case of favourable ambient conditions conserve the vacuum pump if
a storage of more than 3 months is anticipated.
lMake sure that all openings are hermetically sealed; use adhesive
tape to fasten loose parts (such as o-rings, flat seals, etc.).
NOTE: VCI is the abbreviation for “volatile corrosion inhibitor”. The
VCI molecule is an organic corrosion inhibitor in the vapour phase.
Integrated in various carriers such as film, cardboard, paper, foam, li-
quid and powder, it protects parts against corrosion as a result of its
action in vapour phase. However, VCI packaging can attack plastic sur-
faces and surfaces of other elastomers. If in doubt, please contact your
nearest distributor. VCI packaging provides several years of protection
against corrosion, even under harshest conditions: overseas shipment,
extended storage before use.
lWrap the vacuum pump in VCI film
Transport
Page 6

lStore the vacuum pump
–if possible in its original packaging,
–indoors,
–dry,
–in a dust free and
–vibration free area
Starting-up of the vacuum pump after storage
lPlease ensure that all protective agents such as gaskets, plugs or
adhesive tapes that were used for the protection of the pump, are
removed.
lCommission the vacuum pump as described in chapter “Installa-
tion and Commissioning”
Installation and
Commissioning
Installation prerequisites
CAUTION
In case of non-compliance with the installation prerequisites, parti-
cularly in case of insufficient cooling:
Risk of damage or destruction of the vacuum pump and its compo-
nents!
Risk of personal injury!
The installation prerequisites must be complied with.
lPlease ensure that the integration of the vacuum pump is com-
pliant with the safety requirements of the Machine Directive
2006/42/EC (concerning the responsibility of the system’s manu-
facturer into which the vacuum pump is to be incorporated, please
also refer to the note in the EC-Declaration of Conformity).
WARNING
Local regulations regarding the motors and electric control ele-
ments must be observed when installing the pump in potentially
explosive environments. Before start-up, make sure that all safety
measures have been followed.
Local installation
–Make sure the oil type corresponds to the ambient conditions, see
“Oil type”
–Ambient pressure: atmospheric
–Humidity range: 20 à 95%
–Altitude: up to 1000 m
lMake sure that the cooling liquid fulfills the following require-
ments:
–Temperature: 10 - 25 °C
–Cooling liquid pressure: max. 6 bar (relative)
lMake sure that the cooling liquid is neutral and clean
lMake sure that the cooling liquid outlet is unpressurised
lMake sure that the environment conditions correspond to the pro-
tection class of the motor (according to motor nameplate)
lMake sure that the vacuum pump is placed on or fastened to a ho-
rizontal surface
lMake sure that the vacuum pump and chassis assembly are level to
within 1° in all directions when measured from a suitable machined
pump surface e.g. the pump inlet
lPrior to final fixation of the pump, ensure that the chassis and fixa-
tion positions are all in contact with the installation base/ base
frame; use suitable shim material where necessary.
The maximum permissible space between the pump chassis/ fixa-
tion positions and installation base/ base frame = 0.05 mm
lMake sure that the vacuum pump cannot inadvertently or intentio-
nally be used as a support for heavy objects
lMake sure that the vacuum pump cannot be hit by falling objects
lMake sure that the vacuum pump is at least 1 m away from any
wall
lMake sure that the vacuum pump is easily accessible and that the
selected installation site fulfills the requirements for assembly/
dismantling
lMake sure that no temperature-sensitive part (such as plastic,
wood, cardboard, paper, electronic parts) come into direct contact
with the hot surfaces of the vacuum pump
lMake sure that the installation site or assembly area is ventilated in
such a way that adequate cooling of the vacuum pump is assured
CAUTION
During operation the surface of the vacuum pump may exceed tem-
peratures of 90° C.
Risk of burns!
lMake sure that the vacuum pump cannot be touched inadvertently
during operation, provide a guard if necessary
lMake sure that the oil sight glasses (OSG) will remain easily acces-
sible
If the oil change is meant to be performed on site:
uMake sure that the oil drain ball valves as well as the oil filler
plugs, are easily accessible.
Suction Connection
lMake sure that the protection that prevents the ingress of foreign
matter during transport, has been removed before connecting up
the vacuum pump to the piping.
CAUTION
Do not put hands into the inlet aperture.
Risk of body damage!
CAUTION
The ingress of foreign objects or liquids can destroy the vacuum
pump.
In case the inlet gases can contain dust or other foreign solid particles:
uMake sure that a suitable filter or protection screen is installed
at the inlet of the vacuum pump
lMake sure that the nominal diameter of the inlet line is at least
equal to the diameter of the inlet flange to prevent a drop in the
performance of the vacuum pump in the case of a smaller
cross-section.
lMake sure that the vacuum pump is connected with leak proof li-
nes.
CAUTION
Once the inlet line has been connected up, make sure that the sys-
tem does not leak. Leakage of dangerous substances must be pre-
vented!
Installation and Commissioning
Page 7

lMake sure that the inlet line is equipped with a shut-off device
upstream of the inlet flange, so that the flow of drawn gases can
be stopped
lMake sure that the inlet line does not exercise any pressure on the
inlet flange. Use bellows if necessary.
lThe inlet flange has the following dimension:
–DN 100 PN 16 or
–ASME B16.5 4'' 150 16S
In case of long inlet lines the pipe diameter should be larger than the
inlet flange to prevent a drop in the performance of the vacuum pump.
