briwatec ZIRKON D060 D User manual

ZIRKON
D060 D – D140 D
Dry-running rotary vane compressors
Translation of the original instructions
briwatec GmbH
Schönauer Str. 62
79669 Zell i. W.
Germany
Telephone no. [phone]
Fax no. [phone]
Email [email protected]
Website www.briwatec.de
Managing directors: Markus Britsche, Michael Wagner
District Court: Freiburg i. Br. HRB 700368
VAT number.: 11088/10922
Value added tax identification-no.: DE 814 742 383

Contents
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 2
1Contents
1Contents ........................................................................................................ 2
2Introduction ................................................................................................... 3
2.1 Information about the operating manual ............................................. 3
2.1 Limitation of liability.......................................................................... 3
2.2 Copyright .......................................................................................... 3
2.4 Spare parts ....................................................................................... 4
2.5 Service............................................................................................. 4
2.6 EC-Declaration of Conformity.............................................................. 5
3Safety ............................................................................................................ 6
3.1 General ............................................................................................. 6
3.2 Description of safety instructions ........................................................ 6
3.3 General safety advice......................................................................... 6
3.4 Personnel requirements ..................................................................... 7
3.5 Definitions of terms ........................................................................... 8
3.6 Intended use..................................................................................... 8
3.7 Improper operation............................................................................ 9
3.8 Protective measures by the operator/user ........................................... 9
4Technical specifications ..................................................................................10
4.1 Name plate ......................................................................................10
4.2 Technical Information .......................................................................10
5Functional description ....................................................................................11
5.1 Conditions of use ..............................................................................11
5.2 Construction.....................................................................................12
6Transport storage ..........................................................................................13
6.1 Safety instructions for transport.........................................................13
6.2 Lifting and transporting the machine..................................................13
6.3 Storage............................................................................................13
7Commissioning ..............................................................................................14
7.1 Setup...............................................................................................14
7.2 Installation .......................................................................................14
7.3 Commissioning .................................................................................16
8Operation......................................................................................................17
9Maintenance..................................................................................................18
9.1 Air Filter ...........................................................................................18
9.2 Vanes ..............................................................................................20
10 Troubleshooting.............................................................................................22
11 Index of Figures ............................................................................................24

Introduction
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 3
2Introduction
2.1 Information about the operating manual
These instructions describe the handling of the dry running ZIRKON rotary
vane compressor of the series type:
ZIRKON D060 D to D140 D
A condition for secure operation is adherence to all safety and operating
instructions.
The operating instructions must be carefully read through before
commencement of any operation! They are an integral part of the
equipment and must at all times be kept in close proximity to the machinery
for immediate use by the operating and maintenance personnel.
The company ‘briwatec GmbH‘ will not be held liable for workplace accidents,
damage to the equipment, production losses or completion disorders that
occur as a result of non-observance of the operating instructions.
Furthermore, the local accident-avoidance directions and general safety
regulations in respect of the operation of machinery will apply.
The figures serve for a general understanding of the machinery and may
differ somewhat from the actual construction thereof.
Components produced by other suppliers have their own safety instructions
and guidelines. These must also be observed.
2.1 Limitation of liability
All data and directions in this introduction have been assembled with due
consideration of the corresponding norms and regulations, of the state of
the art as well as of our own knowledge and experience.
The company ‘briwatec GmbH‘ will not be held liable for damages due to:
Non-observance of the operating directions
Misuse of equipment
Employment of unqualified personnel
Use of spare parts that have not been provided by the company
‘briwatec GmbH‘
Arbitrary alteration of machinery components or of accessories (supply
list from the company ‘briwatec GmbH‘)
The responsibilities agreed in the supply contract, the general commercial
conditions as well as the conditions of supply by the company ‘briwatec
GmbH‘ , and the regulations current at the time of signing of the contract will
apply.
We reserve the right to make technical changes with a view to improving the
operating conditions and further development.
2.2 Copyright
The transfer of the operating instructions to third parties without written
permission from the company ‘briwatec GmbH‘ is prohibited.
NOTE!
A
ll data contained herein, texts, drawings, pictures and other illustrations are
protected by copyright and are subject to commercial patent rights.
A
ll misuse thereof is liable to prosecution!
Read the operating
instructions!
Observe the operating
instructions!

