Transcript
ALKIN
®
W31 (old designation #12T3) Series 3 Stage High Pressure Compressors 100 – 330 Bars ½ to 4 kW Parts Book
CONTENTS Nr.
SECTION
I.1. I.2. I.3.
Foreword Introduction Safety 1. General Rules 2. Pressure release 3. Fire & Explosion 4. Moving Parts 5. Hot Surfaces 6. Toxic and irritating Substances 7. Electrical Shock 8. Lifting Installation 1. Inspection 2. Location 3. Service piping 4. Electrical Check 5. Sheaves and belt alignment W31 Series Compressors Specific Instructions 1. General points to be observed 2. Gas Compressors Technical Data 1. Model Designations 2. Performance Data 3. Stage Pressures 4. P & I Diagram – W31x2 Series 5. P & I Diagram – W31 Series Operation Cylinder Filling Air Filter Purifier Purifier Cartridge Replacement Air Purifier Care Long Term Storage Restarting After Long Term Storage Maintenance LUBRICANT Maintenance Table Maintenance Procedures 1. General 2. Torque Values 3. Torque Sequence 4. Valves Trouble Shooting Addendum for Gas Compressors System layout W31x2 Series Compressors System layout W31 Series Compressors Wiring Diagram Parts Manual
I.4.
I.5. I.6.
I.7.
I.8. I.9. I.10
I.11. I.12. I-13. I.14. II.
Page 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 5 5 6 6 6 6 7 7 8 8 8 9 9 9 9 10&11&12 13 14 14 15 17
Instruction Manual
W31- Series Breathing Air Compressors Page 1.
I – 1. Foreword Your new ALKIN air or gas 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. Section I - General Information & Rules In this section general rule 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.
Section II- Specific Data & Instructions In this section, the specific data of the equipment supplied, description of components and the system, including the construction, Process and Instrumentation, controls, wiring diagrams, operation & special maintenance rules –if any- are indicated. Section III – Drawings & Spare parts In this Section, the specific parts lists of the equipment supplied takes place.
I – 3. Safety - GENERAL RULES 1.
GENERAL
All ALKIN air and gas compressors are designed and manufactured with equipment, allowing safe operation of the compressors. It is the users 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 this compressor. 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)
Pull the check ring under pressure on both safety valves weekly to make sure that they are not blocked, clogged or otherwise disabled. On gas compressors test the safety valves periodically as per the specific 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. 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, draining or adding oil. Do not permit liquids such as air line 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 receiver or any part welded to the receiver or to the piping. Any such works or the receiver manufacturer can only make repairs; subsequently a hydrostatic pressure test will be required for re-certification for worthiness of the receiver for use as a pressure vessel. 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.
Instruction Manual 4. Moving Parts Keep Hands, arms and other parts of the body and clothing away from 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.
W31- Series Breathing Air Compressors Page 2. Operate the compressor only in well ventilated areas. Lubricant used in this compressor are specific oils to operate high pressure air and gas compressors, preventing carbon collection under heat and extreme operating conditions. Do not change the lubricant with another make. Accidental ingestion and skin contact should be avoided. Wash with soap and water after skin contact. If swallowed, seek medical treatment promptly. 7.
Keep the compressor, hoses, tools and personnel at least 3 meters (10ft) from power lines, panels, and underground cables. Keep al 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.
Hot Surfaces, Sharp Edges and Sharp Corners. 8.
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.
Electrical Shock
Toxic and Irritating Substances
Do not use air from this compressor for breathing except in full compliance with OSHA standard 29 CFR 1910 and any other Federal, State and local codes and regulations.
Lifting
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. Keep lift operator in constant attendance whenever the compressor suspended. Set the compressor down on level surfaces, capable of carrying its full weight.
I – 4. INSTALLATION - GENERAL RULES 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
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 would be trouble free. Make the following checks before attempting any start up:
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. Use 150 mm (6”) thick concrete foundation to bolt the compressor down. Use shims to level and tighten the compressor. Do not exert force bolting the receiver down, as this will created unwanted stresses in the structure of the vessel. Use shims to take the gaps between the feet and the concrete foundation.
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.
3.
5. Sheaves and V-belt alignment check
SERVICE PIPING
Service air (or gas) piping should be installed in full compliance with all Federal, State and local codes, standards and regulations. A shut off valve should be installed to isolate the compressor receiver from the service line. Air outlets should be piped from top of the service line for drop legs. Drain legs should also be installed to remove condensating water vapor from the air piping.
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.
Compressor and driver sheaves should be checked 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. When operating, the V-belt should have a slight bow on the lower section of the belt.
W31- Series Breathing Air Compressors Page 3.
Instruction Manual I – 5.
W31 Series Compressors - Specific Instructions
General Points to be observed 1. Make sure that the compressor operates in a well ventilated and clean area and that no contaminants such as smoke, toxic gases, fumes, odor generating vapors will not enter the compressor through its inlet filter 2. The inlet filter should always be clean and in good condition; replace it on time or when needed. 3. Maintain the compressor in accordance with the specific instructions indicated in this manual. 4. The pressure vessels or bottles must be inspected, maintained, and used in strict accordance with the pressure vessel codes in force in the location of use. 5. Do not attempt to repair the compressor if you are not trained to do so.
6. Do not alter the safety valve settings. 7. Do not alter or modify the compressor, do not use it for any other prupose than it is designed for, do not operate it with parameters other than those specified in the nameplate. FOR GAS COMPRESSORS 1. Make sure all gas connections are tight and no leaks exist. 2. All the safety valve exhaust ports and the moisture drains are connected to a single manifold. This manifold have to be piped to an open and remote area where -in case the safety valve blows- it will discharge the gas with no immediate danger to any persons, and will not create a fire hazard. 3. Inspect the fittings, connections, safety valves and drains, shaft seal area periodically to insure that there are no gas leaks.
