SEALEY SAC1276B Compressors with Cast Cylinders Instruction Manual

SEALEY SAC1276B Compressors with Cast Cylinders

Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these instructions and maintained properly, give you years of trouble free performance.

SYMBOLS

OVERVIEW

SAC1276B illustrated (SAC2276B differs slightly)

1. Direct Compressed Air Outlet
2. Tank
3. On/Off Switches
4. Reset Switches
5. Pressure Gauge
6. Condensate Drain Tap

SAFETY

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. 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.
   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.
2. 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.
3. Ensure that cables are always protected against short circuit and overload.
4. Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure that none are loose.
5. 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 1.1.10. below).
6. DO NOT pull or carry the appliance by the power cable.
7. DO NOT pull the plug from the socket by the cable.
8. DO NOT use worn or damaged cables, plugs or connectors.
   Immediately have any faulty item repaired or replaced by a qualified electrician.
9. A 32amp supply is required and we recommend that a 32Amp industrial round pin plug should be fitted and connected to a 32Amp supply having a Type C breaker. If in doubt, you must contact a qualified electrician to ensure that a suitably rated supply is available.

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.

GENERAL SAFETY

• ✓ Familiarise yourself with the application and limitations of the compressor.
• ✓ 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.
• ✓ Before moving, or maintaining the compressor ensure it is unplugged from the mains supply and that the air tank pressure has been vented.
• ✓ 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.
• ✓ 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 gun, check that the area selected for spraying is provided with an air changev system/ventilation.
• ✓ Ensure the air supply valve is turned off before disconnecting the air supply hose.
• ✓ Use the compressor in a well ventilated area and ensure it is placed on a firm surface.
• ✓ Keep tools and other items away from the compressor when it is in use, and keep area clean and clear of unnecessary items.
• ✓ Ensure the air hose is not tangled, twisted or pinched.
• ✓ Keep children and unauthorised persons away from the working area.
• ✗ DO NOT disassemble compressor for any reason. The unit must be checked by qualified personnel only.
• ✗ DO NOT use the compressor outdoors, or in damp, or wet, locations.
• ✗ DO NOT operate within the vicinity of flammable liquids, gases or solids.
• ✗ DO NOT touch compressor cylinder, cylinder head or pipe from head to tank as these may be hot.
• ✗ DO NOT use this product to perform a task for which it has not been designed.
• ✗ DO NOT deface the certification plate attached to the compressor tank.
• ✗ DO NOT cover the compressor or restrict air flow around the unit whilst operating.
  ❒ DANGER! DO NOT direct the output jet of air towards people or animals.
• ✗ DO NOT operate the compressor without an air filter.
• ✗ DO 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:
• ✗ 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.
• ✗ DO NOT subject the tank to impact, vibration or to heat and DO NOT allow contact with abrasives or corrosives.
• ✗ Drainb condensation from tank and inspect inside walls for corrosion as per the maintenance schedule and have a detailed tank inspection carried out annually. The tank shell must not fall below the certified thickness at any point.
  ❒ WARNING! If an electrical fuse blows, ensure it is replaced with an identical fuse type and rating.
• ✓ When not in use for a prolonged period, and if possible, store the compressor carefully in a safe, dry, childproof location.
• ✓ When the compressor is not in use, it should be switched off, isolated from the mains supply and the air drained from the tank.

INTRODUCTION & SPECIFICATIONS

INTRODUCTION

High output units suitable for the professional workshop. Both units are fitted with two genuine 3hp motors and two identical pumps. Twin capacitors and a centrifugal switch aid trouble free starting on a 230V 32A supply. They are supplied with a control box that allows stepped start up. Pumps feature heavy-duty full cast cylinders capped by alloy heads for improved heat dissipation and long life. Heavy-duty drive guards protect belt and flywheel that is designed to force air over the pump to aid cooling. Supplied with full CE certification and test certificates.

PREPARATION

1. Remove compressor from packaging and inspect for any shortages or damage. If anything is found to be missing or damaged, contact your supplier.
2. Save the packing material for future transportation of the compressor. It is recommended that the packing is stored 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. Confirm that the mains voltage corresponds with the voltage shown on the compressor data plate. Fit a suitable 3 pin industrial plug – see section 1.1.10. of the Safety Instructions.
4. Take care to transport the compressor correctly, DO NOT overturn it or lift it with hooks or ropes.
5. Anti-Vibration Feet are available as an optional extra from your Sealey stockist If to be fitted: raise the compressor using a suitable pallet truck or fork lift and push the supports into the base of each foot (fig.3)
6. Position the compressor on a flat surface or with a maximum permissible inclination of 10° (fig.1). Site in a well ventilated area, protected against atmospheric pollution and not in a place subject to explosion hazard. If the surface is inclined and smooth, check if the compressor moves whilst in operation. If the surface is in a raised position, make sure the compressor cannot fall, securing it in a suitable way.
7.  To ensure good ventilation and efficient cooling, the compressor’s belt guard must be at least 100cm from any wall (fig.2).
8. Remove the plastic transit plug from the oil filler hole (figs.4 & 5) and replace it with the filler/breather plug. It is a push fit, ensure that it is pushed fully home.
9. Before using the compressor, check the oil level by observing the sight glass as shown in figs.4 & 5. If the oil is not up to the max. mark, it should be topped up with synthetic oil (see section 5.7. for recommended oils). We DO NOT recommend using mineral oil in these compressors. DO NOT overfill.
   
   
   
   

OPERATION

❒ WARNING! Ensure that you have read, understood and apply Section 1 Safety Instructions.
❒ 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, and could cause damage to the compressor.
NOTE: 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.

STARTING THE COMPRESSOR

1. Check that both switches (on the control box and the pressure switch housing) are in the OFF (0) position. Plug into the main electrical supply. To turn the compressor on, turn the switch on the control box (fig.6) to the ‘1’ position and then turn the switch on the pressure switch housing (fig.7) clockwise to position ‘I’.
   The first motor/pump will start up followed a few seconds later by the second motor/pump.
2. When starting the compressor for the first time, leave it running with no air tools connected to the air outlet. Make sure that the pressure in the tank rises and that the compressor stops automatically when the maximum pressure value allowed – written on the plate and shown on the gauge (fig.7) – is achieved. The compressor will now operate automatically.
   The pressure switch stops the motor when the maximum tank pressure is reached and restarts it when the pressure falls below the minimum threshold – approx. 2bar (29psi) less than the maximum pressure.
3. To stop the compressor, first turn the main switch (fig.7) to the ‘0’ position and then turn the switch on the control box (fig.6) to the ‘0’ position. The compressed air inside the compressor heads will flow out, making the restart easier and preventing the motors from being damaged. DO NOT, other than in an emergency, stop the compressor by switching off at the mains, or by pulling the plug out, as the pressure relief will not then operate and motor damage may result upon restart.
4. The motors of the compressor are fitted with a thermal breaker located in the housing on top of the motors. The manual resetting buttons are located in the end of the housings as shown in fig.10A. When the individual breaker is tripped, wait for a few minutes and then press the reset button.
   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.7) indicates the pressure inside the main tank,
   NOT the pressure supplied to the air equipment. Should the pressure in the main tank exceed the pre-set switch maximum, the safety valve will activate.
   ❒ WARNING! For this reason DO NOT tamper with, or adjust, the switch or safety valve.
   
   

MAINTENANCE

In order to keep the compressor in good working condition, periodic maintenance is essential.
IMPORTANT! Failure to carry out maintenance tasks may invalidate the warranty on your compressor.

