Sealey SAC5030VE User manual

INSTRUCTIONS FOR:
COMPRESSOR 50ltr
DIRECT DRIVE 3.0hp
MODEL No: SAC5030VE
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.
SAC5030VE Issue No: 3 - 25/06/12
We recommend that you discuss the installation of an
industrial round pin plug and socket with your electrician.
 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
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 - see fuse rating below.
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. When a BS 1363/A UK 3 pin plug is
damaged, cut the cable just above the plug and dispose of the
plug safely.
Fit a new plug according to the following instructions (UK only).
a) Connect the GREEN/YELLOW earth wire to the earth
terminal ‘E’.
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.
Double insulated products, which
are always marked with this
symbol , are fitted with live
(brown) and neutral (blue) wires
only. To rewire, connect the wires
as indicated in diagram.
DO NOT connect either wire to
the earth terminal.
1.1.10. Products which require more
than 13 amps are supplied
without a plug. In this case you
must contact a qualified electrician
to ensure that a suitably rated
supply is available.
RECOMMENDED
FUSE RATING:
13 AMP
Original Language Version
© Jack Sealey Limited

4. OPERATION
Aluminium cylinders with cast iron liners give reduced weight and
improved resistance to wear. Suitable for general-purpose workshop
applications. Pump head directly coupled to heavy-duty induction
motor for reliable operation. Precision welded receiver tank
manufactured to meet Pressure Vessel Directive 87/404/EEC. Fitted
with fully automatic pressure cut-out switch, air regulator and tank
and supply pressure gauges. Supplied with handle and wheels for
easy manoeuvrability. Fitted with ASTA/BS approved non-rewirable
plug.
3. PREPARATION
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. 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.
3.3. Confirm that the mains voltage corresponds with the voltage
shown on the compressor data plate.
3.4. Assemble the wheels (fig.A.X) and rubber feet (fig.A.Y) to
the main frame using using the nuts, bolts and washers
supplied.
3.5. The compressor should be operated on a flat surface, or one
that does not exceed 10° either transversely or longitudinally
(fig.1), and should be in a position that allows good air
circulation around the unit.
3.6. Remove the plastic transit plug from the oil filler hole.
3.7. Before using the compressor check the oil level by referring
to the oil sight glass (fig.2C). If the oil level is not up to the
red centre mark it should be further topped up with
recommended oil (See section 5.7). Screw the filler/breather
cap into the aperture as shown in fig.2B.
3.8. Screw the back half of a filter unit into the downward facing
port openings in each head as shown in fig.2.A. Place a filter
cover over each threaded rod protruding from the back half
of the filter and secure each with a wing nut. Refer also to
fig.4.
fig.2
WARNING! Ensure that you have read, understood and
apply Section 1 safety instructions.
4.1. 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.
4.2. 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).
fig.A
2. INTRODUCTION & SPECIFICATION
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.
3Drain condensation from tank daily.
 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.
MODEL............................................................................ SAC5030VE
Motor output ..............................................................................3.0hp
Voltage/phase ...................................................................230V - 1ph
Rated supply.................................................................................13A
Noise level................................................................................ 97LwA
Air displacement ....................................................... 11.6cfm-328l/m
Maximum free air delivery .......................................... 8.1cfm-230l/m
Tank capacity...............................................................................50ltr
Max pressure ................................................................. 116psi / 8bar
Weight..........................................................................................37kg
Dimensions (W x D x H).....................................660 x 420 x 650mm
fig.1
SAC5030VE Issue No: 3 - 25/06/12
Original Language Version
© Jack Sealey Limited

