Vortec HAZLOC VORTEX A/C Use and care manual

Please read all instructions BEFORE attempting to use this product
IMPORTANT
HAZLOC
VORTEX A/C
OPERATION & SAFETY
INSTRUCTIONS
Models 7215, 7225, 7235, 7270, 7515, 7525, 7535, 7570
(Includes all BSP versions of models listed above)
10125 Carver Road, Cincinnati, OH 45242
Phone: [phone] • Fax: [phone]
Toll Free: 800-441-7475
www.vortec.com • [e-mail]

WARNING: COMPRESSED AIR COULD CAUSE DEATH, BLINDNESS
OR INJURY
1. Do not operate a HazLoc Vortex A/C at compressed air pressures above 100 psig (7 Bar).
2. Do not operate at compressed air temperatures above 120°F (49°C).
3. Avoid direct contact with compressed air.
4. Do not direct compressed air at any person.
5. When using compressed air, wear safety glasses with side shields.
Introduction
The Hazardous Location Vortex A/C ("HazLoc Vortex A/C") is designed to cool industrial control cabinets located in
hazardous locations, using only filtered and dried compressed air to generate the cooling. The HazLoc Vortex A/C shall
only be used in conjunction with a properly sized enclosure purge and pressurization system that must be able to vent
the additional air introduced by the HazLoc Vortex A/C. (The purge and pressurization system must be selected and
supplied by the end user.)
The cooling air produced by the HazLoc Vortex A/C in the enclosure is vented into the hazardous area (outside of the
enclosure) through the purge system’s spark arrestor vent. The spark arrestor vent must be properly sized to accept the
additional cold air flow generated by the HazLoc Vortex A/C to prevent over-pressurization of the enclosure.
It is the end user’s responsibility to ensure that the correct spark arrestor vent is used and that the purge system
functions properly when integrated with the HazLoc Vortex A/C.
DO NOT operate the HazLoc Vortex A/C on a sealed and unvented enclosure as pressure in the enclosure will increase
and damage or injury could result. The HazLoc Vortex A/C has a built-in mechanical thermostat(s) that requires no
electricity.
Compressed Air Supply
The compressed air system’s intake must originate in a non-hazardous area. Compressed air piping must be fabricated
from noncombustible materials suitable for the conditions present. The pressurized air supply provided to the HazLoc
Vortex A/C must be of the same quality as that used to purge and pressurize the enclosure it is installed on. Models
7270 and 7570 will require up to 70 scfm (1980 slpm) of compressed air at 90 to 100 psig (6 to 7 bar) when both stages
of the unit are operating at full capacity.
The compressed air supply must be filtered (5 micron maximum) to remove water and dirt. For Models, 75xx, a 5 micron
filter is supplied for this purpose (Vortec model 701S-24A, -36A or -40A). If oil is present in the compressed air supply,
remove the oil using an optional 0.01 micron coalescing filter (Vortec model 701S-48 or 701S-54). If an oil removal filter
is necessary, install it downstream of the 5 micron filter. Locate the filters in a non-hazardous location to facilitate easy
filter element changes. Change the filter elements as needed (see Maintenance).
It is highly recommended to dry the compressed air (to remove water vapor) using a refrigerated air dryer. Failure to dry
the air adequately may result in frost or ice forming internally and resulting in decreased cooling air flow and cooling
capacity.
GENERAL SAFETY CONSIDERATIONS
WARNING! Explosion Hazard: Substitution of components may impair suitability for Class I Division 2.

