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PREDATAIR HYDRAULICAIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200 Fax: 1-250-740-3201

1

Installation Manual

PREDATAIR

Hydraulic Air Compressor

1.0 General Information ................................................................... 3 1.1 Specifications and Components ............................................... 3

2.0 Installation Requirements .......................................................... 5 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 ................................................................... 29 6.2 Hydraulic Line Sizing .............................................................. 29 6.3 Hydraulic System Filtration ..................................................... 34 6.4 Hydraulic Oil Reservoir ........................................................... 35 6.5 Avoiding Cavitation ................................................................. 38

Accessory Products from VMAC .................................................. 39

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Local: 1-250-740-3200

Fax: 1-250-740-3201 2

Document #1930150 Installation Manual for PREDATAIR Hydraulic Air Compressor Changes and Revisions

Version Revision Details Revised by/date Approved Implemented

00 Original manual IB 14 Sept 2007 SM 03 Dec 2007 07 Dec 2007

A ECN: 10-029, Added fuse to

control box.

SH19 Aug 2010 SM 14 Sept 2010 15 Sep 2010

B ECN: 11-016, Figure 9

Rewired for clarity, Hydraulic

requirements reviewed

AC 25 Jan 2011 SJ 28 Feb 2011 7 Mar 2011

C ECN 11-118, added synthetic

hydraulic oil allowed, added

Therminator to accessory

products

MH 23 Sep 2011 SM 30 Sep 2011 4 Oct 2011

D ECN 14-042: Added

Predatair 60 HHP install

information

MH 25Jun2014 MP/RD 15 Jul 2014 16 Jul 2014

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.

Register online: vmacair.com/support/warranty/ at time of installation for any subsequent warranty claim to be considered valid.

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 2007 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.


3

Printed in Canada

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 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. 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 electro/pneumatic control system.

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.

H400001/H600002 Safety features include:

2,800 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 and hydraulic oil

H600004 Safety features include:

3,300 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 and hydraulic oil

Do not disable or bypass the over-temperature shutdown circuit. Failure of the shutdown system could result in equipment damage, injury or death. !


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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 factory-set at 150 psi. This can be adjusted using the display box. To reduce the pressure, use a Filter Regulator Lubricator (FRL).

Compressor air filter(must have proper ventilation)

Oil cooler (inside cover,must have proper ventilation)

Air discharge portwith check valve

Hydraulic fluid inletHydraulic fluid return

Blowdown cap withinternal coalescing filter

Minimum clearancefor servicing - 6 inches

Compressor oil fill(shipped full from the factory)

Oil level sight glass(make sure this can be easilyaccessed for daily inspection)

Compressor oil drain

Oil filter

Cooling fan

Minimum clearance for servicing - 6 inches

Pressure sensor

Figure 1 – System components


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Figure 2 – System wiring

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


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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

The PREDATAIR 40 requires higher hydraulic flow and pressure than a typical 30-40 CFM system. Check pump, hose and connection ratings and requirements.

The PREDATAIR is designed to sufficiently cool the compressor and hydraulic oil for its own use only. Additional hydraulic oil cooling is required if other hydraulic equipment is being used on the same circuit.

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. 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 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). Failure to observe these requirements will result in damage to the system.


7

PREDATAIR Tank

Auxiliary Tank

One-way check valvebuilt into PREDATAIRtank

Install this line high on the tank, not at the bottom

Figure 3 – Auxiliary tank connection A one-way check valve is built into the PREDATAIR tank. Do not install an additional check valve as this may cause undesirable operations.

2.2 Ventilation Requirements

During operation, the PREDATAIR 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.

2.2.1 Top Mounting

This is the preferred mounting location. Placing the unit on top of the service body (Figure 4) 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

2.2.2 Enclosed Mounting

Enclosed mounting is not recommended for most applications due to the significant heat generated.

Mounting the PREDATAIR in an enclosure (Figure 4) 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 (i.e. a pull-out drawer).

!


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Top mount

Enclosed mount

Figure 4 – 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 PREDATAIR 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 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.

BatteryRelay

PREDATAIR60

Remote switchDoor switch

Figure 5 – Door switch

!


9

2.3 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.

2.3.1 PREDATAIR60 and PREDATAIR40

Hydraulic System Pressure will vary considerably during compressor operation (Figure 13). The system pressure varies between 900 and 2,400 psi during normal operation. The pump must be rated for 2,400 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. 2.3.2 PREDATAIR60 HHP

Hydraulic System Pressure will vary considerably during compressor operation (Figure 14). The system pressure varies between 900 and 2,700 psi during normal operation. The pump must be rated for 3,200 psi steady operation and 3,400 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.

