Alkin HW-1500 Series Operator's Manual
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Alkin HW-1500 Series Operator's Manual

High pressure water cooled air compressors
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HIGH PRESSURE WATER COOLED
AIR COMPRESSORS
HW-1500 SERIES
OPERATOR MANUAL

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Summary of Contents for Alkin HW-1500 Series

  • Page 1 HIGH PRESSURE WATER COOLED AIR COMPRESSORS HW-1500 SERIES OPERATOR MANUAL...
  • Page 3 HIGH PRESSURE WATER COOLED AIR COMPRESSOR MODELS HW 1500 AC MOTOR - - HW 1500 DC MOTOR -...
  • Page 5 © This manual or any parts thereof cannot be copied by any means, or used for any other purposes other than servicing HW 1500 Series compressors, unless specific written permission of ALKIN® is received.  ALKIN KOMPRESÖR SAN. ve Tic. Ltd. Şti Cüneytbey Mah.

  • Page 6: Table Of Contents

    CONTENTS GENERAL INFORMATIONS ............2 General ......................2 1.1. General Safety Information ..............2 1.2. Safety Tags ..................3 ABOUT COMPRESSOR ..............8 General ......................8 2.1. Compressor Unit ................. 9 2.2. Technical Data .................. 16 2.3. Process and Instrumentation Diagram (P&ID) ......... 17 2.4.
  • Page 7 TROUBLESHOOTING ..............55 DECLERATION OF CONFORMITY WARRANTY CERTIFICATE...
  • Page 8 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 Compressors. For any questions please feel free to call our Menderes plant, in İzmir-Turkey.

  • Page 9: General Informations

    1.1. General Safety Information All ALKIN air compressors are designed and manufactured with equipment and components that allow safe operation of the compressors. However, it is the user’s responsibility 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.

  • Page 10: Safety Tags

    Hot Surfaces, Sharp Edges and Corners Avoid physical contact with hot oil, hot surfaces, sharp edges and corners. Keep all parts of the body away from all points of air discharge and away from hot cylinder heads, discharge pipes and intercooler ALKIN COMPRESSORS...
  • Page 11 Make adjustments only when the compressor is shut off. When necessary, make adjustments, then start the compressor to check if the adjustment is correct or not. If incorrect, shut the compressor, blow down the air, re-adjust, than re-start to check the adjustment. ALKIN COMPRESSORS...
  • Page 12 Keep a suitable BC or ABC fire extinguisher(s) nearby while servicing and operating the compressor. Keep oil rags, trash, leaves litter and other combustibles away from the compressor. Do not spray volatile materials into the compressor ALKIN COMPRESSORS...
  • Page 13 Figure 1 – Lifting and transporting by forklift Do not distract the forklift operator during carriage. Verify the lifting hook has a safety clamp, and ensure a robust fastening with tough ropes or chain. Avoid the compressor swinging while suspended, by using guide ALKIN COMPRESSORS...
  • Page 14 * Interference of compressor operating parameters by third parties without approval of Alkin Compressors, * Failure to comply with compressor control and component replacement times, * Interventions that do not comply with Alkin Compressors maintenance / repair instructions, * Removal of compressor label,...

  • Page 15: About Compressor

    HW-1500 series high pressure water cooled air compressor is a single-acting, four- stage that compresses the air from atmospheric pressure to 275 bar pressure. The stages are placed in two sequential cylinder blocks.

  • Page 16: Compressor Unit

    HW 1500 SERIES HIGH PRESSURE WATER COOLED AIR COMPRESSORS 2.1. Compressor Unit HW 1500 series (AC Motor) high pressure water cooled compressor covers the following basic groups. Figure 2 – HW 1500 series compressor general layout (AC motor) ALKIN COMPRESSORS...
  • Page 17 HW 1500 SERIES HIGH PRESSURE WATER COOLED AIR COMPRESSORS HW 1500 series (AC Motor) high pressure water cooled compressor covers the following basic groups. Figure 3 – HW 1500 series compressor general layout (DC motor) ALKIN COMPRESSORS...

  • Page 18: Technical Data

    50 mm Cylinder bore (4 stage) 25,4 mm Oil capacity 10 liter Yağ basıncı 4-12 bar Cooling water need 40 l/min Nominal water pressure 10 bar Permissible water pressure till 40 bar Weight 1200 kg Dimensions WxLxH 740x1600x1320 mm ALKIN COMPRESSORS...