Supply compressed air to the HazLoc Vortex A/C with 3/8" schedule 40 pipe when the pipe length is less than 10 feet
(3m). If pipe length exceeds 10 feet (3m) but is less than 30 feet (9m), use 1⁄2" pipe. If pipe length exceeds 30 feet (9m)
but is less than 100 feet (30m), use 3⁄4" pipe. Use appropriate pipe adapter fittings when terminating the supply pipe
at the HazLoc Vortex A/C. (The model 701S-40A compressed air filter that is supplied with the model 7570 has 3/4"-14
NPT ports. The model 703S-40A compressed air filter that is supplied with the 7570BSP has 3/4"-14 BSP ports.).
Maintenance
The only maintenance involved with the HazLoc Vortex A/C is normal element changes to the compressed air filter.
The filter element should be changed when there is a decrease in performance or when pressure drop across the filter
exceeds 5 psig (0.3 bar).
The compressed air supply to the unit must be shut off before changing the filter element. The compressed air filter
should be located in a nonhazardous area so that normal filter element maintenance can be carried out without risk of
hazardous substances entering the enclosure. If the compressed air filter must be located in the hazardous area, electric
power to the enclosure must be shut off while performing filter maintenance and then routine purge system startup
procedures should be followed when filter maintenance is complete and before power is applied to the enclosure.
The HazLoc Vortex A/C has only two moving parts (the mechanical thermostat/valve and the check valve) which are not
serviceable in the field. Do not disturb the setting of the thermostat. Evidence of tampering with the thermostat may void
the warranty.
If it is suspected that the compressed air filter has not been maintained after an extended period of operation, there may
be pipe scale or foreign material in the HazLoc Vortex A/C. If the unit is not cooling sufficiently, there may be pipe scale
or foreign material in the orifices of the generator(s) in the unit.
1. To check, shut off all electric power to the protected enclosure and follow any purge system shutdown procedures.
Shut off the compressed air supply to the HazLoc Vortex A/C. Before opening the enclosure door, allow sufficient
time for any internal components to cool down completely.
2. Detach the 5/8” (16 mm) ID vinyl tubing from the check valve assembly (assemblies, for dual units) and remove the
check valve assembly (assemblies) from the cold air outlet fitting(s) of the HazLoc Vortex A/C.
3. Remove the brass cold air outlet fitting(s) from the bottom of the unit (with a 1” (25 mm) open end wrench).
4. Remove the O-ring(s). Then remove the red, blue or brown generator(s).
5. Inspect the six slots in each generator for foreign material and clean if necessary.
6. Clean the cavity in the HazLoc Vortex A/C that the generator(s) were located in if necessary.
7. Reassemble the generator(s), O-ring(s) and cold air outlet fitting(s) in reverse order. Tighten the cold air outlet(s) to at
least 100 inch pounds (11 newton meters) torque.
8. Attach the check valve assembly (assemblies) to the cold outlet fitting(s) making sure the air flow through the check
valve(s) are in the proper direction. Tighten all pipe connections securely. Reattach the 5/8” (16mm) vinyl tubing to
the check valve outlet(s). Open the compressed air supply valve(s) to the HazLoc Vortex A/C. Follow purge system
startup procedures before applying electric power to the enclosure.