Introduction
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 4
Duplication in any type or form – even extracts – as well as the utilization
and/or communication of the contents hereof are not permitted without
written authorization by the company ‘briwatec GmbH‘ .
2.4 Spare parts
The company ‚‘briwatec GmbH‘ recommends the use of original spare parts.
Original spare parts possess special quality properties and provide reliable
and safe functionality;
Development of the special use of the equipment
Manufacture in high quality and value
12-Months guarantee after installation or shipment (other than
worn-out components) or other agreed conditions.
NOTE!
T
he use of non-original spare parts can alter the properties of the equipment
and put its safety at risk!
T
he company ‘briwatec GmbH‘ is absolved of any liability for damage that
results there from.
DISPOSAL!
Worn-out components (indicated in the spare parts list) are waste products.
A
fter exchange, the worn-out components should be disposed of in accordance
with the national regulations.
2.5 Service
For servicing queries, the company ‘briwatec GmbH‘ can be contacted as
follows:
briwatec GmbH Tel. [phone]
Schönauer Str. 62 Fax. [phone]
79669 Zell i. W. [email protected]
Germany www.briwatec.de
For faster response to your queries, please have available the following data
and information:
Serial number
Which activity has already been undertaken?
Prior to service works on-site, the motor has to be disconnected from the
circuit by a qualified electrician so that an unforeseen start does not occur.
For servicing work, we recommend that the manufacturer or its local branch
or sub-contractor be engaged, especially where possible repairs under
warranty are involved.
The address of the servicing station appropriate for yourselves can be
obtained from the manufacturer (see the manufacturer’s address). Following
a repair or prior to re-start-up, the jobs indicated under “Installation“ and
“Start-up“ must be carried out as for the initial start-up procedure.
Service work:

Introduction
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 5
2.6 EC-Declaration of Conformity
Figure 1 EC-Declaration of conformity

Safety
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 6
3Safety
3.1 General
The ZIRKON rotary vane compressor has been constructed, completed and
tested in accordance with the safety guidelines of the latest state of the art,
and has been released in a technically safe and impeccable condition.
Nevertheless, dangers can occur with use of the machinery, for persons and
objects, if it is used in an improper manner.
The operating instructions must be read comprehensively and the safety
directions must be adhered to.
The operating directions that are attached to the machinery must be followed
and must be kept in a readily readable condition. This relates, for example,
to:
Connection indicator
Data and motor identification plate
Instructions and warning plates
In the event of non-conforming operation, all liabilities and warranties on the
part of the company briwatec GmbH are rescinded.
3.2 Description of safety instructions
Safety instructions refer to particular dangers. These are indicated in this
guide book by way of symbols.
SAFE refers to 4 basics in the description of the safety instructions:
Severity of danger (Signal word)
Type and origin of the danger (description)
Consequence of non-observance
Avoidance (measures to avoid a danger)
The corresponding warning symbol serves to identify the point of danger.
Model construction of safety directions:
DANGER!
DESCRIPTION OF THE
T
YPE AND ORIGIN OF THE DANGER!

Measures taken to avoid the danger
3.3 General safety advice
The following general safety instructions are used according to the type of
danger:
DANGER!
Refers to an immediate, dangerous situation that results in death or serious
injury if not avoided.

