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Please read this manual carefully before you operate your Your compressor is backed up with worldwide sales and service
compressor. This will enable you to start-up your compressor in the organization, ready to accommodate your everyday needs for parts
proper manner, as well as maintain it using the simple instructions in & service.
the maintenance section of this manual. This way your air
compressor will always be in top operating condition, giving you For any questions, please feel free to call our Menderes plant, in
years of trouble free service. Izmir - Turkey.
ALKIN air compressors are well known with their faultless design Here are the contact details:
and unique features combined with the best materials and
I – 2. Introduction
Section II- Specific Data & Instructions
This manual is consists of three main sections. In this section, the specific data of the equipment supplied,
Section I - General Information & Rules description of components and the system, including the
In this section general rule for location selection, installation, construction, Process and Instrumentation, controls, wiring
operation, maintainence and trouble shooting, warranty terms are diagrams, operation & special maintenance rules –if any- are
taking place. These are general rules that need to be observed in all indicated.
air and gas applications. Section III – Drawings & Spare parts
In this Section, the specific parts lists of the equipment supplied
takes place.
1. GENERAL Psi) for blow cleaning purposes, and without use of proper protective
equipment as per OSHA Standard Section 29 CFR 1910.242 (b). Do
All ALKIN air and gas compressors are designed and manufactured not engage in horseplay with hoses as serious injury or death may
with equipment, allowing safe operation of the compressors. It is the result.
user’s responsibility however, to safely operate and maintain the Drain daily the condensate from the air receiver, as it may accelerate
compressor, observe the rules and instructions, as well as the local the internal rusting and corrosion of the receiver.
safety codes, to minimize the risk of accidents and injury. The
following safety precautions are offered only as a guideline, and it is 3. Fire and Explosion
recommended to follow them along with the locale safety codes and
regulations. Clean up oil spills immediately, if and when it occurs. Shut off the air
Those who have been trained to do so, and who have read and compressor and allow it to cool. Keep sparks, flame and other
understood the contents of this manual should only operate this sources of ignition away and do not allow smoking in the vicinity
compressor. Failure to do so will increase the risks of accidents and when checking, draining or adding oil. Do not permit liquids such as
bodily injury. air line anti-icer system anti-freeze compound, or oil film or any
Never start this compressor unless it is safe to do so. Do not operate other combustible substance to accumulate on any external or
it with known unsafe condition. Tag the compressor and render it internal surfaces of the compressor. Wipe down with aqueous
inoperative by disconnecting the power supply, so that others who industrial cleaner or steam to clean as required. Do not use
may not know of the unsafe condition will not attempt to operate it flammable solvents for cleaning purposes.
until the unsafe condition is corrected. Disconnect the power supply prior to attempting any repair or
Install, use and operate this air compressor only in full compliance cleaning. Tag the power supply to avoid unexpected start by
with all pertinent O.S.H.A. requirements (USA & Canada), and all someone else.
relevant Federal, State and local codes and regulations. Keep electrical wiring, including terminals, in good condition. Replace
Do not modify this compressor and do not use beyond the specified any wiring that has cracked, cut, abraded or otherwise degraded
limits and speeds except with prior written approval of ALKIN. insulation or terminals that are worn, discolored and corroded. Keep
all terminals clean and tight.
2. Pressure Release (air compressors only) Keep grounded conductive objects such as tools, away from exposed
live electrical parts such as terminals, to avoid arcing which might
Pull the check ring under pressure on both safety valves weekly to serve as a source of ignition.
make sure that they are not blocked, clogged or otherwise disabled. Do not attempt to weld on the receiver or any part welded to the
On gas compressors test the safety valves periodically as per the receiver or to the piping. Any such works or the receiver
specific instructions and local regulations. Do not open the oil filling manufacturer can only make repairs; subsequently a hydrostatic
plug or any other connection, tube, hose, fitting, valve etc. when the pressure test will be required for re-certification for worthiness of the
compressor is running or when it is standing by (waiting for the receiver for use as a pressure vessel.
pressure switch signal to re-start). Switch off the main electrical Keep a suitable BC or ABC fire extinguisher(s) nearby while servicing
switch, shut off the discharge valve and vent all pressurized sections and operating the compressor. Keep oil rags, trash, leaves litter and
before attempting to dismantle such components. other combustibles away from the compressor.
Keep all persons away from the discharge opening of hoses, tools Do not spray volatile materials into the compressor intake, as serious
accessories during venting. Do not use air pressure above 2 Bars (30 damage to the compressor and personal injury or death may result.
W31- Series Breathing Air Compressors
Instruction Manual Page 4.