  • Page 19: Process And Instrumentation Diagram (P&Id)

    This is, when the compressed air is used to fill all the cylinders at that single pressure. By looking at the P&ID, you can see the general layout of the system and operational turns. Figure 4 – HW-1500 series compressor P&ID (AC Motor) ALKIN COMPRESSORS...
  • Page 20 HW1500 SERIES HIGH PRESSURE WATER COOLED AIR COMPRESSORS Figure 5 – HW 1500 series compressor P&ID (DC Motor) ALKIN COMPRESSORS...

  • Page 21: Identification Of The Compressor

    HW 1500 SERIES HIGH PRESSURE WATER COOLED AIR COMPRESSORS 2.4. Identification of the Compressor Each compressor has an identification label attached to its frame. ALKIN COMPRESSORS...

  • Page 22: Principles Of Operation

    If there is a visible damage, it should be replaced. CONSULT ALKIN COMPRESSORS FOR REPLACEMENT OR MAINTENANCE Crankshaft: It is overhung type; that means the bearings are on one side, and the crank pin (where connecting rods are mounted) are on the other side.
  • Page 23 Large bearings in conjunction with low speeds, allow very long crankshaft life. Replace this part when life of bearings is over. CONSULT ALKIN COMPRESSORS FOR REPLACEMENT OR MAINTENANCE Connecting Rods: In the compressor there are 2 connecting rods made of ductile cast iron in total.
  • Page 24 265 bar IMPORTANT: Consult the nearest ALKIN dealer or ALKIN for replacement or maintenance Intake Filter: Inlet Filter is used to filter the air particles in the first stage. Replace the inlet filter element in the periods shown in Maintenance Table.
  • Page 25 30 minutes and this time can be changed depending on special operating conditions. Muffler: It is designed to minimize the sudden sound level of the pressure which is discharged out of the system together with water that accumulates. ALKIN COMPRESSORS...
  • Page 26 : Lights up when Water Pressure is Low. Emergency Stop : This light turns on when the emergency stop is pressed. HORN : Nonfunctional. : Resets fault lights after eliminating the faults. TEST : Checks whether the fault lights are on. ALKIN COMPRESSORS...

  • Page 27: Startup

     Press the stop button to stop the compressor before the top pressure. The compressor does not automatically switch on after the stop button is pressed.  Set the main switch to the off position so that the compressor is not switched on again.  Close the water inlet valve. ALKIN COMPRESSORS...

  • Page 28: Long Term Switching Off

     Refill the oil every year unless you reach the replacement time of the oil stated in the Maintenance Table. ALKIN COMPRESSORS...

  • Page 29: Electrical Controls

    1 hour to lubricate inner parts in failure to do so, the oxidization may arise on the inner parts and cause trouble for the operator and compressor during next start up. ALKIN COMPRESSORS...

  • Page 30: Maintenance

    The priority is working hours for the compressor control and part replacement. However, if the specified working hours do not expire depending on the operating conditions of the compressor, the specified periods (3 months, 6 months etc.) must be taken into consideration. ALKIN COMPRESSORS...

  • Page 31: Planned Maintenance (Hourly)

    500 hours maintenance Suction filter change Check suction and discharge valves Check rings Every 2000 hours 1000 hours maintenance Oil seal change Belt change Measure & check cylinder liners Valves change Rings change and 4 stage piston change ALKIN COMPRESSORS...

  • Page 32: Planned Maintenance (On A Daily Basis)

     The plug in the extension end is fitted with a vent pipe (Ø16) to make the oil filling (10 liters).  The vent pipe is detached from the extension end and attached to the oil retainer body. ALKIN COMPRESSORS...

