BUSCH COBRA User manual

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Instruction Manual
COBRA
Dry Screw Vacuum Pumps
NS 0600 C
0870570426/A0006_en / Original instructions / Modifications reserved 16/06/2021

Table of Contents
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Table of Contents
1 Safety .......................................................................................................................................4
2 Product Description ..................................................................................................................5
2.1 Operating Principle .......................................................................................................... 6
2.2 Application....................................................................................................................... 6
2.3 Start Controls ................................................................................................................... 6
2.4 Standard Features ............................................................................................................ 7
2.4.1 Water Cooling.......................................................................................................7
2.4.2 Resistance Thermometer (TSA)..............................................................................7
2.4.3 Sealing Systems .....................................................................................................7
2.5 Optional Accessories ........................................................................................................ 7
2.5.1 Silencer.................................................................................................................. 7
2.5.2 Barrier Gas System................................................................................................. 7
3 Transport ..................................................................................................................................8
4 Storage .....................................................................................................................................9
5 Installation................................................................................................................................9
5.1 Installation Conditions...................................................................................................... 9
5.2 Connecting Lines / Pipes .................................................................................................. 9
5.2.1 Suction Connection ............................................................................................... 10
5.2.2 Discharge Connection ...........................................................................................10
5.2.3 Cooling Water Connection .................................................................................... 11
5.2.4 Barrier Gas System Connection (Optional)............................................................. 13
5.2.5 Dilution Gas System Connection (Optional)........................................................... 14
5.3 Filling Oil.......................................................................................................................... 15
5.4 Filling Cooling Liquid........................................................................................................ 17
5.5 Electrical Connection ........................................................................................................ 17
5.5.1 Wiring Diagram Three-Phase Motor (Pump Drive) ................................................ 19
5.5.2 Wiring Diagram Solenoid Valve (Optional) ............................................................ 20
5.6 Electrical Connection of the Monitoring Devices............................................................... 20
5.6.1 Wiring Diagram Resistance Thermometer.............................................................. 20
6 Commissioning.........................................................................................................................20
6.1 Conveying Condensable Vapours..................................................................................... 21
7 Maintenance.............................................................................................................................22
7.1 Maintenance Schedule ..................................................................................................... 23
7.2 Oil Level Inspection.......................................................................................................... 23
7.2.1 Oil Level, Machine Operating................................................................................ 23
7.3 Oil Colour Inspection ....................................................................................................... 24
7.4 Cooling Liquid Level Inspection ........................................................................................ 24
7.5 Oil Change....................................................................................................................... 25
7.6 Cooling Liquid Change..................................................................................................... 28
8 Overhaul...................................................................................................................................29
9 Decommissioning.....................................................................................................................29
9.1 Dismantling and Disposal ................................................................................................. 29
10 Spare Parts................................................................................................................................30
11 Troubleshooting .......................................................................................................................30
12 Technical Data..........................................................................................................................33
13 Cooling Liquid..........................................................................................................................33

Table of Contents
0870570426_NS0600C_A0006_IM_en 3
14 Oil ............................................................................................................................................34
15 EU Declaration of Conformity...................................................................................................35

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

Product Description | 2
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2 Product Description
EB IN
OUT
PMR CLP
CWI SI
OFPSV
CWO
ODP, MPNP
OUT
CLF EB OFP
ODP
PHE
CLD
OSG
CLV
OSG
MP
MTB
TSA MP
CWO CWI
Helium Version
PHE Plate heat exchanger CLD Cooling liquid drain plug
CLF Cooling liquid fill plug CLP Cooling liquid pump
CLV Cooling liquid vent plug EB Eye bolt
CWI Cooling water inlet CWO Cooling water outlet
IN Suction connection MP Magnetic plug
MTB Motor terminal box NP Nameplate
ODP Oil drain plug OFP Oil fill plug
OSG Oil sight glass OUT Discharge connection
PMR Plug for manual rotation of rotors SI Silencer
SV Safety valve TSA Resistance thermometer
(oil temperature)
NOTE
Technical term.
In this instruction manual, we consider that the term ‘machine’ refers to the ‘vacuum
pump’.

2 | Product Description
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NOTE
Illustrations
In this instruction manual the illustrations may differ from the machine appearance.
2.1 Operating Principle
The machine works on the one-stage, twin-screw pump principle.
Two screw rotors are rotating inside the cylinder. The pumped medium is trapped
between the cylinder and screw chambers, compressed, and transported to the gas out-
let. During the compression process, the two screw rotors do not come into contact with
each other nor with the cylinder. There is no need for a lubrication or an operating fluid
in the compression chamber.
2.2 Application
The machine is intended for the suction of air and other dry, non-aggressive, non-toxic
and non-explosive gases.
Conveying of other media leads to an increased thermal and/or mechanical load on the
machine and is permissible only after a consultation with Busch.
The machine is intended for the placement in a non-potentially explosive environment.
For suction of up to 100% of helium gas, a specific machine execution is available. This
Helium Version can be identified on the pump nameplate, code “L” at the digit 9: i.e. NS
0600 C TL3
The machine is capable of maintaining ultimate pressure, see Technical Data [►33].
The machine is suitable for continuous operation.
Permitted environmental conditions, see Technical Data [►33].
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.