I – 6. TECHNICAL DATA The model designation for these series compressors have been changed as follows: Old Model Designation 12T3 12T3x2
New Model Designation W31 W31x2
The W31x2 series are duplex configuration of the W31 series compressors, utilizing the same three-stage compressor unit on both series. The group consisting both series are called Junior Series. Model Designations indicate the following details:
W31 – 2 – 225 – P2 Purifier (size 2 – Equivalent of Bauer P21) – Operating Pressure in Bars (multipy by 14,5 to get this value in Psi) Basic two pressures are : 225 Bars (3260 Psi) 310 Bars (4500 Psi) If different pressure is required, specify in the model designation like : W31-2-240-P2 , which means the compressor you want should operate at 240 Bars (3480 Psi). Max. Pressure for this range compressors is 4500 Psi. Higher pressures are available with different cylinder heads. Specify your needs indicating the maximum operating pressure you need.
Motor Power in kilowatts; 2 indicated 2,2 kW (3HP), 4 indicates 4 kW (5½ W indicates the cylinder configuration to be of W type (three cylinders); 3 indicates 3 stages, and 1 indicates this compressor to have a free air General specifications of the Junoir Series Breathing Air Compressors (W31 and W31x2 series) are as follows: Performance Data Operating Pressure
JUNIOR SERIES
ALKIN Model
Bars
Psi
Motor Power
FAD
Lt/min Cfm
HP
kW
3
2,2
W31-2-225-P2
225
3260
W31-4P-225-P2
225
3260
W31-2-310-P2
310
4500
3
2,2
W31-4P-310-P2
310
4500
5,5 HP petrol eng
4
W31X2-4-225-P2
225
3260
5,5
4
W31X2-6P-225-P2
225
3260
8 HP petrol eng
5,5
W31X2-4-310-P2
310
4500
5,5
4
W31X2-6P-310-P2
310
4500
8 HP petrol eng
5,5
100
201
3,6
7,1
5,5 HP petrol eng.
RPM
Bore x Stroke st
1 Stage nd 2 Stage rd 3 Stage Stroke
5
Nr.of Stages
: 60 mm : 36 mm : 14 mm : 40 mm
3
1200 60&36 &14 x40 [2x]
W31- Series Breathing Air Compressors Page 4.
Instruction Manual Stage Pressures Stage
Operating Pressure 200 Bars (2900 Psi)
Operating Pressure 300 Bars (4350 Psi)
1st stage discharge
3,5 - 4,0 Bars
3,5 - 4,5 Bars
2nd stage discharge
25,0 - 30,0 Bars
25,0 - 35,0 Bars
3rd stage discharge
200 Bars
200 Bars
P & I Diagrams W31x2 Duplex compressor series P & I Diagram P&I Diagram- W31x2 (old designation 2x12T3)
COMPRESSORS®
SAFETY VALVE
3rd Stg. 1st stg. SAFETY VALVE
PURIFIER
AIR INLET
DRAIN VALVE
AIR FILTER
Drain SWITCH GAGE
Drain 200 300
100
400
0
SAFETY VALVE
PRESSURE GAGE
INTERCOOLER 1st stg-2nd stg. 0
bar
400
FILLING VALVE
2nd Stg. INTERCOOLER 2nd stg./3rd stg.
26/11/2000
SAFETY VALVE
CONDENSATE SEP. AFTERCOOLER
Date :
INTERCOOLER 1st stg-2nd stg.
2nd Stg. INTERCOOLER 2nd stg./3rd stg.
6993-3
Drw. Nr. :
ALKIN
3rd Stg. 1st stg. SAFETY VALVE
FILLING YOKE
AIR INLET
PRESSURE GAGE
AIR FILTER PRIORITY VALVE
CONDENSATE SEP. AFTERCOOLER
0 bar
400
Drain FILLING YOKE
Fig.1 P&I Diagram W31x2 ALKIN P&I Diagram- W31 Series (old model #12T3) 3 Stage Air Compressors COMPRESSORS® Menderes-IZMIR-TURKEY TEL: 0090 232 78 222 90 FAX: 0090 232 78 222 89
D.Nr: 6993-2
P & I Diagram for W31 seris compressors SAFETY VALVE
3rd Stg. INTERCOOLER 2nd stg.-3rd stg.
1st stg. SAFETY VALVE
INTERCOOLER 1st stg-2nd stg.
2nd Stg.
AIR INLET AIR FILTER Pressure Gage
CONDENSATE SEP.
SAFETY VALVE
PURIFIER
AFTERCOOLER
Drain
FILLING YOKE Drain
Fig.2 P&I Diagram W31
W31- Series Breathing Air Compressors Page 5.
Instruction Manual
I – 7. Operation 1st STAGE
1st STAGE AIR DISCHARGE
3rd STAGE
AIR INLET
2nd STAGE OIL FILL CRANKSHAFT
2nd STAGE AIR DISCH.
OIL LEVEL GAGE
CRANKCASE
3rd STAGE AIR INLET
2nd STAGE AIR DISCHARGE
2nd STAGE AIR INLET
3rd STAGE 90° ROTATED
OIL DRAIN
2nd STAGE 90° ROTATED
Fig.3 W31 Compressor 1. Read this manual carefully and make sure that everything is clear. Do not let anyone to interfere or operate the compressor who has not learned and/or who is not qualified to do so. 2. Make sure that the persons in charge of filling are thoroughly familiar with the compressor, the operating principles, connecting the hose, gage readings and the filling procedure. 3. Check that the compressor is located in a wellventilated are and is far from fumes, smoke and toxic gases. The compressor should sit on a horizontal floor, or should be leveled so that the maximum inclination does not exceed 5%. 4. Check the mains supply against the motor nameplate data to insure that the voltages and phases correspond. 5. Check the oil level. The correct level should be about the middle of the plastic sight gage. Do not overfill the compressor. 6. Jog the compressor (start it for a few seconds) to verify that the direction of rotation is correct. If it is not, reverse the phases on three phase motors, at the switch box (not on the motor terminal box). Qualified electricians must carry out all electrical works. 7. If the direction is correct you may start the compressor. Observe for the first time the pressure and the general operating status of the
compressor and make sure that the unit is sitting on the floor properly, there is no vibration, knocks or irregular sounds. 8. Prior to first operation and subsequent to each maintenance work, turn the compressor flywheel manually to verify that the compressor is turning freely. 9. Prior to first operation or subsequent to a maintenance / repair work, operate the compressor for at least 10 minutes with the condensate valves fully open, with no pressure built up; this will allow all the parts to be properly lubricated before the compressor is operated under load (before compressing air). 10. Open the filling valve when operating the compressor. Cylinder Filling Operation 1. WARNING:Never open the filling valve unless a bottle is connected and its valve is open. Otherwise hose whipping may cause serious injury. 2. Connect the yoke to the bottle. Open the valve of the bottle. Open the filling valve. 3. Run the compressor; on systems with automatic stop pressure switch, the compressor will stop at the pre set pressure. When stops, shut the valve of the bottle; remove the yoke.
