Installation and User`s Manual RAPTAIR MF Multifunction
Contents
1. A300010 Compressor Service Kits Raptair MF 200 HR A500023 Raptair MF 400 HR A500024 Air compressor service kit includes oil filters seals and O rings 200 hour 6 month and 400 hour 12 month service interval kits are available Diesel Engine Service kit A500007 Kubota engine service kit will contain an engine oil filter fuel filter and 1 06 USG 4 liters of 15W40 engine oil First 50 Hour and Every 100 Hour Engine Service Kit available VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 23 7 0 Operating the RAPTAIR MF 7 1 Control System Features LJ Starting and stopping the control system with the Display box key switch or remote wire L_ Load detection with Generator or PTO priority when running the compressor LJ Automatic engine shutdown if no air use is detected LJ Automatic engine restart with air use minimum air pressure low engine or compressor temperature or low battery voltage LJ Multiple adjustable system parameters for delays pressures and restart options L Monitoring the compressor engine coolant and manifold temperature probe connection and temperature range L Monitoring air pressure sensor connection and over pressure LJ Detection of engine under speed over speed running when not expected no tach signal starting error and low oil level LJ Monitoring low battery voltage LJ Low fuel level warning for Raptair2. VMAC Vehicle Mounted Air Compressors Toll Fax Free 1 800 738 8622 Local 1 250 740 3200 1 250 740 3201 45 Do not use flammable solvents to clean the inside of the If a solvent has been used rinse the cover AN cover thoroughly with water and dry it before installing the cover Fire in the compressor can cause an explosion ia Filter Retainer a Air Filter Cover J Air Filter E Remove the masking tape or cloth from the compressor air intake The new VMAC filter is oval make sure that the filter fits over the machined step on the intake housing Do not use compressed air or perform any other tasks around the filter and cover until both are replaced Never clean the filter element with compressed air as this will allow some contaminates into the compressor system Always replace the air filter element L Place the filter cover over the air filter and secure it with the cover nut VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 46 8 4 Replacing Compressor Oil and Filter 8 4 1 Changing Compressor Oil AN Follow all safety precautions LJ Clean debris and dust from the area around the drain plug in the bottom of the separator tank VR70 Figure 5 Oil Filter and Drain Plug Location LJ Use a drip tray to prevent oil from dripping onto the belt and or battery and drain oil into a container that can hold at least 4 liters of oil
3. Dispose of the oil in accordance with the Environmental Protection Laws in your location LJ Remove and replace the oil filter at this time as noted in section 0 L_ Clean debris and dust from the area around the oil fill port of the air oil separator manifold to prevent contamination 4 liters of VMAC certified oil is required to fill the system E Unscrew and remove the oil fill port cap Use a funnel inserted into the port and pour in the required amount of VMAC oil L Follow the oil level checking procedure in Section 8 2 1 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 47 8 4 2 Changing Compressor Oil Filter AN Follow all safety precautions LJ Clean debris and dust from the area around the air oil separator tank and the filter to prevent contamination LJ Remove the filter by turning it counterclockwise using a suitable filter wrench Check the filter to make sure that the threaded nipple did Gi not unscrew with the filter If it is in the filter remove it carefully to avoid thread damage coat the threads that go into Separator Tank Base with a small amount of Loctite blue and install it into the Tank base Compressor Oil Filter Nipple If Compressor Oil Filter Nipple is stuck in Oil Filter remove and Loctite into Tank Base before installing Filter Compressor Oil Filter Figure 6 Compressor Oil Filter L Check the gasket seali
4. It is the responsibility of the user to know the pressure and air flow requirements of the tools powered by the air compressor system An appropriate air pressure regulator and lubricator can be externally installed to the outside of the air supply valve Failure to regulate the air pressure may cause damage to the tool Electrical Hazards and Grounding Ensure the ground point connection is connected to the vehicle body chassis to prevent shock hazards Ensure the vehicle is properly grounded when operating the unit Ground using a Green 10AWG AC rated wire to a minimum 3 8 inch post The RAPTAIR MF Multifunction Diesel Drive has an external ground post near the fuel lines The generator produces potentially lethal voltages and current Modification of the generator system must never be attempted and any work on the electrical components must be done by a qualified electrician Ensure any components attached to generator system meet the electrical regulations in the jurisdiction the unit is being used in DC Battery Jump Starting Working near Lead acid batteries is dangerous Batteries may generate explosive gasses during regular operation Lead acid batteries may explode if exposed to a spark Set the current control knob output to 0 and select the desired voltage before connecting jumper cables to the battery Never attempt to jump start a frozen battery Never over charge a battery Vehicle Mounted Air Compressors Toll F
5. LJ Clean loose dust and debris from the area around the filter cover to prevent contaminants from entering the system LJ Remove the air filter cover retaining clamps and the cover LJ Immediately cover the air intake with a clean cloth to prevent contamination entering the intake hose and compressor Do not use compressed air or perform any other tasks around the filter and cover until both are replaced Never clean the filter element with compressed air as this will allow some contaminates into the compressor system Always replace the air filter element LJ Remove the filter element from the filter cover Clean the inside of the cover with a clean dry cloth Do not use flammable solvents to clean the inside of the cover If a solvent has been used rinse the cover thoroughly with water and dry it before installing the cover Fire in the compressor can cause an explosion L_ Remove the cloth from the compressor air intake O Place the filter into the cover and secure it with the cover clamps 8 3 2 Compressor Air Filter LJ Clean loose dust and debris from the area around the compressor air filter cover to prevent contaminants from entering the system O Remove the air filter cover retainer and the cover E Immediately cover the compressor air intake with masking tape or a clean cloth to prevent contamination LJ Remove the filter element from the filter cover Clean the inside of the cover with a clean dry cloth
6. e 12V CV mode used for jump starting or charging 12V DC systems Use the current control dial to limit the amount of current Before connecting jumper leads to a battery for jump starting set the current knob to 0 and the voltage to the desired setting If connecting unit to equipment for battery boost or charge ensure proper voltage setting is selected before connecting cables Improper voltage selection could damage equipment Also ensure cables are rated for 300A 1 5 4 PTO Port Option The Raptair MF Multifunction Diesel Drive has provisions for an optional SAE A port power take off under the starter on the exhaust side of the engine This is able to power up to a 20HP load through a serpentine belt and a 12V clutch Typically this is fitted with a hydraulic pump and is customizable to your individual needs Equipment connected to this must be capable of operating at the port speed of 2700 RPM Shaft driven and high inertia loads may require special considerations please contact VMAC Tech Support for details Due to the many types of equipment that can be connected to the SAE A port the Raptair Multifunction Diesel Drive controller is not able to monitor the load or control the equipment The system will monitor the engine RPM and will deactivate the compressor if it falls below the low RPM threshold for proper generator frequency output When choosing equipment care should be taken to determine the typical expected loa
7. Part or Adjustment Reason Record 2 Date Performed by Part or Adjustment Reason Record 3 Date Performed by Part or Adjustment Reason Record 4 Date Performed by Part or Adjustment Reason 58 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 Record 5 Date Performed by Part or Adjustment Reason Record 6 Date Performed by Part or Adjustment Reason Record 7 Date Performed by Part or Adjustment Reason Record 8 Date Performed by Part or Adjustment Reason VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 10 3 VMAC Warranty 1 1 1 1 2 2 2 1 2 2 2 3 2 4 2 5 2 6 60 GENERAL PROVISIONS AND LIMITATIONS VMAC Global Technology Inc hereafter VMAC warrants to each original retail purchaser hereafter Buyer of its new RAPTAIR MF Systems hereafter Product s from VMAC or its authorized Dealers that such Product s are at the time of delivery to the Buyer free of manufacturer defects in material and workmanship See Kubota manual for engine warranty NO WARRANTY IS MADE WITH RESPECT TO Any Product s which have in VMAC s judgment been subject to negligence accident or improper storage installat
