Van Air Systems AC-65 Guide

PAGE 1
WARNING
READ ALL INFORMATION IN THIS MANUAL BEFORE BEGINNING INSTALLATION OR OPERATION OF THE
AFTERCOOLER.
BEFORE STARTING INSTALLATION AND/OR MAINTENANCE PROCEDURES, TURN OFF THE MAIN POWER TO THE
AFTERCOOLER AND COMPLETELY DEPRESSURIZE THE UNIT TO PREVENT PERSONAL INJURY.
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS UNIT WHILE IT IS PRESSURIZED.
NEVER OPERATE THIS AFTERCOOLER ABOVE THE RATED OPERATING CONDITIONS. OPERATION ABOVE SPECIFIED
CONDITIONS WILL RESULT IN DECREASED PERFORMANCE, POSSIBLE DAMAGE TO THE UNIT AND/ OR PERSONAL
INJURY.
NEVER OPERATE THIS AFTERCOOLER IF THERE IS A LEAK IN THE CORE. IMMEDIATELY TAKE THE UNIT OUT OF
SERVICE AND FIX OR REPLACE THE CORE.
NEVER REMOVE THE FAN GUARD WHILE THE AFTERCOOLER IS OPERATING. CONTACT WITH THE ROTATING FAN
BLADES MAY RESULT IN SERIOUS PERSONAL INJURY.
April 2022
REV -
P/N 32-0362
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS
AIR-COOLED AFTERCOOLER
FOR COMPRESSED AIR SYSTEMS
MODELS AC-65 thru AC-125
(ALL VOLTAGES)

PAGE 2
SPECIFICATIONS SECTION 2
2.1 SPECIFICATIONS
WEIGHT
AC-65 .............. 40 LBS
AC-105 .............45 LBS
AC-125 .............. 55 LBS
DIMENSIONS ................See Section 3.2
INLET/OUTLET CONNECTIONS
AC-65 .......... 1" NPT (F)
AC-105 ........ 1-1/2" NPT (F)
AC-125.......... 1-1/2" NPT (F)
MAXIMUM WORKING PRESSURE
ALL MODELS ..............250 PSIG
MAXIMUM WORKING TEMPERATURE
ALL MODELS ..............350OF
MATERIALS OF CONSTRUCTION
CABINET .....................Steel with baked enamel nish
SHROUD .....................Painted Steel
FAN GUARD................Steel with baked enamel nish
FAN ..............................Aluminum hub Polypropylene blades
CORE ..........................Brazed aluminum bar & plate
MOTOR .......................TEFC
MOTOR SPECIFICATIONS AND DATA
See Wiring Diagram, Figure 5 on page 6.
FAN DATA (AMBIENT AIR FLOW)
AC-65 & AC-105 ..........800 SCFM
AC-125.........................1425 SCFM
ELECTRICAL REQUIREMENTS
AC-65-6 ......................115/230-1-60, 3.0 FLA
AC-65-7 ......................208-230/460-3-60, 1.4 FLA
AC-105-6 ....................115/230-1-60, 3.0 FLA
AC-105-7 ....................208-230/460-3-60, 1.4 FLA
AC-125-6 ....................115/230-1-60, 3.7 FLA
AC-125-7 .....................208-230/460-3-60, 2.2 FLA
MAXIMUM CAPACITY (SCFM)
Rated capacities are based on the following conditions: Inlet
and approach temperature at inlet pressures 80 to 125 PSIG.
Approach Temperature: The number of degrees above the
ambient temperature to which the aftercooler reduces the
compressed air. A higher approach does not mean better
performance.
INLET TEMP.
APPROACH
TEMP. OF
MODEL
AC-65
AC-105
AC-125
15
87
158
296
10
61
112
216
5
29
56
109
20
101
180
337
5
26
51
97
10
56
105
204
15
69
126
241
20
82
149
280
5
24
47
90
10
45
85
166
15
62
116
223
20
74
138
265
5
21
40
77
10
37
71
138
15
51
97
189
20
61
114
220
5
19
37
72
10
34
67
130
15
45
85
166
20
54
101
196
150OF 200OF 350OF250OF 300OF
MAXIMUM PRESSURE DROP LESS THAN 3 PSI.