If you have any doubts, contact your Busch representative.
Discharge connection
CAUTION
Do not put hands into the outlet aperture.
Risk of body damage!
The following instructions for connection to the discharge side only ap-
ply if the drawn gas is discharged into a suitable environment by the
vacuum pump.
lMake sure that the protection, that was fitted to prevent the in-
gress of particles during transport, has been removed before the
vacuum pump is connected up to the vacuum pipe
lMake sure that the nominal diameter of the discharge line corres-
ponds at least to the diameter of the exhaust flange of the vacuum
pump in order to prevent a drop in the performance of the vacuum
pump, in case of use of a smaller cross-section
CAUTION
When the discharge piping has been connected up, make sure that
the system does not leak. Leakage of dangerous substances must be
prevented!
lThe placement of the PT100 (TSA+/0102); Busch recommends
that the PT100 is installed in either the exhaust outlet flange of the
pump or in a suitably prepared exhaust spool piece at a distance of
<100 mm from the pump outlet.
lMake sure that the discharge line is fitted in such a way so as to
prevent any liquids or condensates to re-enter the vacuum pump
(siphon, discharge line sloping away from the pump)
lBusch recommendeds that the pump is fitted with isolation valves
in both the inlet and outlet connection pipe work to the pump.
When not operational the pump must be isolated from the system
in order to prevent liquids entering a none-operational pump.
lMake sure that the discharge line does not exercise any pressure
onto the exhaust flange. Mount bellows if necessary
lThe outlet flange has the following dimension:
–DN 80 PN 16 or
–ASME B16.5 3'' 150 16S
In the case of long discharge lines, the line cross-section should be lar-
ger than the exhaust flange in order to prevent a drop in the perfor-
mance of the vacuum pump. If you have any doubts, contact your
Busch representative.
Cooling liquid connections (CLI, CLO)
The cooling liquid is generally connected up with a flexible hose.
Connection diameter:
–G 1/2, ISO 228-1
Connection of cooling liquid in cylinder (INJ)
The cooling liquid in cylinder is generally connected up with a flexible
hose.
Connection diameter:
–G 1/2, ISO 228-1
Electrical connection/ Checks
lMake sure that the requirements according to EMC-Directive
2014/30/EU as well as the current EN-standards, electrical and oc-
cupational safety directives and the local or national regulations
respectively, are complied with (this is the responsibility of the de-
signer of the machinery into which the vacuum pump is to be in-
corporated; see also the corresponding comments in the
EC-Declaration of Conformity).
lMake sure that the power supply is compatible with the data on
the nameplate of the drive motor
lMake sure that an overload protection according to EN 60204-1 is
provided for the drive motor
lMake sure that the drive of the vacuum pump will not be affected
by electric or electromagnetic interference; if unsure please seek
advice from your Busch representative
Fitting the drive motor
When fitting or replacing the drive motor observe the assembly proce-
dure for the coupling.
CAUTION
During assembly of the coupling, make sure that value for the cou-
pling axial distance is adhered to.
When this value is not followed, the coupling can be damaged.
Fitting the coupling
Description Type
Coupling Samiflex A4
Axial displacement
When fitting/ replacing the motor or during maintenance of the cou-
pling, assembly tolerances have to be respected in order to prevent
axial displacement.
lFit the coupling hubs onto the respective shafts of the vacuum
pump and the drive motor
lAxially move the unit motor/ coupling hub in such a way until the
axial distance between the coupling halves = 3.5 mm
If the unit motor/ coupling hub is already fitted:
uMove the coupling hubs on the shafts in order to reach the
axial distance
lLock the coupling hubs by tightening the set screws
uTightening torque: 10 Nm
Coupling alignment
The recommended radial and angular displacement/ alignment limita-
tions for the NC 1500 B VR pump/ coupling alignment should not ex-
ceed 0.01 mm in any direction.
Installation
Fitting
lMake sure that the “Installation Prerequisites” are complied with
lFit or install the vacuum pump at its final location
Installation and Commissioning
Page 8

Electrical connection
WARNING
Risk of electrical shock, risk of damage to equipment.
Electrical installation work must only be executed by qualified per-
sonnel that knows and observes the following regulations:
- IEC 364 or CENELEC HD 384 or DIN VDE 0100, respectively,
- IEC-Report 664 or DIN VDE 0110,
- VBG 4 or corresponding national accident prevention regulation.
CAUTION
The connection schemes given below are typical. Specific orders or
deviating connection schemes for certain markets may apply.
Risk of damage to the drive motor!
Please check drive motor connections inside the terminal box and
refer to the drive motor connection instructions.
lConnect the drive motor electrically
lConnect the earth line
lTwo earth connections are also available on the pump base frame,
dia. 10.5 mm
Delta connection (Low voltage):
Star connection (High voltage):
CAUTION
Operation of the pump in the wrong direction of rotation, even for
a short period of time, can destroy the vacuum pump.
