BUSCH COBRA PLUS Instruction Manual

Dry screw vacuum pumps air-cooled version (acv)

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COBRA PLUS

Dry Screw Vacuum Pumps

DX 0650 A PLUS, DX 0950 A PLUS

Air-Cooled Version (ACV)

Instruction Manual

2000090907 | -0001_en-US | Original instructions

2025/03/03

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Page 1 COBRA PLUS Dry Screw Vacuum Pumps DX 0650 A PLUS, DX 0950 A PLUS Air-Cooled Version (ACV) Instruction Manual 2000090907 | -0001_en-US | Original instructions 2025/03/03...
Page 2: Table Of Contents
Table of Contents Table of Contents Safety ..................................Product Description ............................. Operating Principle ............................. Intended Use ............................... Start Controls............................... Standard Features............................... 2.4.1 Air Cooling ............................. 2.4.2 Temperature Switch ..........................2.4.3 Sealing Systems ............................ Optional Accessories............................2.5.1 Gas Ballast Valve........................... 2.5.2 Silencer ..............................
Page 3 Table of Contents Cleaning the Silencer (Optional)........................Oil Change................................Cooling Liquid Change ............................Overhaul ................................Decommissioning ..............................10.1 Dismantling and Disposal ..........................Troubleshooting ..............................Technical Data ..............................Oil ................................... Cooling Liquid ............................... EU Declaration of Conformity ..........................UK Declaration of Conformity..........................Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en 3 | 68...
Page 4: Safety
1 | Safety Safety Prior to handling the machine, this instruction manual should be read and understood. If anything needs to be clarified, please contact your manufacturer 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.
Page 5: Product Description
Product Description | 2 Product Description NOTE Illustrations. In this instruction manual, the machine illustrations are of the COBRA DX 0950 A. Although they differ from the COBRA DX 0650 A, the principles and operation are similar. EPIV GBS GB CLV1 CLV2 BGC, BGF, BGM, BGR, BGV...
Page 6 2 | Product Description Description Barrier gas pressure regulator (PRV) – op- Solenoid valve (Barrier gas) – option* tion* Condensate drain Communication I/O port - option Control unit Cooling liquid drain plug Cooling liquid fill plug Cooling liquid pump CLV1 Cooling liquid vent valve (Heat exchanger) CLV2 Cooling liquid vent plug (Machine)
Page 7: Operating Principle
The machine is intended for indoor placement in a non-potentially explosive environment. The machine is designed for indoor installations. For outdoor installations, consult your Busch repre- sentative for special precautions.
Page 8: Start Controls
2 | Product Description Start Controls The machine is equipped with a Variable Speed Drive (VSD) including a PLC and a Touch Screen. Standard Features 2.4.1 Air 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.
Page 9: Optional Accessories
CAUTION Electro-pneumatic inlet valve pressure. Risk of injuries! Risk of damage to the machine! ● Busch recommends the installation of a pressure sensor with the following range and accuracy values. Pressure sensor range and accuracy Range: 0-1000 mbar Accuracy: +/- 7.0 mbar NOTE To actuate the valve, compressed air or nitrogen must be supplied.
Page 10: Otto Iot Box
2.5.5 OTTO IoT Box The machine can be equipped with the OTTO IoT Box. It allows the vacuum pump to be connected to the Busch Cloud and collect live measured data during its operation. The IoT system consists in: ● The IoT Box ●...
Page 11 Product Description | 2 Power Supply ● 24VDC power supply - Max 1.5A Remote Pump Start It allows the machine to be started by an external signal. If pins 1 and 10 are bridged, the machine will start according to the settings of the HMI. NOTE In case of a remote-control start, the machine must be integrated in the user's safety chain (signal warning the user to stop the machine in case of problem or emergency stop).
