Vanair AIR N ARC RELIANT 150 Series User manual

ALL-IN-ONE POWER SYSTEMS®
WELDER • GENERATOR • AIR COMPRESSOR • BATTERY BOOSTER
OPERATION MANUAL & PARTS LIST
©2014 Vanair Manufacturing, Inc.
All rights reserved
090051-OP_r0
Effective Date:
2-2014
NOTE
Read this manual before installing,
operating or servicing this
equipment. Failure to comply with
the operation and maintenance
instructions in this manual WILL
VOID THE EQUIPMENT WARRANTY.
NOTE
Use only Genuine Vanair Parts.
Inspect and replace damaged
components before operation.
Substituting non-Vanair
components WILL VOID THE
COMPRESSOR WARRANTY!
Vanair Manufacturing, Inc.
10896 West 300 North
Michigan City, IN 46360
Phone: [phone]
[phone]
Service Fax: [phone]
Parts Fax: [phone]
Sales Fax: [phone]
www.vanair.com
NOTE
Making unauthorized modifications to
the system components WILL VOID THE
WARRANTY!
Always inform Vanair Manufacturing,
Inc. before beginning any changes to the
Air N Arc system.
KEEP THE MANUAL
WITH THE VEHICLE

This limited warranty supersedes all previous Vanair warranties
and is exclusive with no other guarantees or warranties
expressed or implied.
LIMITED WARRANTY—Subject to the expressed terms and
conditions set forth below, Vanair Mfg., Inc. (“Vanair”), of
Michigan City, Indiana (USA), warrants to the original retail
purchaser of new Vanair equipment that such equipment is free
from defects in materials and workmanship when shipped by
Vanair.
For warranty claims received by Vanair within the applicable
warranty periods described below, Vanair will repair or replace
any warranted equipment, parts or components that fail due to
defects in material or workmanship or refund the purchase price
for the equipment, at Vanair’s discretion. Vanair is not
responsible for time or labor to gain access to the machine to
preform work. WARRANTY WILL BE VOID IF GENUINE VANAIR
PARTS AND FLUIDS ARE NOT USED.
Vanair must be notied in writing within thirty (30) days of any
such defect or failure. No warranty work or returns without prior
authorization is allowed. Vanair will provide instructions on the
warranty claim procedures to be followed.
Warranty will commence upon receipt of the Warranty
Registration Card. If the Warranty Registration Card is not
received within six (6) months of shipment from Vanair, the
warranty commencement date shall be thirty (30) days from the
date of shipment from Vanair. Records of warranty adherence
are the responsibility of the end user.
1. Lifetime Warranty Parts – 3 Years Labor
• Rotary Screw Air Compressor Air End
2. 6 Years Parts – 3 Years Labor
• Vanair Super Capacitor (VSC)
3. 3 Years Parts – 1 Year Labor
• Reciprocating Compressor Air End
• Generators
• Welders
4. 2 Years Parts – 1 Year Labor
• Hydraulic Motors
• Hydraulic Pumps
5. 1 Year Parts – 1 Year Labor
• All electronics including, but not limited to:
(i) I/O Boards
(ii) Modules
(iii) Panel Boxes
(iv) Instrumentation
(v) Clutches
(vi) Solenoids
(vii) Running Gear/Trailers
(viii) Compressor/Hydraulic Coolers, including Fan
and Radiator Core
This Limited Warranty shall not apply to:
1. Consumable components, such as shaft seals,
valves, belts, lters, capacitors, contactors, relays,
brushes or parts that fail due to normal wear and use.
2. Items furnished by Vanair, but manufactured by
others, such as engines and trade accessories (these items
are covered by the manufacturer’s warranty, if any).
3. Equipment that has been modied by any party other
than Vanair or equipment which has not been used and
maintained in accordance with Vanair’s specications.
4. Equipment which has been improperly installed
and/or improperly operated, based upon Vanair’s
specications for the equipment or industry standards.
5. Equipment installed by non-authorized or third party
personnel.
Vanair products are intended for purchase and use by
commercial/industrial users and persons trained and
experienced in the use and maintenance of industrial
equipment.
In the event of a warranty claim covered by this Limited
Warranty, the exclusive remedies shall be, at Vanair’s sole
discretion: (i) repair; or (ii) replacement; (iii) where authorized in
writing by Vanair in appropriate cases, the reasonable cost of
repair or replacement at an authorized Vanair service facility ; or
(iv) payment of (or credit for) the purchase price (less reasonable
depreciation based upon actual use) upon return of the
equipment at the warranty claimant’s risk and expense. Vanair
will pay standard ground freight for any warranty item shipped
to and from Vanair or (Vanair designated facility) within the rst
year of the applicable warranty period. Any additional expedited
freight cost is the responsibility of the purchaser.
TO THE GREAT EXTENT PERMITTED BY APPLICABLE LAW, THE
REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES APPLICABLE TO THE VANAIR EQUIPMENT. IN NO
EVENT SHALL VANAIR BECOME LIABLE FOR DIRECT, INDIRECT,
SPECIAL, PUNITIVE, INCIDENTAL OR CONSEQUENTIAL DAMAGES
(INCLUDING LOSS OF PROFIT OR LOST BUSINESS
OPPORTUNITY), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY. IN NO EVENT SHALL VANAIR BECOME
OBLIGATED TO PAY MORE ON ANY WARRANTY CLAIM THAN THE
PURCHASE PRICE ACTUALLY PAID BY THE ORIGINAL RETAIL
PURCHASER.
THIS LIMITED WARRANTY IS MADE IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A
PARTICULAR PURPOSE, OR ANY OTHER WARRANTY OR
GUARANTY ARISING BY OPERATION OF LAW. ANY WARRANTY
NOT EXPRESSLY PROVIDED HEREIN, IMPLIED WARRANTY,
GUARANTY AND ANY REPRESENTATION REGARDING THE
PERFORMANCE OF THE EQUIPMENT, AND ANY REMEDY FOR
BREACH OF CONTRACT, IN TORT, OR ANY OTHER LEGAL THEORY
WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY
IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE, OR
COURSE OF DEALING ARE EXCLUDED AND DISCLAIMED BY
VANAIR.
Some states in the United States of America do not allow
limitations of how long an implied warranty lasts, or the
exclusion of incidental, indirect, special or consequential
damages, and as such, the above limitations and exclusions may
not apply to you. This warranty provides specic legal rights.
Other rights may be available to you, but may vary from state to
state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be saved, the limitations and
exclusions set out forth above may not apply. This Limited
Warranty provides specic legal rights, and other rights may be
available, but may vary from province to province.
AIR N ARC®
ALL-IN-ONE POWER-SYSTEMS®
RELIANT™ SERIES
POWERFLEX™ SERIES
PRO SERIES
CONTRACTOR SERIES
VIPER™ SERIES
FST™ SERIES
10896 W. 300 N.
MICHIGAN CITY, IN 46360
[phone]
VANAIR.COM
EFFECTIVE: JAN 8, 2016
(844) VAN - SERV
[e-mail]
[e-mail]
090088_r1 MOBILE POWER SOLUTIONS

AIR N ARC®150 SERIES TABLE OF CONTENTS
090051-OP_r0 (FEB-2014) PAGE - I
TABLE OF CONTENTS
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
WARRANTY .............................................. BEHIND COVER
TABLE OF CONTENTS...................................................... I
WARRANTY CLAIM PROCEDURE................................... V
CLAIMS PROCESS FOR WARRANTED PARTS ...................................................................................V
PROCEDURE..........................................................................................................................................V
SECTION 1: SAFETY ........................................................1
1.1 GENERAL INFORMATION ............................................................................................................1
1.2 DANGERS, WARNINGS, CAUTIONS, AND NOTES ....................................................................1
1.3 INTERNATIONAL SAFETY SYMBOL............................................................................................1
1.4 ARC WELDING HAZARDS............................................................................................................1
1.4.1 ELECTRICAL SHOCK CAN KILL........................................................................................................................ 1
1.4.2 FUMES AND GASES CAN BE HAZARDOUS.................................................................................................... 2
1.4.3 BUILD UP OF GAS CAN INJURE OR KILL........................................................................................................ 3
1.4.4 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING...................... 3
1.4.5 ARC RAYS CAN BURN EYES AND SKIN.......................................................................................................... 3
1.4.6 WELDING CAN CAUSE FIRE AND EXPLOSION.............................................................................................. 3
1.4.7 FLYING METAL CAN INJURE EYES.................................................................................................................. 4
1.4.8 HOT PARTS CAN CAUSE SEVERE BURNS..................................................................................................... 4
1.4.9 NOISE CAN DAMAGE HEARING....................................................................................................................... 4
1.4.10 MAGNETIC FIELDS CAN AFFECT PACEMAKERS........................................................................................... 4
1.4.11 CYLINDERS CAN EXPLODE IF DAMAGED...................................................................................................... 4
1.5 ENGINE HAZARDS .......................................................................................................................5
1.5.1 BATTERY EXPLOSION CAN BLIND .................................................................................................................. 5
1.5.2 FUEL CAN CAUSE FIRE OR EXPLOSION........................................................................................................ 5
1.5.3 MOVING PARTS CAN CAUSE INJURY.............................................................................................................. 5
1.5.4 HOT PARTS CAN CAUSE SEVERE BURNS..................................................................................................... 6
1.5.5 ENGINE EXHAUST GASES CAN KILL .............................................................................................................. 6
1.5.6 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING...................... 6
1.5.7 BATTERY ACID CAN BURN SKIN AND EYES .................................................................................................. 6
Continued on next page...