8. which includes enough to fill the oil filter The filter holds 0 3 litres of oil The compressor holds about 0 5 litres of oil E Check the level the oil has reached on the oil level sight glass a A S NS JE bya J NS A Sign Glass SS ee Window 6 ey DPED SS SS Drain Plug VR70 Figure 4 Checking Compressor Oil Level LJ Use a funnel inserted into the oil fill port on the air end below the coalescing filter LJ Turn the compressor clutch clockwise as oil is poured into the funnel until the oil is at the top of the sight glass i Replace the cap on the oil fill port and tighten LJ Start the system following the start up procedure in section 7 3 1 LJ Allow the system to pressurize E Turn off the system using the shutdown procedure in section 7 3 2 E Wait 5 minutes then drain the air fully to depressurize the system O Check for oil leaks E Repeat until the oil level sight tube shows the oil level in the air oil separator tank is in the operational range VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 44 8 3 8 3 1 Replacing the Air Filters Engine Air Filter Follow all safety precautions For ease of service the A engine air filter is located just under the roof of the RAPTAIR MF behind the service panel The engine air filter is also equipped with a filter minder switch at the back and is monitored by the control system
9. which perform mechanical separation The second stage uses a special separation element which delivers dry air to the outlet The second stage is a spin on type coalescing filter Air pressure regulation is achieved with an electro mechanical inlet valve settable through the Display box The system pressure is pre set at 150 psi but can be increased up to 175 psi Do not unnecessarily increase the pressure setting as the compressor load increases with system pressure and will limit the power available to run other loads before the system disengages the compressor To adjust the pressure refer to section 7 4 6 and use a Filter Regulator Lubricator FRL to set the final tool pressure The compressor is protected by a paper type replaceable air filter and a spin on type oil filter VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 10 Safety features include e 200 PSI relief valve in separation manifold e blow down valve to discharge system pressure on shutdown e temperature safety sensors in compressor oil separation manifold and engine coolant Do not disable or bypass the over temperature shutdown circuits Failure of the shutdown system could result in equipment damage injury or death A liquid to liquid cooler maintains operating temperatures in an optimal performance range which increases system durability and reduces the temperature of the compressed air 1 5 2
10. BATT VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 39 7 7 Adjusting System Parameters See section 7 4 6 for adjusting settings Below is a table of the adjustable settings accessible though the display box diagnostics section SYSTEM PARAMETER TABLE Setting Description Adjustment Default 0 5 1 2 5 10 15 i Unload Delay Delay time to unload 30 minutes Never 1 min 3 1 2 5 10 15 30 Standby Delay Delay time to standby minutes Never 5 min Operating System 80 to 150PSI System Pressure Pressure 5PSI increments 150PSI PSI below system Top up Pressure pressure to allow inlet to 1 tera Pal 10PSI open and build pressure Air rate set point for High Air Use Rate pressure based restart 0 E AA 3 0PSl sec condition i Pressure Restart Air pressure set point for 80 to 150PSI 420PSI PSI pressure based restart 5PSI increments Allow to restart the SC heam engine if engine is Enable Disable Enabled 9 beginning to freeze Disable Auto Timer for disabling Always 30 min 60 min 120 min 60 min Restart Delay automatic engine restart N ever In Standby allow the ee engine to restart based Enabled Disabled Enabled on low battery level Engine will restart if Battery Restart 10 0 14 0V 0 1V Lower Threshold below this threshold for incrernienis 12 1V 30 seconds in Standby Battery Restart System will start duration 1
11. PRESSURE If the previous error is present the air pressure xxx x PSI is displayed aa REN Engine RPM is not detected Wire may be cut 34 tach sensor on bell housing may be loose or NOT DETECTED fuel problem caused engine to stop suddenly 35 ENGINE CRANK The engine did not start during the crank TIME OUT cycle 36 ENGINE OIL LOW Oil level in the diesel engine is low 7 ENGINE TEMP Temperature sensor on the diesel engine is 3 PROBE OPEN unplugged or wire to control box has been cut ENGINE TEMP Temperature sensor on the diesel engine is 38 PROBE SHORT shorted ENGINE TEMP TOO The diesel engine is too cold to start 39 COLD TO START 40 ENGINE The diesel engine is too hot to start OVER TEMP 41 SERVICE PANEL The service panel is open It must be closed OPEN before the unit is run 42 FUEL LEVEL LOW Fuel level for the diesel engine is low It must PLEASE RE FILL be re filled before the unit is run Unexpected engine operation can have many UNEXPECTED ka A 27 ENGINE OPERATION causes It is likely due to RPM detected during an OFF state DISPLAY CANBUS A CAN bus error between the Display box and p CONN ERROR Control box End of Errors End of errors screen Pressing ENTER will try a OK to Retry to restart the system 2 ENGINE RPM Engine speed went below 2000RPM for 3 5 UNDERSPEED seconds 38 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 7 6 2 Warning Messages Li
12. Reduce operating angle Test air operated equipment for proper operation and connect to supply valve Incorrect start up shutdown procedures Observe start up shutdown procedures detailed in this manual Objectionable noise level Excessive gear wear VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 Replace gearbox assembly 55 10 0 Warranty 10 1 Maintenance and Repair Records System Installation System ID number Compressor Serial Number System Installed by Address Date Installed 50 Hour Inspection Date Performed by Address Parts replaced or notes 200 Hour or 6 month service Date Performed by Address Parts replaced or notes VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 56 Fax 1 250 740 3201 400 Hour or 12 month service Date Performed by Address Parts replaced or notes 600 Hour or 18 month service Date Performed by Address Parts replaced or notes 800 Hour or 24 month service Date Performed by Address Parts replaced or notes VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 57 10 2 Part Replacement or Adjustment Record Record 1 Date Performed by
13. block Use caution when removing the filter so as to avoid catching the scavenge screen orifice on the bottom of the scavenge tube on the lip of the coalescing filter This scavenge screen orifice is attached to the scavenge tube by a push to connect fitting if the fitting has come off of the tube re insert the tube into the fitting ensuring that the tube is fully engaged Gi Check the filter to make sure that the threaded nipple did LJ Check the gasket sealing surface of the manifold block for contamination old gasket material or damage Make sure the new filter is a VMAC filter part 3600079 This is a high pressure filter Use of other filters not rated to the required pressure may cause the filter to rupture LJ Apply a thin coating of compressor oil to the coalescing filter sealing gasket and coat the end of the threaded nipple as there is also an O ring inside the coalescing filter VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 50 E Spin the filter onto the threaded nipple until the gasket contacts the sealing surface of the manifold block E Tighten the filter an additional 3 4 to 1 turn to seat the sealing gasket Gi Never over tighten the filter as this may damage the seal or filter LJ Check the oil level following the oil level checking procedure in Section 8 2 1 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 2
14. cccceeseeeeeeneeeeeeeneeeeeenaeeeeeeaas 52 Clearing Service ReminderS ccccceeeeeeeeeeeteeeeeeeeees 53 Troubleshooting ceeececeeeeeeeeeeeeeeeenseeeeeenseeeeeenseeeeeenseeneeenss 54 Warranty cafeteria hte T 56 Maintenance and Repair Records s es 56 Part Replacement or Adjustment Record ee 58 VMAG Waranty sie tian are Aina 60 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 Document 1930264 Installation and User s Manual for VMAC System D600007 RAPTAIR MF Multifunction Diesel Drive Changes and Revisions Version Revision Details Revised by date Approved Implemented A ENGINEERING RELEASE MH 15 May 2015 JR RD 08 Jun 2015 09 Jun 2015 Notice Manuals and products are subject to change without notice Trademarks VMAC is a registered trademark of VMAC Division of Mangonel Corporation Loctite is a registered trademark of Loctite Corporation Important Information The information in this manual is intended for certified VMAC installers who have been trained in installation procedures 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 Follow all safety precautions for mechanical work If you have difficulty with the install
