Vmac PREDATAIR User manual

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Owner’s Manual
PREDATAIR
Hydraulic Air Compressor
General Information..........................................................................3
Safety Precautions..........................................................................3
Installation Instructions ...................................................................4
Specifications and Components .....................................................5
Operating the PREDATAIR ..............................................................7
Startup.............................................................................................7
What to Expect at Startup...............................................................7
Shut-down.......................................................................................8
Cold Weather Operation .................................................................9
Hot Weather Operation...................................................................9
Hydraulic Oil....................................................................................9
Automatic Shutdown.......................................................................9
Display Box Messages..................................................................10
System Adjustments .....................................................................13
Menu Headings.............................................................................13
Troubleshooting .............................................................................17
Maintaining the PREDATAIR .........................................................20
Adding Compressor Oil.................................................................20
Replacing the Air Filter..................................................................21
Changing Oil and Filter .................................................................22
Changing the Coalescing Filter.....................................................23
System Wiring Diagram ................................................................25
Warranty ..........................................................................................26
Maintenance and Repair Records ................................................28
Parts Replacement or Adjustment Record ...................................30
Accessory Products from VMAC ..................................................32

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Document 1930149
Owner’s Manual PREDATAIR Hydraulic Air Compressor
Changes and Revisions
Version
Revision Details
Revised
Approved
Implemented
0
Original manual
IB 14 Sept 2007
SM 03 Dec 2007
07 Dec 2007
A
ECN 08-197
SL 14 July 2008
SM 20 Sep 2010
21 Sep 2010
B
ECN 11-118
MH 23 Sep 2011
SM 30 Sep 2011
4 Oct 2011
C
ECN 14-042
MH 25 Jun 2014
MP/RD 16 Jul 2014
16 Jul 2014
Important Information
The information in this manual is intended for installers who have
knowledge and experience in hydraulic system installation 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. If you have difficulty
with the installation, contact VMAC.
Follow all safety precautions and standard shop practices for
mechanical work.
The VMAC 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 2008
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.
Printed in Canada

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General Information
Safety Precautions
Observe the following general safety rules:
pay attention to operations; do not leave the equipment
unattended
follow safe work practices and wear the appropriate safety
equipment when operating air-powered equipment,
particularly eye and hearing protection
avoid all contact with pressurized air, because if it penetrates
your skin it can enter your bloodstream and kill you
to prevent compressor explosion or fire, make sure that the
air entering the compressor is free of flammable vapors
vaporized oil propelled by high-pressure air is an explosive
mixture
do not breathe the compressor air, vaporized oil is a
respiratory hazard
stay clear of all moving parts
Observe these rules when operating the compressor:
do not bypass or disable the oil temperature sensors
do not expose the tank or compressor to extreme heat
do not perform any service until the system has been
completely blown-down and you have verified that all air has
been discharged
do not repair or service a pressurized system
maintenance and repair on system components should only
be performed by qualified personnel
the vehicle must be in park (for automatic transmissions) or
neutral (for manual transmissions) with the park brake or air
spring brake fully applied before starting the compressor and
at all times during compressor operation
use a regulator in the output line to precisely control the final
air delivery pressure
do not operate the compressor while driving
do not tamper with the pressure relief valve
do not attempt to repair or modify any component

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Installation Instructions
Detailed information is provided in a separate publication, Installation
Manual PREDATAIR Hydraulic Compressor, which provides specific
information for each different application.
This information includes recommendations and other important
information for correct installation. The information in the installation
manual is intended for use by trained, professional technicians with
the knowledge, tools, and equipment to do the job properly and
safely. Installation should not be performed by persons without the
appropriate skills.
Do not attempt to install the PREDATAIR without the
appropriate installation manual.
As part of the installation process, ensure that the Operation
Instruction Card is affixed near the PREDATAIR in an obvious
location so that users can easily see it and refer to the procedures.
!

