This document is an operation and maintenance manual for Clarke electric motor driven air compressors.
Function Description
The Clarke air compressor is designed to supply compressed air to air-powered tools for a wide range of applications, including spraying, sanding, drilling, and cutting. It is an electric motor-driven unit that compresses air and stores it in an air receiver for later use.
Important Technical Specifications
The manual covers several models, including SE15, PE15, PE16, PEH15, PEH16, SE18, SE19, SE25, SE26, SE29, SE36, SE37, and SE46. All listed models operate at a rated load of 100 PSI.
Key specifications for these models are provided in a data table:
- Major Dimensions (m): Ranging from 0.95 x 0.4 x 0.75 m (PE15) to 1.54 x 0.52 x 1.2 m (SE46).
- Sound Pressure (Mean Value dB LAeq): Ranging from 80 dB (PE16, PEH16, SE19) to 89 dB (SE46).
- A-Weighted Sound Power Level (Calculated Sound Power Level): Ranging from 93.5 dB (PE16, PEH16) to 104 dB (SE46).
- K= (Declared Single-Number Noise): Ranging from 96 dB (PE16, PEH16) to 107 dB (SE46).
- Weight: Ranging from 58 kg (PE15) to 187 kg (SE46).
The manual also provides suggested fuse ratings for various motor sizes (KW/HP) for both single-phase (D.O.L.) and three-phase (415V DOL and Star Delta) motors. For example:
- 0.75 KW (1.0 HP): 13 amp (single phase), 10 amp (three phase DOL).
- 2.2 KW (3.0 HP): 30 amp (single phase), 16 amp (three phase DOL).
- 7.5 KW (10.0 HP): 30 amp (three phase DOL), 25 amp (three phase Star Delta).
Usage Features
Installation:
- The compressor should be installed on a firm, level surface, preferably with anti-vibration pads for stationary models. Direct bolting to the floor is not recommended.
- When moving the compressor, use a pallet or slings beneath the receiver near the domed ends, employing a forklift truck or wheeled gantry crane. Be aware of off-centre loads.
- The installation environment should be dust and damp-free with adequate ventilation for air intake to the pump and cooling for the pump and electric motor.
- A minimum clearance of 500mm around the machine is required for servicing.
- The power cable from the main supply must be appropriately sized for the motor's starting and running load, especially if the compressor is far from the power source.
- Electrical installations must be carried out by a qualified electrician, using a suitably fused plug or isolator. If a circuit breaker is used, it must be motor-rated and sized to allow for motor starting.
- Compressors should be connected to the mains electricity supply via an earth leakage protection device (RCD).
Starting the Compressor:
- Open all outlet valves before starting.
- Switch on the isolator (mains supply).
- Switch on the pressure switch (lift knob or twist switch).
- Check rotation: The flywheel/fan should blow air over the pump.
- For the first operation, run the compressor for 10 minutes with outlet valves open.
- Close valves and verify that the pressure does not exceed the maximum working pressure stated on the machine plate. If it does, stop the machine, vent the system, and contact the Clarke Service Department.
- Note: For compressors up to 3HP models, an auto bleed valve will operate and vent air for a few seconds, which is normal.
Stopping the Compressor:
- Switch off at the pressure switch (push knob down or turn switch).
- Isolate from the mains supply.
- Drain the air receiver by releasing the drain tap.
- Warning: Compressor pumps and delivery pipes will remain hot for some time after use.
Outlet Pressure Adjustments (Portable Compressors):
- To increase pressure, turn the pressure adjusting knob clockwise.
- To decrease pressure, turn the knob anticlockwise.
- Outlet taps are opened by sliding the knurled section away from the body and closed by pushing it towards the body.
- Note: The pressure gauge reading may differ by approximately 1 bar depending on whether the outlets are open/closed.
- Stationary compressors are not supplied with outlet pressure adjustment facilities.
Overload Button (Single Phase Only):
- If the electric motor's automatic overload detector trips:
- Switch off at the pressure switch.
- Allow the compressor to cool for 5-10 minutes.
- Press the Reset button.
- Switch on the pressure switch.
- Repeated tripping indicates a potential fault, requiring contact with the Clarke service department.
Maintenance Features
General Checks (Before Starting):
- Check compressor pump oil level using the dipstick or sight glass (to the marked level).
- Ensure the pressure switch ON/OFF switch is in the OFF position.
Lubrication:
- Use Clarke compressor oil as indicated on the machine plate.
Maintenance Chart:
A detailed maintenance schedule is provided:
- Daily: Check oil level, drain air receiver.
- Weekly: Check/clean intake filter, check/clean oil breather, clean fan and cooling fins.