15. expires first Compressor Brackets Air Oil Separator Tank and Oil Cooler All other components of Product s not listed in 3 2 are warranted against manufacturer defects in materials and workmanship for a period of 12 months or 1 000 hours of operation whichever expires first Replacement components of Product s listed in 3 2 excluding VMAC factory rebuilt components shall be warranted for the remainder of the original warranty period If the original warranty period has expired replacement components of Product s listed in 3 2 and purchased by Buyer excluding VMAC factory rebuilt components shall be warranted for a period of 12 months or 1 000 hours of operation whichever expires first VMAC factory rebuilt components shall be warranted for a period of 6 months from date of shipment from VMAC Replacement components of Product s listed in 3 3 shall be warranted for the remainder of the original warranty period If the original warranty period has expired replacement components of Product s listed in 3 3 and purchased by Buyer shall be warranted for a period of 12 months or 1 000 hours of operation whichever expires first VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 61 4 VMAC OBLIGATIONS 4 1 VMAC s obligation is limited to repairing or at VMAC s option replacing during normal business hours at an authorized service facility of VMAC any compo
16. minus TOP UP PSI ie 150PSI 10PSI 140PSI the inlet will open and fill to system pressure and reset the idle timer HIGH AIR RATE Air rate is a change in time of pressure PSI seconds used to monitor if an air tool is being used Setup of this parameter depends on the air tool and tank size A small tank using a large tool will have a large air rate if the tank size is increased the air rate will be lower This parameter allows a quick restart response when the system is in STANDBY rather than reaching the restart pressure to restart the system RESTART PRESSURE This parameter is used to restart the system when pressure has gone below the set value in STANDBY COLD ENGINE RESTART This will allow the engine to restart if temperature has dropped below a preset value in STANDBY DISABLE AUTO RESTART Disable the engine from restarting in STANDBY after an adjustable time ALLOW LOW BATTERY RESTART Allow to restart the engine from STANDBY if the voltage threshold is below BATTERY RESTART LOWER THRESHOLD for 30 continuous seconds BATTERY RESTART LOWER THRESHOLD Low battery threshold for a restart request BATTERY RESTART UPPER THRESHOLD After a low battery restart the system will stay in RUNNING until battery voltage is above the upper voltage threshold to start the BATTERY RESTART DELAY BATTERY RESTART DELAY Delay to keep the idle timer reset so the battery will charge A 2 minute delay is typical fora RAPTAIR batte
17. one terminal connected to the yellow remote start wire and the other to the ground on the RAPTAIR MF 4 5 Cold Climate Option The 110VAC Cold Climate heaters are used to warm the engine and compressor system in cold weather conditions A minimum 700W power inverter connected to the truck is required for heater usage or connected to external AC power prior to starting Heaters should be run for 90 minutes prior to starting the system in cold conditions time will vary depending on ambient temperature VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 20 In cold weather the RAPTAIR MF needs to be connected permanently to the vehicle s battery internal battery is not sufficient in extreme cold weather Connections should be made to the external battery at the battery terminals The diesel drive will charge the vehicle batteries while running While the RAPTAIR MF is in the STANDBY state it will also monitor battery voltage and restart to charge the batteries if the battery voltage gets too low These settings can be adjusted See Kubota engine manual for engine oil and fuel recommendations for cold climate operation VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 21 5 0 Completing the Installation 5 1 Before Operation Checklist Make sure that the following have been completed before operating the RAPTAIR M
18. request can be made by LJ Pressing ON ENTER from the Display Box E Turning the key to the START position E Grounding the Remote Start wire System State GLOW PLUG Sets the initial delay for the glow plugs based on engine temperature 1 to 15 seconds The engine restart buzzer is enabled for 3 seconds then paused for 3 seconds before going into the next state to crank the engine The glow plugs are enabled during the buzzer cycle and during engine cranking Temperature Glow Plug Delay Less than 20 C 68 F 15 seconds Between 20 C 68 F Linear extrapolation from 15 seconds to 1 second and 40 C 104 F Greater than 40 C 104 F_ 1 second System State STARTING The control system will attempt to start the engine The control system will allow the engine to attempt to start for 20 seconds If the engine fails to start the control system will flag a starting error to the Display Box System State WARMING The control system will wait until the engine and compressor temperatures are above 5 C 41 F before loading the compressor system and going to the RUNNING state VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 26 System State STARTING CLUTCH This state engages the compressor clutch to build air Each time the clutch is disengaged a delay is put in place to allow internal compressor pressure to drop Once the delay is reached the c
19. to the RUNNING state if pressure is below the Restart Pressure If the system continues to not detect air use it will continue to count down the delay to STANDBY timer If the Delay To STANDBY timer has finished counting down the system will go to STANDBY mode If the Genset or PTO switch is activated the control system will not go into STANDBY mode VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 28 System State STANDBY In STANDBY mode the control system will shut down the engine as it has detected no further air use The control system is still operating and able to restart with air use The LED beacon module is enabled to identify that the engine is able to restart When the LED beacon module is illuminated the system ore and engine is able to restart when air use is detected As with UNLOAD mode to return to RUNNING mode the operator needs to dump air greater than the preset air rate values this will restart the engine The system will also return to the RUNNING state if pressure is below the Restart Pressure If Allow Cold Engine Restart is enabled the engine will restart when it detects engine or compressor temperature is below 5 C 23 F As with many settings this can be disabled through the Control Box The Disable Auto Restart Delay setting will prevent the system from restarting the engine after a preset time once in the STANDBY state
20. 0 0 15 0V 0 1V 12 8V Upper Threshold timer if above value increments i Once above Upper Battery Restart Threshold stay running 1 2 5 10 15 30 2 min Duration for duration to charge battery minutes 40 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 7 8 Cold Weather Operation If the cold weather kit for the RAPTAIR MF is installed plug in the kit as per section 4 5 to warm the engine and the compressor before operating Press the ON ENTER button or turn the key to the START position The Display box will display GLOW PLUG mode on the screen and delay starting the engine from 1 to 15 seconds depending on the engine temperature After this delay the engine should start and run The control system will go into WARMING mode monitoring the engine temperature and compressor temperature Once both temperatures have warmed to a preset level the system will enter RUNNING mode and build to full system pressure VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 41 8 0 Routine Maintenance Maintenance is a planned program which provides an orderly series of service and inspection procedures together with cleaning A well planned maintenance program lowers maintenance costs reduces down time and can prevent possible accidents due to failed components wae RAPT f J AIR MF
21. 1 250 740 3200 Fax 1 250 740 3201 62 7 DISCLAIMER AND WARRANTY SERVICE 7 1 Any labor costs claimed in excess of VMAC s set rate and or times are not provided by this warranty If applicable any labor costs in excess of VMAC rate schedules caused by but not limited to location or inaccessibility of the equipment travel time or labor provided by unauthorized service personnel are not provided by this warranty 7 2 This warranty is in lieu of all other warranties or obligations express or implied VMAC expressly disclaims all implied warranties of merchantability or fitness for a particular purpose 7 3 Warranty claims must be pre authorized by VMAC and the components returned via prepaid freight using the designated Returned Merchandise Authorization number and form VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 63
22. 50 740 3200 Fax 1 250 740 3201 51 8 6 Engine Maintenance Refer to the Kubota Engine manual supplied with the RAPTAIR MF VMAC p n 1900919 After first 50 hours Change engine oil Replace engine oil filter Every 100 hours Change engine oil Clean fuel filter Every 200 hours Change engine oil Clean fuel filter Replace engine oil filter The Display Box will inform the operator when engine and compressor servicing is due Refer to Section 7 6 2 for the Display box servicing message list Engine service reminders do not need to be cleared in the Display Box Reminders will show 10 hours before and 10 hours after the engine service intervals 8 6 1 Draining Engine Oil E Locate the drain hose below the belt and remove from clamps to drain into container LJ Remove plug and drain the oil into a container large enough to hold at least 1 1 2 US Gallons 6 liters After the oil has drained replace the plug and secure hose back into clamps 8 6 2 Adding Engine Oil LJ Oil can be added using an accordion funnel with the engine s fill cap on the top of the engine VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 52 8 7 Clearing Service Reminders Perform appropriate compressor servicing as per section 8 0 Engine servicing reminders do not need to be cleared LJ Turn the key switch to the RUN position do not start the unit LJ Enter Diagn