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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 coalescing element, which delivers dry air to
the outlet.
Pressure regulation is achieved with a mechanical inlet control valve
and an adjustable pressure regulator.
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.
Safety features include:
2,800 psi hydraulic pressure relief valve for Predatair40/60
3,300 psi hydraulic pressure relief valve for Predatair60 HHP
200 PSI relief valve in oil/air tank
blow-down valve to discharge system pressure on shutdown
temperature safety sensors in the compressor, hydraulic oil
discharge from the cooler and hydraulic oil return at the
manifold
Do not disable or bypass the over-temperature
shutdown circuit. Failure of the shutdown system could
result in equipment damage, injury or death.
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. Ventilation is critical for
proper operation. See the Installation Manual PREDATAIR Hydraulic
Compressor for details.
The system pressure is factory-set at 150 psi. Pressure can be
adjusted between 100 and 150 psi by using the display box. To
reduce the operating pressure, use a Filter Regulator Lubricator
(FRL).
!

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Compressor air filter
(must have proper ventilation)
Oil cooler (inside cover,
must have proper ventilation)
Air discharge port
with check valve
Hydraulic fluid inlet
Hydraulic fluid return
Blowdown cap with
internal coalescing filter
Minimum clearance
for servicing - 6 inches
Compressor oil fill
(shipped full from
the factory)
Oil level sight glass
(make sure this can be easily
accessed for daily inspection)
Compressor oil drain
Oil filter
Cooling fan
Minimum clearance
for servicing - 6 inches
Pressure sensor

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Operating the PREDATAIR
Startup
1. If installed inside a cabinet or enclosure, open the door or cover
completely and secure in the open position to provide proper
ventilation. Refer to the installation manual for instructions on
installing a wiring interlock to prevent operation when the door or
cover is closed.
2. Open the hydraulic shut-off valve (if equipped).
3. Check the compressor oil level at the sight glass in the tank and
the hydraulic oil level in the hydraulic system tank.
4. Turn on power to the PREDATAIR.
5. Engage the hydraulic system.
6. Start the PREDATAIR with the “ON” switch on the display box.
7. Watch the display for system status information.
8. If a cold climate kit (A700146) is installed, it will automatically
activate in cold weather.
What to Expect at Startup
1. The green light on the display box will illuminate.
2. If the temperature is below -13°F (-25°C) the green light will
slowly blink and the display will read “HYD OIL TOO COLD”. The
hydraulic oil must be preheated before the cold climate kit will
activate.
If the temperature is between -13°F (-25°C) and 5°F (-15°C) the
green light will slowly blink and the display will read “HYD OIL
WARMING, HYD XXXF/XXXC”.
if a cold climate kit is installed it will energize to speed warm-
up of the hydraulic oil
if the system has been wired for two-speed operation, the
engine will idle up after 10 seconds to speed warm-up of the
hydraulic oil
Once the temperature of the hydraulic oil is above 5°F (-15°C),
the cold climate kit will turn off and the idle will drop and startup
will proceed normally. The display will indicate this with “SOFT
START XXC”.

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3. The compressor will activate and build air pressure to
approximately 40 psi until the compressor has reached operating
temperature.
4. When the compressor reaches operating temperature it will “load
up” and build air pressure to system pressure, (120psi). If the
system has been wired for two-speed operation, the engine will
speed up to build air pressure faster. If the hydraulic oil has not
reached 41°F (5°C), or the compressor has not reached 70°C
(158°F), air pressure will only build to 120 psi to reduce the load
on the hydraulic system. The compressor can still be used during
this stage of operation.
5. Once the system reaches full pressure, the compressor will
unload and, if the engine speed had increased, it will drop to
base speed to unload the hydraulic system. You may hear a hiss
as air pressure is reduced to approximately 40 psi. If air pressure
does not drop below the restart point after two minutes, the
hydraulic motor will turn off and the display will read “STANDBY
XXX PSI”. This delay time is adjustable.
6. When air is used and the pressure drops, the sequence of load
up and unload will repeat, along with truck engine speed if the
system is wired for two speed operation. The system may restart
occasionally even without air use to maintain correct compressor
operating temperatures.
A small reservoir is recommended to reduce cycling
between the load and unload modes.
Shut-down
1. When operations are complete, stop the PREDATAIR with the
“OFF” button. Residual pressure in the compressor will blow-
down automatically.
2. Disengage the hydraulic system.
3. Close the hydraulic shut-off valve (if equipped).
4. Turn off the power supply to the PREDATAIR.
!

