Clarke XRV100 Troubleshooting guide

OPERATION & MAINTENANCE
INSTRUCTIONS
Rev a: 1003
MODEL NO: XRV100
PART No: 6920291
PARAFFIN/DIESEL HEATER
PARAFFIN/DIESEL HEATER

-1- -14-
Thank you for purchasing this CLARKE, Paraffin/Diese fired Space Heater.
This portab e heater is designed for industrial applications only . As with a
mechanica equipment, optimum performance wi on y be achieved if the
correct app ication and servicing procedures are fo owed. P ease read this
manua thorough y and fo ow the instructions carefu y before attempting to use
the heater. In doing so you wi ensure the safety of yourse f and that of others
around you, and you can ook forward to it giving you ong and re iab e service.
Guarantee
This CLARKE product is guaranteed against fau ty manufacture for a period of 12
months from the date of purchase. P ease keep your receipt as proof of
purchase. This guarantee is inva id 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.
Fau ty goods shou d be returned to their p ace of purchase, no product can be
returned to us without prior permission. This guarantee does not effect your
statutory rights.
Contents PAGE
Safety Precautions ......................................................................... 2
E ectrica Connections................................................................... 3
Assemb y ......................................................................................... 4
Insta ation ....................................................................................... 5
Operation..................................................................................... 6-7
Starting Procedure ......................................................................... 7
Maintenance ............................................................................... 8-9
Specifications ............................................................................... 10
Troub e Shooting........................................................................... 11
Parts Diagram ............................................................................... 12
Parts List ....................................................................................13-14
Parts List
37 AXCAVALEUR1500UKSP2 Power Cord inc P ug 1
38 AXCRUSCGRYP#025F20 Left Side Pane 1
39 AX1016001600 Screw 4
42 AX1035001211 Fuse 5A 1
43 AX1001007736 Cover 1
44 AX1047003711 Contro Board 1
45 AX1002005711 Gasket 1
46 AX1002002100 Rubber Gasket 1
47 AX1023002411 Ba 1
48 AX1023004511 Spring 1
49 AX1023002511 Screw 1
50 AX1017002111 Nut 1
51 AX1067006911 Cap 1
52 AX1067007000 Drain cap 1
53 AXCRUSCGRY028C20 Right Side pane 1
56 AX1002001111 Nozz e Gasket 1
57 AX1023004111 Spring 1
58 AX1018001311 Washer 4
59 AX1001014711 Suction Fitting 1
60 AX1078000411 Rubber Hose L=200mm 1
61 AX1067005800 Hose Connector 2
62 AX1042003611 So enoid Va ve 1
63 AX1094078411 Exhaust Hood 1
64 AX1001015680 Spacer 6
65 AX1032001900 Switch 1
66 AX1002002755 Switch Cover 1
67 AX1043000600 Socket Casing 1
68 AX1043000400 Socket 1
69 AX1052001800 Banking P ug 1
PARTS & SERVICE TEL: [phone]
or e-mail as follows:
PARTS: Parts clarkeinternational.com
SERVICE: Service clarkeinternational.com

Safety Precautions
WARNING!
Lack of ventilation can cause Carbon Monoxide poisoning.
CARBON MONOXI E CAN KILL
Signs of Carbon Monoxide poisoning are, headaches, dizziness and/or nausea.
Shou d 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 ung condition, anaemia or under the
inf uence of a coho , or those at high a titudes, are more ike y to be effected by
Carbon Monoxide than others.
Read, and make sure you fu y understand the fo owing precautions and the
hazards associated with this type of equipment.
 Ensure the app iance is proper y earthed.
 Use ONLY c ean paraffin or Diese Oi .
 Use ONLY with the e ectrica vo tage specified
 Use ONLY in we venti ated areas. Provide fresh air venti ation of at east 3 ft
2
for every 100,000 BTU/ hr of rating.
 Use heater in accordance with a fire regu ations.
 Keep chi dren and anima s away from heater at a times.