Safety
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 7
WARNING!
Refers to a possibly dangerous situation that could lead to death or serious
injury, if not avoided.
CAUTION!
Refers to a possibly dangerous situation that could lead to slight or minor injury
or to damage of objects if not avoided.
The following indicators are used in this guide book:
NOTE!
T
his symbol refers to an important state of affairs.
Relevant instructions for the installation, operation or maintenance are provided.
RECYCLING!
T
his symbol refers to relevant instructions for disposal.
Materials must be separated and disposed of individually.
Similarly, the instructions for the disposal of lubricants (oils and greases) as well
as of additives must be observed!
3.4 Personnel requirements
WARNING!
Danger from inadequately qualified personnel
Inappropriate actions can lead to serious personnel injury and material damage.
T
herefore:

All operations must be permitted to be undertaken only by qualified
personnel!
Electrical equipment Work with electrical installations may only be undertaken by expert
electricians in accordance with electro-technical regulations.
This refers to work on the installation, operation, repair to and maintenance
of electrical equipment.
Operation of the machine Operation of the machinery may only be undertaken by trained or instructed
personnel. The operator must be conversant with the basic directions
regarding safety at work and accident avoidance, and must have been
trained in the management of the machinery. The operator must have read
and understood the operating instructions prior to start-up of the machinery.

Safety
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 8
3.5 Definitions of terms
Trained persons/operators ... have been trained by the operator in regard to the tasks given to him
and the possible dangers from inappropriate actions.
Qualified personnel ... because of their technical training, knowledge and experience as well as
their knowledge of the appropriate directions, are capable of carrying out the
tasks given to them and able to identify dangers and how to avoid them.
Machine ... Connection-ready combination of the compressor housing, rotor and
motor.
Motor ... Driving motor of the compressor.
Highest permissible
Pressure difference ... Air pressure difference upon the built-in motor
Noise emission ... The given noise at any particular load condition as numerical value, the
noise level in dB(A) in accordance with EN ISO 3744.
3.6 Intended use
The machines of the series ZIRKON D are intended for use for the
compression of closed systems or for the maintenance of permanent
pressure up to the differential pressures indicated in the relevant data texts.
The machine may only be operated in the following manner:
Only when the machine is operated in a technically faultless
condition
When the machine is not in a partially assembled condition
When the machine is in an ambient temperature and suction
temperature between 5and 40 C. At temperatures outside this
range please refer to the supplier.
The machine can be used in the following media:
Air having a relative humidity of 30% to a maximum of 90%,
Dry, non-aggressive gases.
WARNING!
Danger when used in non-prescribed manner!
A
ny use of the machinery that is outside and/or alternative to the prescribed
manner can lead to dangerous situations.
ZIRKON rotary vane compressors should only be used in the prescribed
manner.
All instructions in the operating manual should be strictly adhered to.
Claims of any kind in respect of damage due to non-prescribed use are not
permitted. The operator alone is liable for damage due to non-prescribed use.

Safety
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 9
3.7 Improper operation
Mis-usage can result from the following methods of operation:
No dangerous substances may be sucked into the machine such, for
example, as:
° combustible or explosive gases or fumes,
° steam,
° aggressive gasses.
The use of the machine in non-industrial establishments, in which the
necessary precautions and safety measures have not been undertaken.
The installation in explosion-prone environments.
Alterations to the machinery and its component accessories.
3.8 Protective measures by the operator/user
The machine is operated in commercial/industrial situations. The operator of
the machine is, therefore, subject to the legal requirements in respect of
working safety. In addition to the safety regulations stated in this operating
manual, the applicable safety-, accident- and environmental protection
regulations must be adhered to for operation of this machinery.
In this regard, it should be specially noted that:
Hot parts of the machine must not be accessible or be provided with
protective contact means.
Personnel should not be placed in danger from free suction or expulsion
of medium substances.
Danger from electrical energy should be prevented.
The operator must be conversant with the relevant protection-at-work
regulations and must ascertain any situation judged to comprise
dangerous conditions when the work-place of the machinery will have
special safety regulations. These should be available to him as operating
instructions for using the machinery.
The operator must undertake tests throughout the operation of the
machinery to check whether the operating instruction being followed by
him actually conform to the prescribed instructions for operating the
machinery and, if necessary, modify accordingly.
The operator must clearly regulate and establish the adequacy of the
installation, operation, fault removal and maintenance.
The operator must ensure that all co-workers involved in operation of the
machinery have read and understand these operating instructions. In
addition, he must subject the personnel to training sessions at regular
intervals and keep them informed about dangers.
DANGER!
Safe access to the operating components!
If operating components are displaced and unreachable, there is the risk of
injury and life-threatening injury.