Figure 6

0

10

20

30

40

50

60

70

12 11 10 9 8 13 14 15 16 17 18 19 20 21 Hydraulic Flow (GPM)

PREDATAIR 60

0

10

20

30

40

50

60

70

12 11 10 9 8 13 14 15 16 17 18 19 20 21 Hydraulic Flow (GPM)

PREDATAIR 40

PREDATAIR 60 HHP

Air Flow (CFM)


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2.3.3 PREDATAIR40

For single speed operation a minimum of 9 GPM and a maximum of 14 GPM hydraulic oil flow is required. For two speed operation, a minimum of 8 GPM and a maximum of 14 GPM hydraulic oil flow is required (Figure 6). 2.3.4 PREDATAIR60

For single speed operation a minimum of 14 GPM and a maximum of 21 GPM hydraulic oil flow is required. For two speed operation, a minimum of 13 GPM and a maximum of 21 GPM hydraulic oil flow is required (Figure 6).

2.3.5 PREDATAIR60 HHP

For single speed operation a minimum of 12 GPM and a maximum of 18 GPM hydraulic oil flow is required. For two speed operation, a minimum of 11 GPM and a maximum of 18 GPM hydraulic oil flow is required (Figure 6).

These are nominal values only. Tests should be performed to confirm that the desired CFM has been achieved due to variations in hydraulic system efficiency, load and flow.

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.

2.4 Electrical Requirements

The PREDATAIR requires steady 20 Amps @ 12 VDC (nominal) 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 ignition switched through a relay to reduce the risk of battery drain when the engine is off. Main 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


11

gauge power wire to be routed directly and permits the use of a light (18 AWG) wire between the relay and the control switch (Figure 7).

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 5 ft. 12AWG

5 ft. to 8 ft. 10AWG

More than 8 ft. 8AWG

Table 1 – Wire gauge size

3.0 Installing the PREDATAIR 3.1 Mounting the Compressor

1. Remove the unit from the packing. Make sure that the four rubber isolator mounts remain fastened to the unit base.

2. Remove the two ORB plugs from the manifold on the side of the compressor and install suitable ORB fittings to match your connection requirements. The cold climate kit (A700146) can be installed at this time.

Some hydraulic oil will run out when the fittings are removed.

3. Remove the 3/4 inch NPT plug fitting from the tank and install a suitable fitting to connect to the air delivery system.

4. Drill four 13/32 inch holes in the selected mounting location spaced at 22 inches wide and 14 inches deep. Fasten the unit in place using Loctite on the threads. A mounting bracket kit (A700140) is available.

Do not mount the unit directly to the body without the rubber insulators, as this will result in considerable vibration and noise during operation.

5. Refer to Section 6.0 for hydraulic system recommendations. An

independent hydraulic system is recommended to simplify installation and troubleshooting. Connect hydraulic and air hoses

!


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to the unit. Use a shut-off valve if you have other hydraulic devices operating within the same system.

Direction of hydraulic flow is critical. If reversed, high pressure buildup may cause damage to the compressor and a potential hose burst hazard.

3.2 Connecting the Wiring

Battery

Fuse

+

Display boxinside cabinetprotected fromweather

PR

ED

ATA

IR6

0

Battery

Fuse or circuit breaker

30A PREDATAIR

see table 1 for correct wire gauge

** *

*

Red

Green

Ignition-switchedrelay

Figure 7

!


13

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. The PREDATAIR will turn on when the circuit between the yellow wire and ground is completed by the switch or relay. The PREDATAIR will turn off when the switch or relay opens the circuit. The display box can be used to see messages, but if the system is operated using the remote wire, the push buttons on the display box are disabled. The PREDATAIR can be operated without a display box by using the remote wire but messages and diagnostics will not be available.

3.3 Speed Control

The PREDATAIR has the ability 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.

It is not essential that the two speed feature be used, it is entirely acceptable to run the PREDATAIR constantly at a fixed engine rpm and pump GPM. There are, however, several advantages to the two speed feature which should be considered when deciding whether to go with two speed or single speed operation.

Two speed operation offers these advantages:

lower fuel consumption.

lower noise.

lower wear rate on engine, hydraulic pump and compressor.

greater latitude for flexible service intervals.

better cold start behavior. The preferred approach for speed control is to keep the hydraulic flow as low as possible when the PTO first starts, then when the PREDATAIR is engaged, the engine idles up for the desired performance. For single speed operation, the throttle would idle up to achieve the desired CFM when power to the PREDATAIR is turned on (Figure 8).


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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).

The system must be at or above the minimum hydraulic oil flow before starting the PREDATAIR.

