Vmac PREDATAIR60 Installation Manual
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Vmac PREDATAIR60 Installation Manual

Hydraulic compressor
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Hydraulic Compressor
1.0 General Information ...................................................................3
1.1 Specifications and Components ...............................................3
2.0 Installation Requirements..........................................................6
2.1 Ventilation Requirements..........................................................6
2.2 Hydraulic Requirements..........................................................11
2.3 Electrical Requirements ..........................................................12
2.4 Air Receiver Requirements .....................................................13
3.0 Installing the PREDATAIR60 ...................................................15
3.1 Mounting the Compressor.......................................................15
3.2 Connecting the Wiring.............................................................15
3.3 Speed Control .........................................................................20
4.0 Completing the Installation .....................................................23
4.1 Before Operation Checklist .....................................................23
4.2 After Engaging the Hydraulics Checklist.................................23
5.0 Testing Ventilation ...................................................................26
5.1 Calculating Duty Cycle............................................................26
5.2 Testing the Installation ............................................................28
5.3 Analyzing the Test Results .....................................................31
6.0 Hydraulic System Data.............................................................34
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
Ordering Parts.................................................................................44
VMAC - Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
Fax: 1-250-740-3201
PREDATAIR60
1

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  • Page 1: Table Of Contents

    2.0 Installation Requirements............6 2.1 Ventilation Requirements............6 2.2 Hydraulic Requirements............11 2.3 Electrical Requirements ............12 2.4 Air Receiver Requirements .............13 3.0 Installing the PREDATAIR60 ...........15 3.1 Mounting the Compressor............15 3.2 Connecting the Wiring.............15 3.3 Speed Control .................20 4.0 Completing the Installation .............23 4.1 Before Operation Checklist .............23...

  • Page 2: Installation Manual

    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.

  • Page 3: General Information

    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.
  • Page 4 Minimum clearance for servicing - 6 inches Oil cooler (inside cover, must have proper ventilation) Hydraulic fluid return Hydraulic fluid inlet Figure 1 – System components VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 5 Figure 2 – System wiring VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 6: Installation Requirements

    • 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.
  • Page 7 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.
  • Page 8 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 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 9 (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). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 10 Figure 7 – Minimum clearances VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 11: Hydraulic Requirements

    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).

  • Page 12: Electrical Requirements

    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...

  • Page 13: Air Receiver Requirements

    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.
  • Page 14 Auxiliary Tank PREDATAIR60 Tank 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. VMAC – Vehicle Mounted Air Compressors...

  • Page 15: Installing The Predatair60

    (Figure 11) • power-actuating remote switch (Figure 12) • direct-actuating switch (Figures 13 and 14) The preferred method is to use a ground-actuating remote switch. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 16 18 AWG Remote switch see table 1 for correct wire gauge Battery Fuse Relay Remote Switch Figure 11 – Ground actuating This method keeps heavy current-carrying wires short. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 17 18 AWG Remote switch see table1 for correct wire gauge Battery Fuse Relay Remote Switch Figure 12 – Power actuating This method keeps heavy current-carrying wires short. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 18 Battery Fuse Remote Switch Figure 13 – Direct actuating This method is NOT recommended, because the heavy current carrying wires are too long. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 19 Battery Fuse Switch Figure 14 – Direct actuating alternative This is a more functional method for direct power wiring as the current carrying wires are much shorter. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 20: Speed Control

    3.3 Speed Control The PREDATAIR60 has the facility to signal for a higher engine speed under high air demand conditions and for a lower engine speed under low air demand conditions. Most work trucks either have a built in electrically activated idle up system or an after-market product may be available which will provide this function.
  • Page 21 Single Speed For single speed operation, do not use the purple wire from the PREDATAIR60 wire harness. Connect a throttle control so that the engine goes to the desired speed when the compressor is engaged (Figure 15). From PREDATAIR60 activation circuit...
  • Page 22 Speed 1 Speed 2 Set Speed 1 to the miniumum GPM rating Set Speed 2 to achieve the desired CFM Throttle control Figure 16 – Two speed operation VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 23: Completing The Installation

    4.1 Before Operation Checklist Make sure that the following have been completed before operating the PREDATAIR60 for the first time: Check the compressor oil level. The compressor has been filled to the correct level prior to shipping, but the oil is very clear and it is difficult to see the level.

