Senco PC0968 User Manual
Questions? Comments? call SENCO's toll-free Action-line: 1-800-543-4596 or e-mail: toolprof@senco.com
PC0968
Electric Air Compressor
Senco Products, Inc.
8485 Broadwell Rd.
Cincinnati, OH 45244
Operating Instructions
Warnings for the safe use of this compressor are included in this manual.
Des mises en garde pour une utilisation en toute sécurité de ce compresseur
sont incluses dans ce manuel.
En este manual se incluyen avisos para el uso seguro de este compresor.
© 2003 by Senco Products, Inc.
PC0968 Revised July 31, 2003
(Replaces 6/30/03)
1
TABLE OF CONTENTS
INTRODUCTION ................................................................... 3
SAFETY ALER
INSPECTION .........................................................................
SAFETY
ELECTRICAL ................................................................ 4
EXPLOSION OR FIRE..................................................
BURSTING ...................................................................
BREATHING .................................................................
BURNS .........................................................................
FLYING OBJECTS ........................................................
MOVING PARTS........................................................... 7
NEGLIGENCE ..............................................................
AIR COMPRESSOR DAMAGE..................................... 7
COMPRESSOR FEATURES .................................................
PREPARATION.................................................................... 10
INITIAL SET-UP ......................................................... 10
LOCATION .................................................................. 10
ELECTRICAL .............................................................. 10
OPERATION........................................................................ 11
PRE-ST
START-UP .................................................................. 11
SHUTDOWN .............................................................. 11
T..................................................................... 3
WARNINGS ............................................................ 4
ART CHECKLIST ........................................... 11
3
5
5
6
6
6
7
8
MAINTENANCE................................................................... 11
TROUBLESHOOTING ................................................... 12-14
SPECIFICATIONS ............................................................... 15
WARRANTY ........................................................................ 16
2
3
INTRODUCTION
Congratulations on the purchase of your new SENCO® Air Compressor! You can be assured your SENCO Air
Compressor was constructed with the highest level of precision and accuracy. Each component has been rigorously
tested by technicians to ensure the quality, endurance and performance of this air compressor.
This operator’s manual was compiled for your benefit. By reading and following the simple safety, installation and
operation, and maintenance steps described in this manual, you will receive years of troublefree
operation
from your new SENCO Air Compressor. . The contents of this manual are based on the latest product
information available at the time of publication. The manufacturer reserves the right to make changes in price,
color, materials equipment, specifications or models at any time without notice.
SAFETY ALERT!
A ”
DANGER, WARNING or CAUTION
” safety warning will be surrounded by a ”SAFETY ALERT BOX”.
This box is used to designate and emphasize Safety Warnings that must be followed when operating this
air compressor. Accompanying the safety warnings are “Signal Words” which designate the degree or
level of hazard seriousness. The “Signal
Words” used in this manual are as follows:
DANGER:
Indicates an imminently hazardous situation which, if not avoided,
WILL result in
death or serious injury
.
WARNING:
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
CAUTION:
Indicates a potentially hazardous situation which, if not avoided
MAY result in
minor or moderate injury or damage to the air
compressor
.
The symbols set to the left of this paragraph are “Safety Alert Symbols”.
These symbols are used to call attention to items or procedures that could
be dangerous to you or other persons using this equipment.
ALWAYS PROVIDE A COPY OF THIS MANUAL
TO ANYONE USING THIS EQUIPMENT. READ ALL
INSTRUCTIONS IN THIS MANUAL AND ANY INSTRUCTIONS SUPPLIED BY MANUFACTURERS OF
SUPPORTING EQUIPMENT BEFORE OPERATING THIS AIR COMPRESSOR AND ESPECIALLY POINT OUT
THE “SAFETY
WARNINGS” TO PREVENT THE POSSIBILITY OF PERSONAL INJURY TO THE OPERATOR.
INSPECTION
Unbox the air compressor and write in the serial number in the space provided below. Inspect for signs of obvious
or concealed freight damage. Be sure that all damaged parts are replaced and any mechanical problems are
corrected prior to the operation of the air compressor.