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Cold Weather Operation
The compressor will not start if the hydraulic oil temperature is lower
than 5 F (-15 C). Refer to the installation manual for more detailed
information. Observe the following precautions:
if temperatures are below 41 F (5 C), cover the PREDATAIR
during transit (if exposed) and pre-heat by circulating hydraulic
oil through the system before starting the compressor
if temperatures are below 5 F (-15 C), install a cold climate kit
(A700146) and circulate the hydraulic oil through the system
do not allow ice or snow to build up around the air filter and inlet
control valve
Hot Weather Operation
Thermal protection will prevent operation if the temperature is too
high:
If temperatures are above 100 F (37 C), reduce the compressor
duty cycle.
Provide additional hydraulic oil cooling.
Provide proper ventilation if the compressor is inside a cabinet or
enclosure. Cool air results in better performance and higher
CFM.
Hydraulic Oil
Use hydraulic oil that is correctly rated for the operational
temperature range of the equipment.
Automatic Shutdown
If the compressor or hydraulic oil gets too hot, the over-temperature
circuit will disengage the hydraulic system, preventing operation. The
red indicator light will illuminate and the display box will show a
message identifying the problem.
If this problem persists, refer to the troubleshooting section in this
manual.
1. Turn the compressor switch to the “OFF” position.

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2. Allow a few minutes for the air system to vent pressure and for
the oil to drain back to the tank, then check the oil level through
the sight-glass on the compressor tank. Oil level must be
checked with the vehicle in a level position, not on a slope. If the
oil level is low, add compressor oil until the correct level is
reached.
3. Check the hydraulic oil to ensure that it is not low; add hydraulic
oil until the correct level is reached.
Display Box Messages
System Check
The display will show:
VMAC –WWW.VMACAIR.COM
Both red and green lights will flash.
The display will show:
SYSTEM CHECK / SYSTEM READY
The system will go to the Ready State.
Ready State
The display will scroll through the following messages:
VMAC
PH# 250 740 3200
HRS:XXXX:XX
If the system is due for a 500 hr service, it will display:
HRS:XXXX:XX 500S
Additional possible messages:
WARM HYD OIL
If the hydraulic oil temperature is below +5 F(–15 C).
CHECK AIR FILTER
Every 100 hrs the system will remind the operator.

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Initial Startup
During initial startup, the display may show the following:
SOFT START XXXC
The system has started, but the compressor oil temperature
is still cool. The system is in “Unload” Mode, until the
compressor has come up to temperature.
HYD OIL TOO COLD
The hydraulic oil is below -13 F (-25 C), and the system is
cautioning the operator to preheat the hydraulic oil. The
PREDATAIR will not start.
HYD OIL WARMING, HYD XXXF/XXXC
The hydraulic oil is between -13 F(-25 C) and +5 F(-15 C),
and if installed, the cold climate kit (A700146) has been
turned on to help warm the hydraulic oil. The PREDATAIR
won’t start until the hydraulic oil has warmed to +5 F(-15 C).
Normal Operation
The following data can be reviewed by pressing the ON button
repeatedly:
XXXPSI/XXXKPA
COMP XXXF/XXXC
HYD XXXF/XXXC
HRS:XXXX:XX
The following message will be displayed if the system was running,
and the air pressure stayed above the restart pressure for the
duration of the standby delay time:
STANDBY XXXPSI
The hydraulic solenoid is off, and the system is monitoring
air pressure and compressor and hydraulic oil temperatures.
If the air pressure drops below the restart pressure, or the
compressor oil temperature drops below its minimum, it will
restart and rebuild air.

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Error Messages
Refer to the Troubleshooting section for problem resolution details.
OVER TEMP COMP
Compressor is too hot.
OVER TEMP HYD
Hydraulic oil is too hot.
COMP PROBE SHORT
Compressor temperature probe has failed in a shorted
condition.
COMP PROBE OPEN
Compressor temperature probe has failed in an open
condition.
HYD PROBE SHORT
Hydraulic temperature probe has failed in a shorted
condition.
HYD PROBE OPEN
Hydraulic temperature probe has failed in an open condition.
BATTERY LOW
The control box has sensed a low supply voltage.
PRESSURE SENSOR?
The pressure sensor has failed or is disconnected.
CONNECTION ERR
There is a connection problem between the control box in
the PREDATAIR and the display box.

