Alkin W32 Series User manual

ALKIN Compressors Menderes / Izmir / TURKEY
Tel : [phone] Fax : [phone]
ALKIN®
W32 Series
3 Stage High Pressure
Breathing Air Compressors
225 – 350 Bars
Instruction Manual & Parts Book

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 0.
CONTENTS
Nr. SECTION Page
I-1. Foreword 1
I-2. Introduction 1
I-3. Safety 1. General
2. Pressure release
3. Fire & Explosion
4. Moving Parts
5. Hot Surfaces
6. Toxic and irritating Substances
7. Electrical Shock
8. Lifting
1
1
1
2
2
2
2
2
3
I-4. General information
1. General
2. Desing
3. Compressor block
4. Functional description
3
3
3
3
4
Compressor block,front view 5
I-5. P&I (Process & Instrument) diagram
1. Single pressure P&I diagram
2. Dual pressure P&I diagram
3. Mariner compressors P&I diagram
6
6
7
7
I-6. Principles of operation 8
I-7. Description of major compenents
1. Major Components-Compressor Unit
2. Major Components-System
9
9
9
I-8. Description of Controls
1. Automatic start-stop control
2. Manuel start-automatic stop control
10
10
10
I-9. Model Designations 11
I-10. Ownership Records 12 & 13
I-11. Installation
1. Inspection
2. Location
3. Piping
4. Electrical Check
5. Shaves and V-belt Alignment Check
14
14
14
14
14
14
I-12. Operation
1. Initial Start-up Procedure
2. Oil Recommendation
3. Adjusments 3.1. Pressure switch adjustment
3.2. Soft starter adjustment
3.3. Safety valve adjustment
3.4. Drain timer adjustment
15
15
15
15
15
15
15
16
Comissioning report-Initial start up 17 & 18
I-13. Maintenance
1. General
2. Daily
3. Weekly
4. Every 120 hours
5. 300 hours
6. 500 hours
7. 1000 hours
8. As required
19
19
19
19
19
19
19
19
19
Maintenance table 20
I-14. Maintenance Procedures 1. General
2. Torque Values
3. Torque Sequence
4. Valves
5. Intake filter
6. Intermadiate separator
7. Fınal separator/filter system
8. Lubrication system
21
21
21
21
22 & 23 & 24
24
25
25 & 26 & 27
27 &28
I-15. Trouble Shooting 28 & 29 & 30 & 31
II. Parts Manuel

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 1.
© This manual or any parts thereof cannot be copied by any means, or used for any other purposes other
than servicing Alkin W32 series compressors, unless specific permission of Alkin®in writing is received.
I – 1. Foreword
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.
ALKIN air compressors are well known with 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.
For any questions, please feel free to call our Menderes
plant, in Izmir - Turkey.
Here are the contact details :
Address : ALKIN – Menderes 35470 Izmir – Turkey
Phone : +90 – 232 – 782 22 90 (10 lines) Fax : +90 – 232 – 782 22 89 e mail : [email protected]
I – 2. Introduction
This manual is consists of three main sections.
1. Section I - General Information & Rules
In this section general rules for location
selection, installation, operation, maintainte-
nance and trouble shooting, warranty terms
are taking place. These are general rules that
need to be observed in all air and gas
applications.
2. Section II- Specific Data & Instructions
In this section, the specific data of the
equipment supplied –if any- are indicated.
3. Section III – Drawings & Spare parts
In this Section, the specific parts lists of the
equipment supplied takes place.
I – 3. Safety
1. GENERAL
All ALKIN air and gas compressors are designed and
manufactured with equipment & components that
allow safe operation of the compressors. It is the
user’s responsibility however, 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 injury. The
following safety precautions are offered only as a
guideline, and it is recommended to follow them along
with the locale safety codes and regulations.
This compressors 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 injury.
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 O.S.H.A. Requirements
(USA & Canada), and all relevant Federal, State and
local codes and regulations.
Do not modify this compressor and do not use beyond
the specified limits and speeds except with prior
written approval of ALKIN.
2. Pressure Release (air compressors only)
Have the safety valves tested periodically by certified
service personell and in conformity with the specific
manufacturer’s instructions and local regulations. 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 (waiting for the

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 2.
pressure switch signal to re-start). Switch off the main
electrical switch, shut off the discharge valve and vent
all pressurized sections before attempting to
dismantle such components.
Keep all persons away from the discharge opening of
hoses, tools accessories during venting. Do not use air
pressure above 2 Bars (30 Psi) for blow cleaning
purposes, and without use of proper protective
equipment as per OSHA Standard Section 29 CFR
1910.242 (b). Do not engage in horseplay with hoses
as serious injury or death may result.
Drain daily the condensate from the air receiver, as it
may accelerate the internal rusting and corrosion of
the receiver.
3. 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.
Do not attempt to weld on the pressure vessels or any
other parts or to the piping. Any such works or repairs
can only be made by certified technicians and with
prior written approval of the manufacturer.
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.
4. 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 belt guard removed.
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, than start
the compressor to check if the adjustment. 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.
5. Hot Surfaces, Sharp Edges and Sharp 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
surfaces. Wear personal protective equipment,
including gloves and protective hat when working on
or around the compressor. Keep a first aid kit handy.
Seek medical assistance promptly in case of injury.
Don’t ignore small cuts and burns as they may lead to
infections.
6. Toxic and Irritating Substances
Do not use air from this compressor for breathing
unless it is equipped with proper purification
equipment and in full compliance with OSHA standard
29 CFR 1910 and any other Federal, State and local
codes and regulations.
Operate the compressor only in well ventilated areas.
Lubricants used in this compressor are typical
industrial oils designed for use in high-pressure
compressors. Accidental ingestion and skin contact
should be avoided. Wash with soap and water after
skin contact. If swallowed, seek medical treatment
promptly.
7. Electrical Shock
Keep the compressor, hoses, tools and personnel at
least 3 meters (10ft) from power lines, panels and
underground cables.