23. During operation the RAPTAIR MF can develop AN considerable heat Proper ventilation is vital for proper operation and to avoid damage to components Ensure there is a minimum of 6 150mm clearance between cooler grills on diesel drive units and any other components mounted on the vehicle Also ensure there is a good supply of cool air to the service panel side of the unit and good exhaust from the radiator side Direct the diesel exhaust to vent to atmosphere and in a safe location The engine radiator fan pushes hot air from the unit Cold air is drawn in through the service panel 2 2 1 Top Mounting This is the preferred mounting location Placing the unit on top of the service body Figure 2 2 Mounting locations provides the best access to ambient air and provides the best cooling Maintain a minimum of 6 between the service panel and radiator to solid objects Maintain a minimum of 2 to the other sides VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 14 2 2 2 Enclosed Mounting Enclosed mounting is not recommended for most applications due to the significant heat generated Ensure there will not be recirculation between the radiator output and the service side perforated panel Mounting the RAPTAIR MF in an enclosure Figure 2 2 Mounting locations will limit access to ambient air restrict the escape of hot air from around the unit and have an advers
24. F for the first time LJ Check the compressor oil level The compressor has been filled to the correct level prior to shipping Note that the oil is very clear and it is difficult to see the level E Check the engine coolant level LJ Check the engine oil level LJ Check fuel level LJ Do a final inspection to make sure that all fasteners and connections are tight LJ Ensure ground point is connected E Check that all hoses and wiring are secure and protected VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 22 6 0 Accessory Products from VMAC To order parts contact your nearest VMAC dealer or contact VMAC directly at 250 740 3200 or 1 800 738 8622 Have the system serial number a description of the part and the quantity The following accessories are also available from VMAC Eliminator Aftercooler A800070 Removes up to 80 of moisture from compressed air Quick installation automatic drain and compact design Filter Regulator Lubricator A700151 Removes lubricants water and dirt from the air stream Adds atomized tool oil to lubricate tools Reduces pressure for longer tool life Hose Reel A700007 Secure compact retractable hose storage in a sturdy reel Air Receiver Tank 10 Gal w o fittings A300046 10 Gal fittings incl A300047 20 Gal w o fittings A300043 35 Gal w o fittings A300009 35 Gal fittings incl
25. Generator Option The generator produces both AC and DC power The AC portion of the generator produces 3 phase power Each leg of the generator goes through the 30A 3 phase breaker Two of the legs go through a 20 A breaker and to 120V GFCI receptacles found on the panel of the generator One leg goes to a 240V 30A plug There is also a 3 phase plug that is capable of transmitting the full power of the generator The generator switch disables the AC and DC output of the generator and will shut off any plugs on the unit 1 5 3 Welder Battery Boost Charger The welder is capable of producing 300A DC There is a thermal switch inside the generator to protect against thermal damage If the thermal switch is tripped the light will illuminate on the user panel that is indicated as welder alarm If the DC thermal switch is tripped the generator will continue to produce AC power The welder selection dial performs the following functions e Weld Mode This setting produces CC output for stick welding e 48V This is a CV mode that could be used to power a MIG pack Use the current control dial to limit the amount of current e 36V CV mode Use the current control dial to limit the amount of current VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 11 e 24V CV mode used for jump starting or charging 24V DC systems Use the current control dial to limit the amount of current
26. Installation and User s Manual RAPTAIR MF Multifunction Diesel Drive 1 0 General INformation ccceecceceseeseeeeeseeeeeeeeeeeeeseseeeeeseeeeeees 4 1 1 FOSWOlG aer onn E E aie aii elena ee 4 1 2 Warranty Registration 0 0 eeceeeeeeeeeeesneeeeeeneeeeeenaeeeeeeaaes 4 1 3 Important Safety Notice ecceceeeeeeeeeeeeeeeeeeeaeeteeeeeaes 4 1 4 Safety MeSSAGeS eecceeeceeceeeeeeeeeeeeneeeeeeeeseaeeeeaaesteneeeeaes 5 1 5 Specifications and Component ccccceceeeeeseeeeeeeeees 10 2 0 Installation Requirement ccsseccceseeneeeeeeeeeeeseeeeeeesnees 13 2 1 Air Receiver Requirement cceeeesseceeeeseeeeeeeneeeeeeaes 13 2 2 Ventilation Requirement ce eecceeeesneeeeeesneeeeeeneeeeeeaaes 14 3 0 Installing the RAPTAIR MP csseecsseeeeeseesseeeesneeeeeeees 16 3 1 Mounting the Diesel Drive Compressor System 16 4 0 Electrical Connections cccecseteeseeeeeeeeeeeteeeeteeeeseeeeeeeees 19 4 1 LED Beacon Module Connection ccceecceeeeeereeees 19 4 2 Display Panel Assembly Connections ceceeeeee 19 4 3 Welder Option Control Panel ccccccceeeeeeeesteeeeneeeees 20 4 4 Remote Start Wirind cccccceeececeeeeeeeeeceeeeeeeeeeeesaeeeeeeeeaes 20 4 5 Cold Climate Option cccecececeseeeeeeeeeeeeeeeeeeessaeeseneeeeaes 20 5 0 Completing the Installation ccssssseseeseeseeseeenses 22 5 1 Before Oper
27. MF fuel tank LJ Air filter restriction warning LJ Error and warning message logging data logging E Operator Compressor Servicing reminders 200 and 400 hours E Buzzer module to warn before engine start L LED beacon module to identify when the unit is able to restart O Hour meter VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 24 7 2 Control System Operation SYSTEM READY ON ENTER Button Pushed Remote enable wire to GND Key to start position GLOW PLUG Glow plug delay STARTING CRANKING STOPPING ON ENTER Button Pushed all arrows to STOPPING Engine running WARMING Engine and Compressor at temperature greater than 5 C 41 F STARTING CLUTCH UNLOAD delay reached UNLOAD STANDBY STANDBY delay reached Figure 1 Control System Flow Diagram At System Pressure Top up Pressure System below Engine or Compressor below 5 C 23 F and Allow Cold Engine Restart is enabled or Air pressure below Restart Pressure Air use detected or ON ENTER Button Pushed or Disable Auto Shutdown Delay Reached VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 25 7 2 1 Control System Terminology System State SYSTEM READY Compressor system is ready for operation and awaiting a start request A start
28. MULTIFUNCTION DIESEL DRIVE ENGINE AND COMPRESSOR MAINTENANCE CHECK LIST SERVICE INTERVAL MAINTENANCE ITEM AFTER EVERY EVERY Change engine oil engine Change engine oil Clean fuel filter E i Replace engine oil filter Replace air cleaner element Change compressor oil and replace compressor oil filter Change compressor coalescing filter For a complete Engine Maintenance Check List refer to the Kubota Diesel Engine Operator s Manual For compressor maintenance refer to the RAPTAIR MF Owner s Manual Figure 3 Engine and Compressor maintenance check list Shut down the RAPTAIR MF Diesel Drive Compressor wait for 5 minutes After 5 minutes discharge all air to ensure the system is fully depressurized VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 42 Torque Specifications STANDARD GRADE 8 NATIONAL COARSE THREAD Size 1 4 5 16 3 8 7 16 1 2 9 16 5 8 Ya Foot pounds ft lb 9 18 35 55 80 110 170 280 Newton meter Nem 12 24 47 74 108 149 230 379 STANDARD GRADE 8 NATIONAL FINE THREAD Size 3 8 7 16 1 2 5 8 A Foot pounds ft lb 40 60 90 180 320 Newton meter Nem 54 81 122 244 434 METRIC CLASS 10 9 Size M8 M10 M12 M14 M16 Foot pounds ft lb 19 41 69 104 174 Newton meter Nem 25 55 93 141 236 8 1 Compressor Servicing and Main
29. This prevents the engine from restarting accidentally if left unattended If the Low Battery Restart is enabled the system will restart if the battery voltage is below the Low Battery Threshold for more than 30 seconds If the generator or PTO switch is activated while the engine is in STANDBY the engine will restart System State STOPPING When the control system is running and the ON ENTER button on the Display Box is pressed the control system will enter the STOPPING state The stop solenoid will engage for 10 seconds to allow the engine to shutdown and an additional 10 second delay to blowdown all internal pressure from the system After the stopping sequence has finished the system will revert back to the READY state VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 29 7 3 Starting and Stopping the RAPTAIR MF 7 3 1 Starting the System LJ Check the oil level in the tank LI Check for any fluid leaks around the unit E Ensure pneumatic equipment is securely connected and discharge valve is closed L Turn the key switch to the RUN position E Wait for the Display Box to finish going through the System Check If there are no errors the system will be in System Ready state L Turn the key to the START position hold for about 1 second then release or press the ON ENTER button LJ Display box should go into Glow Plug mode for 1 to 15 seconds then Starting m