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System Adjustments
Entering DIAGNOSTICS mode
Turn the system off, push and hold OFF button for 5 sec. The
display will show DIAGNOSTICS, release the OFF button.
The system will slowly scroll through menu headings.
Entering a Heading
When the heading that you want is displayed, press and hold the ON
button. When it enters that selection, release the ON button.
Scrolling
While in a heading, you can scroll through data and variables by
using the ON and OFF buttons just like up and down arrows on a
keyboard.
Exiting a heading
Once changes have been made, press and hold both ON and OFF
buttons at the same time, and the system will return to the
DIAGNOSTICS main menu.
Exiting DIAGNOSTICS mode
While DIAGNOSTICS is displayed, press and hold both ON and OFF
buttons at the same time.
Menu Headings
DIAGNOSTICS
Used to return to normal operation.
Press and hold both the ON and OFF buttons at the same time to
exit Diagnostics mode and return to normal operation.
ERROR LOG
Record of the last ten system errors.
This information can be recorded on the VMAC troubleshooting form
and faxed to VMAC to assist in troubleshooting issues. Scroll
through each error with the ON and OFF buttons.

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SERVICE LOG
Clears service messages, and records the last ten system service
times.
If the display has been showing a reminder for the 500 hour service,
once the service has been completed, you can enter this section and
clear the message. This also records the system hours when the
service was completed. The display will show:
500HR CLEAR?
Push and hold the ON button for 5 seconds, it will be cleared. Scroll
through each recorded service with the ON and OFF buttons.
AIR TEMP. SENSOR
Allows temporary over-ride of the compressor temperature sensor.
This is only intended for use in an emergency to
complete a job when servicing the unit is not
immediately possible. Running without a temperature
sensor may result in failure of the unit and/or damage to
the hydraulic system, and is not recommended.
To temporarily disable the temperature sensor, press and hold the
ON button for 2 seconds. The display will show:
NO AIR TEMP PRB?
Press and hold the ON button for 5 seconds. The display will show:
TEMP PROBE DIS
The air temperature sensor has been disabled.
If you press and hold the OFF button for 5 seconds, the display will
show:
TEMP PROBE EN
The air temperature sensor has been enabled.
!

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HYD TEMP. SENSOR
Allows temporary over-ride of the hydraulic temperature probe.
This is only intended to be used in an emergency to
complete a job when servicing the unit is not
immediately possible. Running without a temperature
sensor may result in failure of the unit and/or damage to
the hydraulic system, and is not recommended.
To temporarily disable the temperature sensor, press and hold the
ON button for 2 seconds. The display will show:
NO HYD TEMP PRB?
Press and hold the ON button for 5 seconds. The display will show:
TEMP PROBE DIS
The air temperature sensor has been disabled.
If you press and hold the OFF button for 5 seconds, the display will
show:
TEMP PROBE EN
The air temperature sensor has been enabled.
SYSTEM PRESSURE
Allows adjustment of the maximum system pressure.
Range: 110 to 150 psi
Factory setting: 150 psi
Press and hold the ON button for 2 seconds. The display will show:
ADJ OFF PRES XXX
The XXX is the current pressure setting in psi. Scroll through the
range of settings. When the desired setting is displayed, exit
normally and the change will be made.
!

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RESTART PRESSURE
Allows adjustment of the system restart pressure.
Range: 80 to 120 PSI (limited to 30psi or more below the UNLOAD
PRESSURE). Factory Setting: 120 psi
Press and hold the ON button for 2 seconds. The display will show:
ADJ ON PRES XXX
The XXX is the current pressure setting in psi. Scroll through the
range of settings. When the desired setting is displayed, exit
normally, and the change will be made.
DELAY TO STANDBY
Allows adjustment of the time delay before the system goes to
STANDBY mode and turns off the compressor.
Range: 30sec, 45sec, 1, 2, 5, 10, 15, 30 min and Never.
Factory Setting: 2 min.
Scroll through the range of settings using the ON and OFF buttons.
When the desired setting is displayed, exit normally, and the change
will be made.
COLD START LOG
A record of the last ten cold-start temperatures below 32F(0 C).
This information can be recorded on the VMAC troubleshooting form
and faxed to VMAC to assist in troubleshooting issues.
Scroll through each logged cold-start temperature using the ON and
OFF buttons.

