User Manual - VIAIR Corporation
Contents
1. Safety N 2 Valve Plumbing Diagram Figure 1 Switch TFitting af BSP Adapters For Air Lockers T Fitting Leader Hose 1 0 From Compressor gt Gallon OR Tank Compression Fitting upg Drain T Cock Tank Fittings Install supplied fittings for the air tank in areas where they are most appropriate for your installation using thread sealant or Teflon tape Make sure that the safety valve is installed in the top of the tank and that the drain cock is installed in the lowest position of the tank Be sure that all fittings are accessible since you may have to plumb each fitting as needed to utilize the air tank properly IMPORTANT Tank is rated for 150 PSI maximum working pressure Tank is NOT to be used as a breathing device Bleed pressure from tank before servicing or adding attachments Use only attachments or tools rated for 150 PSI working pressure or less CAUTION DO NOT PRESSURIZE YOUR TANK UNTIL YOU HAVE INSTALLED ALL NECESSARY PORT FITTINGS AND ACCESSORIES Apply sealant to threads of fittings prior to assembly and tighten each part with a wrench Do not over tighten if your port fittings are made from brass since brass threads can be stripped Always release air from tank before servicing WARNING FAILURE TO DRAIN TANK AND REMOVE CONDENSATION WILL CAUSE TANK TO RUST PREMATURELY To remove accumulated condensation in2. Your Vital Air Source ULTRA LIGHT DUTY ONBOARD AIR SYSTEM PART NO 10000 Your Viral Air Source IMPORTANT It is essential that you and any other operator of this product read and understand the contents of this manual before installing and using this product SAVE THIS MANUAL FOR FUTURE REFERENCE USER MANUAL ULTRA LIGHT DUTY ONBOARD AIR SYSTEM Thank you for purchasing this complete self contained onboard air system Contained in one package you ll find everything you ll need to install a high performance onboard air source for your vehicle Please follow these instructions to install your new system OBA Components 1 1 0 Gallon 4 port VIAIR Air Tank 1 98C model VIAIR compressor with leader hose and check valve Check to make sure that you have eight labeled packages in your kit Each package contains the parts needed for specific areas of installation and may contain smaller bags within each package for specific uses PARTS PACKAGES Package 1 Pressure Switch amp Relay A B af a ea 4d a A Pressure Switch 85 PSI on 105 PSI off 1pc B 40 amp relay 1pc Package 2 Fittings aa Oy D i E F G HD MK to om amp m pa D oll 1 4 NPT Drain Cock 1pc 1 4 NPT 145 PSI Safety Valve 1 pc 1 4 NPT Compression Fitting 1pc 1 4 NPT Male Plug 1pc T Fitting 1 4 M x 1 4 F x 1 8 F NPT 2pcs anmMoO Package 3 Air
3. Use this compressor with 12 volt DC systems only This product should never be left unattended during use Guidelines for Selecting Mounting Location The selection of proper mounting location for your air compressor will help ensure a long and trouble free compressor service life Please pay close attention to the following Select a FLAT UPRIGHT amp SECURE LOCATION where the compressor can be mounted To maximize air compressor performance install compressor as CLOSE TO THE BATTERY as possible so that length of positive lead wire is as short as possible This compressor is moisture amp dust resistant but NOT WATERPROOF or DUSTPROOF Do not mount compressor in locations where the unit is likely to come in contact with water or excessive dirt If it is necessary to mount the air compressor further from the battery such as inside your vehicle or in the bed of your pickup VIAIR recommends using wire larger than 12 AWG as a positive lead for remote installation Do not mount compressor near areas where flammable liquids are stored Use thread sealant for proper fitting installation Teflon tape is not recommended Properly sealed recommended torque is 12 to 15 ft Ibs 98C Compressor Wiring See Figure 3 on back of manual 1 2 3 4 Disconnect ground cable from vehicle s battery Temporarily position the air compressor in the location where it will be mounted Route ground wire to the negative post of the batt