SERIAL NUMBER__________________________________________
If you have Questions or Comments call SENCO’s
toll-free Action-line: 1-800-543-4596 or, e-mail:
toolprof@Senco.com
Please have the following information available for all service calls:
1. Model Number
2. Serial Number
3. Date and Place of Purchase
Senco, 8485 Broadwell Road, Cincinnati, OH 45244
SAFETY WARNINGS
READ ALL SAFETY WARNINGS BEFORE USING AIR COMPRESSOR
HAZARD
RISK OF
ELECTRIC SHOCK
OR
ELECTROCUTION
POTENTIAL CONSEQUENCE
Serious injury or death could occur if
the air compressor is not properly
grounded.
powered by electricity and may cause
electric shock or electrocution if not
used properly
Electrical shock may occur from
electrical cord.
Electrical shock may occur if air
compressor is not operated properly.
Your air compressor is
.
PREVENTION
Make sure the air compressor is
plugged into a properly grounded
outlet which provides correct
voltage and adequate fuse
protection.
Check power cord for signs of
crushing, cutting or heat damage.
Replace faulty cord before use.
Keep all connections dry and off the
ground. Do not allow electrical
cords to lay in water or in such a
position where water could come in
contact with them. Do not touch
plug with wet hands.
Do not pull on the electrical cord to
disconnect from the outlet.
Never operate air compressor in
wet conditions or outdoors when it
is raining.
Serious injury or death may occur if
electrical repairs are attempted by
unqualified persons.
Never operate air compressor with
safety guards/covers removed or
damaged.
Any electrical wiring or repairs
performed on this air compressor
should be done by Authorized
Service Personnel in accordance
with National and Local electrical
codes.
Before opening any electrical
enclosure, always shut off the air
compressor, relieve pressure and
unplug the air compressor from the
power source. Allow air compressor
to cool down. Never assume the air
compressor is safe to work on just
because it is not operating. It could
restart at any time!
4
5
SAFETY WARNINGS
READ ALL SAFETY WARNINGS BEFORE USING AIR COMPRESSOR
POTENTIAL CONSEQUENCE
Serious injury or death may occur from
normal electrical sparks in motor and
pressure switch.
Serious injury may occur if any air
compressor ventilation openings are
restricted, causing the air compressor
to overheat and start on fire.
Serious injury or death may occur from
an air tank explosion if air tanks are
not properly maintained.
Serious injury may occur from an air
compressor malfunction or exploding
accessories if incorrect system
components, attachments or
accessories are used.
HAZARD
RISK OF
EXPLOSION OR FIRE
RISK OF
BURSTING
PREVENTION
Always operate air compressor in a
well ventilated area free of
flammable vapors, combustible
dust, gases or other combustible
materials.
If spraying flammable material,
locate the air compressor at least
20 feet away from the spray area.
(An additional hose may be
required.)
Never place objects against or on
top of air compressor. Operate air
compressor at least 12 inches away
from any wall or obstruction that
would restrict proper ventilation.
Drain air tank daily or after each use
to prevent moisture buildup in the
air tank.
If air tank develops a leak, replace
the air tank immediately. Never
repair, weld or make modifications
to the air tank or its attachments.
Never make adjustments to the
factory set pressures.
Never exceed manufacturers
maximum allowable pressure rating
of attachments.
Because of extreme heat, do not
use plastic pipe or lead tin soldered
joints for a discharge line.
Never use air compressor to inflate
small, low pressure objects such as
toys.
SAFETY WARNINGS
READ ALL SAFETY WARNINGS BEFORE USING AIR COMPRESSOR
HAZARD
RISK TO
BREATHING
RISK OF
BURNS
POTENTIAL CONSEQUENCE
Serious injury or death could occur
from inhaling compressed air. The air
stream may contain carbon monoxide,
toxic vapors or solid particles.
Sprayed materials such as paint, paint
solvents, paint remover, insecticides,
weed killers, etc. contain harmful
vapors and poisons.
