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PREDATAIR60
Installation Manual
45 pgs2.23 Mb0

Vmac PREDATAIR60 Installation Manual

VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
Fax: 1-250-740-3201
1
Installation Manual
PREDATAIR60
Hydraulic Compressor
1.1 Specifications and Components ...............................................3
2.1 Ventilation Requirements..........................................................6
2.2 Hydraulic Requirements..........................................................11
2.3 Electrical Requirements ..........................................................12
2.4 Air Receiver Requirements .....................................................13
3.1 Mounting the Compressor.......................................................15
3.2 Connecting the Wiring.............................................................15
3.3 Speed Control .........................................................................20
4.1 Before Operation Checklist .....................................................23
4.2 After Engaging the Hydraulics Checklist.................................23
4.3 Setup, Performance Testing and Adjustments .......................24
5.1 Calculating Duty Cycle............................................................26
5.2 Testing the Installation ............................................................28
5.3 Analyzing the Test Results .....................................................31
6.1 Hydraulic Oil Type...................................................................34
6.2 Hydraulic Line Sizing ..............................................................35
6.3 Hydraulic System Filtration .....................................................40
6.4 Hydraulic Oil Reservoir ...........................................................40
6.5 Avoiding Cavitation .................................................................44
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Document #1930125
Installation Manual for VMAC System H600001 PREDATAIR60 Hydraulic Compressor
Changes and Revisions
Version Revision Details Revised by/date Approved Implemented
00 Original manual IB June 16 2006 SM 25 Aug 2006 28 Aug 2006
Important Information
The information in this manual is intended for certified VMAC installers who have been trained in installation procedures and for people with mechanical trade certification who have the tools and equipment to properly and safely perform the installation. Do not attempt this installation if you do not have the appropriate mechanical training, knowledge and experience.
Follow all safety precautions for mechanical work. If you have difficulty with the installation, contact VMAC.
The VMAC warranty form is located at the back of this manual. This warranty form must be completed and mailed or faxed to VMAC at the time of installation for any subsequent warranty claim to be considered valid.
To order parts, contact your VMAC dealer. Your dealer will ask for the VMAC serial number, part number, description and quantity. To locate your nearest dealer, call 1-800-738-8622.
Copyright 2006
All trademarks used in this manual are the property of the respective copyright holder.
The contents of this manual may not be reproduced in any form without the express
written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.
Printed in Canada
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1.0 General Information
Read this manual before beginning the installation so that you can understand the hydraulic, electric (Figure 2) and ventilation requirements. This will ensure a successful installation and effective operation of the PREDATAIR60 (Figure 1).
1.1 Specifications and Components
This is a flooded-lobe, rotary screw compressor (filled with VMAC certified and approved synthetic oil) driven by a hydraulic motor. Compression occurs when inlet air (at normal atmospheric pressure) enters a chamber where it is trapped between the rotating rotor lobes. A lubricated pitch line provides sealing. As the lobes mesh, they reduce the volume of the air, compressing it to the desired pressure.
The system has a two-stage air/oil separator. The first separation stage consists of baffles, which perform mechanical separation. The second stage uses a special separation element, which delivers dry air to the outlet.
Pressure regulation is achieved with a mechanical inlet control valve and an adjustable pressure regulator.
The compressor is protected by a paper-type replaceable air filter and a spin-on type oil filter. Oil is removed from the delivered service air by a coalescing separator element.
Safety features include:
• 2,650 psi hydraulic pressure relief valve
• 200 PSI relief valve in oil/air tank
• blow-down valve to discharge system pressure on shutdown
• temperature safety sensor in compressor
Do not disable or bypass the over-temperature shutdown circuit. Failure of the shutdown system could result in equipment damage, injury or death.
A liquid-to-air cooler maintains operating temperatures in an optimal performance range which increases system durability and reduces the temperature of the compressed air.
The system pressure is pre-set at 150 psi. Do not increase this pressure setting as it will also increase the hydraulic operating pressure. To reduce the pressure, use a Filter Regulator Lubricator (FRL).
!
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Compressor air filter (must have proper ventilation)
Oil cooler (inside cover, must have proper ventilation
)
Air discharge port with check valve
Hydraulic fluid inlet
Hydraulic fluid return
Blowdown cap with internal coalescing filter
Minimum clearance for servicing - 6 inches
Compressor oil fill (shipped full from the factory)
Oil level sight glass (make sure this can be easily accessed for daily inspection)
Compressor oil drain
Oil filter
Cooling fan
Regulator on inlet valve (inside cover)
Minimum clearance for servicing - 6 inches
Figure 1 – System components
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Figure 2 – System wiring
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2.0 Installation Requirements
The information in this section is very important for proper operation of the compressor. Read these requirements before beginning installation.
Before installing the compressor, examine the possible locations and consider the following factors when selecting a location:
• it is convenient for making electrical, hydraulic and air connections and does not require extensive plumbing
• hose and wire lengths will be the shortest possible and a minimum number of 90 degree fittings will be used
• the oil level at the sight glass can be checked easily
• there will be sufficient clearance around the unit for good air
circulation and effective cooling
• it can be serviced easily without having to disconnect lines or remove and reposition the unit
• it will be protected from excessive exposure to the elements and possible incidental damage from other operations
• it is away from heat sources such as engines, exhaust systems or other components that generate heat
• it is not in a location where it will be exposed to high contamination levels, including combustible gases
2.1 Ventilation Requirements
During operation, the PREDATAIR60 can develop considerable heat, as much as a house furnace.
Proper ventilation is vital for proper operation and to avoid damage to components.
If you are installing the compressor into a new configuration, refer to section 5.0 Testing Ventilation for information.