Always allow for efficiency loss as the hydraulic oil heats. Operate the system for at least one hour at full load and monitor hydraulic flow at speed 1 and speed 2 (if applicable). Adjust as required to ensure that speed 1 flow does not drop below the minimum requirement. A flow meter should be temporarily plumbed into the PREDATAIR return line to confirm actual hydraulic flow. A load tester with the load valve adjusted to zero can be used. 3.3.1 Single Speed

For single speed operation, do not use the purple wire from the PREDATAIR wire harness. Connect a throttle control so that the engine goes to the desired speed when power to the PREDATAIR is turned on (Figure 8).

Red

Purple

Green

From PREDATAIRPower circuit

Throttle control

12V input whenPower circuit isswitched on

Speed 1

Set speed 1 to achieve desired CFM

(not connected)

Figure 8 – Single speed operation


15

3.3.2 Two Speed

Speed 1 This is typically set for the minimum GPM rating. The engine stays at base idle when only the PTO is engaged. This is desirable for cold climate start-up as it keeps hydraulic pressure low during warm-up. 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 throttle speed that will provide the maximum GPM rating (Figure 9)

Red

Purple

Green

From PREDATAIRPower circuit

Throttle control

12V input when activation circuit is switched onand the purple wire is grounded by the control system

Speed 1 Speed 2

Set Speed 1 to the miniumum GPM ratingSet Speed 2 to achieve the desired CFM

86

87

87A

30

85

Figure 9 – Two speed operation


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4.0 Completing the Installation

4.1 Before Operation Checklist Make sure that the following have been completed before operating the PREDATAIR 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.

Check the hydraulic oil level

Do a final inspection to make sure that all fasteners and connections are tight.

Check that all hoses and wiring are secure and protected.

4.2 After Engaging the Hydraulics Checklist

Place the truck in a safe operating position and block the wheels. Ensure that there are no people around the truck before beginning the test.

Circulate the hydraulic fluid to warm it before activating

the PREDATAIR when temperatures are below -15 C.

Make sure that the following have been completed:

□ Operate the system with an air tool for at least 1/2 hour (1 hour preferred). If this is a new configuration or design, operate for at least 1 hour at the expected duty cycle to confirm acceptable CFM and temperature performance (see section 5.0 Testing Ventilation). Check hydraulic flow to ensure that the desired GPM is maintained.

□ Check all components once the compressor and truck engine have been turned off and the system has cooled

!


17

□ Check the compressor and hydraulic system oil levels after the compressor and truck engine have been shut down and the oil level has had time to stabilize.

4.3 Setup, Performance Testing and Adjustments

This system has been adjusted at the factory for general operation. If your tests indicate that adjustment is necessary, refer to the owner’s manual for specific instructions on how to adjust the system.

You can test the system operation using the tools that will be operated by the system or you can test operations using an orifice (Figure 10) to simulate tool use. See section 5.1, Table 3 to determine the correct orifice size

Figure 10 – Test tool

1. Install the test tool in the air reservoir tank outlet fitting.

Make sure there are no leaks in the test tool. A reservoir tank is recommended. The system may not idle down or unload without a small reservoir of air or if there are leaks in the lines or fittings.

2. Make sure that the ball valve is closed.

3. Place the manual transmission in neutral or the automatic transmission in park and fully apply the park brake.

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.


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7. Slowly open the ball valve on the test tool and observe the operation. If the throttle enable wire has been connected, the engine should idle up as the pressure drops to 120 psi.

If the air pressure drops below 100 psi, increase hydraulic flow to bring the pressure back up. Do not exceed specifications

8. Close the ball valve to allow the system pressure to rise. When

the control system does not sense air use for a few seconds, it will unload the compressor. You should hear a hissing noise as the air vents. If the air pressure doesn't drop, after approximately another 20 seconds, the engine will idle down to the lower speed setting.

9. After one minute (if the air pressure still hasn’t dropped) the

compressor will stop turning and the hydraulic oil will continue to circulate through the cooler. The system will continue to monitor hydraulic oil temperature and will run the cooling fan as required. 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.


19

5.0 Testing Ventilation The following procedure is recommended when a new installation configuration is being developed. The procedure is not necessary for repeat installations with the same configuration.

5.1 Calculating Duty Cycle

Duty cycle can be determined based on expected tool use or by identifying the desired CFM of the system. Refer to Table 3 to determine duty cycle from a given CFM consumption.

The rated consumption of an air tool is listed as an average based on a 25%

duty cycle. For example, a 1/2” impact might be listed by the manufacturer

as 5 CFM rather than the true consumption of 20 CFM. Do not use the

average rating in calculating duty cycle. Typical air consumption of some

pneumatic tools is:

1/2” impact – 20 CFM

3/4” impact – 30 CFM

Blow-off nozzle with 0.040” orifice – 2 CFM

Carbon arc gouger – 25 CFM

Pneumatic hammer – 4 CFM

Determine what tools will be used, their actual CFM, and how many

minutes in an hour they will be used. Form 1 can be copied and used to

determine duty cycle. A sample calculation is shown in Table 2.

