Clarke SE Ranges Installation and operation manual

AIR COMPRESSOR
OPERATING & MAINTENANCE
INSTRUCTIONS 0307
©
AIR COMPRESSOR

Thank you for purchasing this CLARKE Industrial Air Compressor.
Before putting to use, please read this booklet thoroughly to ensure that installation
is correctly carried out and the maintenance schedules correctly followed. This, in
turn, will ensure the compressor will provide you with long and trouble free service.
Please note that electrically driven machines are designed for indoor use only.
CONTENTS
Safety Precautions .......................................................................... 4
Noise Levels ..................................................................................... 4
Installation ....................................................................................... 5
Suggested Fuse Ratings ................................................................. 5
Electrical Connections ................................................................... 6
Lubrication ...................................................................................... 6
Before Starting Compressor ........................................................... 6
To Start Compressor ........................................................................ 7
To Stop Compressor ........................................................................ 7
General Arrangement - Stationary............................................... 7
General Arrangement - Portable ................................................. 9
Air Receiver Pressure Adjustments ................................................ 10
Outlet Pressure Adjustments .......................................................... 12
Trouble Shooting ............................................................................. 13-17
Maintenance Chart ....................................................................... 17
Declaration of Conformity (Electrically driven machines only) ..... 19
This Clarkeproduct is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt as proof of
purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
GUARANTEE
3

SAFETY PRECAUTIONS
Before using your compressor it is in your own interest to read and pay attention to
the following safety rules:
♦COMPRESSED AIR IS DANGEROUS - Never direct a jet of air at people or animals.
♦Do not operate your air compressor with any guards removed.
♦Electrical or mechanical repairs should only be carried out by a qualified
electrician/engineer. If you have a problem, contact your local dealer, or
our Service Department on
020 8988 7400
♦Before attempting any repair ensure pressure is expelled from the air receiver
and disconnect from electrical supply.
♦Do not leave pressure in air receiver overnight or when transporting.
♦Do not adjust or tamper with any safety valves. The maximum working pressure
of the compressor is clearly stated on the machine.
♦Exercise caution when transporting the machine to avoid tipping the machine over.
♦Do not operate in a wet/damp environment.
♦Locate your air compressor on a firm flat surface and ensure an adequate
supply of clean air is available to the pump unit.
♦Do not exert any strain on electrical cables and ensure that air hoses are not
tangled or wrapped around machinery etc.
♦The cylinder head and delivery pipes of your compressor become quite hot
during operation. Do not touch. After switching off remember to leave an
adequate cool-down period before touching.
♦Ensure that any equipment/tool used in conjunction with your compressor
has a safe working pressure exceeding the output pressure of the machine.
♦When disconnecting air hoses or other equipment from your compressor ensure
that the air supply is turned off at the machine outlet and expel all pressurised
air from within the air hose and other equipment attached to it.
♦If using your compressor for paint spraying:
a) Never spray close to any source of flame or heat.
b) Always ensure that the spraying area has adequate fresh air ventilation.
c) Hazardous paints require special apparatus (see paint manufacturers
recommendations).
♦Never let anyone operate the compressor unless they have had the necessary
instructions.
♦Permanently installed pipework systems should be designed and installed by
a competent engineer.
NOISE LEVELS
These machines produce noise levels in excess of 70dB(A). Persons working in the
vicinity of the machine must be provided with suitable ear protection.
4

INSTALLATION
Before installing your machine, check that its air output is sufficient for the
equipment to be used. The air output from the compressor must be more than the
volume of air required. We recommend the following:
1. Firm and level site, and the use of floor mountings for stationary compressors -
anti-vibration pads. (Do not bolt machines directly to the floor).
2. Dust and damp free environment.
3. Adequate ventilation for:-
a) Air intake to compressor pump (in order to draw in clean air).
b) Cooling to compressor pump, engine or electric motor.
c) Engine exhaust gases.
4. Do not operate compressor in the vicinity of combustible materials.
5. To allow sufficient access for servicing, a minimum clearance of 500mm must
be allowed around the machine.
6. The power cable from the main supply must be large enough to carry the
starting and running load of the electric motor. This is particularly relevant if
the compressor is some distance from the source of supply.
7. Electrical installations should be completed by a qualified electrician.
8. Electrical connection to the mains supply must be via a suitably fused (see
table below) approved plug or isolator (allowing sufficient capacity for motor
starting). If using a circuit breaker in place off uses, ensure it is Motor Rated
and of sufficient size to allow for motor starting.
9. Compressors should be connected to mains electricity supply via an earth
leakage protection device (RCD), particularly if used outdoors.
SUGGESTED FUSE RATINGS
MOTOR SIZE SINGLE PHASE THREE PHASE MOTORS 415V
KW HP MOTOR D.O.L. 240V D.O.L. STAR DELTA
0.75 1.0 13 amp 10 amp
1.1 1.5 13/15 amp 10 amp
1.5 2.0 20 amp 10 amp
1.9 2.5 20 amp
2.2 3.0 30 amp 16 amp
3.0 4.0 40 amp 20 amp
4.0 5.5 50 amp 25 amp
5.5 7.5 30 amp
7.5 10.0 25 amp
11.0 15.0 30 amp
15.0 20.0 35 amp
5