Product Description | 2
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2.4 Standard Features
2.4.1 Water Cooling
The machine is cooled by a cooling liquid circuit in the cylinder cover and cylinder.
The cooling liquid pump (CLP) allows a recirculating flow in the cooling liquid chamber.
The cooling liquid is cooled by a plate heat exchanger (PHE) which must be connected to
the water main.
The water cooled motor is connected in series to the plate heat exchanger.
2.4.2 Resistance Thermometer (TSA)
The resistance thermometer monitors the A-side oil temperature of the machine. A
second resistance thermometer might be installed to monitor the exhaust gas tempera-
ture.
Warning and trip signals must be set, see Wiring Diagram Resistance Thermometer
[►20].
2.4.3 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.
Depending on the application, the sealing systems efficiency can be improved with a
barrier gas system, see Barrier Gas System [►7].
2.5 Optional Accessories
2.5.1 Silencer
A silencer at the discharge connection (OUT) can be provided to reduce the exhaust gas
noise.
2.5.2 Barrier Gas System
The barrier gas system allows the supply of compressed air or nitrogen into the motor
side shaft seals in order to improve the sealing efficiency.
This device is available either with or without nitrogen panel.

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

Storage | 4
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4 Storage
• Seal all apertures with adhesive tape or reuse provided caps.
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
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.
• Make sure that the environment of the machine is not potentially explosive.
• Make sure that the ambient conditions comply with the Technical Data [►33].
• 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 the oil sight glass (OSG) remains easily visible.
• Make sure that enough space remains for maintenance work.
• Make sure that the machine is placed or mounted horizontally, a maximum of 1° in
any direction is acceptable.
• Check the oil level, see Oil Level Inspection [►23].
• Check the cooling liquid level, see Cooling Liquid Level Inspection [►24].
• Make sure that the cooling water complies with the requirements, see Cooling Water
Connection [►11].
5.2 Connecting Lines / Pipes
• Remove all protective covers before installation.
• Make sure that the connection lines cause no stress on the machine‘s connection; if
necessary use flexible joints.
• Make sure that the line size of the connection lines over the entire length is at least as
large as the connections of the machine.
In case of long connection lines it is advisable to use larger line sizes in order to avoid a
loss of efficiency. Seek advice from your Busch representative.

5 | Installation
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5.2.1 Suction Connection
WARNING
Unprotected suction connection.
Risk of severe injury!
• Do not put hand or fingers in the suction connection.
NOTICE
Ingress of foreign objects or liquids.
Risk of damage to the machine!
If the inlet gas contains dust or other foreign solid particles:
• Install a suitable filter (5micron or less) upstream from the machine.
Connection size(s):
– DN100 ISO-K, DIN 28404 or DN100 ISO-F, DIN 28404
If the machine is used as part of a vacuum system:
• Busch recommends the installation of an isolation valve in order to prevent the
machine from turning backwards.
5.2.2 Discharge Connection
Connection size(s):
At the machine discharge connection:
– DN100 ISO-K, DIN 28404 or DN100 ISO-F, DIN 28404
At the silencer (SI) discharge connection:
– DN63 ISO-K
• 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 [►33].

Installation | 5
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5.2.3 Cooling Water Connection
Standard version
CWI CWO
PHE
CWI Cooling water inlet CWO Cooling water outlet
PHE Plate heat exchanger
Helium version
PHE
CWO CWI
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 8
Water pressure bar 1.5 ... 5
Supply temperature °C
°F
+5 ... +30
+41 ... +86
Required pressure differential across supply
and return
bar ≥ 1.5

5 | Installation
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• 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 ... 9
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, copper
NOTE
Water hardness unit conversion.
1 mg/l (ppm) = 0.056 °dh (german degree) = 0.07 °e (english degree) = 0.1 °fH (french
degree)

Installation | 5
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5.2.4 Barrier Gas System Connection (Optional)
Without nitrogen panel
PRV FR
BGC
MAN
FME
BGC Barrier gas connection FME Flow meter
FR Flow regulator MAN Manometer
PRV Pressure regulating valve
With nitrogen panel
PRV MV
BGC MAN
FME, FS NIP
BGC Barrier gas connection FME Flow meter
FS Flow switch MAN Manometer
MV Solenoid valve NIP Nitrogen panel
PRV Pressure regulating valve
• Connect the barrier gas connection (BGC) to the gas supply.
Connection size:
– G1/4, ISO 228-1

