Van Air Systems AC 50 User Manual

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

AIR-COOLED AFTERCOOLER

FOR COMPRESSED AIR SYSTEMS

MODELS AC-50 thru AC-130

(ALL VOLTAGES)

JULY 2005

REV. A

P/N 32-0225

WARNING

BEFORE STARTING INSTALLATION OR MAINTENANCE PROCEDURES, TURN OFF ELECTRICAL POWER AND COMPLETELY DEPRESSURIZE THE UNIT. FAILURE TO HEED THIS WARNING MAY RESULT IN SERIOUS PERSONAL INJURY AND/OR DAMAGE TO THE UNIT.

NEVER REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS UNIT WHILE IT IS UNDER PRESSURE.

WHEN INSTALLING THIS UNIT, ALWAYS COMPLY WITH THE NATIONAL ELECTRICAL CODE AND ALL OTHER APPLICABLE FEDERAL, STATE AND LOCAL CODES.

NEVER OPERATE THIS AFTERCOOLER IF THERE IS A LEAK IN THE CORE. IMMEDIATELY TAKE THE UNIT OUT OF SERVICE AND FIX OR REPLACE THE CORE.

NEVER OPERATE THE AFTERCOOLER ABOVE THE MAXIMUM RATED OPERATING CONDITIONS, AS OUTLINED IN SECTION 3.1.

NEVER REMOVE THE FAN GUARD WHILE THE AFTERCOOLER IS OPERATING. CONTACT WITH THE ROTATING FAN BLADE(S) MAY RESULT IN SERIOUS PERSONAL INJURY.

DURING NORMAL OPERATION, THE INLET PIPING MAY REACH TEMPERATURES OF 150oF TO 400oF. CONTACT WITH THE PIPING MAY RESULT IN SERIOUS PERSONAL INJURY.

HANDLING INSTRUCTIONS SECTION 1

1.1 HANDLING THE AFTERCOOLER

CAUTION

NEVER LIFT THE AFTERCOOLER BY THE CORE OR INLET AND OUTLET.

WHEN MOVING OR LIFTING THE UNIT, PROTECT THE CORE FROM ACCIDENTAL DAMAGE.

1.2 EQUIPMENT CHECK

Inspect the aftercooler for any damage that may have occured during shipment. Inspect all items shipped with the unit.

IF THE UNIT HAS BEEN DAMAGED DURING SHIPMENT:

(1) Notify carrier immediately

Take extreme care when unpacking, moving or installing. The core is exposed. Damage to the core or fins may render the unit inoperable.

PRINTED IN THE U.S.A. PAGE 1

(2) DO NOT operate the unit before consulting factory

ASSEMBLY, LEG INSTALLATION SECTION 2

2.1 INSTALLING THE LEGS

This unit was shipped without the legs installed. The legs should be installed before placing the aftercooler in the piping system. Carefully lift and support the unit several feet from the floor.

Position the legs against the unit and fasten them in place using the fasteners provided. Make sure the fasteners are tightened in place.

SPECIFICATIONS AND DIMENSIONS SECTION 3

3.1 SPECIFICATIONS

WEIGHT

AC-50 ...................... 110 LBS AC-100 .................. 140 LBS

AC-60 ...................... 110 LBS AC-110 .................. 145 LBS

AC-70 ...................... 120 LBS AC-120 .................. 200 LBS

AC-80 ...................... 120 LBS AC-130 .................. 300 LBS

AC-90 ...................... 140 LBS

DIMENSIONS .............. See Section 3.2

INLET/OUTLET CONNECTIONS

AC-50 .............. 1" NPT (F) AC-100 ........ 1-1/2" NPT (F)

AC-60 .............. 1" NPT (F) AC-110 ........ 1-1/2" NPT (F)

AC-70 .............. 1-1/2" NPT (F) AC-120 ........ 2" NPT (F)

AC-80 .............. 1-1/2" NPT (F) AC-130 ........ 2" NPT (F)

AC-90 .............. 1-1/2" NPT (F)

MAXIMUM WORKING PRESSURE

ALL MODELS .................. 250 PSIG

MAXIMUM WORKING TEMPERATURE

ALL MODELS .................. 350OF

MATERIALS OF CONSTRUCTION

CABINET ......................... Galvanized steel

FAN GUARD ................... Steel with baked enamel finish

FAN ................................. Heavy gauge aluminum with steel hub

CORE .............................. Aluminum fins on copper tubes

MOTOR ........................... Open vented

MOTOR SPECIFICATIONS AND DATA

See Wiring Diagram, Figure 5 on page 6.