Installation
To maintain the hazardous location rating, the HazLoc Vortex A/C MUST be installed in one of the following
configurations on the enclosure (please refer to the HazLoc Vortex A/C Assembly illustrations):
a. Top mounted in an upright and vertical orientation, on a flat horizontal surface
b. Side mounted, on a flat vertical surface of the enclosure, the compressed air inlet pointing up on Models 7xx5, with
the stainless steel shroud facing to the floor. For Models 7x70, when side mounted, the compressed air inlet must
be pointing down, and the stainless steel shroud facing the floor. If side mounted, locate the Vortex A/C so that it
is near the top of the enclosure.
1. The HazLoc Vortex A/C must be installed on the top of the enclosure on a flat horizontal surface of a Type 4X
enclosure. Alternately, the HazLoc Vortex A/C can be mounted on the side of the enclosure. When the unit is side
mounted (on a flat vertical surface of a Type 4X enclosure), the compressed air inlet for Models 7xx5 must be
pointing up, and the stainless steel shroud must face down; and for Models 7x70 (dual unit), the compressed air inlet
must be pointing down, and the stainless steel shroud must face down toward the floor.
If side mounted, it is best if the unit is located near the top of the enclosure.
2. Find a location for the HazLoc Vortex A/C on your enclosure so that there is sufficient clearance for the internal
mechanical thermostat(s) and cold air outlet(s) and check valve assembly (assemblies), and, so that the entire
mounting “footprint” of the HazLoc Vortex A/C is supported by the enclosure. Position the unit so that the stainless
steel shroud on the back of the unit is away from personnel, if possible. Also, position so that no internal enclosure
components obstruct air flow around the mechanical thermostat(s). The HazLoc Vortex A/C should be located
adjacent to the purge system’s spark arrestor vent. This will allow the mechanical thermostat(s) to sense temperature
of the airflow exiting the vent and respond faster to the temperature changes in the enclosure.
3. Cut a 1 15/16" (49 mm) diameter hole (1 1/2" knockout size) for the single units, and two holes on 4” (102 mm)
centers for the dual unit in the selected location of the flat horizontal (or vertical) surface of the enclosure. De-burr
any sharp edges around the hole.
4. Remove the 1 1/2" electrical locknut(s) from the HazLoc Vortex A/C. Insert the threaded portion(s) of the
HazLoc Vortex A/C into the 1 15/16" (49 mm) hole(s) in the enclosure. (Be careful not to damage the mechanical
thermostat(s) during installation.)
5. From inside the enclosure, screw the 1 1/2" electrical locknut(s) onto the threads of the HazLoc Vortex A/C. Tighten
the locknut(s) securely to compress the 1/8" (3 mm) thick sealing gasket(s) that are located between the enclosure
surface and the HazLoc Vortex A/C.
6. Attach the Check Valve assembly (assemblies) to the cold air outlet(s) of the HazLoc Vortex A/C (3/8”-18 NPT
thread) inside the enclosure. The Check Valve(s) can be attached to the HazLoc Vortex A/C with the supplied 3/8"
NPT straight pipe nipple(s) OR with the supplied 3/8" NPT pipe elbow(s). The orientation of the Check Valve assembly
is not important, it will function in any position, however, the airflow direction through the Check Valve(s) is important.
Attach the Check Valve(s) so that the arrow on the Valve(s) point away from the HazLoc Vortex A/C. Suitability of the
Check Valve(s), provided with the HazLoc Vortex A/C, to prevent air from leaking out from the purged and pressurized
enclosure must be verified during installation.
7. Mount the Cold Air Muffler(s) inside the enclosure near the HazLoc Vortex A/C. (You will need a surface area of
approximately 2" x 9" (50 mm x 230 mm) to mount each muffler.) (The Muffler(s) can be mounted in any orientation:
horizontal or vertical.) Using the supplied Muffler Mounting Clamp(s) (with double sided tape), attach the Clamp(s) at
the desired location(s). (Clean the mounting surfaces so that the double sided tape bonds securely.)
8. If desired, the Clamp(s) can be permanently mounted to the enclosure using the supplied mounting hardware. Two
5/32" (4 mm) diameter holes positioned on 3⁄4" (19 mm) centers must be drilled to mount each Muffler Clamp with
the supplied plastic push-rivets.
9. Snap the Cold Air Muffler(s) into the Mounting Clamp(s).
10.Cut a sufficient length of the 5/8" (16 mm) inside diameter vinyl tubing from the supplied #7000-75 Cold Air Ducting
Kit(s) to connect the outlet(s) of the Check Valve(s) to the Cold Air Muffler(s). Attach the length(s) of vinyl tubing

securely onto the hose barbs of the Check Valve(s) and the Muffler(s). Ensure that the vinyl tubing has no sharp
bends or kinks. Direction of cold air flow through the Muffler(s) is not important.
11.Attach all (or a portion of) the remaining supplied vinyl tubing of the Cold Air Ducting Kit(s) to the opposite hose barb
connection(s) on the Cold Air Muffler(s). Holes can be punched or drilled into this 5/8" (16 mm) tubing to distribute
the cold air evenly inside your enclosure, or, the entire cold air output can be directed to a heat sensitive component.
If the end of the 5/8" (16 mm) vinyl tubing is plugged, at least 25 x 1/8" (3 mm) diameter holes should be punched or
drilled into the tubing to allow the cold air to escape. Use the self-adhesive tubing clamps provided with each kit to
locate and hold the vinyl tubing in place.
12.Connect the compressed air filter (supplied with 75xx models) to the compressed air inlet on the side of the HazLoc
Vortex A/C with a length of 3/8” pipe (not supplied). Install the compressed air filter as close as possible to the
HazLoc Vortex A/C, in a location where the temperature does not exceed 125°F (52°C). Allow the filter to hang at the
side of the enclosure as shown in the installation drawing. Use an 11/16” (18 mm) wrench to hold the air fitting on
the side of the HazLoc Vortex A/C stationary while tightening the pipe connections. Note the air flow direction arrow
on top of the filter. See Maintenance section for recommendations on location of the compressed air filter.
13.Connect the compressed air supply to the inlet of the air filter. See “Compressed Air Supply”.
Operation
It is recommended to operate the HazLoc Vortex A/C at 90 to 100 psig (6-7 bar) compressed air pressure. If compressed
air pressure exceeds 100 psig (7 bar), it is essential to regulate the pressure down to 100 psig (7 bar) with Vortec’s
model 208R or 208RX pressure regulator. Operation at pressures less than 90 psig (6 bar) and above 100 psig (7 bar) will
affect the operation. When properly sized for the application, the HazLoc Vortex A/C will maintain the internal enclosure
temperature between 75-100°F (24-38°C). Enclosure temperatures can momentarily reach 125°F (52°C) during initial
start-up and after long periods of inactivity. Variations in heat load and compressed air conditions can affect thermostat
operation. The mechanical thermostat will regulate an internal valve to minimize compressed air usage and maintain
enclosure temperatures within the range specified. In some applications, the HazLoc Vortex A/C may run continuously
at lower air usage with the benefit of always keeping the enclosure under slight internal pressure. In other applications,
the HazLoc Vortex A/C may cycle on and off to maintain enclosure temperatures. When the HazLoc Vortex A/C is not
cooling, the Check Valve(s) shutting off the air passage from the enclosure interior to the exterior and allowing the
purge/pressurization system to maintain slight pressure in the enclosure. Do not apply excessive heat or a flame to the
mechanical thermostat(s) to “test” them for operation. Damage to the product may result that is not covered under the
warranty.
NOTICE: The thermostat’s reaction to temperature change depends on several factors: the internal and external heat
loads, enclosure size and proximity to the heat source. When the internal heat load is zero (or very low) and when
external temperatures are below 50°F (10°C), the thermostat will take longer to react to air temperature increases. There
will be a lag between the rising air temperature and when the thermostat reacts, which can result in temperatures inside
the enclosure exceeding 125°F (52°C). When air and thermostat temperatures equalize, the reaction to temperature
change is improved and the lag is minimized.
Troubleshooting
Insufficient cooling may be caused by the following:
1. Undersized compressed air line size.
2. Compressed air pressure at the product is too low.
3. Partial or complete blockage of internal compressed air path(s), due to dirt.
4. Water vapor in the compressed air supply.
5. Loose cold air outlet fitting(s). This may occur if not tightened properly after being disassembled for cleaning.
If trouble persists, please contact Vortec at 1-800-441-7475.