30. ation contact VMAC The VMAC warranty form is located at the back of this manual This 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 2013 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 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 1 0 General Information 1 1 Foreword Read this manual before beginning the installation so that you can understand the requirements This will help ensure the successful installation and proper operation of the RAPTAIR MF This manual provides maintenance repair and troubleshooting instructions for the RAPTAIR MF Multifunction Diesel Drive Proper and regular servicing provides continued high performance and long life For more information contact VMAC KEEP THIS MANUAL WITH THE RAPTAIR MF UNIT FOR USER REFERENCE i 1 2 Warranty Registration The VMAC warranty form is located at the back of this manual This warranty form must be completed and maile
31. ation Checklist c ccccccesceseeeeesseeeeeseeeeeees 22 6 0 Accessory Products from VMAC ccccsseceeesseeeeeseees 23 7 0 Operating the RAPTAIR MP csssccssseeeesteesseeeeseeeeeseees 24 7 14 Control System Features cecccceeeeeseeeeeeeseeeeeeeeeeeenees 24 7 2 Control System Operation ccccccceeeeseeeeeeeseeeeeeseeeeeeees 25 7 3 Starting and Stopping the RAPTAIR MF ees 30 7 4 Display Box MeSSAQGES eceeeeeeeeeeeeeeneeeeeeeaeeeseenaeeeeeenaes 31 7 5 Automatic Shutdown and Restart c cceeeceesseeeeeseeeeeeees 37 7 6 Checking Messages and Errors cccsceeeeceeesteeeeseeeenees 37 7 7 Adjusting System Parameters cccsceeseceeeseeeeeteeeeeees 40 7 8 Cold Weather Operation ccccccccseeeseeceeeeeeeeeeeeeeeenees 41 8 0 Routine Maintenance ccseccceseeeeeeseeeseeeeneesesestenseeesnees 42 Continued on next page VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 8 1 8 2 8 3 8 4 8 5 8 6 8 7 9 0 10 0 10 1 10 2 10 3 Compressor Servicing and Maintenance Schedule 43 Checking and Adding Compressor Oil cceeeeee 44 Replacing the Air Filter oo eccceeeeeeeeeeeeeeneeeeeenaeeeeeeaas 45 Replacing Compressor Oil and Filter cecsseeeeeeees 47 Replacing the Coalescing Filter cccccsseeessssteeeeeeees 49 Engine Maintenance
32. ay damage the equipment or render it unsafe Be aware that it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions 1 4 2 Fire and Explosion Hazards Fire in the compressor can cause an explosion and flame projection Should this occur there is potential for serious injury or death Vaporized oil propelled by high pressure air is an explosive mixture VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 You must observe the following when operating the compressor e Constant vigilance is necessary around high energy equipment e Be attentive for unexplained changes in operation parameters and record any changes e Never bypass or disable the temperature sensors e Never expose the tank or compressor to extreme heat e Ensure that the air entering the compressor is free of flammable vapors VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 1 4 3 Personal Hazards Follow all safe work practices Wear the appropriate safety equipment gt amp Do not breathe the compressor air Vaporized oil is a respiratory hazard Always use the appropriate personal protective 6 equipment particularly eye and hearing protection when operating air powered equipment The compressor system is under sufficient pressure that a leak could force the ai
33. by VMAC VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 54 Troubleshooting Table SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Frequent relief valve operation Pressure control line plugged or frozen Remove and clear the line System still at high pressure Wait for system blow down or bleed off all system pressure Defective relief valve Replace the valve Compressor does not run High system pressure High oil temperature system will not start with more than 10 psi system pressure See frequent over temperature shut down Frequent over temperature shut down Low oil level Check oil level with equipment on level ground Restricted oil lines Check for kinked or pinched lines Plugged oil filter Replace oil filter Cooler not functioning or plugged Replace or clean oil cooler Engine cooling system failure high engine temperature Correct problem Excessive oil in the air High ambient temperatures Oil temperature sensor failure Coalescing separator Reduce duty cycle Replace if defective Replace element failure Clogged scavenge Clean or replace line screen High oil level Check oil level with Operating angle in excess of 15 degrees from horizontal Air operated equipment is faulty or not correctly connected to supply valve equipment on level ground
34. cut wires for installer connection at the RAPTAIR MF and the Display Panel The table below has recommended wire sizes for a typical installation The size may need to be increased for long distance routings between the two components to avoid excessive voltage drops VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 19 mae Suggested Display Panel Wire Description Gauge Display box connections 18AWG 4 terminal connector Key Switch Supply Power Red wire 14AWG Key Switch Return Power Orange wire 14AWG Key Switch Run key Yellow wire 18AWG PTO GENSET COMPRESSOR switch 18AWG connections 5 terminal connector 4 3 Welder Option Control Panel The remote welder control panel has two supplied connections about 8ft max length required for operation 14pin ribbon cable connector and 2pin connector The mating connection points are located inside the Welder Control Panel Mount the welder control panel inside a dry cabinet away from moisture 4 4 Remote Start Wiring The RAPTAIR MF has the ability to remotely start with a single wire interface to the Control Box A blunt cut yellow wire is located near the Control Box With the key switch in the RUN position grounding the wire will enable the compressor system Once the ground is interrupted the control system will stop the engine Use a SPST Single Pole Single Throw switch
35. d combinations and duty cycle of your specific needs so as to not overload the system as the system may not be able to maintain air pressure in the reservoir tank See section 3 1 1 for PTO installation details 1 5 5 PTO Hydraulic Pump Options e 5 8 10 GPM hydraulic pump 3500psi VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 12 2 0 Installation Requirements The information in this section is very important for proper operation of the system Read these requirements before beginning installation Before installing the RAPTAIR MF examine the possible locations and consider the following factors when selecting a location e Hose lengths will be the shortest possible and a minimum number of 90 degree fittings will be used e Oil level at the sight glass can be checked easily e Sufficient clearance around the unit for good air circulation and effective cooling e Can it be serviced easily without having to disconnect lines or remove and reposition the unit Service panel is accessible and can be removed e Protected from excessive exposure to the elements and possible incidental damage from other operations e Away from heat sources such as engines exhaust systems or other components that generate heat e Not in a location where it will be exposed to high contamination levels including combustible gases e Exhaust can be routed away from coolers to open air and not
36. d or faxed to VMAC at the time of installation for any subsequent warranty claim to be considered valid 1 3 Important Safety Notice The information contained in this manual is based on sound engineering principles research extensive field experience and technical information Information is constantly changing with the addition of new models assemblies and service techniques If a discrepancy is noted in this service manual contact VMAC prior to initiating or proceeding with service Current information may clarify the issue Any person with knowledge of such discrepancies who performs service and repair assumes all risks Only proven service procedures are recommended Anyone who departs from the specific instructions provided in this manual must first assure that their safety and that of others is not being compromised and that there will be no adverse effects on performance or the operational safety of the equipment VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 VMAC will not be held responsible for any liability injuries loss or damage to individuals or to equipment as a result of the failure of any person to properly adhere to the procedures set out in this manual or standard safety practices Safety should be your first consideration in performing service operations If you have any questions concerning the procedures in this manual or require any more information on
37. details that are not included in this manual please contact VMAC before beginning repairs Torque Specifications STANDARD GRADE 8 NATIONAL COARSE THREAD Size 1 4 5 16 3 8 7 46 1 2 9 16 5 8 ya Foot pounds ft lb 9 18 35 55 80 110 170 280 Newton meter Nem 12 24 47 74 108 149 230 379 STANDARD GRADE 8 NATIONAL FINE THREAD Size 3 8 7 16 1 2 5 8 Foot pounds ft lb 40 60 90 180 320 Newton meter Nem 54 81 122 244 434 METRIC CLASS 10 9 Size M8 M10 M12 M14 M16 Foot pounds ft lb 19 41 69 104 174 Newton meter Nem 25 55 93 141 236 1 4 Safety Messages ZN This symbol is used to call your attention to instructions concerning your personal safety Watch for this symbol it points out important safety precautions it means Attention become alert Your personal safety is involved Read the message that follows and be alert to the possibility of personal injury or death Be alert your safety is involved While it is impossible to warn about every conceivable hazard let good common sense be your guide This symbol is used to call your attention to instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 This symbol is used to call your at
