Alkin W32 Series Instruction Manual & Parts Book
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Alkin W32 Series Instruction Manual & Parts Book

3 stage high pressure breathing air compressors 225 – 350 bars
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ALKIN
®
W32 Series
3 Stage High Pressure
Breathing Air Compressors
225 – 350 Bars
Instruction Manual & Parts Book
ALKIN
Compressors
Menderes / Izmir / TURKEY
Tel : (0090) 232 782 2290
Fax : (0090) 232 782 2289

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  • Page 1 ALKIN ® W32 Series 3 Stage High Pressure Breathing Air Compressors 225 – 350 Bars Instruction Manual & Parts Book ALKIN Compressors Menderes / Izmir / TURKEY Tel : (0090) 232 782 2290 Fax : (0090) 232 782 2289...

  • Page 2: Table Of Contents

    Instruction Manual W32- Series Medium-Vertical Compressors CONTENTS SECTION Page I-1. Foreword I-2. Introduction I-3. Safety General Pressure release Fire & Explosion Moving Parts Hot Surfaces Toxic and irritating Substances Electrical Shock Lifting I-4. General information General Desing Compressor block Functional description Compressor block,front view I-5.

  • Page 3: I - 1. Foreword

    © This manual or any parts thereof cannot be copied by any means, or used for any other purposes other ® than servicing Alkin W32 series compressors, unless specific permission of Alkin in writing is received. I – 1. Foreword Your new ALKIN air compressor will provide you with best materials and workmanship.

  • Page 4: Fire & Explosion

    Instruction Manual W32- Series Medium-Vertical Compressors pressure switch signal to re-start). Switch off the main 4. Moving Parts electrical switch, shut off the discharge valve and vent Keep Hands, arms and other parts of the body and pressurized sections before attempting clothing away from the belts, pulleys and other dismantle such components.

  • Page 5: Lifting

    If you must lift the compressor, lift in full compliance level surfaces, capable of carrying its full weight. with codes and regulations. Make sure entire lifting, rigging and supporting structure has been inspected, I – 4. General Information on W32 Series 3 Stage Compressors 1. General W32 Series compressors...

  • Page 6: Functional Description

    The oil pump (1) is coupleled to and driven by the cranksaft. It pumps oil from the oil sump (5) through The W32 series compressors incorporate stainless steel the oil fine filter (2) and a minimum presure valve (3) valves on all 3 stages. They are designed to have an...

  • Page 7: Compressor Block,Front View

    Instruction Manual W32- Series Medium-Vertical Compressors Compressor block, front view Fig. 2 Compressor block, front view Intake filter 8 Intermediate separator Cylinder, 3 stage 9 Oil filter housing Plug, Oil filler neck 10 Oil level gage Oil filler neck 11 Intercooler Safety valve, 2 stage 12 Cylinder, 2...

  • Page 8: P&I (Process & Instrument) Diagram

    : Aftercooler Drain Drain Pilot Valve Solenoid Drain NEXT ASS'Y Application Field Title Page Date Name ALKIN W32 SERIES 3 STAGES SINGLE PRESSURE P&I DIAGRAM 13.07.2002 BREATHING AIR COMPRESSORS Resp. Modification Date Name Edited COMPRESSORS® Drawing Number Check Scale Weight...

  • Page 9: Dual Pressure P&I Diagram

    : Aftercooler Drain Drain Pilot Valve Solenoid Drain NEXT ASS'Y Application Field Title Page Date Name ALKIN W32 SERIES 3 STAGES DUAL PRESSURE P&I DIAGRAM 13.07.2002 BREATHING AIR COMPRESSORS Resp. Modification Date Name Edited COMPRESSORS® Drawing Number Check Scale Weight...

  • Page 10: I - 6. Principles Of Operation

    Instruction Manual W32- Series Medium-Vertical Compressors I – 6. Principles of Operation 1st Stage Cover Inlet Valve Ass'y 1st Stage Valve Ass'y (3rd Stage) Inlet Valve Ass'y 1st Stage (2 nd Stage) Piston Ass'y Connecting Rod 3rd Stage Cover (1st Stage) 1st Stage Cylinder Dicharge Valve Ass'y...

  • Page 11: Description Of Major Compenents

    This unique device saves to pay compressors. extra attention to the belt tightening on W32 series machines. Crankshaft : It is overhung type; that means the bearings are on one side, and the crank pin (where The Electrical Panel: It is located at the front view / connecting rods are mounted) are on the other side.