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 3.
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.
8. Lifting
The vertical configured compressors are provided with
slots in the base to accept the forks of standard pallet
jacks. Use this method to move the compressor
around.
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 wet weight of the compressor . If you are
unsure of the weight, check before lifting. Make sure
the lifting hook has a functional safety latch, and is
fully engaged on the sling(s).
Use guide ropes to prevent twisting or swinging of the
machine once it has been lifted off the ground. Keep
all persons clear from under and away from the
compressor when it is suspended.
Lift the compressor no higher than necessary. Keeps
lift operator in constant attendance whenever the
compressor suspended. Set the compressor down on
level surfaces, capable of carrying its full weight.
I – 4. General Information on W32 Series 3 Stage Compressors
1. General
The W32 Series compressors are three stage,
reciprocating type, aircooled, pump lubricated
compressors.
The pressure range these compressor operate vary
depending on the cooling system and valve heads
installed and it ranges from 100 Bars (1500 psi) to 350
Bars (5080 psi). Do not attempt to modify a
compressor to operate at a higher-pressure
range without written approval of Alkin. Failure
to do so may result in heavy damage to equipment,
injury or death.
The compressor is built with oversize intercoolers and
an aftercooler to allow superior performance, longer
life and lower operating.
2. Desing
The compressor unit comprises the following major
assemblies:
• Compressor block
• Drive motor
• Frame and housing assembly with instrument panel
• Automatic condensate drain
• Filling panel
• Filter set
• Elecritric control system
All units are equipped as standart as follows:
• Filter system
• Final pressure swich gage
• Automatic condensate drain unit and condensate
collector tank
• Instrument panel with all three-stage pressure
gauges, oil pressure gauge, final pressure switch
gauge and hourmeter.
Filling panel with two filling valves and filling hoses
with 200 bar filling adaptors.
3. Compressor block
The Compressor blocks are of a three stage, three
cylinders desing. The cylinders are arranged in a “W”
form, 1st stage in the centre, 2nd stages on right and 3rd
stage on the left side lookingfrom the filter side.
The compressor blocks used in the Medium-Vertical
compressor units are particularly suitaple for
continuous operation because of their rugged design
and the corrosion resistant inter mediate filter and
cooler assemblies. Smoth is a particular feature of this
ALKIN design. The balans of masses of the 1st rank is
zero. The moving parts of the driving gear are all
equaly balanced. This retults in a vibration free
running.
The driving gear is fitted with three bearings. It is here
that the energy saving cylinder roller bearings are put
to use. The upper and lower connecting rod bearings
are also roller bearings. This allows for an even longer
life, which lasts at least 30,000 operating hours. All
valves have freee access for time saving maintenance.
There is no need for dismantling of pipes or pressure
gauges.
The compressor is built with oversize intercoolers and
an aftercoolers to allow superior performance, longer
life and lower operating.The W32 series compressors
are equipped with oversize stainless steel intercoolers
between the 1st & 2nd and 2nd & 3rd stage cylinders
and stainless steel aftercooler downstream the 3rd

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 4.
stage cylinder. A moisture trap (or condensate
separator) is installed Downstream the 2nd stage
intercooler and oil&water separator is installed
downstream the aftercooler. Moisture trap and oil &
water separator connected to automatic drain valves
that periodically open and drain the condensate in
these traps. The opening intervals and duration is set
by a time control relay found in the electrical control
panel of the compressor (see the controls section).
This time relay can be adjusted for both functions.
Normal –factory set- values of the drain valve timer are
15 minutes closed, and 6 seconds open operation.
A safety valve is installed between each stage and after
the final stage to protect the system against an
unexpected pressure rises due to a malfunctioning
valve or component. These safety valves must be
inspected periodically to insure proper operation and
set pressure verification (see the maintenance schedule
for inspection periods).
The W32 series compressors incorporate stainless steel
valves on all 3 stages. They are designed to have an
onobstructed passage of air with no pressure loss; they
are easy to maintain and replace. Particular
attention must be paid to valve maintenance, as
these valves are the basis for proper operation of the
compressor package. Do not use oils other than the
recommended oils in this manual for keeping the
valves clean and free of carbon collection. Unsuitable
oils will cause carbonization which will collect on the
valve discs and springs, resulting in improper sealing of
valves, This will increase the operating temperatures,
generating a chain reaction for further deterioration of
the oil and valve operation.
4. Functional description
The compressor is provided with a forced-feed
lubrication. The oil presure is prodused by a low reving
gear pump (1). The oil pressure is approximately 5
bar.
CAUTION
This oil pump will operate in the correct sense of
rotation, only. Otherwise, no oil presssure will
be built up resulting in damage of the
compressor block.
The oil pump (1) is coupleled to and driven by the
cranksaft. It pumps oil from the oil sump (5) through
the oil fine filter (2) and a minimum presure valve (3)
to the 3rd stage and lubricates all moving parts of the
compressor block.
The minimum pressure valve allows for oil pressure
gauge and electronic oil pressure monitoring.
Fi
g
. 1 Lubrication system