Instruction Manual 4. On
compressors with no automatic stop pressure switch, the safety valve will blow when it reaches the maximum working pressure. STOP the compressor at this point. 5. Shut the bottle valve and remove the yoke.
Air Filter Check the intake filter element every 50 hours; clean blowing air from inside out. Replace the element every 3 months or earlier, depending on the environmental conditions.
W31- Series Breathing Air Compressors Page 6. 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 compressint air. See specific instructions for diesel driven units.
200 100
Purifier The compressor will safely operate between 5° C to 40° C; lower temperatures may cause blockage, while higher temperatures may effect the purification efficiency. The following table is provided as a guideline for replacing the purifier cartridge. It must be remembered however, that there might be additional factors that may affect the purifier cartridge life. Pressure Swtichgage The W31 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. When the main motor is stopped by the pressure switch, the two top fans keep working for an additional period of time (generally 4 to 10 minutes depending on the ambient temperatures); this is controlled by a timer (0-30 min setting range) . This feature is incorporated in the system to permit good cooling even after the compressor stops, thus allowing the next start in a cooler state. This improves the valve life and the performance, it protects the lubricant and prolongs the overall life of the compressor. On diesel engine driven
0
300
400
#7248 Fig.4 Pressure Switch Gage Pressure Switch 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 it self. 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
WARNING The oil inside the pressure control switch-gage is special dielectric oil. DO NOT USE ANY OTHER OIL TO TOP UP OR FILL THE PRESSURE SWTICHGAGE Purifier Cartridge Performance Table Ambient Temp C
Factor
Compressed air qty Nr.of 10 Lt Bottles - cu.m filled to 200 bars (c.f.)
Nr.of 10 Lt Bottles filled to 300 bars
Purifier Cartridge efficient operating hours.
5
2,25
416 (14.689)
208
139
69
10
1,85
341 (12.041)
171
114
57
15
1,35
254 (8.969)
127
85
42
20
1
186 (6.568)
93
62
31
25
0,75
143 (5.049)
72
48
24
30
0,6
112 (3.955)
56
37
19
Air Purifier Care WARNING : Before replacing the cartridge, clean the moisture separator and the purifier housing
thoroughly. Install the cartridge with care, making sure that the o-rings are in good condition and are in place.
Instruction Manual
W31- Series Breathing Air Compressors Page 7.
I – 8. Long Term Storage Long Term Storage:
Follow these instructions whenever the compressor will not be used for six months or more: 1. Store the compressor indoors, in a dry and clean room. 2. Run the compressor under pressure for about 10 minutes 3. Check all the pipes, fittings, filters, drain points, safety valves and make sure there are no leaks. 4. When the compressor is warm, shut it down. 5. Drain the condensate from the moisture trap and the purifier. 6. Remove the intake filter; jog the compressor for a few seconds, while spraying a small amount (5 - 6 cc) of compressor oil through its intake. Stop the compressor. 7. Close all the valves. 8. Remove the mains supply. 9. Place a dust cap at the intake port.
10. See specific motor / engine instructions for long term storage. Restarting after long term storage:
1. Clean the dust from the compressor. 2. Remove the dust cap from the intake port. 3. Check the oil level; make sure there are no leaks or sweating around the connections, gaskets etc. 4. Run the compressor until warm, for about 1o minutes, with all the drain valves, filling valve (or outlet valve) opens. (the compressor will run against atmospheric pressure with no load) 5. Check for leaks at the connections, fittings, safety valves etc. 6. Stop the compressor; drain the oil while still hot; install a new purifier cartridge and an intake filter element. 7. Run the compressor again; verify that there are no leaks. 8. Put the compressor in normal service.
W31- Series Breathing Air Compressors Page 8.
Instruction Manual
I – 9. Maintenance Lubricants: The compressor crankcase is designed to take 0,250 Lt. Oil. The lubricants have to be changed every 100 working hours. In any case, if these hours are not reached within 6 months, replace the oil no later than every 6 months. Use the proper lubricant at all times. Do not mix different lubricants. Here is a list of recommended oils:
Lubricant to be used an all W31 Series High Pressure compressors :
UL 751
Maintenance Table Maintenance Ð
Period Î
I:Inspect/M:Maintain/R:Replace Oil Change INTAKE FILTER V - BELT
DAILY I M R ;
WEEKLY I M R ; ;
100 Hours 400 Hours 1000 Hours I M R I M R I M R ; ; ;
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 & Aftercooler 2. Flywheel, cylinder fins 3. General SWITCHES & GAGES 1 Pressure Switch-gage Settings (W31x2) 2. Pressure Gages SAFETY VALVES COMPRESSOR VALVES Piston Rings 1st & 2nd stages 3rd Stage ELECTRICAL (for W31x2 Series) 1. Contactor/Soft Starter connections 2. Contacts 3. Current (loaded and unloaded) 3. Terminals (tighten the screws) Filling Valves Whips & Yokes Vibration Mounts, motor mounts
Purifier Cartridge
; ; ;
;
;
;
;
;
; ; ;
;
;
; ; ; ;
; ; ; ; Check ; Replace
;
; ;
; ; ; ;
; ;
; ; ; See Purifier Performance Table Section on
; ; ; ; page 6
W31- Series Breathing Air Compressors Page 9.