ELECTRICAL CONNECTIONS
IMPORTANT - SINGLE PHASE MACHINES ONLY
The wires in the mains lead of this machine are coloured in accordance with the
following code:
Green and Yellow – Earth
Blue – Neutral
Brown – Live
As the colours of the wires in the lead of this appliance may not correspond with
the coloured markings identifying the terminals in your plug, proceed as follows.
•The wire which is coloured green and yellow must be connected to the
terminal which is marked with the letter E or by the earth Symbol ( ) or coloured
green or green and yellow.
•The wire which is coloured blue must be connected to the terminal which is
marked with the letter N or coloured black.
•The wire which is coloured brown must be connected to the terminal which is
marked with the letter L or coloured red.
WARNING: This machine must be earthed.
LUBRICATION:-
Pump: Use Clarke compressor oil, as indicated on machine plate.
Engine: (Petrol or diesel) refer to maker’s handbook.
BEFORE STARTING COMPRESSOR, CHECK:-
1. Compressor Pump Oil Level by - (a) Dipstick (to level marked)
or - (b) Sight glass (see fig.1) Fig.1
2. Engine oil and fuel levels (where applicable) see
manufacturers handbook for details.
3. (a) Automatic Control:- Pressure switch ON/OFF switch is in
the OFF position
(b) Genie Control:- Ensure bleed valve is open. (See Fig.5, item 2).
WARNING
1.Before starting compressor, open all outlet valves.
2.The following start and stop instructions must be followed in the correct
sequence to avoid serious damage to the compressor/motor.
6

TO START COMPRESSOR – ELECTRIC MACHINES
1. Switch on isolator (mains supply)
2. Switch on pressure switch (lift knob or twist switch). (Fig.2, item 22)
3. Check rotation (Flywheel/Fan blows air over pump)
4. Run compressor for 10 minutes with outlet valves open (first time of operation only).
5. Close valves and check that pressure does not exceed maximum working
pressure (stamped on machine plate), adjust if required (see ‘Pressure
Adjustments’ later in this manual).
TO START COMPRESSOR – ENGINE DRIVEN MACHINES
1. Open bleed valve (fig.5, item 2). N.B. since the CFP9BH does not have a bleed
valve (only a small bleed hole) ensure no equipment is connected to the air
compressor outlet, and that the pressure adjusting knob (fig.6, item 1) is set to
minimum.
2. Start engine in accordance with engine manufacturers instructions.
3. Close bleed valve and allow compressor to run for 10 minutes (first time of
operation only).
4. Close valves and check that pressure does not exceed maximum working
pressure (stamped on machine plate), adjust if required (see ‘Pressure
Adjustments’ later in this manual).
TO STOP COMPRESSOR – ELECTRIC MACHINES
1. Switch Off at the pressure switch (Push knob down or turn switch). (Fig.2, item 22)
2. Isolate from the Mains Supply.
2. Drain air receiver (release drain tap).
TO STOP COMPRESSOR – ENGINE DRIVEN
1. Allow machine to run for 2 minutes off load (with outlet valves open).
2. Switch off engine (see manufacturers handbook).
3. Drain air receiver (release drain tap).
WARNING:
Compressor pumps, delivery pipes etc., and engines will remain hot for some
time after use.
NOTE: When starting compressors up to and including the 3HP models, an auto
bleed valve will operate and air will be heard vent. This is quite normal and should
not cause concern. The valve should close after several seconds. Should it fail to
close, consult your Clarke dealer.
7