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 5.
Compressor block, front view
14
1 13
2
3 12
4
5
6 11
10
7
8
9
Fi
g
. 2 Compressor block, front view
1 Intake filter
2 Cylinder, 3rd stage
3 Plug, Oil filler neck
4 Oil filler neck
5 Safety valve, 2nd stage
6 Aftercooler
7 Hose, oil drain
8 Intermediate separator
9 Oil filter housing
10 Oil level gage
11 Intercooler
12 Cylinder, 2nd stage
13 Safety valve, 1st stage
14 Cylinder, 1st stage.

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 6.
I – 5. P&I (Process & Instrument) 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.
Some compressors are designed to operate at a “single
pressure” (see P & I diagram drwg#7862-1). This is,
when the compressed air is used to fill all the cylinders to
that single pressure. On some other systems there
might be different cylinders that need to be filled to
two different pressures. For instance some cylinders
are filled to 3200 psi, and others to 4500 psi. In
such applications “dual pressure” controls are used
to operate the compressors to the selected pressure
between the two available set pressures see P & I
diagram drwg#7862-2).
The following P & I diagram refers to a compressor that operates at single pressure
0000 400 4 00 400400 bar bar barbar
100 300
200
400
0
PA
R
6014
C
ALKIN
COMPRESSORS®
Menderes-IZMIR-TURKEY
TEL: [phone]
FAX: [phone]
Application Field
Drawing Number
Title Page
Pg.
Edited
Date
Date
Name
Name
Check
Norm
1
1
Modification
Material Surface
Scale Weight
Resp. 13.07.2002 R/K W32 SERIES 3 STAGES
BREATHING AIR COMPRESSORS SINGLE PRESSURE P&I DIAGRAM
7862-1 A
NEXT ASS'Y
Oil 1st stg. 2nd stg. 3rd stg.
Minimum Pressure Pressure Pressure Pressure
Pressure Pressure Switch
Gage Gage Gage Gage
Valve Gage
1st stg.
2nd stg.
IC (2-3)
AC
3rd stg.
Oil Pump
Oil Pump
2nd stg.
3rd stg.
3rd stg.
IC(1-2)
Particle
Condansate
IC (1-2) : 1st stg.-2nd stg intercooler
IC (2-3) : 2nd stg.-3rd stg intercooler
AC : Aftercooler
Condansate
Check
Drain Pilot Drain
Drain
Purifier
Safety
Priority
Filling
Safety
Safety
Removal
Separator
Collector Tank
Valve
Solenoid
Yoke
Valve
Valve
Valve
Valve
Valve
Valve
Filter
7702
www.alkincompressors.com
Fi
g
. 3 P&I dia
g
ram (sin
g
le pressure)

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 7.
The following P&I diagram refers to a compressor that operates at “dual pressures”.
0000400400400400 bar bar barbar
100 300
200
400
0
PA
R
6014
C
ALKIN
COMPRESSORS®
Menderes-IZMIR-TURKEY
TEL: [phone]
FAX: [phone]
Application Field
Drawing Number
Title Page
Pg.
Edited
Date
Date
Name
Name
Check
Norm
1
1
Modification
Material Surface
Scale Weight
Resp.
13.07.2002 R/K
W32 SERIES 3 STAGES
BREATHING AIR COMPRESSORS DUAL PRESSURE P&I DIAGRAM
7862-2 A
NEXT ASS'Y
Oil 1st stg. 2nd stg. 3rd stg.
1st stg.
2nd stg.
IC (2-3)
AC
3rd stg.
Oil Pump
Oil Pump
2nd stg.
Minimum
3rd stg.
3rd stg.
IC(1-2)
Particle
Condansate
IC (1-2) : 1st stg.-2nd stg intercooler
IC (2-3) : 2nd stg.-3rd stg intercooler
AC : Aftercooler
Condansate
Check
Drain Pilot Drain
Drain
Purifier
Pressure Pressure Pressure Pressure
Safety
Pressure
Priority
Filling
Selector
Pressure
220 Bar
Pressure Switch
Pressure
Safety
Safety
Remaval
Separator
Collector Tank
Valve
Solenoid
Yoke
Valve
Gage Gage Gage Gage
Valve
Valve
Valve
Valve
Pilot Switch
Safety Valve
Gage
Selector
Valve
Valve
Valve
Filter
7702
www.alkincompressors.com
The following P&I diagram refers to a compressor that operates at “mariner compressors”.
0
0
0
400
400
400
bar
bar
bar
ALKIN
COMPRESSORS®
Menderes-IZMIR-TURKEY
TEL: [phone]
FAX: [phone]
Application Field
Drawing Number
Title Page
Pg.
Edited
Date
Date
Name
Name
Check
Norm
1
1
Modification
Material Surface
Scale Weight
Resp.
13.07.2002 R/K
W32 SERIES 3 STAGES
BREATHING AIR COMPRESSORS TYPE MARINER P&I
7862-3 A
NEXT ASS'Y
Oil
1st stg.
2nd stg.
IC (2-3)
AC
3rd stg.
Oil Pump
Oil Pump
Pressure gage
2nd stg.
Minimum
3rd stg.
3rd stg.
IC(1-2)
Condansate
IC (1-2) : 1st stg.-2nd stg intercooler
IC (2-3) : 2nd stg.-3rd stg intercooler
AC : Aftercooler
Check
Purifier
Filling valve Yoke
Pressure
Safety
Pressure
Safety
Safety
Separator
Drain
Drain
Valve
Gage
Valve
Valve
Valve
Valve
7702
www.alkincompressors.com