Serious injury could occur from
touching exposed metal parts.
These areas can remain hot for some
time after the air compressor is
shutdown.
PREVENTION
Never inhale air from the air
compressor either directly or from
breathing device connected to the air
compressor
Operate air compressor only in a well
ventilated area. Follow all safety
instructions provided with the
materials you are spraying. Use of a
respirator may be required when
working with some materials.
Never allow any part of your body or
other materials to make contact with
any exposed metal parts on the air
compressor
.
.
a
RISK
OF FLYING
OBJECTS
Soft tissue damage can occur from the
compressed air stream.
Serious injury can occur from loose
debris being propelled at a high speed
from the compressed air stream.
Always wear OSHA required “Z87”
safety glasses to shield the eyes
from flying debris.
Never point the air stream at any part
of your body, anyone else or animals.
Never leave pressurized air
compressor unattended. Shut off air
compressor and relieve pressure
before attempting maintenance,
attaching tools or accessories.
Always maintain a safe distance from
people and animals while operating
the air compressor.
Do not move the air compressor
while air tank is under pressure. Do
not attempt to move the air
compressor by pulling on the hose.
6
7
POTENTIAL CONSEQUENCE
Risk of bodily injury from moving parts.
This air compressor cycles
automatically when the pressure
switch is in the “On/Auto” position.
Risk of injury from negligent use.
Risk of major repair
.
SAFETY WARNINGS
READ ALL SAFETY WARNINGS BEFORE USING AIR COMPRESSOR
RISK FROM
NEGLIGENCE
RISK
OF AIR COMPRESSOR
DAMAGE
HAZARD
RISK FROM
MOVING PARTS
PREVENTION
Always turn off air compressor when
not in use. Bleed pressure from the
air hose and unplug from electrical
outlet before performing
maintenance. All repairs to the air
compressor should be made by an
Authorized Service person. Never
assume the air compressor is safe
to work on just because it is not
operating. It could restart at any time!
Do not operate without protective
covers/guards. Replace damaged
covers/guards before using the air
compressor
.
Never allow children or adolescents
to operate this air compressor!
Stay alert-watch what you are doing.
Do not operate the air compressor
when fatigued or under the influence
of alcohol or drugs.
Know how to stop the air
compressor. Be thoroughly familiar
with controls.
Do not operate air compressor
without an air filter.
Do not operate air compressor in a
corrosive environment.
Always operate the air compressor
in a stable, secure position to prevent
air compressor from falling.
Follow all maintenance instructions
listed in this manual.
! SAVE THESE INSTRUCTIONS !
COMPRESSOR FEATURES
13
11
4
3
12
5
6
2
10
9
1
1 Motor/Pressure Switch
Air Compressor Pump
2
Safety Relief
3
Tank Pressure Gauge
4
5
Outlet Pressure Gauge
6
Pressure Regulator
7
Discharge Line
8
9
10
11
12
13
Volt Electric Power Cord
115
Ventilation Openings/Protective Shroud
Quick Disconnect
Air Filter
Tank Drain
Cold Start Valve
V
alve
7
8
8
COMPRESSOR FEATURES
1) MOTOR/PRESSURE SWITCH: This switch is used to start or stop the air
compressor. Moving the switch to the Auto (On) position will provide automatic
power to the pressure switch which will allow the motor to start when the air tank
pressure is below the factory set cut-in pressure. When in the Start/ Stop Option,
the pressure switch stops the motor when the air tank pressure reaches the factor
set cut-out pressure. For safety purposes, this switch also has a pressure release
valve located on the side of the switch designed to automatically release compressed
air from the air compressor pump head and its discharge line when the air compressor
reaches cut-out pressure or is shut off.
the switch to the Off position will remove power from the pressure switch and stop
the air compressor.
2)
MOTOR THERMAL OVERLOAD: The electric motor has a thermal
overload protector. If the motor overheats for any reason, the thermal overload will
cut off power, thus preventing the motor from being damaged. Wait until the motor is
cool. Motor also has a magnetic breaker. Reset switch if it is tripped.
