Clarke XR55 Installation and operation manual

Part Nos.
6920268 • 6920270• 6920280 • 6920290
PARAFFIN/DIESEL HEATERS
Model Nos.
XR55 • XR75 • XR105 • XR 155
LS0114

2
Thank you for purchasing this CLARKE, Paraffin fired Space Heater.
This range of portable heaters is designed for industrial applications only. As with
all mechanical equipments, optimum performance will only be achieved if the
correct application and servicing procedures are followed. Please read this
leaflet thoroughly and follow the instructions carefully before attempting to use
the heater. In doing so you will ensure the safety of yourself and that of others
around you, and you can look forward to it giving you long and reliable service.
GUARANTEE
This CLARKE product 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.
CONTENTS PAGE
Safety Precautions ........................................................................ 3
Electrical Connections ................................................................. 4
Unpacking ..................................................................................... 5
Assembly ........................................................................................ 6
Operation ...................................................................................... 6
Starting Procedure ........................................................................ 8
Parts & Service............................................................................... 8
Maintenance ................................................................................ 9
Storage .......................................................................................... 10
Parts Diagram ................................................................................ 12
Parts List .......................................................................................... 13
Trouble Shooting ............................................................................ 15
Specifications ................................................................................ 18

3
SAFETY PRECAUTIONS
WARNING!
Lack of ventilation can cause Carbon Monoxide poisoning.
CARBON MONOXIDE CAN KILL
Signs of Carbon Monoxide poisoning are, headaches, dizziness and/or nausea.
Should anyone show these signs, they must GET FRESH AIR IMMEDIATELY.
Turn off the heater and have it serviced before using again.
Pregnant women, persons with a heart or lung condition, anaemia or under the
influence of alcohol, or those at high altitudes, are more likely to be effected by
Carbon Monoxide than others.
Read, and make sure you fully understand the following precautions and the
hazards associated with this type of equipment.
• Use ONLY clean paraffin, Diesel Oil.
• NEVER use Gasoline, Naphtha, Paint thinners, Alcohol or other highly
flammable fuels.
• Use ONLY with the electrical voltage specified
• NEVER use the heater where Gasoline, Paint thinner or other highly flammable
vapour or high dust content is present.
• Ensure the appliance is properly earthed.
• Use ONLY in well ventilated areas. Provide ventilation of at least 2.75 square
feet of fresh air for every 100,000 BTU/ hr of rating.
• The minimum clearance from any combustible materials is 8 feet (250cm)
from hot air outlet and 4 feet (125cm) from the top and sides.
• Maintain the heater on a stable, level surface whilst hot or operating, or a fire
could occur.
• Keep children and animals away from heater at all times.
• When used with a thermostat, bear in mind, the heater may start at anytime.
• Store the heater in a level position when filled, or fuel leakage may occur.
• Use heater in accordance with all fire regulations.
• NEVER use heater in living or sleeping areas.
• NEVER leave a heater plugged in without adult supervision if children or
animals are likely to be present.
• NEVER move, handle, refuel or service the heater when it is hot, operating or
plugged in.
• NEVER cover or impede air flow into or out of heater.
• NEVER attach duct work to the front of heater.
• Disconnect the heater from the power supply when not in use.

4
ELECTRICAL CONNECTIONS
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply through an
approved 13 amp BS 1363 plug, or a suitably fused isolator switch.
WARNING! THIS APPLIANCE MUST BE EARTHED
IMPORTANT: The wires in the mains lead are coloured in accordance with the
following code:
Green & Yellow - Earth
Blue - Neutral
Brown - Live
As the colours of the flexible cord of this appliance may not correspond with the
coloured markings identifying terminals in your plug proceed as follows:
Connect GREEN & YELLOW cord to terminal marked with a letter “E” or Earth
symbol “ ” or coloured GREEN or GREEN & YELLOW.
Connect BROWN cord to terminal marked with a letter “L” or coloured RED
Connect BLUE cord to terminal marked with a letter “N” or coloured BLACK
If this appliance is fitted with a plug which is moulded onto the electric cable (i.e.
non-rewirable) please note:
1. The plug must be thrown away if it is cut from the electric cable. There is a
danger of electric shock if it is subsequently inserted into a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace a detachable fuse carrier, ensure that the correct
replacement is used (as indicated by marking or colour code).
4. Replacement fuse covers can be obtained from your local dealer or most
electrical stockists.
We recommend that this machine is connected to the mains supply through a
Residual Current Device (RCD).
Fuse Rating
The fuse in the plug must be replaced with one of the same rating (13 amps) and
this replacement must be ASTA approved to BS1362.
If in doubt, consult a qualified electrician. Do not attempt any electrical repairs
yourself.