Operating components should not be displaced and safe access should be
available.
In addition, the operator is responsible for ensuring that the machinery is
permanently in a faultless technical condition.

Technical specifications
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 10
4Technical specifications
4.1 Name plate
The name plate contains the relevant technical information about the
machine.
In the event of technical service queries the model references, date of
manufacture and serial number must be available.
Figure 2 Type plate
The highest permitted flow volume and pressure are dependent upon the size
of construction and are indicated on the model plate.
4.2 Technical Information
The following technical details and noise emissions apply to the ZIRKON series:
Figure 3 ZIRKON technical data
The flow volume with free passage comprises 60, 80, 100 and 140 m3 /h at
50Hz operation. The dependence of the air exhaust on the exhaust pressure is
indicated in the relevant data pages.
The noise pressure level or noise production level according to EN ISO 3744,
measured at 1 m intervals at one operating position at about 2/3 of the
permitted total pressure differential and connected conduits without pressure
restricting valve, are given in the table of figure 3 as having a tolerance of ±3
dB(A).
Hearing protection ! To prevent hearing damage through lengthy presence in the vicinity of an
operating machine, the use of hearing protection means is recommended.

Functional description
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 11
5Functional description
5.1 Conditions of use
The ZIRKON rotary vane compressors are intended for use in the commercial
sector, i.e. the safety arrangements conform to DIN EN ISO 13857 for
persons aged from 14 years.
They are suitable for the transport of air having a relative humidity of 30% to
a maximum of 90% and of dry, non-aggressive gases.
Pressure difference The highest permissible pressure difference (excess pressure) for air is
dependent upon the component motor. It is indicated on the type plate, or
can be found for standard pressures/frequencies in the following data pages:
Construction series Data sheet No..
ZIRKON D060 D D131
ZIRKON D080 D D155
ZIRKON D100 D D156
ZIRKON D140 D D157
At operations above the stated pressure differences, the motor becomes
over-loaded. In addition to the pressure difference, the highest permissible
current strength indicated on the type plate must be adhered to.
Since the charge is dependent upon the thickness of the transport medium,
the transport of gases will have different pressure difference limits than those
for air. Please consult the manufacturer.
DANGER!
Unintentional stoppage or interruption:
In the case of an operation in which an unintentional stoppage of or inter-
ruption in the compressor leads to a risk of injury to personnel or damage to
equipment, appropriate safety measures to the equipment must be initiated!

Functional description
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 12
5.2 Construction
The ZIRKON rotary vane compressors comprise the following main components:
Abb. 4 ZIRKON main components
1. Cooling air inlet
2. Direction of rotation arrow
3. Terminal box
4. Connection for suction conduit
5. Connection for pressure conduit
6. Transport lifting eye
7. Cooling air discharge
8. Type plate
5.3 Function
The machines of the ZIRKON series have a suction side and pressure side
each with a connection threading (figure 4, positions 4 and 5). The sucked
air is cleaned by passing across a built-in fine filter.
The machine is encased in a sound cover made of tin. A ventilator is situated
on the coupling, through which the cooling takes place.
Accessories For the machinery types of the ZIRKON series the following accessories are
available if required:
Pressure regulation valve
Check valve
Motor-protection switch
Hose connection
Additional suction filter

