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Instruction Manual

 

W32- Series Medium-Vertical Compressors

 

 

Page I - 20.

 

MAINTENANCE TABLE 

 

  

 

Maintenance                    Period   

DAILY 

WEEKLY 

300 Hours 

500 Hours 

1000 

Hours

 

I:Inspect/M:Maintain/R:Replace  

I M R  I M R  I M R  I  M R  I M R 

LUBRICATION 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.   Oil  

   

 

   

 

 

 

 

 

 

   

 

 

2.   Crankcase Cleaning 

 

 

 

 

 

 

 

 

 

 

   

 

   

INTAKE FILTER 

 

 

 

   

 

 

   

 

 

   

 

 

V - BELT 

 

 

 

   

 

   

 

   

 

 

 

 

Pressure Vessels w/o 

auto.drain 

vlv.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.   Condensate Drain 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

2.   Pressure vessel test 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

PIPING & CONNECTIONS 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1. Leaks 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

2.  Tightening of bolts & fittings 

 

 

 

 

 

 

 

   

 

   

 

   

CLEANING 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.   Intercoolers 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

2.   Aftercooler 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

3.   Flywheel 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

4.   Cylinders 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

5.   General 

 

 

 

 

 

 

 

   

 

   

 

   

6. 

 

 

Sintered 

metal 

filter 

                

SWITCHES & GAGES  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.   Oil Pressure Switch-gage Settings 

 

 

 

 

 

 

   

 

   

 

   

 

2. 

 

 

Pressure 

Gages 

             

 

 

 

 

SAFETY VALVES 

 

 

 

 

 

 

   

 

   

 

   

 

COMPRESSOR VALVES 

 

 

 

 

 

 

   

 

 

   

 

 

 

Piston Rings 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

st

 & 2

nd

  

 

 

 

 

 

 

 

 

 

 

 

 

   

 

3

rd

 stages 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

ELECTRICAL 

 

 

 

 

 

 

   

 

   

 

 

   

1.   Contactor connections 

 

 

 

 

 

 

 

 

 

   

 

 

   

2.   Contacts 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. 

 

 

Current 

(loaded 

and 

unloaded) 

                

 

3.   Terminals (tighten the screws) 

 

 

 

 

 

 

 

 

 

 

   

 

   

Drain Collector Filter 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

Filling Valves 

 

 

 

 

 

 

   

 

   

 

   

 

Whips & Yokes 

 

 

 

 

 

 

   

 

   

 

   

 

Vibration Mounts, motor mounts 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

Filter Cartridges 

Every 300 Hours 

Purifier Cartirdge 

Every 120 Hours 

Surroundings of the compressor 

Check daily for a clean and well ventilated surrounding in the compressor room

. 

General Overhaul 

As it may be necessary. Consult your dealer or the factory for details. 

Other equipment, filling stations cylinders, 
pipe network etc. 

As may be required. Consult in case of specific applications 

 

See the specific instructions section to check if additional service / maintenance requirements apply to the specific 
equipment delivered to you. 

Содержание W32 Series

Страница 1: ...ALKIN Compressors Menderes Izmir TURKEY Tel 0090 232 782 2290 Fax 0090 232 782 2289 ALKIN W32 Series 3 Stage High Pressure Breathing Air Compressors 225 350 Bars Instruction Manual Parts Book...

Страница 2: ...tart 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 a...

Страница 3: ...eed 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...

Страница 4: ...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 compr...

Страница 5: ...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 assemblie...

Страница 6: ...d 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 ope...

Страница 7: ...7 8 9 Fig 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...

Страница 8: ...P I diagram drwg 7862 2 The following P I diagram refers to a compressor that operates at single pressure 0 0 0 0 400 400 400 400 bar bar bar bar 100 300 200 400 0 P A R 6014 C ALKIN COMPRESSORS Mend...

Страница 9: ...ority 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 Safet...

Страница 10: ...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...