38. e effect on cooling Make sure that adequate ventilation is provided so the cooling system will function properly i e a pull out drawer f Top mount FARRAR Enclosed mount It is not possible to make absolute recommendations regarding ventilation because of the widely differing circumstances that are possible Duty cycle ambient temperature and enclosure shape are some of the important variables Ideal ventilation will provide good airflow through the unit with no restrictions Cool ambient air ducted to the cooler and installing an exhaust fan to remove hot air is recommended Ensure exhaust from the diesel engine is routed in a way to prevent recirculation back into the unit VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 15 3 0 Installing the RAPTAIR MF 3 1 Mounting the Diesel Drive Compressor System E Locate a suitable mounting position for the RAPTAIR MF Place the unit and check for clearances to any other objects LJ Determine suitable mounting bolt locations There are holes predrilled in the mounting plates of the unit but new holes can be drilled in any locations on these plates except where the vibration isolation mounts are located Ensure there is a minimum of 4 bolts securing the unit 2 on each mount plate O Drill holes a
39. ed When an error is present the WARNING LED will flash on off and the screen will display ERRORS DETECTED followed by the following list of errors The user MUST scroll through ALL the displayed errors by pressing the NEXT button before the unit can re try the start sequence VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 37 ERROR MESSAGE TABLE Bae Error Message Displayed Cause COMP TEMP SENSOR Temperature sensor on the compressor is 5 FAILED OPEN unplugged or wire to control box has been cut COMP TEMP SENSOR Temperature sensor on the compressor is 6 FAILED SHORT shorted COMP TOO COLD Compressor is too cold to start The i XX X F xxX xOC temperature is displayed COMP OVER TEMP Compressor is too hot to start The S xx x F xx x C temperature is displayed MANIFOLD TEMP Temperature sensor on the manifold is 9 FAILED OPEN unplugged or wire to control box has been cut 10 MANIFOLD TEMP Temperature sensor on the manifold is FAILED SHORT shorted 11 MANIFOLD ERROR The coalescer should be checked There is a CHECK COALESCER possibility of a plug 12 AIR PRESS SIGNAL Low voltage reading on the air pressure VOLTAGE LOW transducer AIR PRESS SIGNAL Over voltage reading on the air pressure 13 VOLTAGE HIGH transducer AIR PRESS SENSOR Air pressure is too high to start the engine 14 TOO HIGH AIR
40. ing the exhaust system E Ensure the exhaust pipe has suitable clearance and does not come in contact with anything LJ i extending the exhaust externally to the unit a suitable flex coupling or flex pipe must be used to prevent damage to the muffler and exhaust system of the unit VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 18 4 0 Electrical Connections There are five main electrical connections to the RAPTAIR MF Display Panel Assembly Key Switch Display Box and PTO GENSET COMPRESSOR ON OFF Switches Remote Start Wire Welder Control Panel optional Cold Climate kit 110VAC Cold Climate Kit Heater Connection 4 1 LED Beacon Connection to inform the operator that the RAPTAIR MF is able to i The 2 LED beacons will illuminate in STANDBY mode restart when air use is detected 4 2 Display Panel Assembly Connections To fully utilize the features of the RAPTAIR MF the display panel with the key switch and display box should be mounted in a convenient location for the operator protected from extreme weather The Display box is splash proof but not fully sealed Ensure that it will not get kicked or hit by tools and equipment Mount the Display Panel inside the cab or a cabinet There are separate connectors for the Display box cable and the key switch in the same location as the Air Discharge Port Pigtails have been provided with blunt
41. ion application operation or maintenance or have been repaired or altered in such a way that affects the Product s adversely Components or accessories manufactured warranted and serviced by others Damages caused from normal maintenance service and repairs and corrections with minimum action such as adjustments and inspections or replacement of items such as service filters belts seals and service kits Consequential damages caused by Product s failure Any Product s if other than VMAC s genuine components are used in the Product s Normal wear and tear of Product s VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 3 3 1 3 2 3 3 3 4 3 5 3 6 WARRANTY PERIOD The warranty period will commence upon installation of the Product s The returned warranty registration form marks the date of installation If the warranty registration form has not been received by VMAC within 6 months from the date of installation of the Product s then the warranty period will be deemed to commence 30 days from date of shipment from VMAC For the full warranty period to apply installation of Product s must be completed within 36 months from the date of shipment of the Product s from VMAC The following components of Product s are warranted against manufacturer defects in materials and workmanship for a period of 24 months or 2 000 hours of operation whichever
42. lutch is able to re engage and the system to build air System State RUNNING When using an air tool the control system should be in the RUNNING state If the air pressure stays above System Pressure minus Top up Pressure the Delay to Unload timer will start counting down Once the timer reaches the delay time the system will switch to the UNLOAD state If air pressure drops below System Pressure minus Top up Pressure the system will reset the Delay to Unload timer ie 150 PSI 10 PSI 140 PSI If a low battery restart is triggered the system will keep the Unload timer reset until the battery voltage is above the upper voltage threshold and has completed the low battery restart timer duration The control system monitors engine load It will disable the compressor system if the generator or PTO switches are enabled and engine speed drops below 3200RPM Once the engine speed increases RPM the compressor will automatically re engage the clutch VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 27 System State UNLOAD In UNLOAD mode the control system will disable the compressor clutch To return to the RUNNING state the control system calculates the air use rate of the air tool PSI second If the air use rate is above a preset value HIGH AIR USE RATE the system will detect that an air tool is used and will switch states The system will also return
43. nd secure the RAPTAIR MF to the truck Use a minimum of 4 2 in each plate 1 2 12 mm bolts Use bolts washers and locknuts or Loctite E Connect a ground wire to the ground terminal found on the bottom of the generator side of the unit beside the air outlet Ensure this is connected to the vehicle or sufficient ground point for safe operation Consult with a certified electrician for safe grounding points if unsure Failure to connect sufficient electrical ground could cause severe injury or death Ensure electrical connections are made in accordance with electrical guidelines in the operation jurisdiction LJ Remove the 12 cap from the air outlet found on the bottom of the generator side of the unit Connect to the air delivery system 3 1 1 Optional PTO Equipment Installation A N Ensure PTO equipment falls within power guidelines at 2700 RPM and is rated to a minimum of 2700 RPM L To install PTO equipment remove the small service hatch on the exhaust side panel VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 16 LJ Ensure input shaft of PTO equipment can rotate freely before attached to PTO port LJ Attach PTO equipment to port following manufactures guidelines E Ensure any hoses or wires attached to PTO equipment are routed away from sharp edges or hot surfaces 3 1 2 Optional Fuel tank installation E The fuel tank will be installed on the generato
44. nent which in VMAC s judgment is proven to be defective as warranted 4 2 _VMAC s obligation is limited to Product s proven to be warranted No liability is accepted for any consequential damages injuries or expenses directly or indirectly related to Product s failure 5 BUYER OBLIGATIONS 5 1 Buyer shall notify VMAC of the alleged defect within 10 days of initial discovery and return the allegedly defective component s within 30 days of initial discovery 5 2 The Buyer must prepay all costs associated with the warranty claim and submit receipts and or invoices to VMAC for evaluation 5 3 If required by VMAC the Buyer must return components claimed under this warranty to a facility designated by VMAC for evaluation to establish a claim under this warranty 5 4 Buyer shall maintain and service VMAC Product s in accordance with the VMAC Product s Owner s Manual 6 WARRANTY REGISTRATION VALIDATION 6 1 A warranty registration form is provided to the Buyer with the Product s The form must be fully completed by the Buyer and returned to VMAC upon completion of the installation of the Product s to validate the warranty Warranty registration can also be completed online on the VMAC website at http www vmac ca index php warrantyregistration Warranty claims will not be processed unless VMAC has received a fully completed warranty registration form VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local