Transport storage
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 13
6Transport storage
6.1 Safety instructions for transport
DANGER!
Danger from suspended loads!
Danger of injury and injury leading to fatal injury from falling loads!
Do not stop under swaying loads
Maintain sufficient distance from swaying loads
Be mindful of the centre of gravity
Observe the accident When lifting and transporting the machinery be aware of the technical safety
prevention regulations! regulations and the general accident prevention regulations as well as the accepted
regulations of the state of the art.
6.2 Lifting and transporting the machine
The machines in the series may only be suspended from the lug provided
(see position 6, figure 4).
The machine may swing outwards. Be aware of the centre of gravity when
lifting and follow the lifting instructions!
Packaging The machine must be correctly packed in the original packaging prior to
transporting to its destination. The package must be fixed on a Europalette
or similar system so that the machine cannot tip over.
The packaging should protect the individual components up to their
assembly, from transportation damage, corrosion and other damage.
Therefore, the packaging must not be disturbed and only removed shortly
before assembly.
ENVIRONMENTAL DAMAGE THROUGH DISPOSAL!
Packaging material is a valuable product and can, in many cases, be re-
used or carefully prepared and re-used. Therefore:
The packaging material must be disposed of in an environmentally
friendly manner
The local disposal regulations should be observed ; if necessary, a
company qualified in disposal matters should be contracted to do
so.
6.3 Storage
The machinery of the construction series ZIRKON must be stored in a dry
situation that has normal air humidity
At a relative humidity above 80% it is recommended that the site is enclosed
in a sealed cover containing a drying agent.
Storage for longer than one year should be avoided.

Commissioning
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 14
7Commissioning
7.1 Setup
INFORMATION!
A
ll illustrated numbered components refer to the positions in the illustration of
figure 4 on page 12.
During assembly and setup of the machine care should be taken to ensure that
the cooling air inlet (position 1) and the cooling air outlet (position 7) are at
least 10 cm away from adjacent walls.
For de-assembly of the filter box cover, cover hood and exhaust screen, 30 cm
space must be available for maintenance work.
Assembly of the ZIRKON can be undertaken on a stable and secure surface
without the need for fixed footings.
For assembly on an lower construction we recommend a fixture having elastic
rubber shock absorbers.
Vibration of machines of the ZIRKON construction series is minimal.
INFORMATION!
For assembly at levels greater than 1000 metres above sea-level, reduced
output is noticeable.
In this case, we advise prior advice from the manufacturer.
7.2 Installation
WARNING!
Mortal danger from electrical shocks!
Non-professional handling of electrical components can lead to life-threatening
electric shocks, if undertaken with insufficient experience.
Electrical installations should only be undertaken by qualified personnel
Fused security for the construction should be carried out via the main
junction box.
T
AKE CARE!
A
ccident avoidance directions should be observed:
For all activities involving the assembly and start-up procedures, the accident
avoidance regulations “Compressors“ VBG 16 must be observed!

Commissioning
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 15
1. The connection for pressure conduit, figure 4, position 5.
The compressed air is channeled through the connection in the pressure
conduit and fed to the generator.
INFORMATION!
With too narrow and/or long conduits the output of the machine is reduced!
2. The electrical data is indicated on the type plate (position 8) or on the motor
type plate. The motors conform to DIN EN 60034 and are displayed in
Safety type IP 55 and isolation class F. The corresponding connection
scheme is displayed in the junction box of the motor (not present where the
circuit has a plug connection). The motor data should be compared with the
existing grid (current type, tension, grid frequency and permitted current
strength).
For information regarding single-phase and triple-phase alternating current
as well as connection setting see below!
3. The motor and motor protection switch (for security a motor protection
switch and for draught exclusion of the connecting cable a cable threading
are provided).
INFORMATION!
We recommend the use of motor protection switches where switching off is
dependent upon a possible excess current which becomes time-delayed.
Short-term excess current can occur during a cold start of the compressor!