5
Wiring Diagram
Legend
FC - Photocell
FS - In-Line Fuse
M - Motor
T/R - Transformer
IN - ON/OFF Switch
TS - Thermostat
UNPACKING ref. Fig.1
Unpack and check the heater for possible shipping
damage. If any damage is found, immediately notify
the dealer from whom heater was purchased.
These models (except XR55) are equipped with wheels
and handles.
The loose items listed below, can be found in
the shipping carton.
1. Handle (2)
2. Wheel Support Frame (3)
3. Wheels - 2 pcs
4. Axle (6)
5. End Caps - 2 PCs (5)
6. Washers - 2 pcs
7. Screws w/nuts and washers 6 sets (7)
External Thermostsat
A suitable external thermostat for measuring ambient temperature, should be
fitted between points X and Y (Wiring diagram), by a qualified electrician only.
Fig. 1

6
ASSEMBLY ref. Fig.1
1. Slide the axle (6) through the wheel support frame (3), and install the wheels
on the axle.
NOTE: The extended wheel hubs should be facing inwards.
Position the caps (5) on the axle ends and gently tap with a hammer to secure.
2. Position heater on the wheel support frame assembly, with air outlet end over
the wheels.
3. Use the screws and nuts (7) to attach the handle (2), to the top of the fuel tank
flange. The screws will go through the handles, the fuel tank flange, and the
wheel support frame.
4. Tighten all nuts.
OPERATION
Understanding the basic operation of the heater, will reinforce the need to
maintain the unit in top condition at all times, whilst always observing the safety
precautions.
The heater comprises four basic systems:
1. The fuel system.
2. The air system.
3. The ignition system.
4. The safety control system.
Fig. 2

7
1. The Fuel System.
Fuel is held in the tank at the base of the system, at atmospheric pressure. An air pump,
mounted on the end of the motor, draws air through a filter, compresses it, and forces it
through a second filter, and via an air line, directly to the burner head nozzle. The speed of
the air over the nozzle, causes a depression. Fuel is therefore forced up the tube by
atmospheric pressure, through a filter, and out of the nozzle in the form of a spray.
It is important to ensure that the vent in the filler cap is not blocked at any time, otherwise
fuel will not reach the nozzle.
This heater is capable of burning
Paraffin or Diesel oil. NEVER use petrol.
As these fuels burn at different
rates, provision is made to ensure
that the correct volume of air is
allowed into the combustion
chamber for each type of fuel.
This is achieved by means of a
blanking plate, at the rear of the
burner, shown in Fig. 3,
The blanking plate is factory set to burn PARAFFIN, so that tab’A’ covers vent ‘B’
WARNING!
TO BURN DIESEL, THE BLANKING PLATE MUST BE MOVED TO THE POSITION SHOWN IN
FIG.3, OTHERWISE DAMAGE TO THE COMBUSTION CHAMBER WILL OCCUR
NOTE:
A. In the case of MODEL XR75, there is insufficient room to store the blanking plate in the position
shown above. The plate should therefore be removed and retained for possible future use.
B. In the case of Model XR55, no changes are required for the burning of Diesel oil.
2. The Air System.
Additional air is supplied to the combustion chamber by a fan, which is mounted on
the opposite end of the motor shaft to the Air Pump. Openings around the burner
head allow a portion of this air to be drawn into the combustion chamber, where it
mixes with the air and fuel from the nozzle, and ensures that all the fuel is burned,
preventing the emission of black smoke.
The remaining air is directed around and over the combustion chamber, until it finally mixes
with the heated air from the combustion chamber, and is ejected as a jet of clean hot air.
3. The Ignition System.
A constant arc is struck between the electrodes, which ignites the air and fuel
mixture. It is important that the electrode gap is correctly maintained, otherwise
arcing will not take place...see Maintenance.
4. The Safety Control System.
A light sensitive photo cell (flame sensor) trips the motor if the flame goes out for
any reason, causing the heater to shut down.
Fig. 3