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Troubleshooting
System OFF, Power ON
Message/Problem
Possible Cause
Corrective Action
HYD OIL TOO COLD
The hydraulic oil
temperature is below
+5F(–15 C).
Pre-heat the hydraulic oil before
running the system.
No power to display box
Fuse popped or bad
connection
Check components, replace fuse
inside Predatair.
ON button pressed/Initial startup
Message/Problem
Possible Cause
Corrective Action
SOFT START XXXPSI
The system has started,
but the compressor oil
temperature is still cool.
The system is in “Unload” Mode,
until the compressor has come up
to temperature +122F(50C).
HYD OIL TOO COLD
The hydraulic oil is below
-13F (-25C).
The system is cautioning the
operator to preheat the hydraulic oil
before starting the PTO system.
The Cold Climate Kit (A700146)
can be installed to speed warm-up
once the hydraulic oil temperature
has reached
–13F(-25C).
HYD OIL WARMING, HYD
XXXF/XXXC
The hydraulic oil is
between
-13F(-25C) and +5F(-15C).
Keep circulating hydraulic fluid until
the system warms sufficiently to
start. If installed, the Cold Climate
Kit (A700146) will speed warm-up.
The Predatair won’t start until the
hydraulic oil has warmed to +5F(-
15C).
PREDATAIR does not
start when the ON button
is pressed.
Inappropriate conditions
for start-up.
Check display box for messages.
Hydraulic solenoid failure.
Check solenoid and connections.
Hydraulic motor or
compressor seized.
Check motor and compressor will
roll-over.
Running
Message/Problem
Possible Cause
Corrective Action
STANDBY XXXPSI
The air pressure stayed
above the restart pressure
for the duration of the
standby delay time.
The hydraulic solenoid is off, and
the system is monitoring air
pressure and compressor and
hydraulic oil temperatures. If the
air pressure drops below the restart
pressure, or the compressor oil
temperature drops below its
minimum, it will restart and rebuild
air.
Air pressure won’t build
past approx. 40psi.
The system is in SOFT
START.
Wait for the compressor to warm
up.
Unload solenoid on inlet
valve has failed or problem
with wiring connections
Check solenoid and wiring.

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Pressure sensor has failed
or problem with wiring
connections
Check pressure sensor and wiring.
Low system air pressure.
Air reservoir drain open.
Close valve.
Air leak.
Check all fittings.
Check air lines for wear/damage.
System demands exceed
compressor delivery.
Reduce air demand.
Check for correct amount of
hydraulic flow for the desired CFM.
Blowdown system stuck.
Check for air venting from
blowdown cap while running.
Compressor stalling/not
building air.
Hydraulic relief valve
lifting.
Check hydraulic pressure while
running.
Check for other relief valves in
system set too low. Minimum
setting 2800psi.
Hydraulic flow too low.
Check for correct amount of
hydraulic flow for the desired CFM.
Ensure that engine rpm is being
maintained when load is applied.
UNLOAD solenoid failure.
Check solenoid and wiring.
General
Message/Problem
Possible Cause
Corrective Action
CHECK AIR FILTER
Every 100 hrs, the system
reminds the operator to
check the air filter.
Check air filter and replace as
needed. Message will stop
automatically after 6 hrs of
operation.
HRS:XXXX:XX 500S
Every 500 hrs, the system
reminds the operator to
service the compressor.
Perform service as per Owners
manual using VMAC service kit.
Once complete, enter the
Diagnostics Mode and clear the
service reminder. Refer to the
appropriate section in the Owners
manual.
OVER TEMP COMP -
Compressor is getting too
hot and is shutting down.
Low compressor oil.
Check oil level and fill as required.
Oil flow restricted.
Check oil filter for blockage.
Remove hoses and check for
blockage.
Check cooler for blockage.
Fan not operating.
Check connections.
Check fan and relay.
Insufficient air-flow or
ventilation.
Make sure the cooler and air filter
are not blocked.
Open door if installed in a cabinet.
Improve ventilation.
Move the PREDATAIR out of the
cabinet.
Failed temperature probe
or bad wiring connection.
Check the temperature probe and
wiring connections.
OVER TEMP HYD -
Hydraulic oil is getting too
hot and the compressor is
shutting down.
Insufficient air-flow or
ventilation.
Make sure the cooler is not
blocked.
Open door if installed in a cabinet.
Improve ventilation.