BUSCH COBRA Oxygen NC 0400 B User manual

O2
Instruction Manual
COBRA Oxygen
Dry Screw Vacuum Pumps
NC 0400 B (water-cooled version)
0870573767/-0001_en / Original instructions / Modifications reserved 19/03/2019
Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland

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 Start Controls .......................................................................................................5
2.4 Standard Features.................................................................................................6
2.4.1 Water Cooling ...........................................................................................6
2.4.2 Temperature Switch...................................................................................6
2.4.3 Thermometer.............................................................................................6
2.4.4 Gas Ballast Valve........................................................................................6
2.4.5 Sealing Systems .........................................................................................6
2.4.6 Terminal Box..............................................................................................6
3 Transport ..................................................................................................................... 7
4 Storage......................................................................................................................... 7
5 Installation................................................................................................................... 8
5.1 Installation Conditions .......................................................................................... 8
5.2 Connecting Lines / Pipes ......................................................................................9
5.2.1 Suction Connection....................................................................................9
5.2.2 Discharge Connection................................................................................10
5.2.3 Cooling Water Connection ........................................................................10
5.3 Filling Oil..............................................................................................................11
5.4 Filling Cooling Liquid ............................................................................................ 13
5.5 Electrical Connection ............................................................................................14
6 Commissioning............................................................................................................ 15
6.1 Conveying Condensable Vapours ......................................................................... 17
6.2 Gas Purging Procedure ......................................................................................... 17
6.3 Restart Procedure ................................................................................................. 17
7 Maintenance................................................................................................................ 18
7.1 Maintenance Schedule.......................................................................................... 20
7.2 Oil Level Inspection .............................................................................................. 20
7.3 Cooling Liquid Level Inspection ............................................................................21
7.4 Replacing the Gas Ballast Filter (Optional) ............................................................ 21
7.5 Oil Change...........................................................................................................22
7.6 Cooling Liquid Change ......................................................................................... 25
8 Overhaul...................................................................................................................... 26
9 Decommissioning ........................................................................................................ 26
9.1 Dismantling and Disposal...................................................................................... 26
10 Spare Parts................................................................................................................... 27
11 Troubleshooting........................................................................................................... 28
12 Technical Data ............................................................................................................. 30
13 Cooling Liquid ............................................................................................................. 30
14 Oil ............................................................................................................................... 30
15 EU Declaration of Conformity ...................................................................................... 32

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 anything
on the product.
The machine is intended for industrial use. It must be handled only by technically trained
personnel.
Always wear appropriate personal protective equipment in accordance with the local
regulations.
The machine has been designed and manufactured according to state-of-the-art meth-
ods. Nevertheless, residual risks may remain. This instruction manual highlights potential
hazards where appropriate. Safety notes and warning messages are tagged with one of
the keywords DANGER, WARNING, CAUTION, NOTICE and NOTE as follows:
DANGER
... indicates an imminent dangerous situation that will result in death or serious injuries if
not prevented.
WARNING
... indicates a potentially dangerous situation that could result in death or serious injuries.
CAUTION
... indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
... indicates a potentially dangerous situation that could result in damage to property.
NOTE
... indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.

2 | Product Description
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2 Product Description
EB
IN, IS
OUT
PMR CLP
CWI
TS
OFP
SV
CWO
MP
ODP
CLFGB CLG
MP
TM CLD
PHE
OSG
MTB
NP
OFP
ODP
OSG
SI
CD
RSTPTB
CD Condensate drain CLD Cooling liquid drain plug
CLF Cooling liquid fill plug CLG Cooling liquid sight glass
CLP Cooling liquid pump CWI Cooling water inlet
CWO Cooling water outlet EB Eye bolt
GB Gas ballast valve IN Suction connection
IS Inlet screen MP Magnetic plug
MTB Motor terminal box NP Nameplate
ODP Oil drain plug OFP Oil fill plug
OSG Oil sight glass OUT Discharge connection
PHE Plate heat exchanger PMR Plug for manual rotation of rotors
PTB Pump terminal box RST Reset button
SI Silencer SV Safety valve
TM Thermometer TS Temperature switch