Страница 11: ...ed 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 panel...

Страница 12: ...ssure 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...

Страница 13: ...grated 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 Ty...

Страница 14: ...rocess 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...

Страница 15: ...del 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 c...

Страница 16: ...ng 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 ELEC...

Страница 17: ...over 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...

Страница 18: ...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 f...

Страница 19: ...ttending the Commissioning Full Name Position In charge of Signature Equipment Details Model Serial Nr Date of purchase Date of comissioning Application Medium R Air R Gas specify PRELIMINARY CHECKS R...

Страница 20: ...when the compressor stops R V 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 afte...

Страница 21: ...rs to insure proper cooling 3 Check the V belt tension The proper tension should allow 13 mm deflection with a 1 kg 2 pounds weight applied on the center of each belt 4 Every 120 Hours Change or re fi...

Страница 22: ...Y VALVES COMPRESSOR VALVES Piston Rings 1st 2nd 3rd stages ELECTRICAL 1 Contactor connections 2 Contacts 3 Current loaded and unloaded 3 Terminals tighten the screws Drain Collector Filter Filling Val...

Страница 23: ...hnical training knowledge and experience that will permit to perform the common maintenance functions without the need of detailed instructions 2 TORQUE VALUES The following table indicates the torque...

Страница 24: ...presor maually using the flywheel and checkwhether all items have been correctly installed 30 minutes after restarting the copressor unit stop unit let is cool down to ambient temperature and retigten...

Страница 25: ...ith a precision straightedge that the underside of the cylinder head is flat if necessary use an emery cloth to smoth out the surface CAUTION Valve spring and valve plate must not be jammed Fig 10 Rem...

Страница 26: ...ecessary loosen valve first by using a 13 mm spanner on the flat surfaces Lift out pressure valve 5 together with o ring 4 Reinstall pressure valve 5 in reverse sequence Put O ring 4 into valve head 7...

Страница 27: ...zation The oil and water separator must be replaced when the maximum permissible no of load cycles has been reached The cycles are counted by the cycles counter of the compressor control unit After th...

Страница 28: ...tely while still warm Check valves coolers separators purifier and all pneumatic tubes and hoses for deposits If deposits are detected perform the following Change or clean valves coolers separators p...

Страница 29: ...ate Remove the compressor cylinder head add a new gasket and reassemble 6 Compressor mounting loose Tighten 7 Deflected crankshaft or crankshaft bearing failure Replace crankshaft 8 Excessive dirt or...

Страница 30: ...acity of the compressor b Increase your air capacity with an additional compressor unit 10 PRESSURE VESSELS DO NOT HOLD THE PRESSURE WHEN THE COMPRESSOR IS UNLOADED 1 Faulty check valve Relieve the ve...

Страница 31: ...automatic tightening slides consult factory 6 Speed too slow Check the compressor speed 15 RECEIVER PRESSURE BUILDS UP TOO FAST 1 Water in the storage cylinders filters Drain the receiver frequently...

Страница 32: ...COME UP TO NOMINAL OPERATING SPEED 1 Low voltage Check line voltage 2 Loose motor control gear terminals Check motor and starter terminals for good contact tighten if needed 3 Poor power regulation u...

Страница 33: ...PARTS LIST W32 SERIES 3 STAGES HIGH PRESSURE MEDIUM VERTICAL COMPRESSORS 240 350 BARS ALKIN Compressors Menderes Izmir Turkey Tel 0090 232 782 22 90 Fax 0090 232 782 22 89...

Страница 34: ...1 1 16 7727 Cover Crankcase 1 1 17 7731 Bolt DIN EN 24017 M8x40 8 8 6 1 18 7729 01 O ring 56 87x1 78 NBR 70 Sh 1 1 19 7726 Shaft seal 30x47x8 72NBR902 1 1 20 7725 Cover 1 1 21 7730 Countersunk screw D...

