Clarke XEV11/100, XE18-200, XE25-200, XE26-200, XE29-270 User guide

AIR COMPRESSOR

XE RANGE - ELECTRIC MOTOR DRIVEN

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS

LS0720 - ISS 5

INTRODUCTION

Thank you for purchasing this CLARKE compressor which is designed to supply
compressed air to air powered tools for a wide range of applications such as
spraying, sanding, drilling, and cutting.

Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safe operation
of the compressor.

Please Note, these compressors are for indoor use only.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.

This guarantee is invalid 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.

Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.

This guarantee does not effect your statutory rights.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.

In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.

SPARE PARTS AND DIAGRAMS

Spare parts and diagrams are available on request by contacting our parts
and service department on 020 8988 7400.

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MODELS COVERED AND NOISE DATA

Model Number Sound Power level

dB(LWA)

XEV11/100 98 81

XEPV11/50 98 75

XEPVH11/50 98 75

XEP15/50 101 78

XEPV16/50 99 77

XEPVH16/50 99 77

XE15/150 98 81

XEV16/100 98 82

XEV16/150 101 84

XEV16/200 101 84

XEV26/200 99 81

XE18/200 104 87

XET19/200 100 83

XE25/200 102 84

XE29/270 105 87

XE37/270 106 88

Sound Pressure level
dB(LAEQ)

RESIDUAL RISK

Although this manual contains extensive safety warnings and information on the
safe operation of your compressor, every tool does have certain residual risks
which cannot be compleatly excluded with warnings or safety devices. This
compressor must therfore always be operated with caution.

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SAFETY PRECAUTIONS

Before using your compressor it is in your own interest to read and pay
attention to the following safety rules:

1. COMPRESSED AIR IS DANGEROUS - Never direct a jet of air at people or
animals.

2. Do not operate your air compressor with any guards removed.

3. Electrical or mechanical repairs should only be carried out by a qualified
electrician/engineer. If you have a problem, contact your local dealer, or our
Service Department on 020 8988 7400

4. Before attempting any repair ensure pressure is expelled from the air receiver
and disconnect from electrical supply.

5. Do not leave pressure in air receiver overnight or when transporting.

6. Do not adjust or tamper with any safety valves. The maximum working pressure
of the compressor is clearly stated on the machine.

7. Exercise caution when transporting the machine to avoid tipping the machine
over.

8. Do not operate in a wet/damp environment.

9. Locate your air compressor on a firm flat surface with AVMs and ensure an
adequate supply of clean air is available to the pump unit.

10. Do not exert any strain on electrical cables and ensure that air hoses are not
tangled or wrapped around machinery etc.

11. The cylinder head and delivery pipes of your compressor become quite hot
during operation. Do not touch. After switching off remember to leave an
adequate cool-down period before touching.

12. Ensure that any equipment/tool used in conjunction with your compressor has
a safe working pressure exceeding the output pressure of the machine.

13. When disconnecting air hoses or other equipment from your compressor
ensure that the air supply is turned off at the machine outlet and expel all
pressurised air from within the air hose and other equipment attached to it.

14. If using your compressor for paint spraying:

• Never spray close to any source of flame or heat.

• Always ensure that the spraying area has adequate fresh air ventilation.

• Hazardous paints require special apparatus (see paint manufacturers

recommendations).

15. Never let people operate the compressor unless they have had the necessary
training.

16. Permanently installed pipework systems should be designed and installed by a
competent engineer.

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INSTALLATION

Before installing your machine, check that its air output is sufficient for the
equipment to be used. The air output from the compressor must be more than
the volume of air required. We recommend the following:

1. Firm and level site, and the use of floor mountings for stationary

compressors - anti-vibration pads. (Do not bolt machines directly to the
floor).

WARNING: MOVE THE COMPRESSOR ON A PALLET OR USING SLINGS
BENEATH THE RECEIVER NEAR TO THE DOMED ENDS, EMPLOYING A FORK
LIFT TRUCK OR WHEELED GANTRY CRANE. BEWARE OF OFF CENTRE
LOADS. THE WEIGHT OF THE COMPRESSOR IS SHOWN ON THE DATA TABLE
ON PAGE 2.