  • Page 12: I - 8. Description Of Controls

    Instruction Manual W32- Series Medium-Vertical Compressors I – 8. Description of Controls Compressor Controls : The W32 Series compressor the system; when the low cut out pressure (in this may operate with the following two controls : example 3200 psi) is reached, the pressure switch will 1.

  • Page 13: Model Designations

    Instruction Manual W32- Series Medium-Vertical Compressors I.9. Model Designations W32 – 5 - 310 – F P4 N Filling Panel – Type N (integral) , Type M (removable) Purifier – Size 2 , 4 or 6 : P2 (up to 230 Lt/min – 8,5 cfm) Power in kW P4 (up to 450 Lt/min –...

  • Page 14: Ownership Records 12

    13 mm Belt Size Number of belts Pressure Control Type Pressure switchgage Model Make Alkin Cut In pressure Cut out pressure Differential P Other Data Electrical Control Panel & Motor Starter Drawing Number Parts List Number Page I - 12.
  • Page 15 Instruction Manual W32- Series Medium-Vertical Compressors Electrical Panel Panel type Drawing Number Starter Type List of Components Description Make Designation Model Rating Main Switch (isolator) On-off switch Emergency stop button Hourmeter Main motor overload relay Star / delta timer relay ……………….

  • Page 16: I - 11. Installation

    Discharge Piping - If piping is required between the compressor package and the filling station, properly The W32 Series compressors are supplied with a self- selected stainless stell pipes must be used. The piping tightening rotary slide; therefore these are no should be installed in full compliance with all Federal, adjustments need to be made.

  • Page 17: Initial Start-Up Procedure

    . If any questions, call the switch extending into the crankcase. nearest ALKIN distributor, service or factory. Extreme Cold Operating Conditions: Operating Be sure all the preparations described in the conditions at below freezing temperatures must be installation section of this manual have been made.

  • Page 18: Drain Timer Adjustment

    Instruction Manual W32- Series Medium-Vertical Compressors WARNING • Do not adjust the safety valves and do not alter their original settings. Only authorized service technicians are certified to make such adjustments. If required, replace and return the old one for reconditioning to the factory or to a dealer nearest you.

  • Page 19: Comissioning Report - Initial Start Up

    Instruction Manual W32- Series Medium-Vertical Compressors COMISSIONING REPORT – INITIAL START UP CUSTOMER DETAILS Name of the Company Address Contact Name Position Phone Name of Plant Where Equipment Installed (If different than the above) Address Contact Name Position Phone Distributor Persons Attending the Commissioning Full Name Position...
  • Page 20 Instruction Manual W32- Series Medium-Vertical Compressors START UP CHECKS Remarks Signature Direction of rotation Start up current and voltage Amps. Volts Fill in the pressure reading table Pressure switch cut out pressure Bars Main Motor Current and voltage at full load Amps.

  • Page 21: I - 13. Maintenance

    Instruction Manual W32- Series Medium-Vertical Compressors I – 13. MAINTENANCE 1. GENERAL pounds) weight applied on the center of each belt. As you proceed through this section, it will be easy to see how simple is the compressor to maintain. By Every 120 Hours: Change or re-fill the purifier following these recommendations, you will get long cartridge.

  • Page 22: Maintenance Table

    Instruction Manual W32- Series Medium-Vertical Compressors MAINTENANCE TABLE Maintenance Period DAILY WEEKLY 300 Hours 500 Hours 1000 Hours I:Inspect/M:Maintain/R:Replace LUBRICATION 1. Oil 2. Crankcase Cleaning INTAKE FILTER V - BELT Pressure Vessels w/o auto.drain vlv. 1. Condensate Drain 2. Pressure vessel test PIPING &...

  • Page 23: I - 14. Maintenance Procedures

    Instruction Manual W32- Series Medium-Vertical Compressors I – 14. MAINTENANCE PROCEDURES CAUTION Bring the main isolating switch to “Off” [or `0`] position before attempting doing any repair work on the unit to prevent accidental (or automatic) starting. Blow down all pressure from the compressor, filter & purifier and isolate the unit from any outside sources of air pressure such as filling stations, cylinders etc.