Prior to starting-up of the vacuum pump, please ensure that the va-
cuum pump is connected up correctly.
lDetermine the direction of rotation with the arrow sign on the fan
cover of the motor
lPress the start button and hold briefly
lWatch the fan of the drive motor and determine the direction of
rotation just before the fan stops
If the fan is turning in the wrong direction:
uSwitch around any two of the drive motor wires in the terminal
box
The level switch condensate (LSC) and the solenoid valve condensate
(SVC) must be so integrated into the controller in order that the sole-
noid valve will be opened with a pending level for 5 seconds.
Technical data of the level switch condensate
(LSC)
Technical data Level switch
Busch part no. 0652 556 531
Manufacturer Endress & Hauser
Type FTL50 (electrical FEL 58)
Material of the protection tube 1.4435
EC Approval type KEMA 99 ATEX 0523
Type of protection Ex ia IIC T6
Connection G 3/4**(male)
Electrical data FEL 58
Ui16 VDC
Ii150 mA
Pi1W
Li0
Ci0
Technical data Level switch
Busch part no.
Manufacturer DWYER Instruments, Inc.
Type L6EPB-S-S-3-A
Material Brass or 303 SS
Temperatur limit -4° to 220°F (-20 to 105°C)
Max. Pressure 200 (13.8) psig (bar)
North-American Approvals UL & CSA approvals
EC Approval type KEMA 04 ATEX 2128
Type of protection EX II G Ex d IIC T6
Connection G 3/4
Electrical data
Electrical connections 18 AWG
Electrical rating 5 A at 125/250 VAC (V~)
Installation and Commissioning
Page 9

Technical data of the solenoid valve
condensate (SVC)
Technical data Solenoid valve
Busch part no. 0654 000 092
Manufacturer Parker Lucifer
Type 2/2 valvel, DN 3 G 1/4
Valve reference 121 V 5363
Electrical reference 495907
EC Approval type LCIE 03 ATEX 6451 X
Type of protection Ex db mb IIC T4/ T5/ T6 / 2GD +
130°C
Electrical data
Ui24 VDC
In360 mA
Pni 8 W
Technical data Solenoid valve
Busch part no.
Manufacturer Asco Redhal
Type EF8210G094
Watt rating/ Isolation class 16.1/ F
Material Brass
Max. fluid temperature 180°F
Operating pressure differential 0-15 psi
North-American approvals UL & CSA approvals
Connecting up of lines/ pipes
uConnect the suction line
lConnect the discharge line
lMake sure that all provided covers, guards, hoods etc. are fitted
Control condensate return
Filling up with oil
The COBRA vacuum pumps are always delivered without oil (see
chapter “Oil Type” for information on recommended oils).
NOTE: The quantities of oil are different between the quantity indica-
ted for the motor side (A) and the quantity indicated for the inlet side
(B). Respect the values indicated in the table “Oil quantity”.
NOTE: The procedure of filling up with oil is identical for both sides. It
will be described in this operating instructions only for a single side.
Please repeat the following operations for the second side.
lPrepare the quantity of oil specified in the table “Oil quantity”
NOTE: The quantity of oil specified in the operating instructions is of
informative nature only. Check the oil level with the help of the various
oil sight glasses (OSG) on the vacuum pump.
CAUTION
Before changing the type of oil, make sure that the new type is
compatible with the old type. If necessary, flush the vacuum pump.
lUnscrew the oil filler plug (OFP) (motor side including filter pot)
lFill in oil
lMake sure that the filling level is on MAX-mark of the oil sight
glasses (OSG)
lMake sure that the seal ring in the oil filler plug is not damaged,
replace oil filler plug if necessary
lFit the oil filler plug and tighten up
lBefore any transport, make sure that the oil has been drained out
of the vacuum pump.
CAUTION
Once filled with oil, the vacuum pump should not be lifted or mo-
ved anymore.
Installation and Commissioning
Page 10
no
yes
Solenoid valve
SVC opened
for 5 sec.
High level LSC ?

CAUTION
The vacuum pump must remain in a horizontal position once it has
been filled with oil.
Filling in cooling liquid (CLI, CLO)
The COBRA vacuum pumps are always delivered without cooling
liquid.
NOTE: Make sure that the cooling liquid corresponds to the conditions
described in the “Installation prerequisites”.
lConnect the cooling liquid inlet (CLI) and outlet (CLO) connections
lOpen the cooling liquid supply
lAdjust the cooling liquid flow rate to 12 l/ min
Filling in cooling liquid in cylinder (INJ)
The COBRA vacuum pumps are always delivered without cooling
liquid.
NOTE: Make sure that the cooling liquid corresponds to the conditions
described in the “Installation prerequisites”.
lConnect the connection of the cooling liquid in cylinder (INJ)
lStart the vacuum pump
lOpen the cooling liquid supply
lAdjust the cooling liquid flow rate to 3-6 l/ min
NOTE: Before stop the vacuum pump, close the injection of the cooling
liquid in cylinder and let the vacuum pump run for 1 minute, in order
to dry the vacuum pump.