2.1.1 Top Mounting
This is the preferred mounting location. Placing the unit on top of the service body (Figure 3) provides the best access to ambient air and provides the best cooling. Maintain a minimum of 6” between the sides of the compressor housing and all other solid objects
!
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2.1.2 Enclosed Mounting
Mounting the PREDATAIR60 in an enclosure (Figure 3) will limit the access to ambient air, restrict the escape of hot air from around the unit and have an adverse effect on cooling. Make sure that adequate ventilation is provided so the cooling system will function properly.
Top mount
Enclosed mount
Figure 3 – Mounting locations
It is not possible to make absolute recommendations regarding ventilation because of the widely differing circumstances that are possible. Duty cycle, ambient temperature and enclosure shape are some of the important variables.
Significant ventilation and additional cooling will be required if the PREDATAIR60 is mounted in the same enclosure as the hydraulic oil reservoir. The heat generated during operation will continue to heat the hydraulic oil, even with fresh, ambient air entering the cooler
Ideal ventilation will provide good airflow through the unit with no restrictions (Figure 4). Cool ambient air ducted to the cooler and exhaust fan are recommended.
!
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Figure 4 – Ideal ventilation with ambient air vent of a suitable
size for the application
Avoid installing deep into enclosures that will not permit adequate air circulation (Figure 5).
Enclosure
Enclosure
Figure 5 – Avoid deep installation
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The effects of hot air recirculation drastically reduce cooling but those effects can be reduced by using air dams (Figure 6).
Top view
Hot air recirculating
Top v ie w
Dams installed to block recirculation
Figure 6 – Reducing hot air recirculation
Recommended minimum clearances if no back ventilation is possible are very important (Figure 7) but are not adequate for 100% operational capacity (see section 5.0 Testing Ventilation).
Enclosure sizes (Figure 8) should meet minimum requirements for optimum operation (see section 5.0 Testing Ventilation).
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6”
6”
6”
6”
Figure 7 – Minimum clearances
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22”
24”
With back ventilation Without back ventilation
Figure 8 – Recommended enclosure size
If the PREDATAIR60 is mounted inside a service body with a door that needs to be manually opened to provide ventilation, install a switch on the door so that the compressor will only operate when the door is open (Figure 9).
Battery
Relay
PREDATAIR60
R
emote s
witch
Door switch
Figure 9 – Door switch
2.2 Hydraulic Requirements
If the compressor is being installed on a truck that does not have a hydraulic system, you will find information on selecting and installing hydraulic components in section 6.0 Hydraulic System Data.
Compressor capacity depends on hydraulic flow. For single speed operation a minimum of 14 GPM and a maximum of 20 GPM hydraulic oil flow is required. For two speed operation, a minimum of 12 GPM and a maximum of 22 GPM hydraulic oil flow is required.
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Nominal Air Flow vs Hydraulic Flow
0
10
20
30
40
50
60
70
12 13 14 15 16 17 18 19 20 21 22
Hydraulic Flow (GPM
)
A
i
r
F
l
o
w
(
C
F
M
)
These are nominal values only. Due to variations in hydraulic system efficiency, load and flow tests should be performed to confirm that the desired CFM has been achieved.
If the compressor is being installed on a truck that already has a functioning hydraulic system, check the specifications for that system to ensure that it meets minimum requirements.
The information in this manual is based on a fixed displacement pump. Special considerations may be required for a variable displacement pump.
2.3 Electrical Requirements
The PREDATAIR60 requires a steady 17 Amps @ 12 VDC to operate. A 30 Amp fuse or circuit breaker is recommended.
To assure an un-interrupted supply of power, the ground wire should be routed either to the negative terminal of the battery or to a substantial, fully grounded point on the vehicle chassis, located in an area which will provide a good ground at all times.
Power should be tapped directly from the positive terminal of the battery through a relay with a contact rating of at least 20 Amps. Using a relay allows the heavy gauge power wire to be routed directly and permits the use of a light (18 AWG) wire between the relay and the control switch.
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2.3.1 Wire Size Selection
Selecting the correct wire size is vital for proper operation. If the wire size is too small, voltage drop will be excessive and the compressor will operate erratically. Measure the length required for both the power wire and the ground wire, add them together and select the correct wire size from Table 1.
Total length of Power wire PLUS Ground wire Recommended Wire Gauge
Less than 10 ft. 12AWG
10 ft. to 15 ft. 10AWG
More than 15 ft. 8AWG
Table 1 – Wire gauge size
Never connect the PREDATAIR60 so that it switches on at the same time as the PTO is engaged. This can cause sudden, excessive hydraulic pressure which can damage components.
2.4 Air Receiver Requirements
The PREDATAIR60 uses an unloader system which minimizes fuel burn, equipment wear, cooling load, enclosure temperature, hydraulic temperature and noise, when compressed air is not being used. For this unloader system to work most efficiently, and to avoid having the compressor loading and unloading too frequently, some air receiver volume is very beneficial.
If the plumbing downstream from the PREDATAIR60 is tight, a 5 gallon air receiver is adequate. If a receiver tank is not possible, then consider using the existing welded tubular structure within the service body as an air receiver. For reference, 21’ of 3/16” wall 2-1/2” x 2-1/2” square tube has a volume of 5 gallons.
If you use an auxiliary air tank with this system, the line to the auxiliary tank must be installed as high as possible (not in the bottom of the tank) to prevent water from clogging the line (Figure 10). Failure to observe these requirements will result in damage to the system.
!
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PREDATAIR60 Tank
Auxiliary Tank
One-way check valve built into PREDATAIR60 tank
Install this line high on the tank, not at the bottom
Figure 10 – Auxiliary tank connection
A one-way check valve is built into the PREDATAIR60 tank. Do not install an additional check valve as this may cause undesirable operations.
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