Tool Description CFM x Operating Time

(min/hr) = CFH

x =

x =

x =

x =

x =

x =

Total CFH (Cubic Feet per Hour)

Duty Cycle = Total CFH ÷ 3600 x 100%

= ____ ÷ 3600 x 100%

= ____%

Form 1 – Duty Cycle Calculation


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Tool Description CFM x Operating (min/hr)

= CFH

1 1” impact 40 x 5 = 200

2 1/2” impact 20 x 5 = 100

3 Blow-off nozzle 2 x 5 = 10

4 Diaphragm pump 15 x 10 = 150

x =

x =

Total CFH (Cubic Feet per Hour) 460

Duty Cycle = Total CFH ÷ 3600 x 100%

= 460 ÷ 3600 x 100%

= 13%

Table 2 – Sample calculation Use Table 3 to find the orifice size and expected CFM based on the calculated duty cycle.

Duty Cycle Orifice Size Drill Size Consumption

5% 0.036 #64 3 CFM

10% 0.050 #55 6 CFM

15% 0.065 #52 9 CFM

20% 0.073 #49 12 CFM

30% 0.089 #43 18 CFM

40% 0.103 #37 24 CFM

50% 0.120 #31 30 CFM

60% 0.137 #29 36 CFM

70% 0.147 #26 42 CFM

80% 0.158 #21 48 CFM

90% 0.167 #19 54 CFM

100% 0.176 #16 60 CFM

Table 3 – Orifice sizes


21

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.

2. Temporarily mount a thermometer 5 to 10 feet away from the vehicle (this is ambient temperature, T1).

3. Temporarily mount a second thermometer (Figure 11) 2 inches away from where the air will enter the cooler (T2).

2”

Thermometer - T2

Figure 11 – Analyzing temperatures

4. Install a 1/2 inch or greater ball valve in the outlet of the receiver or use a test tool (Figure 12).

5. Drill an orifice in a plug and install it in the ball valve (see Table 3 for orifice sizes).

6. Fill the receiver with compressed air to a nominal 150 psi.

7. Open the ball valve fully and allow air to escape through the plug with the drilled orifice.

8. Leave the ball valve fully open for the duration of the test.


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Compressor

Air receiver

Ball valve

Orifice drilled in plug

Pressure gauge

Figure 12 – Test setup

If the air pressure drops below 100 psi, increase hydraulic flow to bring the pressure back up. Do not exceed hydraulic flow specifications

9. Test the system for 1 hour at the maximum duty cycle. Make sure that you can read the temperature for the duration of the test without disturbing the system by opening cabinets or other functions.

10. Record “T2” every 30 seconds during the last 10 minutes of the test. Record “T1” at the 50 minute and 60 minute marks.

Copy and use Form 2 on the following page for your calculations.

11. For the analysis, “T1” is the average of the two “T1” readings and “T2” is the average of the 20 “T2” readings taken in step 10. “T3” is the maximum ambient temperature to which the vehicle will be exposed.

If the system shuts down at any point during the test, check the display box for messages and cross-reference them to the table in the Owner’s Manual. If the system shuts down due to an over-temperature condition, check all oil levels, improve ventilation and repeat the test once the system has cooled.


23

Time (min:sec) T1 T2

50:00

50:30

51:00

51:30

52:00

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


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5.3 Analyzing the Test Results

Copy and use Form 3 for the analysis.

T1 = ________ Current ambient temperature (Average from Form 1)

T2 = ________ Cooler intake temperature (Average from Form 1)

T3 = ________ Maximum expected ambient temperature that the truck will

see

Duty Cycle = _______% See Section 5.1

No. of speeds: 1 or 2 (Circle one)

Tmax = _______ See Table 4

Tx = T3+T2-T1 The expected cooler intake temperature at maximum

ambient temperature

Tx = ___+___-___ = _____

Tmax = _____ & Tx = ______ If Tmax is greater than or equal to Tx,

the ventilation is OK. If Tmax is less than Tx, more ventilation is required,

or the duty cycle must be reduced when the ambient air temperature is

greater than:

T3-(Tx-Tmax) = ____ - (____ - ____) = _____

Conclusion:

Form 3 – Ventilation Analysis


25

Duty Cycle Tmax

1 Speed 2 Speed

10% 150 F (66 C) 160 F (71 C)

20% 143 F (62 C) 151 F (66 C)

30% 135 F (57 C)` 142 F (61 C)

40% 128 F (53 C) 133 F (56 C)

50% 121 F (49 C) 124 F (51 C)

60% 114 F (46 C) 115 F (46 C)

70% 107 F (42 C) 107 F (42 C)

80% 99 F (37 C) 99 F (37 C)

90% 89 F (32 C) 89 F (32 C)

100% 85 F (29 C) 85 F (29 C)

Table 4 – Determining Temperature TMAX

Table 5 shows a sample analysis using Form 3. Measures for correcting inadequate ventilation include:

Reduce GPM and repeat the test.