Страница 35: ...PRESSOR FIGURE 2 Bare Compressor 21 22 23 24 25 7802 02 030105 D look at figure 4 look at figure 4 look at figure 4 look at look at look at figure 5 figure 5 figure 5 14 20 11 19 2 5 16 15 3 1 2 11 12...

Страница 36: ...crew DIN 912 M8x35 8 8 SST 6 2 10 7710 Cylinder 2nd stg 1 2 11 7729 17 O ring 59 99x2 62 FKM 75 Sh 2 2 12 7736 Guide cylinder 2nd stg 1 2 13 7729 03 O ring 70x2 NBR 75 Sh 2 2 14 7780 03 Stud DIN 835 M...

Страница 37: ...5 7729 24 O ring 42 52x 2 62 FKM 75Sh 1 3 6 7789 02 Cover for oil filter 1 3 7 6882 06 Allen screw M8x25 2 3 8 7091 11 Lock washer M8 2 3 9 7091 09 Washer M8 6 3 10 6882 02 Allen screw M8x35 4 3 11 78...

Страница 38: ...S VERTICAL COMPRESSORS FIGURE 4 Valve Assemblies 1 0 15 1 3 5 78 0 2 0 4 2 10 80 3 D 1 8 17 1 9 2 0 1 5 2 6 2 5 2 7 2 2 2 3 2 4 1 6 9 4 1 2 6 2 5 2 7 21 3 6 2 8 3 7 3 8 4 0 3 9 34 6 5 7 8 29 33 14 13...

Страница 39: ...2nd stg disch valve 1 4 19 6888 03 Spring 2nd stg disch valve 1 4 20 6203 03 Disc 2nd stg disch valve 1 4 21 6888 04 Seat 2nd stg disch valve 1 4 22 6888 01 Cap 2nd stg disch valve 1 4 23 6894 02 Was...

Страница 40: ...1 5 7 7709 Piston 1 5 8 7009 Ring set 1 5 9 7707 Piston pin 1 5 10 7003 02 Lock ring piston pin 2 5 11 7808 Piston complete 3rd stage 1 5 12 7706 Guide piston 1 5 13 7720 Piston 1 5 14 7808 01 Ring s...

Страница 41: ...rew cap 1 6 13 7729 13 O ring 45x2 NBR 70sh 1 6 14 7836 12 Top cover ass y 1 6 15 7836 11 Center screw 1 6 16 7836 10 Aerating washer 1 6 17 7765 06 Filter element 1 6 18 7765 07 Baffle funnel 1 6 19...

Страница 42: ...63 06 Filter element 1 7 11 7763 08 Filter seat 1 7 12 7729 11 O ring 9 75x1 78 FKM 85 sh 1 7 13 7763 05 Center screw 1 7 14 7168 24 Backing ring 1 7 15 7168 25 O ring 72 4x5 33 NBR 70 sh 1 7 16 7168...

Страница 43: ...ex Screw M6x10 SST 2 8 8 7091 10 Washer M6 SST 2 8 9 7168 47 Bottom Cover 1 8 10 7047 14 O Ring 10 3x2 6 1 8 11 7047 13 O Ring 12 7x2 6 1 8 12 7293 Purifier Element 1 8 13 7168 40 Plug Assy 1 8 14 786...

Страница 44: ...t 1 9 5 6883 02 Acorn nut M8 1 9 6 7091 09 Washer M8 1 9 7 7894 01 Filter complete 1 9 8 7894 05 Nut 4 9 9 7894 04 Threaded hose 1 9 10 7894 02 Filter housing 1 9 11 7894 06 Sleeve 1 9 12 7894 11 Filt...

Страница 45: ...RESSOR FIGURE 10 W32 Compressed Air Piping 1st To 3rd Stage 7802 11 110105 E 17 19 16 10 14 35 7 21 20 5 4 2 31 4 23 23 27 28 24 24 25 25 26 26 25 25 26 26 24 24 7 15 7 22 21 22 34 34 20 9 36 12 6 6 2...

