Sealey SAC3203B3PH User manual

From
pump
To receiver
Decompression
tube from switch
fig.1
Non return valve
Hose reel tidy
Ball valve
Original Language Version SAC3203B3PH Issue No: 1 - 27/10/14
©Jack Sealey Limited
1.1 ELECTRICAL SAFETY.
 WARNING! It is the user’s responsibility to read, understand and comply with the following:
You must check all electrical equipment and appliances to ensure they are safe before using. You must inspect power supply leads, plugs and all
electrical connections for wear and damage. You must ensure the risk of electric shock is minimised by the installation of appropriate safety
devices. An RCCB (Residual Current Circuit Breaker) should be incorporated in the main distribution board. We also recommend that an RCD
(Residual Current Device) is used with all electrical products. It is particularly important to use an RCD together with portable products that are
plugged into an electrical supply not protected by an RCCB. If in doubt consult a professional 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 all portable electrical appliances, if used on business premises, to be tested by a qualified
Electrician at least once a year, using a Portable Appliance Tester (PAT).
1.1.2 The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of the appliance, and the
safety of the appliance operator. If in any doubt about electrical safety, contact a qualified Electrician.
1.1.3 Ensure the insulation on all cables and the product itself is safe before connecting to the mains power supply. See 1.1.1. & 1.1.2.
above and use a Portable Appliance Tester (PAT).
1.1.4 Ensure that cables are always protected against short circuit and overload.
1.1.5 Regularly inspect power supply, leads, plugs and all electrical connections for wear and damage, especially power connections, to ensure that
none are loose.
1.1.6 Important: Ensure the voltage marked on the product is the same as the electrical power supply to be used and check that plugs are fitted with the correct
capacity fuse. If an electrical fuse blows, ensure it is replaced with an identical fuse type and rating.
1.1.7 DO NOT pull or carry the powered appliance by its power supply lead or output cables.
1.1.8 DO NOT pull power plugs from sockets by the power cable.
1.1.9 DO NOT use worn or damage leads, plugs or connections. Immediately replace or have repaired by a qualified Electrician. This
particular compressor is supplied without a mains plug. Follow the instructions below regarding the fitting of an appropriate plug.
1.2 MODEL SAC3203B3PH REQUIRES A 415V 3 PHASE SUPPLY AND MUST HAVE AN APPROPRIATE PLUG FITTED.
 WARNING! ELECTRICAL INSTALLATION OF THE COMPRESSOR TO A 3 PHASE 415VOLT SUPPLY MUST ONLY BE CARRIED OUT BY A
QUALIFIED ELECTRICIAN. Ensure the power supply cable is connected to the Earth.
1.2.1 This product must be fitted with a 3 phase plug wired as illustration in (fig.2), wired to an appropriately fused supply.
Connect GREEN/YELLOW wire to Earth ‘E’
Connect BROWN wire to L1 Terminal.*
Connect BLACK wire to L2 Terminal.*
Connect the GREY wire to L3 Terminal.*
*NOTE: The cable core colours found in the mains cable on this compressor are consistent with Amendment 2 to 7671:2001. When completed,
check there are no bare wires, that all wires have been connected correctly and the cable restraint is tight.
WARNING! IT IS ESSENTIAL TO OBSERVE ANTI-CLOCKWISE (fig.1) PULLEY DIRECTION ON INITIAL START UP. IF CLOCKWISE
OBSERVED, STOP IMMEDIATELY AND CONSULT A QUALIFIED ELECTRICIAN TO INVERT 2 PHASES.
1.2.2 DO NOT use this product with a standard extension cable. Only use ARMOURED extension cable
IMPORTANT USER INFORMATION! Over-current protection of the power circuit is required in accordance with 7.2 of EN 60204-1:2006. The
supply disconnecting device to be in accordance with 5.3 of EN60204-1:2006. Ask a qualified electrician about compliance. The use of extension
leads to connect these compressors to the mains is not recommended.
(Grey) to L3 'E' Earth
green/yellow
Mains
cable
(Black) to L2
(Brown) to L1
fig.2
IMPORTANT!
Anti-clockwise
rotation
(label on guard)
see 1.2.1
INSTRUCTIONS FOR:
COMPRESSOR 200LTR BELT DRIVE 3.0HP
415V/3PH WITH FRONT CONTROL PANEL
MODEL NO: SAC3203B3PH
1. SAFETY
Control Panel
(g.7)
Swivel castor with brake
2-Pneumatic
tyres 1.5bar
Receiver
Switches
(g.8)
Motor
3~ph
Pump
(g.5)
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.
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.

