Clarke XR80 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0618 - ISS 5
ORIGINAL INSTRUCTIONS
DIESEL/PARAFFIN HEATERS
MODEL NO: XR80, XR110, XR160, XR210
PART NO: 6931004, 6931006, 6931008, 6931012

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INTRODUCTION
Thank you for purchasing this CLARKE product.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully..
This is a forced air unit, where a fan pushes the air through the heater body.
Proper combustion depends upon this air flow; therefore, the heater must not
be, modified or operated with parts removed or missing. Likewise, safety
systems must not be circumvented or modified in order to operate the heater.
FUNCTION AND OPERATING PARAMETERS
This is a multi-fuel (Diesel or Paraffin), forced air heater. It’s intended use is for
drying and the warming of commercial/industrial buildings where adequate
ventilation is provided.
• It must be operated as prescribed in the operating manual.
• Is not intended to be used for domestic use or for the heating of
habitable areas.
• Is not intended to be used to reach and maintain a certain level of
human thermal comfort within an enclosed space in which the heater is
situated.
• Is not intended to be used in enclosed areas with restricted ventilation.
• Is not for use in areas with high levels of fluctuating drafts.
• Is not intended for warming animals or live stock.
SAFETY SYMBOLS
The following symbols appear on the unit.
Hot Surface, do not
touch
High Voltage

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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.
SAFETY WARNINGS
Your safety is important to you and to others, so please read these instructions
before you operate this heater.
1. Failure to comply with the precautions and instructions provided with this
heater can result in death, serious bodily injury and property loss or
damage from the hazards of fire, explosion, burns, asphyxiation, carbon
monoxide poisoning, and/or electric shock.
2. Only persons who understand and follow the instructions should use or
service this heater.
3. When used, the heater should rest on a suitable insulating material at least
1” thick and extending 3 feet or more beyond the heater in all directions
4. Not for home or recreational vehicle use.
5. Do not use petrol or volatile fuels.
6. Disconnect the heater from the power supply before adding fuel.
7. Always re-fuel outdoors away from any open flame or other sources of
ignition.
8. Do not use an external fuel source.
9. Do not use the heater where flammable liquids or vapours may be present.
10. Do not start the heater when the chamber is hot.
11. Plug the electrical cable into a properly grounded mains socket.

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GENERAL PRECAUTIONS
VENTILATION
Even though this heater operates very close to 100 percent combustion
efficiency, it still produces small amounts of carbon monoxide.
Carbon monoxide (CO) is toxic.
CO can build up in a confined spaces and failure to provide adequate
ventilation can be fatal.
The early symptoms of asphyxiation caused by inadequate ventilation are:
Be sure to follow all warnings in this manual.
WE RECOMMEND THE USE OF A CARBON MONOXIDE
DETECTOR
BYSTANDERS
When the heater is to be operated in the presence of other people the user is
responsible for informing those present of the safety precautions and of the
hazards involved.
• headache • nausea
• dizziness • dry mouth or sore throat

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ELECTRICAL CONNECTIONS
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved BS1363/A plug fitted with a BS1362 13 amp fuse.
If the plug has to be changed because of damage, it must be removed and a
replacement fitted, following the wiring instructions shown below. The old plug
must be discarded safely, as insertion into a power socket could cause an
electrical hazard.
• The BLUE wire must be
connected to the
terminal which is
marked N or coloured
black.
• The BROWN wire must
be connected to the
terminal which is
marked L or coloured
red.
• The YELLOW AND
GREEN wire must be
connected to the terminal which is marked E or or coloured green.
We strongly recommend that this machine is connected to the mains supply
through a Residual Current Device (RCD)
If you are not sure, consult a qualified electrician. DO NOT try to do any
repairs.
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.
WARNING: WIRES IN THE MAINS LEAD ARE COLOURED IN
ACCORDANCE WITH THE FOLLOWING CODE:
GREEN/YELLOW = EARTH, BLUE = NEUTRAL, BROWN = LIVE.
Plug must be BS1363/A approved.
Always fit
Ensure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
Earth
(Green and
a 13 Amp
the cable is firmly held by the clamp
fuse.
Yellow)