* Maximum ratings restricted by pressure drop: actual thermal capacities are higher.
If outside storage is required, the unit MUST BE adequately
covered to prevent rain or snow from accumulating on the after-
cooler. The unit must be placed on a paved surface to keep it
out of standing water and mud.
1.3 EQUIPMENT CHECK
Inspect the aftercooler for any damage that may have oc-
cured during shipment. Inspect all items shipped with the
unit.
IF THE UNIT HAS SHIPPING DAMAGE:
(1) Notify carrier immediately
(2) DO NOT operate the unit before consulting
factory
HANDLING SECTION 1
1.1 HANDLING THE AFTERCOOLER
CAUTION
NEVER LIFT THE AFTERCOOLER BY THE CORE.
WHEN MOVING OR LIFTING THE UNIT, PROTECT
THE CORE FROM ACCIDENTAL DAMAGE.
Take extreme care when unpacking, moving or installing. The
core is exposed and damage to the core or ns may render the
unit inoperable.
1.2 STORAGE INSTRUCTIONS
The unit should be stored indoors and covered with a tarpaulin
to keep it clean. The location should be free from corrosive
gasses and extreme humidity, which will cause damage to the
unit.

PAGE 3
SPECIFICATIONS SECTION 2
2.2 DIMENSIONS AND COMPONENT LOCATIONS
M IN/OUT
1" NPT
1-1/2" NPT
1-1/2" NPT
MODEL
AC-65
AC-105
AC-125
A
16.00"
15.87"
19.75"
B
14.12"
14.12"
46.50"
C
13.81"
15.13"
16.25"
L
13.88"
13.88"
17.75"
K
5.00"
5.00"
5.00"
J
6.88"
8.25"
8.25"
H
12.63"
14.00"
14.00"
G
6.81"
5.50"
5.50"
F
0.63"
1.31"
1.31"
E
12.00"
12.00"
16.00"
D
5.94"
7.31"
7.31"
INSTALLATION SECTION 3
3.1 LOCATION
DO NOT LOCATE THIS AFTERCOOLER WHERE PER-
SONNEL MAY CONTACT THE INLET PIPING UNLESS
THE UNIT IS PROTECTED BY WARNING SIGNS AND/
OR A BARRIER. DURING NORMAL OPERATION, THE
INLET PIPING MAY BECOME EXTREMELY HOT (150OF
TO 400OF). CONTACT MAY RESULT IN SERIOUS PER-
SONAL INJURY.
DO NOT INSTALL THIS UNIT IN AN ENVIRONMENT OF
CORROSIVE GASES OR CHEMICALS. MAKE SURE
THAT THE MATERIALS USED IN THIS UNIT (listed on
page 2) ARE COMPATIBLE WITH THE ATMOSPHERIC
CONDITIONS.
The aftercooler should be located far enough away from the
compressor so that there are no vibrations transmitted from the
compressor. A FLEXIBLE HOSE MUST BE INSTALLED IN
THE PIPING TO VALIDATE THE WARRANTY AND TO PRE-
VENT DAMAGE TO THE AFTERCOOLER FROM VIBRATION
IN THE PIPING! REFERENCE Section 3.3 for instructions.
The location should be level and capable of supporting the
aftercooler and all components and piping to be installed. The
aftercooler must be level to allow proper drainage of uids from
the outlet manifold.
CAUTION
The aftercooler must be installed at least 1 foot from walls or
obstructions. It is important for the unit to have an adequate
air supply for cooling at all times. If more than one unit is to be
installed in the same area, allow at least 1 foot between them.
Aftercoolers equipped with a TEFC motor can be installed
indoors or outdoors. If the unit is to be installed outdoors or
in an area where ambient temperatures can fall below 38OF,
precautions must be made to prevent freeze-up and damage
to the unit. The drain lines and separator must be heat traced
and/or insulated and the unit should be protected from the wind,
REFERENCE Section 3.5 for details.