 The minimum c earance from any combustib e materia s is 300cm from hot air
out et, 60cm from the sides and f ue, and 150cm from the top.
 Maintain the heater on a stab e, eve surface whi st hot or operating, or a fire
cou d occur.
 Store the heater in a eve position when fi ed, or fue eakage may occur.
 When used with a thermostat, bear in mind, the heater may start at anytime.
 NEVER use the heater where Gaso ine, Paint thinners or other high y f ammab e
vapours or high dust content is present.
 NEVER use Gaso ine, Naphtha, Paint thinners, A coho or other high y
f ammab e fue s.
 NEVER use heater in iving or s eeping areas.
 NEVER eave a heater p ugged in without adu t supervision if chi dren or
anima s are ike y to be present.
 NEVER move, hand e, refue or service the heater when it is hot, operating or
p ugged in.
 NEVER cover or impede air f ow into or out of heater.
 NEVER attach duct work to the front of heater.
 Disconnect the heater from the power supp y when not in use.
Parts List
Item No Part No Description ty
1 AX1006000311 Rear Guard 1
2 AX1086001711 Air In et Fi ter 1
3 AX1094007311 Compression P ate 1
4 AX1002001311 Gasket 1
5 AX1086000111 Air Out et Fi ter 1
6 AX1094007211 Cover 1
7 AX1094008211 Stator Ring 1
8 AX1099001811 Rotor 1
9 AX1099001411 Bade 4
10 AX1001008311 Screw 1
11 AXMANTGRY4020 Hand e 1
12 AX1040005611 Motor 230vo t 50hz 1
13 AX1094006111 Motor Bracket 1
14 AX1033004111 Ignition Transformer 1
15 AX1094077811 Lower Casing 1
16 AX1094013111 Bracket 1
17 AX1050000311 F ame Sensor 1
18 AX1087006111 Impe or 1
19 AX1094078011 Upper Casing 1
20 AX1039033211 HT Cab e 1
21 AX1030001111 Ignition E ectrode 1
22 AX1094007111 Combustion Head 1
23 AX1067006011 Hose Connector 1
24 AX1088005711 Nozz e 1
25 AX1078000211 Hose L=170mm 1
26 AX1078001611 Hose L=230mm 1
27 AX1086001911 Oi Fiter 1
28 AX1036001611 Safety Thermostat 1
29 AX1043002655 Cab e + Connector 1
30 AXCAMERAGRY025 Combustion Chamber 1
31 AXSERBGRYP040STD20 Tank 1
32 AX1022000911 End Cap 2
33 AX1004000200 Whee 200mm Ø 2
34 AXASSALEGRY4001 Ax e 1
35 AX1094004311 Fi er Cap 1
36 AXTELAIOTGRY04020 Frame 1
-13- -2-

Electrical Connections
Connect the mains ead to a standard, 230 Vo t (50Hz) e ectrica supp y through an
approved 13 amp BS 1363 p ug, or a suitab y fused iso ator switch.
WARNING! THIS APPLIANCE MUST BE EARTHE
IMPORTANT: The wires in the mains ead are co oured in accordance with the
fo owing code:
Green & Ye ow - Earth
B ue - Neutra
Brown - Live
As the co ours of the f exib e cord of this appiance may not correspond with the
co oured markings identifying termina s in your p ug proceed as fo ows:
Connect GREEN & YELLOW cord to termina marked with a etter E or Earth
symbo   or co oured GREEN or GREEN & YELLOW.
Connect BROWN cord to termina marked with a etter L or co oured RED
Connect BLUE cord to termina marked with a etter N or co oured BLACK
If this app iance is fitted with a p ug which is mou ded onto the e ectric cab e (i.e.
non-rewirab e) p ease note:
1. The p ug must be thrown away if it is cut from the e ectric cab e. There is a
danger of e ectric shock if it is subsequent y inserted into a socket out et.
