Alkin W4 series User manual

SERIES

BREATHING AIR COMPRESSORS

W 4 S E R I E S

H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R

HIGH PRESSURE BREATHING AIR COMPRESSORS

(W4 SERIES)

Instruction Manual & Parts List

Instruction

Manual

W 4 S E R I E S

H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R

A L K I N C O M P R E S S O R S

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other than servicing Alkin W4 series compressors, unless specific permission of Alkin®in writing is

received.

ALKIN KOMPRESOR San. ve Tic. Ltd. Sti

Cuneytbey Mh. Tabas Yolu Kume Evleri No.3, Menderes

35470 Izmir - TURKIYE

Tel: +90 232 78 222 90 • Fax: +90 232 78 222 89

www.alkin-compressors.com

 
W 4 S E R I E S 
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 
 
 
ii 
CONTENTS 
0 SAFETY................................................................................................................................. 6 
1 General .................................................................................................................................................... 6 
1.1 General safety information...................................................................................................................6 
1.2 Pressure release..................................................................................................................................6 
1.3 Fire and Explosion ...............................................................................................................................6 
1.4 Moving parts.........................................................................................................................................7 
1.5 Hot Surfaces, Sharp Edges and Sharp Corners..................................................................................7 
1.6 Toxic and Irritating Substances............................................................................................................7 
1.7 Electrical Shock....................................................................................................................................8 
1.8 Lifting....................................................................................................................................................8 
0 General information on W4 series 4 Stage compressors....................... 10 
1 General ..................................................................................................................................................10 
2 P&I (Process & Instrument) Diagram......................................................................................12 
3 Principles of Operation ..................................................................................................................13 
4 Description of Major Components ............................................................................................14 
4.1 Major Components - Compressor Unit ..............................................................................................14 
4.2 Major Components –System.............................................................................................................15 
5 Description of Controls ..................................................................................................................16 
5.1 Compressor Controls.........................................................................................................................16 
6 Owner records ...................................................................................................................................18 
0 Installation..................................................................................................................... 20 
1 Inspection.............................................................................................................................................20 
2 Location.................................................................................................................................................20 
3 Piping .....................................................................................................................................................20 
4 Electrical check..................................................................................................................................21 
5 Wiring ....................................................................................................................................................21 
6 Sheaves and V-belt alignment check........................................................................................21 
0 Operation ........................................................................................................................ 22 
1 Initial start-up Procedure .............................................................................................................22 
2 Oil recommendation........................................................................................................................22 
3 Adjustment ..........................................................................................................................................23 
3.1 Pressure Swtich Adjustment..............................................................................................................23 
3.2 Sequential Drain Timer Adjustment...................................................................................................23 
3.3 Safety Valve Adjustment....................................................................................................................24 
0 Maintenance .................................................................................................................. 28 
1 General ..................................................................................................................................................28 
2 Daily........................................................................................................................................................28 
3 Weekly...................................................................................................................................................28 
4 Every 120 hours ................................................................................................................................28 
5 300 hours maintenance .................................................................................................................28 

 
 