4. your pressure switch the compressor will shut off Inspect all air line connections for leaks with soap and water solution If a leak is detected the air line may not be cut squarely or pushed all the way in Tighten connections if needed USER MANUAL ULTRA LIGHT DUTY ONBOARD AIR SYSTEM 98C OPERATING INSTRUCTIONS IMPORTANT The 98C has a maximum working pressure of 130 PSI and is capable of 10 duty cycle Always operate the compressor at or below the MAXIMUM PRESSURE RATING of the compressor Operation exceeding maximum pressure ratings and or duty cycle will result in damage to air compressor 1 To prevent discharge of your vehicle s battery and to provide peak performance we strongly recommend that you keep the vehicle s engine running while using the air compressor 2 ONLY OPERATE THE AIR COMPRESSOR IN WELL VENTILATED AREAS 98C Compressor Maintenance amp Repairs 1 Periodically check all electrical and fitting connections Clean and tighten as needed 2 Periodically check all mounting screws Tighten as needed 3 Replace air filter element periodically Replacement frequency depends on operating frequency and operating environment For frequent use in dusty environment you should replace air filter element more often 4 Regularly clean dust and dirt from compressor 5 Your air compressor is equipped with permanently lubricated maintenance free motor Never lubricate compressor 6 Repairs should be performed by
5. 8 Minutes and rested for 32 Minutes 8 min on 8 min on 32 min off 20 Duty Cycle DUTY CYCLE REFERENCE CHART DUTY CYCLE 100PSI 72 F MINUTES ON OFF 15 6 Min On 34 Min Off 17 7 Min On 30 Min Off 20 8 Min On 32 Min Off 22 9 Min On 30 Min Off 25 10 Min On 30 Min Off 30 13 Min On 30 Min Off 33 15 Min On 30 Min Off 100 Continuous Duty ABOUT RATED WORKING PRESSURE To ensure trouble free service life of your compressor always operate compressor within rated working pressure of the compressor Never use a pressure switch with a higher cut off pressure than compressor s rated working pressure USER MANUAL ULTRA LIGHT DUTY ONBOARD AIR SYSTEM TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION Tank pressure drops when 1 Loose drain cock 1 Tighten drain cock compressor s shut off 2 Check valve leaking 2 Replace check valve or 3 Loose connections compressor s 3 Check all connections with soap and water solution and tighten Compressor runs continuously 1 Excessive air usage 1 Decrease air usage and air flow lower than normal 2 Loose connections 2 Check all connections with 3 Worn piston ring or inlet soap and water solution and valve tighten 4 Clogged air filter element 3 Repair or replace compressor 4 Replace air filter element Compressor runs continuously 1 Bad pressure switch 1 Replace pressure switch causing safety valve if equip
6. Manufacturer or Manufacturer s Authorized Service Agencies only CAUTION Never touch the air compressor or fittings connected to the air compressor with bare hands during or immediately after use Leader hose and fittings will become very HOT during and after use NOTE Always mount the compressor at a point higher than the inlet port of the tank to keep moisture from being able to seep back to the tank PRESSURE SWITCH WITH RELAY INSTALLATION Your VIAIR Ultra Light Duty Onboard Air System comes complete with a pressure switch and a 40 amp relay that will turn on the compressor at 80 PSI and off at 105 PSI The pressure switch has a 1 8 NPT inlet at the bottom that will need to be installed into the 1 8 NPT port of the T fitting supplied in package 2 using thread sealant to allow it to be plumbed directly to your air tank For Relay installation see Relay Wiring Schematic contained in Figure 2 Pressure Switch with Relay Installation Tips 1 Never install your pressure switch in direct line from the inlet port coming from the compressor Tank pressure can be misread by the pressure switch Mount the pressure switch on the tank where it receives air pressure reading from deflected air 2 Never use a pressure switch that is rated beyond your compressor s rated Maximum Working Pressure 130 PSI 3 Replace with P N 90101 if the pressure switch requires replacement Testing Your Onboard Air System Run the system to build pres