Product Description | 2
0870573767_NC0400B_O2_WCV_-0001_IM_en 5 / 36
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
pump’.
2.1 Operating Principle
The machine works on the one-stage, twin-screw pump principle.
Two screw rotors are rotating inside the cylinder. The pumped medium is trapped
between the cylinder and screw chambers, compressed, and transported to the gas out-
let. During the compression process, the two screw rotors do not come into contact with
each other nor with the cylinder. There is no need for a lubrication or an operating fluid
in the compression chamber.
2.2 Application
The machine is intended for the suction of air and other dry, non-aggressive, non-toxic
and non-explosive gases.
The oxygen version is especially designed for conveying gases with an increased oxygen
content (volume content greater than 21% and up to 100%).
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 capable of maintaining ultimate pressure, see Technical Data [►30].
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [►30].
2.3 Start Controls
The machine comes without start controls. The control of the machine is to be provided
in the course of installation.
The machine can be optionally equipped with a starter unit or a variable-frequency drive.

2 | Product Description
6 / 36 0870573767_NC0400B_O2_WCV_-0001_IM_en
2.4 Standard Features
2.4.1 Water Cooling
The machine is cooled by a cooling liquid circuit in the cylinder cover and cylinder.
The cooling liquid pump (CLP) allows a recirculating flow in the cooling liquid chamber.
The cooling liquid is cooled by a plate heat exchanger (PHE) which must be connected to
the water main.
2.4.2 Temperature Switch
The temperature switch monitors the oil temperature of the machine.
The machine stops automatically when the oil temperature reaches 100 °C.
If the temperature switch (TS) has tripped:
• Follow the procedure to restart the machine, see Restart Procedure [►17].
2.4.3 Thermometer
The thermometer allows a visual display of the cooling liquid temperature.
2.4.4 Gas Ballast Valve
The gas ballast valve mixes the process gas with a limited quantity of ambient air to
counteract the condensation of vapour inside the machine.
The gas ballast valve has an influence on the ultimate pressure of the machine, see Tech-
nical Data [►30].
A ball valve enables to open or close the gas ballast flow.
2.4.5 Sealing Systems
The machine is equipped with labyrinth seals on the motor side and suction side.
Sealing systems prevent the process gas going to the bearings chambers.
2.4.6 Terminal Box
The machine is equipped with a terminal box (PTB) including an overload protection for
the motor.
The motor and the temperature switch (TS) are wired to the terminal box.

Transport | 3
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3 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
NOTICE
In case the machine is already filled with oil.
Tilting a machine that is already filled with oil can cause large quantities of oil to in-
gress into the cylinder.
• Drain the oil prior to every transport or always horizontally transport the machine.
Machine weight:
see the technical data or the nameplate (NP)
WARNING
Lifting the machine using the motor eye bolt.
Risk of severe injury!
• Do not lift the machine using the eye bolt fitted to the motor. Only lift the machine as
previously shown.
• Check the machine for transport damage.
If the machine is secured to a base plate:
• Remove the machine from the base plate.
4 Storage
• Seal all apertures with adhesive tape or reuse provided caps.
If the machine is to be stored for more than 3 months:
• Wrap the machine in a corrosion inhibiting film.
• Store the machine indoors, dry, dust free and if possible in original packaging
preferably at temperatures between 5 ... 55 °C.