3.2 MOUNTING THE UNIT
After selecting the proper location as outlined above, the
aftercooler should be mounted to the installation surface.
Mounting holes are provided on the leg support braces.
Reference Section 2.2 for mounting hole locations and dimen-
sions. Use hardware (not supplied) sized for the mounting holes.

PAGE 4
INSTALLATION SECTION 3
DIMENSIONS MAXIMUM WORKING PRESSURE
MODEL
AC-65
AC-105 & AC-125
HOSE
FH-1
FH-1-1/2
PART NO.
83-0735
83-0736
A
12"
16"
B
1" NPT
1-1/2" NPT
70OF
525 PSIG
450 PSIG
300OF
460 PSIG
395 PSIG
400OF
435 PSIG
370 PSIG
WEIGHT
2.0 LBS
3.0 LBS
FIGURE 3A FLEXIBLE HOSE
FIGURE 3B RECOMMENDED INSTALLATION
3.3 FLEXIBLE HOSE INSTALLATION
IMPORTANT
A FLEXIBLE HOSE MUST BE INSTALLED BETWEEN
THE COMPRESSOR AND AFTERCOOLER TO
VALIDATE THE WARRANTY ON THE AFTERCOOLER.
The exible hose must be installed perpendicular to the direction
of vibration from the compressor.
If a exible hose was not ordered with the aftercooler, one can
be ordered from your Van Air distributor. Figure 3A lists the
hose required for each aftercooler model.
3.4 PIPING INSTALLATION
CAUTION
ALL PIPING MUST BE ADEQUATELY SUPPORTED AND
ISOLATED FROM VIBRATION. EXCESSIVE STRESS OR
VIBRATION IN THE PIPING WILL CAUSE DAMAGE TO
THE AFTERCOOLER CORE.
TO ENSURE PROPER OPERATION, MAKE SURE THAT
THE INLET AND OUTLET PIPING ARE CORRECTLY
CONNECTED TO THE UNIT. REFERENCE FIGURE 2.2.
If the aftercooler is to be installed in an existing piping system,
clean the piping to remove accumulated dirt, pipe scale, oil, and
other contaminants before installing the unit.
A properly sized pressure relief valve should be installed after
the compressor and before any block valves. The relief valve
should be installed in compliance with all applicable federal,
state, and local codes.
To isolate the aftercooler for maintenance, install bypass piping
around the aftercooler and separator (if installed). Reference
Figure 3B.
Connect the inlet piping to the inlet of the aftercooler, reference
Section 2.2 for location. Make sure that the exible hose is
properly installed before the aftercooler inlet. Provide supports
wherever necessary to prevent stress on the aftercooler.
Supports should be installed close to the inlet and outlet
manifolds. Use either overhead or sti󰀨-leg type supports.

PAGE 5
INSTALLATION SECTION 4
FIGURE 3C SEPARATOR
D
1" NPT
1-1/2" NPT
E
1/8" NPT
1/4" NPT
MWP
(PSIG)
200
200
MAX
120
400
MIN
11
60
FLOW (SCFM)
A
10.00"
17.00"
B
3.35"
6.70"
C
0.98"
2.00"
MODEL
S-10-AD
S-30-M
SEPARATOR
S-10-AD
S-30-M
AFTERCOOER
AC-65
AC-105 & AC-125
PART NO.
83-0751
83-0751
DRAIN
FD-1
FD-1
PART NO.
83-0744
83-0746
3.5 FREEZE PROTECTION
If the aftercooler is to be installed in a location where ambient
temperatures may fall below 38oF, heat tracing and/or insulation
must be used on the outlet piping to the separator, the separa-
tor, and the drain piping. The aftercooler must be protected
from the direct wind, i.e. a roof and/or walls.
The aftercooler should be turned o󰀨 when ambient temperatures
fall below 38oF.
3.6 SEPARATOR INSTALLATION
CAUTION
IF THE SEPARATOR DRAIN IS TO BE CONNECTED INTO
A REMOTE OR COMMON DRAIN LINE, MAKE SURE
THAT IT IS VENTED.