Commissioning
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 16
Three-phase alternating current:
With three-phase alternating current three alternating tensions are carried
across five connections that have a timed relationship to one another, a so-
called phased relationship.
Figure 5 Connection for three-phase alternating current
a. ∆-- Connection (triangular), lower tension (Example: 230 V)
b. Y – Connection (star-shaped), higher tension (Example 400 V)
Standard Tension Range
50 Hz 60 Hz
220 / 380 V ± 5%
230 / 400 V ± 10%
240 / 415 V ± 5%
265 / 460 V ± 10%
7.3 Commissioning
NOTE!
T
he maximum number of starts per hour may not exceed 10
1. The motor start-up and current direction should be checked with the
arrow direction on the housing, see figure 4, position 2
CAUTION!
T
HE PRESSURE CONDUIT MUST NOT BE CONNECTED!
With this start-up the pressure conduit must not be connected. With reverse
flow of the compressor and connected pressure conduit, a vacuum can build up
that can lead to damage to the vanes and actual fracture of the discs.
2. Connect the pressure conduit at the position 5 in figure 4. Notice: if
the compressor is connected to the application via a conduit in excess
of 3 m in length, we recommend the inclusion of a non-return valve
between the pump and the conduit. This will avoid reverse flow after
shut-down.
3. A pressure-regulation valve is optional. The regulation of the pressure
is carried out by turning the regulation knob; take note of the indicated
turning direction.
ba

Operation
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 17
8Operation
Noise emission We recommend that in prolonged presence in the vicinity of the operating
compressor, the operator uses a personal hearing protection device in order
to avoid permanent damage to the hearing organ.
HOT SURFACE!
Surface temperatures in excess of 70°C!
A
t hot operating temperatures the surface temperatures of components can rise
above 70°C. Risk of burns!
Avoid touching the components.
Wear protective gloves.
Before start-up of the operation, the correct set up for the machine, the
installation and start-up (trial run) should be organized.
See chapter 7 “Start-up“ page 14.
The machine should be checked prior to start-up in respect of observance of
the service measures! See chapter 9 “Service“, page 18.

Maintenance
B115 06/16 Rev.2 ZIRKON D060 D – D140 D 18
9Maintenance
DANGER!
Before undertaking maintenance works:
For maintenance activities, the machine must be secured by withdrawal of the
circuit plug or operation of the main switch to separate it from the E-Grid and
to ensure against re-switch-on.
Pressure-conducting conduits must be purged of air before disassembly!
Maintenance must not be carried out on operation-warm machinery (danger of
injury through contact with hot components)!
All machines have a permanent lubrication at the bearings. This must not be
re-lubricated.
For maintenance operations, the vanes and the filter cartridge of the inlet
filter must be checked, see chapter 9.1 and 9.2.
For maintenance of the filter and vanes the exhaust screen and casing lid
must be unscrewed.
For this purpose the fixing screws must be withdrawn and the screen and lid
removed.
9.1 Air Filter
NOTE!
If there is insufficient maintenance of the filter, the compressor has a reduced
functionality!
The filter cartridge for the suction air, depending on the degree of
contamination, should be cleaned by purging from inside to outside.
The operational readiness of the degree of separation will be reduced in
spite of cleaning the filter. Therefore, we recommend replacement of the
filter every half year.
Filter replacement:
Filter replacement is carried out in the following manner:
Unscrew the filter box cover figure 6, position 3
The filter cartridge is withdrawn, figure 6, position 1
The filter cartridge is cleaned and/or exchanged
The re-assembly is carried out in the reverse manner.

B115 06/16 Rev.2 ZIRKON D060 D – D140 D 19
Figure 6 Filter housing, cartridge
1. Filter cartridge
2. Filter box gasket
3. Filter box cover
Abb. 7 Open housing, vanes
1. Vane
2. Housing boring
3. Housing cover
4. Vane/housing lid
Maintenance

B115 06/16 Rev.2 ZIRKON D060 D – D140 D 20
9.2 Vanes
Vane control:
The machines of the series ZIRKON D060 D to D140 D have 4 carbon vanes
that wear out during operation by rubbing. In order to achieve faultless
operation, the vanes must be checked for wear at regular intervals.
For this purpose the vanes have to be disassembled:
The cover is removed
Housing lid is unscrewed, figure 7 position 3
The vanes are removed for checking, figure 7 position 3
Minimum height and condition of the vanes are checked.
The vanes must have the following height (A):
Construction series Minimum height A
ZIRKON D060 D 36 mm
ZIRKON D080 D 36 mm
ZIRKON D100 D 41 mm
ZIRKON D140 D 41 mm
Abb. 8 vane height A
Maintenance