Limited Warranty
HazLoc Vortex A/C compressed air enclosure cooling products manufactured by ITW Air Management will be
replaced or repaired if found to be defective due to manufacture within ten years from the date of invoice. Refer to our
website www.vortec.com for full warranty details and limitations. ITW Air Management makes no specific warranty of
merchantability or warrant of fitness for a particular purpose.
Elevated Surface Temperatures
Because the HazLoc Vortex A/C operates using the vortex principle, hot exhaust air is generated and released at low
pressure from the opening in the stainless steel shroud on the back of the unit. This exhaust air can reach temperatures
up to 225°F (107°C) under normal conditions. (Normal conditions are compressed air inlet pressure of 90 to 100 psig
(6-7 bar) and compressed air inlet temperature of 70°F (21°C)). The HazLoc Vortex A/C models can be operated at
compressed air temperatures that do not exceed 120°F (49°C). The HazLoc Vortex A/C models have a Temperature
Class of T4.
Sizing the Spark Arrestor Vent to the HazLoc Vortex A/C
As stated in the introduction, the HazLoc Vortex A/C must be used in conjunction with an enclosure purge and
pressurization system. The purge system must have a spark arrestor vent that allows the cold air flow (produced by the
HazLoc Vortex A/C) and the pressurization air flow to safely escape the protected enclosure, without creating too little
or too much pressure in the enclosure. Add the pressurization air flow to the cold air flow as found in the table below to
determine the total air flow through the spark arrestor vent.
HAZLOC VORTEX A/C COLD AIR FLOW (AT 90 TO 100 PSIG (6-7 BAR) OPERATING PRESSURE)
Vortec Model Cold Air Flow
7515, 7215, 7515BSP, 7215BSP 7 ft3/minute (198 liters/minute)
7525, 7225, 7525BSP, 7225BSP 14 ft3/minute (396 liters/minute)
7535, 7235, 7535BSP, 7235BSP 23.5 ft3/minute (665 liters/minute)
7570, 7270, 7570BSP, 7270BSP 47 ft3/minute (1330 liters/minute)
Contact the purge system manufacturer or Vortec if assistance is needed in selecting the correct spark arrestor vent to
allow proper purging and pressurization.
Two Stage Cooling (Models 7270 and 7570, and BSP versions)
Under normal operation, the first stage cooler (the cold air outlet that is nearest to the compressed air inlet) will
activate first. This will either reduce the rate of temperature rise in the enclosure, or, it will begin to reduce the enclosure
temperature, depending on the total heat load in the enclosure. If the total heat load is significant and the temperature
continues to rise, the second stage cooler will activate, doubling the amount of cooling air. In locating the two Cold Air
Ducting Kits, consideration should be given to the two stage cooling capability of the unit. The dual cold air outlets and
Cold Air Ducting Kits provide for increased flexibility in directing refrigerated air into the enclosure. For example, the first
stage cooler’s output could be directed at a primary source of heat within the enclosure (PLC’s, VFD’s, transformers,
etc.) and the second stage ducting could be punched or drilled (as described earlier) and routed for overall cold air
distribution throughout the enclosure.