5 | Installation
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Version with nitrogen panel:
• Electrically connect the solenoid valve (MV), see Wiring Diagram Solenoid Valve
[►20].
• Electrically connect the flow switch (FS) of the flow meter, see Wiring Diagram
Flow Switch.
• Make sure that the gas complies with the following requirements:
Gas type Dry nitrogen or air
Gas temperature °C 0 ... 60
Maximum gas pressure bar 13
Recommended pressure setting at the
pressure regulating valve (PRV)
bar 3
Filtration µm 5
Recommended flow rate SLM* 3,5 ... 5,5
Air quality (only for air) Acc. to ISO
8573-1
Class 5.4.4.
* standard litre per minute
5.2.5 Dilution Gas System Connection (Optional)
PRV MVDGC MAN FME, FR NIP
DGC Dilution gas connection FME Flow meter
FR Flow regulator MAN Manometer
MV Solenoid valve NIP Nitrogen panel
PRV Pressure regulating valve
• Connect the dilution gas connection (DGC) to the gas supply.
Connection size:
– G1/4, ISO 228-1
• Electrically connect the solenoid valve (MV), see Wiring Diagram Solenoid Valve
[►20].

Installation | 5
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• Make sure that the gas complies with the following requirements:
Gas type Dry nitrogen
Gas temperature °C 0 ... 60
Maximum gas pressure bar 13
Recommended pressure setting at the
pressure regulating valve (PRV)
bar 2.5
Filtration µm 5
Recommended flow rate SLM* 30
* standard litre per minute
5.3 Filling Oil
NOTICE
Use of an inappropriate oil.
Risk of premature failure!
Loss of efficiency!
• Only use an oil type specified on the pump nameplate.
For oil type and oil capacity see Technical Data [►33] and Oil [►34].
1
2
Busch Oil
3
MAX
MIN
4
Check oil level
Oil filling at the motor side

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

Installation | 5
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5.4 Filling Cooling Liquid
For cooling liquid type and cooling liquid capacity see Technical Data [►33] and
Cooling Liquid [►33].
4
1
2
Cooling
liquid
Zitrec M-25
3
Fill up to the top of the vent orifice

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.
• Make sure that the power supply for the motor is compatible with the data on the
nameplate of the motor.
• The electrical installation must comply with applicable national and international
standards.
• Provide a lockable disconnect switch on the power line so that the machine is com-
pletely secured during maintenance tasks.
• Provide an overload protection according to EN 60204-1 for the motor.
• Make sure that the motor of the machine will not be affected by electric or electro-
magnetic disturbance from the mains; if necessary seek advice from Busch.
• Connect the protective earth conductor.
• Electrically connect the motor.
WARNING
The operating rotational speed of the drive motor must correspond to the pump’s name-
plate value. Do not exceed the mentioned rotational speed.
nmax = 3000 min-1 ► 50Hz +/- 2%
nmax = 3600 min-1 ► 60Hz +/- 2%
Risk of damage to the machine!
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).
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 connection instructions/diagrams.

Installation | 5
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5.5.1 Wiring Diagram Three-Phase Motor (Pump Drive)
Motor connectors: Connection of motor temperature
switches (recommended):
T9
T8
T6
T7
T5
T3
T1
T2
T4
P1
P2
P3
P4
P1 P2
MTS1 MTS2 MTS3
Control voltage: ≤ 250 V
Max current: 1.6 A
MTS = Motor temperature switch (in mo-
tor coil)
Double star connection (low voltage):
T1
T6T3
T5T8
T4
T2
T7
T9
Star connection (high voltage):
T1
T6T3
T5T8
T4
T2
T7
T9
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.
The intended rotation direction of the motor is defined by the illustration below:
IN
• Jog the motor briefly.
• With a phase rotation tester, check if the wiring corresponds to the correct direction of
rotation.
If the rotation of the motor must be changed:
• Switch any two of the motor phase wires.

6 | Commissioning
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5.5.2 Wiring Diagram Solenoid Valve (Optional)
Part no.: 0654 000 092
U = 24 VDC ; Pmax = 8 W
Contact: Normally closed
2 (-)
1 (+)
PE
5.6 Electrical Connection of the Monitoring Devices
NOTE
In order to prevent potential nuisance alarms, Busch recommends that the control system
is configured with a time delay of at least 20 seconds.
5.6.1 Wiring Diagram Resistance Thermometer
Part no.:
PT100 : 0651 543954
Supplier reference:
PT100: Albert Balzer AG
ref. : TFE/ BDAE
P&ID position:
TSA
Wiring without transmitter:
1
2
3
4
1 and 2 = Red ; 3 and 4 = White
Electrical data (PT100):
Ui=30VDC; Ii=100mA; Pi=0.1 … 0.75 W
Warning signal: a warning signal can be
set prior the trip signal.
Trip signal:
Ttrip (TSA+/0104) = 80°C (A side)
6 Commissioning
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.
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 [►17].