6 500 hours maintenance .................................................................................................................29 
7 1000 hours maintenance...............................................................................................................29 
8 2000 hours maintenance...............................................................................................................29 
9 As required ..........................................................................................................................................29 
10 MAINTENANCE TABLE................................................................................................................30 
11 Maintenance procedures ............................................................................................................31 
11.1 General ............................................................................................................................................31 
11.2 Torque values ..................................................................................................................................31 
11.3 Servicing 1st stage valve..................................................................................................................31 
11.4 Servicing 2nd stage valve .................................................................................................................31 
11.5 Servicing 3rd &4th stage valve...........................................................................................................32 
11.6 Piston ring replacement ...................................................................................................................33 
11.7 Crankshaft bearing replacement......................................................................................................36 
11.8 Oil seal replacement ........................................................................................................................37 
11.9 Piston&piston pin removal and replacement ................................................................................37 
11.10 Cylinder&piston removal and replacement....................................................................................37 
11.11 Air head replacement.....................................................................................................................38 
11.12 Precautions for storing...................................................................................................................38 
11.13 Intercoolers and aftercooler...........................................................................................................39 
11.14 Automatic drain valves...................................................................................................................39 
11.15 Filtration equipment ....................................................................................................................39 
0 Trouble shooting......................................................................................................... 41 
0 Part List............................................................................................................................ 46 
1 Crankcase Assy ..................................................................................................................................47 
2 Connecting Rods................................................................................................................................49 
3 1st&2nd Stage Assy..........................................................................................................................51 
4 3rd Stage Assy....................................................................................................................................53 
5 4th Stage Assy ....................................................................................................................................55 
6 Pistons ...................................................................................................................................................57 
7 Pipe Lines .............................................................................................................................................59 
8 Intercoolers (1st&2nd Stage)......................................................................................................63 
9 3rd Stage Intercooler & 4th Stage Aftercooler.....................................................................65 
10 Water Separators ...........................................................................................................................67 
11 Discharge Line.................................................................................................................................69 
12 Filter Panel........................................................................................................................................73 
13 Coelescer Filter Assy.....................................................................................................................77 
14 Purifier Assy .....................................................................................................................................79 
15 Pressure Gauge Lines ...................................................................................................................81 
16 Drive Assy..........................................................................................................................................83 
17 General Connectors.......................................................................................................................85 
18 Filling Panel –Dual Pressure ....................................................................................................89 
19 Filling Panel –330 Bar.................................................................................................................91 
20 Filling Panel –225 Bar.................................................................................................................93 

W 4 S E R I E S

H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R

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 in the maintenance

section of this manual. This way the proper manner, as well as maintain it using the simple instructions your air compressor will always be in

top operating condition, giving you years long trouble free service.

LKIN 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 KOMPRESOR San. ve Tic. Ltd. Sti

Cuneytbey Mh. Tabas Yolu Kume Evleri No.3 , Menderes

35470 Izmir - TURKIYE

Tel: +90 232 78 222 90 •Fax: +90 232 78 222 89 •e-mail: alkin@alkin-compressors.com

Foreword

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H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R

W 4 S E R I E S

H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R

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1.1 General

1.1.1 General safety information

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.

Those who have been trained to do so, and who have read and understood the contents of this manual should only

operate these compressors. 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.

1.1.2 Pressure release

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 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.

1.1.3 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.

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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.

1.1.4 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.

1.1.5 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.

1.1.6 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.

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1.1.7 Electrical Shock

Keep the compressor, hoses, tools and personnel at least 3 meters (10ft) from power lines, panels 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.

1.1.8 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.

W 4 S E R I E S

H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R

W 4 S E R I E S

H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R

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2.1 General

The W4 Series compressors are four stage , reciprocating type, aircooled, splash 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 415 Bars (6000 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 & discharge temperatures.

The first and second stage cylinders are built in a common cylinder assembly (see Figure 1 in this section). The first stage

compression occurs in the up-stroke of the piston, and the second stage compression in the down-stroke.

Figure 1

The third and fourth stage compression takes place in the up-stroke of 3rd and 4th stg steeple piston working in its

crosshead guide and cylinder.

The W4 series compressors are equipped with oversize copper intercoolers between the 1st & 2nd and 2nd & 3rd stage

cylinders and stainless steel intercooler between the 3rd and 4th stage cylinders and stainless steel aftercooler downstream

Section

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the 4th stage cylinder. A moisture trap (or condensate separator) is installed Downstream the 2nd & 3rd stage

aftercoolers and downstream the aftercooler. Each of these moisture traps is 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 W4 series compressors incorporate stainless steel valves on all 4 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.

Lubrication is created by dipstick found in the bottom of the 4th stage connecting rod. While the crankshaft rotating, the

connecting rod reciprocates and the dipstick enters the oil bath in the bottom of the crankcase; while coming out of this

oil bath, the dipstick splashes oil to the moving parts of the compressor. Efficient oil wiper rings control the economical

lubrication of the system.

See the process and instrument diagram to study the general system layout and operation sequence

Figure 2

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2.2 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 Figure 3). 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 Figure 4).

