BUSCH COBRA DS 3161 C Instruction Manual
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BUSCH COBRA DS 3161 C Instruction Manual

Dry screw vacuum pumps
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COBRA
Dry Screw Vacuum Pumps
DS 3161 C
Instruction Manual
0870739180 | B0004_en-US | Original instructions
10/10/2023

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Summary of Contents for BUSCH COBRA DS 3161 C

  • Page 1 COBRA Dry Screw Vacuum Pumps DS 3161 C Instruction Manual 0870739180 | B0004_en-US | Original instructions 10/10/2023...

  • Page 2: Table Of Contents

    Table of Contents​ Table of Contents Preface ................................... Congratulations on your purchase ........................Product Description ............................. COBRA DS 3161 C ..............................Use ..................................Operating Principle ............................. 2.3.1 COMBI ..............................2.3.2 Gas Flow Checks ........................... Oil Circuit................................Cooling.................................. Nitrogen System..............................Optional Functions/ Use of Available Accessories ..................
  • Page 3 Table of Contents 6.1.7 Electrical Connection/ Checks ......................Installation ................................6.2.1 Mounting ............................... 6.2.2 Electrical Connection..........................6.2.3 Equipment Connections (with Options)..................... 6.2.4 Connection of Lines/ Pipes ........................6.2.5 Oil Filling ..............................6.2.6 Cooling Liquid Filling..........................6.2.7 Direct Cooling Checking ........................6.2.8 Nitrogen Supply Checking........................

  • Page 4: Preface

    1 | Preface​ Preface Congratulations on your purchase 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 pres- sure solutions worldwide. These operating instructions contain information for ●...

  • Page 5: Product Description

    Product Description​ | 2 Product Description COBRA DS 3161 C OSG 3 OSG 2 OSG 1 Description Suction connection Discharge connection Cooling water connections Nitrogen connections Backing vacuum pump DP 0600 C Lifting eyebolt Emergency stop button Electrical connections Extracting ventilator...
  • Page 6 2 | Product Description​ COBRA DP 0600 C TS 5 OSG 1 TS 1 FS 1 TS 3 TS 4 OSG 2 DGR 1 DGR 2 FS 2 TS 2 Description Glycol circulating pump Cooling water inlet connection Cooling water outlet connection Regulating valve, cooling water Nitrogen connection DGR 1...
  • Page 7 Product Description​ | 2 Process Gas Diagram Description Process gas inlet Process gas outlet Cooling water regulating valve (CWR1) Cooling liquid pump (CLP) Heat exchanger (HE) Nitrogen flow meter, dilution gas (FME) Nitrogen pressure reducer (PRV) Magnetic valve (MV), regulating valve with soleneoid valve, dilution gas Regulating valve, dilution gas DP Regulating valve, dilution gas at ex-...
  • Page 8 2 | Product Description​ COBRA NS 0600 C Description Inlet Outlet Cooling liquid Cooling water Barrier gas Screw rotors Dilution gas (dil 2) Dilution gas (dil 1) Motor klixon PUMA WY 3600 A Description Inlet Outlet Booster lobe Cooling water 8 | 68 Instruction Manual COBRA DS 3161 C_EN_en...

  • Page 9: Use

    2.3.1 COMBI The COBRA DS 3161 C vacuum pumps are a combination of a screw vacuum pump NS 0600 C (DP) and a Booster vacuum pump WY 3600 A (MB). The COMBI vacuum pumps are streamlined. The COBRA DS vacuum pumps are COBRA NS screw vacuum pumps with cooling water and nitrogen circuits.

  • Page 10: Gas Flow Checks

    2 | Product Description​ The drive motor of Booster vacuum pump is a water-cooled canned motor. The WY 3600 A rotary lobes vacuum pumps are equipped with an automatic by-pass valve that limits the differential pressure between inlet and outlet. 2.3.2 Gas Flow Checks A pressure sensor TS1 at the discharge monitors the discharge pressure.

  • Page 11: Optional Functions/ Use Of Available Accessories

    ● FME: nitrogen flow rate, dilution ● CWM: cooling water flow rate in motors/ transmission / variable speed drives See "Installation and Maintenance Instructions, Busch PLC and Busch LCD (No. 0870758077)". On/ Off Switch The vacuum pump is delivered with a circuit breaker. The function start/ stop can be done in Local by using the LCD controller or in Remote by the production machine.

  • Page 12: Safety

    The maintenance instructions must be followed and observed. These installation and maintenance instructions must be read and understood before the vacuum pump is used. If you have any doubts, contact your Busch representative. Safety Information The vacuum pump is designed and manufactured in compliance with the latest technical standards and safety regulations.