Page 12 2 | Product Description External Safety Switch It allows to add an external safety element. Remove the bridge and put a dry contact instead. NOTE The bridge is mandatory in case of a remote-control use. NOTE According to the standard factory setting, there is a bridge on the terminals inside the control unit (CU).
Page 13: Dry Contact
Product Description | 2 Dry Contact ● M12 connector: Max 30VAC/DC 1.5A ● On terminal: Max 250VAC/DC 10A ● Activation according to the settings of the HMI. Modbus Control For more information: ● See Modbus Control and Ethernet Settings [➔ 28]. Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en 13 | 68...
Page 14: Main Power Switch / Breaker
2 | Product Description 2.5.7 Main Power Switch / Breaker The machine can be equipped with a power switch for connecting or disconnecting it from the mains. In case this power switch is not installed, an equivalent device must be installed in the customer's system.
Page 15: Transport
Transport | 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.
Page 16: Storage
4 | Storage Storage ● Seal hermetically all apertures with the caps provided with the machine, or with adhesive tape if the caps are no longer available. ● Store the machine indoors, in a dry place, away from dust and vibrations and if possible, in original packaging, preferably at temperatures between 5 ...
Page 17: Installation
Installation | 5 Installation Installation Conditions NOTICE Use of the machine outside of the permitted installation conditions. Risk of premature failure! Loss of efficiency! ● Make sure that the installation conditions are fully respected. Description ~120 cm ~5 cm ~50 cm ~50 cm ●...
Page 18: Connecting Lines / Pipes
● Without inlet flange: Ø 99 mm, M8 x8 If the machine is used as part of a vacuum system: ● Busch recommends the installation and use of an isolation valve to prevent the machine from running backwards. ● Busch also recommends not opening the isolation valve until at least the minimum machine speed has been reached.
Page 19: Discharge Connection
Installation | 5 5.2.2 Discharge Connection Description Standard exhaust without silencer (SI) Bottom view of the machine Auxiliary port NOTICE Discharge gas flow obstructed. Risk of damage to the machine! ● Make sure that the discharged gas will flow without obstruction. Do not shut off or throttle the discharge line or use it as a pressurized air source.
Page 20: Barrier Gas System Connection (Optional)
5 | Installation 5.2.3 Barrier Gas System Connection (Optional) Description Barrier gas connection Flow meter Manometer Solenoid valve Pressure regulating valve ● Connect the barrier gas connection (BGC) to the gas supply. Connection size: – G1/4”, ISO 228-1 ● Make sure that the gas complies with the following requirements: Gas type Dry nitrogen or air Gas temperature...
Page 21: Electro-Pneumatic Inlet Valve Connection (Optional)
Installation | 5 5.2.4 Electro-Pneumatic Inlet Valve Connection (Optional) Description Electro-pneumatic inlet valve (EPIV) Compressed air or nitrogen intake Elbow screw fitting, connexion size Ø 10 mm Connection size: ● DN100 ISO-F The electro-pneumatic inlet valve (EPIV) must be connected to compressed air or compressed nitro- gen gas source.
Page 22: Filling Oil
5 | Installation Filling Oil NOTICE Use of inappropriate oil. Risk of premature failure! Loss of efficiency! ● Use only a type of oil previously approved and recommended by the manufacturer. For oil type and oil capacity see Technical Data and Oil [➔ 62] chapters. 22 | 68 Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en...
Page 23: Cooling System Cover Removal
When the oil filling is achieved: ● Write down the oil change date on the sticker. If there is no sticker (part no. 0565 568 959) on the machine: ● Order it from your Busch representative. Cooling System Cover Removal NOTE Before filling or changing the cooling liquid and electrically connecting the cooling system.
Page 24: Filling Cooling Liquid
5 | Installation Filling Cooling Liquid The machine is already dispatched with cooling liquid. If it is not the case: ● Electrically connect the cooling system, see Electrical Connection of the Cooling System [➔ 29]. ● Fill in the machine with cooling liquid according to the following procedure. For cooling liquid type and cooling liquid capacity see Technical Data and Cooling Liquid [➔ 63].
