BUSCH COBRA ATEX NC 0100-0300 B Instruction Manual Download Page 1

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Instruction Manual

COBRA ATEX

Dry Screw Vacuum Pumps
NC 0100-0300 B (water-cooled version)

0870203597/-0001_en / Original instructions / Modifications reserved

11/12/2019

Ateliers Busch S.A.
Zone industrielle, 2906 Chevenez
Switzerland

Summary of Contents for COBRA ATEX NC 0100-0300 B

Page 1: ...Manual COBRA ATEX Dry Screw Vacuum Pumps NC 0100 0300 B water cooled version 0870203597 0001_en Original instructions Modifications reserved 11 12 2019 Ateliers Busch S A Zone industrielle 2906 Chevenez Switzerland ...

Page 2: ...tation Diagram 13 3 Transport 16 4 Storage 16 5 Installation 17 5 1 Installation Conditions 17 5 2 Connecting Lines Pipes 18 5 2 1 Suction Connection 18 5 2 2 Discharge Connection 19 5 2 3 Cooling Water Connection 19 5 2 4 Barrier Gas System Connection 21 5 2 5 Dilution Gas System Connection Optional 22 5 2 6 Purge Gas System Connection 24 5 2 7 Flame Arrester Bypass Connection Optional 25 5 3 Ear...

Page 3: ...ng Procedure 41 6 5 Trip Procedure 42 7 Maintenance 42 7 1 Maintenance Schedule 43 7 2 Oil Level Inspection 43 7 3 Cooling Liquid Level Inspection 44 7 4 Oil Change 45 7 5 Cooling Liquid Change 48 7 6 Calibration Procedure of the Electrical Devices 49 7 6 1 Procedure A 49 7 6 2 Procedure B 49 7 6 3 Procedure C 49 7 6 4 Procedure D 49 7 6 5 Procedure E 49 7 6 6 Procedure F 49 7 6 7 Procedure G 50 7...

Page 4: ...as been designed and manufactured according to state of the art methods Nevertheless residual risks may remain This instruction manual highlights po tential hazards where appropriate Safety notes and warning messages are tagged with one of the keywords DANGER WARNING CAUTION NOTICE and NOTE as follows DANGER indicates an imminent dangerous situation that will result in death or serious injuries if...

Page 5: ... drain valve CLF Cooling liquid fill plug CLP Cooling liquid pump CWD Cooling water drain plug CWI Cooling water inlet CWO Cooling water outlet CWP Cooling water pump EB Eye bolt EV Expansion vessel FA Flame arrester FME Flow meter FS Flow switch GC Gas connection IN Suction connection MAN Manometer MP Magnetic plug MTB Motor terminal box MV Solenoid valve NIF Nitrogen inlet filter NP Nameplate OD...

Page 6: ...ng liquid fill plug CLP Cooling liquid pump CWD Cooling water drain plug CWI Cooling water inlet CWO Cooling water outlet CWP Cooling water pump EB Eye bolt EV Expansion vessel FME Flow meter FS Flow switch GC Gas connection IN Suction connection MAN Manometer MP Magnetic plug MTB Motor terminal box MV Solenoid valve NIF Nitrogen inlet filter NP Nameplate ODP Oil drain plug OFP Oil fill plug OSG O...

Page 7: ...silencer and gas ballast valve Options NP1 CD Condensate drain CLD Cooling liquid drain valve CLF Cooling liquid fill plug CLP Cooling liquid pump CWD Cooling water drain plug CWI Cooling water inlet CWO Cooling water outlet CWP Cooling water pump EB Eye bolt EV Expansion vessel IN Suction connection MP Magnetic plug MTB Motor terminal box NP Nameplate ODP Oil drain plug OFP Oil fill plug OSG Oil ...

Page 8: ... 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 and non toxic gases Explosive gases and vapour mixtures can be drawn according to the scope of the Direct ive ATEX 2014 34 EU It is necessary to check and ensure that the process media is compatible with the pump materials and that the...

Page 9: ...rter unit or a variable frequency drive 2 4 Standard Features 2 4 1 Thermometer The thermometer allows a visual display of the cooling water temperature in the cooling water chamber 2 4 2 Sealing Systems The machine is equipped with labyrinth seals on the motor side and suction side Other sealing systems are optionally available see Mechanical Seals 10 or PTFE Shaft Seals 11 Sealing systems preven...