  • Page 13: Safety Stickers

    Safety​ | 3 NOTE ... indicates helpful tips and recommendations, as well as information for efficient and trou- ble-free operation. CAUTION The COBRA DS system includes provision for the secondary containment of liquids leaks such as water and oil. Safety Stickers COBRA NS 0600 C Description Warning! Hot surface! Do not touch!

  • Page 14: Noise Emission

    3 | Safety​ COBRA DS 3161 C Noise Emission Refer to the table “Technical data” for the permissible noise levelling free field conditions according to EN ISO 2151. CAUTION The sound level of the vacuum pump within a certain perimeter of the vacuum pump is high.

  • Page 15: Lock Out/ Tag Out Procedure (Type 1 Of Electrical Work)

    Safety​ | 3 Type 3 Equipment is energized. Energized circuits are exposed and inadvertent contact with uninsulated energized parts is possible. Potential exposures are no greater than 30 volts rms, 42.4 volts peak, 60 volts dc or 240 volt-amp in dry locations. Type 4 Equipment is energized.

  • Page 16: Seismic Zone Installation

    3 | Safety​ Seismic Zone Installation Upon receipt, the vacuum pump is fixed on the transport pallet with two brackets. ● Convey the vacuum pump to its final location with a pallet truck before removing it from its sup- port. ●...

  • Page 17: Information Over The Lubricants

    NS 0600 C WY 3600 A Oil quantity (Liter) Oil type Busch YLC 250 B, Art. No. 0831 131 400 (0,5 l ≈ 1 kg) ● Replacement: After 5000 h (see “Maintenance Schedule [➔ 47]”). 3.8.2 Cooling Liquid Cooling liquid filling...

  • Page 18: Decommissioning Procedure

    3 | Safety​ Decommissioning Procedure When the product arrives at the end of the lifetime, it is necessary to proceed to the decontamina- tion of the vacuum pump. CAUTION Only authorized personnel may carry out any dismantling on the vacuum pump. Before work begins, the operator of the vacuum pump must fill in a form or a “Declaration Regarding Con- tamination of Vacuum Equipment and Components”...

  • Page 19: Transport

    Transport​ | 4 Transport The COBRA DS vacuum pumps are tested and checked in our factory before careful packing. Check the packaging for transport damage when the goods arrive. The vacuum pump can withstand tem- peratures between -25°C and +55°C during transport. Transport in Packed State Packed on a pallet, the vacuum pump can be moved with a hand forklift truck.
  • Page 20 4 | Transport​ In case the vacuum pump was bolted to a pallet with fixing bolts: ● Unscrew the fixing bolts in the base frame. CAUTION In case of a vacuum pump filled with oil, make sure that by lifting the inclination angle of the vacuum pump do not exceed 5°...

  • Page 21: Storage

    Storage​ | 5 Storage Temporary Storage ● Make sure that the intake and exhaust flanges are closed (put on the protective caps included in the delivery package of the vacuum pump) ● Store the vacuum pump: ● if possible, the vacuum pump should be stored in its original packaging, ●...

  • Page 22: Installation And Commissioning

    6 | Installation and Commissioning​ Installation and Commissioning Installation Prerequisites CAUTION In case of non-compliance with the installation prerequisites, particularly in case of insuffi- cient cooling: Risk of damage or destruction of the vacuum pump and its components! Risk of personal injury! The installation prerequisites must be complied with.
  • Page 23 Installation and Commissioning​ | 6 NOTE 1° (german degree = 1° dGH) = 1,78° (french degree) = 1,25 e (english degree) = 17,9 mg/kg Ca- CO3 (american hardness). ● Make sure that the cooling water is neutral and clean. ● Make sure that the cooling water outlet is unpressurised. ●...

  • Page 24: Dimensional Drawing

    Cooling water outlet 3/8'' Inlet DN 160 ISO-K Outlet DN 63 ISO-KF Emergency stop Busch PLC Remote Control (Moveable) Main switch ● Make sure that the vacuum pump is at least 1 meter away from any wall to ensure good cooling.

  • Page 25: Discharge Connection

    – DN 160 ISO-K In the case of long intake lines, the line cross-section should be larger than the intake flange to pre- vent a drop in the performance of the vacuum pump. If you have any doubts, contact your Busch representative.

  • Page 26: Cooling Water Connection

    ● Make sure that an overload cut-out according to EN 60204-1 is provided for the motor. ● Make sure that the drive of the vacuum pump is not disturbed by any electric or electromagnetic interferences. If you have any doubts, contact your Busch representative. Installation 6.2.1...

