Alkin HW-1500 Series User manual

HIGH PRESSURE WATER COOLED
AIR COMPRESSORS
HW-1500 SERIES
OPERATOR MANUAL

HIGH PRESSURE WATER
COOLED AIR COMPRESSOR
MODELS
- HW 1500 AC MOTOR -
- HW 1500 DC MOTOR -

ALKIN COMPRESSORS
High Pressure Water Cooled 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 HW 1500 Series compressors,
unless specific written permission of ALKIN® is received.
ALKIN KOMPRESÖR SAN. ve Tic. Ltd. Şti
Cüneytbey Mah. Tabaş Yolu Küme Evleri No.3
Menderes, İzmir
Tel: [phone]
Fax: [phone]
www.alkin.com.tr
- January, 2020 -

CONTENTS
GENERAL INFORMATIONS........................................................2
1. General.........................................................................................................2
1.1. General Safety Information ................................................................2
1.2. Safety Tags.........................................................................................3
ABOUT COMPRESSOR.................................................................8
2. General.........................................................................................................8
2.1. Compressor Unit.................................................................................9
2.2. Technical Data..................................................................................16
2.3. Process and Instrumentation Diagram (P&ID).................................17
2.4. Identification of the Compressor......................................................19
2.5. Principles of Operation.....................................................................20
2.6. Major Components...........................................................................20
2.6.1. Compressor unit...........................................................................20
2.7. Startup ..............................................................................................25
2.7.1. Operation......................................................................................25
2.7.2. Switching off................................................................................25
2.7.3. Long Term Switching Off............................................................26
2.8. Oil recommendation.........................................................................26
2.9. Electrical Controls............................................................................27
2.9.1. Wiring...............................................................................................27
2.10. Storage..............................................................................................27
MAINTENANCE............................................................................28
3. General.......................................................................................................28
3.1. Planned Maintenance (Hourly).........................................................29
3.2. Planned Maintenance (On a daily basis) ..........................................30
3.3. Oil Change........................................................................................30
3.4. Oil Filter Cleaning .......................................................................31
3.5. Suction Filter Change...................................................................31
3.6. Spare Parts for 5K2021003M type Electric Motor...........................31
3.7. 1st and 3rd Stage Maintenance.......................................................31
3.8. 2nd and 4th Stage Maintenance......................................................37
3.9. Replacement of Crank..................................................................43
3.10. Replacement of Muffler Filter Element .......................................49
3.11. Revision of Pneumatic Discharge Valves ....................................49
3.12. Revision of Oil Seal.....................................................................52
3.13. Revision of Zinc...........................................................................53

TROUBLESHOOTING.................................................................55
DECLERATION OF CONFORMITY
WARRANTY CERTIFICATE

HW 1500 SERIES
HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
1
LKIN air compressor will provide you with the solid and reliable
performance that you should expect from an 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 trouble free service.
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.
Here are the contact details:
ALKIN KOMPRESÖR SAN. ve Tic. Ltd. Şti
Cüneytbey Mah. Tabaş Yolu Küme Evleri No.3
Menderes, İzmir
Tel: [phone] • Fax: [phone]
www.alkin.com.tr
In all correspondences, please provide serial number and a copy of invoice.
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.
A

HW1500 SERIES
HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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GENERAL INFORMATIONS
1. General
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. The following safety precautions are offered only as a guideline and it is
recommended to follow them along with the local safety codes and regulations.
This compressor should only be operated by those who have been trained to do so,
and who have read and understood the contents of this manual. Failure to do so
will increase the risks of accidents and bodily injuries. Please read also the manual
of the equipment (electric, etc.) delivered together with the compressor and
perform the instructions.
Never start this compressor unless it is safe to do so. Do not operate it with known
unsafe condition. Tag the compressor and render it inoperative by disconnecting
the power supply, so that others who may not know of the unsafe condition will not
attempt to operate it until the unsafe condition is corrected.
Install, use and operate this air compressor only in full compliance with all
pertinent requirements and all relevant federal, state and local codes and
regulations.
Do not modify this compressor and do not use beyond the specified limits
(pressure, etc.) and speeds except with prior written approval of ALKIN.