  • Page 33: Oil Filter Cleaning

     Remove the cover by pulling it in the direction of the hole axis.  Suction (5.41) and force (5.36) valves are removed.  Repair or replacement is done.  Place the valve elements according to the order shown. O-rings should be lubricated with heat-resistant grease. ALKIN COMPRESSORS...
  • Page 34  The suction tube and the force tube connected to the first stage (both ends) are removed.  The nuts (M10x13,80) on the 3rd stage cylinder (5.28) are removed.  The cylinder is carefully pulled up without damaging the piston rings. ALKIN COMPRESSORS...
  • Page 35  Two bolts on the valve are fitted to the M8 holes simultaneously and tightened. This will allow the 1st stage valve to disengage from the cylinder.  When replacing the new valve, O-rings (5.21, 5.22, 5.23) should also be lubricated with grease resistant to high temperatures. ALKIN COMPRESSORS...
  • Page 36 1st stage piston (5.03) from the connecting rod.  Remove the piston pin (5.04).  Take the piston to a clean surface.  With the aid of the piston ring pliers, the piston rings on the 3rd stage piston (5.06) are removed. ALKIN COMPRESSORS...
  • Page 37 WARNING: Each piston ring should be positioned so that its opening forms an angle of 180° with the upper opening.  The cylinder liners are measured with the help of the comparator. The cylinder liners out of the following wear tolerance should be sent to ALKIN for replacement. Wear Tolerances Stage cylinder liner : Ø195...
  • Page 38 "TOP" are fitted on the top. WARNING: Each piston ring should be positioned so that its opening forms an angle of 180° with the upper opening.  Firstly, O-ring (5.21) is greased and seated on the channel on the 1st stage cylinder. ALKIN COMPRESSORS...

  • Page 39: Nd And 4 Th Stage Maintenance

     The cover is pulled out by turning in the direction of the hole axis.  On the top of the 4th stage valve (6.36), any M6 bolt is tightened and the valve is pulled out by turning in the direction of the hole exis.  Repair or replacement is done. ALKIN COMPRESSORS...
  • Page 40 HW1500 SERIES HIGH PRESSURE WATER COOLED AIR COMPRESSORS ALKIN COMPRESSORS...
  • Page 41  The plates on which the heat exchangers are connected and the crankcase are removed. If there are connected pipes, remove them.  The bolts (6.09-M10x50) connected to the crankcase of the 2nd stage cylinder (6.08) are removed. ALKIN COMPRESSORS...
  • Page 42  With the help of the piston ring pliers, the piston rings on the 2nd stage piston (6.02) are removed.  The piston is thoroughly washed with the aid of a (cleaner) diesel fuel before piston rings are installed. Make sure that there are no pollutants such as dust and oil on the piston. ALKIN COMPRESSORS...
  • Page 43 WARNING: Each piston ring should be positioned so that its opening forms an angle of 180° with the upper opening.  The cylinder liners are measured with the help of the comparator. The cylinder liners out of the following wear tolerance should be sent to ALKIN for replacement. Wear Tolerances Stage cylinder liner ...
  • Page 44 WARNING: Each piston ring should be positioned so that its opening forms an angle of 180° with the upper opening.  Firstly, O-ring (6.21) is greased and seated on the channel on the 2nd stage cylinder. ALKIN COMPRESSORS...

  • Page 45: Replacement Of Crank

     Be sure that all pipes are removed.  Remove all water separators from the crankcase. The pulley housing (6.15) bolts (16.16) are removed. ALKIN COMPRESSORS...
  • Page 46  The same bolt is screwed into the empty holes on the bushing (16.13) and tightened clockwise. It is ensured that the pulley and the busing are separated from each other.  First, the busing is separated from the crank. Then the pulley is removed. ALKIN COMPRESSORS...
  • Page 47  The connecting rod lower parts (4.07) are pulled downwards.  The connecting rods are removed from the crankcase.  The connecting rod is combined with the bolts of the lower and upper parts to measure the hole. ALKIN COMPRESSORS...
  • Page 48 HW1500 SERIES HIGH PRESSURE WATER COOLED AIR COMPRESSORS  The crank weights (3.02, 3.13) are removed by unscrewing the bolts (3.03). ALKIN COMPRESSORS...
  • Page 49 The new seal is nailed in the cover.  The crank bearing bolts (1.14) are removed. The crank bearing (1.12) is removed from the crankcase and crank by pulling out. The bolt (1.10) fixed on the crankcase is removed. ALKIN COMPRESSORS...
  • Page 50 : 0,065 (min), 0.090 (max.) Allowed Space : 0.2 mm  New cranks and bearings are installed following the dismantling process reversely. All dismantled O-rings are replaced with new ones. The O-rings to be fitted are greased and placed. ALKIN COMPRESSORS...

