Clarke XE10/100 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0817 - ISS 2
ORIGINAL INSTRUCTIONS
AIR COMPRESSOR
XE RANGE - ELECTRIC MOTOR DRIVEN

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INTRODUCTION
Thank you for purchasing this CLARKE compressor which is designed to supply
compressed air to air powered tools for a wide range of applications such as
spraying, sanding, drilling, and cutting.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safe operation
of the compressor.
MODELS COVERED
SPARE PARTS AND DIAGRAMS
Spare parts and diagrams are available on request by contacting our parts
and service department on 020 8988 7400.
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required 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.
XE10/100 XEP15/50 XEV11/100
XE15/150 XEPV11/50 XEV16/100
XE18/200 XEPV11/50 XEV16/150
XE25/200 XEPV16/50 XEV16/200
XE29/270 XEPV16/50
XE37/270 XET19/200

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ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.
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.
RESIDUAL RISK
Although this manual contains extensive safety warnings and information on the
safe operation of your compressor, every tool does have certain residual risks
which cannot be compleatly excluded with warnings or safety devices. This
compressor must therfore always be operated with caution.

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
SAFETY PRECAUTIONS
Before using your compressor it is in your own interest to read and pay
attention to the following safety rules:
1. COMPRESSED AIR IS DANGEROUS - Never direct a jet of air at people or
animals.
2. Do not operate your air compressor with any guards removed.
3. 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
4. Before attempting any repair ensure pressure is expelled from the air receiver
and disconnect from electrical supply.
5. Do not leave pressure in air receiver overnight or when transporting.
6. Do not adjust or tamper with any safety valves. The maximum working pressure
of the compressor is clearly stated on the machine.
7. Exercise caution when transporting the machine to avoid tipping the machine
over.
8. Do not operate in a wet/damp environment.
9. Locate your air compressor on a firm flat surface with AVMs and ensure an
adequate supply of clean air is available to the pump unit.
10. Do not exert any strain on electrical cables and ensure that air hoses are not
tangled or wrapped around machinery etc.
11. 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.
12. Ensure that any equipment/tool used in conjunction with your compressor has
a safe working pressure exceeding the output pressure of the machine.
13. 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.
14. If using your compressor for paint spraying:
• Never spray close to any source of flame or heat.
• Always ensure that the spraying area has adequate fresh air ventilation.
• Hazardous paints require special apparatus (see paint manufacturers
recommendations).
15. Never let people operate the compressor unless they have had the necessary
training.
16. Permanently installed pipework systems should be designed and installed by a
competent engineer.

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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:-
• Air intake to compressor pump (in order to draw in clean air).
• Cooling to compressor pump, and electric motor.
4. To allow sufficient access for servicing, a minimum clearance of 500mm
must be allowed around the machine.
5. 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.
6. Electrical installations should be completed by a qualified electrician.
7. Electrical connection to the mains supply must be via a suitably fused (see
table on page 6) approved plug or isolator (allowing sufficient capacity for
motor starting). If using a circuit breaker, ensure it is motor rated and of
sufficient size to allow for motor starting.
8. Compressors should be connected to mains electricity supply via an earth
leakage protection device (RCD).
WARNING: MOVE THE COMPRESSOR ON A PALLET OR USING SLINGS
BENEATH THE RECEIVER NEAR TO THE DOMED ENDS, EMPLOYING A FORK
LIFT TRUCK OR WHEELED GANTRY CRANE. BEWARE OF OFF CENTRE
LOADS. THE WEIGHT OF THE COMPRESSOR IS SHOWN ON THE DATA TABLE
ON PAGE 2.

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ELECTRICAL CONNECTIONS
See wiring lable on the power cable.
SUGGESTED FUSE RATINGS
LUBRICATION
Pump: Use Clarke compressor oil, as indicated on machine plate.
MOTOR SIZE SINGLE PHASE
MOTOR D.O.L.
THREE PHASE MOTORS 415V
KW HP DOL 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 25 amp
5.5 7.5 30 amp
7.5 10.0 25 amp

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
BEFORE STARTING COMPRESSOR, CHECK:-
1. Compressor Pump Oil Level using (a) Dipstick (to level
marked) or (b) sight glass (see fig.1)
2. Automatic Control:- Pressure switch ON/OFF switch is in
the OFF position.
TO START COMPRESSOR
1. Switch on isolator (mains supply)
2. Switch on pressure switch (lift knob or twist switch). (See “GENERAL
ARRANGEMENT” on page 8., item 22)
3. Check rotation (Flywheel/Fan blows air over pump)
4. Check that pressure does not exceed maximum working pressure
(stamped on machine plate), if the pressure exceeds the maximum
working pressure stated, stop the machine (see below), vent the system
and contact the Clarke Service Department.
TO STOP COMPRESSOR
1. Switch off at the pressure switch (Push knob down or turn switch).
2. Isolate from the Mains Supply.
3. Drain air receiver (release drain tap).
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.
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.
WARNING: COMPRESSOR PUMPS, DELIVERY PIPES WILL REMAIN HOT FOR
SOME TIME AFTER USE.