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SAFETY PRECAUTIONS
1. Check the heater thoroughly for damage. Never operate a damaged
heater.
2. This heater is for indoor use only.
3. Use in well ventilated spaces and provide at least 2 sq. ft. (0.19 sq.m.) of air
opening near the floor and 2 sq. ft. (0.19 sq. m.) near the ceiling directly to
outdoors. Increase air openings for each additional heater.
4. Always keep combustibles, like paper and wood at least 8 ft. (2.4 m) from
the front of the heater and 3 ft. (1 m) from the top, sides and rear.
5. Locate the heater10 ft. (3 m) from canvas or plastic coverings and secure
them to prevent movement.
6. Make sure that the heater is not directly exposed to rain or water spray.
7. Never use in living spaces and/or where children may be present.
8. Operate on a stable, level surface.
9. Do not use with ductwork. Do not restrict air inlet or exit.
10. Do not move or service the heater while hot or in operation.
11. Use only in accordance with local regulations and relevant building codes.
12. The heater is not to be used by children or persons with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge.
13. If the supply cable is damaged, it must be replaced by the manufacturer,
its service agent, or similarly qualified persons in order to avoid a hazard.
UNPACKING
1. Remove heater from carton.
2. Remove all protective material which may have been applied to the
heater for shipment.
CAUTION: DUE TO THE HIGH SURFACE AND EXHAUST TEMPERATURES,
ADULTS AND CHILDREN MUST KEEP CLEAR OF THE UNIT TO AVOID BURNS
OR CLOTHING IGNITION.

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ASSEMBLY
1. Pass the axle through the wheel
frame as shown
2. Place a spacer onto each end.
3. Place a wheel on to each end.
4. Place a flat washer onto each
end
5. Secure everything in place by
inserting a split pin into the small
hole at the end of the axle.
6. Place the handle into position
and secure using four 50 mm bolts
and nuts provided (2 each side).
7. Place the wheel assembly into
position and secure using four
30 mm bolts and nuts provided (2
each side).

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PREPARATION
FUELS
Diesel or paraffin are the only fuels that should be used in this heater.
FILLING THE FUEL TANK
IMPORTANT: Before filling the fuel tank the first time or after extended
storage periods, drain the fuel tank of any moisture or condensation.
1. Follow all of the “Safety Precautions”.
2. Remove the fuel cap.
NOTE: If you lose the fuel cap a
replacement must be
obtained before use, this is
available from your local
Clarke service department
part number GF0K070000.
3. Fill the fuel tank with clean diesel
or paraffin.
• In cold weather, condensation
may develop in the tank if the tank is empty and it is recommended
that a tablespoon of de-icer be added for each gallon of fuel in the
tank.
• When filling the heater, make sure that the heater is level and do not
overfill. Use a funnel or can with a long fill spout.
• Fill with a minimum of 4 litres of fuel.
LOCATION
• Locate heater at a safe distance from combustible materials.
• When used, the heater should rest on suitable insulating material at
least 1 inch thick and extending 3 ft. or more beyond the heater in
all directions.

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OPERATING INSTRUCTIONS
HEATER START UP
1. Make sure power switch is in the
OFF position.
2. Turn thermostat to lowest setting.
3. Plug the heater into the mains
power supply.
4. Turn the thermostat to highest
setting.
5. Start heater by setting the power
switch to the ON position.
• The switch illuminates in the ON position.
6. Adjust thermostat to desired setting.
NOTE: Heater will cycle on/off as heat is required.
HEATER SHUT DOWN
1. Set the power switch to the OFF
position.
2. For extended shutdown, unplug
the heater from the mains supply.
BEFORE STORAGE
• Clean the heater as described
in the MAINTENANCE section.
• We recommend completely
filling the tank with fuel for
extended storage to minimize condensation inside the tank.

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MAINTENANCE, STORAGE AND SERVICING
DAILY SCHEDULE
GENERAL
1. Make a general visual inspection of the heater for loose or damaged parts.
2. Check nuts and bolts are secure.
3. Damaged parts should be repaired or replaced before using the heater
again.
4. Check heater operation to be sure it is operating normally as follows:
• The flame is contained within the heater.
• The flame is essentially yellow.
• There is no strong disagreeable odor, eye burning or other physical
discomfort.
• There is no smoke or soot internal or external to the heater.
• There are no unplanned or unexplained shut downs of the heater
REMOVE DUST
Clean the heater twice a season (more often under dusty conditions).
1. Remove accumulated dust from the transformer, burner, motor and fan
blades with compressed air.
2. Wipe clean with a clean dry cloth.
FUEL TANK (EVERY 500 HOURS)
Clean twice a season (during frequently used periods, clean twice a month).
Drain and flush the fuel tank with clean fuel.
The XR160 and XR210 has a rubber
drain plug (part number
GF125KT240000) on the bottom of the
tank. Place a suitable container
beneath the drain plug and pull out
the plug, replace the plug before
filling the tank again.
WARNING: TO PREVENT PERSONAL INJURY, UNPLUG THE HEATER FROM
THE MAINS SUPPLY BEFORE SERVICING.

