VMAC A500246 Voltage Sense Interlock for Multifunction Power Systems Installation Guide

VMAC A500246 Voltage Sense Interlock for Multifunction Power Systems

Product Information

Specifications

• Product Name: A500246 Voltage Sense Interlock
• Compatibility: Multifunction Power Systems (MF)
• Manufacturer: VMAC
• Website: www.vmacair.com

Product Usage Instructions

Installation

1. Ensure that the power system is turned off and disconnected from any power source.
2. Locate the appropriate installation area for the A500246 Voltage Sense Interlock.
3. Position the interlock securely in the desired location, ensuring proper alignment for connections.
4. Connect the interlock to the power system using the provided wiring harness.
5. Tighten all connections securely to prevent any loose connections.
6. Verify that all connections are properly made and secure.
7. Turn on the power system and test the functionality of the interlock.

Safety Precautions

It is important to adhere to the following safety precautions during installation, service, or repair:

• Only perform proven service procedures recommended in this manual.
• Prioritize safety and ensure that no compromise is made to personal safety or equipment operational safety.
• Contact VMAC Technical Support for any questions or additional information before starting any work.

Warnings and Notices

This manual contains important warnings, cautions, and notices that must be followed to reduce the risk of personal injury and prevent damage to the equipment. Pay attention to the following symbols:

• Attention Symbol: This symbol indicates instructions concerning personal safety. Read the message carefully and be aware of the possibility of personal injury or death.
• Equipment Damage Symbol: This symbol highlights instructions on a specific procedure that, if not followed, may damage or reduce the useful life of the compressor or other equipment.
• Additional Instructions Symbol: This symbolcalls attention to additional instructions or special emphasis on a specific procedure.

Warranty

VMAC offers a standard warranty for the A500246 Voltage Sense Interlock. For complete warranty information, including requirements for both VMAC Standard Warranty (Limited) and VMAC Lifetime Warranty (Limited), please refer to our current published warranty located at: www.vmacair.com/warranty.

Frequently Asked Questions (FAQ)

Q: What is the compatibility of the A500246 Voltage Sense Interlock?
A: The A500246 Voltage Sense Interlock is compatible with Multifunction Power Systems (MF).

Q: Where can I find technical support for VMAC products?
A: For technical support, please contact VMAC Technical Support at 888-241-2289 or visit our Knowledge Base at kb.vmacair.com.

Q: Are there any safety precautions I should follow during installation?
A: Yes, it is important to prioritize safety during installation. Refer to the safety precautions section in the user manual and contact VMAC Technical Support for any questions or concerns.

Installation Manual for VMAC
Accessory
A500246 Voltage Sense Interlock for
Multifunction Power Systems

www.vmacair.com

VMAC – Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
VMAC Knowledge Base: kb.vmacair.com

Document: 1901201
Changes and Revisions

Revision| Revision Details| Revised by| Checke| d by| | Implemented
---|---|---|---|---|---|---
Eng.| Tech.| Qual.
Mech.| Elec.
A| Initial release| MSP| N/A| CAB| BDJ| LPH| 26 Jul. 2022
B| ECN: 22-157 Add install instructions| MSP| N/A| CAB| BDJ| N’A| 30 Aug. 2022

Additional Application Information
For use with Multifunction Power Systems (MF).

Registered Trademarks
All trademarks mentioned in this manual are the property of their respective owners. VMAC’s use of manufacturers’ trademarks in this manual is for identification of the products only and does not imply any affiliation to, or endorsement of said companies.

Important Information

The information in this manual is intended for certified VMAC installers who have been trained in installation and service procedures and/or for anyone with mechanical trade certification who has the tools and equipment to properly and safely perform the installation or service. Do not attempt installation or service without the appropriate mechanical training, knowledge and experience.
Follow all safety precautions. Any fabrication for correct fit in modified vehicles must follow industry standard “best practices”.

Notice
Copyright © 2022 VMAC Global Technology Inc. All Rights Reserved. These materials are provided by VMAC for informational purposes only, without representation or warranty of any kind, and VMAC shall not be liable for errors or omissions with respect to the materials. The only warranties for VMAC products and services are those set forth in the express warranty statements accompanying such products and services, if any, and nothing herein shall be construed as constituting an additional warranty. Printing or copying of any page in this document in whole or in part is only permitted for personal use. All other use, copying or reproduction in both print and electronic form of any part of this document without the written consent of VMAC is prohibited. The information contained herein may be changed without prior notice.