Instruction Manual
I – 10. MAINTENANCE PROCEDURES CAUTION Bring the main isolating switch to “Off” [or `0`] position before attempting doing any repair work on the unit to prevent accidental (or automatic) starting. Blow down all pressure from the compressor, filter & purifier and isolate the unit from any outside sources of air pressure such as filling stations, cylinders etc. These simple precautions will prevent fatal accidents
1. GENERAL
2. TORQUE VALUES The following table indicates the torque values to which a torque wrench should be set for tightening the various size attaching bolts & nuts. Use these values to set a torque wrench to tighten these fastners at intervals indicated in the Maintenance table.
This section covers the operations which the general users may not be too familiar. It is expected that the user would have the average technical training & knowledge and experience that will permit to perform the common maintenance functions without the need of detailed instructions.
TORQUE VALUE TABLES Bolt or screw
Thread
Max.torque
Hex and allen head
M6
10 Nm (7 ft.lbs)
Hex and allen head
M8
25 Nm (18 ft.lbs)
Hex and allen head
M 10
45 Nm (32 ft.lbs)
Hex and allen head
M 12
75 Nm (53 ft.lbs)
Hex and allen head
M 14
120 Nm (85 ft.lbs)
Hex and allen head
M 16
200 Nm (141 ft.lbs)
Pipe connections (swivel nuts)
Finger-tight+1/2turn
3. TORQUE SEQUENCE
1 3
2
1
4
6
3
4
5 2
Fig. 5 Torque sequene
Instruction Manual
W31- Series Breathing Air Compressors Page 10.
4. VALVES CAUTION In order to avoid damaging the special tool or the valve when using the tool, ensure that it is pushed properly and firmly into the valve bore so that it will not tilt when it is turned
4.1. Initial operational check of valves After roughly half an hour’s operation, Valves should be checked. Note that intake line to valve heads shold be hand warm and outlet-piping shold be hot. Valves are then operating properly.
Should the intake pipe to the valve head of second stage heat up excessively, and first stage safety valve blow off, this would be an indication that either intake or pressure valve of second stage is malfunctioning. It is, therefore, necessary to remove the valve head and to check and these valves, or to replace them.
• • • • • • • • •
•
• •
4.2. General instructions for changing the valves Always replace valves as a complete set. Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in diesel oil or petroleum and clean with soft brush. Lubricate valves before installing with weicon AS 040, order no. N19753, or equivalent. Check individual components for excessive wear. If the valve seat and valve disks are dented, replace the valves. Valve head screws must be tightened with a torque wrench.(see page I-9) Check the valve space in the valve heads for dirt and clean, if necessary. Use only satisfactory gaskets and o-rings on reasembly. Observe the correct sequence when fitting together again. After finishing all maintenance work on the valves, turn the compresor 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 valve studs and cap nuts. Otherwise valves could work loose due to setings of the gaskets. Remove and check the valves every 1000 operating hours. Replace the valves every 2000 operating hours to avoid fatigue failure.
3.3. Changing the valves of the 1st stage Removal of 1st stage pressure valve: • Remove cap nut • Loosen allen set screw • Remove the coupling Assamble in reverse sequence
Intake and pressure valve of the 1st stage is combined in one plate valve under the valve head. Check that marks “TOP” is really at the top when installed. 3.4. Changing valves of the 2nd stage • Unscrew intake and presure lines from the cylinder head (7, Fig.6). • Remove internal hex. Screws fixing cylinder head and completely remove the cylinder head from the cylinder. • Insert two metal pins – 8-mm diameter, any length – in the holes in the cylinder head and secure these in a vice with the cylinder head on top.
1
5
2 3 4 7
6
Fig. 6 •
Valves, 2nd stage
Unscrew intake valve body with the special tool.Fig.7)
CAUTION
In order to avoid damaging the special tool or the valve vhen using the tool, ensure that it is pushed properly and firmly into the valve bore so that it is will not tilt when it is turned. • • •
Turn the cylinder head and replace it on the metal pins. Unscrew the cap nut (1, Fig. 6) refer to Fig.8. Unscrew stud (2) approx. 5 turns.
Instruction Manual
W31- Series Breathing Air Compressors Page 11. CAUTION Valve spring and valve plate must not be jammed.
Fig. 7 Removing the intake valve • •
Unscrew screw - in pressure plug (3), take out the pressure valve parts. Clean intake and pressure valves and check for damages. Valve seats and plate valves must not show any signs of wear damage. Replace damaged parts.
Fig. 9 removing the screw-in pressure plug Check valve function. To do so, blow compressed air through the valve in the direction of flow. • Secure the intake valve as follows: Peen the cylinder head aluminium on the screw-in thread of the intake valve in two places opposite one another with a smal drift pin, diameter approx. 5mm (fig. 10) • Insert the pressure valve parts and the o-ring. •
Fig. 10 Securing the intake valve Fig. 8 Unscrewing the cap nut • • •
Check O-ring (4), replace if necessary. Clean cylinder head. Check that the intake pressure valve bores are in perfect condition. Check with a precision straightedge that the underside of the cylinder head is flat, if necessary use an emery cloth to smoth out the surface.
NOTE Check the pressure valve function and stroke by lifting the valve plate. •
Screw in the screw-in pressure plug with a pressure pad and tighten. NOTE Ensure thad the stud is unscrewed.
Instruction Manual • • •
Screw in the stud firmly, fit a new gasket and secure with the cap nut. Put the cylinder head on the cylinder and secure it with the internal hex.screws, for the correct torque value, see page I – 9. Reconnect the intake and pressure lines.
4.5. Changing the valves of the 3rd stage For removal and installation of the 3rd stage intake valve proceed according to 4.4. Pressure valve (5) is merely inserted into valve head (7). It is sealed y Oring (4) and fixed to the valve head by stud (3).
W31- Series Breathing Air Compressors Page 12.
Reinstall pressure valve (5) in reverse sequence: • Put O-ring (4) into valve head (7). Check O-ring for abrasions. • Insert pressure valve (5). Put on valve head covers (8). • Fix valve head (7) with internal hex.screws. • Screw in and fasten stud (3).
CAUTION Check intake and pressure valves together, only.