Page 25: Electrical Connection
● Make sure that the motor of the machine will not be affected by electric or electromagnetic dis- turbance from the mains. If necessary, contact your Busch representative for more information. ● Make sure that the EMC of the machine is compliant with the requirements of your supply net- work system, if necessary, provide further interference suppression (EMC of the machine, see EU Declaration of Conformity [➔ 64] or UK Declaration of Conformity [➔ 65]).
Page 26: Plus Machine
● If the machine is equipped with a power connector, install a residual current protective device to protect persons in case of a defective insulation. ● Busch recommends installing a type B residual protective device suitable for the electrical in- stallation.
Page 27: Main Power Supply Connection
Electrical Connection | 6 NOTICE The admissible motor speed exceeds the recommendation. Risk of damage to the machine! ● Check the admissible motor speed range, see Technical Data. NOTICE The motor frequency is below 20 Hz. Risk of damage to the machine! ●...
Page 28: Modbus Control And Ethernet Settings
6 | Electrical Connection Optional Industrial Quick Connector [➔ 14] ● Pin configuration (380-460VAC) Description Not used Plug Maximum current 80A @ 40°C Maximum voltage 480V Square cable sq 1.5 … 16 mm² AWG gauge AWG 16 … 6 Cable entry M32 x 1.5mm Modbus Control and Ethernet Settings The user interface (HMI) works in Modbus with “Holding Registers”, readable and writable, 16 bits.
Page 29: Electrical Connection Of The Cooling System
Electrical Connection | 6 Electrical Connection of the Cooling System DANGER Live wires. Risk of electrical shock! ● Electrical installation work must only be executed by qualified personnel. NOTE No additional wiring is required to connect the air-cooling system of the machine. There is on- ly one connection to be made to the main power supply of the machine.
Page 30: Commissioning
7 | Commissioning Commissioning CAUTION During operation the surface of the machine can reach temperatures over 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 people are present in the vicinity of a machine that is not insulated from noise for extended peri- ods of time: ●...
Page 31: Description Of User Interface Functions
Commissioning | 7 As soon as the machine is used under normal operating conditions: ● Measure the motor current and record it as reference for future maintenance and trouble- shooting work. NOTE COBRA machines require a certain warm-up time to reach maximum performance. Description of User Interface Functions The following functions and parameters are available on the TOUCH SCREEN - HMI interface: ●...
Page 32: Roles And Users
● Reset hours before the next service, ● Set the remote control and monitoring parameters. Role 3 ► Busch Service Only authorized personnel from Busch Service have this level of access rights. NOTE In case of any questions related to the machine settings: ●...
Page 33: Home
Commissioning | 7 7.1.2 Home 7.1.2.1 Main The display “HOME > MAIN” is the main display. It is mainly useful for live monitoring. 7.1.2.2 Monitoring (Operating Data) The display “HOME” > “MONITORING” shows the operating values. It is divided into three different screens/pages. Screen/Page MONITORING 1 Instant absorbed power.
Page 34 7 | Commissioning Screen/Page MONITORING 2 Inlet pressure. Indicates the pressure at the inlet of the pump when the pump is equipped with the inlet valve and when the function is activated. Motor frequency. Indicates in Hz the current drive frequency. IGBT temperature.
Page 35 Commissioning | 7 7.1.2.3 Alarms The display “HOME” > “ALARM” shows the history of the alarms’ signals registered by the pump mon- itoring sensors. When an alarm occurs, an audible alarm sounds, and the user must acknowledge the default on the HMI interface.
Page 36: Operations
Pressure control (target pressure) <5 ... 1000 mbar ● For smooth process pressure control, it is required to adjust the PID parameters. ● For more information, contact your Busch representative. 36 | 68 Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en...
Page 37 Commissioning | 7 Ecomode (Option - function associated to the Pressure control). The Ecomode stops the machine when the inlet pressure has reached the preset "ecomode pres- sure" within a defined time delay and will restart once the inlet pressure exceeds the "restart pres- sure".
