Sealey SAC5020E110V.V2 User manual

INSTRUCTIONS FOR:
COMPRESSOR 50LTR DIRECT DRIVE 2HP 110V
MODEL No: SAC5020E110V.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.
1. SAFETY INSTRUCTIONS
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 OR
PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
IMPORTANT! The use of extension leads to connect this
compressor to the mains is not recommended as the resulting
voltage drop reduces motor, and therefore pump performance.
1.2. GENERAL SAFETY
3 Familiarise yourself with the application and limitations of the
compressor.
3 Ensure 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, pressure switch or safety valve.
3 Before moving, or maintaining the compressor ensure it is
unplugged from the mains supply and that the air tank pressure
has been vented.
3 Maintain 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.
3 Read 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 a gun, check that the area selected for spraying
is provided with an air change/ventilation system.
3 Ensure the air supply valve is turned off before disconnecting
the air supply hose.
3 To move the compressor use the handle only. Maintain unit’s
centre of gravity when lifting. DO NOT attempt to lift or move
the compressor by any other means.
3 Use the compressor in a well ventilated area and ensure it is
placed on a firm surface.
3 Keep tools and other items away from the compressor when
it is in use, and keep area clean and clear of unnecessary
items.
3 Ensure the air hose is not tangled, twisted or pinched.
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
1.1.2. 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 (110volt, 16amp).
1.1.7. DO NOT pull or carry the appliance by the power cable.
1.1.8. DO NOT pull the plug from the socket by the cable.
1.1.9. DO NOT use worn or damaged cables, plugs or connectors.
Immediately have any faulty item repaired or replaced by a
qualified electrician. A U.K. 110 volt plug with BS approval is
fitted. In case of damage, cut off and fit a new plug according
to the following instructions, discard old plug safely.
a) Connect the GREEN/YELLOW earth wire to the earth
terminal.
b) Connect the BROWN live wire to the live terminal ‘L’.
c) Connect the BLUE
neutral wire to the neutral
terminal ‘N’.
d) After wiring, check that
there are no bare wires,
that all wires have been
correctly connected, that
the cable outer insulation
extends beyond the cable
restraint and that the
restraint is tight.
NOTE: If using a
transformer to supply the
compressor, it must be
rated at a minimum of
2kVA to allow the
compressor to run
efficiently.
Original Language Version
©Jack Sealey Limited SAC5020E110V.V2 Issue No: 1 - 21/02/14
Recommended
Fuse Rating: 16Amp

2. INTRODUCTION & SPECIFICATION
Features aluminium cylinder head with cast iron cylinder giving
added resistance to wear over time. Suitable for general-purpose and
workshop applications. Pump heads are directly coupled to a heavy-
duty induction motor for reliable operation. Welded tank complies
with latest European standards. Fitted with fully automatic pressure
cut-out switch with twin gauges displaying tank and working
pressures. Fitted with a BS EN 60309 approved 16Amp 110V plug.
4. TOOL SELECTION
IMPORTANT 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 - and so it is
important that, before choosing equipment, you study
the ‘Free Air Delivery’ figures shown in the Specification
Chart.
5. OPERATION
WARNING! ENSURE THAT YOU HAVE READ,
UNDERSTOOD AND APPLIED SECTION 1 SAFETY
INSTRUCTIONS.
5.1. Make sure that the main switch (fig.3.1) is ‘OFF’ (down).
5.2. Check the oil level by looking through the sight glass (See
fig.2B).
5.3. Ensure that the tank drain valve is closed (fig.5).
5.4. Close the outlet pressure regulator by turning the knob
clockwise (fig.3.2).
5.5. Connect the air tool required to the compressor via an air line
connected to the air outlet.
5.6. Plug the mains cable into the mains supply and start the
compressor by pulling up the main switch.
5.7. Allow the pressure in the tank to rise to the maximum at
which point the compressor will automatically cut out. Tank
pressure is shown on the larger gauge (fig.3.5).
5.8. Begin to gradually open the regulator by turning the knob
until the small gauge registers the required operating
pressure specified for the tool to be used. Always adjust up
to the required pressure rather than down from a higher
pressure. The required setting, once achieved, can be
locked by screwing the locking ring (fig.3.3) up tight
underneath the adjusting knob.
5.9. You can now begin to use the tool. The compressor will
operate automatically cutting in and out as required to
restore the air pressure in the tank. The pressure switch
(fig.3.7) stops the motor when the maximum tank pressure is
reached and restarts it when pressure falls below the
minimum threshold - approximately 2bar (29psi) less than the
maximum pressure.
Note: a)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 appliance.
b)The main gauge (fig.3.5) indicates the pressure inside the
main tank, NOT the pressure supplied to the air equipment,
which is shown on the smaller gauge (fig.3.4). Should the
pressure in the main tank exceed the pre-set switch (fig.3.7)
maximum, the safety valve (fig.3.6) will activate.