GENERAL ARRANGEMENT
1. Air Compressor Pump 8. Drain Tap 16. Oil Level Sight Glass
2. Electric Motor 9. Inspection Plug 17. –
(or petrol/diesel engine) 10. Non-Return Valve 18. –
3. Belt & Pulley Guard 11. Air Bleed Valve 19. Air Delivery Pipe
4. Pressure Switch 12. Oil Drain Plug 20. Air Bleed Pipe
5. Pressure Gauge 13. Saddle 21. Air Receiver
6. Safety Valve 14. Air Intake Filter 22. On/Off switch
7. Ball Valve 15. Oil Filler/Breather 23. Auto Air Bleed
NOTES:
1. On some electric driven and all petrol/diesel models, item 10 is replaced by a
pressure unloading genie for constant run operation. In this case items (4),
(11) and (20) are deleted.
2. On automatic machines 10 H.P. & above a solenoid valve is fitted to the
delivery pipe.
3. On automatic machines 10 H.P. & above, an Auto Star Delta (ASD) starter is
fitted, ready to be mounted to a wall or panel etc. It is IMPORTANT to note
that NO ADJUSTMENTS should be made to this component.
The ASD should be connected to a 3-phase supply by a qualified technician.
A. STATIONARY
NB: Must be mounted on anti-vibration pads.
Fig.2
8

1. Air Compressor Pump 8. Drain Tap 16. Oil Level Sight Glass
2. Petrol/Diesel Engine 9. Inspection Plug 17. Air Filter/Regulator
(or electric motor) 10. Auto Air Bleed (see Fig.7)
3. Belt & Pulley Guard 11. Air Bleed Valve 18. Outlet Air Pressure
4. Pressure Gauge 12. Air Govenor (see Fig.5) Gauge
5. Oil Drain Plug 13. Saddle 19. Air Delivery Pipe
6. Safety Valve 14. Air Intake Filter 20. –
7. Air Outlet Valve 15. Oil Filler Breather 21. Air Receiver
N.B. On Electric Portable Machines items 11 and 12 are replaced with a Non-
Return Valve and a Pressure Switch, as shown on page 7.
GENERAL ARRANGEMENT
B. PORTABLE Fig.3
9

AIR RECEIVER PRESSURE ADJUSTMENTS
WARNING:
THE SAFETY VALVE (ITEM 6, FIG. 2 & 3) FITTED TO THIS COMPRESSOR IS FACTORY
SET AND MUST NOT BE ADJUSTED.
If it is necessary to alter the pressure settings on the compressor please remember
that increasing the pressure will NOT increase the volume of air supplied.
Any adjustments must be made with the compressor at working pressure.
ELECTRIC MACHINES
WARNING:
DISCONNECT FROM ELECTRICITY SUPPLY BEFORE REMOVING ANY COVER.
a. NEMA Pressure Switch (shown with cover removed).
PRESSURE ADJUSTMENT:
To increase the cutout pressure, turn the hexagon (A) on
top of the pressure switch clockwise.
To reduce the cut out pressure, turn it anticlockwise.
RANGE ADJUSTMENT:
To increase the pressure differential between cut in and
cutout, turn the toothed wheel (B) situated under the large
spring anticlockwise, using a screwdriver. In it’s present
position, the pressure SWITCH is set to the minimum range.
NOTE: These operations must always be performed with
the PRESSURE SWITCH under pressure.
Fig.4
b. CONDOR Pressure Switch - Type MDR1 (shown with cover removed).
Toremove the cover, complete with rotary switch, simply
unscrew and remove the single securing screw, adjacent
to the rotary switch, and pull off the cover.
Pressure adjustment is effected by turning the screw ‘A’
clockwise to increase, anticlockwise to reduce.
No provision is made for pressure differential.
An information sheet for this component is provided with
the machine’s documentation
10

c. CONDOR Pressure Switch Type MDR3
The cover is removed by unscrewing the two securing screws - one at each side,
and pulling off the cover complete with rotary switch.
A. PRESSURE ADJUSTMENT:
To increase the cutout pressure, turn the hexagon (A) on top of the pressure switch
clockwise using a screwdriver.
To reduce the cut out pressure, turn it anticlockwise.
B. RANGE ADJUSTMENT:
Pressure differential between cut in and cutout, is preset and should not tampered
with.
ENGINE DRIVEN MACHINES (Except CFP9BH - see page 12)
Air Governor -Pressure unloading genie
1. Air Delivery Pipe from Compressor Pump.
2. Bleed Valve
3. Exhaust Filter
4. Pressure Adjustment Knob
5. Lock Nut.
To adjust pressure slacken lock nut (5).Turn pressure adjusting knob (4) clockwise
to increase pressure,anti-clockwise to decrease. Tighten lock nut (5) when correct
pressure isobtained.
WARNING:
Do not exceed the maximum working pressure of the machine, as marked on
the CLARKE AIR specification plate.
Fig.5
An information sheet
for this component is
provided with the
machine’s
documentation
11