Removal and reinstallation of 3rd stage pressure valve (Fig. 11). • Remove acorn nut (1), rewind stud (3) up to three or four turns. • Remove internal hex. Screw (9) fixing valve head (7), take off valve head cover (8). • Put two screwdivers into the groove of outlet valve body, see fig. 12. If necessary loosen valve first by using a 13-mm spanner on the flat surfaces. Lift out pressure valve (5) together with o-ring (4).
1 9
2 3
8
4 5
7 6
Fig. 11 Valve head 3rd stage
Fig. 12 Removal of 3rd stage pressure valve • •
Put on gasket (2) Screw on acorn nut (1).
Instruction Manual
W31- Series Breathing Air Compressors Page 13.
I – 11. Trouble Shooting 1. COMPRESSOR WILL NOT OPERATE
Probable Cause
Remedy
1. No electrical power
Switch the power on
2. Motor starter overload tripped
Re-start and check if trips again. Make sure that the compressor is not starting against load, such as against pressurized purifier. Check the pressure switch; replace if needed.
3. Pressure switch not making contact 2. Slow filling
1. Intake filter blocked 2. One or more valve sets are not closing due to dirt or carbon collection 3. Worn piston springs; compressed air blowing into the crankcase 4. Worn cylinders 5. Leaks in the system
Replace the filter element Check the interstage pressure against the values indicated in this manual. Check the valves; clean or replace the valves. Replace the piston rings. Replace the cylinders Check, correct fault.
3. Pressure is not building up
1. Mositure separatro drain valve, filling valve or other fittings leaking 2. Safety valves are blowing at pressures below their settings
Check, re-seal, and tighten.
3. Pressure gage reading faulty
Check with another pressure gage; Replace the pressure gage if required.
Replace the safety valve or have it re-set by authorized services.
4. Safety Valves Blowing
1. If 1st stage valve is blowing, the 2nd stage valve may not be properly closing. 1. If 2nd stage valve is blowing, the 3rd stage valve may not be properly closing.
Check, replace the 2nd stage valves if required.
3. The safety valve is faulty 4. The 3rd stage piston is stacked
Check; replace. Replace the piston ass'y
Check, replace the 3rd stage valves if required.
5. Compressor running hot
1. Hot ambient, insufficient ventilation 2. Inlet and discharge valves are worn or dirty and not closing properly. 3. Wrong direction of rotation
4. Low oil level
Check and make sure that the ambient temperatures are below +40º C; provide sufficient ventilation to the area. Check, clean valves; replace if required. Check the arrow; the compressor flywheel must blow air onto the cylinders; if the direction of rotation is wrong, reverse the phases and make sure it is running in the right direction. Check; re fill.
6. Odors in the compressed air
1. Purifier cartridge saturated 2. Improper oil 3. Wrong direction of rotation
4. Carbonization of valves
Replace the cartridge Drain the oil; flush and fill the compressor with proper oil (0,25 Lt) Check the arrow; the compressor flywheel must blow air onto the cylinders; if the direction of rotation is wrong, reverse the phases and make sure it is running in the right direction. Clean; make sure that the ambient temperatures are within permissible limits.
Instruction Manual
W31- Series Breathing Air Compressors Page 14.
Warning 1. Do not alter safety valve settings 6. 2. Do not alter pressure switch setting out with the operational limits of the compressor. 3. Do not repair the hoses; if damaged replace. 4. Do not use work hoses; check the hose 7. periodically. 5. Check for leaks from time to time by using soaped water. 8.
Before any maintenance or repair works, isolate the mains supply blow down all the compressed air from within the purifier and other elements - if any-. Do not carry any works if you are not familiar with the principles and basics of high-pressure compressors. Call on the factory for any assistance.
I – 12. Addendum For Gas Compressors The gas compressors are supplied with safety valves Also make sure that all electrical works are done the discharge ports of which have to be piped to according to local safety regulations. remove the gas blown to a remote and safe area. For See the drawings that are attached when the convenience the safety valves discharge ports are compressor is built for gas applications, to identify the piped to a single manifold. Pipe this manifold to an various system components. area where -if the safety valve blows, the gas will not create a hazardous situation. I – 13. System Layout
985(38,8")
W31x2 Series electric motor driven compressors
47
0( 1
8,5 ")
88
5
) ,8" (34
Drwg.# 7365
W31- Series Breathing Air Compressors Page 15.
Instruction Manual
W31 Series electric motor driven compressors 340
770
Safety Valve
450
Purifier
Wheel
Condensate Separator Drain Valve Oil Discharge Plug
Oil Level Belt Guard
Drw# 6991-01 Purifier Drain Valve
W31 Series mariner compressors 850
340
Belt Guard Purifier
450
Safety Valve
Drw# 6991-02
Condensate Separator Drain Valve Oil Discharge Plug
Wheel
Oil Level
Instruction Manual
W31- Series Breathing Air Compressors Page 16.
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
3 stage breathing air compressor W31 – 2 – P2
Type Model Serial Number Medium Application Rated Free Air (gas) delivery Operating Pressure
Air Breathing Air Cylinder filling 100 lt/min BAR
General Arrangement Drwg. Process & Instrument Drwg. Production File Number Relevant Drawing Numbers Parts List
Compressor Unit Model Year Application Stroke Electric Motor Type Power (kW) Voltage Insulation
Type Max. Operating Press. Air 40
F
Current Rating
Oil Type LP Bore x nr.of LP cyl.
Make Power (HP) Frequency Frame Full Load Current
Recip. UL 751 88
Serial Number Inlet Pressure
Atmospheric
Other HP Bore
36&14
Serial Number RPM Phase Type Off Load Current
2950 3 IP54
Drive
Type Belt Section
Belt dr. 13 mm
Compressor Flywheel Belt Size
Pressure Control Type Pressure switchgage Model Differential Cut out pressure P. Other Data Electrical Control Panel & Motor Starter Drawing Number Parts List Number
Motor Sheave Number of belts
Make Cut In pressure
Alkin
W31- Series Breathing Air Compressors Page 17.
Instruction Manual
COMISSIONING REPORT – INITIAL START UP CUSTOMER DETAILS
Name of the Company Address Contact Name
Position
Phone
Fax
Phone
Fax
Name of Plant Where Equipment Installed (If different than the above) Address Contact Name
Position
Distributor Persons Attending the Commissioning Full Name Position
In charge of
Signature
Equipment Details
Application Medium
Date of purchase
Serial Nr.