Saving the operating parameters
As soon as the vacuum pump is working under normal conditions after
being switched on:
lMeasure the working current of the motor and keep it as reference
value for all future maintenance and repair work
Installation and Commissioning Parameters
Continuous cooling liquid injection rate* 3-6 L/ min
Minimum constant cooling liquid injection
rate 2 l/min
Pump cooling liquid 12 l/ min
Ambient temperature air -20...60°C
Ambient temperature cooling liquid 10...25°C
Maximum exhaust gas temperature
To be measured within 100 mm of exhaust
outlet (TSA+/0102)
80°C
Recommended exhaust gas temperature
(Process conditions dependant) 60°C
Maximum cooling jacket temperature 55°C
Maximum operational temperature difference
between cooling jacket temperature and
exhaust outlet temperature
70°C
*The quantity of cooling liquid injected should be sufficient to ensure
that at no time during the operation of the pump, the maximum ex-
haust gas outlet temperature is exceeded.
Should the operating conditions of your pump fall outside of the re-
commended parameters as outlined, please contact your local Busch
agency for advice.
Recommendations on operation
Application
WARNING
The vacuum pump is designed for operation under the conditions
described below.
In case of disrespect of the above, risk of damage or destruction of
the vacuum pump!
The vacuum pump must only be operated under the conditions
described below.
The COBRA vacuum pumps have been designed for use in industrial
applications and similar industries.
They can be used to draw gases, gas mixtures and hydrocarbon gases.
WARNING
When using toxic, inflammable and/ or explosive gases, make sure
that the system corresponds to applicable local and national safety
regulations and that all applicable safety measures are followed.
All product-specific safety regulations must be observed.
Solid particles must not enter the vacuum pump.
The vacuum pump is thermally suitable for continuous use at any pres-
sure between atmospheric pressure and ultimate pressure.
Max. permissible number of startings per hour: 6.
CAUTION
During operation the surface of the vacuum pump can exceed tem-
peratures of 90°C.
Risk of burns!
The vacuum pump must be protected against contact during opera-
tion. If touching the pump is unavoidable, wait until the surface
temperature has cooled down or wear protective gloves.
CAUTION
The sound level of the pump within a certain perimeter of the pump
is high.
Risk of hearing damage.
Users, who are spending a longer period of time in the vicinity of a
non-insulated vacuum pump, must wear suitable ear protection.
CAUTION
The COBRA vacuum pumps are always delivered without oil.
Operation without oil will destroy the vacuum pump within a short
period of time.
The vacuum pump must remain in a horizontal position once it has
been filled with oil.
CAUTION
The COBRA vacuum pumps are always delivered without cooling
liquid.
Operation without cooling liquid will destroy the vacuum pump wi-
thin a short period of time!
Installation and Commissioning
Page 11

lMake sure that all provided covers, guards, hoods etc. remain fit-
ted
lMake sure that protective devices will not be disconnected
lMake sure that there is no leakage in the system, the escape of
dangerous substances must be avoided
lMake sure that the “Installation Prerequisites” are complied with
and will remain so, and ensure that adequate cooling is guaranteed
If the pump is shut down for a longer period of time:
CAUTION
If there is a risk of frost, all the cooling liquid must be drained out of
the vacuum pump if the pump is shut down for a longer period of
time!
–Drain the cooling liquid
uRemove the cooling liquid inlet (CLI) and outlet (CLO) connec-
tions
uRemove the connection of the cooling liquid in cylinder (INJ)
uUnscrew the cooling liquid drain plugs (CLD)
uDrain the cooling liquid
uRefit the cooling liquid drain plugs
uRefit the cooling liquid inlet (CLI, INJ) and outlet (CLO)
connections
uCollect the cooling liquid and re-use it or dispose of it accor-
ding to local or national regulations
NOTE: When the pump has not been in operation for a few days or
when a sticky substance has been drawn, it is possible that the two ro-
tor screws of the COBRA vacuum pump stick to each other. Unscrew
the access cover to the rotor screws (situated on the cylinder-cover at
the inlet side). Loosen the rotors from each other with an Allen key and
an extension by turning them clockwise by hand.
Switching the vacuum pump on/ off
First start-up of the system
lMake sure that the “Installation Prerequisites” are followed
lOpen the cooling liquid supply (CL)
uAdjust the flow rate to 12 l/ min
lStart the vacuum pump
lOpen the injection of cooling liquid in the cylinder (INJ)
uWith the pump operating at 60 Hz/3600 rpm and an inlet
pressure < 100 mbar. Adjust the cooling liquid flow rate to 3-6
l/min or a quantity sufficient to ensure an exhaust gas outlet
temperature <80°C
uCheck the exhaust gas outlet temperature <80°C
If the vacuum pump is equipped with a solenoid valve at the inlet:
uOpen the solenoid valve
If the vacuum pump is equipped with a shut-off valve at the inlet:
uOpen the shut-off valve
Switching off the system
uApply an inlet pressure of between atmospheric pressure and
650 hPa (abs.); ensure the exhaust gas outlet temperature
does not exceed 80°C.
lClose the injection of cooling liquid in the cylinder (INJ)
uLet the vacuum pump run for 1 minute
lStop the vacuum pump
lClose the cooling liquid supply (CL)
Busch recommends that the pump is fitted with isolation valves in both
the inlet and outlet connection pipe work to the pump. When not ope-
rational the pump must be isolated from the system in order to prevent
liquids entering a none-operational pump.
uClose the system shut-off valve
lThe system must be disconnected from the power supply
Re start procedure following an Emergency Shut Down
of the system
Prior to attempting to restart the system, ascertain the reason for the
emergency shut down and rectify the fault.
uWith the pump electrically isolated from the power supply and
vacuum system, all appropriate safety precautions, work per-
mits, warning boards, safety equipment and perimeter must be
put into place.
uDrain and collect any residual liquids from the pumping cham-
ber, in compliance with all local restrictions and requirements.
