Alkin W31 series User manual

W31
SERIES

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InstructionsManual
and Parts List

A L K I N K O M P R E S Ö R
High Pressure Breathing Air Compressor
© 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 KOMPRESÖR San. ve Tic. Ltd. Şti
İbrahim Turan Caddesi No: 127, Menderes
35470 İzmir
TURKEY
Tel: [phone] • Fax: [phone]
www.alkin.com.tr

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Contents
1.0 GENERAL INFORMATION..........................................................................................................11
1.1 General...................................................................................................................... 11
1.1.1 General Safety ......................................................................................................................... 11
1.1.2 Safety Tags............................................................................................................................... 11
1.1.3 Pressure Release...................................................................................................................... 11
1.1.4 Fire and Explosion.................................................................................................................... 12
1.1.5 Moving Parts............................................................................................................................ 12
1.1.6 Hot Surfaces, Sharp Edges and Corners................................................................................... 12
1.1.7 Toxic and Irritating Substances................................................................................................ 13
1.1.8 Electrical Shock........................................................................................................................ 13
1.1.9 Lifting and Carrying.................................................................................................................. 13
1.1.10 Tags........................................................................................................................................ 14
1.2 About Compressor.....................................................................................................14
1.2.1 General .................................................................................................................................... 14
1.2.2 Technical Data ......................................................................................................................... 18
1.3 Process and Instrument (P & I) Diagram .................................................................... 19
1.4 Principles of Operation..............................................................................................22
1.5 Lubrication System ....................................................................................................22
1.6 Description of Major Components.............................................................................23
1.6.1 Major Components –Compressor Unit ................................................................................... 23
1.6.2 Major Components –System .................................................................................................. 24
1.7 Description of Controls..............................................................................................26
1.7.1 Manual Start ............................................................................................................................ 26
1.7.2 Auto Stop................................................................................................................................. 26
1.7.3 Auto Drain ............................................................................................................................... 26
1.8 Installation ................................................................................................................26
1.8.1 Inspection ................................................................................................................................ 26
1.8.2 Location ................................................................................................................................... 27
1.8.3 Piping ....................................................................................................................................... 27
1.9.4 Electrical Controls.................................................................................................................... 27
1.9.5 Wiring ...................................................................................................................................... 28
1.10 Storage ....................................................................................................................28
1.11 Operation ................................................................................................................29
1.11.1 Initial Start-Up Procedure...................................................................................................... 29
1.11.2 Oil Recommendation ............................................................................................................. 30
1.11.3 Extremely Cold Ambient Temperatures ................................................................................ 30
1.11.4 Motor Lubrication.................................................................................................................. 30
1.11.5 Adjustments .......................................................................................................................... 30
1.11.6 Cylinder Filling Instructions ................................................................................................... 31
2.0 MAINTENANCE ............................................................................................................................. 33
2.1 General...................................................................................................................... 33
2.2 Maintenance Procedure ............................................................................................33
2.3 Maintenance Table....................................................................................................35
2.3.1 Maintenance –Check Table..................................................................................................... 35
2.3.2 Replacement Table .................................................................................................................. 36
2.4 Torque Values ...........................................................................................................37
2.5 Maintenance Instructions..........................................................................................37
2.5.1 Oil Level Check......................................................................................................................... 37
2.5.2 Leak Check ............................................................................................................................... 37
2.5.3 Auto Drain Valves Check.......................................................................................................... 38
2.5.4 Intake Filter Check ................................................................................................................... 38
2.5.5 V-belt Alignment Check ........................................................................................................... 38
2.5.6 Components Check.................................................................................................................. 38
2.5.7 Serpentines, Intercoolers and Aftercooler, Flywheel Cleaning................................................ 39
2.5.8 Current Check .......................................................................................................................... 39