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 8.
I – 6. Principles of Operation
1st Sta
g
eCover
3rd Sta
g
eCover
1st Sta
g
e
V
alve
A
ss'y
1st Sta
g
e
Connectin
g
Rod
Connectin
g
Rod
Connectin
g
Rod
Piston
A
ss'y
Piston Liner
1st Sta
g
e
Piston
A
ss'y
(1st Sta
g
e)
(2 nd Sta
g
e)
(3rd Sta
g
e)
(3rd Sta
g
e)
(3rd Sta
g
e)
Cylinder
V
alve Head
V
alve Head
Dischar
g
e
V
alve
A
ss'y
Inlet
V
alve
A
ss'y
Dichar
g
e
V
alve Ass'y
Inlet
V
alve
A
ss'y
(2nd Sta
g
e)
(3rd Sta
g
e)
(3rd Sta
g
e)
(3rd Sta
g
e)
(2nd Sta
g
e)
(2 nd Sta
g
e)
Cylinder (2nd Sta
g
e)
Piston
A
ss'y (2nd Sta
g
e)
Guide Cylinder (2nd Sta
g
e)
Crankcase
#7786
Fi
g
. 5 W32 com
p
ressor unit section.
The P & I diagram have to be reviewed carefully
to understand the principle of operation. The air
is drawn at atmospheric pressure, through the
inlet filter (see Fig.5) into the 1st stage cylinder on
the up-stroke of the piston (see Fig.5). The up-stroke
motion of the piston will cause compression and the air
will be forced out of the cylinder through 1st stage
discharge valve (see Fig.5). Air will than pass through
the intercooler tubes between the 1st and 2nd stages
and into the 2nd stage compression chamber. Here, the
air is compressed to the 2nd stage compression level
and forced through the 2nd stage valves + 2nd stage
intercooler + moisture separator + 3rd stage inlet valve
into the 3rd stage cylinder. Here, the air is compressed
to the final pressure level and forced out to the
aftercooler, oil & water separator (pre-filter), than
passing through a check valve enters the purifier
chamber, where it is purifier and prepared to be used
for breathing purposes. A priority (or minimum
pressure valve) is installed downstream the purifier;
this valve prevents the air to exit the purifier until the
pressure builts to approximately 180 bars (2610 psi), a
pressure level where the purification process is more
efficient than at lower pressures. The air is than ready
to be directed to a filling panel and with proper
connections to the cylinders to be filled.
The intercoolers and the aftercoolers are desighed to
dissipate the head generated from the previous
compression cycle, redusing the air temperatures,
allowing the water vapors to condensate and settle in
the bottom sections of the moisture separators. The
moisture separator and the oil & water separator (pre-
filter) are equipped with an automatic drain valve. The
drain valve is a 3 way pneumatic valve controlled by a
3-way solenoid valve. This solenoid valve sends or
removes the control air from the drain valves,
thusletting them to open or close. The solenoid itself is
controlled by a sequential timer relay in the electrical
panel. The dual time adjustment on this relay allows to
adjust the duration (t1~ 15 min) during which the
solenoid will remain energised (=the drain valve will
remain closed), and the length of time (t2~ 6 seconds)
during which the solenoid will become de-energised
(=the drain valve will open and perform the drain
function).
The compressor starts and stops with automatic
regulation by a pressure switchgage (see section I-8
for adjustments and functional details).