Ensure the pump is free to rotate by hand. Once assured that
the pump is empty, replace all previously removed drain plugs.
When the work has been completed follow the procedure "Start-up
procedure after maintenance"
lRemove the warning board and safety perimeter
lCheck the lubrication oil levels according to chapters "Checking
the oil level"
lConnect the pump to the power supply
lMake sure that the "Installation Prerequisites" are followed
lOpen the cooling liquid supply (CL)
lStart the vacuum pump
lOpen the injection cooling liquid into the cylinder (INJ), adjust the
flow rate to the required amount to maintain the pump outlet tem-
perature <80°C.
Maintenance
DANGER
In case the vacuum pump has conveyed gases that have been
contaminated with foreign materials that are dangerous to health,
the oil and condensates will also be contaminated.
These foreign materials can infiltrate the pores, recesses and other
internal spaces of the vacuum pump.
Danger to health when the vacuum pump is dismantled.
Danger to the environment.
Always wear protective clothing when carrying out maintenance
work.
Before any maintenance work, the inlet and outlet piping as well as
the vacuum pump itself must be flushed with nitrogen.
CAUTION
Only authorised personnel may carry out any dismantling on the va-
cuum pump. Before work begins, the operator of the vacuum pump
must fill in a form or a “Declaration Regarding Contamination of
Vacuum Equipment and Components” that provides information on
possible dangers and appropriate measures.
If this form has not been filled in completely and signed by a res-
ponsible person, the vacuum pump may not be dismantled.
CAUTION
Before any maintenance work is started, a safety perimeter of at
least 1 [m] around the machine must be set up.
Maintenance
Page 12

CAUTION
During operation the surface of the vacuum pump may reach tem-
peratures in excess of 90 °C.
Risk of burns!
Before starting any maintenance work, make sure that the vacuum
pump has been fully switched off and that it cannot accidentally be
switched on again. Follow the shutdown procedure in the section
“Stopping procedure for maintenance”:
lClose the injection of cooling liquid in the cylinder (INJ)
uLet the vacuum pump run for 1 minute
lStop the vacuum pump
lClose the cooling liquid supply (CL)
lSwitch off the power supply (the vacuum pump must be fully dis-
connected from the power supply)
lPut up label or warning board “Maintenance in progress” on or
next to the pump
CAUTION
The oil temperature can reach a value of 100°C!
Danger of burns!
lMake sure that the oil circuit and the cooling liquid circuit have
been drained before moving the vacuum pump
lMake sure that any cleaning materials used to clean the vacuum
pumps have been disposed of according to local and national regu-
lations
Before disconnecting the different connections, make sure that the inlet
and exhaust lines of the vacuum pump have been brought to atmos-
pheric pressure
When the maintenance work has been finished, follow the procedure
“Start-up procedure after maintenance”:
lRemove the label or warning board “Maintenance in progress”
lCheck the cooling liquid level according to chapters “Checking the
oil level”
lConnect the pump up to the power supply
lMake sure that the “Installation Prerequisites” are followed
lOpen the cooling liquid supply, adjust the flow rate
lStart the vacuum pump
lOpen the injection of cooling liquid in the cylinder, adjust the flow
rate
Maintenance program
NOTE: The maintenance intervals depend on the individual operating
conditions. The intervals given below should be considered as initial
guidelines which should be shortened or extended as appropriate. In
particularly heavy duty operation such as high dust loads in the envi-
ronment or in the process gas, it can become necessary to shorten the
maintenance intervals significantly.
Monthly:
lCheck the vacuum pump for oil leaks (condensate drain plug (CD)
- in case of leaks, have the vacuum pump repaired (Busch service)
lCheck the vacuum pump for cooling liquid leaks - in case of leaks,
have the vacuum pump repaired (Busch service)
In case of operation in a dusty environment:
uCheck the motor hood for dirt, if necessary clean
lCheck the oil level (see “Checking the Oil”) and condition; change
the oil if contaminated.
lCheck the oil level (see “Checking the Oil”)
lCheck the different cooling liquid flow rates
In case of operation in a dusty environment:
uMake sure that the operating room is clean and free of dust;
clean the room if necessary
lMake sure that the vacuum pump has been switched off and that
it cannot accidentally be switched on again
lCheck the electrical connections
lCarry out a visual inspection of the vacuum pump
Yearly:
lMake sure that the vacuum pump has been switched off and that
it cannot accidentally be switched on again
lDrain and fill in new oil (see “Draining the Oil” and “Filling in new
oil”)
If the inlet is equipped with a mesh screen:
uCheck the mesh screen at the inlet and clean it if necessary
Every 5000 operating hours:
lCheck the cooling liquid lines
lDrain and fill in new oil (see “Draining the Oil” and “Filling in new
oil”)
Every 10’000 operating hours:
lDrain and fill in new oil (see “Draining the Oil” and “Filling in new
oil”)
lCheck the seals and replace them if necessary
lCheck the inlet and discharge lines and clean or replace them if ne-
cessary
Every 16’000 operating hours, at the latest
after 4 Years:
Have a major overhaul done on the vacuum pump (Busch service)
Stopping procedure for maintenance
lApply an inlet pressure of between atmospheric pressure and 650
hPa (abs.); ensure the exhaust gas outlet temperature does not ex-
ceed 80°C.
lClose the injection of cooling liquid in the cylinder (INJ)
uLet the vacuum pump run for 1 minute
lStop the vacuum pump
lClose the cooling liquid supply (CL)
lSwitch off the power supply (the vacuum pump must be discon-
nected from the power supply)
lPut up label or warning board “Maintenance in progress” on or
next to the pump.