7. Electrical Shock
I – 6. TECHNICAL DATA
The model designation for these series compressors have been changed as follows:
The W31x2 series are duplex configuration of the W31 series compressors, utilizing the same three-stage compressor unit on both series. The
group consisting of both series are called Junior Series. Model Designations indicate the following details:
W31 – 2 – 225 – P2
Purifier (size 2 – Equivalent of Bauer P21) – refillable
Operating Pressure in Bars (multipy by 14,5 to get this value in Psi)
Basic two pressures are :
225 Bars (3260 Psi)
310 Bars (4500 Psi)
If different pressure is required, specify in the model designation like : W31-2-240-P2 , which means the
compressor you want should operate at 240 Bars (3480 Psi).
Max. Pressure for this range compressors is 4500 Psi. Higher pressures are available with different cylinder
heads. Specify your needs indicating the maximum operating pressure you need.
General specifications of the Junior Series Breathing Air Compressors (W31 and W31x2 series) are as follows:
Performance Data
Operating
Pressure FAD Motor Power
ALKIN Model Bars Psi Lt/min Cfm HP kW RPM Bore x Stroke Nr.of Stages
100 3,6 rd
3 Stage : 14 mm
W31-2-310-P2 310 4500 3 2,2 Stroke : 40 mm
W31-4P-310-P2 310 4500 5,5 HP petrol eng 4
1200 3
W31X2-4-225-P2 225 3260 5,5 4
W31X2-6P-225-P2 225 3260 8 HP petrol eng 5,5 60&36 &14 x40
201 7,1 [2x]
W31X2-4-310-P2 310 4500 5,5 4
W31X2-6P-310-P2 310 4500 8 HP petrol eng 5,5
W31- Series Breathing Air Compressors
Instruction Manual Page 7.
Stage Pressures
Stage Operating Pressure 200 Bars (2900 Psi) Operating Pressure 300 Bars (4350 Psi)
1st stage discharge 3,5 - 4,0 Bars 3,5 - 4,5 Bars
2nd stage discharge 25,0 - 30,0 Bars 25,0 - 35,0 Bars
3rd stage discharge 200 Bars 200 Bars
P & I Diagrams
W31x2 Duplex compressor series P & I Diagram
Drw. Nr. :
6993-3
ALKIN
COMPRESSORS®
P&I Diagram- W31x2 (old designation 2x12T3) Date :
26/11/2000
SAFETY INTERCOOLER
VALVE 1st stg-2nd stg.
CONDENSATE
SEP. Drain
100 300
0 400
PRESSURE GAGE
SAFETY INTERCOOLER
VALVE 1st stg-2nd stg.
0 40 0
b ar
PRIORITY VALVE
b ar
CONDENSATE
SEP.
Drain
AFTERCOOLER
FILLING YOKE
SAFETY
INTERCOOLER
VALVE 1st stg-2nd stg.
2nd Stg.
3rd Stg.
INTERCOOLER 1st stg. AIR INLET
2nd stg.-3rd stg. AIR FILTER
SAFETY VALVE
Pressure Gage
CONDENSATE
SEP. SAFETY VALVE
PURIFIER
AFTERCOOLER Drain
FILLING YOKE
Drain
I – 7. Operation
1st STAGE
1st STAGE
AIR DISCHARGE AIR INLET
3rd STAGE
2nd STAGE
OIL FILL
CRANKSHAFT
2nd STAGE
AIR
DISCH. OIL
LEVEL
CRANKCASE
GAGE
2nd STAGE
3rd STAGE 90° ROTATED
90° ROTATED
Fig.3 W31 Compressor
1. Read this manual carefully and make sure that and the general operating status of the
everything is clear. Do not let anyone to interfere compressor and make sure that the unit is sitting
or operate the compressor who has not learned on the floor properly; there is no vibration, knocks
and/or who is not qualified to do so. or irregular sounds.
2. Make sure that the persons in charge of filling are 8. Prior to first operation and subsequent to each
thoroughly familiar with the compressor, the maintenance work, turn the compressor flywheel
operating principles, connecting the hose, gage manually to verify that the compressor is turning
readings and the filling procedure. freely.