Page 10: ...vided to reduce the exhaust gas noise A non return flap can be optionally added to the silencer 2 5 3 Resistance Thermometer The resistance thermometer monitors gas temperature It can be installed at three differ ent places depending on the ATEX classification Warning and trip signals must be set see Wiring Diagram Resistance Thermometer 33 2 5 4 Pressure Transmitter The pressure transmitter monit...

Page 11: ... 6 Explanation of ATEX Classification The ATEX classification is written on the nameplate of the machine NP see below a marking example Inside i Outside o II 2G Ex h IIB T3 Gb X II 2G Ex h IIB T3 Gb X Explosion group inside the machine Equipment category for explosive gases inside the machine Equipment category for gas and dust outside the machine Equipment group II not for mining application Expl...

Page 12: ...X X X X X X X A B C D TSA 0103 ATEX MOT IIB i II 1G c IIB3 T4 T3 o II 2G c IIC T4 T3 X X X SA 0701 X X X X X MV MV2 MV3 MV2 MV3 MV2 MV2 FS 0501 FS 0501 X X PS 0301 X X X E F i II 2G Ex h IIB T4 T3 Gb o No ATEX zone i II 3G Ex h IIC T4 T3 Gc o II 3G Ex h IIB T4 T3 Gc X X X i II 2G Ex h IIB T4 T3 Gb o II 2G Ex h IIB T4 T3 Gb i II 2G Ex h IIB T4 T3 Gb o II 2G Ex h IIC T4 T3 Gb X X G i II 3G Ex h IIC ...

Page 13: ...6 NC0100B DN50 PN16 NC0200 0300B MV5 GC G1 4 For dilution gas system only or optional Barrier gas system Purge gas system Dilution gas system Flushing liquid device variant With gas lubricated double mechanical seals P ID for classification A and B Flame arrester bypass see ATEX classification chapter 2 7 1 For dilution gas system only CPL Coupling CWI Cooling water inlet CWO Cooling water outlet ...

Page 14: ...ation C D and E optional Barrier gas system Purge gas system Dilution gas system Flushing liquid device variant With plate heat exchanger With direct cooling Air see ATEX classification chapter 2 7 1 With gas lubricated double mechanical seals For dilution gas system only With gas lubricated double mechanical seals CLP Cooling liquid pump CPL Coupling CWI Cooling water inlet CWO Cooling water outl...

Page 15: ... or P ID for classification F G and H optional Barrier gas system Purge gas system Dilution gas system Flushing liquid device variant With plate heat exchanger With direct cooling With gas lubricated double mechanical seals Air see ATEX classification chapter 2 7 1 For dilution gas system only CLP Cooling liquid pump CPL Coupling CWI Cooling water inlet CWO Cooling water outlet CWP Cooling water p...

Page 16: ... in gress into the cylinder Drain the oil prior to every transport or always horizontally transport the machine Make sure that the eyebolt EB is 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 4 Storage Seal ...

Page 17: ...tor 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 see Oil Level Inspection 43 If the machine...

Page 18: ...sions 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 m...

Page 19: ...N 1092 1 for NC 0200 B and NC 0300 B At the silencer SI discharge connection Optional DN40 PN16 EN 1092 1 for NC 0100 B DN50 PN16 EN 1092 1 for NC 0200 B and NC 0300 B 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 ...

Page 20: ...oling water system Make sure that the cooling water complies with the following requirements Supply capacity l min 2 4 Water pressure bar 3 6 direct cooling 1 6 plate heat exchanger Supply temperature C 10 25 Required pressure differential across supply and return bar 3 direct cooling 0 5 plate heat exchanger To reduce the maintenance effort and ensure a long product lifetime we recommend the foll...

Page 21: ...g Diagram Solenoid Valve 32 Electrically connect the flow switch FS of the flow meter see Wiring Diagram Flow Switch 35 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 for labyrinth seals oil lu...

Page 22: ... NIP Nitrogen panel PRV Pressure regulating valve PRV DGC MAN FME FR NIP FS 0504 optional MV2 optional MV5 MV5 DGC Variante NIF optional DGC Dilution gas connection FME Flow meter FR Flow regulator FS Flow switch MAN Manometer MV Solenoid valve NIF Nitrogen inlet filter NIP Nitrogen panel PRV Pressure regulating valve Connect the dilution gas connection DGC to the gas supply Connection size G1 4 I...