TABLE OF CONTENTS AIR N ARC®150 SERIES
PAGE - II 090051-OP_r0 (FEB-2014) Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
SECTION 1: SAFETY (CONTINUED)
1.5.8 ENGINE HEAT CAN CAUSE FIRE......................................................................................................................6
1.5.9 EXHAUST SPARKS CAN CAUSE FIRE..............................................................................................................6
1.6 COMPRESSED AIR HAZARDS.................................................................................................... 6
1.6.1 BREATHING COMPRESSED AIR CAN CAUSE SERIOUS INJURY OR DEATH...............................................6
1.6.2 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING.......................6
1.6.3 COMPRESSED AIR CAN CAUSE INJURY.........................................................................................................7
1.6.4 TRAPPED AIR PRESSURE AND WHIPPING HOSES CAN CAUSE INJURY....................................................7
1.6.5 HOT METAL FROM AIR ARC CUTTING AND GOUGING CAN CAUSE FIRE OR EXPLOSION.......................7
1.6.6 HOT PARTS CAN CAUSE SEVERE BURNS......................................................................................................7
1.6.7 READ INSTRUCTIONS........................................................................................................................................7
1.7 ADDITIONAL SYMBOLS FOR INSTALLATION, OPERATION AND MAINTENANCE.................. 7
1.7.1 FALLING UNIT CAN CAUSE INJURY..................................................................................................................7
1.7.2 OVERHEATING CAN DAMAGE MOTORS..........................................................................................................7
1.7.3 FLYING SPARKS CAN CAUSE INJURY..............................................................................................................7
1.7.4 OVERUSE CAN CAUSE OVERHEATING...........................................................................................................8
1.7.5 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING.......................8
1.7.6 TILTING OF TRAILER CAN CAUSE INJURY......................................................................................................8
1.7.7 READ INSTRUCTIONS........................................................................................................................................8
1.7.8 H.F. RADIATION CAN CAUSE INTERFERENCE................................................................................................8
1.7.9 ARC WELDING CAN CAUSE INTERFERENCE.................................................................................................8
1.8 CALIFORNIA PROPOSITION 65 WARNINGS.............................................................................. 9
1.9 PRINCIPAL SAFETY STANDARDS .............................................................................................. 9
1.10 EMF INFORMATION ..................................................................................................................... 9
1.11 SAFETY DECALS ......................................................................................................................... 10
1.12 DISPOSING OF MACHINE FLUIDS.............................................................................................. 10
SECTION 2: SPECIFICATIONS.........................................11
TABLE 2A: SPECIFICATIONS ................................................................................................................ 11
TABLE 2B: UNIT WEIGHT AND DIMENSIONS...................................................................................... 12
SECTION 3: INSTALLATION............................................13
3.1 MACHINE PACKAGE RECEIPT/INSPECTION ............................................................................ 13
3.2 MACHINE PACKAGE PREP.........................................................................................................13
3.3 SERVICE BODY PREP................................................................................................................. 14
3.4 MACHINE PACKAGE MOUNTING ............................................................................................... 14
Continued on next page...

AIR N ARC®150 SERIES TABLE OF CONTENTS
090051-OP_r0 (FEB-2014) PAGE - III
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
SECTION 4: OPERATION..................................................17
4.1 GENERAL INFORMATION............................................................................................................17
4.2 ENGINE START-UP AND SHUTDOWN PROCEDURE................................................................17
4.2.1 ENGINE START-UP............................................................................................................................................ 18
4.2.2 ENGINE SHUTDOWN......................................................................................................................................... 18
4.3 ENGINE THROTTLE CONTROL FUNCTIONS.............................................................................19
4.4 OPERATING THE WELDER..........................................................................................................20
4.5 OPERATING THE GENERATOR ..................................................................................................21
4.6 OPERATING THE AIR COMPRESSOR........................................................................................22
4.7 EXTREME CONDITION OPERATION...........................................................................................22
4.7.1 COLD WEATHER OPERATION ......................................................................................................................... 22
4.7.1.1 ENGINE OPERATION.......................................................................................................23
4.7.2 HIGH TEMPERATURE OPERATION................................................................................................................. 23
4.7.3 HIGH ALTITUDE OPERATION........................................................................................................................... 23
SECTION 5: MAINTENANCE ............................................25
5.1 GENERAL INFORMATION............................................................................................................25
5.2 ROUTINE MAINTENANCE SCHEDULE .......................................................................................25
5.3 MAINTENANCE SCHEDULE TABLE ............................................................................................26
5.4 REPLACEMENT PARTS................................................................................................................31
5.5 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES ...................................................31
5.5.1 ADJUSTING THE ENGINE SPEED.................................................................................................................... 32
5.5.2 REPLACING AND RE-TENSIONING THE COMPRESSOR AND/OR GENERATOR DRIVE BELTS................ 32
5.5.2.1 ACCESSING THE DRIVE BELTS - REMOVING THE BELT GUARD SHIELD.............................32
5.5.2.2 REPLACING THE BELT GUARD SHIELD ............................................................................32
5.5.2.3 RE-TENSIONING THE AIR COMPRESSOR DRIVE BELT.......................................................32
5.5.2.4 COMPRESSOR BELT SIZING............................................................................................33
5.5.2.5 COMPRESSOR BELT LINK DISENGAGEMENT ....................................................................34
5.5.2.6 COMPRESSOR BELT ASSEMBLY......................................................................................35
5.5.2.7 TRACKING COMPRESSOR BELT ONTO PULLEY GROOVE..................................................35
5.5.2.8 RE-TENSIONING OR REPLACING THE GENERATOR SERPENTINE BELT ..............................37
5.5.2.9 RE-TENSIONING THE GENERATOR SERPENTINE BELT......................................................37
5.5.2.10 REPLACING THE GENERATOR SERPENTINE DRIVE BELT ..................................................37
5.5.3 SERVICING THE FUSE...................................................................................................................................... 38
5.6 STORAGE AND INTERMITTENT USE.............................................................................................39
5.6.1 INTERMITTENT USE.......................................................................................................................................... 39
5.6.2 LONG TERM STORAGE..................................................................................................................................... 39
Continued on next page...

TABLE OF CONTENTS AIR N ARC®150 SERIES
PAGE - IV 090051-OP_r0 (FEB-2014) Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
SECTION 6: TROUBLESHOOTING................................41
6.1 GENERAL INFORMATION .........................................................................................................41
6.2 TROUBLESHOOTING GUIDE ....................................................................................................42
SECTION 7: ILLUSTRATED PARTS LIST......................51
7.1 PARTS ORDERING PROCEDURE............................................................................................... 51
TABLE 7A: RECOMMENDED SPARE PARTS LIST..................................................................... 52
7.2 AIR COMPRESSOR...................................................................................................................... 54
7.3A FRAME ASSEMBLY (ALL 10 GALLON MODEL OPTIONS)......................................................... 56
7.3B FRAME ASSEMBLY (ALL 30 GALLON MODEL OPTIONS)......................................................... 56
7.3C FRAME ASSEMBLY (ALL SKID-MOUNT MODEL OPTIONS)...................................................... 56
7.4 ENGINE AND DRIVE PARTS (1 OF 2)......................................................................................... 58
7.4 ENGINE AND DRIVE PARTS (2 OF 2)......................................................................................... 60
7.5 BELT GUARD ASSEMBLY............................................................................................................ 62
7.6 ELECTRICAL SYSTEM................................................................................................................. 64
7.7 CONTROL ASSEMBLY (30 GALLON AND SKID-MOUNT REMOTE OPTIONS)........................ 68
7.8A AIR TANK (ALL 10 GALLON MODEL OPTIONS)........................................................................ 70
7.8B AIR TANK (ALL 30 GALLON MODEL OPTIONS)........................................................................ 72
7.9 DECAL LOCATIONS..................................................................................................................... 74
7.10 WIRING DIAGRAM........................................................................................................................ 76
7.11A INSTALLATION AND DIMENSIONS - 10 GALLON TANK MOUNT ............................................. 77
7.11B INSTALLATION AND DIMENSIONS - 30 GALLON TANK MOUNT.............................................. 78
7.11C INSTALLATION AND DIMENSIONS - SKID-MOUNT................................................................... 79
7.12 HOSE INSTALLATION GUIDE...................................................................................................... 80

AIR N ARC®150 SERIES WARRANTY PROCEDURE
090051-OP_r0 (FEB-2014) PAGE - V
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
CLAIMS PROCESS FOR
WARRANTED VANAIR PARTS
This process must be used by owners of
Vanair®equipment in situations where a
warranted item needs repair or replacement
under the terms of the purchase warranty.
Do not return items to Vanair without prior
authorization from the Vanair Warranty
Administrator.
PROCEDURE:
When a customer needs assistance with
troubleshooting a system and/or returning
parts, follow the steps below.
1. Locate the machine’s serial number:
The machine package serial number plate is
located inside the machine compartment on
the floor near to the generator mounting
location (see Figure W-1).
The engine and the compressor also have
individual serial numbers respectively (see
Figure W-1). For engine warranty issues,
consult the Engine Operator’s Manual for
the engine’s limited warranty details. For
particular compressor unit issues, the
compressor serial number may be needed.
In any case, engine and/or compressor
issues can be confirmed using the machine
serial number as found in Figure W-1.
2. Have a list of the symptoms/condition/
malfunctions along with any applicable
temperature and pressure readings, and
also the number of operational hours
available (if applicable):
Note that the above information will also
need to be included on the Return Material
Authorization Form (per Step #6); this form
is necessary for warranty processing if the
warranty claim is deemed valid by the
service case review.
3. Contact the Vanair®Service Department
by phone [phone]) to speak with
a Service Technician.
4. Vanair Service will troubleshoot the
problem based on the information
provided by the customer, and attempt to
return the unit to service as quickly as
possible.
5. If the unit cannot be returned to service,
and Vanair determines this matter is a
warranty issue, the Service Technician
will assign an RMA (Return Material
Authorization) number that will provide
for the return of the item to Vanair for
analysis and a final determination as to
the item’s warranty status.
6. Warranty Claims are solicited via a
Return Material Authorization (RMA)
Form. This form can be obtained via
download from the web site, or requested
directly from the Vanair Service
Department:
Once a current form has been obtained,
follow the instructions given on the form to fill
in the information needed. This form is used
for the purpose of soliciting a warranty case.
All of the field information except for the
bottom section block fields, which includes
NOTE
The RMA number must be placed on the
outside of the package being returned.
WARRANTY CLAIMS
PROCEDURE

WARRANTY PROCEDURE AIR N ARC®150 SERIES
PAGE - VI 090051-OP_r0 (FEB-2014) Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
800-526-8817
260940
MODEL NUMBER
SERIAL NUMBER
MAXIMUM PRESSURE
COMPRESSOR INPUT RPM
ww w.vanai r.com
C
B
A
KOHLER
MODELNO.XXXXX
SERIALNO.XXXXX
S/NXXXXX
KEY DESCRIPTION KEY DESCRIPTION
AENGINE SERIAL NUMER TAG CMACHINE SERIAL PLATE / SERIAL
NUMBER
BCOMPRESSOR SERIAL NUMBER TAG
Figure W-1: Machine Serial Number Location

AIR N ARC®150 SERIES WARRANTY PROCEDURE
090051-OP_r0 (FEB-2014) PAGE - VII
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
Disposition of Goods, Notifications and
Additional Notes, will be required.
Customers have 30 days after the RMA
number is issued to return the item. If the
part is not returned within this period, the
RMA is void and any claims will be denied.
Before sending a warranty part to a
customer, Vanair®will need a P.O. or credit
card number to cover the cost of the part and
shipping. After the part is analyzed and
deemed to be covered under warranty,
Vanair will issue credit to the customer. All
parts eligible for warranty must have the
RMA number on the invoice at the time of
purchase.
No items can be returned “freight collect”.
Freight costs will be addressed at the time
the claim is closed. The customer pays any
additional costs for warranty parts delivered
through expedited services (i.e., Next Day,
Second Day).
VANAIR WILL NEVER ACCEPT ANY
INVOICES FOR PARTS RETURNED: ANY
PARTS RETURNED VIA INVOICE WILL BE
RETURNED FREIGHT COLLECT: NO
PARTS ARE TO BE RETURNED FREIGHT
COLLECT!
Vanair Mfg., Inc. strives to continuously
improve its customer service. Please forward
any questions, comments, or suggestions to
Vanair Service (219-879-5100, ext. 400) or
e-mail us ([e-mail]).
NOTE
All labor claims or invoices must be
approved by the Vanair Warranty
Administrator prior to starting repair work
along with the cost of the repair. All paper
work associated with the returned item
and warranty repair cost must reference
the RMA number issued against the part,
and be forwarded to Vanair within 30 days
of the completion of work.