Start-up after maintenance
lRemove label or warning board “Maintenance in progress”
lCheck the oil level according to the chapters “Checking the oil le-
vel”
lConnect the pump up to the power supply
lMake sure that the “Necessary installation instructions” are follo-
wed
lOpen the cooling liquid supply, adjust the flow rate of the cooling
liquid (CL)
uAdjust the flow rate to 12 l/min
lStart the vacuum pump
lOpen the injection of cooling liquid in the cylinder, adjust the flow
rate of the injection of cooling liquid (INJ)
Maintenance
Page 13

uWith the pump operating at 60 Hz/3600 rpm and an inlet
pressure < 100 mbar. Adjust the cooling liquid flow rate to
3-6 l/min or a quantity sufficient to ensure an exhaust gas ou-
tlet temperature <80°C
uCheck the exhaust gas outlet temperature <80°C
lIf the vacuum pump is equipped with a solenoid valve at the inlet:
uOpen the solenoid valve
lIf the vacuum pump is equipped with a shut-off valve at the inlet:
uOpen the shut-off valve
Checking the oil
Checking the oil level
lMake sure that the vacuum pump is switched off and cannot acci-
dentally be switched on again
lCheck the oil level on the different oil sight glasses
If the oil level is below the required level:
uTop up with oil (see “Topping up Oil”)
If the oil level is above the required level:
uCheck the evacuation of the condensates.
uChange the oil (see “Change the oil”)
Topping up with oil
NOTE: Under normal conditions there should be no need to top up
with oil in-between the recommended oil change intervals. A signifi-
cant drop in the oil level indicates a malfunction (see “Troubleshoo-
ting”).
NOTE: The procedure of filling up with oil is identical for both sides. It
will be described in this operating instructions only for a single side.
Please repeat the following operations for the second side.
CAUTION
Fill in oil only through the oil filler holes.
CAUTION
Risk of injury (burns) with open oil filler orifice.
Risk of injury in case of badly screwed-in plugs.
Remove the oil filler plugs only when the vacuum pump is stopped.
The vacuum pump must only be operated when the oil filler plugs
are firmly tightened up and do not leak.
lMake sure that the vacuum pump is switched off and cannot acci-
dentally be switched on again
lRemove the oil filler plug (OFP) (motor side including filter pot)
lTop up with oil
lMake sure that the oil level is on MAX-mark of the oil sight glass
lMake sure that the seal of the oil filler plug are not damaged and
replace plug if necessary
lRefit the oil filler plug and tighten up
Checking the colour of the oil
NOTE: The original colour of the oil used on the COBRA vacuum
pumps is dark. Under operation, no indication can be provided by
means of the colour.
Life-span of the Oil
The oil life depends very much on the ambient and operating condi-
tions. Under normal conditions the oil must be changed every 5000
operating hours.
Under very unfavourable operating conditions the oil life can be less
than 500 operating hours. A very short oil life time indicates either a
malfunction (see “Troubleshooting”) or unsuitable operating
conditions.
If there is no experience available regarding the oil life under the pre-
vailing operation conditions, it is recommended to have the oil analy-
sed every 500 operating hours and thus to establish the oil change
interval accordingly.
Oil change
NOTE: The procedure of oil change is identical for both sides. It will be
described in this operating instructions only for a single side. Please re-
peat the following operations for the second side.
WARNING
In case the vacuum pump has conveyed gases that have been
contaminated with harmful foreign materials, the oil will also be
contaminated.
Danger to health during the change of contaminated oil.
Danger to the environment.
Wear protective equipment during the change of contaminated oil.
Contaminated oil is hazardous waste and must be disposed of se-
parately in compliance with applicable regulations.
Draining used oil
NOTE: After switching off the vacuum pump at normal operating tem-
perature wait no more than 20 minutes before the oil is drained.
lMake sure that the vacuum pump is switched off and cannot acci-
dentally be switched on again
lMake sure that the vacuum pump is vented to atmospheric pres-
sure
lPut a drain tray underneath the oil drain ball valve (ODV)
lOpen the oil drain ball valve (ODV)
lDrain the oil
When the oil flow has stopped:
lClose the oil drain ball valve (ODV)
lSwitch on the vacuum pump for a few seconds
lMake sure that the vacuum pump is switched off and cannot acci-
dentally be switched on again
lOpen the oil drain ball valve again and drain any remaining oil
lClose the oil drain ball valve (ODV) again
lDispose of the used oil in compliance with applicable regulations
Filling in new oil
NOTE: The quantities of oil are different between the quantity indica-
ted for the motor side (A) and the quantity indicated for the inlet side
(B). Respect the values indicated in the table “Oil quantity”.