THE DISCHARGE FROM THE SEPARATOR MAY CON-
TAIN COMPRESSOR LUBRICANTS. COMPLY WITH ALL
REGULATIONS CONCERNING DISPOSAL OF SUCH
FLUIDS.
When the process air is cooled by the aftercooler, moisture
condenses and accumulates in the outlet of the aftercooler.
To e󰀩ciently remove this liquid from the air system, a
separator with a FD-1 oat drain must be installed immediately
downstream of the aftercooler.
Install the separator as outlined in the Installation, Operation,
and Maintenance Instructions supplied with the component. If
a separator was not ordered with the aftercooler, one can be
ordered from your VAN AIR distributor.
3.7 ELECTRICAL CONNECTIONS
CAUTION
TURN OFF MAIN POWER SUPPLY BEFORE WIRING TO
THE AFTERCOOLER.
MAKE SURE THAT ALL USER SUPPLIED WIRING
IS PROPERLY SIZED TO HANDLE THE AMPERAGE
REQUIRED BY THE AFTERCOOLER AND ANY AD-
DITIONAL EQUIPMENT. ALWAYS COMPLY WITH THE
NATIONAL ELECTRICAL CODE AND ALL APPLICABLE
FEDERAL, STATE AND LOCAL CODES.
IF THE AFTERCOOLER IS TO BE INSTALLED OUT-
DOORS OR IN AN EXTREMELY HUMID ATMOSPHERE,
MAKE SURE THAT ALL WIRING AND COMPONENTS
ARE PROPERLY RATED.
VERIFY THAT THE POWER SOURCE MATCHES THE AF-
TERCOOLER ELECTRICAL REQUIREMENTS BEFORE
MAKING ANY CONNECTIONS. REFERENCE MOTOR
DATA TAG FOR INFORMATION.
TO PREVENT POSSIBLE ELECTRICAL SHOCK, IT IS IM-
PORTANT THAT THIS UNIT IS PROPERLY GROUNDED.
The aftercooler electrical requirements are listed on the
equipment data tag and in Figure 2. If there are any
discrepancies between the data tag and Figure 2, use the
information on the tag.
Remove the cover from the electrical junction box on the after-
cooler motor. Using the wiring diagram on the motor as refer-
ence, make the necessary wiring connections. Several ways
to wire the unit are listed below. Make the connections for the
pertinent application(s).
1. DEDICATED POWER SUPPLY AND DISCONNECT
Install a properly sized fused disconnect before the
aftercooler. Make the necessary wire connections and re-
install the junction box cover.
2. INTERLOCKED WITH COMPRESSOR MOTOR STARTER
The aftercooler can be interlocked with the air compressor
starter. This allows the aftercooler to operate only when the
air compressor is operating.
If a set of auxiliary, normally open contacts is available on the
air compressor magnetic starter, make necessary wiring con-
nections from the contacts to the aftercooler.
If a set of auxiliary contacts is not available, use a properly
sized contactor. Wire the contactor's holding coil in parallel
with the air compressor starter holding coil. Make the neces-
sary wiring connections from the contactor to the aftercooler.
3.7-1 FAN MOTOR ROTATION
The rotation of the fan motor(s) is important. Units with 3
phase power should be checked for proper rotation after
installation.
Energize the unit. Observe the rotation and air ow direction.
referece Section 2.2 for air ow direction. If the air does not
ow in the proper direction, turn o󰀨 the unit and switch two of
the main power legs.

PAGE 6
4.1 START UP
Pressurize the compressed air system. If the aftercooler was
interlocked with the compressor, the aftercooler will begin to
operate immediately. If the aftercooler was wired on a separate
electrical source, turn on the source.
Open the inlet and outlet isolation valves on the aftercooler (if
installed). Close the bypass valve. The aftercooler is ready for
operation.
4.2 OPERATION
The operation of the aftercooler is simple. The fan rotates,
moving ambient air across the core. The ambient air ow cools
the compressed air inside the core. The aftercooler will
automatically operate as long as electrical power is supplied to
the unit.