7. Out Air Line H H Air Line for Remote Mounting Air Filter Package 4 Electrical Fuse Holder amp 20 ft 12 Gauge Wire 1pc J 20 amp Fuse 1pc K Push on Female Terminals 4pcs L 16 gauge Butt Connectors 2pcs M 16 gauge Ring Terminal 1pc Package 5 N all N T Fitting 1 4 M x 1 4 F x 1 4 F NPT 1pc Package 6 BSP Adapters for Air Lockers o for use with Package 5 El O BSP Adapters 1 4 M to 1 8 F BSP 2pcs Package 7 Compressor Installation P Q RST Qammmm 4 5 Leader Hose Bracket Clip 1 pc Mounting Bolts 4pcs Flat Washers 8pcs Locking Washers 4pcs Nuts 4pcs Hoov Package 8 Air Tank Installation U ty X A Mounting Bolts 2pcs Flat Washers 4pcs Locking Washers 2pcs Nuts 2pcs Rubber Tank Mount Bushings 2pcs lt KMS lt C S amp S USER MANUAL ULTRA LIGHT DUTY ONBOARD AIR SYSTEM 1 0 GALLON AIR TANK amp PLUMBING Your 1 0 gallon air tank comes with four 1 4 NPT port openings To insure safe amp trouble free use of your air tank install the drain cock and a safety pressure relief valve See Figure 1 Q
8. ery or to an appropriate grounding point and cut ground wire to length as needed Mount the 98C air compressor with the two 13 64 5 mm bolts nuts washers and locking washers provided Use of thread locker is recommended This air compressor comes with a heavy duty heat resistant stainless steel braided leader hose This leader hose is designed to prolong the life of your air line Do not remove this leader hose from air compressor IMPORTANT Please note the leader hose that came with your compressor has a built in inline check valve pre installed Do not remove inline check valve from leader hose To mount hose bracket drill holes with 3 16 drill bit and push self anchoring hose bracket pin into hole Route leader hose through hose bracket and secure hose by pressing bracket clamp into locked position To remove hose from the hose bracket simply press down on the hose clamp release tab to release bracket clamp Connect compressor s positive lead wire to one of the leads of your pressure switch 10 Make sure that your compressor setup is properly fused The 98C pulls approximately 12 amps of power Always locate fuse as close as possible to power source 12 Before connecting to power source check to make sure that all connections are made properly 13 Connect and test compressor system by running the compressor for a short time to build up pressure in your air tank 14 Once air pressure reaches preset cut out pressure of
9. essor laa o e ere 10 14 12 10 10 10 15 12 10 10 8 8 20 10 10 8 6 6 25 10 8 6 6 6 30 10 8 6 6 4 40 8 6 6 4 4 50 6 6 4 4 2 60 6 4 4 2 2 Wiring Diagram Figure 3 an g a a H 11o 4 87 30 Fuse Battery To Keyed Power Source Pressure Switch LIMITED WARRANTY VIAIR Corporation warrants this product when properly installed and under normal conditions of use to be free from defects in workmanship and materials for a period of one year from its original date of purchase To receive warranty service or repair please contact VIAIR Corporation Returns should be made within one year of the date of purchase after a Return Goods Authorization RGA number has been assigned by VIAIR Corporation To obtain RGA fax a copy of your receipt to 949 585 0188 For complete warranty details please visit www viaircorp com warranty PLEASE NOTE THIS WARRANTY COVERS PRODUCT DEFECTS ONLY IT DOES NOT COVER INCIDENTAL OR CONSEQUENTIAL DAMAGES AS RESULT OF MISUSE OR ABUSE Your Vital Air Source 15 EDELMAN e IRVINE CA 92618 TEL 949 585 0011 FAX 949 585 0188 www viaircorp com USER MANUAL