  • Page 24: Setup, Performance Testing And Adjustments

    135 psi. If the air pressure drops below 100 psi, increase hydraulic flow to bring the pressure back up. Do not exceed specifications VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 25 You should hear a hissing noise as the air vents. The engine should idle down to the lower speed setting. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 26: Testing Ventilation

    Total CFH (Cubic Feet per Hour) Duty Cycle = Total CFH ÷ 3600 x 100% = ____ ÷ 3600 x 100% = ____% Form 1 – Duty Cycle Calculation VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 27 0.103 24 CFM 0.120 30 CFM 0.137 36 CFM 0.147 42 CFM 0.158 48 CFM 0.167 54 CFM 100% 0.176 60 CFM Table 3 – Orifice sizes VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 28: Testing The Installation

    5.2 Testing the Installation 1. Install the PREDATAIR60 with ventilation that seems reasonable for the application. Use maximum ventilation for high duty cycle, high ambient temperature applications. Somewhat less ventilation may be acceptable for low duty cycle, low ambient temperature applications.
  • Page 29 Owner’s Manual. If the system shut down due to and over-temperature condition, check all oil levels, improve ventilation and repeat the test once the system has cooled. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 30 52:30 53:00 53:30 54:00 54:30 55:00 55:30 56:00 56:30 57:00 57:30 58:00 58:30 59:00 59:30 60:00 Total ÷ 2 ÷ 20 Average Form 2 – Temperature Data VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 31: Analyzing The Test Results

    T3-(Tx-Tmax) = ____ - (____ - ____) = _____ Conclusion: Form 3 – Ventilation Analysis VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 32 “Reduce • compressed air usage when outside air temperature is • greater than x°F (y°C). For example 85°F (29°C) from the example analysis. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 33 T3-(Tx-Tmax) = _100_ - (_166_ - _151_) = _85F_ Conclusion: Ventilation must be increased or the duty cycle reduced when the ambient temperature is greater than 85F Table 5 – Example Ventilation Analysis VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 34: Hydraulic System Data

    2,400 psi during normal operation. The pump must be rated for 1,900 psi steady operation and 2,600 psi intermittent to allow an additional 200 psi for pressure drop in the hydraulic lines (external to the PREDATAIR60) during startup with cold oil. 3000...

  • Page 35: Hydraulic Line Sizing

    The following provides specific line sizing recommendations (inside diameter) for vehicle hydraulic system installations intended for use with the PREDATAIR60 compressor system under the following conditions: • Extreme Cold Climate where temperatures are below -4°F (-20°C)
  • Page 36 The following tables, hydraulic flow is below minimum specifications. These flow ratings are for startup only, not for operation of the PREDATAIR60. Refer to Section 2.2 Hydraulic Requirements for flow specifications. 6.2.1 Suction Line Sizing Failure to select the correct suction line size can result in pump cavitation and premature pump failure.
  • Page 37 If hydraulic oil tank is below the pump, deduct 10% from the hose length limits for each 1 foot that the oil level in the tank is below the pump suction port. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 38 Choose a return line size from Table 11 (based on 10 ft/sec fluid velocity), then upsize the line, if necessary, using Table 12. Failure to follow this return line sizing procedure can lead to failure of the shaft seal on the PREDATAIR60 hydraulic motor during cold startup of the hydraulic pump.
  • Page 39 3 ft hose size selection from Table 10 line size 3/4” from Table 11 need to upsize to 1-1/4” conclusion use 1-1/4” return line VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 40: Hydraulic System Filtration

    GPM on some mobile hydraulic systems. For a 20 GPM hydraulic system, this equates to a size range from 2 gallons (14 lbs) to 60 gallons (430 lbs) of oil. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 41 The recommended size of hydraulic oil reservoir for use with the PREDATAIR60 is 15 to 25 gallons. It is wise to stay towards the high end of this range if one or more of these conditions exist: • large cylinders are being used in the system •...
  • Page 42 It maintains constant atmospheric pressure above the oil. • A sight-glass provides a direct visual indication of oil level without opening up the reservoir. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...
  • Page 43 • A reservoir heater for preheating the hydraulic oil prior to startup in extreme cold climate conditions. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

  • Page 44: Avoiding Cavitation

    Make sure that the reservoir is of sufficient size Ordering Parts To order parts, contact your nearest VMAC dealer or contact VMAC directly at 250.740.3200 or 1.800.738.8622. Have the system serial number, a description of the part and the quantity. The following accessories are also available from VMAC.
  • Page 45 Includes oil, filters, seals and O-rings. 200 hour and 400 hour service interval kits are available Cold Climate Kit Preheats the hydraulic oil during cold startup of the PREDATAIR60 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Local: 1-250-740-3200 Fax: 1-250-740-3201...

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