Page 38: Operation Parameters
Change parameter values. Risk of damage to the machine! ● For all the following functions with parameterization, Busch strongly recommends waiting until the end of a pump cycle before changing any parameter value! The display “OPERATIONS > PARAMETERS” shows the operation parameters.
Page 39 Commissioning | 7 Screen/Page PARAMETERS 2 Inlet valve control (Option). This menu allows the control and setting of the opening parameters of an inlet valve installed at the inlet side of the vacuum pump (not included in the scope of delivery of the vacuum pump). ●...
Page 40 7 | Commissioning Screen/Page PARAMETERS 3 Dry Contact ● M12 connector: Max 30VAC/DC 1.5A ● On terminal: Max 250VAC/DC 10A ● Activation according to the settings of the HMI. 7.1.3.3 Operation Week Planner The "week planner" function allows definition of a weekly schedule for starting or stopping the ma- chine automatically using the current local settings.
Page 41 Commissioning | 7 As soon as the schedule is filled in, the control mode “Local/Auto” has to be activated (by “Role 2” us- ers only, see Roles and Users [➔ 32]): ● Go the second screen/page of “OPERATIONS” > “MODE” (see chapter Operation Modes). ●...
Page 42: Maintenance
7 | Commissioning 7.1.4 Maintenance The display “MAINTENANCE” shows the maintenance and service intervals of the machine. ● Press “Set” to define the “Oil service” and “Overhaul” intervals. ● Press “Reset” to reset the operating hours (running hours) to 0 after an oil change and/or over- haul.
Page 43 Commissioning | 7 Screen/Page SETTING 2 On the second screen/page, it is possible to edit some pump parameters like the pressure control settings (PID) or to activate/deactivate pump functions such as the pressure sensor (Option) or OT- Screen/Page SETTING 3 On the third screen/page, it is possible to access the internal settings of the HMI by pressing the button for two seconds.
Page 44 RJ45 port). This protocol uses the IP address of the HMI (192.168.0.100 by default), port 5900 and a password (“adm” by default). A remote viewer such as VNC can also be used. ● For more information, contact your Busch representative. 44 | 68...
Page 45 Commissioning | 7 7.1.5.2 Model Screen/Page MODEL 1 Screen/Page MODEL 2 The "SYSTEM > MODEL" display provides the following information. On screen/page 1: – Type and model of vacuum pump, – Version of HMI software, – Version of the VSD PLC software. On screen/page 2: –...
Page 46: Ethernet Settings
7 | Commissioning 7.1.5.3 Ethernet Settings ● To configure the ethernet settings according to your network: ● Go to “SYSTEM” > “ETHERNET”. ● Change the values on the right side of the screen (Change settings). ● Press on the switch button to save the new settings. NOTE The current Ethernet values are displayed in the left side of the screen (Ethernet settings).
Page 47: Conveying Condensable Vapors
(e.g. "dead leg") with drain. ● Water vapor within the gas flow is tolerated within certain limits. The conveyance of other vapors shall be agreed upon with Busch. Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en...
Page 48: Maintenance
8 | Maintenance Maintenance DANGER Live wires. Risk of electrical shock! ● Electrical installation work must only be executed by qualified personnel. DANGER Maintenance work without disconnecting the variable speed drive. Risk of electrical shock! ● Disconnect and isolate the variable speed drive before attempting any work on it. High voltages are present at the terminals and within the variable speed drive for up to 10 min- utes after disconnection of the electrical supply.
Page 49 Risk of injuries! Risk of premature failure and loss of efficiency! ● Maintenance work must only be executed by qualified personnel. ● Respect the maintenance intervals or ask your Busch representative for service. NOTICE Using inappropriate cleaners. Risk of removing safety stickers and protective paint! ●...
Page 50: Maintenance Schedule
● Change the cooling liquid, see Cooling Liquid Change [➔ 55]. ● Clean the magnetic plugs (MP). Every 25000 hours or after 4 ● Have a major overhaul on the machine (contact Busch). years Oil Level Inspection ● Stop the machine.
Page 51: Cooling Liquid Level Inspection
