Sealey Power PRODUCTS SAC3103B, Power PRODUCTS SAC3503B Instructions Manual

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INSTRUCTIONS FOR:

COMPRESSOR 50/100ltr BELT DRIVE

3.0hp WITH FRONT CONTROL PANEL.

MODEL Nos: SAC3503B/SAC3103B

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 OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.

1. SAFETY INSTRUCTIONS

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.

1.1.10. Model Nos SAC3503B and SAC3103B are supplied with a

flying lead without a plug. Jack Sealey Limited recommend a 16 amp protected supply. When connecting to a 16 amp protected supply, contact a qualified electrician, to ensure connection to a suitably rated supply. *Provided a good 230V supply is available and the lead length is not increased from that supplied, the compressor may operate from a 13 amp supply. This very much depends upon the quality of your power supply.

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.

RECOMMENDED

FUSE RATING:

*13 AMP

See 1.1.10 for power supply options.

Decompression tube from switch

Non return valve

To receiver

From pump

1.2 Wiring a BS 1363/A UK 3 Pin Plug If in doubt contact a qualified electrician.

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.

Original Language Version

Hose reel tidy

fig.1

SAC3503B/SAC3103B Issue No: 1 - 01/06/13

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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 moving or 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. 3 Keep children and unauthorised persons away from the

working area. 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. 7 DO 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.

7 DO NOT operate the compressor without an air filter. 7 DO NOT allow anyone to operate the compressor unless

they have received full instructions. 7 DO NOT operate the compressor if you are tired, under the influence of alcohol, drugs or intoxicating medication.  WARNING! If an electrical fuse blows, ensure it is replaced with an identical fuse type and rating. 3 When not in use, store the compressor carefully in a safe, dry, childproof location  WARNING! The air tank is a pressure vessel and the following safety measures apply: 7 DO NOT tamper with the safety valve, DO NOT modify or alter the tank in any way and DO NOT strap anything to the tank.

7 DO NOT subject the tank to impact, vibration or heat. 7 DO NOT allow contact with abrasives or corrosives. 3 Drain condensation from tank daily.

2. INTRODUCTION & SPECIFICATION

A V-pump belt driven compressor, 50/100ltr, 3hp with bespoke front control panel, with two outlets, one regulated and one direct. The pump features heavy-duty fully cast cylinders, capped by alloy heads for improved heat dissipation and long life. Suitable for professional workshop applications. Powered by a heavy-duty induction motor for reliable operation. Twin capacitors and a centrifugal switch aid trouble free startup on a good *16amp supply. Precision continuously welded receiver tank manufactured to meet Pressure Vessel Directive 2009/105/EC. Fitted with fully automatic pressure cut-out switch, air regulator, receiver and supply pressure gauges. Supplied with handle and wheels for easy manoeuvrability.

MODEL: .............................................................................SAC3503B

Motor output: .............................................................................3.0hp

Voltage/phase: ..................................................................230V - 1ph

Rated supply: .............................................................................. *16A

Speed at pump (rpm):.................................................................1140

Noise level: ............................................................................96dB(A)

Air displacement: ....................................................12.25cfm-347l/m

Maximum free air delivery: ......................................... 9.5cfm-270l/m

Tank capacity: ..............................................................................50ltr

Max pressure: ...............................................................145psi /10bar

Weight: ........................................................................................65kg

Dimensions (W x D x H): ...................................820 x 490 x 760mm

MODEL: .............................................................................SAC3103B

Motor output: .............................................................................3.0hp

Voltage/phase: ..................................................................230V - 1ph

Rated supply: .............................................................................. *16A

Speed at pump (rpm):.................................................................1140

Noise level: ............................................................................96dB(A)

Air displacement: ....................................................12.25cfm-347l/m

Maximum free air delivery: ......................................... 9.5cfm-270l/m

Tank capacity: ............................................................................100ltr

Max pressure: ...............................................................145psi /10bar

Weight: .....................................................................................71.5kg

Dimensions (W x D x H): ...................................980 x 500 x 800mm

fig.2

Trip reset button (4.3.7.)

fig.3

Chocks

Fully

inated

1.5bar

Original Language Version

Wall

1000mm nominal

SAC3503B/SAC3103B Issue No: 1 - 01/06/13

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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 and swivel castor using the nuts, bolts and washers supplied (fig.8).

3.5. The compressor should be operated on a horizontal flat surface, or one that does not exceed 5° either transversely (tyres fully inflated to 1.5bar) or longitudinally with chocks (fig.3), and should be in a position that allows good air circulation around the unit (see 1000mm nominal).

3.6. Before using the compressor check the oil level by referring to the oil sight glass (fig.4C). 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 5.7). To top up unscrew plug (fig.4B).

3.7. Screw the back half of a filter unit into the port openings in each head as shown in (fig.4.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.7).

Breather (at rear)

fig.4

Drain plug

the specification plate and shown on the gauge (fig.5.4). This may take in excess of 5 minutes. The compressor will now operate automatically. The pressure switch (fig.5.1) 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.

4.3.5. Stop the compressor by pushing the switch knob (See fig.5.1) 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.

4.3.6. The output pressure is regulated by the pressure regulator (fig.5.2). Turn the knob clockwise to increase pressure and counterclockwise to reduce it. The knob can be locked at any required setting by tightening the locking ring (fig.5.5) 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 gauge (fig.5.4) indicates the pressure inside the main tank. The gauge (fig.5.3) indicates the pressure supplied to the air equipment. Should the pressure in the main tank exceed the pre-set switch (fig.5.1) maximum, the safety valve (fig.5.6) 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. The reset button is on the side of the box (fig.2). 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.

4. OPERATION

 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). 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 on/off switch. To turn the compressor "on" pull the switch knob upwards. To turn the compressor "off" push the knob downwards. (See fig.5.1)

4.3.2. Check that the on/off switch is in the “off” position and the regulator tap (fig.5.2) is closed (Zero ‘0’ bar).

4.3.3. Plug mains lead into mains supply and start the compressor by pulling the switch knob (fig.5.1) upwards.

4.3.4. Leave the compressor running with no air line or tools connected, and regulator (fig.5.3) set to maximum pressure (fully clockwise). Make sure that the pressure in the tank rises and that the compressor stops automatically when the maximum pressure value is reached. This value is written on

Original Language Version

Non Regulated supply (receiver pressure)

Utility brackets

fig.5

Control Panel

and

Ancilliaries

Regulated supply

Manifold

Pull up (on) push down (off)

Restart

Decompression tube

Receiver

Switch/motor cable

SAC3503B/SAC3103B Issue No: 1 - 01/06/13

AC Supply

Page 4

5. MAINTENANCE

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.

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.6). Place a container under the valve and slowly open the valve by turning counterclockwise.

Drain valve underside

fig.6

of receiver, ensure shut on start up (4.3) drain daily (5.3.)

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 plug (see fig.4.B) then unscrew oil drain plug (see fig.4) 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.

5.6. OPERATIONS TO BE CARRIED OUT EVERY 500 HOURS:

a) Replace air filter. (See fig.7) 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.

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.7) 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.

fig.7

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.

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.

Axle bolt

Plain washer.

Spacers

Pneumatic wheel

fig.8

Receiver leg

Spring washer/ nut

Plain washer/ spring washer/ spacer.

Original Language Version

Receiver leg

Nut/spring washer

Bolt

Swivel castor

SAC3503B/SAC3103B Issue No: 1 - 01/06/13

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6. TROUBLESHOOTING

FAULT POSSIBLE CAUSE REMEDY

1A) Pressure drop in the tank Air leaks at connections Run compressor to max. pressure, switch off.

1B) Pressure drop in the tank Air leaks from safety valve It should be replaced, unless leaking at a joint

Brush soap solution over connections and look for

bubbles. Tighten connections showing leaks.

If problem persists contact Authorised Service Agent

which can be sealed.

1C) Pressure drop in the tank Air leaks from cylinder head gasket Check tightness of head bolts. If leak continues

2) Pressure switch valve leaks when compressor is idle

3) Air leaks from tank body or tank welds Internal corrosion caused by infrequent tank

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.2) and restart unit. If

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

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

Non-return valve seal defective Empty the air tank. Referring to fig.9, remove the

draining or non permitted modifications to tank

Head gasket or valve fault

contact authorised Service Agent

non-return valve cap (3), spring (2) and seal (1).

Clean the seal and its seat, or if necessary replace

the seal

Tank could rupture or explode. Cannot be repaired

DISCONTINUE USE IMMEDIATELY

repeated tripping occurs replace the check valve or

contact authorised Service Agent

Replace filter element.

Contact Authorised Service Agent

See g.1 for location and section 6.2

fig.9

Parts support is available for this product. To obtain a parts listing and/or diagram,

please log on to www.sealey.co.uk, email sales@sealey.co.uk or telephone 01284 757500.

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.

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.

Sole UK Distributor, Sealey Group,

Kempson Way, Suffolk Business Park, Bury St. Edmunds, Suffolk, IP32 7AR

Original Language Version

01284 757500

01284 703534

SAC3503B/SAC3103B Issue No: 1 - 01/06/13

www.sealey.co.uk

Web

sales@sealey.co.uk

Page 6

Original Language Version

SAC3503B/SAC3103B Issue No: 1 - 01/06/13