Alkin W31 series User manual

HIGH PRESSURE BREATHING
AIR COMPRESSORS
W31 SERIES
OPERATOR MANUAL

W31 SERIES HIGH PRESSURE
BREATHING AIR
COMPRESSOR MODELS
- MARINER - - VERTICAL –
- PETROL ENGINE - - DIESEL ENGINE -

Quality Assurance is not an action but a habit for us….

ALKIN COMPRESSORS
High Pressure Breathing Air Compressors
Operator Manual
© This manual or any parts thereof cannot be copied by any means or used for
anyother purposes other than servicing ALKIN W31seriescompressors unless
specific written permission of ALKIN® is received.
©ALKIN COMPRESSORS
Kazım Karabekir mah. Bekir Saydam cad. No : 94/1 35865
Torbalı, IZMIR
Phone : [phone]
Fax : [phone]
www.alkin.com.tr
www.alkin-compressors.com
- W31-2023-01-ENG-

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...............................................................................10
2.2. Technical Data..................................................................................15
2.3. Process and Instrumentation Diagram (P&ID).................................18
2.4. Identification of the Compressor ......................................................21
2.5. Principles of Operation.....................................................................22
2.6. Lubrication System...........................................................................23
2.7. Major Components...........................................................................23
2.7.1. Compressor unit...........................................................................23
2.7.2. System..........................................................................................25
2.8. Description of Controls ....................................................................28
2.8.1. Operation control .........................................................................28
2.8.2. Drain control................................................................................28
2.9. Handling and Installation .................................................................29
2.9.1. Unpacking....................................................................................29
2.9.2. Handling.......................................................................................29
2.9.3. Inspection.....................................................................................29
2.9.4. Location .......................................................................................29
2.9.5. Piping...........................................................................................30
2.9.6. Electrical controls ........................................................................31
2.9.7. Wiring ..........................................................................................31
2.10. Storage..............................................................................................31
2.11. Operation..........................................................................................33
2.11.1. Initial start-up procedure..........................................................33
2.11.2. Oil Recommendation........................................................................34
2.11.3. Extremely cold ambient temperatures .....................................35
2.11.4. Motor lubrication.....................................................................35
2.12. Adjustment .......................................................................................35
2.13. Cylinder filling instructions..............................................................36
MAINTENANCE............................................................................39
3. General.......................................................................................................39
3.1. Maintenance Table ...........................................................................41

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. V-Belt alignment check................................................................44
3.3.6. Components check.......................................................................45
3.3.7. Serpentines, Intercoolers and aftercooler, flywheel cleaning.......45
3.3.8. Current check...............................................................................45
3.3.9. Safety valve check .......................................................................46
3.3.9.1. Safety valve replacement.........................................................46
3.3.10. Check valve check...................................................................46
3.3.10.1. Check valve replacement.........................................................46
3.3.11. Priority valve check.................................................................47
3.3.11.1. Priority valve replacement.......................................................47
3.3.12. V-Belt replacement..................................................................47
3.3.13. Purifier cartridge refill kit replacement....................................48
3.3.14. Oil change................................................................................48
3.3.15. Intake filter replacement..........................................................49
3.3.16. Auto drain valve adjustment with repair kit.............................49
TROUBLESHOOTING.................................................................51
DECLERATION OF CONFORMITY
WARRANTY CERTIFICATE

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
1
Dear Customer,
ALKIN air compressors 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.
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. For any questions, please feel free to call
our Torbalı plant, in İzmir-Turkey.
Here are the contact details:
Pre-Sales Support Services
[e-mail]
[phone] (Ext:206)
After Sales Support Services
[email protected]m.tr
[phone] (Ext:209)
In all correspondences, please provide serial number and a copy of the 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.

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
2
GENERAL INFORMATIONS
1. 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. 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 also read 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 it beyond the specified limits
(pressure, etc.) and speeds except with prior written approval of ALKIN.