3) AIR INTAKE FILTER: This filter is designed to clean air coming into the pump. To
ensure the pump continually receives a clean, cool, dry air supply this filter must
always be clean and ventilation opening free from obstructions. The filter can be
removed for cleaning by using warm, soapy water. Rinse the filter and air dry.
4) AIR COMPRESSOR PUMP: To compress air, the piston moves up and down in
the cylinder. On the downstroke, air is drawn in through the air intake valve while
the exhaust valve remains closed. On the upstroke, air is compressed, the intake
valve closes and compressed air is forced out through the exhaust valve, into the
discharge line, through the check valve and into the air tank.
This allows the motor to restart freely. Moving
1
2
3
5) SAFETY RELIEF VA
relieving pressure from the system when the compressed air reaches a predetermined
level. The valve is preset by the manufacturer and must not be modified in any way
To
verify the valve is working properly, pull on the ring. Air pressure should escape.
When the ring is released, it will reseat.
6) AIR TANK DRAIN VALVE: The drain valve is used to remove moisture from the air
tank(s) after the air compressor is shut off.
when more than 10 PSI of air pressure is in the air tank! To open the drain valve,
turn the knob counterclockwise. Tilt tank to ensure that all condensation drains
through valve.
7) AIR TANK PRESSURE GAUGE: The air tank pressure gauge indicates the
reserve air pressure in the air tank (s).
8) OUTLET PRESSURE GAUGE: The outlet pressure gauge indicates the air
pressure available at the outlet side of the regulator. This pressure is controlled
by the regulator and is always less or equal to the air tank pressure.
9) PRESSURE REGULA
controlled by the regulator knob. Turn the pressure regulation knob clockwise to
increase discharge pressure, and counterclockwise to decrease discharge
pressure.
LVE: This valve is designed to prevent system failures by
NEVER attempt to open the drain valve
TOR: The air pressure coming from the air tank is
5
.
6
7
8
9
10
10) DISCHARGE LINE: Please note that the discharge line is very hot.
9
10
PREPARATION
INITIAL SET-UP:
1.
Read safety warnings before setting-up air compressor
.
LOCATION:
CAUTION
In order to avoid damaging the air compressor, do not incline the air compressor
transversely or longitudinally more than 10°.
1. Place air compressor at least 12 inches away from obstacles that may prevent proper ventilation.
Do not place air compressor in an area:
-where there is evidence of oil or gas leaks.
-where flammable gas vapors or materials may be present.
WARNING
Serious injury or death may occur if electrical sparks from motor and pressure switch
come in contact with flammable vapors, combustible dust, gases or other
combustible materials. When using the air compressor for spray painting, place the
air compressor as far away I from the work area as possible, using extra air hoses instead of
extension cords.
-where air temperatures fall below 32°F or exceed 104°F.
-where extremely dirty air or water could be drawn into the air compressor.
ELECTRICAL:
DANGER
Improper connection of the equipment-grounding conductor can result in a risk
of shock or electrocution. Check with a qualified electrician or service personnel
if you are in doubt as to whether the outlet is properly grounded. Do not use any type of
adapter with this product. If repair or replacement of the cord or plug is necessary, do not
connect the grounding wire to either flat blade terminal. The wire with insulation having
an outer surface that is green with or without yellow stripes is the grounding wire.
WARNING
This product must be grounded. If there should be a malfunction or breakdown,
grounding
provides a path of least resistance for electric current to reduce the
risk of electric shock. This product is equipped with a cord having an equipmentgrounding conductor and a grounding type plug. The plug must be plugged into an
appropriate outlet that is properly installed and grounded in accordance with all local
codes and ordinances.
1. SENCO® DOES NOT RECOMMEND THE USE OF EXTENSION CORDS as this can create power loss and
overheating of the motor. Use of an additional air hose is recommended rather than an extension cord. If use of an
extension cord is unavoidable, it should be plugged into a GFCI found in circuit boxes or protected receptacles.