Printed in Canada

Safety

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, service techniques and running OEM changes. If a discrepancy is found in this manual, contact VMAC Technical Support prior to initiating or proceeding with installation, service or repair. Current information may clarify the issue. Anyone with knowledge of such discrepancies, who proceeds to perform 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 ensure that their safety and that of others is not being compromised, and that there will be no adverse effects on the operational safety or performance of the equipment.
VMAC will not be held responsible for any liability, consequential damages, injuries, loss or damage to individuals or to equipment as a result of the failure of anyone to properly adhere to the procedures set out in this manual or standard safety practices.
Safety should be the first consideration when performing any service operations. If there are any questions concerning the procedures in this manual, or more information is required, please contact VMAC Technical Support prior to beginning work.

Safety Messages
This manual contains various warnings, cautions and notices that must be observed to reduce the risk of personal injury during installation, service or repair and the possibility that improper installation, service or repair may damage the equipment or render it unsafe.

Warranty

VMAC Standard Warranty (Limited)
For complete warranty information, including both VMAC Standard Warranty (Limited) and VMAC Lifetime Warranty (Limited) requirements, please refer to our current published warranty located at: www.vmacair.com/warranty

If you do not have access to a computer, please contact us and we will be happy to send you our warranty.
VMAC’s warranty is subject to change without notice.

VMAC Lifetime Warranty (Limited)

A VMAC Lifetime Limited Warranty is offered on the base air compressor only and only on UNDERHOOD, Hydraulic Driven, Transmission Mounted, Gas and Diesel Engine Driven Air Compressors, Multifunction Power Systems, and other products as defined by VMAC, provided that (i) the purchaser fully completes and submits a warranty registration form within 3 months of purchase, or 200 hours of operation, whichever occurs first; (ii) services are completed in accordance with the Owner’s Manual; (iii) proof of purchase of applicable service kits are made available to VMAC upon request.
The VMAC Lifetime Warranty is applicable to new products shipped on or after 1 October, 2015.

Warranty Registration
Warranty registration for VMAC systems can be completed online or by filling in the form at the back of each system installation manual. Warranty registration must be completed and sent to VMAC at the time the system is put into service for any subsequent warranty claim to be considered valid.
There are 4 ways the warranty can be registered with VMAC:

www.vmacair.com/warranty
[email protected]
877-740-3202

VMAC – Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3

VMAC Warranty Claim Process

VMAC warranty work must be pre-authorized by VMAC. Claims are processed via our dealer network. If you are not a VMAC dealer, please select one to work with via our Dealer Locator: https://www.vmacair.com/dealer-locator/

1. Communicate with VMAC Technical Support at 1-888-241-2289 or [email protected] to help diagnose/troubleshoot the problem prior to repair. VMAC technical support will require the VMAC System ID, and the hours on the compressor.
2. VMAC will provide direction for repair or replacement of the failed components.
3. If requested, failed parts must be returned to VMAC for evaluation.
4. Dealers may login to the VMAC website to view the “VMAC Labour Time Guide” (under “Agreements”) to see the allowable warranty labour times.
5. Warranty invoices must include the Service Ticket number, VMAC System ID#, hours on the compressor, and a detailed description of the work performed.
6. VMAC Warranty does not cover consequential damages, overtime charges, mileage, travel time, towing/recovery, cleaning or shop supplies.
7. Dealers submit warranty claims on behalf of the Vehicle Owner/End User affected by the defective part(s). The dealer ensures that all warranty credits are refunded back to the Vehicle Owner/End User who made the initial warranty claim.

In order to qualify for Lifetime Warranty (Limited), the completed warranty registration form must be received by VMAC within 3 months of the buyer receiving the Product(s), or 200 hours of operation, whichever occurs first.
If the completed warranty registration form has not been received by VMAC within 3 months of the buyer receiving the Product(s), or 200 hours of operation, the “Standard” warranty period will be deemed to commence 30 days from the date of shipment from VMAC.

Failure to follow the warranty claim process may result in denial of the warranty claim.

VMAC Product Warranty Policies & Warranty Registration can be found on the VMAC website (see previous page for URL).