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HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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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
Read Instruction Manual
This compressor should only be used by persons who are trained in the
use of compressors, knowledgeable and who have read this manual and
understood the contents. Otherwise, it will increase the risk of accidents
and the possibility of injury. Also read the instruction manual of the equipment
supplied with the compressor (such as an electric motor) and follow the
instructions.
Use Headphones
The protective headphones are used to protect against continuous noise
that exceeds the permissible sound level and thus can cause permanent
hearing damage.
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

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HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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surface. Wear personal protective equipment, including gloves and protective hat
when working on or around the compressor.
Keep a first aid kit handy. Call for medical assistance promptly in case of injury.
Do not ignore small cuts and burns as they may lead to infections.
Electrical Shock
Keep the compressor, hoses, tools and personnel at least 3 meters (10 ft.)
away from power lines, panel and underground cables.
Keep all parts of the body and any hand held tools or other conductive
objects away from exposed live parts of the electrical system. Maintain dry footing,
stand on insulating surfaces, and do not contact any other portion of the
compressor when making adjustments or repairs to exposed parts of the electrical
system.
Earthing
This machine has an earth connection to the electrical leakage. Be sure to
connect the ground wire and check your grounding line. No grounding or
sufficient grounding; In case of failure of the machine and electric
leakage, it gives the electric current to the outer body and if it is contacted with the
machine, it may cause electric current and result in serious injuries and death.
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.
Moving Parts
Keep hands, arms and other parts of the body and clothing away from
the belts, pulleys and other moving parts. Do not attempt to operate the
compressor with the canopy cover removed at flywheel side.
Wear snug fitting clothing and confine long hair when working around the
compressor, especially when exposed to hot and/or moving parts. Make sure all
persons are clear of the compressor prior to attempting to operate it.
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.

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HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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Keep hands, feet, floors, controls and walking surfaces clean and free from oil,
water, anti-freeze or other liquids to minimize the possibility of slips, falls and
shock hazard.
Pressure Release
Run the compressor to see if the safety valves are operating properly or
not. See and ensure, safety valves are discharging the pressure on their
adjusted pressure values. Do not open the oil filling plug or any other
connection, tube, hose, fitting, valve etc. when the compressor is running or when
it is standing by (in only automatic start/stop compressors waiting for the pressure
switch signal to re-start). Switch off the main electrical switch, shut off the
discharge valve and discharge all pressurized sections before attempting to
dismantle such components.
Keep all persons away from the discharge opening of hoses, tools and accessories
during discharge. Do not use air pressure above 7 Bars (101 Psi) for blow cleaning
purposes, without use of proper protective equipment. Do not let the hoses move
free or don’t play games with the filling hoses as they may cause accidents and
injuries. Drain daily the condensate from the purifier, as it may accelerate the
internal rusting and corrosion of the purifier.
Fire and Explosion
Clean up oil spills immediately if and when it occurs. Shut off the air
compressor and allow it to cool. Keep sparks, flame and other sources of
ignition away and do not allow smoking in the vicinity when checking
and draining or adding oil. Do not permit liquids such as airline anti-icer system
anti-freeze compound, or oil film or any other combustible substance to
accumulate on any external or internal surfaces of the compressor. 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. Tag the
power supply to avoid unexpected start by someone else.
Keep electrical wiring, including terminals in good condition. Replace any wiring
that has cracked, cut, abraded or otherwise degraded insulation or terminals that are
worn, discolored and corroded. Keep all terminals clean and tight. Keep grounded
conductive objects such as tools, away from exposed live electrical parts such as
terminals, to avoid arcing which might serve as a source of ignition.
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