When using an extension cord, observe the following:
Cable Length Wire Gauge
Up to 25 feet 12 AWG
Up to 100 feet 10 AWG
Up to 150 feet 8 AWG
Up to 250 feet 6 AWG
Use only 3-blade extension cords that have 3-blade grounding-type plugs and 3-slot cord connectors that will
accept the plug from the product. Use only extension cords having an electrical rating not less than the rating of
the product. Do not use damaged extension cords. Examine extension cord before using and replace if damaged.
Do not abuse extension cord and do not yank on any cord to disconnect. Keep cord away from heat and sharp
edges. Always shut off the air compressor switch before removing the plug from the receptacle.
11
OPERATION
PRE-START CHECKLIST:
1. Remove any moisture in the air compressor air tank. Remove excessive pressure with an air tool, then open
the air tank drain valve in the bottom of the air tank. Close tightly when drained.
WARNING: Risk of bodily injury. NEVER attempt to open the drain valve when
more than 10 PSI of air pressure is in the air tank!
2. Make sure the air compressor Motor Switch is in the “OFF” position.
3.
Make sure all safety valves are working correctly.
4.
Make sure all guards and covers are in place and securely mounted.
START-UP:
1.
Ensure the lever on the pressure switch box is in the “OFF” position.
2.
Plug the power cord into a grounded outlet.
3. Move the lever on the pressure switch box to the “AUTO” position.
4. START/STOP OPTION:
Turn it to the ON
position.
This will allow the air compressor
to “START” building
up pressure in the air tanks and “STOP” when correct pressure is achieved. When pressure
drops with usage,
the air compressor will “START” building up pressure again.
5. Set pressure by adjusting the pressure regulator knob counterclockwise for less pressure and clockwise for
more pressure.
6.
If you notice any unusual noise or vibration, stop the air compressor and refer to “Troubleshooting”.
SHUTDOWN:
1. To stop the air compressor, move the lever on the pressure switch box to the “OFF” position. NEVER stop the
air compressor by unplugging it from the power source. This could result in risk of electrocution.
2. Drain air from the air tank by releasing air with an attached air tool or by pulling on the safety relief valve ring.
3. Once pressure in the air tanks register under 10 pounds, open the drain valve under each air tank to drain any
moisture.
4.
Allow the air compressor to cool down.
5.
Wipe air compressor clean and store in a safe, non-freezing area.
MAINTENANCE
Read the instruction manual before performing maintenance. The following procedures must be performed when
stopping the air compressor for maintenance or service.
1.
Turn off air compressor.
WARNING: Never assume the air compressor is safe to work on just because it is not
operating. It could restart at any time!
2. Disconnect cord from main power supply.
3.
Open all drains.
4.
Wait for the air compressor to cool before starting service.
MAINTENANCE CHART
PROCEDURE DAILY WEEKLY MONTHLY
Drain condensation in air tank(s) X
Check for unusual noise/vibration X
Check for air leaks X
Inspect air filter
X
Clean exterior of compressor
X
Check safety relief valve
X
12
TROUBLESHOOTING
Symptom 1. Motor will not run or restart.
Power cord not plugged in.
Motor/Pressure switch in “OFF” position.
Motor thermal overload switch has
tripped.
Fuse blown or circuit breaker has tripped.
Wrong gauge wire or length of extension
cord.
Air tank pressure exceeds motor/
pressure switch “cut-in” pressure.
Pressure release valve on motor/
pressure switch has not unloaded pump
head pressure.
Defective motor, motor capacitor, motor/
pressure switch, or check valve.
Plug
cord into grounded outlet.
Move switch to “ON”
position.
Turn air compressor off, wait until motor is cool, then check
motor circuit breaker.
Replace
fuse or reset circuit breaker.
Check for proper fuse amperage.
Check
for low voltage conditions.
Disconnect any other electrical appliances from circuit or
operate air compressor on its own branch circuit.
Check chart on page #10 for proper gauge wire and cord length.
Motor
will start automatically when air tank pressure drops
below
“cut-in” pressure of motor/pressure switch.