General Information

Optional Equipment Compatibility
While VMAC strives to design systems compatible with optional OEM equipment (such as running boards), it is impractical to develop systems that accommodate every OEM and aftermarket option or add-on. Whenever possible, VMAC endeavors to advise of compatibility issues in the “Additional Application Information” section of the manual. Even when specific optional equipment is determined by VMAC to be incompatible, it does not preclude the vehicle upfitter or end user from modifying the optional equipment to make it compatible with the installed VMAC system. VMAC does not warrant or accept responsibility or liability for the fitment, function, or safety of any products modified in any way not expressly outlined in the installation manual.

Before Starting
Read this manual prior to beginning the installation to ensure familiarity with the components and how they will fit on the vehicle. Identify any variations from the application list such as vehicle model, engines, or optional equipment (e.g., dual alternator, active steering assist, etc.).
Open the package, unpack the components and identify them using the Illustrated Parts List (IPL) included in the Fastener Pack.

Hose Information
Depending on other installed equipment, it might be necessary to move the air/oil separation tank from its intended location. The hoses used in VMAC compressor systems have a specific inner liner that is compatible with VMAC compressor oil. Use of hoses other than those supplied or recommended by VMAC may cause compressor damage and may void your warranty. Please contact VMAC for replacement hoses and further information.

Ordering Parts
To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. Locate the nearest dealer online at www.vmacair.com/dealer-locator or call 1-877-912-6605.

Special Tools Required

None.
All fasteners must be torqued to specifications. Use manufacturers’ torque values for OEM fasteners.

The torque values supplied in Table 1 are intended for VMAC supplied components, or for use as a guide in the absence of a torque value provided by an OEM.

Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts) unless otherwise stated.

Torque values are with Loctite applied unless otherwise specified.

Table 1 — Torque Table

Standard Grade 8 National Coarse Thread

Size (in)| 1/4| 5/16| 3/8| 7/16| 1/2| 9/16| 5/8| 3/4
Foot pounds (ft•lb)| 9| 18| 35| 55| 80| 110| 170| 280
Newton meter (N•m)| 12| 24| 47| 74| 108| 149| 230| 379
Standard Grade 8 National Fine Thread

Size (in)| 3/8| 7/16| 1/2| 5/8| 3/4
Foot pounds (ft•lb)| 40| 60| 90| 180| 320
Newton meter (N•m)| 54| 81| 122| 244| 434
Metric Class 10.9

Size (mm)| M6| M8| M10| M12| M14| M16
Foot pounds (ft•lb)| 4.5| 19| 41| 69| 104| 174
Newton meter (N•m)| 6| 25| 55| 93| 141| 236

Voltage Sense Interlock

Installation and Operation

Installation
The Welder Control Box includes an 8 ft harness with (×4) plugs.

• Mount the Welder Control Box in a convenient location that is protected from the weather.
• Locate harness bundle with the connectors near the main air discharge from the MF.
• Plug one side of the “T” harness with the (×2) flat 5-pin connectors into the matching connector at the MF unit and the other side into the connector running to the rocker switches on the Display Panel.
• Connect the (×2) Welder Control Box connectors into the matching connectors in the main harness bundle.

Operation
This generator has been equipped with a voltage monitoring circuit to ensure that charging/welding voltages are operating correctly for the intended process.
The order of operations for connecting batteries or moving the system into weld mode must be followed exactly or the system disables itself and the generator must be reset.

Charging / Boosting Procedure

Working near lead/acid batteries is dangerous. Batteries contain sulphuric acid and may generate hydrogen gas during regular operation. Lead/acid batteries may explode if exposed to a spark.
Never attempt to jump start a frozen battery.
Never overcharge a battery.
Always follow safety precautions when jump starting or charging a battery, including the use of appropriate Personal Protective Equipment.

• Prior to charging or boosting, ensure the MF is not running, and the booster cables are disconnected from the battery to be charged.
• Set the “WELD” selection knob to 0 V.
• Start the MF.
• Engage the generator via the toggle switch located at the display box.
• The voltmeter should read approximately 0 V.