3 Keep children and unauthorised persons away from the
working area.
7 DO NOT dis-assemble compressor for any reason. The unit
must be checked by qualified personnel only.
7 DO NOT use the compressor outdoors, or in damp, or wet,
locations.
7DO NOT operate within the vicinity of flammable liquids,
gases or solids.
7 DO NOT touch compressor cylinder, cylinder head or pipe
from head to tank as these may be hot.
7 DO NOT use this product to perform a task for which it has
not been designed.
7 DO NOT deface the certification plate attached to the
compressor tank.
7 DO NOT cover the compressor or restrict air flow around the
unit whilst operating.
q DANGER! DO NOT direct the output jet of air towards
people or animals.
7DO NOT operate the compressor without an air filter.
7DO 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:
7DO NOT tamper with the safety valve, DO NOT modify or alter
the tank in any way and DO NOT strap anything to the tank.
7DO NOT subject the tank to impact, vibration or to heat and
DO NOT allow contact with abrasives or corrosives.
 WARNING! If an electrical fuse blows, ensure it is replaced
with an identical fuse type and rating.
3When not in use, store the compressor carefully in a safe,
dry, childproof location.
3. PREPARATION & ASSEMBLY
3.1. Remove compressor from packaging and inspect for any
shortages or damage. If anything is found to be missing or
damaged contact your supplier.
3.2. Confirm that the mains voltage corresponds with the voltage
shown on the compressor data plate.
3.3. The compressor should be installed on a flat surface, or one
that does not exceed 10° either transversely or longitudinally,
(see fig.1) and should be in a position that allows good air
circulation around the unit.
3.4. IMPORTANT! Check the oil in the pump is up to the
centre of the sight glass (fig.2B). If not, remove the oil
filler/breather (fig.2A) and fill up with oil. Replace the
filler/breather.
DO NOT ATTEMPT TO RUN THE COMPRESSOR UNTIL
THIS HAS BEEN DONE.
3.5. Ensure that the air vent in the oil filler/breather is free
from debris. If the air vent is blocked, pressure can build
up in the crankcase causing damage to the compressor
and possible personal injury.
3.6. Fit the air filter into the inlet port if required (fig.4).
MODEL: ............................................................... SAC5020E110V.V2
Motor output: ................................................................................2hp
Voltage/phase: .................................................................. 110V - 1ph
Rated supply:................................................................................16A
Noise level: .............................................................................. 97LwA
Air displacement: ........................................................ 6.3cfm/178l/m
Maximum free air delivery:......................................... 4.6cfm/130l/m
Tank capacity:..............................................................................50ltr
Max pressure: .................................................................. 116psi/8bar
Weight: ........................................................................................32kg
Dimensions (W x D x H): ..................................650 x 390 x 669mm
fig.2
fig.1
Original Language Version
©Jack Sealey Limited SAC5020E110V.V2 Issue No: 1 - 21/02/14

6. MAINTENANCE
6.3. OPERATIONS TO BE CARRIED OUT EVERY 100 HOURS:
(or more frequently, if the compressor operates in a very
dusty atmosphere):
a) Check oil level and, if necessary, top up.
b) Remove the filter element (fig.4) and clean by blowing
through with an air line at low pressure, from the clean side.
Alternatively, wash in soapy water, rinse and dry. Do not
operate the compressor without the filter as foreign bodies or
dust could seriously damage the pump.
c) Check for oil leaks
6.4. OPERATIONS TO BE CARRIED OUT EVERY 200 HOURS:
a)Replace the lubricating oil. For oil specifications see
below. Remove the oil filler plug (fig.2A) and undo the drain
bolt (fig.2C), draining the oil into a container. Drain when the
compressor is hot so that oil drains rapidly and completely.
Incline compressor to ensure complete drainage. Replace
the drain bolt and refill with fresh oil through the filler
aperture. DO NOT overfill. Replace plug (fig.2A).
Recommended oil for compressors, Suitable for room
temperatures ranging from +5ºC to +25ºC. SEALEY CPO
or equivalent SAE 40 compressor oil.
Room temperature below +5ºC: SAE 20 compressor oil.
WARNING! Never mix different oils and do not use
non-detergent/low quality oils as the compressor may be
damaged. Dispose of waste oil only in accordance with
local authority requirements.
a)Check the automatic cut-out at max. pressure and the
automatic cut-in at 2 bar below.
6.5. OPERATIONS TO BE CARRIED OUT EVERY 500 HOURS:
a)Replace air filter.
b)Check all tube fittings and electrical connections.
IMPORTANT! Failure to carry out maintenance tasks may
invalidate the warranty on your compressor.
WARNING! Before performing any maintenance operation,
switch off the compressor, disconnect from electricity supply
and release all air from the tank. In order to keep the
compressor in good working condition, periodical
maintenance is essential.