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GENERAL ARRANGEMENT
NOTE: On automatic machines (10 H.P). a solenoid valve is fitted to the
delivery pipe.
NOTE: On automatic machines (10 H.P), 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 electrician.
1 Air Compressor Pump 9 Inspection Plug 17 –
2 Electric Motor (or 10 Non-Return Valve 18 –
3 Wire 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
8 Drain Tap 16 Oil Level Sight Glass
Fig.2
A. STATIONARY
NB: Must be mounted on Anti Vibration Pads
Illustrative
purposes
only

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OUTLET PRESSURE ADJUSTMENTS
PORTABLE COMPRESSORS
1. Pressure Adjusting Knob
2. Outlet Taps
3. 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 (3). 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.
OVERLOAD BUTTON (SINGLE PHASE ONLY)
The electric motor is fitted with an automatic
overload detector which will stop the motor if an
overload is detected.
If this happens,
1. SWITCH OFF THE PRESSURE SWITCH (Push knob
down or turn switch).
• Allow the compressor to cool down for 5-10
minutes.
2. Press the Reset button shown on the right.
3. Switch on pressure switch (lift knob or twist switch).
If the overload trips repeatedly, it may indicate a fault with the compressor, in
this case you should contact the Clarke service department.
OTHER PRODUCTS WITHIN OUR RANGE In addition to Air Compressors from 3–40
cfm, we offer a vast range of air tools and airline equipment. Please ask your
local dealer for details of our range or a copy of our Power Products Catalogue
Illustrative
purposes
only

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
TROUBLESHOOTING CHART
IMPORTANT!
1. Any remedial work that may be required must be carried out by a qualified
electrician/engineer.
2. Disconnect from the mains supply before removing any parts from the
compressor.
3. Empty Air Receiver of Air before dismantling any part of the compressor
unit’s pressure system.
4. If your compressor develops a fault do not use until the fault has been
rectified.
SYMPTOM PROBABLE CAUSE REMEDY
Compressor will
not start
automatically
Fault in electrical installation Let an electrician check
electrical installation.
Current supply failure.
Voltage drop.
Motor starter faulty.
Motor incorrectly connected or
faulty
Starter overload has tripped
out.
Reset by depressing button.
Pressure switch defective. Have pressure switch
changed by an electrician.
Fuse blown. Check fuse rating - replace.
Compressor unit
will not stop
automatically.
Pressure switch defective. Contact Clarke Service
Fuses keep
blowing.
Inadequate size fuse installed. Replace with reference to
chart See page 6.
Fault in motor. Contact Clarke Service
Bleed valve
under pressure
switch blows
whilst
compressor is
not running
Non-return valve leaking. Clean non-return valve or
replace.

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
Bleed valve
under pressure
switch blows
whilst
compressor is
running
Non return valve stuck (NRV)
open at junction of the tank and
the pump delivery pipe.
Drain Tank and remove
inspection nut to clean Non
Return valve
Compressor unit
starts, but stops
again after only
a few
revolutions.
Non-return valve leaking
(compressor unit is on load during
start).
Disconnect from the mains supply
and empty air receiver. Clean
or replace
Non-return valve blocked,
possibly frozen up.
Thaw non-return valve out
(Unit must be installed in frost-
free place).
Solenoid valve leaking or
defective (only applies to 10 HP
machines and above).
Contact Clarke Service
Unusual noise
from
compressor
Bolts loose. Tighten Bolts.
V-Belt flywheel or cooling coil
touching belt guard
Find place of contact and
remedy fault.
Flywheel loose. Tighten flywheel.
Unit installed on an unsuitable
base.
Move unit to a more solid
base
Bearings, piston rings or cylinder
worn.
Contact Clarke Service
Valve broken. Contact Clarke Service
Bearings of electric motor worn Contact Clarke Service
Compressor unit
starts and stops
more frequently
than usual.
Large amount of condensation in
air receiver.
Drain off condensation AT
LEAST once a week.
Leaks in control unit or inspection
cover.
Locate leaks (by means of
soapy water) and repair.
Too little pressure differential. Contact Clarke Service
SYMPTOM PROBABLE CAUSE REMEDY