Model
R Air
R Gas (specify) : …………………………………………………………………
PRELIMINARY CHECKS
Compressor Received properly Location suitable/ventilated Bolitng down-canopy/sub-base Piping in the compressor intact Oil Type Oil Level in the crankcase External Conn.s & Pipework Suitable All electrical connections checked Mains Supply Voltage and Freq. Other Remarks
Date of comissioning
Remarks
R R R R R R R R R R R
Signature
V
Hz
W31- Series Breathing Air Compressors Page 18.
Instruction Manual START UP CHECKS
Remarks
Direction of rotation Start up current and voltage
R R
Fill in the pressure reading table Pressure switch cut out pressure
R
Main Motor Current and voltage at full load
Duty Cycle (…min operating;
R R R R R R R R R R
Other Remarks
R
Max current and voltage ratings & supply frequency conform the nameplate values.
Vibration Noise No back flow in the Check valve when the compressor stops. Interstage and final safety valves not leaking
Ambient Temperature Crankcase oil temperature after 30 minutes of operation Discharge air/gas temperature after 30 minutes of operation
st
1 stage
nd
2 stage
rd
3
Signature Amps.
Volts
R
Bars Amps.
Volts
V °C °C °C min.stops
Min. runnig;
Pressure Readings stage
Hz
1st stage 2nd stage
50 Bars 100 Bars 150 Bars
200 Bars 250 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
3rd stage
Date
PARTS LIST TYPE W31 SERIES 3 STAGES BREATHING AIR COMPRESSORS 225-330 BARS
ALKIN Compressors Menderes/Izmir/Turkey Tel :(0090) 232 782 22 90 Fax : (0090) 232 782 22 89
PARTS LIST - W31 SERIES COMPRESSOR page1
3
9 7
6
2
1
5 4
8
30 10 8
11
7
13
12
14 15
22
18 19
16
23
17
25 24 27 26
21 20 29 28
6979-02-270804 D
FIGURE 1 - COMPRESSOR FRAME ASSEMBLY
PARTS LIST - W31 SERIES COMPRESSOR page 2
Ref N
Part Nr.
Description
Qty
1.1
7867-38
ALLEN SCREW
1
M8x30 SST
1.2
7104-03
SPRING WASHER
1
M8 SST
1.3
6885-01
WASHER
1
M8
1.4
6998
WHEEL-V-belt
1
1.5
6999
OIL SEAL
1
1.6
7003-03
LOCKRING
1
1.7
7030
BEARING
2
1.8
7003-04
LOCKRING
2
1.9
6884-01
NUT-hex
4
1.10
6904-02
COVER-shaft end
1
1.11
6904-03
GASKET-shaft end cover
1
1.12
7000
CRANKSHAFT
1
1.13 1.14
6904-01 6882-09
CRANKCASE ALLEN SCREW
1 4
1.15
8025-01
CONNECTING ROD SET
1
1.16 1.17
7001 7002
ROD-connecting-2nd&3rd stg ROD-connecting-1st stg
2 1
1.18
6885-02
WASHER
1
1.19
7003-01
LOCKRING
1
1.20
6902-01
COVER-crankcase
1
1.21
6893-05
O RING-crankcase cover
1
1.22
6902-02
PLUG-oil filler
1
1.23
6893-11
O RING-oil filler plug
1
1.24
6902-04
OIL LEVEL GAGE
1
1.25
6893-04
O RING-oil disch plug
1
1.26
6882-04
PLUG-oil disch
1
1.27
6894-04
FIBER WASHER
1
1.28
6882-05
SCREW
4
M6x15(FLANSLI)
1.29 1.30
6893-12 7102-03
O RING Key
1 1
5,8x1,9 NBR 70 SH
M8
M8x1,25x20 SST
136,2x3,53 NBR 70 SH
19,5x1,78 NBR 70 SH
20x1,57 NBR 70 SH
PARTS LIST - W31 SERIES COMPRESSOR
15
3rd stg. look at figure 3
14 26
page 3
13
17 16
2 26
19
8
7
20
4
6 9
5
2nd stg. look at figure 3
3
look at figure 4
10
6 11 26
12
6 look at figure 4
8
look at figure 4
21
look at figure 3
18
1 26
7
6979-03-210503 E FIGURE 2 - MODELW31 BARE COMPRESSOR
PARTS LIST - W31 SERIES COMPRESSOR Page 4
Ref N
Part Nr.
Description
Qty
2.1
6881
SOCKET
3
M6
2.2
6883-03
ACORN NUT
1
M6 SST
2.3
6880-01
TIE ROD
4
M6x142 SST
2.4
6872
GASKET
1
2.5
6871
CYLINDER-1st stg
1
2.6
6870
GASKET
3
2.7
7187-02
FITTING-1/8xØ6 for pl. tube
2
2.8
7187-06
ELBOW-1/8xØ6 for pl. tube
2
2.9
6997-02
TUBE-PL
1
2.10
7867-59
ALLEN SCREW
6
M8x35 SST
2.11
7867-63
BOLT-Hex.
4
M6x20 SST
2.12
6834
CYLINDER-2nd stg
1
2.13
7867-68
ALLEN SCREW
6
M8x55 SST
2.14
6884-21
NUT with plastic insert
4
M6 SST
2.15
6880-02
TIE ROD
4
M6x177
2.16
6841
SLEEVE-3th stg
1
2.17
6893-02
O RING
1
2.18
6842
CYLINDER-3th stg
1
2.19
6893-10
O RING
1
2.20
6892
CROSSHEAD CYLINDER-3rd stg.
1
2.25 2.26
6997-01 7091-17
TUBE-PL WASHER
1 12
23,53x1,78;FKM 70 SH
64x2;NBR 70 SH
M6 SST
PARTS LIST - W31 SERIES COMPRESSOR page 5
15
17 1
16
11
6 5
14 12 13 14 3rd STAGE PISTON&RING ASS'Y
10 9
4 3 2 4 1st STAGE PISTON&RING ASS'Y
7 8 9 2nd STAGE PISTON&RING ASS'Y
6979-4-290500 B FIGURE 3 - PISTONS & RINGS ASSEMBLY Ref N
Part Nr.