Страница 46: ...stg 1 10 15 7874 06 Tube 12 sst 1 10 16 7796 Aftercooler 1 10 17 7794 Double strap 3 10 18 6882 12 Allen screw M6x35 3 10 19 7793 Flywheel protector 1 10 20 7813 05 Clamp 2 10 21 6882 06 Allen screw...

Страница 47: ...valve 1 12 10 6436 01 Drain valve 1 12 11 7874 14 Tube 5 16 copper 1 12 12 7874 15 Tube 6 sst 1 12 13 7874 16 Tube 6 sst 1 12 14 7084 05 Elbow 1 12 15 7873 Container 1 12 16 7080 04 Street elbow 1 2...

Страница 48: ...RTICAL COMPRESSOR FIGURE 11 General piping filter purifier Pressure gage piping 7802 13 170603 E 2 27 8 11 6 2 7 8 10 9 17 19 17 17 21 15 17 16 5 2 28 28 1 2 3 4 5 2 13 14 2 2 13 12 25 2 20 18 18 26 2...

Страница 49: ...1 11 13 7874 10 Tube 6 sst 1 11 14 7378 02 Connector 1 11 15 7248 01 Pressure switch gage 1 11 16 7874 18 Tube 6 sst 1 11 17 7820 Pressure gage nipple 4 11 18 7672 06 Elbow 1 4 sst 2 11 19 7874 17 Tub...

Страница 50: ...n 1 13 17 7880 06 O ring 7 52x 1 8 1 13 18 7880 02 Bottle connection ass y 215 bar 1 13 19 7670 13 O ring 7x 1 45 1 13 20 7880 03 Handle Bottle connection 1 13 21 7880 05 Bottle connection 1 13 22 788...

Страница 51: ...Connector 2 14 9 7880 02 Bottle connection ass y 215 bar 1 14 10 7670 13 O ring 7x 1 45 1 14 11 7880 03 Handle Bottle connection 1 14 12 7880 05 Bottle connection 1 14 13 7880 06 O ring 7 52x 1 8 1 14...

Страница 52: ...Connector 2 15 9 7880 01 Bottle connection ass y 330 bar 1 15 10 7670 13 O ring 7x 1 45 1 15 11 7880 03 Handle Bottle connection 1 15 12 7880 04 Bottle connection 1 15 13 7880 06 O ring 7 52x 1 8 1 15...

Страница 53: ...884 02 Nut M6 7 16 14 7091 08 Washer M6 11 16 15 7823 03 Nut Insert M6 4 16 16 6884 05 Nut M4 3 16 17 7867 17 Allen Screw M4x20 3 16 18 6882 10 Allen Screw M6x20 7 16 19 7091 09 Washer M8 4 16 20 6884...

Страница 54: ...21 17 15 7867 71 Hex Screw M10x35 10 17 16 7091 12 Washer M10 32 17 17 7091 13 Lock washer M10 12 17 18 6884 08 Lock hex nut M10 18 17 19 7819 02 Vibration mount 4 17 20 6953 01 Vibration mount 4 17 2...

Страница 55: ...01 Komple Kasnak 1 2 2 7724 01 Kasnak G be i 1 2 3 7716 Kasnak 1 2 4 7867 01 C vata M10x20 1 2 5 7724 02 Kasnak G be i Merkezi 1 2 6 6882 08 Allen Civata M8x25 4 PARTS LIST W32 SERIES VERTICAL COMPRES...

Страница 56: ...8 9 PS1 PS2 SV TD3 L1 TD1 TD1 TD2 C2 C3 CONTROL WIRING DIAGRAM Ie 3 5 0 4 14 15 9 10 11 12 4 6 7 1 2 F1 2A F2 C1 C2 C3 Ie T S R Main Switch TD3 R1 F1 TIMER RELAY DRAIN RELAY AUTO START STOP MAIN FUSE...

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