OUTLET PRESSURE ADJUSTMENTS
CFP9BH
PORTABLE COMPRESSORS
1. Pressure Adjusting Knob
2. Outlet Taps
3. Quick Fit Nuts
4. Pressure Gauge
To adjust outlet pressure:
To increase pressure - turn knob (1) clockwise.
To decrease pressure - turn knob (1)
anticlockwise.
Outlet taps - slide knurled section (2) away
from body to open, push towards body to
close.
NOTE: Pressure Gauge (4). Pressure shown will differ by approximately 1 bar
depending on whether the outlets are open/closed.
STATIONARY COMPRESSORS
These machines are not supplied with the facility to adjust outlet pressure. A
comprehensive range of airline accessories is available from your local CLARKE
stockist.
To adjust outlet pressure - slacken lock nut (2). Turn Pressure Adjusting Knob (1)
clockwise to increase outlet pressure, anticlockwise to decrease. Tighten lock nut
(2) when correct pressure is obtained.
NOTE:
1. When Compressor reaches cut-out pressure air will bleed from bleed hole (4).
2. Item (3) quick fit nut can be removed if required and hose can be fitted using
1/4 BSP nut.
1. Pressure Adjusting Knob
2. Lock Nut
3. Air Outlet
4. Bleed Hole
Fig.6
Fig.7
12

TROUBLE SHOOTING CHART
IMPORTANT!
1. Any remedial work that may be required must be carried out by aqualified
electrician/engineer.
2. Switch off current before removing any parts from the compressor.
3. Empty Air Receiver of Air before dismantling any part of thecompressor unit’s
pressure system.
4. If your compressor develops a fault do not use until the fault hasbeen rectified.
SYMPTOM PROBABLE CAUSES REMEDY
Compressor will not Fault in electrical Let an electrician check
start automatically. installation. electrical installation.
a) current supply failure.
b) voltage drop.
c) motor starter faulty.
d) motor incorrectly
connected or faulty.
e) starter overload has Reset by depressing
tripped out. button.
f) Pressure switch Have pressure switch
defective. changed by anelectrician.
g) Fuse blown. Check fuse rating - replace.
Fuses keep blowing. Inadequate size fuse Replace with reference to
installed. chart on page 2.
Fault in motor. Consult an electrician.
Compressor unit Non-return valve leaking Switch off current and
starts, but stops (compressor unit is on load empty air receiver. Clean
again after only a during start). or replace non-return valve.
few revolutons. Non-return valve blocked, Thaw non-return valve out
possibly frozen up. (Unit must be installed in
frost-free place).
Solenoid valve leaking or Let an electrician inspect
defective (only applies to electrical installation in
10 hp machines and above). accordance with diagram
supplied with starter (10 hp
and above).
13

SYMPTOM PROBABLE CAUSES REMEDY
Compressor unit will not Pressure switch defective. Have pressure switch
stop automatically. changed by an electrician
Pressure switch set at a Adjust pressure switch
pressure higher than the or safety valve
safety valve’s opening WARNING:DO NOT
pressure. ADJUST SAFETY VALVE
ABOVE MAXIMUM
WORKING PRESSURE
DETAILED.
Bleed valve under Non-return valve leaking. Clean non-return valve
pressure switch blows or replace.
whilst compressor is
not running.
Bleed valve under Relief valve leaking. Clean relief valve or
pressure switch change pressure switch.
blows whilst machine
is running.
Compressor runs Suction filter blocked. Change filter.
continuously and can’t V-belt too slack (not Tighten V-Belt.
attain the working applicable to direct
pressure required. drive machines).
Leak between compressor Tighten connection and
block and air receiver/ repair leak.
leaks in or near air receiver.
RPM too low because of Call an electrician.
incorrectly connected
electric motor.
Valves blocked by dirt, Clean or change valves.
paint, dust or coked up.
Inspection cover or plug Empty air receiver and
leaking. change seal.
Suction rendered difficult or Larger fresh-air inlet.
impossible at suction intake
or the air being taken in is
too warm.
Pressure gauge defective. Change pressure gauge.
Unit too small in relation to Connect a supplementary
air consumption. compressor or install a
larger model.
Compressor worn. Have compressor over-
hauled or replace it.
14