  • Page 24: Valves 22

    Instruction Manual W32- Series Medium-Vertical Compressors 4. VALVES CAUTION In order to avoid damaging the special tool or 4.1. Initial operational check of valves the valve when using the tool, ensure that it is After roughly half an hour’s operation, Valves should pushed properly and firmly into the valve bore be checked.

  • Page 25: Valves 22 & 23

    Instruction Manual W32- Series Medium-Vertical Compressors • Turn the cylinder head and replace it on the metal • Check with a precision straightedge that the pins. underside of the cylinder head is flat, if necessary • Unscrew the cap nut (1, Fig. 9) refer to Fig.11. use an emery cloth to smoth out the surface.

  • Page 26: Intake Filter

    Instruction Manual W32- Series Medium-Vertical Compressors • Screw in the screw-in pressure plug with a pressure Reinstall pressure valve (5) in reverse sequence: pad and tighten. • Put O-ring (4) into valve head (7). Check O-ring for abrasions. NOTE • Insert pressure valve (5). Put on valve head cover Ensure thad the stud is unscrewed.

  • Page 27: Intermadiate Separator

    Instruction Manual W32- Series Medium-Vertical Compressors 6. INTERMEDIATE SEPARATOR Proper operation of the individual compressions stages will rely on the intermediate separator being properly serviced. 6.1. Condensate drain Drain condensate every 15 to 30 minutes from these separatrs or ensure that the automatic condensate drain unit drains regulary.

  • Page 28: Fınal Separator/Filter System 25 & 26

    Instruction Manual W32- Series Medium-Vertical Compressors • Change cartridge before reactivating a compressor • Change or clean valves, coolers, separators, unit, which has been out of service for more than 6 purifiers and all pneumatic tubes and hoses from mounths. deposits.

  • Page 29: Lubrication System 27 &28

    W32- Series Medium-Vertical Compressors Instruction Manual I – 15. TROUBLE SHOOTING 1. COMPRESSOR WILL NOT OPERATE 1. No electrical power Switch the power on 2. Motor starter overload tripped Re-start and check if trips again. If it does check if the centrifugal unloader venting air at shutdown, resulting in staring under load.
  • Page 30 W32- Series Medium-Vertical Compressors Instruction Manual 2. Worn piston rings Replace piston rings 3. Excessive oil in the crankcase Drain to the overflow level Drain oil; refill with oil of proper viscosity (see 4. Low oil viscosity recommended oils) 5. Piston rings misassembled If piston rings are upside down, install in proper position ;...
  • Page 31 W32- Series Medium-Vertical Compressors Instruction Manual 7. Comp. rotating in the wrong Correct the direction of rotation. direction 8. Insufficient supply of fresh cooling Check location max. ambient temperature +45 ˚C (110 ˚F) air. 9. Intake or outlet valves nt closing Check and clean valves, replace as necessary.