8
STARTING PROCEDURE
Warning!
Before starting the heater, you MUST ensure that the minimum ventilation
requirements are observed, to avoid the risk of carbon monoxide poisoning.
Ensure the fuel tank is filled with the correct fuel, before plugging in to a suitably
earthed supply. If you are changing the type of fuel, ensure the blanking plate at
the rear of the burner is set to the correct position (see Notes on page 7).
It will be necessary to remove the top cover, by removing its 6 securing screws, to
gain access to the rear of the burner, and the blanking plate.
If necessary, slacken off the blanking plate securing screw, turn the plate to its
required position and tighten the securing screw. Replace the top cover,
then,observing all precautions previously stated, push The start switch - ‘1’
located on the left side of the machine, and shown at 8, fig. 1.
It is important to ensure that adequate ventilation is provided. The following chart
gives the MINIMUM requirements
Minimum fresh air opening requirements
eg. For XR75, a 3ft window must be open by 10" minimum
Minimum
Ventilation ft2
Minimum
Ventilation mtrs2
Heater Model
XR55 1.6 0.15
XR75 2.5 0.23
XR105 3.0 0.28
XR155 4.6 0.43
PARTS & SERVICE
Please contact your nearest dealer, or
CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]

9
MAINTENANCE (ref. Parts List)
IMPORTANT
Before carrying out any adjustment or maintenance, ensure the heater is
switched OFF, disconnected from the mains supply, and has been given
adequate time to cool down, unless otherwise stated.
It is essential that the heater is correctly maintained and kept in top condition at all
times.
Those items requiring regular maintenance comprise,
1. Intake Air Filter (Item 2)
2. Output Air Filter (Item 5)
3. Fan (Item 20)
4. Fuel Nozzle (Item 26)
5. Ignition Electrodes (Item 23)
6. Fuel Filter (Integral part of item 27)
The Intake and Output Air Filters, are accessible by removing the Grille (by
removing the single hex socket centre screw), whereas accessibility to the
remaining items requires the removal of the top cover (by removing the six screws
at the centre joint).
Monthly
Intake Air Filter
Pull off the Intake Air Filter, which lies directly behind the Grille, and wash in a light
detergent. Thoroughly dry before re-installing.
In dusty environments it may be necessary to carry out this procedure weekly.
Never allow the filter to get blocked..
Ignition Electrodes
Having removed the heaters’
top cover, remove the single
screw retaining the electrode
holder. Withdraw the holder,
clean and adjust the gap
between the electrodes, to
4mm.
When re-installing the electrode holder, there must be a gap of 9mm between the
electrodes and the nozzle (see fig. 4). If this adjustment needs to be re-set, it is
preferable to remove the burner head complete, by removing the securing
screws around its’ edge, taking care not to damage the photocell. The electrodes
may then be adjusted to their correct clearance before replacing the Burner
Head.
Fig. 4