❒ WARNING! Before performing any maintenance operation, switch off the compressor, disconnect from electricity supply and release all air from the tank (except for 5.3.a)

1. OPERATIONS TO BE CARRIED OUT AFTER THE FIRST 50 WORKING HOURS:
   a) Check that all bolts/nuts are tight, particularly those retaining the crankcase and cylinder head. b) Replace the lubricating oil – see para 5.5.a.
2. OPERATIONS TO BE CARRIED OUT WEEKLY:
   a) Drain condensation by opening the valve located under the tank (fig.9). Place a container under the valve and open the valve by turning anti-clockwise.
   WARNING! Take care if there is still pressure inside the cylinder as water could flow out with coinsiderable force. Recommended pressure 1 – 2bar max.
   b) Check oil level and, if necessary, top up.
3. OPERATIONS TO BE CARRIED OUT EVERY 50 HOURS:
   (or more frequently, if the compressor operates in a very dusty atmosphere):
   a) Remove the air filter element (fig.8).
   Using stored air from the compressor’s tank, clean the filter with compressed air. (Wear eye protection and DO NOT direct air towards the body or hands). DO NOT operate the compressor without the filter as foreign bodies or dust could seriously damage the pump. Replace the filter element and air filter housing.
   b) Check for oil leaks.
4. OPERATIONS TO BE CARRIED OUT EVERY 100 HOURS:
   a) Check the automatic cut-out at max. pressure and the automatic cut-in at 2 bar below.
5. OPERATIONS TO BE CARRIED OUT EVERY 400 HOURS:
   a) Replace the lubricating oil. For oil specifications see Remove the filler/breather plug, then remove the oil drainer plug (figs.4 and 5), draining the oil into a container. Drain when the compressor is hot so that the oil drains rapidly and completely. Replace oil drain plug and refill through the filler/ breather aperture. Do not overfill. Replace filler/breather plug.
   ❒ WARNING! Never mix different oils and do not use nondetergent/low quality oils as the compressor may be damaged.
   ❒ WARNING! Dispose of waste oil only in accordance with local authority requirements.
   b) Replace air filter. (fig.8)
   c) Check all tube fittings and electrical connections.
   d) Inspect pressure tank inside and out for damage or corrosion.
6. MAINTENANCE SCHEDULE:
   

   Maintenance Operations	Weekly	50hrs	100hrs	400 hrs
   Drain condensation	•
   Check oil level	•
   Clean intake filter		•
   Check for oil leaks		•
   Replace oil				•
   Check cut-out			•
   General cleaning of compressor			•
   Replace air filter				•
   Check tube fittings and electrical connections				•
   Internal & external inspection of tank				•

   

7. RECOMMENDED OILS
   Synthetic oil suitable for temperatures ranging from -5°C to 45°C:
   viscosity 5W50. We DO NOT recommend using mineral oil in
   these compressors.
   Part No.       Qty.                Description
   FSO1         1ltr x 12        Compressor oil fully synthetic
   FSO1S       1ltr x 1          Compressor oil fully synthetic
   FSO5         5ltr x 1          Compressor oil fully synthetic
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.

TROUBLE SHOOTING

Fault	Cause	Remedy
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.
Pressure switch valve leaks when compressor is idle.	Non-return valve seal defective.	Discharge all tank pressure. Referring to fig.11, unscrew valve cap ‘A’. Clean rubber disc ‘B’ and its seat. Refit all parts accurately.
Compressor stops and does not restart.	Power failure. Motor failure.	Check electricity supply and fuse. Contact Authorised Service Agent.
Compressor does not stop at max pressure.	Pressure switch fault.	Contact Authorised Service Agent.
Compressor does not reach max pressure.	Filter clogged. Head gasket or valve fault.	Replace filter element. Contact Authorised Service Agent.
Compressor noisy with metallic knock.	Low oil level. Bearing or piston damage.	Turn off and top up oil immediately. Contact Authorised Service Agent.



ENVIRONMENT PROTECTION Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids according to local regulations.

WEEE REGULATIONS Dispose of this product at the end of its working life in compliance with the EU Directive on Waste Electrical and Electronic Equipment (WEEE). When the product is no longer required, it must be disposed of in an environmentally protective way. Contact your local solid waste authority for recycling information.

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 is required for any claim.

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
| www.sealey.co.uk