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 9.
I – 7. Description of Major Components
I.7.1. Major Components - Compressor Unit
Crankcase : This is the frame that holds everything
on it. It contains the oil that lubricates the system. The
cylinders are mounted on it. The crankshaft is inserted
into the bearing housings which is an integral part of
the crankcase. There is no maintenance or repair
works that need to be done on this part; it needs to be
cleaned inside when the oil is changed. Due to its
unique overhung design, the cleaning inside the
crankcase is made possible as the cover does not carry
the bearing housings as in most other type
compressors.
Crankshaft : It is overhung type; that means the
bearings are on one side, and the crank pin (where
connecting rods are mounted) are on the other side.
This unique feature allows usage of single piece
connecting rods which are far more accurate and safe
than split con rods. Large bearings in conjunction with
low speeds, allow very long crankshaft life.
Connecting Rods : There are three connecting rods
which are similar in the 1st, 2nd stg and the 3rd stage.
The upper and lower connecting rod bearings are roller
bearings. This allows for an even longer life which lasts
at least 30.000 operating hours.
Cylinders : They are cast separately and are made of
high grade casting materials, machined & honed to
fined tolerances for long service life. When worn, they
will need replacement. The compression cylinders on
the 2nd and 3rd stages are mounted on guide cylinder to
guide the crosshead piston ass’y.
Oil Pressure Switch: This switch installed on to
crankcase it is mounted so that when the oil pressure
drops nder 4 bars, the switch is stopping the motor.
Breather: All piston type machines have some
compression leak through the rings into the crankcase;
to prevent pressure build up in the crankcase, a
breather system is provided to allow the crankcase to
“breath”. In the air compressor the crankcase is
connected via a copper tube to the inlet from where
the breathing is made possible, or a breather device is
installed on the crankcase to vent the pressure from
within the crankcase. In the gas compressors the
crankcase is piped to the inlet.
II.5.2. Major Components – System
The Canopy: The canopy is designed to carry the
various components, the compressor unit, the motor
and the electrical panel. It is painted electrostatically
for extended life. It has a door on the top and two
easily removable door panels at sides to easily and
quickly access all parts of the package.
The compressor unit is supported on four vibration
mounts. The vertically mounted compressor / motor
assembly, is a belt driven system; the belts are
automatically tightened by the weight of the motor
which exerts a tightening force onto the rotart slide on
which it is mounted. This unique device saves to pay
extra attention to the belt tightening on W32 series
machines.
The Electrical Panel: It is located at the front view /
left section of the compressor. It accommodates all the
electrical gear to start the motors and control the
system.
Pressure Switch: It is located at the front view /
right section of the compressor. This switch both
indicates the purifier pressure, and the set pressures
on its dial, while serving as a double circuit pressure
switch. It controls the start-stop operation of the
compressor. The pressure-sensing end of the pressure
switch is connected to a port on the purifier; when the
pressure inside the purifier reaches the set pressure, it
cuts off the contnrol circuit, and stops the electric
motor. See the following section for further details.
Automatic Drain Valves: The automatic drain
incorporates a small piston with high pressure in the
bottom, and low pressure on top; the surface where
low pressure acts on is larger than the surface where
the high pressure effectively acts on the piston.
Therefore the force on the top is larger and causes the
piston to sit and seal the high-pressure vent port. The
drain valves are controlled by a solenoid mounted on
the pilot valve fitting. It receives compressed air from
the 2nd stage air inlet and sends it over the 2 drain
valves forcing them to close. When the solenoid is de-
energised, it removes the control air over the top of
the drain valve pistons, allowing the high pressure
acting from the bottom of the pistons, to open and
perform drain operation.
Instrument Panel: It is located at the front view / on
the right section. It incorporates a main isolating
switch, a start/stop button, a hourmeter and an
emergency shutdown switch.
On the left section, it incorporates three-pressure gage,
to indicate the stage pressures, an oil pressure gage, a
pressure switch gage and two filling valves. See the
following section for further details.

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 10.
I – 8. Description of Controls
Compressor Controls : The W32 Series compressor
may operate with the following two controls :
1. Automatic Start – Stop Control : This is the
standard control type for all single pressure compressor
systems. With this type of control, once the
compressor is manually started, it will run till it reaches
the high set pressure where is will automatically stop
(the pressure where the motor will cut-out); after the
pressure drops to the low set-pressure (the pressure
where the motor will cut in), it will automatically re-
start. This control system is standard on all single
pressure compressors.
2. Manual Start – Automatic Stop Control: This
control is used on compressors with dual pressure
controls. The dual pressure systems have two cut out
pressures (at which level the motor will be stopped) :
One is the low cut-out pressure (for example at this
mode, the compressor will stop at 3200 psi), the other
is the high vut-out pressure (for example 4500 psi).
With this type of control, the compressor will always
have to be started manually; there is a valve on the
filling panel which allows the operator to select
between low and high pressure cylinder filling
depending on the type of cylinders being filled. If the
lever is at the “high pressure” mode, the pressure
switch wil sense the high pressure and will cut out at
that pressure (for example at 4500 psi). When the
lever is set to the low pressure mode, an electro-
pneumatic valve will be activated, enabling the low cut-
out pressure circuit of the pressure switch to control
the system; when the low cut out pressure (in this
example 3200 psi) is reached, the pressure switch will
cut out the motor.
In the illustration on the right hand side, the red
needle indicates the high cut out pressure control hand
(showing 340 bars), and the black indicates the low
pressure cut our pressure control hand (showing 230
bars).
Pressure Swtichgage : The W32 series compressors
are controlled by a pressure switch that cuts off the
motor control line when the operating set pressure is
reached; it cuts in when the pressure drops below the
pre set low pressure limit, starting the motor again. On
diesel engine driven compressors, a constant speed
control system is added to the package; this includes
head and discharge unloaders for the compressor unit,
and an unloading system which allows the compressor
to run without compressed air.
100 300
200
400
0
Fi
g
. 6 Pressure switch
g
a
g
e
Instrument & Control Panel – The instrument panel layout is shown in the following illustration.
3rd. Stage Pressure
Pressure Switch Gauge
www.alkincompressors.com
Oil Pr essure
1st Stage Pressure
2nd. Stage Pressure
ONLYQU
A
LIFIED PERSONNEL
SHOULD BE
A
LLOWE D TO
OPER
A
TE
A
ND
/
OR M
A
INT
A
IN
THIS COMPRESSOR
RE
A
D THE INST RUCTIONS
M
A
NU
A
L BEFORE INST
A
LLING,
OPER
A
TING
A
ND M
A
IN T
A
IN IN G
THIS COMPRESSOR
BEW
A
RE OF ELECTRIC
A
L
SHOCK, HOT SURF
A
CES ,
MECH
A
NIC
A
LINJURY,HIGH
A
IR PRESS UR E
DO NO T OPER
A
TE THIS
M
A
CHINE W ITHO UT THE
ENCLOSURE
ON-OFFSWITCH
O
M A IN S W IT C H
00000 00 h
le g
r
and
HOURME TER
EMERGENC
Y
STOP
0010 10
bar bar
0
0
60
400
bar
bar
100 300
400
200
0
G
A
GE
G
A
GE
G
A
GEG
A
GE
G
A
GEBU
T
T
ON
PRESSURE
SWI
T
CH
PRESSUREPRESSURE OIL
PRESSURE
2nd S
T
A
GE1st S
T
A
GE
M
A
IN
SWI
T
CH HOURME
T
ER
PRESSURES
T
OPSWI
T
CH 3rd S
T
A
GEEMERGENC
Y
ON-OFF
V
A
L
V
ES
FILLING
#7895
Fig. 7 Instrument & Control panel