Bleed
the line by moving the switch to the “Off” position.
Contact
Senco Customer Service.
PROBABLE CAUSE
Motor/Pressure switch does not shut off motor when
air compressor reaches “cut-out” pressure and safety
relief valve activates.
Air compressor is incorrectly sized.
PROBABLE CAUSE
Defective pilot valve, the check valve is stuck open.
REMEDY
Move the motor/pressure switch to the “Off” position. If
the motor doesn’t shut off, unplug the air compressor. If
the electrical contacts are welded together, replace the
pressure switch.
Limit the air pressure to the capacity of the air
compressor. Either use a smaller tool or a larger air
compressor
.
REMEDY
Remove, clean or replace.
Symptom 2. When in the Start/Stop option, motor runs continuously.
Symptom 3. Air continues to leak at motor/pressure switch release valve after motor stops.
13
PROBABLE CAUSE
Defective motor/pressure switch.
PROBABLE CAUSE
Possible defective safety relief valve.
Excessive air tank pressure.
PROBABLE CAUSE
Fittings are not tight enough.
PROBABLE CAUSE
Defective or rusted air tank.
PROBABLE CAUSE
Damaged inlet (reed) valve.
TROUBLESHOOTING
REMEDY
Replace.
REMEDY
Operate safety relief valve manually by pulling on ring.
If it still leaks, it should be replaced.
Defective motor/pressure switch. Replace.
REMEDY
Tighten fittings where air can be heard escaping. Check
fittings with soapy water solution. Do not overtighten.
REMEDY
Air tank must be replaced. Do not attempt to repair
air tank!
REMEDY
Contact SENCO Customer Service 888-222-8144.
Symptom 4. Air continues to leak at motor/pressure switch release valve while motor is running.
Symptom 5. Air leaks from safety relief valve.
Symptom 6. Air leaks at fittings.
Symptom 7. Air leak in air tank.
Symptom 8. Air blowing from inlet filter
.
PROBABLE CAUSE
Pressure regulator knob not turned to high enough
pressure or defective pressure regulator.
Restricted air intake filter.
Air leaks.
Air compressor is not large enough for air
requirement.
REMEDY
Adjust pressure regulator knob to proper setting or
replace.
Clean.
Check for leaks and repair.
Check the accessory air requirement. If it is higher than
the CFM or pressure supply of the air compressor, you
need a larger air compressor.
Symptom 9. Insufficient pressure at air tool or accessory.
TROUBLESHOOTING
Symptom 10. Air compressor not making enough air.
PROBABLE CAUSE
Restricted air intake filter.
Defective (reed) valve.
Symptom 11. Moisture in discharge air.
PROBABLE CAUSE
Condensation in air tank caused by high level
of atmospheric humidity or air compressor is
not run long enough.
REMEDY
Clean.
Drain air tank and measure pump up time. Compare to
specifications. If lower, remove pump head and inspect
valve plate, clean or replace.
REMEDY
Drain air tank after every use. Drain air tank more often
in humid weather and use an air line filter.
14
15
SPECIFICATIONS
Model # PC0968
Motor
Horsepower 1.5 (Peak)
Voltage 115
Amperage 8
Hz. 60
Phase Single
RPM 3450
Compressor Pump
Number of Cylinders 1
Compression Stage 1
Lubrication Lubeless
Crankcase Aluminum
Bearings Ball
Cylinder Aluminum/Steel Sleeve
Valves Reed-Single
Head Aluminum
Filter Insert
Motor/Pressure Switch Setting
Cut-out 120 PSI
Cut-in 90 PSI
Controls On/Off
Air tank
Capacity 2 gallon
Performance
CFM Air Displacement
4
CFM @ 90 PSI 2.2
Maximum Pressure 120 PSI
Pump-up Time: 0-125 PSI 68 sec.
Recovery Time: 90-120 PSI 15 seconds
Weight
Net 38 Ibs.
Dimensions
Basic LxWxH 16"x15"x13.5"
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