10. ped 2 Defective safety valve 2 Replace safety valve to open Excessive moisture in discharge 1 Excessive water in air tank 1 Drain tank tilt tank to drain 2 High humidity Drain tank more frequently 2 Move compressor to area with less humidity or use air line filter Compressor will not run 1 No power or power switch 1 Make sure compressor in OFF position switch is ON 2 Blown fuse 2 Disconnect compressors 3 Motor overheats from power source replace 4 Faulty pressure switch fuse Refer to Specifications section for correct fuse amperage 3 Let compressors cool off for about 30 Minutes to allow thermal overload switch reset 4 Replace pressure switch Thermal 1 Lack of proper ventilation or 1 Move compressor to well overload protector cuts out ambient temperature too high ventilated area or area with repeatedly 2 Compressor valves failed lower ambient temperature 2 Repair or replace compressor Excessive 1 Loose mounting bolts 1 Tighten mounting bolts knocking or rattling 2 Worn bearing on eccentric or 2 Repair or replace motor shaft compressor 3 Cylinder or piston ring is worn 3 Repair or replace compressor CAUTION NEVER DISASSEMBLE COMPRESSOR WHILE COMPRESSOR IS PRESSURIZED USER MANUAL ULTRA LIGHT DUTY ONBOARD AIR SYSTEM WIRE GAUGE GUIDE 12 VOLT Length of wire from battery to compr
11. side the tank bleed pressure from tank until pressure is approximately 5 PSI to 20 PSI using drain cock Drain water from tank by opening the drain cock drain valve and close after draining tank If drain cock valve is plugged release all air pressure from tank remove drain valve and clean then reinstall IMPORTANT Replace air tank 2 to 5 years from date air tank was first used Adhering to air tank draining guidelines will prolong the life of your air tank PLEASE NOTE RUSTED TANKS CAN FAIL CAUSING EXPLOSIONS OR FATAL INJURIES Discard tank immediately if tank is rusted SAFETY VALVE When using a safety pressure relief valve point the safety pressure relief valve away from your body when releasing air Use the pull ring on the safety relief valve to vent pressure from the tank before servicing USER MANUAL ULTRA LIGHT DUTY ONBOARD AIR SYSTEM 98C AIR COMPRESSOR INSTALLATION Your Ultra Light Duty Onboard Air System comes complete with a 98C 10 duty cycle compressor Pl ease follow the installation instructions that follow to enjoy the best use of your onboard air system CAUTION To reduce risk of electrical shock or electrocution Do not disassemble the compressor Do not attempt repairs or modifications Refer to qualified service agencies for all service and repairs Do not use this product in or area where it can fall or be pulled into water or liquids Do not reach for this product if it has fallen into liquid
12. sure in tank When air pressure reaches the pressure switch cut out pressure the compressor will shut off Inspect air line connections for leaks with soap and water sprayed with a spray bottle onto connections If leaks are detected lines may not be installed properly Periodically check your system in this manner should your compressor turn on more often than normal without frequent air use Relay Wiring Schematic Figure 2 Pressure Switch 86 Fused Compressor 87 mmm Lead 12 Volt 30 85 To Ground USER MANUAL ULTRA LIGHT DUTY ONBOARD AIR SYSTEM COMPRESSOR APPLICATION GUIDE To ensure that you get the highest level of satisfaction from your compressor performance refer to information below VIAIR COMPRESSOR REFERENCE CHART COMPRESSOR SERIES DUTY CYCLE WORKING PRESSURE 100 SERIES 15 130 PSI 215 SERIES 17 150 PSI 225 SERIES 20 150 PSI 265 SERIES 22 150 PSI 275 SERIES 25 150 PSI 300 SERIES 30 150 PSI 400 SERIES 33 150 PSI 450 SERIES 100 150 PSI 500 SERIES 33 150 PSI 550 SERIES 100 150 PSI ABOUT COMPRESSOR DUTY CYCLE Compressor Duty Cycle refers to amount of time a compressor can be operated in a given time period at 100 PSI amp at a standard ambient temperature of 72 F Duty Cycle is commonly expressed as Compressor On Time Compressor On Time Off Time As an example a compressor that is rated for 20 duty cycle means that compressor can be operated at 100 PSI 72 F for
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