2. Dust and damp free environment.

3. Adequate ventilation for:-

• Air intake to compressor pump (in order to draw in clean air).

• Cooling to compressor pump, and electric motor.

4. To allow sufficient access for servicing, a minimum clearance of 500mm
must be allowed around the machine.

5. The power cable from the main supply must be large enough to carry the
starting and running load of the electric motor. This is particularly relevant if
the compressor is some distance from the source of supply.

6. Electrical installations should be completed by a qualified electrician.

7. Electrical connection to the mains supply must be via a suitably fused (see
table on page 6) approved plug or isolator (allowing sufficient capacity for
motor starting). If using a circuit breaker, ensure it is motor rated and of
sufficient size to allow for motor starting.

8. Compressors should be connected to mains electricity supply via an earth
leakage protection device (RCD).

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ELECTRICAL CONNECTIONS

See wiring lable on the power cable.

SUGGESTED FUSE RATINGS

MOTOR SIZE SINGLE PHASE

KW HP DOL STAR DELTA

0.75 1.0 13 amp 10 amp

1.1 1.5 13/15 amp 10 amp

1.5 2.0 20 amp 10 amp

1.9 2.5 20 amp

2.2 3.0 30 amp 16 amp

3.0 4.0 40 amp 20 amp

4.0 5.5 25 amp

5.5 7.5 30 amp

7.5 10.0 25 amp

MOTOR D.O.L.

THREE PHASE MOTORS 415V

LUBRICATION

Pump: Use Clarke compressor oil, as indicated on machine plate.

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BEFORE STARTING COMPRESSOR, CHECK:-

1. Compressor Pump Oil Level using (a) Dipstick (to level
marked) or (b) sight glass (see fig.1)

2. Automatic Control:- Pressure switch ON/OFF switch is in
the OFF position.

WARNING:

1. BEFORE STARTING COMPRESSOR, OPEN ALL OUTLET VALVES.

2. THE FOLLOWING START AND STOP INSTRUCTIONS MUST BE
FOLLOWED IN THE CORRECT SEQUENCE TO AVOID SERIOUS
DAMAGE TO THE COMPRESSOR/MOTOR.

TO START COMPRESSOR

1. Switch on isolator (mains supply)

2. Switch on pressure switch (lift knob or twist switch). (See “GENERAL
ARRANGEMENT” on page 8., item 22)

3. Check rotation (Flywheel/Fan blows air over pump)

4. Check that pressure does not exceed maximum working pressure
(stamped on machine plate), if the pressure exceeds the maximum
working pressure stated, stop the machine (see below), vent the system
and contact the Clarke Service Department.

TO STOP COMPRESSOR

1. Switch off at the pressure switch (Push knob down or turn switch).

2. Isolate from the Mains Supply.

3. Drain air receiver (release drain tap).

WARNING: COMPRESSOR PUMPS, DELIVERY PIPES WILL REMAIN HOT FOR
SOME TIME AFTER USE.

NOTE: When starting compressors up to and including the 3HP models,

an auto bleed valve will operate and air will be heard vent. This is
quite normal and should not cause concern. The valve should
close after several seconds. Should it fail to close, consult your
Clarke dealer.

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GENERAL ARRANGEMENT

Fig.2

A. STATIONARY

NB: Must be mounted on Anti Vibration Pads

Illustrative
purposes
only

1 Air Compressor Pump 9 Inspection Plug 17 –

2 Electric Motor (or 10 Non-Return Valve 18 –

3 Wire Guard 11 Air Bleed Valve 19 Air Delivery Pipe

4 Pressure Switch 12 Oil Drain Plug 20 Air Bleed Pipe

5 Pressure Gauge 13 Saddle 21 Air Receiver

6 Safety Valve 14 Air Intake Filter 22 On/Off switch

7 Ball Valve 15 Oil Filler/Breather 23 Auto Air Bleed

8 Drain Tap 16 Oil Level Sight Glass

NOTE: On automatic machines (10 H.P). a solenoid valve is fitted to the

delivery pipe.

NOTE: On automatic machines (10 H.P), an Auto Star Delta (ASD) starter

is fitted, ready to be mounted to a wall or panel etc. It is
IMPORTANT to note that NO ADJUSTMENTS should be made to this
component. The ASD should be connected to a 3-phase supply
by a qualified electrician.