  • Page 32: Trouble Shooting 28 & 29 & 30

    W32- Series Medium-Vertical Compressors Instruction Manual 20. AUTOMATIC DRAIN VALVE(S) REMAINS OPEN ALL THE TIME 1. Low 2 stage control air Check the nterstage pressures pressure 2. Faulty pilot solenoid Replace the pilot solenoid 3. Blocked drain vave Clean 4. Worn pilot valve seat Replace drain valve (or if trained to repair, use a repait kit to correct) 21.
  • Page 33 PARTS LIST W32 SERIES 3 STAGES HIGH PRESSURE MEDIUM-VERTICAL COMPRESSORS 240-350 BARS ALKIN Compressors Menderes/Izmir/Turkey Tel :(0090) 232 782 22 90 Fax : (0090) 232 782 22 89...
  • Page 34 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR 7802-01-061104F - Compressor Frame Assembly FIGURE 1 Pos.Nr Part Nr. Description 6882-06 Allen screw DIN EN24017;M8x25;8.8 7774 Plug 7729-15 O-ring 32,92x3,53;FKM;75SHORE 7756 Oil filling pipe 7729-14 O-ring 34,59x2,62;FKM;75 SHORE 7702 Crankcase 7791 Oil sight gage gasket DIN 7603A27x32x2;CU...
  • Page 35 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR look at figure 5 look at figure 5 look at figure 5 7802-02-030105 D - Bare Compressor FIGURE 2...
  • Page 36 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR Pos.Nr Part Nr. Description 7867-02 Hex. bolt DIN 912;M8x75;8.8 7091-09 Washer DIN 125;B 8.4;St;A3A 7781 Gasket 7712 Cylinder-1st stg 6884-03 Hex. nut self-locking DIN 980;N M8;8;A3A 6854-21 O-ring 94.92x2.62;NBR;75 Sh. 7780-01 Stud DIN 835;M8x25;8.8 7780-02 Stud DIN 835;M8x105;8.8...
  • Page 37 PARTS LIST-W32 SERIES VERTICAL COMPRESSORS 7802-03-231204 E - Oil Pump System FIGURE 3 Pos Nr. Part Nr. Description 7735 Cover for oil pump 7789-01 Filter element 7789-03 Rubber gasket 7729-25 O-ring Ø33xØ2,62;FKM;75Sh 7729-24 O-ring Ø42,52xØ2,62;FKM;75Sh 7789-02 Cover for oil filter...
  • Page 38 PARTS LIST-W32 SERIES VERTICAL COMPRESSORS 7 8 0 2 - 0 4 - 2 1 0 8 0 3 D - Valve Assemblies FIGURE 4...
  • Page 39 PARTS LIST-W32 SERIES VERTICAL COMPRESSORS Pos.Nr Part Nr. Description 7787-01 1st stage valve complete 7753 • Top cover-1st stg 7754 • Gasket 7787 • Valve ass'y-1st stage 7785 •• Countersun screw 7784 •• Valve plate 7783 •• Valve plate-Spring 7782 ••...
  • Page 40 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR 7802-05-160603 C - Piston & Rings Ass'y FIGURE 5 Pos.Nr Part Nr. Description 7805 Piston complete - 1st stage 7711 •Piston 7805-04 •Ring set 7713 •Piston pin 7003-02 •Lock-ring , piston pin 7807 Piston complete - 2nd stage 7709 •Piston...
  • Page 41 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR 7802-06-160603 C - Compressor Inlet Filter & Condensate Separator Assembly FIGURE 6 Pos.Nr Part Nr. Description 7764 Inlet filter ass'y 7764-02 • Cover 7764-04 • Spring 7729-05 • O-ring 75x3 ;NBR 7764-03 • Filter element 7729-06 •...
  • Page 42 PARTS LIST-W32 SERIES VERTICAL COMPRESSORS 7802-07-160603 D - Prefilter Ass'y FIGURE 7 Pos.Nr Part Nr. Description 7837 Prefilter ass'y 7837-01 •Body 7837-04 •Top cover ass'y 7837-02 ••Top cover 7729-10 ••O-ring 26,64x2,62;NBR;70sh 7763-04 ••Connector 7729-08 ••O-ring 14x1,78;FKM;85 7763-07 ••Filter element 7729-09 ••O-ring...
  • Page 43 PARTS LIST-W32 SERIES VERTICAL COMPRESSORS 7 8 0 2 -0 9 -1 6 0 6 0 3 D - P4 Purifier Ass'y FIGURE 8 Pos.Nr Part Nr. Description Purifier Ass'y 7857-02 7857-01 •Body 7168-42 •Bottom Cover Ass'y 7168-28 ••Ring 7168-25 ••O-Ring-72,4x5,33...
  • Page 44 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR 7802-10-160603 E - Drain Collector FIGURE 9 Pos.Nr Part Nr. Description 7752-10 Drain collector ass'y 7752-01 •Drain collector body 7752-11 •Tie rod M8x150 7894-09 •Gasket 6883-02 •Acorn nut 7091-09 •Washer 7894-01 •Filter complete 7894-05 ••Nut 7894-04 ••Threaded hose...
  • Page 45 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR 7802-11-110105 E - W32 Compressed Air Piping - 1st To 3rd Stage FIGURE 10...
  • Page 46 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR Pos.Nr Part Nr. Description 10.1 7423-01 Fitting-1/8"xØ6 sst 10.2 7874-01 Tube-Ø6 sst 10.3 7672-12 1/4"x1/4" Elbow 10.4 7816-01 Fitting-1/4"xØ8 sst 10.5 7874-02 Tube-Ø8 sst 10.6 7672-06 Elbow-1/4" sst 10.7 7424-01 Fitting-1/4"xØ12 10.8 7824-03 Tube-Ø12 sst 10.9...