Maintenance | 8 Cooling Liquid Level Inspection ● Stop the machine. ● Let the machine cool down. ● Open the cooling liquid vent valves (CLV1 – CLV2). ● Fill up if necessary, see Filling Cooling Liquid [➔ 24]. ● Close the cooling liquid vent valves (CLV1 – CLV2) in the following order when the cooling liquid is spilling out.
Page 52: Cleaning The Silencer (Optional)
8 | Maintenance Cleaning the Silencer (Optional) Description Bottom view of the machine Unscrew the 4 hexagonal screws to re- move the silencer Unscrew the 16 hexagonal screws to Be careful with the gasket, clean it with disassemble the silencer a clean cloth Wear protective eyewear and mask Use compressed air and cleaning...
Page 53 Maintenance | 8 Description Magnetic plug Description Magnetic plug For oil type and oil capacity see Technical Data and Oil [➔ 62] chapters. Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en 53 | 68...
Page 54 ● Write down the oil change date on the sticker. If there is no sticker (part no. 0565 568 959) on the machine: ● Order it from your Busch representative. 54 | 68 Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en...
Page 55: Cooling Liquid Change
Maintenance | 8 Cooling Liquid Change For cooling liquid type and cooling liquid capacity see Technical Data and Cooling Liquid [➔ 63]. Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en 55 | 68...
Page 56 8 | Maintenance Description Step 3: Open the cooling liquid vent Step 5: Switch on the cooling liquid valves (CLV1, CLV2) pump (CLP) Step 6: Vent air from the cooling sys- Step 7: Close the cooling liquid vent valve (CLV2) when the cooling liquid is spilling out Step 8: Resume cooling liquid filling Step 9: Close the cooling liquid vent...
Page 57: Overhaul
Risk of premature failure! Loss of efficiency! ● Any disassembly of the machine beyond that described in this manual must be carried out by technicians approved by Busch. If the machine has conveyed gas contaminated with foreign materials which are hazardous to health: ●...
Page 58: Decommissioning
10 | Decommissioning Decommissioning 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. CAUTION Hot liquids.
Page 59: Troubleshooting
Solid foreign matter has en- ● Remove the solid foreign tered the machine. matter or repair the ma- chine (contact Busch). Alarm trip of the monitoring ● Let the machine cool down. sensors or the variable speed ● Check the alarm notifica- drive.
Page 60 Oil Change [➔ 52]. The machine runs too hot. ● See problem "The machine runs too hot". For resolution of problems not listed in the troubleshooting table, contact your Busch representa- tive. 60 | 68 Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en...
Page 61: Technical Data
* Circuit breaker (MCCB) Not included in the scope of delivery! ● Line protection must be provided at the customer's site. ● For voltages above 460V, contact your Busch representative. Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en 61 | 68...
Page 62: Oil
13 | Oil VSC 100 ISO-VG Oil type Synthetic Part number 1 L packaging 0831 168 356 Part number 5 L packaging 0831 168 357 Part number 10 L packaging 0831 210 162 Part number 20 L packaging 0831 168 359 Oil suitability ● Oil VSC 100: Suitable for harsh applications. 62 | 68 Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en...
Page 63: Cooling Liquid
Cooling Liquid | 14 Cooling Liquid Zitrec ® M-25 (Ready-to-use) Part number 5 L packaging 0831 563 469 Part number 20 L packaging 0831 238 761 Zitrec ® M-25 coolant (Cooling liquid) is ready-to-use and requires no additional water. For more information, visit www.arteco-coolants.com. Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en 63 | 68...
Page 64: 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 65: 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 66 Notes Notes 66 | 68 Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en...
Page 67 N otes Instruction Manual COBRA DX 0650-0950 A PLUS ACV_EN_en 67 | 68...
Page 68 BUSCH GROUP The Busch Group is one of the world’s largest manufacturers of vacuum pumps, vacuum systems, blowers, compressors and gas abatement systems. Under its umbrella, the group houses two well-known brands: Busch Vacuum Solutions and Pfeiffer Vacuum+Fab Solutions. Together, they offer solutions to a wide range of industries.

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Cobra dx 0650 a plus Cobra dx 0950 a plus