10
Bi-Monthly
Fan.
Having removed the top cover, thoroughly clean the fan using a cloth moistened
with paraffin or light solvent, and dry using an air line if possible.
Output Air Filter.
Remove the grille, and pull off the Intake Air Filter, revealing the 3 screws securing
the filter housing. Remove the screws and pull off the housing to reveal the Output
Air Filter. If contaminated, this filter must be renewed.
In dusty environments this procedure should be carried out, monthly
Nozzle.
Having removed the top cover, gently unscrew and remove the burner head,
and unscrew the nozzle. Clean, using compressed air and a soft brush, if
necessary. DO NOT prod or poke the nozzle in any way, with a metal tool.
Following a period of Storage.
Pump Pressure.
Before putting the heater back into service, following a period of storage, you
should carry out all checks previously specified. In addition, you should test and
adjust if necessary, the Air Pump Pressure, as follows:
Near the centre of the Grille, is a cut-out to accommodate the Air Pump Pressure
Relief Valve, and a plug for installing a Pressure Gauge as shown in fig. 5.
Remove the plug, and install a gauge with a resolution of at least 0.02 bar (0.3psi).
Start the heater, and observe the pressure reading, which should be as follows:
Model Air Pump Pressure
XR55 0.28 - 0.30bar (4.06 - 4.35psi)
XR75 0.26 - 0.33bar (3.84 - 4.8psi)
XR105 0.30 - 0.36bar (4.45 - 5.3psi)
XR155 0.30 - 0.39bar (4.45 - 5.7psi)
To adjust the pressure, insert an Allen key into the hex socket in the end of the Relief
Valve Adjuster, and undo the Adjuster Nut. Turn the Allen key clockwise to increase
pressure, and anticlockwise to decrease. Tighten the securing nut when the
correct pressure is reached, ensuring the Allen key does not turn in the process.
Fig. 5

11
Fuel Filter
Removal of the fuel filter should it become blocked or contaminated, and require
cleaning, involves the removal of the burner head complete. The fuel pipe,
complete with filter, may then be detached, cleaned, using a good quality
solvent, and dried with compressed air. It is recommended however, that if the
filter becomes blocked, the complete assembly - fuel pipe with filter- should be
renewed.
General
It should be noted that should the heater be used with Diesel oil or 35 second oil,
servicing will need to be more frequent, due to the fact that these fuels do not burn
as cleanly as paraffin, and some ‘sooting up’ will therefore occur.
It is recommended, that paraffin be used wherever possible
Storage
Drain all fuel from tank before storing.
1. Drain the fuel tank completely and add approximately one gallon of clean
paraffin. Attach the fuel cap and move the heater forwards and backwards
to circulate the fuel. Remove fuel cap or drain plug and drain tank completely
2. Replace fuel cap or drain plug and properly dispose of the old and dirty fuel.
3. Store the heater in a dry location free from corrosive fumes and dust.
4. Do not store kerosene over summer months for next seasons usage.

12
PARTS DIAGRAM (XR55)

13
PARTS LIST (XR55)
1Rear Guard AX1006000111
2Air Inlet Filter AX1086001711
3Cover AX1094007211
4Gasket AX1002001311
5Air Outlet Filter AX1086000111
6Plate AX1094007311
7Stator Ring AX1094008111
8Rotor Th. 17mm AX1099001611
9Blade Th. 17 Mm AX1099001511
10 Joint AX1001008211
11 Screw AX1016005011
12 Washer AX1018001600
13 Screw AX1016005100
14 Washer AX1018001600
15 Screw AX1016007700
18 Screw AX1023002511
19 Nut AX1017002111
20 Spring AX1023004211
21 Ball AX1023002411
22 Cover AX1001007736
23 Left Side Panel AX020N20
24 Screw AX1016001700
25 Screw AX1016008711
26 Fuse 3,15 A AX1035001111
27 Power Cord AX1500UKSP2
28 Rivet AX1019002800
29 Spacer AX1001015680
30 Switch Cover AX1002002755
31 Switch AX1032001900
32 Burner Control Unit AX1047003611
33 Washer AX1018000800
34 Screw AX1016010200
35 Motor Support AX1094005911
36 Fan AX1087006011
37 Lower Casing AX15911
38 Ignition Transformer AX1033003711
39 Front Disc AX1094051411
40 Filling Cap AX1094004311
41 Tank AX020MN820
42 Right Side Panel AX020C20
43 Comb. Chamber AXGRY015
44 Rubber Gasket AX1002002100
45 Flame Sensor AX1050000311
46 Upper Casing AX015MNG911
47 Handle AX1001002700
48 Motor 70 W AX1040011411
49 Capacitor AX1049001411
50 Suction Gasket AX1002005711
51 Ht Cable + Conn. AX1039033311
52 Ignition Electrode AX1030002311
53 Combustion Head AX1094077211
54 Rubber Hose AX1078000111
56 Hose Holder AX1067006011
58 Nozzle AX1088010111
59 Seeger Ring AX1018004011
60 Nozzle Holder AX1067015911
61 Oil Suction Filter AX1086004011
No. Description Part No. No. Description Part No.