Improve ventilation or install an electric circulation fan to

promote exchange of enclosure air with ambient air and repeat the test.

Place a sticker near the compressor switch stating: “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.


Fax: 1-250-740-3201 26

T1 = 58F Current ambient temperature (Average from Form 2)

T2 = 124F Cooler intake temperature (Average from Form 2)

T3 = 100F Maximum expected ambient temperature that the truck will see

Duty Cycle = 20% See Section 5.1

No. of speeds: 1 or 2 (Circle one)

Tmax = 151F See Table 4

Tx = T3+T2-T1 The expected cooler intake temperature at maximum

ambient temperature

Tx = _100_+_124_-_58_ = _166F_

Tmax = _151F_ & Tx = _166F_ If Tmax is greater than or equal to Tx,

the ventilation is OK. If Tmax is less than Tx, more ventilation is required,

or the duty cycle must be reduced when the ambient air temperature is

greater than:

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


27

6.0 Hydraulic System Data PREDATAIR 40 & PREDATAIR 60 Hydraulic System Pressure will vary considerably during compressor operation (Figure 13). The system pressure varies between 900 and 2,400 psi during normal operation. The pump must be rated for 2,400 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.

Figure 13 – Hydraulic System Pressures

0 2 4 6 8 10 12 14 16 18 20

3000

2000

1000

Time in minutes

Hydra

ulic

pre

ssure

1 2 3 4 5 6 7 8 9 10

OPERATION1. Compressor warming up in unloaded state.2. Compressor filling receiving tank, cold hydraulic fluid.3. Compressor unloading.4. No air consumption, compressor in unloaded state.5. No air consumption, compressor in standby state, hydraulic oil circulating through cooler.

10. No air consumption, compressor in standby state, hydraulic oil circulating through cooler.

6. Brief use of compressed air, compressor tops up receiver and unloads.7. No air consumption, compressor in unloaded state.8. Sustained heavy air consumption, compressor maintains air pressure then tops up receiver and unloads.9. No air consumption, compressor in unloaded state.


Fax: 1-250-740-3201 28

PREDATAIR 60 HHP Hydraulic System Pressure will vary considerably during compressor operation (Figure 14). The system pressure varies between 900 and 2,700 psi during normal operation. The pump must be rated for 3,200 psi steady operation and 3,400 psi intermittent to allow an additional 200 psi for pressure drop in the hydraulic lines (external to the PREDATAIR) during startup with cold oil.

Figure 14 – Hydraulic System Pressures


29

6.1 Hydraulic Oil Type

Use a premium quality MINERAL, OR SYNTHETIC ANTI-WEAR

HYDRAULIC OIL Consider the lowest overnight temperature for the duration of the hydraulic oil in the system at all anticipated vehicle locations:

Extreme Cold Climate with temperatures below -4 F (-20 C)

Cold Climate where temperatures are below 32 F (0 C), but not

lower than -4 F (-20 C)

Temperate Climate with temperatures above 32 F (0 C)

A cold climate kit (A700146) is available to preheat the hydraulic oil at startup.

Extreme cold climate Cold climate Temperate climate

No tank preheat

Tank and suction line preheat

Top mounted

Enclosed mounted

Top mounted

Enclosed mounted

Note 1 AW32 AW22 Note 2

AW32 AW32 AW46

Note 1 A seasonal hydraulic oil change is recommended to get best component life. Recommended oils include:

Summer – when overnight temperatures do not go below 32 F (0 C) AW32.

Winter – when overnight temperature is consistently below 32 F (0 C) Texaco 5606H, PetroCanada Hydrex MV Arctic 15,Shell Fluid 41, Mobil Aero HFA, Anderol Royco 78C. Note 2: When possible change to AW32 during summer months.

Table 6 – Oil selection

6.2 Hydraulic Line Sizing

Industrial hydraulic system design guidelines generally call for the following maximum fluid velocities, which are then used to select line sizes for any particular GPM:

suction 4 ft/sec

return 10 ft/sec

pressure 20 ft/sec

For mobile hydraulics being added to a pre-built chassis, the above guidelines are not comprehensive due to the following factors:

extreme start-up temperature variations

long suction line

piggy-backing of motor case drain flow onto main return line


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Pump failure due to cavitation and motor seal failure due to excess return line pressure can occur if proper allowance is not made for the above factors when line sizes are being determined.