2. Never use the p ug without the fuse cover fitted.
3. Shou d you wish to rep ace a detachab e fuse carrier, ensure that the correct
rep acement is used (as indicated by marking or co our code).
4. Rep acement fuse covers can be obtained from your oca dea er or most
e ectrica stockists.
We recommend that this machine is connected to the mains supp y through a
Residua Current Device (RCD).
Fuse Rating.
The fuse in the p ug must be rep aced with one of the same rating ( 13 amps ) and
must be ASTA approved to BS1362.
Do not attempt any electrical repairs yourself unless fully competent. If in doubt,
consult a qualified electrician.
Parts Diagra
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Wiring Diagram.
FC Photoce FS Fuse 5A
S/W Switch M Motor
TR Transformer TS Safety Thermostat
CF F ame Contro LC EMC Fi ter
Asse bly (Item Nos in brackets a so refer to parts ist on pages (13-14)
Unpack and check the heater for possib e shipping
damage or missing items. If any damage/missing items is
found, immediate y notify your CLARKE dea er where the
heater was purchased.
1. Hand e (11)
2. Whee Support Frame (36)
3. Whee s - 2 pcs (33)
4. Ax e (34)
5. End Caps - 2 PCs (32)
6. Exhaust Hood (63)
6. Screws, nuts and washers 6 sets (X)
To assemb e the heater, proceed as fo ows.
S ide the ax e (34) through the whee support
frame (36). S ide the whee s onto the ax es and fit the
end caps (32) by tapping them on using a soft faced
ma et or simi ar. DO NOT use a meta hammer as this wi
damage the caps.
P ace the heater on the whee support frame with the air out et end over the
whee s, ine up the fixing ho es on the fue tank and whee support frame, p ace the
hand e on the tank and ine up the fixing ho es. Fit screws, washers and nuts (X), DO
NOT tighten nuts unti a screws etc. are in p ace.
Fit the exhaust hood (63), IMPORTANT, the hood is a push fit, must a ways be fitted
even if it is not intended to duct the heater to the outside. It may be necessary to
ease the hood on to the heater due to manufacturing differences in shape.
Fig.1
Troubleshooting
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. aulty Motor/Capacitor. 2. Check and if necessary,
replace.
3. Lock out of appliance
due to overheating. 3. Detect cause of overheating. Check air inlet and outlet.
Wait for 5 minutes, and restart.
If condition persists contact
your Clarke dealer.
4. Internal use Blown. 4. Check and replace fuse.
Motor runs, but the
heater does not ignite. 1. Empty fuel tank, dirty or wrong fuel. 1. Drain dirty or wrong fuel, clean filter and fill with clean
paraffin or equivalent.
2. uel 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
to low temperature. 5. Mix with 10-20% paraffin.
lames emitted from
the flue. 1. Insufficient air flow into combustion chamber. 1. Check air inlet is not blocked. 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,
but flame-out control
system shuts off the
heater.
1. Dirty photocell. 1. Check photocell and ensure
it acknowledges the flame.
(Contact your Clarke dealer)
`2. aulty photocell. 2. Replace photocell.
3. Defective connection
between photocell and
flame-out control.
3. Check, and connect
properly.
4. aulty flame-out control. 4. Check and replace if
necessary .
FAULT CAUSE REMEDY
-11- -4-

Installation
The XRV 100 is designed with a fume exhaust system, a owing it to be ducted to the
outside using suitab e 410mm/5½ducting (not supp ied).
When the heater is insta ed in a c osed environment, with fume venting to the
outside through a duct, an externa air de ivery of approx. 80 m³/h must be assured
for good combustion.
If the heater is insta ed in a c osed environment and fumes are not vented through
a duct, good venti ation of the environment MUST be assured.
To obtain a draught of at east 0.1mbar in the f ue, the f ue MUST rise vertica y for
3m minimum before adding any bends etc.
See Fig. 2 for examp es of how and how not to duct the heater.
For the heater to operate efficient y, adequate venti ation, providing a supp y of
fresh air of at east 260 m²/kw, is necessary.
When using the heater, the safety regu ations in force at the time must be adhered
to. In particu ar, the safety distances from f ammab e materia s shoud be taken into
consideration.
Sides and Flue: 0.60m Air intake End: 0.60m
Top: 1.50m Air Outlet End: 3.00m
IMPORTANT
Before installing fume extraction system, always check with local building and
fire authorities to ensure local regulations are adhered to.
Fig.2
Fuel Filter.
Remova of the fue fi ter shou d it become b ocked or contaminated, and require
c eaning, invo ves the remova of the burner head comp ete. The fue pipe,
comp ete with fi ter, may then be detached, c eaned, using a good qua ity
so vent, and dried with compressed air. It is recommended however, that if the
fi ter becomes b ocked, the comp ete assemb y - fue pipe with fi ter- shou d be
renewed.
General.
It shou d be noted that shou d the heater be used with Diese oi , the interva
between servicing wi be ess, due to the fact that Diese does not burn as c ean y
as paraffin, and some sooting up wi therefore occur.
It is recommended, that paraffin be used wherever possib e
Storage.
Drain a fue from tank before storing.
1. Drain the fue tank comp ete y and add approximate y one ga on of c ean
paraffin. Attach the fue cap and rock the heater backwards and forwards
to circu ate the fue . Remove fue cap or drain p ug and drain tank comp ete y
2. Rep ace fue cap or drain p ug and proper y dispose of the o d and dirty fue .
3. Store the heater in a dry ocation free from corrosive fumes and dust.
4. Do not store paraffin over the summer months for next seasons usage.
Specifications
Thermal Power (BTU/hr) 89,000 Btu/hr
Air Flow 900 m
3
/hr
Fuel Diesel / Paraffin
Tank Capacity 46 Litres
Fuel Consumption. 2.2 kg/h (2.6 lt/hr)
Motor Voltage 230v 50Hz
Power Input 390W (Total) 250 W (Motor)
Current Rating 2.00 A
Length (mm) 930mm
Width (mm) 560mm
Height (mm) 750mm (inc exhaust hood)
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 witho t prior notice.
Always cons lt the machines data plate
-5- -10-

Operation
Understanding the basic operation of the heater, wi reinforce the need to
maintain the unit in top condition at a times, whi st always observing the safety
precautions.
The heater comprises four basic systems:
1. The fue system. 3. The ignition system.
2. The air system. 4. The safety contro system.
1. The Fuel System .
Fue is he d 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 fiter, compresses it, and forces it
through a second fi ter, and via an air ine, directy to the burner head nozze. The speed of
the air over the nozz e, causes a depression. Fue is therefore forced up the tube by
atmospheric pressure, through a fiter, and out of the nozze in the form of a spray.
It is important to ensure that the vent in the fi er cap is not bocked at any time, otherwise
fue wi not reach the nozze.
This heater is capable of burning Paraffin or iesel oil. NEVER use petrol.
Fig.3
. The Air System .
Additiona air is supp ied 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 a ow a portion of this air to be drawn into the combustion chamber, where it
mixes with the air and fue from the nozz e, and ensures that a the fue is burned,
preventing the emission of b ack smoke. The remaining air is directed around and over
Bi-Monthly.
Fan.
Having removed the top cover, thorough y c ean the fan using a c oth moistened
with paraffin or ight so vent, and dry using an air ine if possib e.
Output Air Filter.
Remove the gri e, and pu off the Intake Air Fi ter, revea ing the 3 screws securing
the fi ter housing. Remove the screws and pu off the housing to revea the Output
Air Fi ter. If contaminated, this fi ter must be renewed.
In dirty environments this procedure shou d be carried out month y.
Nozzle.
Having removed the top cover, gent y unscrew and remove the burner head,
and unscrew the nozz e. C ean, using compressed air and a soft brush, if
necessary. DO NOT prod or poke the nozz e in any way, with a meta too .
Following a period of Storage.
Fig. 6
Pump Pressure.
Before putting the heater back into
service, fo owing a period of storage, you
shou d carry out a checks previous y
specified. In addition, you shou d test and
adjust if necessary, the Air Pump Pressure,
as fo ows:
Near the centre of the Gri e, is a cutout to
accommodate the Air Pump Pressure
Re ief Va ve, and a p ug (Fig. 6) for insta ing
a Pressure Gauge.
Remove the p ug, and insta a gauge with
a reso ution of at east 0.02 bar (0.3psi). Start the heater, and observe the pressure
reading, which shou d be as fo ows:
To adjust the pressure Loosen the pressure re ief va ve adjuster nut whi st ho ding
the va ve adjuster using a suitab e f at b aded screwdriver. Turn the adjuster
c ockwise to increase pressure, and antic ockwise to decrease. Tighten the
securing nut when the correct pressure is reached, ensuring the adjuster does not
turn in the process.
IMPORTANT:
T he use of parts other than CLARKE replacement parts may result in safety hazards,
decreased tool performance and may invalidate your arranty.
-9- -6-

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 fue tank is fi ed with c ean diese /paraffin, before p ugging in to a
suitab y earthed supp y.
Observing a precautions previous y stated, push The start switch - I ocated on
the eft side of the machine.
Using the heater with an environment (room) thermostat (not supp ied), remove
the b anking p ug (A Fig.4) from the thermostat socket (B Fig.4) and insert the
thermostat.
Store B anking p ug safe y and re-fit if room thermostat is removed.
AB
Fig.4
the combustion chamber, unti it fina y mixes with the heated air from the combustion
chamber, and is ejected as a jet of cean hot air.
3. The Ignition System.
A constant arc is struck between the e ectrodes, which ignites the air and fue
mixture. It is important that the e ectrode gap is correct y maintained, otherwise
arcing wi not take p ace...see Maintenance.
4. The Safety Control System.
A ight sensitive photo ce (f ame sensor) trips the motor if the f ame goes out for
any reason, causing the heater to shut down.
Set the environment thermostat to maximum temperature.
Switch the heater ON by pressing the ON/Off switch, (I position).
Adjust the environment thermostat to the required temperature.
Maintenance (Item Nos in brackets, ref to Parts List on page 12)
IMPORTANT
Before carrying out any adjustment or maintenance, ensure the heater is
switched OFF, disconnected from the mains supp y, and has been given
adequate time to coo down, un ess otherwise stated.
It is essentia that the heater is correct y maintained and kept in top condition at a
times.
Those items requiring regu ar maintenance comprise,
1. Intake Air Fi ter (Item 2)
2. Output Air Fi ter (Item 5)
3. Fan (Item 18)
4. Fue Nozz e (Item 24)
5. Ignition E ectrodes (Item 21)
6. Fue Fi ter (Integra part of item 27)
The Intake and Output Air Fi ters, are accessib e by removing the Gri e (by
removing the sing e phi ips head screw Fig. 8), whereas accessibi ity to the
remaining items requires the remova of the top cover (by removing the six screws
at the centre joint).
Monthly.
Intake Air Filter.
Pu off the Intake Air Fi ter, which ies direct y behind the Gri e, and wash in a ight
detergent. Thorough y dry before reinsta ing.
In dirty environments it may be necessary to carry out this procedure week y.
Never a ow the fi ter to get b ocked.
Ignition Electrodes.
Having removed the heaters
top cover, remove the sing e
screw retaining the e ectrode
ho der. Withdraw the ho der,
c ean and adjust the gap
between the e ectrodes, to
4mm.
When reinsta ing the e ectrode ho der, there must be a gap of 9mm between the
e ectrodes and the nozz e (see fig. 5). If this adjustment needs to be reset, it is
preferab e to remove the burner head comp ete, by removing the securing
screws around its edge, taking care not to damage the photoce . The e ectrodes
may then be adjusted to their correct c earance before rep acing the Burner
Head.
Fig. 5
-7- -8-