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OUTLET PRESSURE ADJUSTMENTS

Illustrative
purposes
only

PORTABLE COMPRESSORS

1. Pressure Adjusting Knob

2. Outlet Taps

3. Pressure Gauge

TO ADJUST OUTLET PRESSURE:

To increase pressure - turn knob (1)
clockwise. To decrease pressure - turn
knob (1) anticlockwise.
Outlet taps - slide knurled section (2) away
from body to open, push towards body to
close.

NOTE: Pressure Gauge (3). Pressure shown will differ by approximately 1

bar depending on whether the outlets are open/closed.

STATIONARY COMPRESSORS

These machines are not supplied with the facility to adjust outlet pressure. A
comprehensive range of airline accessories is available from your local
CLARKE stockist.

OVERLOAD BUTTON (SINGLE PHASE ONLY)

The electric motor is fitted with an automatic
overload detector which will stop the motor if an
overload is detected.

If this happens,

1. SWITCH OFF THE PRESSURE SWITCH (Push knob
down or turn switch).

• Allow the compressor to cool down for 5-10

minutes.

2. Press the Reset button shown on the right.

3. Switch on pressure switch (lift knob or twist switch).

If the overload trips repeatedly, it may indicate a fault with the compressor, in
this case you should contact the Clarke service department.

OTHER PRODUCTS WITHIN OUR RANGE In addition to Air Compressors from 3–40
cfm, we offer a vast range of air tools and airline equipment. Please ask your
local dealer for details of our range or a copy of our Power Products Catalogue

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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TROUBLESHOOTING CHART

IMPORTANT!

1. Any remedial work that may be required must be carried out by a qualified
electrician/engineer.

2. Disconnect from the mains supply before removing any parts from the
compressor.

3. Empty Air Receiver of Air before dismantling any part of the compressor
unit’s pressure system.

4. If your compressor develops a fault do not use until the fault has been
rectified.

SYMPTOM PROBABLE CAUSE REMEDY

Compressor will
not start
automatically

Compressor unit
will not stop
automatically.

Fuses keep
blowing.

Bleed valve
under pressure
switch blows
whilst
compressor is
not running

Fault in electrical installation Let an electrician check

Current supply failure.

Voltage drop.

Motor starter faulty.

Motor incorrectly connected or
faulty

Starter overload has tripped
out.

Pressure switch defective. Have pressure switch

Fuse blown. Check fuse rating - replace.

Pressure switch defective. Contact Clarke Service

Inadequate size fuse installed. Replace with reference to

Fault in motor. Contact Clarke Service

Non-return valve leaking. Clean non-return valve or

electrical installation.

Reset by depressing button.

changed by an electrician.

chart See page 6.

replace.

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SYMPTOM PROBABLE CAUSE REMEDY

Bleed valve
under pressure
switch blows
whilst
compressor is
running

Non return valve stuck (NRV)
open at junction of the tank and
the pump delivery pipe.

Drain Tank and remove
inspection nut to clean Non
Return valve

Compressor unit
starts, but stops
again after only
a few
revolutions.

Unusual noise
from
compressor

Compressor unit
starts and stops
more frequently
than usual.

Non-return valve leaking
(compressor unit is on load during
start).

Non-return valve blocked,
possibly frozen up.

Solenoid valve leaking or
defective (only applies to 10 HP
machines and above).

Bolts loose. Tighten Bolts.

V-Belt flywheel or cooling coil
touching belt guard

Flywheel loose. Tighten flywheel.

Unit installed on an unsuitable
base.

Bearings, piston rings or cylinder
worn.

Valve broken. Contact Clarke Service

Bearings of electric motor worn Contact Clarke Service

Large amount of condensation in
air receiver.

Leaks in control unit or inspection
cover.

Too little pressure differential. Contact Clarke Service

Disconnect from the mains supply
and empty air receiver. Clean
or replace

Thaw non-return valve out
(Unit must be installed in frost­free place).

Contact Clarke Service

Find place of contact and
remedy fault.

Move unit to a more solid
base

Contact Clarke Service

Drain off condensation AT
LEAST once a week.

