Alkin W31 series User manual
W31
SERIES
W 3 1 S E R IES
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN Kompresör Sanayi ve Ticaret Limited Şirketi
2
InstructionsManual
and Parts List
A L K I N K O M P R E S Ö R
High Pressure Breathing Air Compressor
© This manual or any parts thereof cannot be copied by any means, or used for any other purposes other than servicing ALKIN
W31 Series compressors, unless specific written permission of ALKIN® is received.
ALKIN KOMPRESÖR San. ve Tic. Ltd. Şti
İbrahim Turan Caddesi No: 127, Menderes
35470 İzmir
TURKEY
Tel: +90 232 78 222 90 • Fax: +90 232 78 222 89
www.alkin.com.tr
W 3 1 S E R IES
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN Kompresör Sanayi ve Ticaret Limited Şirketi
6
W 3 1 S E R IES
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN Kompresör Sanayi ve Ticaret Limited Şirketi
7
Contents
1.0 GENERAL INFORMATION..........................................................................................................11
1.1 General...................................................................................................................... 11
1.1.1 General Safety ......................................................................................................................... 11
1.1.2 Safety Tags............................................................................................................................... 11
1.1.3 Pressure Release...................................................................................................................... 11
1.1.4 Fire and Explosion.................................................................................................................... 12
1.1.5 Moving Parts............................................................................................................................ 12
1.1.6 Hot Surfaces, Sharp Edges and Corners................................................................................... 12
1.1.7 Toxic and Irritating Substances................................................................................................ 13
1.1.8 Electrical Shock........................................................................................................................ 13
1.1.9 Lifting and Carrying.................................................................................................................. 13
1.1.10 Tags........................................................................................................................................ 14
1.2 About Compressor.....................................................................................................14
1.2.1 General .................................................................................................................................... 14
1.2.2 Technical Data ......................................................................................................................... 18
1.3 Process and Instrument (P & I) Diagram .................................................................... 19
1.4 Principles of Operation..............................................................................................22
1.5 Lubrication System ....................................................................................................22
1.6 Description of Major Components.............................................................................23
1.6.1 Major Components –Compressor Unit ................................................................................... 23
1.6.2 Major Components –System .................................................................................................. 24
1.7 Description of Controls..............................................................................................26
1.7.1 Manual Start ............................................................................................................................ 26
1.7.2 Auto Stop................................................................................................................................. 26
1.7.3 Auto Drain ............................................................................................................................... 26
1.8 Installation ................................................................................................................26
1.8.1 Inspection ................................................................................................................................ 26
1.8.2 Location ................................................................................................................................... 27
1.8.3 Piping ....................................................................................................................................... 27
1.9.4 Electrical Controls.................................................................................................................... 27
1.9.5 Wiring ...................................................................................................................................... 28
1.10 Storage ....................................................................................................................28
1.11 Operation ................................................................................................................29
1.11.1 Initial Start-Up Procedure...................................................................................................... 29
1.11.2 Oil Recommendation ............................................................................................................. 30
1.11.3 Extremely Cold Ambient Temperatures ................................................................................ 30
1.11.4 Motor Lubrication.................................................................................................................. 30
1.11.5 Adjustments .......................................................................................................................... 30
1.11.6 Cylinder Filling Instructions ................................................................................................... 31
2.0 MAINTENANCE ............................................................................................................................. 33
2.1 General...................................................................................................................... 33
2.2 Maintenance Procedure ............................................................................................33
2.3 Maintenance Table....................................................................................................35
2.3.1 Maintenance –Check Table..................................................................................................... 35
2.3.2 Replacement Table .................................................................................................................. 36
2.4 Torque Values ...........................................................................................................37
2.5 Maintenance Instructions..........................................................................................37
2.5.1 Oil Level Check......................................................................................................................... 37
2.5.2 Leak Check ............................................................................................................................... 37
2.5.3 Auto Drain Valves Check.......................................................................................................... 38
2.5.4 Intake Filter Check ................................................................................................................... 38
2.5.5 V-belt Alignment Check ........................................................................................................... 38
2.5.6 Components Check.................................................................................................................. 38
2.5.7 Serpentines, Intercoolers and Aftercooler, Flywheel Cleaning................................................ 39
2.5.8 Current Check .......................................................................................................................... 39
W 3 1 S E R IES
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN Kompresör Sanayi ve Ticaret Limited Şirketi
8
2.5.9 Safety Valve Check ...................................................................................................................39
2.5.9.1 Safety Valve Replace .............................................................................................................39
2.5.10 Check Valve Check .................................................................................................................40
2.5.10.1 Check Valve Replacement...................................................................................................40
2.5.11 Priority Valve Check ...............................................................................................................40
2.5.11.1 Priority Valve Replacement.................................................................................................40
2.5.12 V-Belt Replacement ...............................................................................................................41
2.5.13 Purifier Cartridge Refill Kit Replacement ...............................................................................41
2.5.14 Intake Filter Replacement......................................................................................................42
2.5.15 Auto Drain Valve Adjustment with Repair Kit ........................................................................42
2.5.16 Oil Change Instructions ..........................................................................................................43
2.5.17 Valve Replace Instructions .....................................................................................................43
2.6 Abrasion Limits..........................................................................................................44
3.0 TROUBLESHOOTING...................................................................................................................45
4.0 PARTS LIST ....................................................................................................................................49
4.1 Crankcase ass’y..........................................................................................................51
4.2 First Stage..................................................................................................................52
4.3 Second stage .............................................................................................................53
4.4 Third stage.................................................................................................................54
4.5 General piping (standart)...........................................................................................55
4.6 General piping (Optional-Auto drain) ........................................................................56
4.7 Aftercooler ................................................................................................................57
4.8 Condensate Separator&Purifier.................................................................................58
4.9 General connectors (electric motor) ..........................................................................59
4.10 General connectors (Petrol engine) .........................................................................60
4.11 Filling line (Standart) ...............................................................................................61
4.12 Filling line(Optional-Dual output).........................................................................62
4.13 Filling line (Optional-Dual pressure) ........................................................................63
5.0 TECNİCAL DRAWİNGS ................................................................................................................65
W 3 1 S E R IES
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN Kompresör Sanayi ve Ticaret Limited Şirketi
9
Your new ALKIN air compressor will provide you with the solid and reliable performance that you should expect from a heavy-duty industrial
air compressor.
Please read this manual carefully before you operate your compressor. This will enable you to start-up your compressor in the proper manner, as well as
maintain it using the simple instructions in the maintenance section of this manual. This way your air compressor will always be in top operating
condition, giving you years long trouble free service.
LKIN air compressors are well known for their faultless design and unique features combined with
the best materials and workmanship. Some of the most important features are centrifugal unloading
regulators, overhung crankshaft design, solid end connecting rods, high efficiency valves, which all
add to the superior and lasting performance of the ALKIN compressors.
Your compressor is backed up with worldwide sales and service organization, ready to accommodate your
everyday needs for parts & service.
Service and parts supply anywhere in the world can be done by an ALKIN Dealer. For any questions, please feel
free to call our Menderes plant, in İzmir-Turkey. Here are the contact details:
Address: ALKIN Kompresör San. ve Tic. Ltd.Sti
Ibrahim Turan Cd. N.127, Menderes
35470 Izmir, TURKEY
Telephone: +90 –232 –78 222 90 (10 Lines)
Fax : +90 –232 –78 222 89
In all correspondences, please provide serial number and a copy of invoice.
Additionally, replacement parts not manufactured or approved by ALKIN can damage your compressor, creating
risks of accidents and injuries.
ALKIN has the right to change information without any prior notice.
Users are expected to safely operate and maintain the compressor, observe the rules and instructions, as well as the
local safety codes, to minimize the risk of accidents and injuries.
FOREWORD
A
W 3 1 S E R IES
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN Kompresör Sanayi ve Ticaret Limited Şirketi
10
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