  • Page 27: Electrical Connection

    Installation and Commissioning​ | 6 6.2.2 Electrical Connection WARNING Risk of electrocution, risk of damage. Electrical installation must be performed by a suitably qualified electrician who knows and fol- lows the following regulations: ● IEC 364 or CENELEC HD 384 or DIN VDE 0100, ●...
  • Page 28 6 | Installation and Commissioning​ Double star connection (low voltage): Star connection (high voltage): MB Motor Connection Motor connectors: Connection of motor temperature switches (recommended): Control voltage: ≤ 250 V Max current: 1.6 A MTS = Motor temperature switch (in motor coil) Double star connection (low voltage): 28 | 68 Instruction Manual COBRA DS 3161 C_EN_en...
  • Page 29 Installation and Commissioning​ | 6 Star connection (high voltage): 6.2.2.1 Power Wiring Connection Power wiring 4 poles Phase L1 Phase L2 Phase L3 Ground 6.2.2.2 Power Connector on Rear Side Power Connector (208V) Description Pump side Phase L1 (Pump side) Phase L2 (Pump side) Phase L3 (Pump side) Ground (Pump side)
  • Page 30 6 | Installation and Commissioning​ Mating connectors Supplier Part description Part number HARTING Housing 6B, Top entry, M32, 1 Lever 0680800049 HARTING Frame 6B, Marking A…F 0680800041 HARTING Insert 200A, 25~40SQ, Female 0676800016 HARTING PE Extension 16SQ 0680800098 Power Connector (400V) Description Pump side Phase L1 (Pump side)

  • Page 31: Equipment Connections (With Options)

    Interface connection (50 poles) / PID In- Monitoring System - Option) terface (Option) The information concerning the use of the Busch PLC and the Busch LCD can be found in the Opera- tion and Maintenance manual (Art. No. 0870758077). Instruction Manual COBRA DS 3161 C_EN_en...

  • Page 32: Connection Of Lines/ Pipes

    ● Prepare the quantity of oil specified in the table “Oil Quantity [➔ 63]”. Oil filling NS 0600 C WY 3600 A Oil quantity (Liter) Oil type Busch YLC 250 B, Art. No. 0831 131 400 (0,5 l ≈ 1 kg) 32 | 68 Instruction Manual COBRA DS 3161 C_EN_en...
  • Page 33 Installation and Commissioning​ | 6 6.2.5.1 COBRA NS 0600 C Oil Filling ● Prepare the quantity of oil specified in the table “Oil Quantity”. NOTE The quantity of oil specified in the installation handbook is of informative nature only. Check the oil level with the help of the various oil sight glasses (OSG1,2,3,4) on the vacuum pump.
  • Page 34 6 | Installation and Commissioning​ ● Make sure that the seal ring in the oil filler plugs is not damaged, replace plugs if necessary. ● Fit the oil filler plugs and tighten up. NOTE It is easier to switch on the vacuum pump with cold oil when the intake line is not closed or when the intake flange is not covered by a rubber plate.
  • Page 35 Installation and Commissioning​ | 6 6.2.5.2 PUMA WY 3600 A Oil Filling Description Oil fill plug (OFP) Oil fill plug (OFP) Oil sight glass (OSG) Oil drain plug (ODP) Oil sight glass (OSG) Oil drain plug (ODP) NOTE The quantity of oil specified in the installation handbook is of informative nature only. Check the oil level with the help of the various oil sight glasses (OSG1,2,3,4) on the vacuum pump.
  • Page 36 6 | Installation and Commissioning​ NOTE It is easier to switch on the vacuum pump with cold oil when the intake line is not closed or when the intake flange is not covered by a rubber plate. DS vacuum pump: ●...

  • Page 37: Cooling Liquid Filling

    Installation and Commissioning​ | 6 6.2.6 Cooling Liquid Filling NOTE The COBRA DS vacuum pumps are generally dispatched with cooling liquid already in the vac- uum pump. Before vacuum pump first startup, control the cooling liquid level. In the event of absence of one or the other of these lubricants, please carry out the filling (see “Cooling Liquid Type/ Quantity [➔ 64]”...

  • Page 38: Direct Cooling Checking

    6 | Installation and Commissioning​ ● Let the vacuum pump run for a few minutes ● Stop the vacuum pump and wait a few minutes. ● Unscrew purge cap on cylinder upper plate. ● Control that cooling liquid level is just under cylinder upper plate. ●...
  • Page 39 Installation and Commissioning​ | 6 Solid particles must not get into the vacuum pump. Procedural errors can result in the pump suck- ing in a certain quantity of liquid. If the pump has sucked in liquid, a short drying time is necessary at the end of the procedure.