HazLoc Vortex A/C Assembly
(Drawings shown below are not to scale)
Models 7515, 7525, 7535, 7215, 7225, 7235
SHOWN TOP MOUNTED ON CUSTOMER'S ENCLOSURE
PURGE SYSTEM SHOWN FOR REFERENCE ONLY
1 3/4" (44 mm)
diameter x 3 7/8"
(98 mm) long muer
and mounting clamp
Hole
1 15/16"
(49 mm)
5 3/8" (137 mm)
5 7/16"
(138 mm)
minimum
4 3/4" (121 mm)
8" (203 mm)
Filter
Purge
system
1 1/4" (32 mm)
diameter x 3 1/16"
(78 mm) long check
valve assembly

HazLoc Vortex A/C Assembly
(Drawings shown below are not to scale)
Models 7570, 7270, 7570BSP and 7270BSP
SHOWN TOP MOUNTED ON CUSTOMER'S ENCLOSURE
PURGE SYSTEM SHOWN FOR REFERENCE ONLY
1 3/4" (44 mm)
diameter x 3 7/8"
(98 mm) long muer
and mounting clamps
(Qty.2)
1 1/4" (32 mm)
diameter x 3 1/16"
(78 mm) long check
valve assembly
(Qty.2)
Holes
1 15/16" (49 mm)
5 3/8" (137 mm)
6 3/8"
(162 mm)
Filter
4 3/4" (121 mm)
8" (203 mm)
Purge
system

LIT0310
FILTER AND REPLACEMENT PART ITEM NUMBERS
Vortec Model Oil Removal Filter Replacement Generator Kits (5 pcs)
7515 701S-48 208GK-15H
7525 701S-48 208GK-25H
7535 701S-54 208GK-35H
7370, 7470 701S-54 208GK-35H
Table 1: Filter Recommendations
Table 2: Determining Compressed Air Line Size
1. Calculate total product compressed air consumption (SCFM, SLPM).
2. Determine length of compressed air line required for connection to main supply.
3. Locate pipe length in left column and read to the right to find the compressed air requirements.
4. Locate pipe size at top of column.
MAXIMUM AIRFLOW (SCFM) THROUGH PIPE AT 5 PSIG PRESSURE DROP (100 PSIG AND 70°F)
Pipe Length
(Feet)
Pipe Size (Nominal) - Schedule 40
1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2
10 29 65 120 254 480 978 1483 2863 4536
20 21 46 85 180 340 692 1049 2024 3208
30 17 37 70 147 277 565 856 1653 2619
40 15 32 60 127 240 489 792 1431 2268
50 13 29 54 114 215 437 663 1280 2029
60 12 26 49 104 196 399 606 1169 1852
70 11 25 46 96 181 370 561 1082 1715
80 10 23 43 90 170 346 524 1012 1604
90 10 22 40 85 160 326 494 954 1512
100 9 21 38 80 152 309 469 905 1435
MAXIMUM AIRFLOW (SLPM) THROUGH PIPE AT 0.3 BAR PRESSURE DROP (6.9 BAR AND 21°C)
Pipe Length
(Meters)
Pipe Size (Nominal) - Schedule 40
1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2
3 821 1840 3396 7188 13584 27677 42117 81023 128369
6 594 1302 2406 5094 9622 19584 29687 57279 90786
9 481 1047 1981 4160 7839 15990 24225 46780 74188
12 425 906 1698 3594 6792 13839 20999 40497 64184
15 368 821 1528 3226 6085 12367 18763 36224 57421
18 340 736 1387 2943 5547 11292 17150 33083 52412
21 311 708 1302 2717 5122 10471 15877 30621 48535
24 283 651 1217 2547 4811 9792 14829 28640 45393
27 269 623 1132 2406 4528 9226 13980 26998 42790
31 255 594 1075 2264 4302 8745 13273 25612 40611
Rubber hose maximum airflow rating: 1/2” I.D. rubber hose = 3/8” pipe; 3/4” I.D. rubber hose = 1/2” pipe