If “ErX” is displayed*:

• *Ensure the booster cables are not shorted together, or connected to the batteries to be charged, and the “WELD” selection knob is set to “0”.
• *Press and hold the “RESET” button for 2 seconds.
• Connect the positive clamp to the positive terminal on the battery.
• Connect the negative clamp to a good ground (ideally on the engine).

Observe the battery voltage using the Voltmeter*.

• *12 V systems should indicate battery voltage above 2.0 V.
• *24 V systems should indicate battery voltage above 14.0 V.

If the battery voltage is below the above values, the generator will not recognize the target and will not unlock the appropriate charge modes.

If the battery voltage is too low,*.

• Disconnect the battery from all loads. This may allow the battery voltage to rise high enough to be recognized by the system.
• If the battery does not recover adequate voltage after being disconnected, battery detection can be temporarily over-ridden by pressing and holding both the “RESET” and “BATTERY INTERLOCK” button for 5 seconds.

Once switched into charge mode, the system will re-enable battery detection after 60 seconds.

• With the battery connected, rotate the “WELD” selection knob to the appropriate charge mode*.
• The voltage should rise as the system begins charging.
• Set the “WELDING CURRENT” knob to 100%.
• Let the batteries charge for at least 5 minutes.
• Try starting the vehicle.

While the MF can provide up to 300 A of start assist, vehicle starters can draw upwards of 1,200 A while starting.
If the vehicle fails to start, allow it to charge for longer before attempting to start again.

• Return the “WELD” selection knob to 0 V.

Weld Procedure

• Prior to starting the MF, set the “WELD” selection knob to 0 V.
• Start the MF.
• Engage the generator via the toggle switch located at the display box.
• The voltmeter should read approximately 0 V.

If “ErX” is displayed*:

• *Ensure the weld cables are not shorted together, or connected to the batteries to be charged, and the “WELD” selection knob is set to “0”.
• *Press and hold the “RESET” button for 2 seconds.
• Press and hold the “WELD INTERLOCK” button while rotating the “WELD” selection knob to “WELD”.
• Adjust the “WELDING CURRENT” and “ARC FORCE” as required.
• Once welding is complete, set the “WELD” selection knob to 0 V (The “WELD INTERLOCK” button is not required when returning the “WELD” selection knob to 0 V).

Getting Started Guide

Read the warnings listed on page 9 prior to proceeding.

Troubleshooting

If the voltmeter detects a voltage or state that is not permitted, an error will be displayed on the screen.
If an error is displayed:

• Disconnect the target battery and ensure the booster, or weld cables are not shorted together.
• Return the “WELD” selection knob to 0 V.
• Press and hold the “RESET” button for 2 seconds.
• If the error persists, contact VMAC for support.

Er 0

|

Voltage detected above bounds for selected mode.

| MF output voltage is greater than 20 V (12 V boost mode) or 38 V (24 V boost mode).

•  Reset system and re-attempt boost procedure

•  Contact Technical Support

Er 1

|

Voltage detected under bounds for selected mode.

| Target battery is less than 2 V (12 V boost mode) or 14 V (24 V boost mode).

•  Check connection between MF boost cables and target battery.

•  Charge target battery in override mode to allow battery voltage to rise high enough to be recognized by system.

•  Target battery float voltage is too low to be charged.

Er 2

|

Reverse polarity detected.

| Reverse polarity of connection from MF boost cables to target battery.

•  Check connection between MF boost cables and target battery. Verify correct polarity

(+ to + and – to -).

Er 3

|

Incorrect mode detected.

| Incorrect charge mode selected for detected target battery voltage.

•  WELD INTERLOCK button not pressed while entering WELD mode.

•  System not started in 0 V mode, Refer to page 9.

•  Select correct charge mode according to target battery voltage.

Er 4

|

Multifunction battery low.

| MF battery voltage less than 9.0 V.

•  Inspect cables/connections to MF battery.

•  Service/replace MF alternator.

Er 5| Multifunction battery high.| MF battery voltage greater than 16.0 V.

•  Service/replace MF alternator.

Er 6

|

MCU Reset.

| •  Inspect wiring harness for damage, short/open circuit.

•  Contact VMAC Technical Support.

888-241-2289
[email protected]
877-740-3202
[email protected]
www.vmacair.com
kb.vmacair.com

1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada

References

• VMAC Knowledge Base
• Find A Dealer - VMAC
• Find A Dealer - VMAC

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