Alkin W31 Series Operator's Manual
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Alkin W31 Series Operator's Manual

High pressure breathing air compressors
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HIGH PRESSURE BREATHING
AIR COMPRESSORS
W31 SERIES
OPERATOR MANUAL

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Summary of Contents for Alkin W31 Series

  • Page 1 HIGH PRESSURE BREATHING AIR COMPRESSORS W31 SERIES OPERATOR MANUAL...
  • Page 3 W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSOR MODELS - VERTICAL – - MARINER - - PETROL ENGINE - - DIESEL ENGINE -...
  • Page 4 Quality Assurance is not an action but a habit for us….
  • Page 5 High Pressure Breathing Air Compressors Operator Manual © 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 COMPRESSORS Kazım Karabekir 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 ................10 2.2. Technical Data .................. 15 2.3. Process and Instrumentation Diagram (P&ID) ......... 18 2.4.
  • Page 7 3.1.1. Check Table ................. 41 3.1.2. Replacement Table ............... 42 3.2. Torque Values .................. 43 3.3. Maintenance Instructions ..............43 3.3.1. Oil level check ................43 3.3.2. Leak check ................... 44 3.3.3. Auto drain valve check..............44 3.3.4. Intake filter check ................. 44 3.3.5.
  • Page 8 Alkin Compressors has a service and sales team that can respond rapidly to your daily spare parts and service requirements. Service and parts supply anywhere in the world can be done by Alkın Compressors.

  • Page 9: General Informations

    General 1.1. General Safety Information All ALKIN air compressors are designed and manufactured with equipment and components that allow the 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

    1.2. Safety Tags Symbol Explanation READ INSTRUCTION MANUAL USE HEADPHONES HOT SURFACE – DO NOT TOUCH EARTHING ELECTRIC HAZARD CAUTION: CAN START AUTOMATICALLY CAUTION: MOVING PARTS DIRECTION OF ROTATION RECOMMENDED COMPRESSOR OIL AIR INLET AIR OUTLET ALKIN COMPRESSORS – 2023-01...
  • Page 11 Can Start Automatically Automatic compressor control, unit may start-up without warning! Before carrying out maintenance and repair work, switch off at the main switch or disconnect from the mains and ensure unit will not restart. ALKIN COMPRESSORS – 2023-01...
  • Page 12 Wipe down with aqueous industrial cleaner or steam to clean as required. Do not use flammable solvents for cleaning purposes. Disconnect the power supply prior to attempting any repair or cleaning. ALKIN COMPRESSORS – 2023-01...
  • Page 13 The height of the compressor from the ground must be max. 10 cm during carriage. Figure 1 – Lifting and transporting by forklift ALKIN COMPRESSORS – 2023-01...
  • Page 14 * Interference of compressor operating parameters by third parties without the 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, * Force majeure ALKIN COMPRESSORS –...

  • Page 15: About Compressor

    10 bar (1500 psi) and 350 bar (5075 psi) depending on valves and the cooling system. Do not attempt to modify the compressor to operate at higher pressure without the written approval of ALKIN. Failure to do so may result in heavy damage to equipment, injury, or death.
  • Page 16 W31 series compressors are equipped with stainless valves at each stage that are designed to maintain the airflow without any loss of pressure. They are easy to maintain and replace.

  • Page 17: Compressor Unit

    W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS 2.1. Compressor Unit W31 series MARINER compressor unit involves the main groups below; Compressor unit 12. Filling valve Electric motor 13. Filling manometer Subbase 14. Yoke Water separator 15. Shock mount Purifier 16. Control panel Priority valve 17.
  • Page 18 23. Pressure switch 26. Start-Stop 24. Drain solenoid 27. Hour meter 25. Auto drain valve Figure 4 – W31 series compressor general layout (auto drain) 28. Pressure selecting valve 33. Filling manifold 29. 300 bar pressure switch 34. 200 bar filling valve 30.
  • Page 19 W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS W31 series VERTICAL compressor unit involves the main groups below; Compressor unit 11. Carriage wheel Electric motor 12. Shock mount Subbase 13. Control panel Water separator 14. Carrying handle Purifier 15. Working hour Priority valve 16.
  • Page 20 W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS W31 series PETROL ENGINE compressor unit involves the main groups below; Compressor unit 10. Intake filter Petrol engine 11. Filling hose Subbase 12. Filling valve Water separator 13. Filling manometer Purifier 14. Yoke Priority valve 15.
  • Page 21 W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS W31 series DIESEL ENGINE compressor unit involves the main groups below; Compressor unit Aftercooler Diesel engine Safety valve Subbase 10. Intake filter Water separator 11. Shock mount Purifier 12. Purifier drain valve Priority valve 13.

  • Page 22: Technical Data

    W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS 2.2. Technical Data The model design for W31 series (mariner and vertical) compressors are based on the below data. Compressor W31 Series Medium Compressed air / Breathing air Intake pressure Atmospheric Outlet number...
  • Page 23 W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS The model design for W31 series compressors (Petrol Engine) are based on the below data. W31 Series – Petrol Engine Compressor Medium Compressed air / Breathing air Intake pressure Atmospheric Outlet number Filter system...
  • Page 24 W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS The model design for W31 series compressors (Diesel Engine) are based on the below data. W31 Series – Diesel Engine Compressor Medium Compressed air / Breathing air Intake pressure Atmospheric Outlet number Filter system...