5. MAINTENANCE
5.1. 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.
5.2. OPERATIONS TO BE CARRIED OUT AFTER THE FIRST
50 WORKING HOURS:
b) Replace the lubricating oil - see para 5.5.
5.3. OPERATIONS TO BE CARRIED OUT DAILY:
a) Drain condensation by opening the valve located under
the tank (fig.5). Place a container under the valve and slowly
open the valve by turning anti-clockwise.
5.4. 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.4) 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
5.5. OPERATIONS TO BE CARRIED OUT EVERY 200 HOURS:
a) Replace the lubricating oil. For oil specifications see 5.7.
Remove the oil filler/breather plug (see fig.2.B) then unscrew
oil sight glass (see fig.2.C) 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 sight glass and refill through the oil filler/breather
aperture. Do not overfill. Replace filler/breather plug.
b) Check the automatic cut-out at max. pressure and the
automatic cut-in at 2 bar 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.
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.
4.3. STARTING THE COMPRESSOR.
4.3.1. Your compressor is fitted with a push/pull type of ON/OFF
switch. To turn the compressor ‘ON’ pull the switch knob
upwards. To turn the compressor ‘OFF’ push the knob
downwards. (See fig.3.1)
4.3.2. Check that the ON/OFF switch is in the “OFF” position, the
regulator tap (fig.3.2) is closed (Zero ‘0’ bar), and air tap
(fig.3.4) is OFF.
4.3.3. Plug mains lead into mains supply and start the compressor
by pulling the switch knob upwards.
4.3.4. When starting the compressor for the first time, leave it
running for several minutes with the air tap (fig.3.4) open to
ensure good distribution of the lubricating oil. Turn the
compressor off and close the air tap. Restart the compressor
and leave it running with air tap (fig.3.4) closed and regulator
(fig.3.2) set to maximum pressure. Make sure that pressure
in the tank rises and that the compressor stops automatically
when the max. pressure value allowed - written on the
specification plate and shown on the gauge (fig.3.6) - is
achieved. The compressor will now operate automatically.
The pressure switch (fig.3.8) stops the motor when the
maximum tank pressure is reached and restarts it when
pressure falls below the minimum threshold - approx. 2 bar
(29psi) less than the maximum pressure.
4.3.5. Stop the compressor by pushing the switch knob (See fig.3.1)
downwards. The compressed air inside the compressor
head will flow out, making 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 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.
4.3.6. The output pressure is regulated by the pressure regulator
(fig.3.2). Turn the knob clockwise to increase pressure and
anticlockwise to reduce it. The knob can be locked at any
required setting by tightening the locking ring (fig.3.3) up
against the underside of the knob. To determine the correct
working pressure for any piece of equipment check the
corresponding manual. When the compressor is not being
used set the regulated pressure to zero so as to avoid
damaging the pressure reducer.
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 equipment or tool.
b)The larger gauge (fig.3.6) indicates the pressure inside the
main tank. The smaller gauge (fig.3.5) indicates the
pressure supplied to the air equipment. Should the pressure
in the main tank exceed the pre-set switch (fig.3.8)
maximum, the safety valve (fig.3.7) will activate.
WARNING! For this reason DO NOT tamper with, or
adjust, the switch or safety valve.
4.3.7. The compressor is fitted with a reset trip, located in the
connection box on top of the motor (see fig.A.Z) The reset
button is on the side of the box (fig.7). Should the trip activate,
leave for 1 minute before pressing the button to reset. For
possible causes of trip activation and remedies see
section 6 Troubleshooting.
fig.3
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.
fig.4 fig.5
SAC5030VE Issue No: 3 - 25/06/12
Original Language Version
© Jack Sealey Limited

5.6. OPERATIONS TO BE CARRIED OUT EVERY 500 HOURS:
a) Replace air filter. (See fig.4)
b) Check all tube fittings and electrical connections.
5.7. 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.
Approximate oil capacity: 0.16 litres.
5.8 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.
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
fig.7
6. TROUBLESHOOTING
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 Press trip reset button (fig.7) 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
fig.6
SAC5030VE Issue No: 3 - 25/06/12
Original Language Version
© Jack Sealey Limited
5.9 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.