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Hydraulic Compressor
1.0 General Information ...................................................................3
1.1 Specifications and Components ...............................................3
2.0 Installation Requirements..........................................................6
2.1 Air Receiver Requirements .......................................................6
2.2 Ventilation Requirements..........................................................7
2.3 Hydraulic Requirements............................................................9
2.4 Electrical Requirements ..........................................................10
3.0 Installing the PREDATAIR .......................................................11
3.1 Mounting the Compressor.......................................................11
3.2 Connecting the Wiring.............................................................12
3.3 Speed Control .........................................................................13
4.0 Completing the Installation .....................................................16
4.1 Before Operation Checklist .....................................................16
4.2 After Engaging the Hydraulics Checklist.................................16
4.3 Setup, Performance Testing and Adjustments .......................17
5.0 Testing Ventilation ...................................................................19
5.1 Calculating Duty Cycle............................................................19
5.2 Testing the Installation ............................................................21
5.3 Analyzing the Test Results .....................................................24
6.0 Hydraulic System Data.............................................................27
6.1 Hydraulic Oil Type...................................................................27
6.2 Hydraulic Line Sizing ..............................................................28
6.3 Hydraulic System Filtration .....................................................33
6.4 Hydraulic Oil Reservoir ...........................................................34
6.5 Avoiding Cavitation .................................................................37
Ordering Parts.................................................................................38
VMAC - Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289 Local: 1-250-740-3200
Fax: 1-250-740-3201
Installation Manual
PREDATAIR
1
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Summary of Contents for Vmac PREDATAIR
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Page 1: Table Of Contents
2.0 Installation Requirements............6 2.1 Air Receiver Requirements ............6 2.2 Ventilation Requirements............7 2.3 Hydraulic Requirements............9 2.4 Electrical Requirements ............10 3.0 Installing the PREDATAIR ............11 3.1 Mounting the Compressor............11 3.2 Connecting the Wiring.............12 3.3 Speed Control .................13 4.0 Completing the Installation .............16 4.1 Before Operation Checklist .............16... - Page 2 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.
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Page 3: General Information
This will ensure a successful installation and effective operation of the PREDATAIR (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 inlet Hydraulic fluid return Figure 1 – System components VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
- Page 5 INLET VALVE Figure 2 – System wiring VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
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Page 6: Installation Requirements
2.1 Air Receiver Requirements A reservoir tank is recommended, particularly for systems using the two-speed function. The PREDATAIR 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. -
Page 7: Ventilation Requirements
If the plumbing downstream from the PREDATAIR is tight (no leaks), a 5 gallon air receiver is adequate. 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 3). - Page 8 Cool ambient air ducted to the cooler and installing an exhaust fan to remove hot air are recommended. If the PREDATAIR 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 5) or the pull-out drawer is extended.
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Page 9: Hydraulic Requirements
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 PREDATAIR) during startup with cold oil. Compressor capacity depends on hydraulic flow. -
Page 10: Electrical Requirements
Special considerations may be required for a variable displacement pump. 2.4 Electrical Requirements The PREDATAIR 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 11: Installing The Predatair
Direction of hydraulic flow is critical. If reversed, high pressure buildup may cause damage to the compressor and a potential hose burst hazard. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201... -
Page 12: Connecting The Wiring
Fuse or circuit breaker PREDATAIR Green Battery see table 1 for correct wire gauge Battery Fuse Ignition-switched relay Display box inside cabinet protected from weather Figure 7 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201... -
Page 13: Speed Control
3.2.1 Remote ON/OFF Connections Connect the yellow remote wire on the harness coming out of the PREDATAIR to one side of a switch or remote control relay module. Connect the other side of the switch or relay to a chassis ground. - Page 14 For two speed operation, speed 1 is activated when power to the PREDATAIR is turned on. This is set for the minimum desired CFM. Speed 2 is connected to the purple wire and set to the maximum desired CFM (Figure 9).
- Page 15 A preset throttle speed is activated when power to the compressor is switched on to provide the minimum GPM rating before starting the PREDATAIR (Figure 9). Speed 2 The purple wire is used to activate a second preset...
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Page 16: Completing The Installation
Circulate the hydraulic fluid to w arm it before activating ° the PREDATAIR when temperatures are below -15 Make su e that the following have been completed: □ perate the system with an air tool for at least 1/2 hour (1 hour preferred). -
Page 17: Setup, Performance Testing And Adjustments
4. Allow the truck to run until the engine is at operating temperature. 5. Operate the air compressor system until the oil is warm. 6. Observe the pressure gauge. Factory default pressure is approximately 150 psi. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201... - Page 18 Once air is used and pressure drops below 120 psi, the compressor will restart and build air pressure. The system may restart occasionally even without air use to maintain correct compressor operating temperatures. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
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Page 19: 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: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201... - Page 20 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: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
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Page 21: Testing The Installation
5.2 Testing the Installation 1. Install the PREDATAIR 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 22 Owner’s Manual. If th system shuts down due to an over-temperature condition, check all oil levels, improve ventilation an repeat the test once the syste m has cooled. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
- Page 23 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: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
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Page 24: Analyzing The Test Results
T3-(Tx-Tmax) = ____ - (____ - ____) = _____ Conclusion: Form 3 – Ventilation Analysis VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201... - Page 25 “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: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
- Page 26 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: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
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Page 27: Hydraulic System Data
2,500 psi during normal operation. The pump must be rated for 1,900 psi steady operation and 2,800 psi intermittent to allow an additional 200 psi for pressure drop in the hydraulic lines (external to the PREDATAIR) during startup with cold oil. 3000... -
Page 28: Hydraulic Line Sizing
The following provides specific line sizing recommendations (inside diameter) for vehicle hydraulic system installations intended for use with the PREDATAIR compressor system under the following conditions: • Extreme Cold Climate where temperatures are below -4°F (-20°C) - Page 29 In the following tables, hydraulic flow can be below minimum specifications. These flow ratings are for startup only, not for operation of the PREDATAIR. Refer to Section 2.3 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 30 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: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
- Page 31 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 PREDATAIR hydraulic motor during cold startup of the hydraulic pump.
- Page 32 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: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
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Page 33: Hydraulic System Filtration
Flow rating of the filter must be equal to or greater than the maximum GPM at which the system will be operated. Use only a filter that is specifically intended for hydraulic systems. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201... -
Page 34: Hydraulic Oil Reservoir
• to keep return flow well below the surface so it does not break the surface and cause aeration of the oil Figure 14 – Reservoir shapes VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201... - Page 35 A return line filter provides the main protection against system contaminants by removing small foreign particles from the hydraulic oil and should be mounted external to the reservoir for high visibility and easy service access. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
- Page 36 A return line flow diffuser mounts to end of return line drop tube and reduces the oil velocity before the oil emerges into the main interior volume of the reservoir; VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201...
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Page 37: Avoiding Cavitation
Wherever possible, use actual suction hose and thin walled barb and clamp type fittings rather than high pressure hydraulic hose and associated heavy walled fittings. • Make sure that the reservoir is of sufficient size VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201... -
Page 38: Ordering Parts
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. Eliminator Aftercooler Removes up to 80% of moisture from compressed air.
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