  • Page 25: 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 9 – W31 series compressor P&ID (standard) ALKIN COMPRESSORS – 2023-01...
  • Page 26 W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS Figure 10 – W31 series compressor P&ID (auto drain) ALKIN COMPRESSORS – 2023-01...
  • Page 27 W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS Figure 11 – W31 series compressor P&ID (dual pressure) ALKIN COMPRESSORS – 2023-01...

  • Page 28: Identification Of The Compressor

    W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS 2.4. Identification of the Compressor Each compressor has an identification label attached to its frame. ALKIN COMPRESSORS – 2023-01...

  • Page 29: Principles Of Operation

    / stop button located on the electric panel. Oil level can be seen by Oil Level Glass located on the front side of the crankcase. Oil level should be checked daily. ALKIN COMPRESSORS – 2023-01...

  • Page 30: Lubrication System

    CONSULT ALKIN COMPRESSORS FOR REPLACEMENT OR MAINTENANCE Connecting Rods: In W31 Series compressors, there are three connecting rods, two of which are the same and the third one is with a stick at the bottom part that serves as the lubricating stick. Connecting...
  • Page 31 The valves must be replaced in every general overhaul period. The valves can be replaced by either ALKIN Service personnel or a trained client. CONSULT ALKIN COMPRESSORS FOR REPLACEMENT OR MAINTENANCE Breather: Every piston-type machine has some compression leakage into the crankcase through the rings.

  • Page 32: System

    SCBA cylinders. The number of filling hoses can be increased upon request. Water Separators: They remove the water condensate from the compressed air occurred in stages under pressure. There are two water separators on W31 series; between 2 and 3 stg. Control Panel (Mariner- Vertical)
  • Page 33 The compressor can be driven by an electric motor, petrol or diesel engine and is belt-driven. IMPORTANT: Please look at the “Petrol/Diesel Engine User Manual” attached to the compressor instruction manual for maintenance periods and actions to be taken. ALKIN COMPRESSORS – 2023-01...
  • Page 34 Whether the priority valve opens or not should be checked according to the periods in the control table. Check Valve: It does not let the compressed air inside the purifier goes back to the stages and protects the compressor to run under back pressure. ALKIN COMPRESSORS – 2023-01...

  • Page 35: Description Of Controls

    HIGH PRESSURE BREATHING AIR COMPRESSORS 2.8. Description of Controls 2.8.1. Operation control In W31 series compressors, starting control is done in 2 ways. I. Manuel start/stop Compressor can be started or stopped by pressing the start / stop button on the control panel.

  • Page 36: Handling And Installation

    The compressor should be located in an area that is sheltered, solid and dry, well ventilated, not exposed to high ambient temperatures, airborne contaminants such as dust, fumes, lint, vapor, steam, gases, engine exhaust, and another contaminant. IMPORTANT: If ambient temperature exceeds 50ᵒC, air conditioning will be necessary. ALKIN COMPRESSORS – 2023-01...

  • Page 37: Piping

    / positioning is required where the compressor air intake can only be supplied with fresh air (see article 2.9.5). Figure 11 – W31 series compressors layout 2.9.5. Piping Inlet Piping: If it is necessary to carry the inlet air filter to a clean location, due to excessive dirt, heat, dampness, or toxic fumes in the near vicinity of the compressor, use a suitable diameter NON-TOXIC transparent steel wire hose;...

  • Page 38: Electrical Controls

    If the compressor will not be working for more than six months for any reason and stored idle during this time, it is suggested to do the following steps before putting it out of reach to keep it in good condition: ALKIN COMPRESSORS – 2023-01...
  • Page 39 • Stop the compressor. • Put the compressor in normal service. NOTE: If the compressor has been stored with the old oil inside for more than 2 years, it should be drained before running and replaced with fresh oil. ALKIN COMPRESSORS – 2023-01...

  • Page 40: Operation

    Follow up the following procedures when making the initial start-up of the compressor. • Make sure that you have read this manual carefully and understand it. If you have any questions, contact ALKIN. • Make sure that all the preparations described in the installation section of this manual have been made.

  • Page 41: Oil Recommendation

    Anderol 755 - Compressor Oil ANDEROL 755 is an ISO 150 synthetic di-ester based compressor lubricant specifically designed to provide long term lubrication in air and process gas compressors. It provides outstanding performance characteristics in splash lubricated reciprocating compressors. ALKIN COMPRESSORS – 2023-01...

  • Page 42: Extremely Cold Ambient Temperatures

    2.11.4. Motor lubrication Electric motors on ALKIN W31 series compressors are supplied with greased and sealed bearings. They do not any need further maintenance. 2.12. Adjustment Pressure switch adjustment (for auto drain models) When adjusting the pressure switch, verify the compressor is operating and make adjustments according to the final outlet pressure.