PAGE - VIII 090051-OP_r0 (FEB-2014)
BLANK PAGE
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817

090051-OP_r0 (FEB-2014) PAGE - 1
AIR N ARC®150 SERIES SECTION 1: SAFETY
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
1.1 GENERAL INFORMATION
The products provided by Vanair®
Manufacturing, Inc., are designed and
manufactured for safe operation and
maintenance. However, it is ultimately the
responsibility of the users and maintainers
for safe use of this equipment. Part of this
responsibility is to read and be familiar with
the contents of this manual before operation
or performing maintenance actions.
1.2 DANGERS, WARNINGS,
CAUTIONS, AND NOTES
1.3 INTERNATIONAL SAFETY
SYMBOL
The symbols shown and defined in Section
1: Safety are used throughout this manual to
call attention to and identify possible
hazards.
The international warning symbol shown
above is used on all decals, labels and signs
that concern information pertaining to bodily
harm. When you see the international
warning symbol, pay extremely careful
attention, and follow the given instructions
or indications to avoid any possible hazard.
1.4 ARC WELDING HAZARDS
1.4.1 ELECTRICAL SHOCK CAN KILL
Touching live electrical parts
can cause fatal shocks or
severe burns. The electrode
and work circuit are
electrically live whenever
the output is on. The input
IMPORTANT
It is mandatory that all operators read this
manual before operating or servicing the
Air N Arc 150 Series All-In-One Power
System. Failure to do so could result in
death, bodily injury or damage to
equipment.
DANGER
Identifies actions or conditions which
will cause death, severe injury,
equipment damage or destructive
malfunctions.
WARNING
Identifies actions or conditions which
may cause death, severe injury,
equipment damage or destructive
malfunctions.
CAUTION
Identifies actions or conditions which
will or can cause injuries, equipment
damage or malfunctions.
NOTE
Additional information (or existing
information) which should be brought to
the attention of operators/maintainers
affecting safety, operation, maintenance,
or warranty requirements.
SECTION 1:
SAFETY

PAGE - 2 090051-OP_r0 (FEB-2014)
SECTION 1: SAFETY AIR N ARC®150 SERIES
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
power circuit and machine internal circuits
are also live when power is on. In semi-
automatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are
electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and
body protection.
Insulate yourself from work and ground using
dry insulating mats or covers big enough to
prevent any physical contact with the work or
ground.
Do not use AC output in damp areas, if
movement is confined, or if there is a danger
of falling.
Additional safety precautions are required
when working in electrically hazardous
conditions such as in damp locations or while
wearing wet clothing; on metal structures
such as floors, gratings, or scaffolds; when in
cramped positions such as sitting, kneeling,
or lying; or when there is a high risk of
unavoidable or accidental contact with the
work piece or ground.
Do not work alone!
Disconnect input power or stop engine
before installing or servicing this equipment.
Lockout/tag out input power according to
OSHA29 CFR1910.147 (see Section 1.9,
Principal Safety Standards).
Properly install and ground this equipment
according to its Owner’s Manual and
national, state, and local codes.
Always verify the supply ground: check and
be sure that input power cord ground wire is
properly connected to ground terminal in
disconnect box or that cord plug is
connected to a properly grounded receptacle
outlet.
When making input connections, attach
proper grounding conductor first and double-
check connections.
Frequently inspect input power cord for
damage or bare wiring and replace cord
immediately if damaged—bare wiring can
kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or
poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the work piece is
required, ground it directly with a separate
cable.
Do not touch electrode if you are in contact
with the work, ground, or another electrode
from a different machine.
Use only well-maintained equipment. Repair
or replace damaged parts at once. Maintain
unit according to manual.
Do not touch electrode holders connected to
two welding machines at the same time
since double open-circuit voltage will be
present.
Wear a safety harness if working above floor
level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal
contact to work piece or work table as near
the weld as practical.
Insulate work clamp when not connected to
workpiece to prevent contact with any metal
object.
Do not connect more than one electrode or
work cable to any single weld output
terminal.
1.4.2 FUMES AND GASES CAN BE
HAZARDOUS
Welding produces fumes
and gases. Breathing these
fumes and gases can be
hazardous to your health.
Keep your head out of the
fumes. Do not breathe the
fumes.
If inside, ventilate the area and/or use local
forced ventilation at the arc to remove