  • Page 51: Replacement Of Muffler Filter Element

    3.10. Replacement of Muffler Filter Element  The nut on the muffler filter element (13.25) is removed.  The filter element is removed. The new seal (13.24) and filter element are inserted and the nut is tightened. 3.11. Revision of Pneumatic Discharge Valves ALKIN COMPRESSORS...
  • Page 52 01). Because the springs that come out during this process will not be used, they are disposed of.  In two of the pneumatic valves, this spring is under the piston and in the valve body. These pneumatic valves are pneumatic discharge valves at low pressure stages (6436-03). ALKIN COMPRESSORS...
  • Page 53 If the manometers are reset, then there is no problem with pneumatic discharge valves. But if interstage pressures do not decrease, there is a problem with the pneumatic discharge valves. In this case, pneumatic discharge valves need to be checked again. ALKIN COMPRESSORS...

  • Page 54: Revision Of Oil Seal

    HW1500 SERIES HIGH PRESSURE WATER COOLED AIR COMPRESSORS 3.12. Revision of Oil Seal  The pulley housing (6.15) bolts (16.16) are removed. ALKIN COMPRESSORS...

  • Page 55: Revision Of Zinc

     The seal is separated from the cover by means of a screwdriver.  The new seal is nailed in the cover.  Assembly process is done in the reverse order of the disassembly. 3.13. Revision of Zinc Zincs are located on the 1st and 2nd stage cylinders. ALKIN COMPRESSORS...
  • Page 56 HW1500 SERIES HIGH PRESSURE WATER COOLED AIR COMPRESSORS The bolts (5.17 or 6.17) on the zinc cover are removed. The zinc is removed with the cover. ALKIN COMPRESSORS...
  • Page 57  Replace the crankshaft. Deflected crankshaft or crankshaft bearing failure  Remove the compressor air heads; clean Excessive dirt or carbon on pistons and valve(s), or replace if worn; piston(s) reassemble. ALKIN COMPRESSORS...
  • Page 58  Consumed purifier cartridge Refill the Purifier cartridge with refilling kit. filling kit 4.7 COMPRESSOR VIBRATION  Mounting bolts are loose Tighten the mounting bolts.  Compressor not properly Level the compressor so that all feet touch the floor. mounted ALKIN COMPRESSORS...
  • Page 59 Sheave or crankshaft wobble keyway or sheave bore 4.12 EXCESSIVE DISCHARGE AIR TEMPERATURE  Remove valves; clean or replace. Dirty valves / carbon on valves  Clean cooling surfaces of the cylinders, Dirty intercoolers and/or cooling intercoolers and aftercooler. surfaces ALKIN COMPRESSORS...
  • Page 60  High compressor speed Check RPM 4.16 COMPRESSOR DOES NOT DISCHARGE WHEN STOPPED  Automatic drain valves blocked Check, disassemble and clean the drain valves; install new o-ring and seat if necessary.  Solenoid valve faulty Check and replace solenoid valve. ALKIN COMPRESSORS...
  • Page 61  Carbonization on valves Clean; make sure that the ambient temperatures are within permissible limits. ALKIN COMPRESSORS...
  • Page 63 HW 1500 SERIES HIGH PRESSURE WATER COOLED AIR COMPRESSORS NOTES: ALKIN COMPRESSORS...
  • Page 64 DECLERATION OF CONFORMITY 2014/35/EU - 2006/42/EC MANUFACTURER: ALKIN KOMPRESÖR SAN.VE TİC.LTD. ŞTİ. ADDRESS: Cüneytbey mah. Tabaş yolu Küme evleri No:3 35470 Menderes/İZMİR Alkın Compressors declare that under our sole responsibility of supply/manufacture of this compressor to which this declaration relates is in conformity with the below standarts and the essential health and safety requirements identified in the above directives.
  • Page 66 5. In case of trouble, the serial number of the compressor, and the nature of the problem must be reported by phone and in writing to ALKIN. 6. Wherever applicable, the terms and conditions of sale of ALKIN prevail and precedes all other terms and conditions.
  • Page 68 ALKIN KOMPRESÖR SAN. ve TİC. LTD. ŞTİ. Cüneytbey mah. Tabaş Yolu Küme Evleri No:3 Menderes-İzmir, TÜRKİYE Tel: +90 232 782 2290 Fax: +90 232 782 22 89 www.alkin.com.tr...

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