OPERATION SECTION 4
MAINTENANCE SECTION 5
5.0 MAINTENANCE INSTRUCTIONS
WARNING
BEFORE STARTING INSTALLATION OR MAINTENANCE
PROCEDURES, TURN OFF ELECTRICAL POWER AND
COMPLETELY DEPRESSURIZE THE UNIT. FAILURE TO
HEED THIS WARNING MAY RESULT IN SERIOUS PER-
SONAL INJURY AND/OR DAMAGE TO THE UNIT.
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON
THIS UNIT WHILE IT IS PRESSURIZED.
DO NOT REMOVE THE FAN GUARD WHILE THE AFTER-
COOLER IS OPERATING. PERSONAL CONTACT WITH
THE ROTATING FAN BLADE MAY RESULT IN SERIOUS
PERSONAL INJURY.
Inspect the aftercooler regularly for loose bolts and connec-
tions, rust and corrosion, and dirty or clogged heat transfer
surfaces.
SCHEDULED MAINTENANCE
MONTHLY
- Clean exterior of the aftercooler core
SEMI ANUALLY
- Grease motors that have alemite ttings. Apply 1 to 2 full
strokes with a grease gun.
YEARLY
- Clean the interior of the aftercooler core
5.1 CORE EXTERIOR CLEANING
The outside of the core should be cleaned regularly. Accumu-
lation of dirt and other contaminants such as oils will greatly
reduce the e󰀩ciency of the aftercooler.
Normal accumulation of dirt can be removed by blowing the
core o󰀨 with compressed air. If the core becomes contaminated
with oil-laden particles, the motor should be removed and the
core can be cleaned with a non-ammable degreaser. Follow
with hot water rinse and dry thoroughly. The core can also be
steam cleaned. Use extreme care when cleaning the core,
as the aluminum ns can be easily damaged. DO NOT USE
CAUSTIC CLEANERS.
CAUTION
NEVER USE SOLVENTS CONTAINING STRONG ACID
OR ALKALINE BASES TO CLEAN THE CORE. DAM-
AGE TO THE CORE MAY OCCUR.
4.3 SHUT DOWN
To shut down the aftercooler, turn o󰀨 the electrical power
source. If the aftercooler was interlocked with the compressor,
the aftercooler will automatically turn o󰀨 with the compressor.
Open the bypass valve and close the inlet and outlet isolation
valves (if installed).
Manually override the automatic drain on the separator to com-
pletely depressurize the aftercooler.
5.2 CORE INTERIOR CLEANING
The inside of the core should be cleaned once a year to return
the unit to full capacity. Excess lubricating uids can build up
on the inside of the core and greatly reduce the e󰀩ciency of the
aftercooler.
Shut down the aftercooler per Section 4.3 and completely
depresusrize the unit. Disconnect the aftercooler from the air
system.
The interior of the core can be cleaned by circulating a mild
cleaning solution through the core to remove the deposits. In
most cases, a mild alkaline solution such as OAKITE or equal
is satisfactory. For extreme conditions, it may be necessary to
use a weak solution of INHIBITED hydrochloric acid. Circulate
the solution through the core until it is clean. Once the core
is clean, thoroughly rinse the core to remove all traces of the
cleaning solution before re-connecting to the air system. Always
follow the instructions supplied with the cleaning agent.
All lters and separators should also be cleaned and serviced
after the inside of the afercooler has been cleaned.
5.3 STORAGE
Store the aftercooler in a dry location that maintains a constant
temperature. The aftercooler shouold not be moved from a
warm area to a cold area in order to minimize condensation
inside the core.
For storage up to 6 months, drain the cooler and seal the open-
ings.
For storage from 6 months to 24 months, ush the cooler with
oil and seal the openings. Remove all protection oil from the
aftercooler before connecting it to air system for operation.
For storage longer than 24 months, completely ll the cooler
with oil and seal the openings. The cooler should be ushed,
inspected, relled with oil and sealed every 24 months during
storage. Drain the aftercooler and remove all protection oil from
the aftercooler before connecting it to air system for operation.