  • Page 47: Pos.nr Part Nr. Description Qty

    PARTS LIST-W32 SERIES VERTICAL COMPRESSOR 7802-14-310504 E - Drain piping FIGURE 12 Pos.Nr Part Nr. Description 12.1 7422-01 Fitting-1/4"xØ6,sst 12.2 7874-12 Tube-Ø6 sst 12.3 7423-01 Fitting-1/8"xØ6,sst 12.4 6398-08 Drain control valve 12.5 5009 Elbow 49w 5/16"x1/8",brass 12.6 7874-13 Tube-Ø5/16,copper 12.7 7134 Tee-1/8x5/16"...
  • Page 48 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR 7802-13-170603 E - General piping (filter-purifier)&Pressure gage piping FIGURE 11...
  • Page 49 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR Pos.Nr Part Nr. Description 11.1 7874-07 Tube-Ø6 sst 11.2 7422-01 Fitting-1/4"xØ6 11.3 7742-03 Connector 11.4 7145-02 11.5 7874-08 Tube-Ø6 sst 11.6 7874-09 Tube-Ø6 sst 11.7 7140 Check valve 11.8 7678-15 Nipple-1/4x1/4 11.9 7084-02 Connector 11.10...
  • Page 50 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR Purifier Priority valve 7802-16-180603 C - Filling piping(dual pressure) FIGURE 13 Pos.Nr Part Nr. Description 13.1 7672-06 Elbow-1/4" 13.2 7422-01 Fitting-1/4"xØ6 13.3 7874-20 Tube 13.4 7672-07 Tee-1/4" 13.5 7191 Pressure selector valve 13.6 7874-21 Tube 13.7...

  • Page 51: Elbow-1/4

    PARTS LIST-W32 SERIES VERTICAL COMPRESSOR Purifier Priority valve 7802-17-180603 D - Filling piping (225 Bar) FIGURE 14 Pos.Nr Part Nr. Description 14.1 7672-07 Elbow-1/4" 14.2 7422 Fitting-1/4"xØ6 14.3 7874-25 Tube 14.4 7874-26 Tube 14.5 7145-02 14.6 7866-01 Filling valve 14.7...

  • Page 52: O-Ring Ø7Xø1.45

    PARTS LIST-W32 SERIES VERTICAL COMPRESSOR Purifier Priority valve 7802-18-180603 D - Filling piping (310 Bar) FIGURE 15 Pos.Nr Part Nr. Description 15.1 7672-07 Elbow-1/4" 15.2 7422 Fitting-1/4"xØ6 15.3 7874-25 Tube 15.4 7874-26 Tube 15.5 7145-02 15.6 7866-01 Filling valve 15.7...

  • Page 53: Plate

    PARTS LIST-W32 SERIES VERTICAL COMPRESSOR 7802-20-281204 C - Front panel assy FIGURE 16 Pos.Nr Part Nr. Description 16.1 7757-33 Front panel 16.2 7757-35 Flywheel protector 16.3 7757-08 Instrument panel 16.4 7757-21 Control panel 16.5 7757-22 Cover-control panel 16.6 7757-25 Plate 16.7...
  • Page 54 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR 1 3 12 78 02 -2 2-10 11 0 4 C Canopy FIGURE 17 Pos.Nr Part Nr. Description 17.1 7757-32 Base part 17.2 7757-13 Anti-vibration frame 17.3 7757-20 Motor base 17.4 7757-26 Belt Guard Bottom Plate 17.5...
  • Page 55 PARTS LIST-W32 SERIES VERTICAL COMPRESSOR - KASNAK KOMPLE FIGURE 18 Pos.Nr Part Nr. Description 7716-01 Komple Kasnak 7724-01 Kasnak Göbeği 7716 Kasnak 7867-01 Cıvata M10x20 7724-02 Kasnak Göbeği Merkezi 6882-08 Allen Civata M8x25...
  • Page 56 RELAY-AUTO START/STOP LOW VOLTAGE FUSE EMERGENCY STOP TIMER RELAY-DRAIN RELAY-PRESSURE SWITCH GAGE CONTACTOR-MAIN RELAY-PRESSURE SWITCH GAGE SOLENOID VALVE-DRAIN CONTACTOR-DELTA LAMB-COMPRESSOR RUNNING CONTACTOR-STAR OVERLOAD ALKIN Application Field NEXT ASS'Y Title Page Date Name CONTROL WIRING DIAGRAM 22/08/2003 SINGLE PRESSURE Resp. Modification...

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