Page 23: ... of the flow meter see Wiring Diagram Flow Switch 35 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 0 5 Filtration µm 5 Recommended flow rate SLM 20 standard litre per minute ...

Page 24: ...el PRV Pressure regulating valve Connect the purge gas connection to the gas supply Connection size G1 4 ISO 228 1 If a flow switch is installed Electrically connect the flow switch FS of the flow meter see Wiring Diagram Flow Switch 35 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 setti...

Page 25: ...0 DN80 DN50 GS 0601 GS 0602 DN40 NC0100B DN50 NC0200 0300B MV6 OUT P1 IV P2 COBRA PMC included in the delivery scope not included in the delivery scope P1 and P2 100 hPa bypass open P1 P2 pressure double check bypass closed bypass open FA Flame arrester GS Limit switch IN Suction connection IV Isolation valve MV Solenoid valve OUT Discharge connection PMC Pneumatic connection Electrically connect ...

Page 26: ...e machine from creating an electrostatic charge Connect the earth connection of the machine ECP Earth connection of the machine ECP 5 4 Filling Oil NOTICE Use of an inappropriate oil Risk of premature failure Loss of efficiency Only use an oil type which has previously been approved and recommended by Busch ...

Page 27: ...CV_Ex_ 0001_IM_en 27 60 For oil type and oil capacity see Technical Data 55 and Oil 55 1 2 B u s c h O il 3 MAX MIN 4 Check oil level Oil filling at the motor side 1 2 B u s c h O il 3 MAX MIN 4 Check oil level Oil filling at the suction side ...

Page 28: ... sticker part no 0565 568 959 on the machine Order it from your Busch representative 5 5 Filling Cooling Liquid This step has to be carried out only if the machine is equipped with a plate heat ex changer For cooling liquid type and cooling liquid capacity see Technical Data 55 and Cooling Liquid 55 1 2 C o o l i n g l i q u i d Z i t r e c M 2 5 3 MAX MIN 4 Check cooling liquid level NC 0100 B NC...

Page 29: ... Level indicator LS Level switch MV Solenoid valve Electrically connect the two level switches LS see Wiring Diagram Level Switch 36 Fill the flushing liquid vessel FLV with a process compatible flushing liquid 5 7 Fitting the Coupling E Coupling hub machine side Coupling hub motor side Coupling spider Radial screw Max admissible torque 10 Nm Machine type Coupling size Value E mm NC 0100 B ROTEX 3...

Page 30: ... 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 advi...

Page 31: ... 8 1 Wiring Diagram Three Phase Motor Pump Drive Delta connection low voltage Star connection high voltage Double star connection multi voltage motor with 9 pins low voltage Star connection multi voltage motor with 9 pins high voltage Double star connection multi voltage motor with 12 pins low voltage 4 4 4 Star connection multi voltage motor with 12 pins high voltage 4 4 4 Delta connection multi ...

Page 32: ...FFKM Ex db mb IIC T4 Ui 24 VDC Procedure G 50 0654 538 544 Parker Lucifer 495910 N7 MV2 MV3 MV5 DN 1 5 with seal in PUR Ex ia IIC T4 Ui 24 VDC Procedure G 50 0654 532 461 Bürkert Type 262 pneumatic Type 6014 C electric MV2 MV3 MV5 MV7 DN 12 with seal in PTFE pneumatic 3 6 bar Ex ia IIC T5 Ui 24 VDC Procedure G 50 or Pro cedure H 50 0654 547 028 Parker Lucifer 495905 F4 MV2 MV3 MV5 DN 3 with seal i...

Page 33: ...art no PT100 Stainless steel 0651 537 910 PT100 Hasteloy 0651 538 233 Transmitter 0643 536 800 optional Supplier reference PT100 Albert Balzer AG ref Stainless steel TFE BDAE ref Hasteloy TFE BVAE Transmitter Endress Hauser ref TMT 187 B41FJA Maintenance procedure Procedure A 49 P ID position TSA 0101 flame arrester temp TSA 0102 internal gas temp TSA 0103 exhaust gas temp Wiring with transmitter ...