6.1. After the first 50 working hours replace the lubricating
oil - see para 6.4.
6.2. OPERATIONS TO BE CARRIED OUT DAILY:
a)Drain condensation by opening the valve located under
the tank. Place a container under the valve and open the
valve by turning anti-clockwise. See fig.5.
b)Check that all bolts/nuts are tight, particularly those
retaining the crankcase and cylinder head.
WARNING! For this reason DO NOT tamper with, or
adjust, the switch or the safety valve.
When the compressor is not being used set the regulated
pressure to zero so as to avoid damaging the pressure
regulator.
5.10. To stop the compressor press down the main switch (fig.3.1).
When the compressor stops there will be a whistling sound
as compressed air is vented from the compressor head.
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 occur and motor damage
may result upon restart.
5.11. When you have finished using the compressor unplug the
unit from the mains power supply.
5.12. Set the outlet pressure on the regulator to zero.
5.13. Remove the air line and air tool.
5.14. The tank must now be drained. This will release the air left in
the tank and drain away condensation that may have formed
within the tank. Choose a suitable location for this operation
and/or make provision to collect the condensation. Wear ear
and eye protection. Open the tank drain valve (See fig.5)
slowly allowing air and moisture to bleed from the tank. After
bleeding close the drain valve to prevent debris building up in
the valve.
WARNING! Water that is allowed to remain in the tank
during storage will corrode and weaken the air tank
which could cause the tank to rupture. To avoid serious
injury drain the tank after each use or daily.
5.15. SAFETY FEATURES
Thermal cut out: If the unit overheats the thermal cut out
will operate and shut the unit down. The thermal cut out will
automatically reset when the unit has cooled down which
may take up to 30 minutes.
6.6. Scheduled maintenance table
Maintenance
Operations
Daily 100 hrs. 200 hrs. 500 hrs.
Drain condensation •
Check oil level •
Clean intake filter •
Check for oil leaks •
Check cut-out •
Replace oil •
General cleaning of
compressor •
Replace air filter •
Check tube fittings and
electrical connections •
6.7. 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 defines the frequency
of the inspection and appoints a person who has specific
responsibility for carrying out the inspection.
6.8. IMPORTANT WARNING - Air contaminants taken into the
compressor will affect optimum performance. Example: Body
filler dust or paint overspray will clog the pump intake filter
and may cause internal damage to pump/motor components.
Please note that any parts damaged by any type of
contamination will not be covered by warranty.
fig.3
fig.4 fig.5
Original Language Version
©Jack Sealey Limited SAC5020E110V.V2 Issue No: 1 - 21/02/14

7. TROUBLESHOOTING
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 will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
01284 757500
01284 703534
[e-mail]
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
Web
email
FAULT CAUSE REMEDY
1A) 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
1B) Pressure drop in the tank Air leaks from safety valve Operate the safety valve manually by pulling on the
ring. If valve continues to leak when in the closed
position it should be replaced
1C) Pressure drop in the tank Air leaks from cylinder head gasket Check tightness of head bolts. If leak continues
contact authorised service agent
2) Pressure switch valve leaks when
compressor is idle
Non-return valve seal defective Empty the air tank. Referring to fig.6, remove the
non-return valve cap (3), spring (2) and seal (1)
Clean the seal and its seat, or if necessary replace
the seal
3) Air leaks from tank body or tank welds Internal corrosion caused by infrequent tank
draining or non permitted modifications to tank
Tank could rupture or explode. Cannot be repaired
DISCONTINUE USE IMMEDIATELY
4A) Motor stops and will not restart Thermal cut out has operated Allow unit to cool for 30 minutes before restarting
4B) Motor stops and will not restart Supply fuse has tripped Reset fuse and restart unit. If repeated tripping
occurs replace the check valve or contact
authorised service agent
5) Compressor stops and does not restart Motor failure Contact Authorised Service Agent
6A) Compressor does not stop at max. pressure Pressure switch fault Contact Authorised Service Agent
6B) Compressor does not stop at max. pressure Filter clogged
Head gasket or valve fault
Replace filter element.
Contact Authorised Service Agent
7) Compressor noisy with metallic knock Bearing or piston damage Contact Authorised Service Agent
8) Excessive moisture in discharged air High humidity environment Drain tank after each use
Environmental Protection.
Recycle unwanted materials instead of disposing of them as
waste. All tools, accessories and packaging should be sorted,
taken to a recycle centre and disposed of in a manner which
is compatible with the environment.
WEEE Regulations.
Dispose of this product at the end of its working life in compliance
with the EU Directive on Waste Electrical and Electronic Equipment.
When the product is no longer required, it must be disposed of in an
environmentally protective way. Contact your local solid waste
authority for recycling information.
Original Language Version
©Jack Sealey Limited SAC5020E110V.V2 Issue No: 1 - 21/02/14
fig.6