PAGE 7
5.5 HOW TO ORDER PARTS
To order parts contact your local VAN AIR representative, or the factory.
When ordering parts, the following information is necessary:
Aftercooler model
Aftercooler serial number
Aftercooler part number
Aftercooler voltage
This information can be found on the data tag located on the aftercooler.
The Service Department can be reached by calling 888-606-9303 or faxing 814-774-3482.
Hours are 8:00 AM EST to 5:00 PM EST, M-F.
TROUBLESHOOTING SECTION 6
6.0 TROUBLESHOOTING
6.1 FAN MOTOR NOT OPERATING
Power failure - Check electrical power source. Check contactors, fuses, or disconnects. Check incoming wiring for
damage. If aftercooler is interlocked with the compressor, check the compressor starter.
Motor failure - Check electrical power source. If power supply is okay, check the motor. Replace if necessary.
6.2 HIGH AFTERCOOLER OUTLET TEMPERATURES
Fan motor not operating - Reference Problem 1.
Dirty core or restricted air ow - Inspect the core for deposits of dirt and/or oils. If the core is contaminated, clean it as outlined
in Sections 5.1 and 5.2. Check for obstructions around the aftercooler. Remove if present.
6.3 INCREASED LIQUID (WATER) CONTENT DOWNSTREAM OF THE AFTERCOOLER
Plugged or damaged separator - Check the separator for damage and proper drain operation. repair or replace as needed.
Separator installed incorrectly - If a separator was installed, check to make sure that it was installed properly. If no separator
was installed downstream of the aftercooler, one should be installed to remove the liquid from the air system.
6.4 EXCESSIVE PRESSURE DROP ACROSS THE AFTERCOOLER
Aftercooler core damaged or clogged - Inspect the core for damage or blockage. If the core is damaged, repair or replace. If
the core is plugged, ush it out as outlined in Section 5.2.
REPLACEMENT PARTS SECTION 7
5.4 REPLACEMENT PARTS
MODEL
AC-65-6
AC-65-7
AC-105-6
AC-105-7
AC-125-6
AC-125-7
ELECTRIC MOTOR
34-1017
34-1018
34-1017
34-1018
34-1019
34-1020
FAN BLADE
26-9025
26-9025
26-9025
26-9025
26-9026
26-9026

PAGE 8
2950 Mechanic Street
Lake City, PA 16423-2095
Phone: [phone]
www.vanairsystems.com
DISCHARGE AIR USED FOR
BREATHING WILL CAUSE SEVERE
INJURY OR DEATH. CONSULT
FILTRATION SPECIALIST FOR
ADDITIONAL FILTRATION AND
TREATMENT EQUIPMENT TO
MEET HEALTH AND SAFETY
REGULATIONS.
DANGER
AIR AND OIL UNDER PRESSURE
WILL CAUSE SEVERE
PERSONAL INJURY OR DEATH.
SHUT DOWN COMPRESSOR
AND RELIEVE SYSTEM OF ALL
PRESSURE BEFORE REMOVING
VALVES, CAPS, PLUGS,
FITTINGS, BOLTS AND FILTERs.
DANGER
ELECTRICAL SHOCK FROM
IMPROPER GROUNDING CAN
CAUSE INJURY OR DEATH.
GROUND UNIT AND RELATED
EQUIPMENT ACCORDING TO
NATIONAL ELECTRICAL CODE
AND LOCAL REGULATIONS.
WARNING WARNING
READ THE OPERATOR'S
MANUAL BEFORE OPERATTING
OR SERVICING THIS UNIT.
FAILURE TO ADHERE TO
INSTRUCTIONS CAN RESULT
IN SEVERE PERSONAL INJURY
OR DEATH. REPLACEMENT
MANUALS CAN BE
DOWNLOADED AT
www.vanairsystems.com
SAFETY PRECAUTIONS
Safety is everybody's business and is based on your use of good common sense. All situations or circum-
stances cannot always be predicted and covered by established rules. Therefore, use your past experience,
watch out for safety hazards and be cautious.