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 11.
I.9. Model Designations
W32 – 5 - 310 – F P4 N
Examples:
♦ W32-4-225/310 P4N 3 Stage 4 kW compressor, dual pressure [225/310] 225 and 310 bars (3260 / 4500 psi),
P4 size purifier [P4], and a integrated filling panel [N].
♦ W31x2-4-310-P2N 3 stage duplex compressor [x2], 4 kW, 310 bars {4500 psi} operating pressure, P2 size
purifier, integrated filling panel [N].
Power in kW
Oil & Particle Removal Filter
Purifier – Size 2 , 4 or 6 : P2 (up to 230 Lt/min – 8,5 cfm)
P4 (up to 450 Lt/min – 16 cfm)
P6 (up to 600 Lt/min – 22 cfm)
Filling Panel – Type N (integral) , Type M (removable)
Operating Pressure in Bars
Options :
Single Pressure
 225 Bars – 3260 psi
 310 Bars - 4500 psi
 Other pressures (specify)
Note : Models up to 6000 psi are
available. Ask for details.
Dual Pressure
 225 / 310 Bars – 3260 / 4500 psi
Other dual pressure range (specify)
Bare pump model
W - Cylinder
Configuration
Number of stages
3 or 4
A
vailable pumps:
W31 - 3 Stage
W32 - 3 Stage
W4 - 4 Stage

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 12.
I – 10. 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 W32 – -
– P4N
Serial Number
Medium Air
Application Breathing Air Cylinder filling
Rated Free Air (gas) delivery lt/min
Operating Pressure BAR
General Arrangement Drwg.
Process & Instrument Drwg.
Production File Number
Relevant Drawing Numbers
Parts List
Compressor Unit
Model Type Recip. Serial Number
Year Max. Operating Pressure Inlet Pressure Atmospheric
Application Air Oil Type UL 751 Other
Stroke 40 LP Bore x nr.of LP cyl. 88 HP Bore 36&14
Electric Motor
Type Sq.cage ind.motor Make Serial Number
Power (kW) Power (HP) RPM 2950
Voltage Frequency Phase 3
Insulation F Frame Type IP54
Current Rating Full Load Current Off Load Current
Drive Type Belt dr. Compressor Flywheel Ø450 mm Motor Sheave
Belt Section 13 mm Belt Size Number of belts
Pressure Control
Type Pressure switchgage Model Make Alkin
Differential P. Cut out pressure Cut In pressure
Other Data
Electrical Control Panel & Motor Starter Drawing Number
Parts List Number

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 13.
Electrical Panel
Panel type
Drawing Number
Starter Type
List of Components
Description Make Designation Model Rating
Main Switch (isolator)
On-off switch
Emergency stop button
Hourmeter
Main motor overload relay
Star / delta timer relay
………………. By-pass timer relay
Drain timer relay
Control Fuse
Main contactor
Delta contactor
Star contactor
Pressure switch gage
Oil pressure switch
Transformer
Selector switch (for dual Pressure)
Direction of rotation relay
Drain control valve(solenoid valve)