3. Check that the compressor is located in a well- 9. Prior to first operation or subsequent to a
ventilated are and is far from fumes, smoke and maintenance / repair work, operate the
toxic gases. The compressor should sit on a compressor for at least 10 minutes with the
horizontal floor, or should be levelled so that the condensate valves fully open, with no pressure
maximum inclination does not exceed 5%. built up; this will allow all the parts to be properly
4. Check the mains supply against the motor lubricated before the compressor is operated
nameplate data to insure that the voltages and under load (before compressing air).
phases correspond. 10. Open the filling valve when operating the
5. Check the oil level. The correct level should be compressor.
about the middle of the plastic sight gage. Do not
overfill the compressor. Cylinder Filling Operation
6. Jog the compressor (start it for a few seconds) to 1. WARNING: Never open the filling valve unless a
verify that the direction of rotation is correct. If it bottle is connected and its valve is open. Otherwise
is not, reverse the phases on three phase motors, hose whipping may cause serious injury.
at the switch box (not on the motor terminal box). 2. Connect the yoke to the bottle. Open the valve of
Qualified electricians must carry out all electrical the bottle. Open the filling valve.
works. 3. Run the compressor; on systems with automatic stop
7. If the direction is correct you may start the pressure switch, the compressor will stop at the pre
compressor. Observe for the first time the pressure set pressure. When stops, shut the valve of the
bottle; remove the yoke.
W31- Series Breathing Air Compressors
Instruction Manual Page 9.
4. On compressors with no automatic stop pressure compressors, a constant speed control system is added
switch, the safety valve will blow when it reaches the to the package; this includes head and discharge
maximum working pressure. STOP the compressor at unloaders for the compressor unit, and an unloading
this point. system which allows the compressor to run without
5. Shut the bottle valve and remove the yoke. compressint air. See specific instructions for diesel
driven units.
Air Filter
Check the intake filter element every 50 hours; clean
blowing air from inside out. Replace the element every
3 months or earlier, depending on the environmental
conditions. 200
WARNING
The oil inside the pressure control switch-gage is special dielectric oil. DO NOT USE ANY OTHER OIL TO
TOP UP OR FILL THE PRESSURE SWTICHGAGE
WARNING: The lifespan of a filter depends on many factors including proper maintenance, humidity
levels, location of compressor, etc. Always air on the side of caution as operating your compressor
without a properly functioning filter can be fatal, particularly if used for breathing air.
Long Term Storage: 10. See specific motor / engine instructions for long
term storage.
Follow these instructions whenever the compressor will
not be used for six months or more: Restarting after long term storage:
1. Store the compressor indoors, in a dry and clean
room. 1. Clean the dust from the compressor.
2. Run the compressor under pressure for about 10 2. Remove the dust cap from the intake port.
minutes 3. Check the oil level; make sure there are no leaks
3. Check all the pipes, fittings, filters, drain points, or sweating around the connections, gaskets etc.
safety valves and make sure there are no leaks. 4. Run the compressor until warm, for about 1o
4. When the compressor is warm, shut it down. minutes, with all the drain valves, filling valve (or
5. Drain the condensate from the moisture trap and outlet valve) opens. (the compressor will run
the purifier. against atmospheric pressure with no load)
6. Remove the intake filter; jog the compressor for a 5. Check for leaks at the connections, fittings, safety
few seconds, while spraying a small amount (5 - 6 valves etc.
cc) of compressor oil through its intake. Stop the 6. Stop the compressor; drain the oil while still hot;
compressor. install a new purifier cartridge and an intake filter
7. Close all the valves. element.
8. Remove the mains supply. 7. Run the compressor again; verify that there are no
9. Place a dust cap at the intake port. leaks.
8. Put the compressor in normal service.
W31- Series Breathing Air Compressors
Instruction Manual Page 11.
I – 9. Maintenance
Lubricants: The compressor crankcase is designed to take 0,250 Lt. Oil. The lubricants have to be changed every
100 working hours. In any case, if these hours are not reached within 6 months, replace the oil no later than every 6
months.
Use the proper lubricant at all times. Do not mix different lubricants. Here is a list of recommended oils:
Maintenance Table
Maintenance Period DAILY WEEKLY 100 Hours 400 Hours 1000 Hours
I:Inspect/M:Maintain/R:Replace I M R I M R I M R I M R I M R
Oil Change
INTAKE FILTER
V - BELT
Pressure Vessels w/o auto drain valve.
1. Condensate Drain
2. Pressure vessel test
PIPING & CONNECTIONS
1. Leaks
2. Tightening of bolts & fittings
CLEANING
1. Intercoolers & After cooler
2. Flywheel, cylinder fins
3. General
SWITCHES & GAGES
1 Pressure Switch-gage Settings (W31x2)
2. Pressure Gages
SAFETY VALVES
COMPRESSOR VALVES
Piston Rings
1st & 2nd stages Check
3rd Stage Replace
ELECTRICAL (for W31x2 Series)
1. Contactor/Soft Starter connections
2. Contacts
3. Current (loaded and unloaded)
3. Terminals (tighten the screws)
Filling Valves
Whips & Yokes
Vibration Mounts, motor mounts
Purifier Cartridge
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. These simple precautions will
prevent fatal accidents
3. TORQUE SEQUENCE
1
3 1
6 3
4 5
2 4
2
Fig. 5 Torque sequene
W31- Series Breathing Air Compressors
Instruction Manual Page 13.
4. VALVES
CAUTION
4.1. Initial operational check of valves
In order to avoid damaging the special tool or
After roughly half an hour’s operation, Valves
the valve when using the tool, ensure that it is
should be checked. Note that intake line to valve
pushed properly and firmly into the valve bore
heads should be hand warm and outlet-piping
so that it will not tilt when it is turned
should be hot. Valves are then operating properly.
Should the intake pipe to the valve head of second Intake and pressure valve of the 1st stage is combined
stage heat up excessively, and first stage safety in one plate valve under the valve head. Check that
valve blow off, this would be an indication that marks “TOP” is really at the top when installed.
either intake or pressure valve of second stage is
malfunctioning. It is, therefore, necessary to 3.4. Changing valves of the 2nd stage
remove the valve head and to check and these Unscrew intake and pressure lines from the
valves, or to replace them. cylinder head (7, Fig.6).
Remove internal hex. Screws fixing cylinder head
4.2. General instructions for changing the and completely remove the cylinder head from the
valves cylinder.
Always replace valves as a complete set. Insert two metal pins – 8-mm diameter, any length
Carefully clean dirty valves. Never use a sharp – in the holes in the cylinder head and secure
tool for this purpose. Soak the valves in diesel oil these in a vice with the cylinder head on top.
or petroleum and clean with soft brush.
Lubricate valves before installing with weicon AS
040, order no. N19753, or equivalent.
1
Check individual components for excessive wear. 5
If the valve seat and valve disks are dented, 2
replace the valves.
Valve head screws must be tightened with a 3
torque wrench.(see page I-9)
Check the valve space in the valve heads for dirt 4
and clean, if necessary.
Use only satisfactory gaskets and o-rings on
reassembly. 7
Observe the correct sequence when fitting
together again. 6
After finishing all maintenance work on the
valves, turn the compressor manually using the
flywheel and check whether all items have been
correctly installed. Fig. 6 Valves, 2nd stage
30 minutes after restarting the compressor Unscrew intake valve body with the special
unit stop unit, let is cool down to ambient tool.Fig.7)
temperature and retighten valve studs and cap
nuts. Otherwise valves could work loose due to
settings of the gaskets.
Remove and check the valves every 1000 CAUTION
operating hours. In order to avoid damaging the special tool or the
Replace the valves every 2000 operating hours valve when using the tool, ensure that it is pushed
to avoid fatigue failure. properly and firmly into the valve bore so that it is
will not tilt when it is turned.
3.3. Changing the valves of the 1st stage
Removal of 1st stage pressure valve: Turn the cylinder head and replace it on the metal
Remove cap nut pins.
Loosen Allen set screw Unscrew the cap nut (1, Fig. 6) refer to Fig.8.
Remove the coupling Unscrew stud (2) approx. 5 turns.
Assemble in reverse sequence
W31- Series Breathing Air Compressors
Instruction Manual Page 14.
CAUTION
Valve spring and valve plate must not be
jammed.
NOTE
W31- Series Breathing Air Compressors
Instruction Manual Page 15.
CAUTION
Check intake and pressure valves together, only.
4
5
2. Slow filling
1. Intake filter blocked Replace the filter element
2. One or more valve sets are not closing Check the interstage pressure against the values indicated in this
due to dirt or carbon collection manual. Check the valves; clean or replace the valves.
3. Worn piston springs; compressed air Replace the piston rings.
blowing into the crankcase
4. Worn cylinders Replace the cylinders
5. Leaks in the system Check, correct fault.
limits.
Warning
1. Do not alter safety valve settings 6. Before any maintenance or repair works, isolate
2. Do not alter pressure switch setting out with the the mains supply blow down all the compressed air
operational limits of the compressor. from within the purifier and other elements - if
3. Do not repair the hoses; if damaged replace. any-.
4. Do not use work hoses; check the hose 7. Do not carry any works if you are not familiar with
periodically. the principles and basics of high-pressure
5. Check for leaks from time to time by using soaped compressors.
water. 8. Call on the factory for any assistance.
)
,8"
(34
5
47
0(1 88
8,5
")
Drwg.# 7365
W31- Series Breathing Air Compressors
Instruction Manual Page 18.