  • Page 40: Switching The Vacuum Pump On/ Off

    6 | Installation and Commissioning​ CAUTION The cooling water flow, which is checked by the flow switch FS2, must be at least 10 l/min. ● Make sure that all caps, safeguards, and similar covers are mounted. ● Make sure that the safeguards are switched on. ●...

  • Page 41: Load Lock Operation Mode

    Installation and Commissioning​ | 6 ● The cooling water flow is factory set on 10 l/min and can be adjusted at the regulating valve CWR. This water circuit is used to cool the motor of the NS pump. It cools also the cylinder and cylinder endplate B-side when temperature of cooling liquid is above 50°C.
  • Page 42 6 | Installation and Commissioning​ time delay which is adjustable in its duration using the parameter « Time Before », will start. As soon as the time delay's duration has elapsed, the modules DP and MB slow down to their min- imum frequency of rotation.

  • Page 43: Standard Operational Time Chart

    Standard Operational Time Chart​ | 7 Standard Operational Time Chart Signal Control Mode (Select LL Mode = EXTERN) Description LCD start or Remote start (tool to 1) Cold start pump) Delay (5 sec) Pump speed Dry pump Booster 2/ MB on delay Pump ready (pump to tool) Process on (tool to pump) Pump start-up...

  • Page 44: Current Control Mode (Select Ll Mode = Auto)

    7 | Standard Operational Time Chart​ Current Control Mode (Select LL Mode = AUTO) Description LCD start or Remote start (tool to 1) Cold start pump) Delay (5 sec) Pump speed Dry pump Booster 2/ MB on delay Pump ready (pump to tool) Chamber open/ close (gate valve on/ Pump start-up off)

  • Page 45: Maintenance

    Maintenance​ | 8 Maintenance DANGER Live wires. Risk of electrical shock. ● Electrical installation work must only be executed by qualified personnel. DANGER In case the vacuum pump has conveyed gases that have been contaminated with foreign ma- terials 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 vac- uum pump.
  • Page 46 8 | Maintenance​ ● Stop the pump with the LCD control (press on STOP button during 10s). ● Press on emergency stop button. ● Switch off the main circuit breaker. ● Switch off the customer’s power supply. ● Switch off the water and nitrogen quick connections (inlet first, then outlet). ●...

  • Page 47: Maintenance Schedule

    (contact Busch). ● Check the vacuum pump for cooling liquid leaks - in case of leaks have the vacuum pump repaired (contact Busch). ● Check the vacuum pump for cooling water leaks - in case of leaks have the vacuum pump repaired (contact Busch).

  • Page 48: Lock Out/ Tag Out Procedure

    8 | Maintenance​ Interval Maintenance work Yearly ● If the intake is equipped with a sieve: If one or more of these accesso- ● Check the sieve at the intake and clean if necessary. ries are installed. ● Check the measuring and safety equipment for working or- der.

  • Page 49: Oil Checking

    NOTE Oil does not normally have to be refilled outside the recommended oil change intervals. A drop in the oil level indicates a fault (see "Alarms and warnings -> Busch PLC and Busch LCD"). CAUTION Only fill in oil through the oil filler opening.

  • Page 50: Oil Color Inspection

    If the oil becomes dark or looks different from the initial color: ● Change the oil immediately, see Oil Change. You can consult your Busch representative in order to find out why this color change has occurred. 50 | 68...

  • Page 51: Oil Change

    Maintenance​ | 8 8.2.4 Oil Change DANGER If the vacuum pump has pumped gases that were contaminated with foreign bodies that are hazardous to health, the oil is also contaminated with these foreign bodies. There is a health hazard when changing contaminated oil. There is also a danger to the envi- ronment.
  • Page 52 8 | Maintenance​ Booster (MB): ● Put a drain tray underneath the oil drain plugs (ODP). ● Unscrew the oil drain plugs (ODP). ● Drain the oil. When the oil flow has stopped: ● Refit the oil drain plugs (ODP) again. ●...
  • Page 53 Maintenance​ | 8 ● Make sure that the seals of the filler cap are not damaged and that they sit properly. Replace them if necessary. ● Screw on the filler cap again. Booster (MB): ● Prepare the quantity of oil needed (see “Oil Type/ Quantity [➔ 63]”). CAUTION The use of chemically contaminated or polluted oil can lead to hazardous pump conditions which could cause personal injury.