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 14.
I - 11. INSTALLATION
1. INSPECTION
The compressor should be inspected and checked for
the following:
1. Damage during shipping, handling etc.
2. Check the compressor nameplate to verify the
equipment conforms the working parameters.
3. Check the electrical motor nameplate to match the
available power and electrical supply.
4. Check if the machine is filled with oil or supplied
dry.
2. LOCATION
IMPORTANT – READ CAREFULLY AND OBSERVE THE
FOLLOWING INSTRUCTIONS
The location where the compressor is installed
determines to a considerable extent the overall
performance and service life of the unit. The
compressor should be located in an area that
will be dry and sheltered, well ventilated, not
exposed to high ambient temperatures, air
borne contaminants such as dust, fumes, lint,
vapor, steam, gases, engine exhaust and other
contaminants. Install the compressor with a
minimum of 600-mm (24”) clearance between adjacent
surfaces, to insure adequate cooling and access for
service.
Install the compressor on a level surface of sufficient
strength to support the static weight of the equipment,
as well as the dynamic forces resulting form its
operation (preferably a 6” [150 mm] concrete floor).
3. PIPING
Inlet Piping: If it is necessary to carry the inlet air
filter to a clean location, due to excessive dirt, heat,
dampness, or toxic fumes in the near vicinity of the
compressor, use 1¼” diameter good quality flexible
hose; the distance from the compressor should not
exceed 3 meters (10 ft). If the inlet filter will be
outdoors, protect it with a proper hood against
moisture.
Discharge Piping - If piping is required between the
compressor package and the filling station, properly
selected stainless stell pipes must be used. The piping
should be installed in full compliance with all Federal,
State and local codes, standards and regulations. If
required, consult the manufacturer for details.
Drain Line Piping – The drain valves insides the
compressor assembly are piped to a collector tank. This
port must be piped with a next larger size pipe to an
area where the condensate can be collected and
disposed off according to local codes and regulations.
Make sure this pipe is as short and as striaght possible
as it is. Make sure the ends of this pipe are firmly
secured to avoid whipping during the venting cycle.
4. ELECTRICAL CHECK
Although all electrical instructions addressed to
the reader directly, the actual inspection, wiring,
installation, maintenance, repair etc. must be
carried out by licensed and certified electricians
only.
Make electrical connections to the compressor in
accordance with the wiring diagrams and in full
compliance with all applicable Federal, State and Local
standards, codes and regulations, including those
dealing with the grounding requirements. A few
electrical checks should be made to insure that the first
start up will be trouble free. Make the following checks
before attempting any start up :
1. Check the line voltage. Verify that the
compressor motor corresponds to mains
specifications.
2. Check the starter and overload for conformity
with the motor power and current data.
3. Check all electrical connections for
tightness, including those in the electrical panel
of the compressor.
4 At start up, check the direction of rotation to
insure flywheel rotating in the direction of the
arrow on it. Although a few minutes of operation
in the wrong direction of rotation will not damage
the compressor, but running it this way in normal
operation will create serious damage as the
cooling air flow will be reversed, preventing the
compressor cylinders to be cooled during
operation.
Wiring – It is important to select the right size wire
and fuses. Install an isolation switch on the wall where
the mains line is carried to, with magnetic protection
and a capacity three times greater than the motor full
load current. Use the same size wire between this unit
and the compressor electrical panel.
5. SHEAVES AND V-BELT ALIGNMENT CHECK
The W32 Series compressors are supplied with a self-
tightening rotary slide; therefore these are no
adjustments need to be made. However it is a good
practice to check at the initial start up the driver
sheave and the compressor flywheel for parallel
alignment of the V grooves. Check the V-belt tension.
Proper tension should be adjusted to give about 13
mm (½”) deflection with a 1-kg (2 pnds) weight
applied at the center of each belt. Check the condition
of the belts periodically (see the maintenance table for
details.).

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 15.
I – 12. OPERATION
1. INITIAL START-UP PROCEDURE
Follow up the following procedure when making initial
start-up of the compressor:
1. Make sure you have read this manual carefully,
and you understand it . If any questions, call the
nearest ALKIN distributor, service or factory.
2. Be sure all the preparations described in the
installation section of this manual have been made.
3. Check the oil level in the crankcase.
4. Check the pressure switch-gage and make sure that
the dials are set to the proper pressure settings.
5. Rotate the compressor flywheel several times by hand
to see that the compressor is free and in working
order.
6. Remove all objects such as tools, rugs, etc. from the
vicinity of the compressor.
7. Jog the compressor to check the direction of rotation.
Rotation must be in the direction of the arrow on the
compressor crankcase and flywheel.
8. Press the start button to start the machine.
9. Check for possible leaks in the piping.
10. Close the filling valves on the filling panel and allows
the pressure to rise to the set point.
Make sure that the compressor stops at the set
pressure.
11. Allow the compressor warm up
12. Open the filling valves and allows the air into the
cylinders to be filled.
13. Observe the
stage pressure and make sure it is within
the limits shown in stage pressure table. Any
deviation from these limits will indicate a mulfunction.
14. After the first 200 hours of operation, shut the
compressor off, drain the oil from its crankcase while
oil is hot. Fill the crankcase with recommended oil
15. FILL IN THE comissioning report and return a
copy to the manufacturer for track record.
2. OIL RECOMMENDATION
The oil level should be checked daily. Top
up to the overfill point when required.
• On all W32 Series Compressors use the
following oil only : CHEMLUBE 751
• Do not use another type of oil without prior written
approval of the manufacturer.
• Do not mix oils.
• If you will have to change the type of oil to another
approved oil, remove the crankcase cover and clean
thoroughly the inner surfaces of the compressor
crankcase. Make sure there will be no lint left inside
after the cleaning.
• Although the Cehmlube 751 lubricants can be used for
1000 hours, we strongly recommend to replace it
every 500 hours for safety. When replacing the oil,
remove the crankcase cover and clean inside the
crankcase with a clean cloth. Do not use kerosene
or gasoline to flush the crankcase. While doing
that, pay attention not to damage the oil level
switch extending into the crankcase.
Extreme Cold Operating Conditions: Operating
conditions at below freezing temperatures must be
reported to the manufacturer for taking necessary
measures to avoid damage. Generally a crankcase
heater is fitted to prevent the effect of cold ambient
temperatures.
Motor Lubrication – Most TEFC motors are
supplied with greased and sealed breaings which do
not need maintenance. Motors with greasing nipples
indicate that it needs to periodically be greased. In
that case you will find a specific instruction booklet
inside this manual which will refer to all
maintenance works regarding the electric motor.
Follow the instructions in this manual.
3. Adjustments
3.1. Pressure Swtich Adjustment: Remove the cap
in the center of the dial of the pressure switch-gage
unit. Insert the special key delivered with your
compressor and turn clockwise to increase or
anticlockwise decrease the setting of the first dial. Than
push the key gently and perform the same operation
for the second dial. When done, remove the key, return
the cap in place and store the key in a safe place so
that unauthorized persons cannot reach. Do not attach
the key onto the switch or canopy itself. The key on a
new compressor is attached in the back of the switch-
gage; open the door and remove it for safe storage
elsewhere. See illustration for the pressure switch gage
on page8.
WARNING
The oil inside the pressure control switch-gage is
a special dielectric oil. DO NOT USE ANY OTHER
OIL TO TOP UP OR FILL THE PRESSURE
SWTICHGAGE.
3.2. Soft Starter Adjustment :
Refer to the specific soft starter manual that is inside
your compressor manual.
3.3. Safety Valve Adjustment :
Safety valves are set slightly above the normal working
pressure of the stage they protect.