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FILTERS
Dirty air filters will cause an imbalance in the air-fuel mixture. The best
indication that this condition exists is an increase in odour or difficulty getting
your heater to ignite. This heater should never be operated without the filters in
place. If required, clean the filters as follows.
ACCESSING THE FILTERS
1. Make sure that the plug is removed from the power supply before carrying
out any maintenance.
2. Remove the six screws shown and
remove the top cover of the
heater.
NOTE: There may be eight screws on
the larger models.
3. Lift out the rear guard.
4. Remove the 3 screws securing the
filter cover.
5. Pull the filter cover away from the
motor.

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AIR INTAKE FILTER CLEANING
6. To clean the air intake filter.
• Remove and wash the filter
element with a mild detergent.
• Dry thoroughly and refit.
• Do not oil the filter element. If
your heater is used where there
is considerable dust or dirt.
• Clean as often as necessary (at
least approximately every 500
hrs.).
NOTE: If the filter is damaged or extremely dirty, a replacement filter of the
same type must be fitted, this is available from your local Clarke service
department part number GF50K100406.
AIR OUTPUT FILTER CLEANING
7. To clean the air output filter (Annually or as required)
• Remove the air output filter and tap the contaminated side gently
on a solid object to remove contaminates.
NOTE: Compressed air or liquids should not be used to clean this filter.
NOTE: If the filter appears damaged or extremely dirty, replace it with a new
filter of the same type must be obtained and fitted this is available from
your local Clarke service department part number GF50K100401.
8. Reinstall clean filter in to the filter body in the same position as it was when
removed.
9. Replace the filter cover and secure using the screws removed in step 4.
NOTE: When replacing the filter cover, make sure that the gasket is firmly in
place and the screws in the filter cover are tight to prevent air leaks. if
the gasket is damaged a replacement must be obtained and fitted
this is available from your local Clarke service department part number
GF50K100407.
10. Refit the rear guard and replace the top cover.
11. Make sure all screws are replaced before use.
STORAGE
Store the heater in a dry location free from fumes or dust.

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TROUBLE SHOOTING
LED OPERATION TROUBLE SHOOTING
Steady ON System
Check
System performing self test. No action required.
Steady
OFF
No action required.
2 Flashes No flame
detected
Heater fails to start.
1. Check fuel level
2. Check the mains plug is correctly fitted and that the
fuse inside it has not blown.
3. Return to Clarke service department for repair.
3 Flashes High limit
switch failure
(unit has
overheated)
Make sure heater is cooled down,
1. Make sure that the power switch is set to the OFF
position.
2. Wait 5 minutes
3. Start heater by setting the power switch to the ON
position.
4 Flashes Flame sensor
Failure
Return to Clarke service department for repair.

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SPECIFICATIONS
WIRING DIAGRAM
Model XR80 XR110 XR160 XR210
Burn Rate: (Btu/hr.) 70,000 100,000 160,000 210,000
Fuel consumption: 1.9 L/hr. 2.8 L/hr. 4.16 L/hr. 3.91L/hr.
Approx Running Time: 11.9 hr 11.4 hr 12.7 13.5
Electrical input: 230V ~50Hz
Power 165 W 204 W 279 W 307W
Max.Outlet Temp: 1300°F (704°C)
Fuel Tank Capacity: 22.7 L 32 L 53 L 53 L
Ignition system: Electric Ignition
Primary Safety Control: Flame failure device
Weight (kg) 17.6 19.85 26.1 26.2
Dimensions (DxWxH) mm 830 x 410 x 648 905 x 413 x 700 1045 x 528 x 692 1030 x 523 x 692

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DECLARATION OF CONFORMITY