  • Page 54: Cooling Liquid Checking

    8 | Maintenance​ Cooling Liquid Checking 8.3.1 Cooling Liquid Level Checking ● Make sure that the vacuum pump has been switched off and that it cannot be switched on again accidentally. ● Let the vacuum pump cool down. ● Check the level of the cooling liquid. ●...

  • Page 55: New Cooling Liquid Filling

    Maintenance​ | 8 ● Unscrew drain plug of cooling liquid. ● Drain the cooling liquid. When cooling liquid stops running out: ● Close the drain plug for the cooling liquid. ● Screw purge caps. ● Screw the drain plug. ● Switch on the vacuum pump and let it run for a few seconds. ●...

  • Page 56: Additional Checking

    8 | Maintenance​ If the inlet line is not equipped with a shut-off device: ● Remove the rubber plate from the inlet flange and connect the inlet line to the inlet flange. ● Wipe cooling liquid that may have run on outside surfaces of vacuum pump. ●...

  • Page 57: Overhaul

    ● Decontaminate the machine as much as possible and state the contamination status in a ‘Dec- laration of Contamination’. Busch will only accept machine accompanied by a signed, fully completed and legally binding "decla- ration of contamination", downloadable from the following link: buschvacuum.com/declaration-of- contamination.

  • Page 58: Removal From Service

    10 | Removal from Service​ Removal from Service DANGER Live wires. Risk of electrical shock. ● Electrical installation work must only be executed by qualified personnel. CAUTION Hot surface. Risk of burns! ● Before doing anything that requires touching the machine, let it cool down first. 10.1 Temporary Removal from Service Before disconnecting the intake and exhaust lines and switching off the cooling water and nitrogen...

  • Page 59: Dismantling And Disposal

    Removal from Service​ | 10 10.3 Dismantling and Disposal DANGER In case the vacuum pump has conveyed gases that have been contaminated with harmful for- eign material which are harmful to health, the oil and the condensates will also be contami- nated with harmful foreign material.

  • Page 60: Spare Parts

    Risk of premature failure! Loss of efficiency! ● 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 are no standard spare parts kits available for this product.

  • Page 61: Troubleshooting

    Busch). Solid foreign matter has en- ● Remove the solid foreign tered the machine. matter or repair the ma- chine (contact Busch). ● Install an inlet filter if neces- sary. A temperature sensor has ● Let the machine cool down.
  • Page 62 Oil Change. The machine runs too hot. ● See problem "The machine runs too hot". For resolution of problems not listed in the troubleshooting table, please contact your Busch repre- sentative. 62 | 68 Instruction Manual COBRA DS 3161 C_EN_en...

  • Page 63: Oil Type/ Quantity

    Oil Type/ Quantity​ | 13 Oil Type/ Quantity 13.1 Oil Type Make sure that the oil type corresponds to specifications: YLC 250 B ISO-VG Oil Type Synthetic Part number 0.5 L packaging 0831 131 400 Part number 1 L packaging 0831 108 878 Part number 5 L packaging 0831 108 879 CAUTION...

  • Page 64: Cooling Liquid Type/ Quantity

    14 | Cooling Liquid Type/ Quantity​ Cooling Liquid Type/ Quantity 14.1 Cooling Liquid Type Make sure that the Cooling Liquid type corresponds to specifications: Zitrec M-25 (ready-to-use) Part number 25 L packaging 0831 563 468 Part number 5 L packaging 0831 563 469 The cooling liquid Zitrec M-25 is ready-to-use and does not require additional water.

  • Page 65: Technical Data

    Technical Data​ | 15 Technical Data DS 3161 C Nominal pumping speed m³/h 3200 ACFM (60 Hz) 1883.2 Ultimate pressure TORR 0.00075 hPa (mbar) 0.001 Nominal motor rating kW (60 Hz) backing pump Nominal motor rating kW (90 Hz) vacuum booster Power consumption at kW MB: (90 Hz) 11.8...

  • Page 66: Eu Declaration Of Conformity

    EU Declaration of Conformity This Declaration of Conformity and the CE-markings affixed to the nameplate are valid for the machine within the Busch scope of delivery. This Decla- ration of Conformity is issued under the sole responsibility of the manufacturer.

  • Page 67: Uk Declaration Of Conformity

    UK Declaration of Conformity This Declaration of Conformity and the UKCA-markings affixed to the nameplate are valid for the machine within the Busch scope of delivery. This Dec- laration of Conformity is issued under the sole responsibility of the manufacturer.
  • Page 68 With a network of over 60 companies in more than 40 countries and agencies worldwide, Busch has a global presence. In every country, highly competent local personnel delivers custom-tailored support backed by a global network of expertise. Wherever you are.

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