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)

Cold Climate where temperatures are below 32 F (0 C), but not

lower than -4 F (-20 C)

Temperate Climate where temperatures are above 32 F (0 C)

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.

Choose a suction hose size from Table 7 (based on 4 ft/sec fluid velocity), then upsize the hose, if necessary, using Table 8, 9 or 10. When consulting these tables, locate line sizes that will provide sufficient oil flow to the pump during startup with cold oil. The system should be designed to run at the lowest GPM possible at startup, then use a throttle control to increase GPM for operations once the oil has warmed.

Space and port size issues at the pump may require a short length of smaller than desired hose. Keep this as short and as large (ID) as possible to limit effect on performance and pump life.

Maximum Operating GPM Suction Hose Size

8-13 1”

14-15 1-1/4”

16-22 1-1/2”

Table 7 – Suction hose size

!

!


31

With tank and Suction Preheat system.

Preheat to –20 C or warmer prior to pump startup. Suction hose sizing same as “Cold Climate” with AW 32 oil.

No tank preheat. Line sizing here is based on strict adherence to Note 1 in Table 1.

Suction hose sizing same as “Cold Climate” with AW 22 oil.

Table 8 – Extreme Cold Climate

GPM during pump start-up and warm-up

Suction hose size AW 22oil

Suction hose size AW 32 oil

8 GPM (or less) 1” up to 1 ft 1-1/4” up to 2.5 ft 1-1/2” above 6 ft 1-3/4” up to 9 ft 2” above 9ft

1-1/4” up to 1 ft 1-1/2” up to 2.5 ft 1-3/4” up to 3.5 ft 2” up to 8 ft 2-1/2” above 8 ft

12 GPM 1-1/4” up to 1.5 ft 1-1/2” up to 4 ft 1-3/4” up to 6 ft 2” up to 12 ft 2-1/2” above 12 ft

1-1/2” up to 1.5 ft 1-3/4” up to 2.5 ft 2” up to 5 ft 2-1/2” up to 13 ft 3” above 14 ft

16 GPM 1-1/2” up to 3 ft 1-3/4” up to 4.5 ft 2” up to 9 ft 2-1/2” above 9 ft

1-1/2” up to 1 ft 1-3/4” up to 2 ft 2” up to 4 ft 2-1/2” up to 10 ft 3” above 10 ft

20 GPM 1-1/2” up to 2 ft 1-3/4” up to 3.5 ft 2” up to 7 ft 2-1/2” above 7 ft

1-1/2” up to 1 ft 1-3/4” up to 1.5 ft 2” up to 3 ft 2-1/2” up to 8 ft 3” above 8 ft

Table 9 – Cold Climate


Suction hose size AW 32oil

Suction hose size AW 46 oil

8 GPM (or less) 1” up to 4 ft 1-1/4” up to 8 ft 1-1/2” above 8 ft

1” up to 1.5 ft 1-1/4” up to 4 ft 1-1/2” up to 9 ft 1-3/4” above 9 ft

12 GPM 1-1/4” up to 5 ft 1-1/2” up to 11 ft 1-3/4” above 11 ft

1-1/4” up to 2.5 ft 1-1/2” up to 6 ft 1-3/4” up to 9 ft 2” above 9 ft

16 GPM 1-1/2” up to 9 ft 1-3/4” up to 13 ft 2” above 13 ft

1-1/2” up to 4 ft 1-3/4” up to 7 ft 2” up to 14 ft 2-1/2” above 14 ft

20 GPM 1-1/2” up to 7 ft 1-3/4” up to 11 ft 2” above 11 ft

1-1/2” up to 2.5 ft 1-3/4” up to 5 ft 2” up to 11 ft 2-1/2” above 11 ft

Table 10 – Temperate Climate


Fax: 1-250-740-3201 32

If the hydraulic oil tank is above the pump, add 10% to the hose length limits for each 1 foot that the oil level in this tank is above the pump suction port.

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.

Example of Suction Line Sizing:

inputs startup/warm-up flow 12 GPM maximum flow 20 GPM climate type cold oil type AW32 tank oil level 4 ft above pump length of hose run 8 ft

hose size selection from Table 2, basic suction hose size

1-1/2” from Table 4, “cold climate” 12 GPM, AW32

1-1/2” is good up to 4’ + 40% (For 4’ tank level) = 5.6’

1-3/4” is good up to 6’ + 40% = 8.4’

conclusion use 1-3/4” ID suction hose (or larger)

6.2.2 Return Line Sizing

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.