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2.5.9 Safety Valve Check ...................................................................................................................39
2.5.9.1 Safety Valve Replace .............................................................................................................39
2.5.10 Check Valve Check .................................................................................................................40
2.5.10.1 Check Valve Replacement...................................................................................................40
2.5.11 Priority Valve Check ...............................................................................................................40
2.5.11.1 Priority Valve Replacement.................................................................................................40
2.5.12 V-Belt Replacement ...............................................................................................................41
2.5.13 Purifier Cartridge Refill Kit Replacement ...............................................................................41
2.5.14 Intake Filter Replacement......................................................................................................42
2.5.15 Auto Drain Valve Adjustment with Repair Kit ........................................................................42
2.5.16 Oil Change Instructions ..........................................................................................................43
2.5.17 Valve Replace Instructions .....................................................................................................43
2.6 Abrasion Limits..........................................................................................................44
3.0 TROUBLESHOOTING...................................................................................................................45
4.0 PARTS LIST ....................................................................................................................................49
4.1 Crankcase ass’y..........................................................................................................51
4.2 First Stage..................................................................................................................52
4.3 Second stage .............................................................................................................53
4.4 Third stage.................................................................................................................54
4.5 General piping (standart)...........................................................................................55
4.6 General piping (Optional-Auto drain) ........................................................................56
4.7 Aftercooler ................................................................................................................57
4.8 Condensate Separator&Purifier.................................................................................58
4.9 General connectors (electric motor) ..........................................................................59
4.10 General connectors (Petrol engine) .........................................................................60
4.11 Filling line (Standart) ...............................................................................................61
4.12 Filling line(Optional-Dual output).........................................................................62
4.13 Filling line (Optional-Dual pressure) ........................................................................63
5.0 TECNİCAL DRAWİNGS ................................................................................................................65

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Your new ALKIN air compressor will provide you with the solid and reliable performance that you should expect from a heavy-duty 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 years long trouble free service.
LKIN air compressors are well known for their faultless design and unique features combined with
the best materials and workmanship. Some of the most important features are centrifugal unloading
regulators, overhung crankshaft design, solid end connecting rods, high efficiency valves, which all
add to the superior and lasting performance of the ALKIN compressors.
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 Dealer. For any questions, please feel
free to call our Menderes plant, in İzmir-Turkey. Here are the contact details:
Address: ALKIN Kompresör San. ve Tic. Ltd.Sti
Ibrahim Turan Cd. N.127, Menderes
35470 Izmir, TURKEY
Telephone: [phone] (10 Lines)
Fax : [phone]
E-mail: [email protected]
In all correspondences, please provide serial number and a copy of invoice.
Additionally, replacement parts not manufactured or approved by ALKIN can damage your compressor, creating
risks of accidents and injuries.
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.
FOREWORD
A

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1.0 GENERAL INFORMATION
1.1 General
1.1.1 General Safety
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.
1.1.2 Safety Tags
Earthing
Hot Surface-Do Not
Touch
Can Start
Automatically
Caution: Moving
Parts
1.1.3 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.
Section
1

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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.
1.1.4 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 intake, as serious damage to the compressor and personal injury
or death may result.
1.1.5 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.
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.
1.1.6 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
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. Don’t ignore small cuts and burns
as they may lead to infections.

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1.1.7 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.
1.1.8 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.
1.1.9 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 F/L 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.
Do not distract the forklift operator while 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 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.

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Note
Do not run the compressor on wooden pallet where the unit is mounted for transportation purposes.
1.1.10 Tags
Symbol
Explanation
CAUTION: MOVING PARTS
CAN START AUTOMATICALLY
HOT SURFACES-DO NOT TOUCH
EARTHING
1.2 About Compressor
1.2.1 General
W31 Series compressors are three stage, reciprocating type, air cooled and splash lubricated compressors. Working
pressure of these compressors, depending on valves and heads, can be between 10 bar (1500 psi) and 350 bar (5000
psi). Do not attempt to modify compressor to operate at higher-pressure without written approval of ALKIN.
Failure to do so may result in heavy damage to equipment, injury or death.
W31 Series compressors are built with oversized intercoolers and aftercooler to allow superior performance, longer
life, and lower operating and discharge temperatures.
W31Series compressors are designed and manufactured with three stage and three cylinders. Cylinders from “W”
shape. From front view, first stage is in the middle, second stage is on the right and third stage is on the left.