- 6 Monthly: Change oil, replace intake filter (if necessary), replace non-return valve (if worn), check/adjust/replace belt tension (if worn, not applicable to direct drive machines), check big end bearings (contact Clarke Service if worn), check main bearings (contact Clarke Service if worn), check piston rings (contact Clarke Service if worn), check cylinder head bolts (refer to torque values).
Torque Values for Cylinder Head Bolts:
Specific torque values (NM) are provided for different model numbers:
- SE11C100, SEV11C100, VVE11A150, PEV11C50, PEVH11C50, PE11C50, PPV11ND50, PPVH11ND50: 18-22 NM
- SE16C150, PE16C50, PEH16C50, SE19C200, SE26C200: 28-32 NM
- SE15C150: 35-37 NM
- SE25C200, SP27C150, VE25A150, SE18C200, VE18A150: 41.2 - 43.2 NM
Troubleshooting Chart:
A comprehensive chart lists common symptoms, probable causes, and remedies, emphasizing that remedial work should be carried out by a qualified electrician/engineer. Examples include:
- Compressor will not start automatically: Fault in electrical installation, current supply failure, voltage drop, faulty motor starter, incorrect motor connection, tripped starter overload, defective pressure switch, blown fuse.
- Bleed valve blows while compressor is not running/running: Non-return valve leaking, relief valve leaking.
- Compressor unit will not stop automatically: Defective pressure switch.
- Compressor unit starts but stops after a few revolutions: Leaking/blocked non-return valve, defective solenoid valve, inadequate fuse size, motor fault, loose bolts, V-belt/cooling coil touching belt guard, loose flywheel, unsuitable base, worn bearings/piston rings/cylinder, broken valve, worn electric motor bearings.
- Fuses keep blowing: Inadequate fuse size, motor fault.
- Unusual noise from compressor: Loose bolts, V-belt/cooling coil touching belt guard, loose flywheel, unsuitable base, worn bearings/piston rings/cylinder, broken valve, worn electric motor bearings.
- Compressor's oil consumption rising: Too much oil, leaks around crankcase, high working temperature due to insufficient cooling, unit too small for air consumption, semi-automatic unit load too small, worn cylinder, blocked intake air filter.
- Compressor runs continuously and can't attain working pressure: Blocked suction filter, slack V-belt, leak between compressor block and air receiver, low RPM due to incorrect motor connection, blocked valves, leaking inspection cover/plug, difficult suction due to intake or warm air, defective pressure gauge, unit too small for air consumption, worn compressor.
- Compressor unit starts and stops more frequently than usual: Large amount of condensation in air receiver, leaks in control unit/inspection cover, too little pressure differential.
- Compressor unit starts when no air is being used: Leaks in pipework system.
- Machine running but not pumping air into receiver (10HP only): Air exhausting from solenoid after starter changes from star to delta.
- Compressor becomes too hot: Insufficient ventilation, low oil level, faulty valves, blown head gasket, dirt on cooling fins/suction filter, unit working at too high pressure, partly blocked non-return valve, compressor overworked.
- Oil in the air delivered: Sump over full, worn cylinder, blocked intake air filter.
- Condensation in crankcase: Compressor over-dimensioned (short operational periods relative to resting periods).
- Condensation at outlet points: Incorrect piping installation, compressor taking in warm air, high delivery air temperature from air receiver.
- Electric motor too hot: Low operational voltage, electrical installation faults, cooling fins blocked by dirt.
Safety Precautions:
- Compressed air is dangerous; never direct a jet of air at people or animals.
- Do not operate with guards removed.
- Electrical or mechanical repairs should only be carried out by qualified personnel.
- Before any repair, ensure pressure is expelled from the air receiver and disconnect from the electrical supply.
- Do not leave pressure in the air receiver overnight or during transport.
- Do not adjust or tamper with safety valves.
- Exercise caution during transport to avoid tipping.
- Do not operate in wet/damp environments.
- Locate the compressor on a firm, flat surface with AVMs and ensure adequate clean air supply.
- Do not strain electrical cables or tangle air hoses.
- Cylinder head and delivery pipes become hot; allow adequate cool-down time before touching.
- Ensure all connected equipment has a safe working pressure exceeding the compressor's output pressure.
- When disconnecting air hoses, turn off the air supply at the machine outlet and expel all pressurized air.
- If paint spraying: never spray near flame/heat, ensure adequate fresh air ventilation, use special apparatus for hazardous paints.
- Only trained personnel should operate the compressor.
- Permanently installed pipework systems should be designed and installed by a competent engineer.
Environmental Recycling Policy:
- The product must not be disposed of with general household waste. It must be disposed of according to WEEE regulations at a recognized disposal facility.
Noise Levels:
- These machines produce noise levels exceeding 70dB(A). Persons in the vicinity must use suitable ear protection.
Residual Risk:
- Despite warnings, residual risks exist. The compressor must always be operated with caution.
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