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
Compressor’s oil
consumption
rising.
Too much oil in compressor. Check oil level 2 or 3 minutes
after stopping.
Leaks around crank case. Contact Clarke Service
Working temperature of
compressor too high because of
insufficient cooling.
Increase ventilation to air
compressor.
Unit too small in proportion to air
consumption.
Connect supplementary.
Semi-automatic unit Load too
small.
Convert to fully automatic
operation.
Cylinder worn Contact Clarke Service
Intake air filter blocked. Clean / Change air filter.
Compressor
runs
continuously
and can’t
attain the
working
pressure
required.
Suction filter blocked. Change filter.
V-belt too slack (not applicable
to direct drive machines).
Tighten V-Belt.
Leak between compressor block
and air receiver/ leaks in or near
air receiver.
Tighten connection and repair
leak or Contact Clarke Service
RPM too low because of
incorrectly connected electric
motor.
Contact Clarke Service
Valves blocked by dirt, paint, dust
or coked up.
Contact Clarke Service
Inspection cover or plug leaking Empty air receiver and
change seal or Contact
Clarke Service
Suction rendered difficult or
impossible at suction intake or the
air being taken in is too warm.
Ensure unobstructed air flow
around the unit.
Pressure gauge defective.
Unit too small in relation to air
consumption of connected
equipment
Install a larger compressor
Compressor worn. Have compressor overhauled
or replace it.
Compressor unit
starts when no
air is being
used.
Leaks in pipework system Locate and repair leaks.
SYMPTOM PROBABLE CAUSE REMEDY

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
Machine
running but not
pumping air
into the
receiver (10HP
only)
Air exhausting from solenoid after
starter has changed direction
from star to delta.
Check solenoid valve
Contact Clarke Service
Compressor
becomes too
hot.
Insufficient ventilation See that sufficient air is
supplied to flywheel or fan of
compressor and that hot air is
properly vented.
Oil level too low (check 2 or 3
times after stopping).
Fill with oil - See page 7.
Fault in valves (machine not
stopping).
Contact Clarke Service
Blown head gasket (machine not
stopping).
Contact Clarke Service
Dirt on cooling fins or suction filter. Clean cooling fins and suction
filter.
Unit working at too high a
pressure
Contact Clarke Service
Non-return valve partly blocked. Clean or thaw out non-return
valve.
Compressor being overworked
and running continuously.
Use a larger compressor
Oil in the air
delivered
Sump over full Reduce oil to correct level
Cylinder worn Contact Clarke Service
Intake air filter blocked Change air filter
Condensation
in crank case
(especially in 2-
stage
compressors).
Compressor over dimensioned
(operational periods to short in
relation to resting periods).
Frequent oil changes
Reduce Cooling of crank case
(e.g. by shielding it from the air
stream).
Contact Clarke Service
Condensation
at outlet points
Piping installation is incorrect Consult your local dealer
Compressor is taking in air that is
too warm
Obtain better fresh air supply
for the compressor.
Delivery temperature of air from
air receiver is too high
Use a larger air receiver
Contact Clarke Service
SYMPTOM PROBABLE CAUSE REMEDY

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
MAINTENANCE CHART
Electric motor
too hot:
Maximum
temperature
90oC (194oF).
Operational voltage too low Call an electrician
Faults in electrical installation Contact Clarke Service
Cooling fins of electric motor
blocked by dirt
Clean Cooling fins
CHECK LIST DAILY WEEKLY 6 MONTHLY NOTES
Oil level Check Change
Air Receiver Drain
Intake Filter Check /
Clean
Replace if necessary
Oil breather Check /
Clean
Fan and cooling fins Clean
Inlet and outlet
valves
If worn Contact Clarke
Service department
Non Return Valve Clean Replace if
worn
Belt Tension Check /
Adjust /
Replace if
worn
Does not apply to
direct drive
Big end bearings Check If worn Contact Clarke
Service department
Main bearings Check If worn Contact Clarke
Service department
Piston Rings If worn Contact Clarke
Service department
Cylinder head bolts Check
Torque
settings
See above for details.
SYMPTOM PROBABLE CAUSE REMEDY

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY