Sealey SAC2203BLN.V2 User manual

INSTRUCTIONS FOR
LOW NOISE BELT DRIVE COMPRESSOR
MODEL NO: SAC2203BLN.V2
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these instructions,
and properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE
THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR
PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
1. SAFETY
1.1. ELECTRICAL SAFETY
WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following: You must check
all electrical products, before use, to ensure that they are safe. You must inspect power cables, plugs, sockets and any other connectors
for wear or damage. You must ensure that the risk of electric shock is minimised by the installation of appropriate safety devices.
A Residual Current Circuit Breaker (RCCB) should be incorporated in the main distribution board. We also recommend that a Residual
Current Device (RCD) is used. It is particularly important to use an RCD with portable products that are plugged into a supply which is
not protected by an RCCB. If in any doubt consult a qualified electrician. You may obtain a Residual Current Device by contacting your
Sealey dealer. You must also read and understand the following instructions concerning electrical safety.
1.1.1. The Electricity at Work Act 1989 requires that all portable electrical appliances, if used on business premises, are tested
by a qualified electrician, using a Portable Appliance Tester (PAT), at least once a year.
1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of those
appliances and the safety of the appliance operators. If in any doubt about electrical safety, contact a qualified electrician.
1.1.3. Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.1.1. and use a
Portable Appliance Tester.
1.1.4. Ensure that cables are always protected against short circuit and overload.
1.1.5. Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure that none is loose.
1.1.6. Important: Ensure that the voltage marked on the appliance matches the power supply to be used and that the plug is fitted
with the correct fuse.
8DO NOT pull or carry the appliance by the power cable.
8DO NOT pull the plug from the socket by the cable.
8DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty item repaired or replaced by a
qualified electrician.
1.1.7. Twin capacitors and a centrifugal switch aid trouble free starting on a good 13amp supply. In some cases a 16amp supply may be
required and we recommend that a 16amp industrial round pin plug should be fitted and connected to a 20amp supply having a Type C
breaker. If in doubt you must contact a qualified electrician to ensure that a suitably rated supply is available.
IMPORTANT! The use of extension leads to connect these compressors to the mains is not recommended as the resulting voltage
drop reduces motor, and therefore pump performance.
1.2. GENERAL SAFETY INSTRUCTIONS
9Familiarise yourself with the application and limitations of the compressor.
9Ensure the compressor is in good order and condition before use. If in any doubt DO NOT use the unit and contact an electrician/service
agent.
WARNING! Compressor must only be serviced by an authorised agent. DO NOT tamper with, or attempt to adjust the pressure switch or
safety valve.
SAC2203BLN.V2 Issue 2 (H, 3, F) 09/07/18
Original Language Version
© Jack Sealey Limited
Refer to
instruction
manual
Warning:
Hot surface
Warning:
Electricity
Wear ear
protection
Warning:
Automatic
startup
1
5
346
fig.1
1. Direct compressed
air outlet.
2. Tank
3. ON/OFF/Reset switch.
4. Pressure gauge.
5. Condensate drain.
6. Hours Run Counter

9Before moving, or maintaining the compressor ensure it is unplugged from the mains supply and that the air tank pressure has been
vented.
9Maintain the compressor in good condition and replace any damaged or worn parts. Use genuine parts only. Unauthorised parts may be
dangerous and will invalidate your warranty.
9Read the instructions relating to any accessory to be used with this compressor. Ensure the safe working pressure of any air appliance
used exceeds compressors output pressure. If using a spray gun, check that the area selected for spraying is provided with an air change
system/ventilation.
9Ensure the air supply valve is turned off before disconnecting the air supply hose.
9To move a transportable compressor use the handle only. Lift the compressor so that the front leg gives enough clearance for
manoeuvring but maintain unit’s centre of gravity in front of the wheels. DO NOT attempt to lift or move the compressor by any other
means.
9Use the compressor in a well ventilated area and ensure it is placed on a firm surface.
9Keep tools and other items away from the compressor when it is in use, and keep area clean and clear of unnecessary items.
9Ensure the air hose is not tangled, twisted or pinched.
9Keep children and unauthorised persons away from the working area.
9Only move the compressor by the handle if portable.
8DO NOT dis-assemble compressor for any reason. The unit must be checked by qualified personnel only.
8DO NOT use the compressor outdoors, or in damp, or wet, locations.
8DO NOT operate within the vicinity of flammable liquids, gases or solids.
8DO NOT touch compressor cylinder, cylinder head or pipe from head to tank as these may be hot.
8DO NOT use this product to perform a task for which it has not been designed.
8DO NOT deface the certification plate attached to the compressor tank.
8DO NOT cover the compressor or restrict air flow around the unit whilst operating.
▲DANGER! DO NOT direct the output jet of air towards people or animals.
8DO NOT operate the compressor without an air filter.
8DO NOT allow anyone to operate the compressor unless they have received full instructions.
WARNING! The air tank is a pressure vessel and the following safety measures apply:
8DO NOT tamper with the safety valve, DO NOT modify or alter the tank in any way and DO NOT strap or weld anything to the tank.
8DO NOT subject the tank to impact, vibration or to heat and DO NOT allow contact with abrasives or corrosives.
9Drain condensation from tank daily and inspect inside walls for corrosion every three months and have a detailed tank inspection carried
out annually. The tank shell must not fall below the certified thickness at any point.
WARNING! If an electrical fuse blows, ensure it is replaced with an identical fuse type and rating.
9When not in use, store the compressor carefully in a safe, dry, childproof location.
9When the compressor is not in use it should be switched off, disconnected from the mains supply and the air drained from the tank.
8DO NOT carry out any welding operations on any pressurised parts of the vessel.
1.3. INSPECTION OF PRESSURE TANK BOTH INTERNAL AND EXTERNAL
1.3.1. Under the Pressure Systems Safety Regulations 2000 it is the responsibility of the owner of the compressor to initiate
 asystemofinspectionthatbothdenesthefrequencyoftheinspectionandappointsapersonwhohasspecicresponsibilityfor
carrying out the inspection.
IMPORTANT WARNING-Aircontaminantstakenintothecompressorwilla󰀨ectoptimumperformance.Example:Bodyllerdustorpaint
 overspraywillclogthepumpintakelterandmaycauseinternaldamagetopump/motorcomponents.Pleasenotethatanypartsdam
aged by any type of contamination will not be covered by warranty.
2. INTRODUCTION
Heavy-duty low noise compressor suitable for garage, bodyshop and industrial applications. Fitted with cast iron cylinder head enabling
slower revving and improved pump life. Fully enclosed, insulated design gives quiet running at just 68dB(A) (at 1mtr) and protects vital
components from damage. Features fully automatic pressure cut out switch and tank pressure gauge. Heavy-duty single phase electric
motor with soft start feature. Control box features tachometer for monitoring use and optimizing service times. Supplied with full CE
certification, test certificate, operating/maintenance manual.
3. i SPECIFICATION
SAC2203BLN.V2 Issue 2 (H, 3, F) 09/07/18
Original Language Version
© Jack Sealey Limited
Model SAC2203BLN.V2
Motor Output 3hp
Supply Voltage 230V
Phase 1ph
Minimum Rated Supply 16A
Speed 1075rpm
Air displacement cfm(ltr/m) 15/425
Noise Level 68dB(A)
Max Free Air Displacement cfm(ltr/m) 10.9/309
Max Pressure 145/10psi(10bar)
Receiver Capacity 200ltr
Outlet 1/2”BSP Female Tap
Dimensions (WxDxH) 1440x440x1210mm
Weight 175kg

4. ASSEMBLY
4.1. Remove compressor from packaging and inspect for any shortages or damage. If anything is found to be missing or damaged contact
your Sealey stockist.
4.2. Save the packing material for future transportation of the compressor. We recommend that you store the packing in a safe location, at
least for the period of the guarantee. Then, if necessary, it will be easier to send the compressor to the service centre.
4.3. Confirm that the mains voltage corresponds with the voltage shown on the compressor data plate.
4.4.  Positionthecompressoronaatsurfaceorwithamaximumpermissible inclination of 100. Site in a well ventilated place, protected
against atmospheric pollution and not in a place subject to explosion hazard. If the surface is inclined and smooth, check if the
compressor moves while in operation. If the surface is inclined make sure it cannot fall, securing it in a suitable way.
4.5.  Toensuregoodventilationande󰀩cientcooling,thecompressor’sbeltguardmustbeatleast100cmfromanywall(g.2).
  Compressorsttedonthetank,withxedfeet,shouldnotberigidlysecuredtotheground.Inthiscase,weadviseyoutot4
anti-vibration supports. Fit the 4 anti-vibration supports, raise the compressor using a suitable pallet truck or fork lift and push the
  supportsontothebaseofeachfoot(g.3).
4.6. Take care to transport the compressor correctly, DO NOT overturn it or lift it with hooks or ropes.
4.7. Remove the plastic transit plug from the oil filler hole (fig.4A) and replace it with the filler/breather plug as shown in fig.4B. It is a
push fit, ensure that it is pushed fully home.
4.8. Before using the compressor, check the oil level by observing the sight glass as shown in fig.5. If the oil is not up to the max mark
it should be topped up with synthetic oil suitable for temperatures ranging from -5°C to 45°C (viscosity 5W50). We DO NOT recommend
using mineral oil in these compressors. DO NOT overfill.
NOTE: To gain access to the pump and motor you must remove the 4 bolts from the top lid of the sound proof casing. For
some servicing such as draining oil, you must also remove the rear panel by removing the 4 bolts.
5. OPERATION
WARNING! Ensure that you have read, understood and apply Section 1 safety instructions.
IMPORTANT! The use of extension leads to connect this compressor to the mains supply is not recommended as the resulting voltage
drop reduces motor, and therefore pump performance and could cause damage to your compressor.
NOTE: Take care when selecting tools for use with the compressor. Air tool manufacturers normally express the volume of air required
to operate a tool in cubic feet per minute (cfm). This refers to free air delivered by the compressor (‘air out’) which varies according
to the pressure setting. DO NOT confuse this with the compressor displacement which is the air taken in by the compressor (‘air in’).
‘Air out’ is always less than ‘air in’ due to losses within the compressor.
5.1. STARTING THE COMPRESSOR
5.1.1. To turn the compressor on, plug mains lead into mains supply, pressthe“ON”buttononthefrontpanelSeeg.6.
5.1.2. When starting the compressor for the first time, leave it running with no air tools connected to the air outlet. Make sure that
pressure in the tank rises and that the compressor stops automatically when the maximum pressure value allowed (written on the
plate and shown on the gauge in fig.6) is achieved. The compressor will now operate automatically. The pressure switch stops the motor
when the maximum tank pressure is reached and restarts it when the pressure falls below the minimum threshold - approx. 2bar (29psi)
less than the maximum pressure.
5.1.3. Stop the compressor by pressing the “OFF/RESET” button in fig.6. The compressed air inside the compressor head will flow out, making
fig.2
fig.4
Oil Drain fig.5
SAC2203BLN.V2 Issue 2 (H, 3, F) 09/07/18
Original Language Version
© Jack Sealey Limited
fig.3

the restart easier and preventing the motor from being damaged. DO NOT, other than in an emergency,stop the compressor by switching
off the mains power, or by pulling the plug out, as the pressure relief will not then operate and motor damage may result upon restart.
5.1.4. The motor of the compressor is fitted with a thermal breaker. The manual resetting button is doubled up with the “OFF” button (fig.6).
When the breaker is tripped, wait for a few minutes and then press the reset button. If the unit keeps tripping investigate and rectify the
cause.
NOTE: If the motor does not cut in and out, but runs continuously when using an air appliance, the capacity of the compressor may be
too small for the equipment or tool.
WARNING! DO NOT tamper with, or adjust, the switch or safety valve.
6. MAINTENANCE
6.1. In order to keep the compressor in good working condition, periodic maintenance is essential.
IMPORTANT! Failure to carry out maintenance tasks may invalidate the warranty on your compressor.
Inspection of pressure tank both inside and out. Under the Pressure Systems Safety Regulations 2000 it is the responsibility of the
 ownerofthecompressortoinitiateasystemofinspectionthatbothdenesthefrequencyoftheinspectionandappointsapersonwho
 hasspecicresponsibilityforcarryingouttheinspection.
WARNING!Beforeperforminganymaintenanceoperation,switcho󰀨thecompressor,disconnectfromelectricitysupplyandrelease
all air from the tank.
NOTE! To gain access to the pump and motor you must remove the 4 bolts from the top lid of the sound proof casing. For some servicing
such as draining oil, you must also remove the rear panel by removing the 4 bolts.
8DO NOToperatethecompressorwithoutthepanelstted.
6.1.1. OPERATIONS TO BE CARRIED OUT AFTER THE FIRST 50 WORKING HOURS:
a) Check that all bolts/nuts are tight, particularly those retaining the crankcase and cylinder head.
b) Replace the lubricating oil.
6.1.2. OPERATIONS TO BE CARRIED OUT WEEKLY:
a) Drain condensation by opening the valve located under the tank (fig.8). Place a container under the valve and open the valve by
turning anti-clockwise.
WARNING! Takecareifthereisstillpressureinsidethecylinderaswatercouldowoutwithconsiderableforce.Recommended
pressure 1 - 2bar max.
b) Check oil level and, if necessary, top up.
6.1.3. OPERATIONS TO BE CARRIED OUT EVERY 50 - 100 HOURS: (or more frequently, if the compressor operates in a very
dusty atmosphere):
a) Remove the air filter element (fig.7). Using stored air from the compressor’s tank, clean the filter with compressed air.
(Wear eye protection and DO NOT direct air towards the body or hands). DO NOT operate the compressor without the filter as foreign
bodies or dust could seriously damage the pump. Replace the filter element and air filter housing.
b) Check for oil leaks.
c) Check the automatic cut-out at max. pressure and the automatic cut-in at 2bar below.
6.1.4. OPERATIONS TO BE CARRIED OUT EVERY 400 - 500 HOURS DEPENDING ON CONDITIONS (IF THE COMPRESSOR
OPERATES IN A DUSTY OR HARSH ATMOSPHERE USE 400 HOURS)
a) Replace the lubricating oil. For oil specifications see 6.2.
Remove the filler/breather plug (see fig.4-B) then open oil drain tap, draining the oil into a container. Drain when the
compressor is hot so that the oil drains rapidly and completely. Replace oil drain plug and refill through the filler/ breather
aperture. DO NOT overfill. Check sight glass for correct level. Replace plug.
WARNING!Nevermixdi󰀨erentoilsandDO NOT use non-detergent/low quality oils as the compressor may be damaged.
WARNING! Dispose of waste oil only in accordance with local authority requirements.
b) Replace air filter. (See fig.7)
c) Check all tube fittings and electrical connections.
d) Inspect pressure tank inside and out for damage or corrosion.
6.2. RECOMMENDED OILS
Synthetic oil suitable for temperatures ranging from -5°C to 45°C: viscosity 5W50. We DO NOT recommend using mineral oil in this
compressor.
Part No. Qty Description
FSO1 1ltr x 12 Compressor oil fully synthetic
FSO1S 1ltr x 1 Compressor oil fully synthetic
FSO5 5ltr x 1 Compressor oil fully synthetic
fig.6
On
Switch
Hours Run
Counter
Tank
Pressure
O󰀨/Reset
Switch
SAC2203BLN.V2 Issue 2 (H, 3, F) 09/07/18
Original Language Version
© Jack Sealey Limited

7. TROUBLESHOOTING
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 [e-mail] www.sealey.co.uk
ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to
a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely
unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids
according to local regulations.
Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior
notice.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
fig.7 fig.8
fig.9
Fault Cause Remedy
Pressure drop in
the tank.
Air leaks at
connections.
Run compressor to max.
pressure, switch off.
Brush soap solution over
connections and look for
bubbles. Tighten connections
showing leaks. If problem
persists contact Authorised
Service Agent.
Pressure switch
valve leaks when
compressor is
idle.
Non-return valve seal
defective.
Discharge all tank pressure.
Referring to fig.9, unscrew
valve cap 'A'. Clean rubber
disc 'B' and its seat. Refit all
parts accurately.
Compressor stops
and does not
restart.
Power failure.
Motor failure.
Check electricity supply and
fuse.
Contact Authorised Service
Agent.
Compressor does
not stop at max
pressure.
Pressure switch fault. Contact Authorised Service
Agent.
Compressor does
not reach max
pressure.
Filter clogged.
Head gasket or valve
fault.
Replace filter element.
Contact Authorised Service
Agent.
Compressor noisy
with metallic
knock.
Low oil level.
Bearing or piston
damage.
Turn off and top up oil
immediately.
Contact Authorised Service
Agent.
SAC2203BLN.V2 Issue 2 (H, 3, F) 09/07/18
Original Language Version
© Jack Sealey Limited