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
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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
DIRECTION OF ROTATION
RECOMMENDED COMPRESSOR OIL
AIR INLET
AIR OUTLET

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
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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 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 handheld 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 adjusting 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.

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
5
Moving Parts
Keephands, 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 the 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
people are clear of the compressor before attempting to operate it.
Only make changes when the compressor is turned off. Make modifications as
needed, then start the compressor to see if the adjustment is accurate. If incorrect,
shut the compressor, blow down the air, re-adjust, then 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 hazards.
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) forblow
cleaning purposes, without the use of proper protective equipment. Do not let the
hoses move free or do not 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 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.

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
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Tag the power supply to avoid an 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.
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 the 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 the 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 as 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

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
7
Do not distract the forklift operator during the carriage. Verify the lifting hook has a
safety clamp and ensures a robust fastening with tough ropes or chain. Avoid the
compressor swinging while suspended, by using guide ropes. Keep all people 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 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

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
8
ABOUT COMPRESSOR
2. General
W31 series compressors are three-stage, reciprocating type, air-cooled, and splash
lubricated compressors. The working pressure of these compressors can be between
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.
W31 series compressors are built with oversized intercoolers and aftercooler to allow
superior performance, longer life, and lower operating and discharge temperatures.
W31 series compressors are designed and manufactured with three stages and three
cylinders. Cylinders from “W” shape. From the front view, the first stage is in the
middle, the second stage is on the right and the third stage is on the left.
Figure 2 –W31 compressor stages

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
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W31 series compressors are designed and manufactured with intercooler located
between 1st and 2nd stage cylinders, and an aftercooler located at the 3rd stage outlet.
There are water separators at the outlet of the 2nd stage intercooler and at the outlet
of the 3rd stage aftercooler. Water separators are connected to auto drain valves that
periodically drain the condensate water. The duration and frequency of opening of
these drain valves are determined by the time relay located in the electric panel. This
time relay can be set for both functions.
There is a safety valve at each stage to prevent an unwanted increase in pressure
resulting from a problem in valves or any other parts. It mustbe periodically checked
that these safety valves are working properly, and they keep their set pressure values.
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 is especially important as they are
the main parts in the 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 COMPRESSORS will not be held liable for any
problems resulting from acting otherwise.

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
10
2.1. Compressor Unit
W31 series MARINER compressor unit involves the main groups below;
1. Compressor unit
2. Electric motor
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 manometer
14. Yoke
15. Shock mount
16. Control panel
17. Start-Stop
18. Hour meter
19. Carrying handle
20. 2nd stage drain valve
21. 3rd stage drain valve
22. Purifier drain valve
Figure 3 –W31 series compressor general layout (standard)

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
11
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. 200 bar pressure switch 35. 300 bar filling valve
31. 300 bar safety valve 36. 200 bar safety valve
32. Pressure valve
Figure 5 –W31 series compressor general layout (double pressure)
Note: Auto start/stop can be installed on compressor(s) upon request.

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
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W31 series VERTICAL compressor unit involves the main groups below;
1. Compressor unit
2. Electric motor
3. Subbase
4. Water separator
5. Purifier
6. Priority valve
7. Check valve
8. Aftercooler
9. Safety valve
10. Intake filter
11. Carriage wheel
12. Shock mount
13. Control panel
14. Carrying handle
15. Working hour
16. Start-Stop
17. Filling hose
18. Filling vane
19. Filling manometer
20. Yoke
Figure 6 –W31 series compressor general layout (standard)

W31 SERIES
HIGH PRESSURE BREATHING AIR COMPRESSORS
ALKIN COMPRESSORS –2023-01
13
W31 series PETROL ENGINE compressor unit involves the main groups below;
1. Compressor unit
2. Petrol engine
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 manometer
14. Yoke
15. Shock mount
16. Carrying handle
17. Purifier drain valve
18. Manual drain valve
Figure 7 –W31 series compressor general layout (petrol engine)