5 | Installation
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5 Installation
WARNING
Lack of oxygen regulation knowledge.
Risk of fire!
• Installation, commissioning and maintenance must only be carried out by qualified
personnel who are informed about the applicable safety regulations and trained in the
handling of oxygen.
• Accident prevention regulations or methods must imperatively be complied with.
Seek further information:
- European Industrial Gases Association “EIGA” www.eiga.eu (EIGA SAG NL 79/04).
- Berufsgenossenschaft Rohstoffe und chemische Industrie "BG RCI” www.bgrci.de
(Merkblatt M 034 Sauerstoff).
5.1 Installation Conditions
WARNING
The machine is not absolutely gas tight.
Risk of fire!
• The installation area must be aired in such a way so as to prevent unacceptable levels
of oxygen.
NOTICE
Use of the machine outside of the permitted installation conditions.
Risk of premature failure!
Loss of efficiency!
• Take care that the installation conditions are fully complied with.
• Make sure that the environment of the machine is not potentially explosive.
• Make sure that the ambient conditions comply with the Technical Data [►30].
• Make sure that the environmental conditions comply with the protection class of the
motor and the electrical instruments.
• Make sure that the installation space or location is vented such that sufficient cooling
of the machine is provided.
• Make sure that cooling air inlets and outlets of the motor fan are not covered or ob-
structed and that the cooling air flow is not affected adversely in any other way.
• Make sure that the oil sight glass (OSG) remains easily visible.
• Make sure that enough space remains for maintenance work.
• Make sure that the machine is placed or mounted horizontally, a maximum of 1° in
any direction is acceptable.
• Check the oil level, fill up if necessary, see Filling Oil [►11].
• Check the oil level, see Oil Level Inspection [►20].
• Check the cooling liquid level, see Cooling Liquid Level Inspection [►21].

Installation | 5
0870573767_NC0400B_O2_WCV_-0001_IM_en 9 / 36
• Make sure that the cooling water complies with the requirements, see Cooling Water
Connection [►10].
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 caps 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.
WARNING
The connection lines can build up an electrostatic charge.
Risk of severe injury!
Risk of explosion!
• The connection lines must be made out of conductive material or provisions must be
made against creating an electrostatic charge.
5.2.1 Suction Connection
WARNING
Unprotected suction connection.
Risk of severe injury!
• Do not put hand or fingers in the suction connection.
NOTICE
Ingress of foreign objects or liquids.
Risk of damage to the machine!
If the inlet gas contains dust or other foreign solid particles:
• Install a suitable filter (5micron or less) upstream from the machine.
Connection size:
– G2
If the machine is used as part of a vacuum system:
• Busch recommends the installation of an isolation valve in order to prevent the
machine from turning backwards.

5 | Installation
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5.2.2 Discharge Connection
Connection size:
– R3
• Make sure that the discharged gas will flow without obstruction. Do not shut off or
throttle the discharge line or use it as a pressurised air source.
• Make sure that the counter pressure (also termed back pressure) at the discharge con-
nection (OUT) does not exceed the maximum allowable discharge pressure, see Tech-
nical Data [►30].
5.2.3 Cooling Water Connection
CWICWO PHE
CWI Cooling water inlet CWO Cooling water outlet
PHE Plate heat exchanger
• Connect the cooling water connections (CWI / CWO) to the water supply.
Connection size:
– G1/2, ISO 228-1 (CWI / CWO)
• Make sure that the cooling water complies with the following requirements:
Supply capacity l/min 4 ... 6
Water pressure bar 1 ... 6
Supply temperature °C +5 ... +30
Required pressure differential across supply
and return
bar ≥ 1
• To reduce the maintenance effort and ensure a long product lifetime we recommend
the following cooling water quality:
Hardness mg/l (ppm) < 90
Properties Clean & clear
PH value 7 … 8
Particle size µm < 200
Chloride mg/l < 100
Electrical conductivity µS/cm ≤ 100
Free chloride mg/l < 0.3
Materials in contact with the cooling water Stainless steel

Installation | 5
0870573767_NC0400B_O2_WCV_-0001_IM_en 11 / 36
NOTE
Water hardness unit conversion.
1 mg/l (ppm) = 0.056 °dh (german degree) = 0.07 °e (english degree) = 0.1 °fH (french
degree)
5.3 Filling Oil
WARNING
Fill the machine with wrong oil type.
Risk of fire!
• Only use oil approved by Busch and suitable for oxygen application, see Oil [►30].
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 [►30] and Oil [►30].
1
2
Busch Oil
3
MAX
MIN
3 mm
4
Check oil level
Oil filling at the motor side

5 | Installation
12 / 36 0870573767_NC0400B_O2_WCV_-0001_IM_en
1
2
Busch Oil
3
MAX
MIN
3 mm
4
Check oil level
Oil filling at the suction side
When the oil filling is achieved:
• Write down the oil change date on the sticker.
Last oil change
__ / __ / ____
Oil type see nameplate
Change interval see
instruction manual
If there is no sticker (part no. 0565 568 959) on the machine:
• Order it from your Busch representative.