SYMPTOM PROBABLE CAUSES REMEDY
Unusual noise from Bolts loose. Tighten Bolts.
compressor. V-Belt flywheel or cooling Find place of contact and
coil touching belt guard remedy fault.
Flywheel loose. Tighten flywheel.
Unit installed on an Move unit to a more solid
unsuitable base. base.
Bearings, piston rings or Replace worn parts or
cylinder worn. change compressor pump
Valve broken. Change valve parts.
Bearings of electric motor Have motor bearing
worn. replaced.
Compressor becomes Insufficient ventilation See that sufficient air is
too hot. supplied to flywheel or
fan of compressor and
that hot air is properly
vented.
Oil level too low (check Fill with oil - see Page 3.
2 or 3 times after stopping).
Wrong direction of Cooling air from flywheel
rotation. fan must blow against
compressor.
Fault in valves (machine Check, clean/replace
not stopping).
Blown head gasket (machine Check and replace gasket
not stopping).
Dirt on cooling fins or Clean cooling fins and
suction filter. suction filter.
Unit working at too high Reset to correct working
a pressure pressure detailed on unit.
Not fully unloading Check pressure unloading
(Govenor control machines genie, adjust if necessary,
only). check valve(s)
Non-return valve partly Clean or thaw out non-
blocked. return valve.
Compressor being Connect to a
overworked and supplementary compressor
running continuously. or install a larger model.
15

Compressor unit starts Large amount of Drain off condensation
and stops more condensation in air receiver. AT LEAST once a week.
frequently than usual. Leaks in control unit or Locate leaks (by means of
inspection cover. soapy water) and repair.
Too little pressure differential. Adj. pressure switch
(see fig.4).
Compressor unit starts Leaks in pipework system Locate and repair leaks.
when no air is being
used.
Compressor’s oil Too much oil in compressor. Check oil level 2 or 3
consumption rising. minutes after stopping.
Leaks around crank case. Change seal and inspect
packing surfaces. Repair
or replace defective parts.
Working temperature of Increase ventilation to
compressor too high because air comprressor.
of insufficient cooling.
Unit too small in proportion Connect supplementary.
to air consumption.
Semi-automatic unit Load too Convert to fully
small. automatic operation.
Cylinder worn. Replace worn parts or send
compressor pump for an
overhaul
Intake air filter blocked. Change air filter.
Oil in the air delivered. Sump over full. Reduce oil to correct level.
Cylinder worn. Replace worn parts or send
compressor pump for an
overhaul.
Governor controlled unit Convert to automatic
running off load for too long control.
a period.
Intake air filter blocked. Change air filter.
Oil level rises although Condensation in oil pump. Compressor over
-no oil has been put in. dimensioned.
Condensation in crank Compressor overdimensioned a) Frequent oil changes.
case (especially in (operational periods too short b) Reduce cooling of crank
2-stage compressors). in relation to resting periods). case (eg. by shielding it
from air stream).
c) Reduce RPM of pump.
SYMPTOM PROBABLE CAUSES REMEDY
16

SYMPTOM PROBABLE CAUSES REMEDY
Condensation at outlet Piping installation incorrect. Consult your local dealer.
points. Compressor taking in air Obtain better fresh-air
which is too warm. supply for compressor.
Delivery temperature of air a) Use a larger air receiver.
from air receiver too high. b) Insert an aftercooler.
Electric Motor too hot: Operational voltage too low. Call an electrician.
maximum temperature Faults in electrical installation Call an electrician.
90 C (194 F). or electric motor.
Cooling fins of electric motor Clean cooling fins.
blocked by dirt.
Machine running but Air exhausting from solenoid Check solenoid valve.
not pumping air into after starter has changed from Call an electrician to
receiver (10 HP and star to delta. check starter.
above).
OTHER PRODUCTS WITHIN OUR RANGEIn addition to Air Compressors from 3–80 cfm, we
offer a vast range of airtools and airline equipment. Please ask your local dealer for
details ofour range or a copy of our Power Products Catalogue
MAINTENANCE CHART
CHECK LIST DAILY WEEKLY 6 MONTHLY
Oil Level Check Change
Air receiver Drain
Intake filter Check/Clean Replace if necessary
Oil breather Check/Clean
Fan and Cooling Clean
Fins
Inlet and Outlet Check Replace if worn
valves
Non-return valve Clean Replace if worn
Belt tension Check/Adjust Does not apply to
direct drive
Big end bearings Check Replace if worn
Main bearings Check Replace if worn
Piston rings Check Replace if worn
17

A Declaration of Conformity is provided for Engine Driven compressors, separately
19