090051-OP_r0 (FEB-2014) PAGE - 3
AIR N ARC®150 SERIES SECTION 1: SAFETY
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
welding fumes and gases.
If ventilation is poor, wear an approved air-
supplied respirator.
Read and understand the Material Safety
Data Sheets (MSDS’s) and the
manufacturer’s instructions for metals,
consumables, coatings, cleaners, and
degreasers.
Work in a confined space only if it is well
ventilated, or while wearing an air-supplied
respirator. Always have a trained watch
person nearby.
Welding fumes and gases can displace air
and lower the oxygen level causing injury or
death. Be sure the breathing air is safe.
Do not weld in locations near degreasing,
cleaning, or spraying operations.
The heat and rays of the arc can react with
vapors to form highly toxic and irritating
gases.
Do not weld on coated metals, such as
galvanized, lead, or cadmium-plated steel,
unless the coating is removed from the weld
area, the area is well-ventilated, and while
wearing an air-supplied respirator. The
coatings and any metals containing these
elements can give off toxic fumes if welded.
1.4.3 BUILD UP OF GAS CAN INJURE
OR KILL
Shut off shielding gas supply
when not in use.
Always ventilate confined
spaces or use approved air-
supplied respirator.
1.4.4 ENCLOSEDSPACESCAN CAUSEA
BUILD-UP OF NOXIOUS FUMES
AND OVERHEATING
Do not use in enclosed
spaces where deadly
exhaust gases can build up
and machine can overheat,
causing fire.
1.4.5 ARCRAYSCAN BURN EYES AND
SKIN
Arc rays from the welding
process produce intense
visible and invisible
(ultraviolet and infrared)
rays that can burn eyes and
skin. Sparks fly off from the
weld.
Wear an approved welding helmet fitted with
a proper shade of filter lenses to protect your
face and eyes from arc rays and sparks
when welding or watching.
(See ANSI Z49.1 and Z87.1 listed in Safety
Standards). Wear approved safety glasses
with side shields under your helmet.
Use protective screens or barriers to protect
others from flash, glare, and sparks; warn
others not to watch the arc.
Wear protective clothing made from durable,
flame-resistant material (leather, heavy
cotton, or wool) and foot protection.
1.4.6 WELDING CAN CAUSE FIRE
AND EXPLOSION
Welding on closed
containers, such as tanks,
drums, or pipes, can cause
them to blow up. Sparks can
fly off from the welding arc.
The flying sparks, hot
workpiece, and hot equipment can cause
fires and burns. Accidental contact of
electrode to metal objects can cause sparks,
explosion, overheating, or fire. Check and
ensure the area is safe before doing any
welding.
Remove all flammables within 35 ft (10.7 m)
of the welding arc. If this is not possible,
tightly cover them with approved covers.
Do not weld where flying sparks can strike
flammable material.
Protect yourself and others from flying
sparks and hot metal.

PAGE - 4 090051-OP_r0 (FEB-2014)
SECTION 1: SAFETY AIR N ARC®150 SERIES
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
Be alert that welding sparks and hot
materials from welding can easily go through
small cracks and openings to adjacent
areas.
Watch for fire and keep a fire extinguisher
nearby.
Be aware that welding on a ceiling, floor,
bulkhead, or partition can cause fire on the
hidden side.
Do not weld on closed containers such as
tanks, drums, or pipes, unless they are
properly prepared according to AWSF4.1
(See Section 1.9, Principal Safety
Standards).
Connect ground cable as close to the
welding area as practical to prevent welding
current from traveling long, possibly
unknown paths and causing electric shock,
sparks, and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
Wear oil-free protective garments such as
leather gloves, heavy shirt, cuffless trousers,
boots, and a cap.
Remove any combustibles, such as a butane
lighter or matches, from your person before
doing any welding.
Follow requirements in OSHA1910.252 (a)
(2) (iv) and NFPA 51B for hot work and have
a fire watcher and extinguisher nearby.
1.4.7 FLYING METAL CAN INJURE
EYES
Sparks and flying metal can
be caused by welding,
chipping, wire brushing, and
grinding. As welds cool, they
can throw off slag.
Wear approved safety
glasses with side shields even under your
welding helmet.
1.4.8 HOT PARTS CAN CAUSE
SEVERE BURNS
Do not touch hot parts bare
handed.
Allow cooling period before
working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
1.4.9 NOISE CAN DAMAGE HEARING
Noise from some processes
or equipment can damage
hearing.
Wear approved ear
protection if noise level is
high.
1.4.10 MAGNETIC FIELDS CAN
AFFECT PACEMAKERS
Pacemaker wearers keep
away.
Wearers should consult their
doctor before going near arc
welding, gouging, or spot
welding operations.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to treat
them carefully.
1.4.11 CYLINDERS CAN EXPLODE IF
DAMAGED
Protect compressed gas
cylinders from excessive
heat, mechanical shocks,
physical damage, slag,
open flames, sparks, and
arcs.

090051-OP_r0 (FEB-2014) PAGE - 5
AIR N ARC®150 SERIES SECTION 1: SAFETY
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
Install cylinders in an upright position by
securing to a stationary support or cylinder
rack to prevent falling or tipping.
Keep cylinders away from any welding or
other electrical circuits.
Never drape a welding torch over a gas
cylinder.
Never allow a welding electrode to touch any
cylinder.
Never weld on a pressurized
cylinder—explosion will result.
Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for
the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when
opening cylinder valve.
Keep protective cap in place over valve
except when cylinder is in use or connected
for use.
Use the right equipment, correct procedures,
and sufficient number of persons to lift and
move cylinders.
Read and follow instructions on compressed
gas cylinders, associated equipment, and
Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1.5 ENGINE HAZARDS
1.5.1 BATTERY EXPLOSION CAN
BLIND
Always wear a face shield,
rubber gloves, and
protective clothing when
working on a battery.
Stop engine before
disconnecting or connecting
battery cables or servicing battery.
Do not allow tools to cause sparks when
working on a battery.
Do not use weld mode to charge batteries or
jump start vehicles.
Observe correct polarity (+ and −) on
batteries.
Disconnect negative (−) cable first and
connect it last.
1.5.2 FUEL CAN CAUSE FIRE OR
EXPLOSION
Stop engine and let it cool
down before checking or
adding fuel.
Always keep nozzle in
contact with tank when
fueling.
Do not add fuel while smoking or if unit is
near any sparks or open flames.
Do not overfill tank—allow room for fuel to
expand.
Do not spill fuel. If fuel is spilled, clean up
before starting engine.
Dispose of rags in a fireproof container.
1.5.3 MOVING PARTS CAN CAUSE
INJURY
Keep away from fans, belts,
and rotors. Keep all doors,
panels, covers, and guards
closed and securely in
place.
Stop engine before installing
or connecting unit.
Have only qualified people remove doors,
panels, covers, or guards for maintenance
and troubleshooting as necessary.
Disconnect negative (−) battery cable from
battery to prevent accidental starting during
servicing.
Keep hands, hair, loose clothing, and tools
away from moving parts.
Reinstall doors, panels, covers, or guards
when servicing is finished and before starting
engine.