Installation | 5
0870573767_NC0400B_O2_WCV_-0001_IM_en 13 / 36
5.4 Filling Cooling Liquid
The machine is already dispatched with cooling liquid.
If it is not the case:
• Fill in the machine with cooling liquid according to the following procedure.
For cooling liquid type and cooling liquid capacity see Technical Data [►30] and
Cooling Liquid [►30].
1
2
Cooling
liquid
Zitrec M-25
3
MAX
MIN
4
Check cooling liquid level

5 | Installation
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5.5 Electrical Connection
DANGER
Live wires.
Risk of electrical shock.
• Electrical installation work must only be executed by qualified personnel.
NOTICE
The admissible motor nominal speed exceeds the recommendation.
Risk of damage to the machine!
• Check the admissible motor nominal speed (nmax) on the nameplate of the machine
(NP).
• Make sure to comply with it.
• Consult the Technical Data [►30] to get more information.
NOTICE
The motor frequency is below 20 Hz.
Risk of damage to the machine!
• The motor nominal speed must always be higher than 1200 min-1 (20 Hz).
• Make sure that the power supply for the motor is compatible with the data on the
nameplate of the motor.
• The electrical installation must comply with applicable national and international
standards.
• Provide a lockable disconnect switch on the power line so that the machine is com-
pletely secured during maintenance tasks.
• Make sure that the motor of the machine will not be affected by electric or electro-
magnetic disturbance from the mains; if necessary seek advice from Busch.
• Connect the power supply and the earth connection to the terminal box (PTB), see
graphic below:
PENL1 L2 L3
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.

Commissioning | 6
0870573767_NC0400B_O2_WCV_-0001_IM_en 15 / 36
The intended rotation direction of the motor is defined by the illustration below:
IN
• Jog the motor briefly.
• Watch the fan wheel of the motor and determine the direction of rotation just before
the fan wheel stops.
If the rotation of the motor must be changed:
• Switch any two of the motor phase wires.
6 Commissioning
WARNING
Lack of oxygen regulation knowledge.
Risk of fire!
• Installation, commissioning and maintenance must only be carried out by qualified
personnel who are informed about the applicable safety regulations and trained in the
handling of oxygen.
• Accident prevention regulations or methods must imperatively be complied with.
Seek further information:
- European Industrial Gases Association “EIGA” www.eiga.eu (EIGA SAG NL 79/04).
- Berufsgenossenschaft Rohstoffe und chemische Industrie "BG RCI” www.bgrci.de
(Merkblatt M 034 Sauerstoff).
WARNING
Machine contaminated with organic material.
Risk of fire!
If there is a suspicion that the machine or the oil is contaminated with organic material:
• The machine must be removed from service and cleaned by specialists (contact your
Busch representative).
NOTICE
The machine can be shipped without oil.
Operation without oil will ruin the machine in short time!
• Prior to commissioning, the machine must be filled with oil, see Filling Oil [►11].
NOTICE
The machine can be shipped without cooling liquid.
Operation without cooling liquid will ruin the machine in short time!
• Prior to commissioning, the machine must be filled with cooling liquid, see Filling
Cooling Liquid [►13].

6 | Commissioning
16 / 36 0870573767_NC0400B_O2_WCV_-0001_IM_en
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.
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.
• Make sure that the installation conditions (see Installation Conditions [►8]) are met.
If the machine corresponds to ATEX Classification (see ATEX Classifications and Associ-
ated Accessories):
• Make sure that the machine has been purged by an inert gas, see Gas Purging
Procedure [►17].
• Turn on the water 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 [►30].
• After a few minutes of operation, perform an Oil Level Inspection [►20].
• After a few minutes of operation, perform a Cooling Liquid Level Inspection [►21].
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.