Description PISTON COMPLETE-1st stg
Qty
3.1
7004
3.2
6899-01
• PISTON-1st stg
1
3.3
6900
• PISTON PIN-1st stg
1
3.4
7003-02
• LOCK RING,PISTON PIN-1st stg
2
3.5
7008
• RING SET-1st stg
1
7008-03
Compression Ring
1
7008-02
Scraper Ring
1
7008-01
Oil Ring
1
PISTON COMPLETE-2nd stg
1
3.6
7005
1
3.7
6836
• PISTON-2nd stg
1
3.8
6837
• PISTON PIN-2nd stg
1
3.9
7003-02
• LOCK RING,PISTON PIN-2nd stg
2
3.10
7009
• RING SET-2nd stg
1
7009-02
Scraper Ring
4
3.11
7006
3.12
6899-02
• PISTON-3rd stg crosshead
1
3.13
6900
• PISTON PIN-3rd stg
1
3.14
7003-02
• LOCK RING,PISTON PIN-3rd stg
2
3.15
7007
3.16
6845
• PISTON-3rd stg
1
3.17
7010 7010-01
• RING SET-3rd stg Compression Ring
1 5
CROSSHEAD PISTON COMPLETE-3rd
PISTON COMPLETE-3rd stg
1
1
PARTS LIST - W31 SERIES COMPRESSOR page 6
2nd STAGE INLET&DISCHARGE VALVE ASSEMBLY
1st STAGE VALVE ASSEMBLY
22 14
11 2
13 10 9 6 5
1
15 16 17
18
11
19
8 7
3
21
20
4 12
3rd STAGE INLET&DISCHARGE VALVE ASSEMBLY
31
22
32
30
37
33 34 35 23
36 29
28 24
27 26 25
6979-01-210904 F
FIGURE 4 - VALVE ASSEMBLIES
PARTS LIST - W31 SERIES COMPRESSOR page 7
Ref N
Part Nr.
Description
Qty
4.1
6873-01
1st STAGE VALVE COMPLETTE
1
4.2
6875
•TOP COVER-1st stg
1
4.3 4.4
6874 6873
•GASKET •VALVE ASS'Y-1st stg
1 1
4.5
6897-01
•2nd STAGE VALVE COMPLETTE
1
4.6
6887-05
•INLET VALVE ASS'Y-2nd stg
1
4.7
6887-01
•• BODY-2nd stg inlet valve
1
4.8
6887-02
•• SPRING-2nd stg inlet valve
1
4.9 4.10
6203-03 6887-03
•• DISC-2nd stg inlet valve •• SEAT-2nd stg inlet valve
1 1
4.11
6894-01
•WASHER
2
4.12
6835-01
•VALVE HEAD-2nd stg
1
4.13
6888
•DISCHARGE VALVE ASS'Y-2nd stg
1
4.14
6888-02
•• BODY-2nd stg disch valve
1
4.15
6888-03
•• SPRING-2nd stg disch valve
1
4.16
6203-03
•• DISC-2nd stg disch valve
1
4.17
6888-04
•• SEAT-2nd stg disch valve
1
4.18
6888-01
•CAP-2nd stg disch valve
1
4.19
6894-02
•WASHER
1
4.20
6893-01
•O RING
1
21,82x3,53 FKM 70 SH
4.21 4.22
7867-33 6883-04
•BOLT •ACORN NUT
2 2
M8x25 SST M8 SST
4.23
6898-01
3rd STAGE VALVE COMPLETTE
1
4.24
6815
•INLET VALVE ASS'Y-3rd stg
1
4.25
6815-01
•• BODY-3rd stg inlet valve
1
4.26
6815-04
•• SPRING-3rd stg inlet valve
1
4.27 4.28
6815-02 6815-03
•• DISC-3rd stg inlet valve •• SEAT-3rd stg inlet valve
1 1
4.29
6843-01
•VALVE HEAD-3rd stg
1
4.30
6814
• DISCHARGE VALVE ASS'Y-3rd stg
1
4.31
6814-01
•• BODY-3rd stg disch valve
1
4.32
6814-04
•• SPRING-3rd stg disch valve
1
4.33 4.34
6814-02 6814-03
•• DISC-3rd stg disch valve •• SEAT-3rd stg disch valve
1 1
4.35
6893-09
•O RING
1
15.6x1.78 FKM 70 SH
4.36 4.37
6844 7867-82
•TOP COVER-3rd stg •BOLT
1 1
M8x30 SST
PARTS LIST - W31 SERIES COMPRESSOR page 8
17 18 16 15
3 1
5 2
10
14 9
4 6
13 12
7 8
11
6979-05-071003 C
FIGURE 5 - W31 INLET FILTER ,CONDENSATE SEPARATOR&PURIFIER ASS'Y Ref N
Part Nr.