Locate leaks (by means of
soapy water) and repair.

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SYMPTOM PROBABLE CAUSE REMEDY

Compressor’s oil
consumption
rising.

Compressor
runs
continuously
and can’t
attain the
working
pressure
required.

Compressor unit
starts when no
air is being
used.

Too much oil in compressor. Check oil level 2 or 3 minutes

Leaks around crank case. Contact Clarke Service

Working tem pe ra ture of
compressor too high because of
insufficient cooling.

Unit too small in proportion to air
consumption.

Semi-automatic unit Load too
small.

Cylinder worn Contact Clarke Service

Intake air filter blocked. Clean / Change air filter.

Suction filter blocked. Change filter.

V-belt too slack (not applicable
to direct drive machines).

Leak between compressor block
and air receiver/ leaks in or near
air receiver.

RPM too low because of
incorrectly connected electric
motor.

Valves blocked by dirt, paint, dust
or coked up.

Inspection cover or plug leaking Empty air receiver and

Suction rendered difficult or
impossible at suction intake or the
air being taken in is too warm.

Pressure gauge defective.

Unit too small in relation to air
consumption of connected
equipment

Compressor worn. Have compressor overhauled

Leaks in pipework system Locate and repair leaks.

after stopping.

Increase ventilation to air
compressor.

Connect supplementary.

Convert to fully automatic
operation.

Tighten V-Belt.

Tighten connection and repair
leak or Contact Clarke Service

Contact Clarke Service

Contact Clarke Service

change seal or Contact
Clarke Service

Ensure unobstructed air flow
around the unit.

Install a larger compressor

or replace it.

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SYMPTOM PROBABLE CAUSE REMEDY

Machine
running but not
pumping air
into the
receiver (10HP
only)

Compressor
becomes too
hot.

Oil in the air
delivered

Condensation
in crank case
(especially in 2­stage
compressors).

Air exhausting from solenoid after
starter has changed direction
from star to delta.

Insufficient ventilation See that sufficient air is

Oil level too low (check 2 or 3
times after stopping).

Fault in valves (machine not
stopping).

Blown head gasket (machine not
stopping).

Dirt on cooling fins or suction filter. Clean cooling fins and suction

Unit working at too high a
pressure

Non-return valve partly blocked. Clean or thaw out non-return

Compressor being overworked
and running continuously.

Sump over full Reduce oil to correct level

Cylinder worn Contact Clarke Service

Intake air filter blocked Change air filter

Compressor over dimensioned
(operational periods to short in
relation to resting periods).

Check solenoid valve

Contact Clarke Service

supplied to flywheel or fan of
compressor and that hot air is
properly vented.

Fill with oil - See page 7.

Contact Clarke Service

Contact Clarke Service

filter.

Contact Clarke Service

valve.

Use a larger compressor

Frequent oil changes

Reduce Cooling of crank case
(e.g. by shielding it from the air
stream).

Contact Clarke Service

Condensation
at outlet points

Piping installation is incorrect Consult your local dealer

Compressor is taking in air that is
too warm

Delivery temperature of air from
air receiver is too high

Obtain better fresh air supply
for the compressor.

Use a larger air receiver

Contact Clarke Service

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SYMPTOM PROBABLE CAUSE REMEDY

Electric motor
too hot:
Maximum
temperature
90oC (194oF).

Operational voltage too low Call an electrician

Faults in electrical installation Contact Clarke Service

Cooling fins of electric motor
blocked by dirt

Clean Cooling fins

MAINTENANCE CHART

CHECK LIST DAILY WEEKLY 6 MONTHLY NOTES

Oil level Check Change

Air Receiver Drain

Intake Filter Check /

Clean

Oil breather Check /

Clean

Fan and cooling fins Clean

Inlet and outlet
valves

Non Return Valve Clean Replace if

worn

Belt Tension Check /

Adjust /
Replace if
worn

Big end bearings Check If worn Contact Clarke

Main bearings Check If worn Contact Clarke

Piston Rings If worn Contact Clarke

Cylinder head bolts Check

Torque
settings

Replace if necessary

If worn Contact Clarke
Service department

Does not apply to
direct drive

Service department

Service department

Service department

See above for details.

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DECLARATION OF CONFORMITY

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