PAGE - 6 090051-OP_r0 (FEB-2014)
SECTION 1: SAFETY AIR N ARC®150 SERIES
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
Before working on generator, remove spark
plugs or injectors to keep engine from
kicking back or starting.
Block flywheel so that it will not turn while
working on generator components.
1.5.4 HOT PARTS CAN CAUSE
SEVERE BURNS
Do not touch hot parts bare
handed.
Allow cooling period before
working on equipment.
1.5.5 ENGINE EXHAUST GASES CAN
KILL
If used in a closed area,
vent engine exhaust outside
and away from any building
air intakes.
1.5.6 ENCLOSEDSPACESCAN CAUSEA
BUILD-UP OF NOXIOUS FUMES
AND OVERHEATING
Do not use in enclosed
spaces where deadly
exhaust gases can build up
and machine can overheat,
causing fire.
1.5.7 BATTERY ACID CAN BURN SKIN
AND EYES
Do not tip battery.
Replace damaged battery.
Flush eyes and skin
immediately with water.
1.5.8 ENGINE HEAT CAN CAUSE FIRE
Do not locate unit on, over,
or near combustible
surfaces or flammables.
Keep exhaust and exhaust
pipes way from flammables.
1.5.9 EXHAUST SPARKS CAN CAUSE
FIRE
Use approved engine
exhaust spark arrester in
required areas — see
applicable codes.
1.6 COMPRESSED AIR
HAZARDS
1.6.1 BREATHING COMPRESSED AIR
CAN CAUSE SERIOUS INJURY OR
DEATH
Do not use compressed air
for breathing.
Use only for cutting,
gouging, and tools.
1.6.2 ENCLOSED SPACES CAN
CAUSE A BUILD-UP OF
NOXIOUS FUMES AND
OVERHEATING
Do not use in enclosed
spaces where deadly
exhaust gases can build up
and machine can overheat,
causing fire.

090051-OP_r0 (FEB-2014) PAGE - 7
AIR N ARC®150 SERIES SECTION 1: SAFETY
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
1.6.3 COMPRESSED AIR CAN CAUSE
INJURY
Wear approved safety
goggles.
Do not direct air stream
toward self or others.
1.6.4 TRAPPED AIR PRESSURE AND
WHIPPING HOSES CAN CAUSE
INJURY
Release air pressure from
tools and system before
servicing, adding or
changing attachments, or
opening compressor oil
drain or oil fill cap.
1.6.5 HOT METAL FROM AIR ARC
CUTTING AND GOUGING CAN
CAUSE FIRE OR EXPLOSION
Do not cut or gouge near
flammables.
Watch for fire; keep
extinguisher nearby.
1.6.6 HOT PARTS CAN CAUSE
SEVERE BURNS
Do not touch hot parts bare
handed.
Allow cooling period before
working on equipment.
1.6.7 READ INSTRUCTIONS
Read Owner’s Manual
before using or servicing
unit.
Stop engine and release air pressure before
servicing.
Use only genuine Air-N-Arc replacement
parts.
1.7 ADDITIONAL SYMBOLS
FOR INSTALLATION,
OPERATION AND
MAINTENANCE
1.7.1 FALLING UNIT CAN CAUSE
INJURY
Use lifting bail to lift unit and
properly installed
accessories only.
Lift and support unit only
with proper equipment and
correct procedures.
If using lift forks to move unit, be sure forks
are long enough to extend beyond opposite
side of unit.
1.7.2 OVERHEATING CAN DAMAGE
MOTORS
Turn off or unplug
equipment before starting or
stopping engine.
Do not let low voltage and
frequency caused by low
engine speed damage
electric motors.
1.7.3 FLYING SPARKS CAN CAUSE
INJURY
Wear a face shield to protect
eyes and face.
Shape tungsten electrode
only on grinder with proper
guards in a safe location
wearing proper face, hand,
and body protection.

PAGE - 8 090051-OP_r0 (FEB-2014)
SECTION 1: SAFETY AIR N ARC®150 SERIES
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
Sparks can cause fires—keep flammables
away.
1.7.4 OVERUSE CAN CAUSE
OVERHEATING
Allow cooling period; follow
rated duty cycle.
Reduce current or reduce
duty cycle before starting to
weld again.
Do not block or filter airflow to unit.
1.7.5 ENCLOSEDSPACESCAN CAUSEA
BUILD-UP OF NOXIOUS FUMES
AND OVERHEATING
Do not use in enclosed
spaces where deadly
exhaust gases can build up
and machine can overheat,
causing fire.
1.7.6 TILTING OF TRAILER CAN
CAUSE INJURY
Use tongue jack or blocks to
support weight.
Properly install unit onto
trailer according to
instructions supplied with
trailer.
1.7.7 READ INSTRUCTIONS
Use only genuine Air N Arc
replacement parts.
Perform engine and air
compressor (if applicable)
maintenance and service
according to this manual
and the engine/air compressor (if applicable)
manuals.
1.7.8 H. F. RADIATION CAN CAUSE
INTERFERENCE
High-frequency (H.F.) can
interfere with radio
navigation, safety services,
computers, and
communications equipment.
Have only qualified persons
familiar with electronic equipment to perform
this installation.
The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
If notified by the FCC about interference,
stop using the equipment at once.
Have the installation regularly checked and
maintained.
Keep high-frequency source doors and
panels tightly shut, keep spark gaps at
correct setting, and use grounding and
shielding to minimize the possibility of
interference.
1.7.9 ARC WELDING CAN CAUSE
INTERFERENCE
Electromagnetic energy can
interfere with sensitive
electronic equipment such
as microprocessors,
computers, and computer-
driven equipment such as
robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld
cables as short as possible, close together,
and down low, such as on the floor.
Locate welding operation 100 meters from
any sensitive electronic equipment.
Be sure this welding machine is installed and
grounded according to this manual.
If interference still occurs, take extra
measures such as moving the welding

090051-OP_r0 (FEB-2014) PAGE - 9
AIR N ARC®150 SERIES SECTION 1: SAFETY
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
machine, using shielded cables, using line
filters, or shielding the work area.
1.8 CALIFORNIA
PROPOSITION 65
WARNINGS
Welding or cutting equipment produces
fumes or gases which contain chemicals
known to the State of California to cause
birth defects and, in some cases, cancer.
(California Health & Safety Code Section
25249.5 et seq.)
Battery posts, terminals and related
accessories contain lead and lead
compounds, chemicals known to the State of
California to cause cancer and birth defects
or other reproductive harm. Wash hands
after handling.
For Gasoline Engines: Engine exhaust
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
For Diesel Engines: Diesel engine exhaust
and some of its constituents are known to
the State of California to cause cancer, birth
defects, and other reproductive harm.
1.9 PRINCIPAL SAFETY
STANDARDS
Safety in Welding, Cutting, and Allied
Processes, ANSI Standard Z49.1, from
Global Engineering Documents (phone: 1-
877-413-5184,
website:www.global.ihs.com).
Recommended Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping, American Welding
Society Standard AWSF4.1, from Global
Engineering Documents (phone: [phone]-
5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70,
from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park,
Quincy, MA 02269-9101 (phone: 617-770-
3000, website: www.nfpa.org and
www.sparky.org).
Safe Handling of Compressed Gases in
Cylinders, CGA Pamphlet P-1, from
Compressed Gas Association, 1735
Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202-4102 (phone: 703-412-
0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA
StandardW117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W
1R3 (phone: [phone] or in Toronto
416-747-4044, website:
www.csainternational.org).
Practice For Occupational And Educational
Eye And Face Protection, ANSI Standard
Z87.1, from American National Standards
Institute, 11 West 42nd Street, New York, NY
10036-8002 (phone: [phone], website:
www.ansi.org).
Standard for Fire Prevention During Welding,
Cutting, and Other Hot Work, NFPA
Standard 51B, from National Fire Protection
Association, P.O. Box 9101, 1 Battery March
Park, Quincy, MA 02269-9101 (phone: 617-
770-3000, website: www.nfpa.org.
OSHA, Occupational Safety and Health
Standards for General Industry, Title 29,
Code of Federal Regulations (CFR), Part
1910, Subpart Q, and Part 1926, Subpart J,
from U.S. Government Printing Office,
Superintendent of Documents, P.O. Box
371954, Pittsburgh, PA 15250 (there are 10
Regional Offices; phone for Region 5,
Chicago, is 312-353-2220, website:
www.osha.gov).
1.10 EMF INFORMATION
Considerations about welding and the effects
of low frequency electric and magnetic fields
welding current, as it flows through welding
cables, will cause electromagnetic fields.
There has been and still is some concern
about such fields. However, after examining
more than 500 studies spanning seventeen
years of research, a special blue ribbon
committee of the National Research Council
concluded that: “The body of evidence, in the
committee’s judgment, has not

PAGE - 10 090051-OP_r0 (FEB-2014)
SECTION 1: SAFETY AIR N ARC®150 SERIES
Vanair Manufacturing, Inc.
vanair.com • 800-526-8817
demonstrated that exposure to power-
frequency electric and magnetic fields is a
human-health hazard.” However, studies are
still going forth and evidence continues to be
examined. Until the final conclusions of the
research are reached, you may wish to
minimize your exposure to electromagnetic
fields when welding or cutting.
To reduce magnetic fields in the workplace,
use the following procedures:
1. Keep cables close together by
twisting or taping them.
2. Arrange cables to one side and
away from the operator.
3. Do not coil or drape cables
around your body.
4. Keep welding power source and
cables as far away from
operator as possible.
5. Connect work clamp to workpiece
as close to the weld as possible.
About Pacemakers:
Pacemaker wearers should consult their
doctor before welding or going near welding
operations. If cleared by your doctor, then
following the above procedures is
recommended.
1.11 SAFETY DECALS
Safety decals are placed onto, or located
near, system components that can present a
hazard to operators or service personnel. All
pertinent decals listed in Section 7.9, Decal
and Plate Locations are located near a
component, which is subject to respect in
terms of safety precautions. Always heed the
information noted on the safety decals.
1.12 DISPOSING OF
MACHINE FLUIDS
Always dispose of machine fluids under the
guidance of all applicable local, regional and/
or federal law.
Vanair encourages recycling when allowed.
For additional information, consult the fluid
container.
WARNING
DO NOT REMOVE OR COVER ANY
SAFETY DECAL. Replace any safety
decal that becomes damaged or illegible.