  • Page 43: Cylinder Filling Instructions

    Turn the screw clockwise to increase the upper pressure, anti-clockwise to lower. Standard Pressure Switches used on ALKIN have a standard differential of 10% of working pressure. For example, a pressure switch set at 200 bar will work between 180 and 200 bar.
  • Page 44 For these reasons mentioned for your own security, breathing air bottles should not be filled in compressor rooms where insufficient fresh air conditions have not occurred. ALKIN COMPRESSORS – 2023-01...
  • Page 45 Disconnect the cylinder. CAUTION If you need to fill at 200 bar, right after a filling at 300 bar, release the pressure at filling valve for a short time until pressure goes down below 200 bar. ALKIN COMPRESSORS – 2023-01...

  • Page 46: Maintenance

    CAUTION ! Even if the compressor is completely off during maintenance and repair work, it must be protected against unexpected restart. Disconnect the power cable and make sure the main switch is in the off position. ALKIN COMPRESSORS – 2023-01...
  • Page 47 13. Operating pneumatic equipment above the recommended operating pressure not only loses energy but can also result in excessive component wear, which further consumes energy. ALKIN COMPRESSORS – 2023-01...

  • Page 48: Maintenance Table

    Also, auto drain valves should be checked to see if they are draining for 5 seconds at every 10 minutes. CONSULT ALKIN IF UNSURE. Open the manual drains beneath water separators at every 10 minutes to drain condensate water.

  • Page 49: Replacement Table

    4000 Safety valve 1 set 09-01 hours / 4 V-belt 1 pcs years CAUTION! Please be advised that compressors that are not maintained according to ALKIN maintenance tables above would be out of warranty. ALKIN COMPRESSORS – 2023-01...

  • Page 50: Torque Values

    If a bank system exists, isolate it by closing the appropriate valves. 3.3.1. Oil level check Instruction no Instruction name Oil Level Check List of tools required None Parts list to be used in replacement kit None ALKIN COMPRESSORS – 2023-01...

  • Page 51: Leak Check

    Depending on ambient temperature and humidity, replace filter element at most every three months. 3.3.5. V-Belt alignment check Instruction no Instruction name V-belt Tension Check List of tools required None Parts list to be used in replacement kit None ALKIN COMPRESSORS – 2023-01...

  • Page 52: Components Check

    Instruction name Current Check List of tools required Ampere meter Parts list to be used in replacement kit None • Check with an ampere meter at max. load for conformity with the motor power and current data. ALKIN COMPRESSORS – 2023-01...

  • Page 53: Safety Valve Check

    Parts list to be used in replacement kit New check valve • If check valve is leaking, remove it with appropriate tool. • Clean its place and install the new check valve. • Start the compressor. Check for leaks with foam water. ALKIN COMPRESSORS – 2023-01...

  • Page 54: Priority Valve Check

    • Remove flywheel grid with appropriate tools. • Remove belts from flywheel and install new ones. Rotate flywheel by hand to check tension. • Reconnect flywheel grid with appropriate tools. Start the compressor and check the proper rotation. ALKIN COMPRESSORS – 2023-01...

  • Page 55: Purifier Cartridge Refill Kit Replacement

    The filtration cartridge are classified as special waste : they must be disposed of in compliance with the anti-pollution standards in force. 3.3.14. Oil change Instruction no Instruction name Oil Change Instructions List of tools required Funnel, bowl, 17 wrench Parts list to be used in replacement Anderol 755 oil ALKIN COMPRESSORS – 2023-01...

  • Page 56: Intake Filter Replacement

    • Remove the piping of auto drain valve with no 14 wrench. • Remove the auto drain valve head with no.22 wrench with counterclockwise rotation. • Remove from the auto drain valve old pistons and spring and clean auto drain valve ass’y with pressurized air. ALKIN COMPRESSORS – 2023-01...
  • Page 57 • Reconnect the piping of auto drain valve with no. 14 wrench, and fittings with no. 19 wrench. • Start the compressor and verify that the drain valve is operating within drain intervals. ALKIN COMPRESSORS – 2023-01...

  • Page 58: Troubleshooting

    • 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 – 2023-01...
  • Page 59 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 • Motor belt and the sheave Align. misaligned ALKIN COMPRESSORS – 2023-01...
  • Page 60 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 intercoolers, and aftercooler. cooling surfaces ALKIN COMPRESSORS – 2023-01...
  • Page 61 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 – 2023-01...
  • Page 62 • Carbonization on valves Clean; make sure that the ambient temperatures within permissible limits. ALKIN COMPRESSORS – 2023-01...
  • Page 63 W31 SERIES HIGH PRESSURE BREATHING AIR COMPRESSORS NOTES: ALKIN COMPRESSORS...

  • Page 65: Decleration Of Conformity

    Model : W31 SERIES This statement is in compliance with the following standards and the above basic health and safety requirements.

  • Page 66: Warranty Certificate

    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 COMPRESSORS Kazım Karabekir mah. Bekir Saydam cad. No: 94/1 35865 Torbalı-İzmir, TÜRKİYE Phone : +90 232 782 2290 Fax : +90 232 782 22 89 www.alkin-compressors.com...

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