Maximum GPM Return Line Size

8-14 3/4”

15-22 1”

Table 11 – Return line size

!


33

Temperate Climate Not Critical. Size as per Table 11

Cold Climate


Return line size (AW 22oil)

Return line size (AW 32 oil)

8 GPM (or less) 3/4” 3/4”

12 GPM 3/4” 3/4” up to 11ft 1” above 11ft

16-20 GPM 1” 1”

Extreme Cold Climate

No Tank Preheat – Line sizing here is based on strict adherence to Note 1 of Table 6

Not critical. Size as per Table11.

With Tank and Suction line preheat. (AW32 oil) Return line not preheated.

GPM during pump startup and warm-up

Return line size

8 GPM (or less) 1” up to 3 ft 1-1/4” up to 8 ft 1-1/2” above 8 ft

12 GPM 1” up to 2 ft 1-1/4” up to 5 ft 1-1/2” up to 12 ft 1-3/4” above 12 ft



Table 12 – Temperature modification Example of Return Line Sizing:

inputs startup/warm-up flow 14 GPM maximum flow 14 GPM climate type extreme cold oil type AW32 with tank and suction line

preheat line length 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


Fax: 1-250-740-3201 34

6.2.3 Pressure Line Sizing

Choose a pressure line size from Table 13 (based on 20 ft/sec fluid velocity), then upsize the line, if necessary, using Table 14.

Maximum GPM Pressure Line Size

8-12 1/2”

13-18 5/8”

19-22 3/4”

Table 13

Temperate Climate

Not Critical. Size as per Table 13

Cold Climate 3/4”

Extreme Cold Climate

No Tank Preheat. Line sizing is based on strict adherence to Note 1 of Table 5

3/4”

With Tank and Suction line preheat. (AW32 oil) Pressure line not preheated.

GPM during pump startup

Pressure Line size

8 (or less) 3/4” up to 7ft 1” above 7ft

12 3/4” up to 5ft 1” above 5ft

16 3/4” up to 3.5ft 1” up to 12ft 1-1/4” above 12ft

20 3/4” up to 3ft 1” up to 9ft 1-1/4” above 9ft

Table 14

Recommended pressure line rating: H400001 3000 psi, or higher H600002 3000 psi, or higher H600004 3500 psi, or higher

6.3 Hydraulic System Filtration

Use a 10 micron return line hydraulic oil filter; 25 micron is acceptable. 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.

!


35

6.4 Hydraulic Oil Reservoir

6.4.1 Size

Hydraulic oil reservoirs range in size from about 3 times the total system GPM on stationary equipment down to 0.1 times the total system 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.

The recommended size of hydraulic oil reservoir for use with the PREDATAIR40 is 10-20 gallons and for the PREDATAIR60 is 15 to 25 gallons. It is wise to stay towards the high end of these ranges or larger if one or more of these conditions exist:

large cylinders are being used in the system

maintenance practices and service intervals by the end user are questionable

no diffuser is being used on the return line where it opens out into the inside of the reservoir

6.4.2 Shape

The reservoir should be tall and narrow, not shallow and broad (Figure 14). The tall, narrow tank is recommended because:

the oil level is well above suction line opening, avoiding the possibility of drawing air into the pump due to a vortex or “whirlpool” effect

more forgiving towards unusual vehicle angles

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


Fax: 1-250-740-3201 36

6.4.3 Material

Many reservoirs provided by PTO. pump suppliers are molded in one piece from polyethylene. This is an excellent material choice from the standpoint of weight, appearance, internal cleanliness, and low leakage. If for any reason a custom reservoir is required, then welded aluminum, steel or stainless steel are all good choices. The inside of the reservoir must be thoroughly cleaned after all the welding is completed. If plain steel is used, then the inner surface should be coated with paint compatible with the hydraulic fluid. 6.4.4 Essential Features

The hydraulic oil reservoir (Figure 15) should have the following features.

The pump inlet line should be near the bottom of the reservoir, well below the oil level and should protrude at least 2” into the reservoir to keep it well clear of surfaces that may collect contaminants.

Baffle plates should be use to prevent sloshing, to force the flow to follow an indirect path from the return line to the suction line in an S-shaped flow when viewed from above, to promote cooling contact with walls, provide time for deaeration and time for contaminants to drop out. They should be notched or have a small end gap to the side wall of reservoir, at opposite ends to produce an “S” shaped flow pattern as viewed from above. The area of notches or end gap should be at least two times the cross sectional area of the suction line.