Page 34: ...ure B 49 P ID position PS 0301 Electrical data Ui 49 VDC Ii 3 A Li 0 µH Ci 0 pF Contact Normally closed 2 1 P Switch point P PS 0301 1300 hPa mbar abs factory default adjustment 5 9 3 Wiring Diagram Pressure Transmitter Part no 0653 537 031 or 0653 541 862 Hastelloy or 0653 206 492 or 0653 212 111 Hastelloy Supplier reference ACS Precont Ex S10 Maintenance procedure Procedure C 49 Connector M12x1 ...

Page 35: ...ed into the flow meter Supplier reference Pepperl Fuchs RC15 14 N3 Maintenance procedure Procedure E 49 P ID position FS 0501 barrier gas flow FS 0503 purge gas flow FS 0504 dilution gas flow 2 1 1 Brown 2 Blue Electrical data Ui 16 VDC Ii 1 3 mA Switching element function NAMUR bistable COBRA type Switch point Barrier gas flow FS 0501 Barrier gas flow FS 0501 Purge gas flow FS 0503 Dilution gas f...

Page 36: ...ng 5 9 7 Wiring Diagram Pressure Switch With Gas Lubricated Double Mechanical Seals Only Part no 0653 518 304 Supplier reference Trafag AG PST4B 9B4 0 6 bar Maintenance procedure Procedure B 49 P ID position PS 0302 Electrical data U 30 V I 0 1 A Contact Normally open 2 3 P PE 1 3 2 1 Switch point Ptrip PS 0302 2 5 bar relative min admissible pressure 5 10 Electrical Connection of the Flame Arrest...

Page 37: ... 0001_IM_en 37 60 5 10 2 Wiring Diagram Solenoid Valve Part no No Busch ref integrated into the pneumatic actuator Supplier reference Parker Lucifer 483580 01 N7 electric Parker Lucifer 341 N 3190 pneumatic Electrical data U 28 VDC I 110 mA 2 1 PE ...

Page 38: ...ning YES T T trip NO TSA 0103 Gas temperature NO YES NO YES Vibration Barrier gas flow Vibration level below the limit value Barrier gas flow sufficient optional if 3G i optional if 3G i optional if 1G i 3G i optional if 2G i 3G i Additional sequences may be added if optional monitoring accessories have been installed SA 0701 FS 0501 NO YES NO TSA 0101 Gas temperature optional if 2G i 3G i T T war...

Page 39: ... 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 26 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 re...

Page 40: ...a Cooling Liquid Level Inspection 44 After a few minutes of operation perform an Oil Level Inspection 43 As soon as the machine is operated under normal operating conditions Measure the motor current and record it as reference for future maintenance and troubleshooting work 6 1 Adjustment of the Thermostatic Valve Direct Cooling Only The adjustment of the thermostatic valve TV influences the tempe...

Page 41: ... Procedure If after the application process a liquid flushing is required START Reduce the motor speed to 10 Hz with the inlet valve closed Open the liquid flushing device solenoid valve The flushing duration depends on the application Adapt the flushing liquid flow acc to the application requirements Close the liquid flushing device END minimum admissible frequency NOTE With gas lubricated double...

Page 42: ...ne is contaminated with hazardous material Wear appropriate personal protective equipment CAUTION Hot surface Risk of burns Prior to any action requiring touching the machine let the machine cool down first NOTICE Using inappropriate cleaners Risk of removing safety stickers and protective paint Do not use incompatible solvents to clean the machine CAUTION Failing to properly maintain the machine ...

Page 43: ...el Inspection 44 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 clean it if necessary Check the silence SI and clean it if ...

Page 44: ...arried out only if the machine is equipped with a plate heat ex changer Shut down the machine For NC 0100 B Let the machine cool down Remove the cooling liquid fill plug CLF Check cooling liquid level MAX MIN MAX MIN MAX MIN For NC 0200 0300 B Check cooling liquid level Fill up if necessary see Filling Cooling Liquid 28 ...

Page 45: ... 45 60 7 4 Oil Change NOTICE Use of an inappropriate oil Risk of premature failure Loss of efficiency Only use an oil type which has previously been approved and recommended by Busch 1 2 3 Oil draining at the motor side Cleaning cloth Drain pan Magnetic plug ...

Page 46: ...300B_WCV_Ex_ 0001_IM_en 1 2 3 Oil draining at the suction side Cleaning cloth Drain pan Magnetic plug For oil type and oil capacity see Technical Data 55 and Oil 55 1 2 B u s c h O il 3 MAX MIN 4 Check oil level Oil filling at the motor side ...

Page 47: ... 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 ...

Page 48: ...he machine is equipped with a plate heat ex changer 1 2 3 4 NC 0100 B NC 0200 B NC 0300 B For cooling liquid type and cooling liquid capacity see Technical Data 55 and Cooling Liquid 55 1 2 C o o l i n g l i q u i d Z i t r e c M 2 5 3 MAX MIN 4 Check cooling liquid level NC 0100 B NC 0200 B NC 0300 B NC 0200 B NC 0300 B NC 0100 B ...

Page 49: ...ated pressure transmitter or send it to an approved laboratory for inspection Reassemble the pressure transmitter on the machine 7 6 4 Procedure D Remove the vibration sensor from the machine Control it with a calibration system or send it to Monitran Ltd 33 Hazlemere Road Penn HP10 8AD UK info monitran com Use an Analog Current Loop Simulator and Tester 4 20mA to test the remaining control loop C...

Page 50: ...nstruction manual attached to the ATEX Accessories Book for detailed information in order to carry out a correct maintenance Machine type Flame arrester Suction connection IN Flame arrester Discharge connection OUT Supplier size Reference Supplier Reference NC 0100 B Cashco DN50 3 x 0 3 IIB3 Cashco DN50 3 x 0 3 IIB3 Cashco DN80 4 x 0 5 IIB3 BS B DN50 930 S50 1 3 x 0 3 e vp BS B DN50 930 S50 1 3 x ...

Page 51: ...at is described in this manual should be done through Busch WARNING Machines contaminated with hazardous material Risk of poisoning Risk of infection If the machine is contaminated with hazardous material Wear appropriate personal protective equipment 9 Decommissioning Shut down the machine and lock against inadvertent start up Turn off the water supply If the machine corresponds to ATEX Classific...

Page 52: ...gulations Dispose of the machine as scrap metal 10 Spare Parts NOTICE Use of non Busch genuine spare parts Risk of premature failure Loss of efficiency and ATEX compliance The exclusive use of Busch genuine spare parts and consumables is recommended for the correct functioning of the machine and to validate the warranty There is no standard spare parts kits available for this product if you requir...

Page 53: ...or repair the ma chine contact Busch Install an inlet filter if ne cessary A temperature sensor has reached the switch point Let the machine cool down See problem The ma chine runs too hot Corrosion in the machine from remaining condensate Repair the machine Check the process and follow the recommenda tion in case of Conveying Condensable Vapours 41 The motor is defective Replace the motor The mac...

Page 54: ...oling Water Connection 19 Ambient temperature too high Observe the permitted ambient temperature see Technical Data 55 Temperature of the process gases at the inlet too high Observe the permitted gas inlet temperature see Technical Data 55 The cooling water pump is defective Repair the machine Oil level too low Top up oil The oil is black Oil change intervals are too long Drain the oil and fill in...

Page 55: ...nge C 20 40 Max allowable counter pressure at the dis charge hPa mbar 300 Max allowable gas inlet temperature C 60 Relative humidity at 30 C 90 Ambient pressure Atmospheric pressure Cooling water requirements See Cooling Water Connection 19 Oil capacity motor side l 1 1 Oil capacity suction side l 0 45 Cooling liquid capacity approx with plate heat exchanger only l 4 5 5 6 5 Weight approx kg 300 3...

Page 56: ...d vacuum pumps Engineering method grade 2 EN 60204 1 2006 A1 2009 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 61000 6 2 2005 Electromagnetic compatibility EMC Generic standards Immunity for industrial environments EN 61000 6 4 2007 A1 2011 Electromagnetic compatibility EMC Generic standards Emission standard for industrial environments EN ISO 13849 1 2015 1 ...

Page 57: ...8 Acoustics Noise test code for compressors and vacuum pumps Engineering method grade 2 EN 60204 1 2006 A1 2009 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 61000 6 2 2005 Electromagnetic compatibility EMC Generic standards Immunity for industrial environments EN 61000 6 4 2007 A1 2011 Electromagnetic compatibility EMC Generic standards Emission standard for ...

Page 58: ...Note ...

Page 59: ...Note ...

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