Description
5.1
6876
INLET FILTER ASS'Y
1
5.2 5.3
6876-01 7831
FILTER ELEMENT NIPPLE
1 1
5.4
6916
CONDENSATE SEPARATOR ASS'Y
1
5.5
6916-01
• BODY
1
5.6
6916-03
• DIFFUZER
1
5.7 5.8
6893-06 6916-02
• O RING • COVER
1 1
5.9
7302
5.10
7302-01
• BODY
1
5.11
6702
• PURIFIER ELEMENT
1
5.12
6702-11
• O RING
1
Ø9.19xØ2.62 NBR
5.13
6702-10
• O RING
1
Ø7,6xØ2,62;NBR
5.14
6893-07
• O RING
2
40,65x5,33;NBR 70 SH
5.15
7302-02
• ADAPTER
1
5.16
7303-03
• COVER
1
5.17 5.18
7867-59 7867-06
• ALLEN SCREW • ALLEN SCREW
1 2
PURIFIER ASSEMBLY
Qty
28,17x3,53;NBR
1
M8x35 SST M8x20 sst
PARTS LIST - W31 SERIES COMPRESSOR page 9
9
12 11 13
14 13
45 15
19
10
18
2 2
1
1 2
2
39 17
17 16 2
4
2
15
21
38
46
7 7 8
28 56
15 24 20
27
27
40
23 22 19
25
41
26
42
29
37
43 44
36
31
35 34 33
30
41 32
6979-06-130704 F
FIGURE 6 - W31 GENERAL PIPING
3
PARTS LIST - W31 SERIES COMPRESSOR page 10
Ref Nr. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27 6.28 6.29 6.30 6.31 6.32 6.33 6.34 6.35 6.36 6.37 6.38 6.39 6.40 6.40.1 6.40.2 6.41 6.42 6.43 6.44 6.45 6.46
Part Nr. 7084-02 7425-01 6907-01 6907-02 7961-05 7961-06 7867-57 6884-25 6908-01 6908-02 7961-04 7961-03 7867-57 6884-25 7672-12 7020 7083-02 7019-01 7422-01 6909-01 6909-02 7961-02 7961-01 7867-45 7091-36 6884-17 7867-57 7890-01 7912-01 7026 7891-01 7891-06 7891-03 7670-13 7880-05 7880-06 7429 7933-01 7933-04 7933-08 7933-20 7829-04 7038-02 7091-32 7867-63 7185-02 7084-01
Description ELBOW FITTING INTERCOOLER ASS'Y-1st stg/2nd stg • INTERCOOLER TUBE ASS'Y • CLAMP • CLAMP • ALLEN SCREW • NUT with plastic insert INTERCOOLER ASS'Y-2nd stg/3rd stg • INTERCOOLER TUBE ASS'Y • CLAMP • CLAMP • ALLEN SCREW • NUT with plastic insert ELBOW CONNECTOR DRAIN VALVE ASSEMBLY PLUG TUBE ASS'Y-Condensate Sep./3rd stg FITTING AFTERCOOLER ASS'Y • AFTERCOOLER TUBE ASS'Y • CLAMP • CLAMP • ALLEN SCREW • WASHER • NUT • ALLEN SCREW NIPPLE-HOSE HOSE-1 m PRESSURE GAGE FILLING VALVE&BOTTLE CONNECTION • FILLING VALVE • HANDLE • O-RING • BOTTLE CONNECTION • O-RING • YOKE SAFETY VALVE SAFETY VALVE SAFETY VALVE SAFETY VALVE SAFETY VALVE O-RING SEAT-BOTTLE CONNECTION LOCK WASHER HEX.BOLT FITTING 3/8"x1/4" TEE 1/4"
Qty 2 6 1 1 1 1 2 2 1 1 1 1 2 2 3 2 2 1 2 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1
¼x¼ Sst ¼xØ10 Sst
M4x20 SST M4 SST
M4x20 SST M4 SST ¼xØ10 Sst ¼ ¼xØ6 Sst
M4x30 SST M4 SST M4 SST M4x20 SST
Ø7XØ1.45 ; NBR 90 Sh Ø10.8xØ2.62 ; NBR 70 Sh
5 BAR 35 BAR 240 BAR 320 BAR
2 1 1 1 1 1
Ø6.07xØ1.78 ; NBR 90 Sh
M8 SST M8X20 Sst;HEX.
PARTS LIST - W31 SERIES COMPRESSOR page 11
4
5
15
22 8 22 7 8 8 22 8 9 8 19 21
3
16 13
7 8
2 12
6 13 14
14 11
10
14
1
13 14
20 18
9 18 17
6979-05-310503 E
17
FIGURE 7 - SUBBASE & BELT GUARD ASSEMBLY Ref N
Part Nr.
Description
Qty
7.1
6913-01
SUBBASE
1
7.2
6913-02
CHANNEL-right
1
7.3
6913-03
CHANNEL-left
1
7.4
6913-14
BELT GUARD
1
7.5
6913-11
PLATE-BELT GUARD
1
7.6
7867-69
BOLT-SHEET IRON
11
7.7
7867-09
ALLEN SCREW
5
M6x20 SST
7.8
7091-17
WASHER
9
M6 SST
7.9
7823-03
NUT-INSERT
5
M6 SST
7.10
6953-02
WHEEL
2
7.11
6953-03
PIN
2
7.12
7867-68
ALLEN SCREW
2
M8x55 SST
7.13
7091-34
WASHER
7
M8 SST
7.14
6884-19
NUT
6
M8 SST
7.15
7867-62
HEX.SCREW
4
M8x20 SST
7.16
7091-32
LOCK WASHER
4
M8 SST
7.17
6953-01
VIBRATION MOUNT
2
7.18
6953-04
SPACER
2
7.19
6913-15
BRACKET
1
7.20
6884-18
NUT
2
M10 SST
7.21 7.22
6884-21 7867-03
NUT ALLEN SCREW
1 3
M6 SST M6x10 SST
PARTS LIST - W31 SERIES COMPRESSOR page 12
5
18 6 19 1 2 3
20 2 3 6
3 4
7
3 4
7
6
9
10 6 14 16 16 17
14 15
8 9 16 16 17
13 2 11
12
6979-08-211003 E FIGURE 8 -Support For Water Separator and Purifier ; Screws Ref N 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 8.19 8.20
Part Nr.
Description
7867-61 7091-32 7091-34 6884-19 7027-01 7091-17 6883-03 7091-35 6884-12 7867-60 7867-06 7027-02 6913-05 7867-57 6913-08 7091-36 6884-17 7867-03 6913-16 7867-77
HEX. SCREW LOCK WASHER WASHER NUT CLAMP-Condensate Sep. WASHER ACORN NUT LOCK WASHER NUT with plastic insert ALLEN SCREW ALLEN SCREW CLAMP-Purifier PLATE ALLEN SCREW SUPPORT WASHER NUT ALLEN SCREW HANDLE HEX. SCREW
Qty 4 10 16 8 1 9 4 2 3 2 2 1 1 2 1 4 2 1 1 4
M8x30 SST M8 SST M8 SST M8 SST M6x157 M6 SST M6 SST M6 SST M6 SST M6x30 SST M8x20 SST M6x287 M4x20 SST M4 SST M4 SST M6x10 M8x35 SST