Figure 3

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Figure 4

2.3 Principles of Operation

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 Figure 2) into the 1st stage cylinder on the down-stroke of the

piston (see Figure 1 in section I-4). 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 and than the manifold (Figure 2). Air will than pass

through the intercooler tubes between the 1st and 2nd stages and into the 2nd stage compression chamber. Note that

the 2nd stage compression chamber, unlike the other 3 cylinders, is the volumetric difference between the 2nd stage

cylinder walls and the lower section of the piston (see Figure 1 in section I-4). On the down-stroke of the same

piston, the air contained in the 2nd stage compression chamber is compressed to the second stage pressure and

forced through the 2nd stage valves + 2nd stage intercooler + 2nd stage moisture separator + 3rd stage inlet valve into

the 3rd stage cylinder. Here, the air is compressed to the 3rd stage compression level. The air than is forced in similar

manner to the 4th stage cylinder where it is compressed to the final pressure level and forced out to the aftercooler,

moisture separator, to a pre-filter unit where it is cleaned of any particles and oil content, 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.

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The intercoolers and the aftercooler are designed to dissipate the heat generated from the previous compression

cycle, reducing the air temperatures, allowing the water vapors to condensate and settle in the bottom sections of

the moisture separators. The 3 moisture separators and the pre-filter unit are equipped with an automatic drain

valve. The drain valve is a 3 way pneumatic valve controlled by a 3 way solenoid valve installe on the piping

adjacent to the centrifugal unloader. This solenoid valve sends or removes the control air from the drain valves,

thus letting them to open or close. The solenoid itself is controlled by a sequential timer relay in the electric panel.

The dual time adjustmens 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 switch (see section 2.5.1 for adjustments

and functional details).

The oil level of can be monitored on a sight gage provided in the right bottom side of the crankcase (next to the

Low oil level switch) –see Figure 2. The oil level can also be checked through the dipstick found in the filling plug.

In principle the level of oil has to be up to the filling plug thread. A low oil level switch is provided to protect the

compressor from lack of oil in its sump. When the oil level drops, the switch cuts off (opens its contacts), thus

cutting the control circuit of the motor starter, and stops the electric motor. A signal lamp is provided to indicate

that the motor stopped as a result of low oil level.

2.4 Description of Major Components

2.4.1 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, and is different on

fourth stage. The 4th stage con.rod has a stick extending in the bottom that enters the oil sump at every

rotation, thus creating splash of oil that lubricates the system. It is equipped with high quality copper- bronze

alloy plated inserts that serve as journal bearings. These journals wear in time and therefore the con rods will

require replacement or renewal of its bushings in when wears.

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 3rd and 4th

stages are mounted on guide cylinder to guide the crosshead piston ass’y.

Head Assembly:

The head assemblies are the cover plates and the valve assemblies housed inside; these assemblies are

mounted on top of the cylinders. The valve assemblies inside the covers need to be maintained periodically;

they need to be opened and cleaned; if valve disks or springs are worn, they need to be replaced. See valve

maintenance section of this manual for futher details.

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Beather:

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.

2.4.2 Major Components System

The Canopy:

The semi open canopy is designed to carry the various components, the electrical panel, and permits lifting the

system through the pallet jack slots. It is painted electrostatically for extended life. It has four easily removable door

panels to easily and quickly access all parts of the package.

The Sub Base:

This is the base carrying the motor & compressor units; it is supported on four vibration mounts; this base plate is

separate from the canopy and with this unique design no vibration is transmitted to the canopy. The vertically

mounted compressor / motor assembly, is a belt driven system; the belts are automatically tightened by the weight

of the motor on which it is mounted. This unique device saves to pay extra attention to the belt tightening on W4

series machines.

The Electrical Panel:

It is mounted inside the fan duct on the top section and can be accessed by removing the top door. It

accommodates all the electrical gear to start the motors and control the system.

Pressure Switch:

This unique Alkin device is installed on the right door, 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.

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

moisture separator and sends it over the 4 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 botto of

the pistons, to open and perform drain operation.

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