14
PARTS DIAGRAM (XR75 + XR105 + XR155)

15
PARTS LIST (XR75 + XR105 + XR155)
No. Description Part No. Part No. Part No.
XR75 XR105 XR155
No. Description
1 Grille AX1001039711 AX1001039811 AX1001039911
2 Air Intake Filter AX1008100911 AX1008100911 AX1008100911
3 Air Pump End Plate AX2003162911 AX2003162911 AX2003162911
4 Gasket AX1001039611 AX1001039611 AX1001039611
5 Air Output Filter AX1001039511 AX1001039511 AX1001039511
6 Air Pump Cover AX2003162811 AX2003162811 AX2003162811
7 Air Pump Ring AX1008100711 AX1008100711 AX1008100811
8 Air Pump Rotor AX1008112511 AX1008112511 AX1008113211
9 Air Pump Blade AX1008112411 AX1008112411 AX1008100311
10 Coupling AX1001042011 AX1001042011 AX1001042011
11 Handle AX2002022211 AX2002022311 AX2002022411
12 Capacitor AX1005108900 AX1005011432 AX1005011432
13 Motor AX1005103211 AX1005103311 AX1005103411
14 Bracket AX2003174511 AX2003174611 AX2003174711
15 Bracket AX2003176311 AX2003176311 AX2003176411
16 Transformer AX1005106111 AX1005106111 AX1005106111
17 Lower Body AX2003174111 AX2003174211 AX2003174311
18 Bracket AX2003176611 AX2003176611 AX2003176611
19 Photocell AX1005105911 AX1005105911 AX1005105911
20 Fan AX1008101611 AX1008101711 AX1008101811
21 Top Cover AX2003173811 AX2003173911 AX2003174011
22 Spark Plug Cap AX1001000521 AX1001000521 AX1001000521
23 Electrode AX1005103111 AX1005103111 AX1005103111
24 Burner Head AX2003162711 AX2003162711 AX2003162711
25 Holder AX1006029111 AX1006029111 AX1006022911
26 Nozzle AX1008100511 AX1008100411 AX1008100611
27 Hose AX200202911 AX2002021011 AX2002021111
28 Screw Fitting AX1006028811 AX1006028811 AX1006028811
29 Coupling AX1006028711 AX1006028711 AX1006028711
30 Thermostat AX1005107911 AX1005107911 AX1005107911