45. ng surface of the air oil separator tank for contamination old gasket material or damage Make sure the new filter is a VMAC filter part number 9200039 This oil filter is a high pressure oil filter not an automotive oil filter which will rupture under high pressure L Apply a thin coating of compressor oil to the filter sealing gasket LJ Spin the filter onto the threaded nipple until the gasket contacts the sealing surface of the air oil separator tank LJ Tighten the filter an additional 3 4 to 1 turn to seat the sealing gasket VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 48 Never over tighten the filter as this may damage the seal or filter LJ Follow the oil level checking procedure in Section 8 2 1 8 5 Replacing the Coalescing Filter Follow all safety precautions S COALESCING FILTER Giora Do not use a screwdriver punched into the side of the filter as this practice can damage the scavenging tube and screen VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 49 THREADED NIPPLE DISCHARGE FITTING SCAVENGING TUBE Figure 7 Avoid Damaging the Scavenge Line not unscrew with the filter If it is in the filter remove it carefully to avoid thread damage coat the threads that go into manifold block with a small amount of Loctite blue and install it into the manifold
46. nu can only be reached from the SYSTEM READY menu by holding both the BACK and NEXT buttons for five seconds This menu allows the user to define parameters of system operation User defined parameters include e System Pressure Unload Delay Standby Delay Top up Pressure High Air Rate Restart Pressure Allow Cold Engine Restart Disable Auto Engine Restart Allow Low Battery Restart Battery Restart Lower Threshold Battery Restart Upper Threshold Battery Restart Delay e Factory Reset Upon entering this menu the user will see information on how to navigate USER SETUP Specifically the following e To scroll through the menu screens press BACK or NEXT e To enter or exit a menu screen press the ENTER or EXIT buttons respectively The user will then see USER SETUP on the display module e Press ENTER to see the parameter screens To return to SYSTEM READY menu press EXIT SYSTEM PRESSURE Allows setting of the maximum working pressure UNLOAD DELAY Time delay to change states from RUNNING to UNLOAD STANDBY DELAY This delay begins after the UNLOAD DELAY has expired For example if UNLOAD DELAY is set to 5 minutes and STANDBY DELAY to 1 minute it will take 6 minutes the RAPTAIR60 to go from RUNNING to STANDBY VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 34 TOP UP PSI This parameter allows tank pressure to be close to system pressure If pressure goes below SYSTEM PRESSURE
47. ode where the engine will crank LJ Once engine speed is stable system will enter System Running mode and is ready for use L Turn the Compressor switch to ON the compressor clutch should engage and start to build air 7 3 2 Stopping the System L Press the Display box ON ENTER button to stop the system LJ The system will go into STOPPING mode for about 25 seconds LJ Turn the key to the OFF position to fully power off all electronics The key switch can be used to shut down the system also However this will directly turn off power to the control system and the system will have to go through its system check before being able to be restarted VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 30 7 4 Display Box Messages SYSTEM CHECK ERRORS No Errors Detected Errors Cleared Press NEXT BACK for 5 seconds SYSTEM READY DIAGNOSTICS USER SETUP Error Detected SYSTEM SETTINGS ON request SYSTEM RUNNING SERVICING VIEW LOGGED ERRORS Menu Selection VIEW LOGGED MESSAGES VIEW LOGGED SERVICES Figure 2 Display Box Flow Diagram VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 31 7 4 1 System Check Menu Ensure the pneumatic equipment is securely connected and turned off To power the control box and display box turn the key
48. or current control state see Control System Operation Pressing the NEXT or BACK buttons in SYSTEM RUNNING menu will take the user to the additional information menu where specific information about the RAPTAIR MF sensors are displayed Pressing the ENTER or EXIT button will initiate the stopping sequence 7 4 4 Stopping Sequence To stop the RAPTAIR MF unit as detailed in section 7 3 2 the user can press the ENTER button at any point during operation in addition the user may also turn the key switch from the RUN position to the OFF position 7 45 Additional Information Menu The additional information menu for the display box allows the user to monitor specific information about the RAPTAIR MF unit The parameters displayed are air pressure air rate engine speed engine temperature compressor temperature time to unload or standby and hour meter The user can scroll through the screens by pressing the BACK and NEXT buttons Pressing the EXIT button will return the display box to SYSTEM RUNNING menu The display box will return to the SYSTEM RUNNING menu after three minutes of no buttons being pressed by default Pressing the ENTER button will initiate the stopping sequence see Control System Operation VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 33 7 4 6 User Setup Menu Details on adjustable parameters are summarized in Section 7 7 User setup me
49. orientated in a way that it will fill up with rain or exhaust flapper installed e Ensure the RAPTAIR MF is grounded to the truck chassis frame and the truck is properly grounded when using the generator 2 1 Air Receiver Requirements A reservoir tank is recommended and required for automatic shutdown of the air compressor system The reservoir tank needs to be a minimum of 5 gal and rated to 200 psi for the air compressor automatic shutdown to operate properly A larger reservoir tank is recommended if possible to allow for longer and more frequent engine shutdown and less air pressure lag to the operator VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 13 The RAPTAIR MF unloads the air pressure in the system which minimizes fuel burn equipment wear enclosure temperature and noise when compressed air is not being used If the plumbing downstream from the RAPTAIR MF is tight has no leaks a 5 gallon air receiver is adequate If you use an auxiliary air tank with this system the line to the auxiliary tank must be installed as high as possible not in the bottom of the tank to prevent water from clogging the line Failure to observe these requirements will result in damage to the system tank Do not install an additional check valve as this Gi A one way check valve is built into the RAPTAIR MF may cause undesirable operation 2 2 Ventilation Requirements
50. ostics mode in the Display Box by holding the NEXT and BACK button for 5 seconds E Use the NEXT button to scroll to the Servicing section Press ENTER to the Servicing section Press ENTER to confirm servicing is completed The system will only allow services to be logged when approaching the 200 hour or 400 hour service reminder time The Display Box shows running time in hours 1 1 o hour VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 53 9 0 Troubleshooting Problem diagnosis for the compressor system should follow sound recognized practice Quick accurate diagnosis of problems is possible by LJ Accurately identifying the problem by operating the system yourself following safety practices LJ Determining possible causes for the problem by understanding how the system operates LJ Isolating the potential causes by accurate testing using the correct recognized procedures L Performing proper repairs using the correct procedures outlined in this manual and the recommended replacements parts LJ Performing proper post repair testing to ensure that the repairs were effective When performing problem diagnostics do not use test practices that are potentially harmful to the people involved or the equipment Electrical testing should be performed according to the processes described in the troubleshooting charts and in conjunction with the manuals provided
51. r oil mixture through the skin directly into your bloodstream This could cause serious injury or death Never adjust or attempt to make any repairs to the system while the engine is running Components and hoses under pressure could fail and cause serious injury or death Never perform maintenance procedures on the system until the compressor has been shut down for at least 5 minutes to ensure the system is fully depressurized After 5 minutes open the discharge valve to ensure the system is depressurized Failure to depressurize the system could cause parts to separate explosively Flying parts could cause serious injury or death Air oil mixture could be sprayed out with sufficient force to penetrate the skin which could cause serious injury or death The engine exhaust and the compressor system get very hot during operation contact with the components or the oil can cause serious burns Allow sufficient time for the system to cool before performing service Components and hoses under pressure could separate suddenly fly out and cause serious injury or death If equipped the auxiliary air tank must be drained before servicing any components in the compressor system VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 1 4 4 1 4 5 1 4 6 VMAC Pressure regulator and or lubricator The compressor can produce air pressures up to approximately 175 PSI 1200 kPa
52. r side of the RAPTAIR MF LJ Connect supply and return fuel lines from the RAPTAIR MF to the fuel tank using supplied hose clamps The supply line is 5 16 and the return line is 3 16 LJ Connect the fuel level sensor connector to the RAPTAIR MF harness VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 3 1 3 Alternate diesel fuel supply Always adhere to all relevant regulations when connecting to the vehicle s fuel system LI tt a larger fuel capacity is desired an alternate supply can be used such as the truck fuel supply when a diesel truck is used E Connect supply and return fuel lines from the diesel drive to an auxiliary tank The supply line is 5 16 and the return line is 3 16 If the auxiliary fuel tank is located below the diesel drive unit a fuel priming pump is recommended in the supply line connecting the RAPTAIR MF fuel supply to the lowest When plumbing into a truck diesel supply avoid Gi point of the truck tank 3 1 4 Exhaust system It is required that the installer supply an adequate exhaust pipe to suit the needs of their application The muffler is supplied with a 1 5 8 ID outlet When installing an exhaust pipe the following steps are to be followed E Connect a suitable 1 5 8 exhaust pipe with an exhaust clamp E Ensure that if the exhaust is pointing upwards there is a suitable flapper cover to prevent water from enter
53. ree 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 1 5 Specifications and Components The Raptair MF Diesel Drive consists of a Kubota D902 24hp 900cc 3 cyl diesel engine belt driving a 45CFM air compressor To increase functionality you can add a 10kW 3 phase generator a 12 24 36 48V battery booster and charger a 300A DC CV CC welder a clutched SAE A Port PTO capable of a maximum 20 hp hydraulic pump or equivalent load or a 5 8 10 GPM 3000psi hydraulic pump 1 5 1 Air compressor The VMAC air end is an oil flooded rotary screw compressor driven by a serpentine belt through a 12V clutch 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 air end clutch is electronically controlled and is automatically disengaged when the engine RPM drops below a set point to ensure that the generator frequency is maintained within the acceptable range PTO loads are not controlled or directly monitored Air pressure in the reservoir tank is maintained when compressor switch is in the on position and is monitored to determine when the compressor needs to engage to top up the tank The system comprises of two stage air oil separation The first separation stage consists of a separation tank with internal baffles
54. ry 5 minutes or greater for additional batteries ie truck batteries VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 35 FACTORY RESET All adjustable parameters will reset to factory settings Pressing ENTER on this screen will display CANCEL Pressing NEXT will show CONFIRM RESET Pressing BACK will display CANCEL again Select the desired option and press the ENTER button VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 36 Fax 1 250 740 3201 7 5 Automatic Shutdown and Restart When an error is detected the controls will automatically shutdown the system show and log the error that caused the issue Also the system will shutdown if no air use is detected and it has idled for a preset amount of time The system can be restarted by using a large amount of air for a short time air rate or dropping of air pressure below an adjustable value The LED beacon module will illuminate when the RAPTAIR MF is in STANDBY mode and is able to restart when air use is detected The buzzer module will enable and alert the operator before the engine starts The system may automatically restart based on Air Usage Rate Restart Pressure engine or compressor temperature or low battery voltage 7 6 Checking Messages and Errors 7 6 1 Errors If an error is present the RAPTAIR MF unit WILL NOT start the compressor until the error is clear
55. sted below are additional messages which may be displayed If a message is present the red WARNING LED will flash on and off These messages appear in both the SYSTEM READY and SYSTEM RUNNING menus WARNING MESSAGE TABLE ae Message Displayed Caus 29 AIR FILTER Air filter is not working or working incorrectly PLUGGED 32 BATTERY VOLTAGE The battery voltage is too low TOO LOW 46 ENGINE RESTART The engine has auto restarted due to the low DUE TO COLD internal temperature 200HR 6MTH SERV This warning will show up 10 hours before the i DUE IN xx HOURS 200 hour service internal The system is due for a service This warning will show after every 200 hours of running the 54 COMPRESSOR SERV compressor 200HR 6MTH Clearing the compressor service reminder is required through the Diagnostic menu 400HR 12MTH SER This warning will show up 10 hours before the DUE IN xx HOURS 400 hour service internal The system is due for a service This warning will show after every 400 hours of running the 55 COMPRESSOR SERV compressor 400HR 12MTH Clearing the compressor service reminder is required through the Diagnostic menu ENGINE SERVICE Engine servicing required See Section 8 6 50 HOURS ENGINE SERVICE 100 hour engine servicing required See 7 100 HRS ENG OIL Section 8 6 ENGINE SERVICE 200 hour engine servicing required See 200 HRS OIL FILT Section 8 6 58 ENGINE RESTART DUE TO LOW
56. switch from the OFF position to the RUN position Once powered a system check is performed During the system check both the WARNING and READY LEDs remain illuminated and SYSTEM CHECK is displayed Gi If any errors are present the WARNING LED will flash on amp off the display will enter the ERRORS menu If no errors are present the system will go to SYSTEM READY menu 7 4 2 System Ready Menu If any messages are present the WARNING LED will flash on amp off and the messages displayed The unit will run as normal when messages are present If no messages are present both the READY and WARNING LEDs will be off The SYSTEM READY menu will change between the following screens SYSTEM READY VMAC PH 250 740 3200 VMAC WWW VMACAIR COM HOUR METER xxxx x Pressing ENTER will initiate the start sequence see Control System Operation Once parameters are in the operating range the SYSTEM RUNNING menu is entered Pressing and holding both the BACK and NEXT buttons for approx 5 seconds will bring up the USER SETUP menu VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 32 7 4 3 System Running Menu If any messages are present the WARNING LED will flash on amp off the READY LED will remain on and the messages will cycle on the display If no messages are present the display will cycle through the SYSTEM RUNNING AIR PRESSURE and TIME TO UNLOAD
57. tenance Schedule The following maintenance schedule should be adhered to to assure good performance and long service life The hours indicated are those displayed on the compressor hour meter Service should be performed at the lesser of the two intervals whichever occurs first Check the Illustrated Parts List for replacement part numbers or call VMAC Every time before start up e Check the level of oil in the air oil separator tank e Check air supply lines are in good working order e Check compressor and hoses for damage or wear e Check after cooler drain collection bottle if equipped Every 200 hours or 6 months as shown on the Display Box More frequently if used in dusty or extreme working conditions e Change compressor oil e Change compressor oil filter e Change compressor air filter Every 400 hours or 12 months as shown on the Display Box e Perform items in the 200 hour 6 month service and e Change coalescing filter VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 43 VMAC certified synthetic oil should be used Failure to iore use this oil may result in damage to the compressor and may void the warranty Contact your nearest VMAC dealer for oil or service kits See our website www vmacair com to find a dealer location 8 2 Checking and Adding Compressor Oil 8 2 1 Check oil level in air oil separator tank The air compressor system holds 4 litres of oil
58. tention to additional instructions or special emphasis on a specific procedure 1 4 1 Safety Precautions Read this information before operating the compressor for the first time Follow the information and procedures in this manual for operation maintenance and repair Observe the following items to reduce the chance of personal injury or equipment damage Follow all safety precautions for mechanical work Moving fan belts and fan blades are an extreme hazard Stay clear of all moving parts when the system is operating Only qualified personnel should perform maintenance and repair on system components and only while the system is properly shut down Proper service and repair are important to the safety of the service technician and the safe reliable operation of the equipment Always use genuine VMAC replacement parts do not use any substitutes The procedures described in this service manual are effective methods of service and repair Some procedures may require the use of tools specially designed for a specific purpose Anyone using a replacement part service procedure or tool must first determine that neither their safety nor the safe operation of the equipment will be compromised by the replacement part service procedure or tool selected This manual contains various warnings cautions and notices that must be observed to reduce the risk of personal injury during service or repair and the possibility that improper service or repair m
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