NOTE: The procedure of filling up with oil is identical for both sides. It
will be described in this operating instructions only for a single side.
Please repeat the following operations for the second side.
lPrepare the quantity of oil needed (see “Oil type/ quantity”)
NOTE: The quantity of oil specified in the operating instructions is of
informative nature only. Check the oil level with the help of the various
oil sight glasses on the vacuum pump.
lMake sure that the oil drain ball valves have been closed
Maintenance
Page 14

CAUTION
Only fill in oil through the oil filler holes.
lRemove the oil filler plug (OFP) (motor side including filter pot)
lFill in oil
lMake sure that the oil level is on the MAX-mark of the oil sight
glass
lMake sure that the seal of the oil filler plug is not damaged and
replace plug if necessary
lRefit the oil filler plug and tighten up
Cooling liquid
Drain the cooling liquid
lMake sure that the vacuum pump is switched off and cannot acci-
dentally be switched on again
lMake sure that the vacuum pump is vented to atmospheric pres-
sure
lPut a drain tray underneath the cooling liquid drain plugs (CLD)
lRemove the cooling liquid inlet (CLI) and outlet (CLO) connections
lRemove the connection of the cooling liquid in the cylinder (INJ)
lRemove the cooling liquid drain plugs (CLD)
lDrain the cooling liquid
uRefit the cooling liquid drain plugs and tighten up
lClose the cooling liquid inlet (CLI, INJ) and outlet (CLO) connec-
tions
lDispose of the used cooling liquid in compliance with applicable re-
gulations
Checking the current consumption
lCheck the current of the motor
An increased current indicates a fault (see “Troubleshooting”)
Checking the motor hood
In case of operation in a dusty environment:
uCheck weekly the motor hood for dirt, if necessary clean with
a brush and compressed air
In case of operation in a clean environment:
uCheck monthly the motor hood for dirt, if necessary clean with
a brush and compressed air
Overhaul
CAUTION
Improper maintenance work on the vacuum pump can damage it.
Risk of explosion!
Non-adherence to the procedure will cancel approval for start-up of
the pump!
Any dismantling of the vacuum pump beyond of what is described
in this manual must be done by specially trained Busch service staff
only.
DANGER
In case the vacuum pump has conveyed gases that have been
contaminated with foreign materials that are dangerous to health,
the oil and condensates will also be contaminated.
These foreign materials can infiltrate the pores, recesses and other
internal spaces of the vacuum pump.
Danger to health when the vacuum pump is dismantled.
Danger to the environment.
Prior to shipping, the vacuum pump must imperatively be deconta-
minated and the degree of contamination must be documented in a
declaration of decontamination (“Declaration of Decontamina-
tion”), which can be downloaded from www.buschvacuum.com.
Busch service will only accept vacuum pumps that come with a com-
pletely filled in and legally binding signed form.
Removal from service
Temporary removal from service
Prior to disconnecting inlet and outlet pipes as well as cooling liquid li-
nes, make sure that all piping is vented to atmospheric pressure
Recommissioning
CAUTION
After a long period of inactivity, it is possible that the rotor screws of
the COBRA vacuum pump are stuck.
Turn the rotor screws manually.
lMake sure that all gaskets, plugs or adhesive tapes have been re-
moved.
lStart the vacuum pump as described in the chapter “Installation
and Commissioning”
Dismantling and Disposal of the
vacuum pump
DANGER
In case the vacuum pump has conveyed gases that have been
contaminated with harmful foreign material which are harmful to
health, the oil and the condensates will also be contaminated with
harmful foreign material.
These foreign materials can infiltrate the pores, recesses and other
internal spaces of the vacuum pump.
Danger to health during dismantling of the vacuum pump.
Danger to the environment.
During dismantling of the vacuum pump protective equipment and
clothing must be worn.
The vacuum pump must be decontaminated prior to disposal.
Prior to shipping, the vacuum pump must imperatively be deconta-
minated and the degree of contamination must be documented in a
declaration of decontamination (“Declaration of Decontamina-
tion”), which can be downloaded from www.buschvacuum.com.
Used oil and condensates must be disposed of separately in
compliance with applicable environmental regulations.
Overhaul
Page 15

When the vacuum pump comes to the end of its life:
–it must be decontaminated
CAUTION
Only authorised personnel may carry out dismantling work on the
vacuum pump. Before work begins, the operator of the vacuum
pump must fill in a form or a “Declaration Regarding Contamination
of Equipment and Components” that provides information on pos-
sible dangers and appropriate measures.
If this form has not been filled in completely and signed, the
vacuum pump may not be dismantled.
–drain the oil
udispose of the used oil in compliance with applicable environ-
mental regulations
–drain the cooling liquid
udispose of the cooling liquid in compliance with applicable en-
vironmental regulations
–dismantle the vacuum pump
CAUTION
During dismantling of the vacuum pump protective equipment and
clothing must be worn
udispose of the vacuum pump as scrap metal
–dispose of the different components of the pump in compliance
with applicable regulations
Removal from service
Page 16

Troubleshooting
WARNING
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
During operation the surface of the vacuum pump may reach temperatures of more than 90 °C.
Risk of burns!
Let the vacuum pump cool down prior to a required contact or wear heat protection gloves.