16
31 Cable AX2005002000 AX2005002000 AX2005002000
32 Combustion Chamber AX2003173511 AX2003173611 AX2003173711
33 Air Diffuser AX2003135211 AX2003135411 AX2003135611
34 Fuel Tank AX2003176511 AX2003177511 AX2003176711
35 Wheel End Cap AX1004047911 AX1004048011 AX1004048011
36 Wheel AX1001040111 AX1001040211 AX1001002000
37 Washer AX1004050511 AX1004050511 AX1004050411
38 Axle AX2002022511 AX2002022611 AX2002022711
39 Fuel Cap AX1006029811 AX1006029811 AX1006029811
40 Lower Frame AX2002021411 AX2002022111 AX2002021511
41 Cable AX1005102600 AX1005102600 AX1005102600
42 Instrument Panel AX2003177211 AX2003177911 AX2003178011
43 Cable Cover AX1005001021 AX1005001021 AX1005001021
44 Switch Cover AX1005092955 AX1005092955 AX1005092955
45 Switch AX1005092855 AX1005092855 AX1005092855
46 Fuse Carrier AX1005099600 AX1005099600 AX1005099600
47 Fuse AX1005002700 AX1005002700 AX1005002700
48 Cover AX1001040411 AX1001040411 AX1001040411
49 Terminal Block (12 pole) AX1005002400 AX1005002400 AX1005002400
50 PCBoard AX1014064311 AX1014064311 AX1014064311
51 Flame Control Board AX1005106011 AX1005106011 AX1005106011
52 Nut AX1004051011 AX1004051011 AX1004051011
53 Plug # # #
54 Drain Plug # # #
55 Screw AX1004049811 AX1004049811 AX1004049811
56 Spring AX1008101111 AX1008101111 AX1008101111
57 Ball AX1004049711 AX1004049711 AX1004049711
58 Blanking Plate # # #
59 Blanking Plate Screw # # #
- Clarke Labels /Decals # # #
Part No. Part No. Part No.
XR75 XR105 XR155
No. Description
cont.
#...See your Clarke dealer

17
TROUBLE-SHOOTING
FAULT CAUSE REMEDY
Motor does not start 1. No power 1. Check power supply, power
cable and fuse, and replace
if necessary. Check External
Thermostat if fitted.
2. Faulty Motor/Capacitor 2. Check and if necessary,
replace
3. Lock out of appliance 3. Detect cause of overheating.
due to overheating. Check air inlet and outlet.
Wait for 5 minutes, and
restart. If condition persists
contact your Clarke dealer
4. Internal Fuse Blown 4. Check an replace fuse
Motor runs, but the 1. Empty fuel tank, dirty or 1. Drain dirty or wrong fuel,
heater does not ignite. wrong fuel. clean filter and fill with clean
paraffin or equivalent.
2. Fuel filter clogged 2. Clean or replace fuel filter
3. Air leaks in fuel line 3. Check pipes, tighten
connections, if necessary
replace pipe.
4. Burner nozzle Clogged 4. Clean nozzle with compressed
air. Replace if necessary
5. Oil viscosity increased due 5. Mix with 10-20% paraffin.
to low temperature.
Flames emitted from 1. Insufficient air flow into 1. Check air inlet is not blocked.
Air Outlet combustion chamber. Check fan is not damaged
and is operating correctly.
2. Pump pressure too high. 2. Check air pump pressure,
and reduce to nominal value.
Heater starts normally, 1. Dirty photocell 1. Check photocell and ensure
but flame-out control it acknowledges the flame.
system shuts off the (Contact your Clarke dealer)
2. Faulty photocell 2. Replace photocell.
3. Defective connection 3. Check, and connect
between photocell and properly.
flame-out control
4. Faulty flame-out control 4. Check and replace if
necessary.

18
Please note that the details and specifications contained herein, are correct at the
time of going to print. However, CLARKE International reserve the right to change
specifications at any time without prior notice. Always consult the machine’s data
plate
SPECIFICATIONS
XR55 XR75 XR105 XR155
Thermal Power (kW) 19.0 26.7 40.7
Thermal Power
(BTU/hr) 51,000 79,000 96,000 150,000
Air Delivery (m3/hr) 400 500 1050
Fuel Cons. (Paraffin -
ltr/hr - approx.) 2.3 2.8 4.3
Tank Capacity 11 L 21 L 30 L 46 L
Motor Voltage 230V 50Hz 230V 50Hz 230V 50Hz 230V 50Hz
Power - Watts 100 150 250
Current Rating
(Input) - Amps 0.68 0.95 2
Length (mm) 805 800 860 920
Width (mm) 350 420 460 560
Height (mm) 345 430 530 615
100
15
350
0.6
1.5

19
DECLARATION OF CONFORMITY