A drain plug, to facilitate draining of old hydraulic oil during service, should be at the lowest point in the reservoir to assure complete draining. It should be installed using an adaptor or housing which does not protrude above the inner surface of the floor of the tank. It should be visible and accessible for removal, with sufficient space available for catching the waste oil.

A return line drop tube is essential if the return line is entering at or near the top of the tank. This minimizes foaming, agitation and aeration of the oil, which is key to system performance and pump reliability.

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.


37

A breather and filler cap provides an opening for adding oil. It also allows filtered air to enter the space above the oil as the oil level goes down and allows air to leave as the oil level goes up. It maintains constant atmospheric pressure above the oil.

A sight-glass provides a direct visual indication of oil level without opening up the reservoir.

Fill cap/breather

Suction fitting

Cleanout cover

Return line

Filter

Anti-foamsplash plate

Drain plug

Baffles

Fluid levelsight glass

Figure 15 – Hydraulic reservoir

6.4.5 Additional Recommended Features

The following features are not essential, but are recommended as measures which will help to maximize hydraulic system reliability, efficiency and life.

Magnetic drain plug(s) trap ferrous particles and should be easily accessed for cleaning.

A temperature gauge, either separate or built into the sight-glass, allows operator to read reservoir oil temperature.

A strainer in the filler neck keeps large contaminants out of the reservoir during oil addition.

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;


Fax: 1-250-740-3201 38

this is important on relatively small reservoirs (less than about 1 gallon per GPM) where severe foaming and aeration can occur if return line flow is not slowed prior to tank entry.

A reservoir heater for preheating the hydraulic oil prior to startup in extreme cold climate conditions.

6.4.6 Features Not Recommended

A suction screen or strainer is not recommended for mobile equipment. The combination of long suction lines, cold startup conditions and probable lack of strainer maintenance causes the suction strainer to be more likely to promote pump damage (due to cavitation) than it is to protect the pump.

A pressurized reservoir is not recommended for work trucks as it is too sophisticated and provides too much potential for loss of overall system reliability if it is not understood and not properly maintained.

6.5 Avoiding Cavitation

Pump cavitation may occur if the suction at the hydraulic pump inlet exceeds 6 InHg (3psi) of vacuum relative to local atmospheric pressure. Cavitation will severely reduce pump life & cause erratic hydraulic system performance. Some steps to take to avoid pump cavitation:

Mount the hydraulic oil tank as high above the pump as possible.

Keep the suction line as short as possible.

Avoid sharp 90 degree bends and sudden area changes in the suction line wherever possible.

Keep all suction hose and fittings as large as possible.

If a suction line screen is used, be sure that it has sufficient high flow rating.

If cold starting with the hydraulic oil at more than 2000 cSt (9200 SUS) viscosity, a no-load warm up interval should be used and a pre-heater should be used on the tank and the suction line.

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


39

Accessory Products from VMAC 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.

Therminator Hydraulic Cooler Capable of removing up to 33,750 BTU/HR from a lightweight and compact package ideal for industrial and commercial work trucks

Eliminator Aftercooler Removes up to 80% of moisture from compressed air. Quick installation, automatic drain and compact design

Filter Regulator Lubricator Removes lubricants, water and dirt from the air stream. Adds atomized tool oil to lubricate tools. Reduces pressure for longer tool life.

Hose Reel Secure, compact, retractable hose storage in a sturdy reel.

Air Receiver Tank Thirty-five gallon capacity in a compact tank, complete with fittings and a gauge.

DE-ICING HEATER

De-icer Kit Insulated rope heater prevents freezing of lines and regulator.

Service Kits Using OEM service products will extend the life of your system. Includes oil, filters, seals and O-rings. 500 hour service interval kits are available


Fax: 1-250-740-3201 40

Cold Climate Kit Preheats the hydraulic oil during cold startup of the PREDATAIR

HOURS

CURTIS

4400743

Switch Panel with Hour Meter Provides switched 12V power up to 30A with digital hour meter for tracking equipment run-time.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622 Fax: 1-250-740-3201

VMAC Product Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty will be void if this form is not received by VMAC within 30 days of installation.

VMAC Dealer Information Company Name: _____________________________________

City: _____________________ State/Prov:_______________

Installer Information Company Name: _____________________________________

City: _____________________ State/Prov:_______________

Installation Date: _____/_____/_____

Day Month Year

Owner Information Company Name:______________________________________

Address: ____________________________________________

City: _____________________ State/Prov: ______________

Zip/Postal: ________________ Phone #: (____)____- _____

Vehicle Information Year: ____________________ Make__________________

Vehicle Identification Number: __________________________

Unit #: ____________________

Product Information System Identification Number: H400001 __________________

H600002 __________________

H600004 __________________

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