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HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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intake, as serious damage to the compressor and personal injury or death may
result.
Toxic and Irritating Substances
Do not use air from this compressor for breathing unless it is equipped
with proper purification equipment. Make sure that Purifier Cartridge is
installed inside the Purifier Housing.
Operate the compressor only in well ventilated areas. Lubricants used in this
compressor are typical synthetic oil. Accidental ingestion and skin contact should
be avoided. Wash with soap and water after skin contact. If swallowed, call for
medical treatment promptly.
Lifting and Carrying
If you must lift the compressor, lift in full compliance with codes and
regulations. Make sure entire lifting, rigging and supporting structure has
been inspected, is in good condition and has a rated capacity of at least
the net weight of the compressor. If you are unsure of the weight, check before
lifting. The distance between forklift’s forks should be sufficient for lifting if the
compressor will be carried and lifted with the forklift. Moreover, the forklift must
have a rated capacity of at least the net weight of the compressor. The forks of the
forklift should be positioned under the compressor just like shown in the figure
below. The height of the compressor from the ground must be max. 10 cm during
carriage.
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

HW 1500 SERIES
HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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ropes. Keep all persons clear from under and away from the compressor when it is
suspended. Lift the compressor not higher than necessary. Keep lift operator in
constant attendance whenever the compressor is suspended.
Set the compressor down on level surfaces, capable of carrying its full weight.
NOTE:
DO NOT RUN THE COMPRESSOR ON WOODEN PALLET WHERE THE
UNIT IS MOUNTED FOR TRANSPORTATION PURPOSES.
Warranty and Liability
Alkın Compressors cannot be held responsible if your compressor is operated
without observing the rules stated in the operator manual.
Your compressor will be out of warranty if:
* Non-compliance with the rules specified in the operator manual,
* Use of parts not produced / approved by Alkın Compressors,
* Installation and operation of the compressor on surface conditions that are not on
a flat and stable,
* Installation and operation of the compressor in conditions that are not in
compliance with national and local occupational safety rules,
* 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,
* Force Majeure

HW1500 SERIES
HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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ABOUT COMPRESSOR
2. General
While air compressors generally convert 19-27% of the energy they receive from
the motor driving them, the remaining part turns into heat. The heat generated
during compression must be removed from the system by air or water cooling in
order to ensure the continuity of the cycle. Air cooled compressors cannot be used
efficiently in applications where high ambient temperature availability and ambient
noise present functional difficulties. Therefore, unlike air-cooled compressors,
water is circulated around the cylinder in order to reduce the heat in the
compression chamber in water-cooled compressors. The high thermal capacity of
the water is a better alternative in applications which high rpm and high ambient
temperature are available, and therefore air cooling is not possible.
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. The first and third stage,
second and fourth stage pistons are designed in a gradual manner and operate in the
cylinder block in the same way to which they belong.

HW 1500 SERIES
HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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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)

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HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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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)

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HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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2.2. Technical Data
The model design for HW 1500 series compressors are based on the below data;
Compressor
AC Motor
DC Motor
Medium
Ship and submarine
Intake pressure
Atmospheric
Layout
Horizontal
Roll
±45º
Trim
±15º
Working pressure
275 bar (3390 psi)
250 bar (3625 psi)
Max working pressure
310 bar (4496 psi)
Free air delivery (FAD)
1500 lt/dk
Voltage
440 V
220V (200-290V)
Power
34,5 kW
27 kW (36 Hp)
Motor protection class
IP 55
IP 23
Motor speed
1750 rpm
1900 rpm
Compressor speed
740 rpm @440V/AC
705 rpm @220V/DC
Diameter of motor pulley
Belt Dimension
Diameter of compressor
pulley
Piston Stroke
Number of stage
4 (1st and 3rd stages in the same block, 2nd and 4th
stages in the same block)
Number of cylinder block
2
Cylinder bore (1st stage)
190 mm
Cylinder bore (2nd stage)
95,5 mm
Cylinder bore (3rd stage)
50 mm
Cylinder bore (4th 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

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HIGH PRESSURE WATER COOLED AIR COMPRESSORS
ALKIN COMPRESSORS
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2.3. Process and Instrumentation Diagram (P&ID)
The following process and instrumentation diagrams are prepared with the drawing
of the physical components rather than pneumatic symbols in order to facilitate the
understanding of the system by users who are not specifically trained to understand
pneumatic symbols.
This compressor is designed to operate at a “auto start-stop” or a “dual pressure”
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)

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Figure 5 –HW 1500 series compressor P&ID (DC Motor)