1.3. 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! The 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 Move the compressor on a pallet or using slings beneath receiver near to domed ends, employing a fork lift truck or wheeled gantry
crane. Beware of off centre loads.
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.
3 Keep children and unauthorised persons away from the working area.
3When not in use, store the compressor carefully in a safe, dry, childproof location.
7 DO NOT disassemble 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 the compressor within the vicinity of flammable liquids, gases or solids.
7 DO NOT touch the compressor cylinder head or pipe from the head to tank as these may be hot.
7 DO NOT use this compressor 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 no welding operations are to be carried out on any pressurised parts of
the vessel. DO NOT allow contact with abrasives or corrosives.
V-pump belt driven compressor, 200ltr. The pump features heavy duty fully cast cylinders, capped by alloy heads for improved heat dissipation
and long life. Suitable for professional workshop applications. The 2 cylinder pump is powered by a 415v 3ph 3.0hp motor. A precision,
continuously welded receiver tank manufactured to meet Pressure Vessel Directive 2009/105/EC. Fitted with fully automatic pressure cut-out
switch and receiver drain valve. Supplied with 2 pneumatic tyred wheels, a leading swivel castor, fixings and 4 core 2.5 metre flying lead.
MODEL: ......................................................................SAC3203B3PH
Motor output: .....................................................................2.2kW/3hp
Voltage/phase: ..................................................................415V - 3ph
Rated supply:..................................................................................6A
Speed at pump:.....................................................................1243rpm
Noise level: ............................................................................96dB(A)
Air displacement cfm (ltr/min): ........................................ 13.4 (380)
Maximum free air delivery cfm (ltr/min):......................... 10.9 (310)
Tank capacity:............................................................................200ltr
Max pressure: ...............................................................145psi /10bar
Weight: ......................................................................................103kg
Dimensions (W x D x H): ...............................1410 x 600 x 1020mm
4.1. Remove compressor from packaging and inspect for any shortages or damage. If anything is found to be missing or damaged
contact your supplier.
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. Assemble the 2 wheels and leading swivel castor, using the nuts, bolts and washers supplied (fig.4).
4.5. The compressor should be operated on a flat surface, or one that does not exceed 5° either transversely or longitudinally
and should be in a position that allows good air circulation around the unit, (see 1000mm nominal perimeter in fig.6).
4.6. Before using the compressor check the oil level by referring to the oil sight glass (fig.5C). On a horizontal surface, if the oil level is not
up to the red centre mark it should be further topped up with recommended oil (See section 6.7). To top up unscrew plug (fig.5B).
4.7. Screw the back half of a filter unit into the port openings in each head as shown in (fig.5A and fig.3). Place a filter cover over each
threaded rod protruding from the back half of the filter and secure each with a wing nut.
4.8. Check the drain valve is fully closed (fig.9)
Original Language Version SAC3203B3PH Issue No: 1 - 27/10/14
©Jack Sealey Limited
2. INTRODUCTION
3. SPECIFICATION
4. ASSEMBLY
5. OPERATION
WARNING! Ensure that you have read, understood and apply Section 1 safety instructions.
5.1. 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 and could damage your compressor.
5.2. 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.

A
C
Drain plug
B
fig.6
Breather (at rear)
A
Chocks
Fully
inated
1.5bar
1000mm
nominal
Wall
Axle bolt
Spacers
Plain washer.
Plain washer/
spring washer/
spacer.
Receiver leg
Spring washer/
nut
Wheel
Receiver leg
Swivel castor
Nut/spring
washer
Bolt
5.3. STARTING THE COMPRESSOR.
5.3.1. Your compressor is fitted with two push buttons for on/off switching. To turn the compressor on push the green "on" button. To turn the
compressor off push the red "off" button. (See fig.8)
5.3.2. Check that the on/off switch is in the “off” position.
5.3.3. Plug the mains lead into mains supply and start the compressor by pushing the green "on" button (fig.8) downwards.
5.3.4. Leave the compressor running with no air line or tools connected. Make sure that the pressure in the tank rises and that the
compressor stops automatically when the maximum pressure is reached. This value is written on the specification plate and may
take in excess of 5 minutes.The compressor will now operate automatically. The pressure switch (fig.8) 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.
5.3.5. Stop the compressor by pushing the red "off" button (fig.8) downwards. The compressed air inside the compressor head will flow out via
the air line tube situated beneath the switch housing. Restart is made easier and prevents 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 occur and motor damage may result upon restart. When the compressor runs correctly and is stopped correctly there will
be:
(a) A whistle of compressed air when the motor stops,
(b) A protracted whistle (about 20-25 seconds) when the compressor starts with no pressure in the tank.
5.3.6. The output pressure is regulated by the pressure regulator (fig.7). Turn the knob clockwise to increase pressure and anti-clockwise
to reduce it. The knob can be locked at any required setting by tightening the locking ring against the underside of the knob. The
required pressure is determined by the pneumatic appliance user manual. When the compressor is not being used, set the regulated
pressure to zero, hence avoiding damage to the pressure reducer.
5.3.7. Two quick release supply sockets offer either full receiver pressure or a regulated supply pressure up to a maximum of the receiver
pressure. A third option 1/4"BSP female connection is via the receiver ball valve (fig.1) with unregulated pressure.
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. Should the pressure in the main tank exceed the pressure switch pre-set pressure maximum, the safety
valve (fig.8) will activate.
WARNING! DO NOT tamper with, or adjust, the pressure switch or safety pressure relief valve.
Original Language Version SAC3203B3PH Issue No: 1 - 27/10/14
©Jack Sealey Limited
5°
max
5°
max
fig.3
fig.5
fig.4
REGULATOR
REGULATED
PRESSURE
RECEIVER
PRESSURE
REGULATED
SUPPLY
UNREGULATED
SUPPLY
fig.7
Control Panel
Gauges
PUMP