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 16.
WARNING
• Do not adjust the safety valves and do not alter their original settings. Only authorized service
technicians are certified to make such adjustments. If required, replace and return the old one for
reconditioning to the factory or to a dealer nearest you.
• Do not remove the leaking safety valves and do not replace it with a plug. This may be extremely
dangerous. If safety valve leaking, replace it.
3.4. Drain Timer Adjustment :
The drain function is controlled by a sequential timer
relay that is located inside the control cabinet. This is
how this relay looks Figure 3.4.1:
1
00
55
10 10
15 15
20 20
25 25
30 30
23ab
Figure 3.4.1
On this relay you will find two dials to control the time
adjustment petentiometers (see Figure 3.4.2)
The dial on the left controls the length of period
during which the vent valve remains open (drains the
condensate).
It is adjustable between 0 to 10 seconds. The dial
does not have figures on; it needs to be proportionally
adjusted. The full scale shows 10 seconds, while half
the scale will indicate 5 seconds.
Normally, it should be set to approximately 5 seconds.
If within 5 seconds all the moisture is drained, and too
much air is wasted, shorten the draining period; if
condensate is not fully drained, increase the draining
period.
The dial on the right is used to adjust the period
during which the drain valve will remain closed. Adjust
this period depending on the specific operating
conditions. This dial controls a potentioemeter that
sets the relay between 0 to 30 minutes. Default value
is 15 minutes.
Draining
AdjustableAdjustable
Drain valve
period
0-30" (min)0-10" (sec)
closed
period
Figure 3.4.2
Fill in the following forms (total 2 pages) at the initial start up. Send a copy to the
manufacturer for record keeping, and retain the original report n the file of your
compressor.

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 17.
COMISSIONING REPORT – INITIAL START UP
CUSTOMER DETAILS
Name of the Company
Address
Contact Name
Position Phone Fax
Name of Plant Where Equipment Installed
(If different than the above)
Address
Contact Name Position Phone Fax
Distributor
Persons Attending the Commissioning
Full Name Position In charge of Signature
Equipment Details
Model
Serial Nr.
Date of purchase Date of comissioning
Application
Medium RAir RGas (specify) : ………………………………………………………………………
PRELIMINARY CHECKS Remarks Signature
Compressor Received properly R
Location suitable/ventilated R
Bolitng down-canopy/sub-base R
Piping in the compressor intact R
Oil Type R
Oil Level in the crankcase R
External Conn.s & Pipework Suitable R
All electrical connections checked R
Mains Supply Voltage and Freq. RV Hz
Other Remarks R
R

Instruction Manual W32- Series Medium-Vertical Compressors
Page I - 18.
START UP CHECKS Remarks Signature
Direction of rotation R
Start up current and voltage RAmps. Volts
Fill in the pressure reading table R
Pressure switch cut out pressure RBars
Main Motor Current and voltage at full load RAmps. Volts
Max current and voltage ratings & supply
frequency conform the nameplate values. R
Vibration R
Noise R
No back flow in the Check valve when the
compressor stops. RV Hz
Interstage and final safety valves not leaking R
Ambient Temperature R ° C
Crankcase oil temperature after 30 minutes of
operation R ° C
Discharge air/gas temperature after 30
minutes of operation R ° C
Duty Cycle (…min operating; RMin. runnig; min.stops
Other Remarks R
Pressure Readings
1st stage 2nd stage 3rd stage 1st stage 2nd stage 3rd stage
50 Bars 200 Bars
100 Bars 250 Bars
150 Bars
Engineer in charge of the plant
Full Name
Remarks
Singature Date
Distributor / Manufacturer’s Representative Attending the Commissioning
Full Name
Remarks
Signature Date
Other Attendants
Full Name
Remarks
Singature Date