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Şekil 2-Compressor Unit
W31 Series compressors are design and manufactured with intercooler serpentine located between 1st-2nd
Stage cylinders, and aftercooler located at the 3rd Stage outlet. There are water separators at the outlet of 2nd
Stage intercooler and at outlet of 3rd Stage aftercooler. Water Separators are connected to auto drain valves
that periodically drains the condensate water. The duration and frequency of opening of these drain valves are
determined by the time relay located in the electric panel. (Please see Check section.) This time relay can be
set for both functions.
There is a Safety Valve at each stage to prevent an unwanted increase in pressure resulted from a problem in
valves or any other parts. It must be periodically checked that, these safety valves are working properly and
they keep their set pressure values. (Please see Maintenance Table.)
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. The maintenance of valves are
especially important as they are the main parts in proper and problem-free working of compressors.
Lubricants not approved by ALKIN can prevent valves from working properly due to the accumulation of
carbon on springs and washers. Valves not working properly will cause an increase in working temperature
and the deterioration of lubricant, thus in return, will further break down the valves.
Max working pressure is 350 bar and, it is dangerous and strictly prohibited to set a value higher than 350 bar.
ALKIN will not be held liable for any problems resulting from acting otherwise.
Working temperature range of the compressor is –10/+50 ºC.

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Compressor Unit involves the main groups below;
1. Compressor Unit
2. Electric Drive
3. Subbase
4. Water Separator
5. Purifier
6. Priority Valve
7. Check Valve
8. Aftercooler
9. Safety Valve
10. Intake Filter
11. Filling Hose
12. Filling Valve
13. Filling Gage
14. Yoke
15. Vibration Mount
16. Control Panel
17. Start-Stop
18. Hourmeter
19. Carrying Handle
20. 2nd Stg. Drain Valve
21. 3rd Stg. Drain Valve
22. Purifier Drain Valve
Şekil 3 - W31 general layout (Standard)

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23. Pressure Switch
24. Drain Solenoid
25. Auto Drain Valve
26. Start-Stop
27. Hourmeter
Şekil 4 - W31 general layout (Auto Drain)
28. Pressure Selecting Valve
29. 300 Bar Pressure Switch
30. 200 Bar Pressure Switch
31. 300 Bar Safety Valve
32. Pressure Gauge
33. Filling Manifold
34. 200 Bar Filling Valve
35. 300 Bar Filling Valve
36. 200 Bar Safety Valve
Şekil 5 - W31 general layout (Auto Drain)
Not
Auto Start / Stop can be installed on compressor(s) upon request.

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1.2.2 Technical Data
The model designation for these series compressors are based on the data below
Model
Motor Power
No. of Outlets
Working Pressure
Purifier
W31 Mariner
Breathing Air
Compressor
2.2 kw
1
200, 300 Bar
P21
Performance Data
Model
Working Pressure
FAD
Motor
Power
RPM
Cylinder
Diameter
No. of
Stages
BAR
PSI
Lt/min
Cfm
HP
kW
Stroke
W31 Mariner
Breathing Air
Compressor
200
2900
90/110
3,25/4
3
2.2
1060 d/d
66x38x14
3
300
4350
40
Stage Pressures
Outlet Pressure
1st Stg. Pressure
2nd Stg. Pressure
3rd Stg. Pressure
Bar
Bar
Bar
200/300 bar
Min.2
Max.5.5
Min. 20
Max. 38
200
300

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1.3 Process and Instrument (P & I) Diagram
The following process and instrument 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 “dual pressure” or a “single pressure” This is, when the
compressed air is used to fill all the cylinders at that single pressure.
By looking at the P&I Diagram, you can see the general layout of the system and operational turns.
Şekil 6 - P & I Diagram (Standard)

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Şekil 7 - P & I Diagram (Auto Drain)