Commissioning | 6
0870573767_NC0400B_O2_WCV_-0001_IM_en 17 / 36
6.1 Conveying Condensable Vapours
The machine, equipped either with a gas ballast valve or a dilution gas system, is suitable
for the conveyance of condensable vapours within the gas flow.
If condensable vapours are to be conveyed:
START
Open the gas ballast
valve* or the
dilution gas sytem*
(solenoid valve)
Warm up the
machine
30 minutes 30 minutes
• Open the inlet
valve
• Perform the process
• Close the inlet
valve
Close the gas ballast
valve*
or
the dilution gas
system*
END
* optional accessories
• Continuously drain condensate from the condensate drain plug (CD) of the silencer
(SI) (Optional).
6.2 Gas Purging Procedure
The machine can optionally be equipped with a purge gas system.
If after the application process a gas purge is required, i.e. after a liquid flushing se-
quence or to render the compression chamber inert:
START
Close the inlet valve Open the purge gas
(solenoid valve)
The flushing duration
depends on the application Close the purge gas
END
min. 200 seconds to render
the machine inert
6.3 Restart Procedure
If the temperature switch (TS) has tripped:
• Solve the problem of the excessive oil temperature, see Troubleshooting [►28].
• Let the machine cool down (approx. 1 hour).
• Press the reset button (RST) of the terminal box (PTB).
• The machine starts up immediately.

7 | Maintenance
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7 Maintenance
WARNING
Lack of oxygen regulation knowledge.
Risk of fire!
• Installation, commissioning and maintenance must only be carried out by qualified
personnel who are informed about the applicable safety regulations and trained in the
handling of oxygen.
• Accident prevention regulations or methods must imperatively be complied with.
Seek further information:
- European Industrial Gases Association “EIGA” www.eiga.eu (EIGA SAG NL 79/04).
- Berufsgenossenschaft Rohstoffe und chemische Industrie "BG RCI” www.bgrci.de
(Merkblatt M 034 Sauerstoff).
WARNING
Machine contaminated with organic material.
Risk of fire!
If there is a suspicion that the machine or the oil is contaminated with organic material:
• The machine must be removed from service and cleaned by specialists (contact your
Busch representative).
WARNING
Use of non-Busch genuine spare parts.
Risk of fire!
• Only use Busch spare parts approved by Busch and suitable for oxygen application.
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.

Maintenance | 7
0870573767_NC0400B_O2_WCV_-0001_IM_en 19 / 36
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.
• Turn off the water supply.
If the machine corresponds to ATEX Classification (see ATEX Classifications and Associ-
ated Accessories):
• Make sure that the machine has been purged by an inert gas, see Gas Purging
Procedure [►17].
• Vent the connected lines to atmospheric pressure.
If necessary:
• Disconnect all connections.

7 | Maintenance
20 / 36 0870573767_NC0400B_O2_WCV_-0001_IM_en
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 oper-
ation, such as high dust loads in the environment or in the process gas, other contamina-
tion or ingress of process material, can make it necessary to shorten the maintenance in-
tervals significantly.
Interval Maintenance work
Monthly • Check the oil level, see Oil Level Inspection [►20].
• Check the cooling liquid level, see Cooling Liquid
Level Inspection [►21].
• Check the machine for oil leaks - in case of leaks have
the machine repaired (contact Busch).
Yearly • Carry out a visual inspection and clean the machine
from dust and dirt.
• Check the electrical connections and the monitoring
devices.
Yearly
In case of those accessories
being installed.
• Check the filter of the gas ballast valve (GB) and
change it if necessary, see Replacing the Gas Ballast
Filter (Optional) [►21].
• Check the inlet filter cartridge, change it if necessary.
• Check the silence (SI) and clean it if necessary.
Every 5000 hours, at the latest
after 1 year
• Change the oil of the gear and bearing housings
(both sides), see Oil Change [►22].
• Change the cooling liquid, see Cooling Liquid
Change [►25].
• Clean the magnetic plugs (MP).
Every 16000 hours, at the
latest after 4 years
• 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
3 mm
MAX
MIN
3 mm
MAX
MIN
3 mm
MAX
MIN
3 mm
MAX
MIN
3 mm
MAX
MIN
3 mm
Oil sight glass on motor side
Oil sight glass on suction side
• Make sure that the oil level is between the middle of the oil sight glass and 3mm
above it.
• Fill up if necessary, see Oil Filling [►11].