Problem Possible Cause Remedy
The vacuum pump does not reach the usual
pressure
The vacuum system or suction line is not
leak-tight
Check the hose or pipe connections for possible
leak
Evacuation of the system takes too long In case a mesh screen is installed on the suction
connection:
The mesh screen on the suction connection is
partly clogged
Clean the mesh screen
If cleaning is required too frequently install a fil-
ter upstream
In case an inlet filter is installed on the suction
connection:
The filter on the suction connection is partly
clogged
Clean or replace the inlet filter, 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
Internal parts worn or damaged Repair the vacuum pump (Busch service)
The vacuum pump does not start The drive motor is not supplied with the correct
voltage or is overloaded
Supply the drive motor with the correct voltage
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 name-
plate
Correct if necessary
In case of high ambient temperature:
Set the trip level of the drive motor starter
overload protection 5 percent above the no-
minal drive motor current
One of the fuses has blown Check the fuses
The connection cable is too small or too long
causing a voltage drop at the vacuum pump
Use sufficiently dimensioned cable
The vacuum pump 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 fan by hand
If the unit vacuum pump/drive motor is still fro-
zen:
Remove the drive motor and check the drive
motor and the vacuum pump separately
If the vacuum pump is blocked:
Repair the vacuum pump (Busch service)
Troubleshooting
Page 17

The drive motor is defective Replace the drive motor (Busch service)
The vacuum pump is blocked Solid foreign matter has entered the vacuum
pump
Repair the vacuum pump (Busch service)
Make sure the suction line is equipped with a
mesh screen
If necessary additionally provide a filter
Corrosion in the vacuum pump from remaining
condensate
Repair the vacuum pump (Busch service)
Check the process
Observe the chapter “Installation and Commis-
sioning, Operating Notes”
The vacuum pump was run in the wrong direc-
tion
Repair the vacuum pump (Busch service)
When connecting the vacuum pump make sure
the vacuum pump will run in the correct direc-
tion (see “Installation”)
Condensate ran into the vacuum pump Repair the vacuum pump (Busch service)
Drain condensate regularly
The vacuum pump starts, but labours or runs
noisily or rattles
The drive motor draws a too high current (com-
pare with initial value after commissioning)
Connections in the drive motor terminal box are
defective
Not all drive motor coils are properly connected
The drive motor operates on two phases only
Check the proper connection of the wires
against the connection diagram
Tighten or replace loose connections
The vacuum pump runs in the wrong direction Verification and rectification see “Installation
and Commissioning”, correct if necessary
Standstill over several weeks or months Let the vacuum pump run warm with inlet clo-
sed
Oil viscosity is too high for the ambient tempe-
rature
Use oil with a better viscosity class
Improper oil quantity, unsuitable oil type Use the proper quantity of one of the recom-
mended oils
(see “Oil”, oil change see “Maintenance”)
No oil change over extended period of time Perform oil change incl. flushing (see “Mainte-
nance”)
Foreign objects in the vacuum pump
Stuck bearings
Repair the vacuum pump (Busch service)
The vacuum pump runs very noisily Defective bearings Repair the vacuum pump (Busch service)
Worn coupling element Replace the coupling element
The vacuum pump runs very hot
(the oil sump temperature shall not exceed
100 °C)
Ambient temperature too high Observe the permitted ambient temperatures
Temperature of the inlet gas too high Observe the permitted temperatures for the in-
let gas
Oil level too low Top up oil
Check the oil filler and drain plugs
Check the mechanical seals
Oil burning by an overheating of the vacuum
pump
Drain oil
Fill in new oil
(see “Maintenance”)
In case the oil life is too short: use oil with bet-
ter heat resistance or retrofit cooling
Mains frequency or voltage outside tolerance
range
Provide a more stable power supply
In case a mesh screen is installed on the suction
connection:
The mesh screen on the suction connection is
partially clogged
Clean the mesh screen
If cleaning is required too frequently install a fil-
ter upstream
Troubleshooting
Page 18

In case an inlet air filter is installed on the suc-
tion connection:
The filter on the suction connection is partially
clogged
Clean or replace the filter
Partial clogging in the suction or discharge line Remove the clogging
Long suction, discharge or pressure line with
too small diameter
Use larger diameter
The oil is black Oil change intervals are too long
The oil was overheated
Drain oil
Fill in new oil
(see “Maintenance”)
In case the oil life is too short: use oil with bet-
ter heat resistance or retrofit cooling
Cooling liquid flow too low No connection to cooling liquid supply Check cooling liquid supply
Cooling liquid pressure too low Apply propoer cooling liquid pressure
Solenoid valve (option) closed Open solenoid valve
Cooling liquid piping obstructed Clean or replace piping
Leakage from cooling liquid piping Check or replace seals
Troubleshooting
Page 19

Spare parts
NOTE: When ordering spare parts or accessories acc. to the table be-
low please always quote the type and the serial no. of the vacuum
pump. This will allow Busch service to check if the vacuum pump is
compatible with a modified or improved part.
This parts list applies to a typical configuration of the standard vacuum
pump. Depending on the specific order deviating parts data may apply.
Spare parts kit
Wearing
parts Description Article No.
STANDARD sealing
Set of seals consisting of all necessary seals
Overhaul
kit consisiting of set of seals and all wearing parts
Spare parts
Page 20