In order to keep the compressor in good working condition, periodic maintenance is essential.
WARNING! Before performing any maintenance operation, switch off the compressor, disconnect from electricity supply and
release all air from the tank.
IMPORTANT! Failure to carry out maintenance tasks may invalidate the warranty on your compressor.
6.1. OPERATIONS TO BE CARRIED OUT AFTER THE FIRST 5 WORKING HOURS:
a) Check that all bolts/nuts are tight, particularly those retaining the crank case and cylinder head.
6.2. OPERATIONS TO BE CARRIED OUT AFTER THE FIRST 50 WORKING HOURS:
b) Replace the lubricating oil - see para 6.5.
6.3. OPERATIONS TO BE CARRIED OUT DAILY:
a) Drain condensation by opening the valve located under the tank (fig.9). Place a container under the valve and slowly open the valve
by turning counterclockwise.
6.4. 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 elements (See fig.3) and clean with compressed air (wear eye protection). DO NOT operate the compressor
without the filters as foreign bodies or dust could seriously damage the pump.
c) Check for oil leaks.
6.5. OPERATIONS TO BE CARRIED OUT EVERY 200 HOURS:
a) Replace the lubricating oil. For oil specifications see 6.7.
Remove the oil filler plug (see fig 5.B) then unscrew oil drain plug (see fig.5) and drain 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 oil drain plug and refill through the oil filler aperture. Do not overfill. Replace oil filler plug.
b) Check the automatic cut-out at max. pressure and the automatic cut-in at 2bar below.
WARNING! Never mix different 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.
6.6. OPERATIONS TO BE CARRIED OUT EVERY 500 HOURS:
a) Replace air filter. (See fig.3)
b) Check all tube fittings and electrical connections.
6.7. Recommended oils;
Recommended oil for compressors, suitable for room temperatures ranging from +5°C to +25°C.
SEALEY CPO or equivalent SAE 40 compressor oil. Room temperature below +5°C: SAE 20 compressor oil.
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.
6.9 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.
fig.9
Drain valve underside
of receiver, ensure it is
closed on start up (4.8)
and drained daily (6.3.).
Original Language Version SAC3203B3PH Issue No: 1 - 27/10/14
©Jack Sealey Limited
6. MAINTENANCE
Pressure switch
and "On" (green)
"OFF" (red)
Push buttons
Control Panel
and ancilliaries
(g.7)
Utility brackets
fig.8
Safety pressure
relief valve
IMPORTANT!
Anti-clockwise
rotation
(label on guard)
see 1.2.1
Receiver

fig.10
Located on tank, see also 7.2
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 24 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 POSSIBLE 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 It should be replaced, unless leaking at a joint
which can be sealed.
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.10, 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 has tripped Press trip reset 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
Parts support is available for this product. To obtain a parts listing and/or diagram,
please log on to www.sealey.co.uk, email [e-mail] or telephone [phone].
7. TROUBLESHOOTING
Original Language Version SAC3203B3PH Issue No: 1 - 27/10/14
©Jack Sealey Limited
Environmental 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 off any fluids (if applicable)
into approved containers and dispose of the product and the fluids according to local regulations.
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 (WEEE). 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 SAC3203B3PH Issue No: 1 - 27/10/14
©Jack Sealey Limited