Safety Valve
Purifier
450
Condensate Separator
Drain Valve Oil Level
Wheel
Oil Discharge Plug Belt Guard
Drw# 6991-01
Purifier
Drain Valve
Belt Guard
Safety Valve
Purifier
450
Condensate Separator
Drain Valve Oil Level
Wheel
Oil Discharge Plug
Drw# 6991-02
W31- Series Breathing Air Compressors
Instruction Manual Page 19.
Ownership Records
If this section is not filled in, we strongly recommend that you make a record of all the data available to
you upon receipt of the equipment. You will need to advise these details on any warranty matters
and/or placing orders for spare parts.
Compressor System
Type 3 stage breathing air compressor
Model W31 – 2 - – P2
Serial Number
Medium Air
Application Breathing Air Cylinder filling
Rated Free Air (gas) delivery 100 lt/min
Operating Pressure BAR
General Arrangement Drawing.
Process & Instrument Drawing.
Production File Number
Relevant Drawing Numbers
Parts List
Compressor Unit
Type Recip. Serial Number
Model
Year Max. Operating Press. Inlet Pressure
Atmos
pheric
Application Air Oil Type UL 751 Other
Stroke 40 LP Bore x nr.of LP cyl. 88 36&14
HP
Bore
Electric Motor
Make Serial Number
Type
Power (kW) Power (HP) RPM 2950
Voltage Frequency Phase 3
Insulation F Frame Type IP54
Current Rating
Full Load Current Off Load Current
Drive
Belt dr. Compressor Flywheel Motor Sheave
Type
Belt Section 13 mm Belt Size
Number
W31- Series Breathing Air Compressors
Instruction Manual Page 20.
of belts
Pressure Control
Pressure switch gage Model Make Alkin
Type
Differential Cut out pressure
P. Cut In
pressure
Other Data
Electrical Control Panel & Motor Starter Drawing Number
Parts List Number
W31- Series Breathing Air Compressors
Instruction Manual Page 21.
CUSTOMER DETAILS
Name of the Company
Address
Distributor
Equipment Details
Model Serial Nr. Date of purchase Date of comissioning
Application
Medium Air Gas (specify) : …………………………………………………………………
PRELIMINARY CHECKS Remarks Signature
Compressor Received properly
Location suitable/ventilated
Bolitng down-canopy/sub-base
Piping in the compressor intact
Oil Type
Oil Level in the crankcase
External Conn.s & Pipework Suitable
All electrical connections checked
Mains Supply Voltage and Freq. V Hz
W31- Series Breathing Air Compressors
Instruction Manual Page 22.
Other Remarks
W31- Series Breathing Air Compressors
Parts Book
Page 23.
Singature Date
Signature Date
Other Attendants
Full Name
Remarks
W31- Series Breathing Air Compressors
Parts Book
Page 24.
Singature Date
W31- Series Breathing Air Compressors
Parts Book
Page 25.
1
2
3
9 5
6
7 4
8
10
8 11
7 13
12
14
15
22 18
19 16
23
17
25
24 21
27
26 20
29 6979-02-200503 C
28
W31- Series Breathing Air Compressors
Parts Book
Page 26.
15
17
16
2 1
26 26
18
look at figure 3
8 19
7
21 20
6
look at figure 4
12
11
26
8 6
look at figure 4
6979-03-210503 E
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14
11 21
2 23
13 15
10
16 18
9 17
6
8
1 5
11 19
7
3 20
4
12
32 22
33 31
21
34
35 23
36
24 37
30
29
28
25
27
26
6979-01-210503 D
15 17
1
6
11 16
5 10
14
4 9
12 3
13 2 8 7
14 4 9
3rd STAGE 1st STAGE 2nd STAGE
PISTON&RING ASS'Y PISTON&RING ASS'Y PISTON&RING ASS'Y
6979-4-290500 B
17
18
16
10
15
3
1 14
5
9
2 4 13
6 12
7
8 11
6979-05-210503 B
11
10
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12
9 17
16
40 2
2
2
1 1
2
37
15
36
14
2
2
4 7
13 1
19 7
3
26
13 5 6
22 25
21 38
20
18 25
9
39
23
24
41 27
42 35
43 34
33 28
32 31
39
29
30
6979-06-020603 D
5 22
22 8
7 8 8 22
8 9
15 3 8 19 7
16 21 8
13
12
6
13
14 9
14 13
18
10 14
11 14
1 17
20 6979-07-310503 E
18
17
5
18
6
19
1
1 2
2 3
3 3
4
6
3 7
4 7
6
9
10
6
14
8
9 13
16
14 2
16 16
17 12
16 11
15
17
6979-08-020603 D