FIGURE 1 LEG INSTALLATION DETAIL

FAN DATA (AMBIENT AIR FLOW)

AC-50 THRU AC-80 ........ 1375 SCFM

AC-90 THRU AC-100 ...... 2450 SCFM

AC-110 ............................ 2350 SCFM

AC-120 ............................ 4600 SCFM

AC-130 ............................ 4700 SCFM

ELECTRICAL REQUIREMENTS

AC-50-1 thru AC-130-1 .......... 115-1-60 w/ ODP motor

AC-50-2 thru AC-130-2 .......... 115-1-60 w/ TEFC motor

AC-50-3 thru AC-130-3 .......... 230-1-60 w/ TEFC motor

AC-50-4 thru AC-130-4 .......... 230-3-60 w/ TEFC motor

AC-50-5 thru AC-130-5 .......... 460-3-60 w/ TEFC motor

MAXIMUM CAPACITY (SCFM)

Rated capacities are based on the following conditions: Inlet and approach temperature at inlet pressures 80 to 125 PSIG.

Approach Temperature: The number of degrees above the temperature of the cooling medium (in this case ambient air) to which the aftercooler reduces the compressed air. A higher approach does not mean better performance.

INLET TEMP.

APPROACH TEMP.

150OF 200OF 350OF250OF 300OF

MODEL

AC-50

AC-60

AC-70

AC-80

AC-90

AC-100

AC-110

AC-120

AC-130

MAXIMUM PRESSURE DROP LESS THAN 3 PSI.

160

184

102

138

160

275

318

119

140

190

220

380

440

125

150

177

235

270

425*

480*

120

145

105

125

207

250

112

142

172

285

345

117

140

177

215

355

430

100

125

110

175

217

100

120

150

240

300

100

124

150

187

300

375

110

145

190

102

130

204

257

110

127

160

250

320

100

135

175

* Maximum ratings restricted by pressure drop: actual thermal capacities are higher.

120

185

240

100

116

148

231

300

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SPECIFICATIONS AND DIMENSIONS SECTION 3

3.2 DIMENSIONS AND COMPONENT LOCATIONS

MODEL

AC-50

AC-60

AC-70

AC-80

AC-90

AC-100

AC-110

AC-120

AC-130

30.50"

43.50"

47.63"

51.68"

46.50"

49.50"

55.50"

50.50"

53.50"

59.50"

22.50"

25.50"

31.50"

22.00"

21.50"

22.00"

14.75"

19.09"

32.09"

36.09"

10.75"

4.00"

28.12"

41.12"

40.80"

44.80"

18.29"

18.23"

18.50"

2.17"

2.79"

2.85"

2.83"

N IN/OUT

1" NPT

1-1/2" NPT

2" NPT

INSTALLATION SECTION 4

4.1 LOCATION

CAUTION

DO NOT LOCATE THIS AFTERCOOLER WHERE PERSONNEL MAY CONTACT THE INLET PIPING UNLESS THE UNIT IS PROTECTED BY WARNING SIGNS AND/OR A BARRIER. DURING NORMAL OPERATION, THE INLET PIPING MAY BECOME EXTREMELY HOT (150OF TO 400OF). CONTACT MAY RESULT IN SERIOUS PERSONAL INJURY.

DO NOT INSTALL THIS UNIT IN AN ENVIRONMENT OF CORROSIVE GASES OR CHEMICALS. MAKE SURE THAT THE MATERIALS USED IN THIS UNIT (listed on the previous page) ARE COMPATIBLE WITH THE ATMOSPHERIC CONDITIONS.

The aftercooler should be located far enough away from the compressor so that there are no vibrations transmitted from the compressor. A

FLEXIBLE HOSE MUST BE INSTALLED IN THE PIPING TO VALIDATE THE WARRANTY AND TO PREVENT DAMAGE TO THE AFTERCOOLER FROM VIBRATION IN THE PIPING! REFERENCE

Section 4.3 for instructions.

level to allow proper drainage of fluids from the outlet manifold.

The aftercooler must be installed at least 1 foot from walls or obstructions. It is important for the unit to have an adequate air supply for cooling at all times. If more than one unit is to be installed in the same area, allow at least 1 foot between them.

Aftercoolers equipped with an ODP motor must be installed indoors. All others can be installed indoors or outdoors. If the unit is to be installed outdoors or in an area where ambient temperatures can fall below 35oF, precautions must be made to prevent freeze-up and damage to the unit. The drain lines and separator must be heat traced and/or insulated and the unit should be protected from the wind. REFERENCE Section 4.5 for details.

4.2 MOUNTING THE UNIT

After selecting the proper location as outlined above, the aftercooler should be mounted to the installation surface. Mounting holes are provided on the leg support braces. Reference Section 3.2 for mounting hole locations and dimensions. Use hardware (not supplied) sized for the mounting holes.

The location should be level and capable of supporting the aftercooler and all components and piping to be installed. The aftercooler must be

PRINTED IN THE U.S.A. PAGE 3

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Van Air Systems AC 50 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual