Vanair Air n arc reliant 300 series User manual

ALL-IN-ONE POWER SYSTEMS®

WELDER • GENERATOR • AIR COMPRESSOR • BATTERY BOOSTER

OPERATION MANUAL & PARTS LIST

090012-OP_r0

Effective Date:

04-12

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

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.

NOTE

Use only Vanair Vanguard™

Premium Synthetic Oil and Genuine

Vanair Parts. Inspect and replace

damaged components before

operation. Substituting non-

Vanguard™ Oil or non-genuine

Vanair filter components WILL VOID

THE COMPRESSOR WARRANTY!

Vanair Manufacturing, Inc.

10896 West 300 North

Michigan City, IN 46360

Phone: (219) 879-5100

(800) 526-8817

Service Fax: (219) 879-5335

Parts Fax: (219) 879-5340

Sales Fax: (219) 879-5800

www.vanair.com

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

(800) 526-8817

VANAIR.COM

EFFECTIVE: JAN 8, 2016

(844) VAN - SERV

SERVICE@VANAIR.COM

PARTS@VANAIR.COM

090088_r1 MOBILE POWER SOLUTIONS

AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®TABLE OF CONTENTS

090012-OP_r0 PAGE - I

TABLE OF CONTENTS

WARRANTY ............................................... BEHIND COVER

TABLE OF CONTENTS......................................................I

GLOSSARY........................................................................IX

G.1 GENERAL TERMS AND DEFINITIONS ........................................................................................IX

G.2 WELDING TERMS AND DEFINITIONS.........................................................................................IX

G.3 AIR COMPRESSOR TERMS AND DEFINITIONS ........................................................................X

WARRANTY CLAIMS PROCEDURE ..............................XIII

CLAIMS PROCESS FOR WARRANTED PARTS....................................................................................XIII

PROCEDURE..........................................................................................................................................XIII

RETURN MATERIAL AUTHORIZATION FORM......................................................................................XVI

INTRODUCTION.................................................................1

EXPERIENCE THE VANAIR ADVANTAGE.............................................................................................1

A NOTE ON MANUAL NAVIGATION......................................................................................................2

SECTION 1: SAFETY ........................................................3

1.1 GENERAL INFORMATION ............................................................................................................3

1.2 DANGERS, WARNINGS, CAUTIONS, AND NOTES ....................................................................3

1.3 INTERNATIONAL SAFETY SYMBOL............................................................................................4

1.4 ARC WELDING HAZARDS............................................................................................................4

1.4.1 ELECTRICAL SHOCK CAN KILL........................................................................................................................ 4

1.4.2 FUMES AND GASSES CAN BE HAZARDSOUS ............................................................................................... 6

1.4.3 BUILD UP OF GAS CAN INJURE OR KILL........................................................................................................ 6

1.4.4 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING...................... 7

1.4.5 ARC RAYS CAN BURN EYES AND SKIN.......................................................................................................... 7

1.4.6 WELDING CAN CAUSE FIRE AND EXPLOSION.............................................................................................. 7

1.4.7 FLYING METAL CAN INJURE EYES.................................................................................................................. 8

1.4.8 HOT PARTS CAN CAUSE SEVERE BURNS..................................................................................................... 9

1.4.9 NOISE CAN DAMAGE HEARING....................................................................................................................... 9

1.4.10 MAGNETIC FIELDS CAN AFFECT PACEMAKERS........................................................................................... 9

Continued on next page...

TABLE OF CONTENTS AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®

PAGE - II 090012-OP_r0

SECTION 1: SAFETY (CONTINUED)

1.4.11 CYLINDERS CAN EXPLODE IF DAMAGED.......................................................................................................9

1.5 ENGINE HAZARDS........................................................................................................................... 10

1.5.1 BATTERY EXPLOSION CAN BLIND...................................................................................................................10

1.5.2 FUEL CAN CAUSE FIRE OR EXPLOSION.........................................................................................................10

1.5.3 MOVING PARTS CAN CAUSE INJURY ..............................................................................................................11

1.5.4 HOT PARTS CAN CAUSE SEVERE BURNS......................................................................................................11

1.5.5 ENGINE EXHAUST GASES CAN KILL ...............................................................................................................11

1.5.6 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING.......................11

1.5.7 BATTERY ACID CAN BURN SKIN AND EYES...................................................................................................12

1.5.8 ENGINE HEAT CAN CAUSE FIRE......................................................................................................................12

1.5.9 EXHAUST SPARKS CAN CAUSE FIRE..............................................................................................................12

1.6 COMPRESSED AIR HAZARDS.................................................................................................... 12

1.6.1 BREATHING COMPRESSED AIR CAN CAUSE SERIOUIS INJURY OR DEATH..............................................12

1.6.2 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING.......................12

1.6.3 COMPRESSED AIR CAN CAUSE INJURY.........................................................................................................13

1.6.4 TRAPPED AIR PRESSURE AND WHIPPING HOSES CAN CAUSE INJURY....................................................13

1.6.5 HOT METAL FROM AIR ARC CUTTING AND GOUGING CAN CAUSE FIRE OR EXPLOSION.......................13

1.6.6 HOT PARTS CAN CAUSE SEVERE BURNS......................................................................................................13

1.6.7 READ INSTRUCTIONS........................................................................................................................................13

1.7 ADDITIONAL SYMBOLS FOR INSTALLATION, OPERATION AND MAINTENANCE.................. 14

1.7.1 FALLING UNIT CAN CAUSE INJURY..................................................................................................................14

1.7.2 OVERHEATING CAN DAMAGE MOTORS..........................................................................................................14

1.7.3 FLYING SPARKS CAN CAUSE INJURY..............................................................................................................14

1.7.4 OVERUSE CAN CAUSE OVERHEATING...........................................................................................................14

1.7.5 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING.......................15

1.7.6 TILTING OF TRAILER CAN CAUSE INJURY......................................................................................................15

1.7.7 READ INSTRUCTIONS........................................................................................................................................15

1.7.8 H.F. RADIATION CAN CAUSE INTERFERENCE................................................................................................15

1.7.9 ARC WELDING CAN CAUSE INTERFERENCE.................................................................................................16

1.8. CALIFORNIA PROPOSITION 65 WARNINGS.............................................................................. 16

1.9 PRINCIPAL SAFETY STANDARDS .............................................................................................. 17

1.10 EMF INFORMATION ..................................................................................................................... 18

1.11 MACHINE CANOPY ACCESS SAFETY SWITCHES ................................................................... 18

Continued on next page...

AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®TABLE OF CONTENTS

090012-OP_r0 PAGE - III

SECTION 1: SAFETY (CONTINUED)

1.12 DISPOSING OF MACHINE FLUIDS..............................................................................................19

SECTION 2: DESCRIPTION ..............................................21

FIGURE 2-1: MAJOR MACHINE COMPONENTS LOCATIONS.............................................................20

2.1 GENERAL DESCRIPTION.............................................................................................................21

2.2 COMPRESSED AIR SYSTEM.......................................................................................................21

2.2.1 COMPRESSOR UNIT......................................................................................................................................... 21

2.2.2 ELECTRONIC INLET VALVE.............................................................................................................................. 22

2.2.3 AIR INLET FILTER.............................................................................................................................................. 23

2.2.4 SECONDARY SPIN-ON AIR/OIL COALESCER................................................................................................. 23

2.2.5 MINIMUM PRESSURE/CHECK VALVE.............................................................................................................. 23

2.2.6 PRESSURE RELIEF VALVE ............................................................................................................................... 23

2.2.7 ADJUSTABLE PRESSURE SWITCH.................................................................................................................. 24

2.2.8 OIL RESERVOIR AND PRIMARY AIR/OIL SEPARATOR................................................................................... 24

2.3 OIL COOLING SYSTEM ................................................................................................................24

2.3.1 COMPRESSOR TEMPERATURE AND PRESSURE SWITCHES ..................................................................... 26

2.3.2 COMPRESSOR SPIN-ON OIL FILTER............................................................................................................... 26

2.4 ENGINE..........................................................................................................................................26

2.5 AC GENERATOR...........................................................................................................................28

2.6 INSTRUMENTATION .....................................................................................................................28

2.6.1 VOLTS/AMPS METER ........................................................................................................................................ 29

2.6.2 WELDER FUNCTION SWITCHES...................................................................................................................... 29

2.6.3 DC CHARGER MODE TOGGLE SWITCH.......................................................................................................... 31

2.6.4 VOLTS/AMPS MANUAL ADJUSTMENT DIAL.................................................................................................... 31

2.6.5 COMPRESSOR ON/OFF TOGGLE SWITCH..................................................................................................... 31

2.6.6 COMPRESSOR AIR PRESSURE GAUGE......................................................................................................... 31

2.6.7 WELDER LEAD JUNCTION................................................................................................................................ 31

2.6.8 BATTERY CABLE RECEPTACLE....................................................................................................................... 31

2.6.9 GENERATOR CONTROL ON/OFF TOGGLE SWITCH...................................................................................... 31

2.6.10 AC VOLTAGE OUTLETS..................................................................................................................................... 31

2.6.11 CIRCUIT BREAKER OVERLOAD TRIP/RESET BUTTONS...............................................................................31

2.6.12 DOOR OPEN INDICATOR LAMP ....................................................................................................................... 32

2.6.13 ALTERNATOR FAIL INDICATOR LAMP.............................................................................................................. 32

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