VIAIR 28021 User manual

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
PART NO. 28021
280C AIR COMPRESSOR KIT

IMPORTANT SAFETY INSTRUCTIONS
CAUTION - To reduce risk of electrical shock or electrocution:
- Donotdisassemble.Donotattemptrepairsormodications.Refertoqualied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otherliquid.
- Donotreachforthisproductifithasfallenintoliquid.
- Usethiscompressorwith12-voltDCsystemsonly.
- Thisproductshouldneverbeleftunattendedduringuse.
WARNING - To prevent injury:
- Neverallowchildrentooperatethiscompressor.Closesupervisionisnecessarywhenthis
compressor is being used near children.
- Thiscompressorwillbecomeveryhotduringandimmediatelyafteruse.Donottouchanypartof
this compressor with bare hands, other than the ON/OFF switch, during and immediately after use.
- Donotusethisproductnearamesorexplosivematerialsorwhereaerosolproductsarebeingused.
- Donotoperatethisproductwhereoxygenisbeingadministered.
- Do not pump anything other than atmospheric air.
- Neverusethisproductwhilesleepyordrowsy.
- Donotuseanytoolsorattachmentswithoutrstdeterminingmaximumairpressureforthat
tool or attachment.
- Neverpointanyairnozzleorairsprayertowardanotherpersonoranypartofthebody.
- ThisaircompressorisequippedwithAutomaticResetThermalProtector,andcanautomatically
 restartafterthethermalprotectorresets.Alwayscutoffpowersourcewhenthermalprotector
 becomesactivated.
- Wear safety glasses or goggles when operating this product.
- Useonlyinwellventilatedareas.
INSTALLATION
Pleasereadandfollowtheinstallationinstructionscarefullytoavoidinjuryordamagetothe
compressororyourvehicle.Eachofouraircompressorsandpartshavebeencarefullyproduced
andpackaged.Beforeyoubegininstallation,pleasefamiliarizeyourselfwithInstallationPartsList
(Fig. 1) of this manual.
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 guidelines:
1. Select a FLAT,UPRIGHTANDSECURE location where the compressor can be mounted.
2.Tomaximizeaircompressorperformance,locatecompressorasCLOSETOTHEBATTERY
 aspossiblesothatlengthofpositiveleadwirerequiredisataminimum.
3.ChoosemountinglocationthatisascoolaspossibleandAWAYFROMHEATSOURCES.
 Thecoolertheambienttemperaturethelesschancethecompressorwilloverheat.
4. This compressor is moisture & splash resistant, but NOTWATERPROOF. Do not mount
compressor in locations where the unit is likely to come in contact with water.
5. Select compressor mounting location where air line can be routed from compressor air inlet
 toremoteinletairlter.MakesureRemoteInletAirFilterislocatedinadrylocation,away
from water splashes.
6.Youwillalsowanttoselectcompressor’smountinglocationwheretheleaderhosebracket
can be mounted to secure the 1.5 ft. leader hose.
7. If it is necessary to mount the air compressor farther away from the battery, such as
 insideyourvehicleorinthebedofyourpickup,useaminimum16AWGpositiveleadwire
for remote installation.
8.Donotmountcompressornearareaswhereammableliquidsarestored.
9.Usethreadsealantforproperttinginstallation.Teontapeisnotrecommended.
 Properlysealed,recommendedtorqueis12to15ft.lbs
USER MANUAL
280C Air Compressor Kit

MOUNTING AND WIRING
1. Disconnectgroundcablefromvehicle’sbattery.
2. Temporarily position the air compressor in the location where it will be mounted.
3. Routegroundwiretothenegativepostofthebatteryortoanappropriategroundingpointand
cut ground wire to length as needed.
4. Mountaircompressorwiththefoursetsof13/64”(5mm)bolts,nuts,washers,andlocking
 washersprovided.(SeeFig.2forMountingInstructions)Useofthreadsealantisrecommended.
5. NOTE:ForRemoteInletAirFilterInstallation,refertoRemoteInletAirFilterInstallation
 InstructionincludedintheRemoteInletAirFilterPackforinstallationofRemoteInletAirFilter.
6. Thisaircompressorcomeswith1.5ft.heavydutyheatresistantleaderhosewith_”ttings.
 Thisleaderhoseisdesignedtoprolongthelifeofyourairline.Donotremovethisleaderhose
from air compressor.
7. IMPORTANT:Pleasenote,theleaderhosethatcomeswithyourcompressormayhaveabuilt-in
 inlinecheckValve.DONOTremoveinlinecheckvalvefromleaderhose.
8. Selectproperlocationtomountleaderhosewithhosebracketprovided.Avoidlocationswhere
leader hose may become tangled with wires and other hoses.
9. Tomounthosebracket,drillhole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.
10.Toremovehosefromthehosebracket,simplypressdownonthehoseclampreleasetabto
release bracket clamp. (Fig. 3)
11.Connectcompressorpositiveleadwiretooneoftheleadsofyourpressureswitch.
12.Makesurethatyourcompressorsetupisproperlyfused.Forappropriatefusesize,referto
 ampdrawofcompressorintheSpecicationssectionofthismanual.
13.Alwayslocatefuseascloseaspossibletopowersource.
14. Before connecting to power source, re-check to make sure that all connections are
properly connected.
15.Connectandtestcompressorsystembyrunningthecompressorforashorttimetobuildup
pressure in your air tank.
16. Once air pressure reaches preset cut out pressure of 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.
(Fig. 1) Standard 280C Air Compressor Kit Installation Parts List:
A.HoseBracket(1pc)
B.MountingBolts(4pcs)
C.FlatWashers(8pcs)
D.LockingWashers(4pcs)
E.Nuts(4pcs)
F.1/4”NPTFx3/8”BarbedFitting(1pc)
G.1/4”NPTMx3/8”BarbedFitting(1pc)
H.3/8”AirLine(1pc)
I.AirLineClips(3pcs)
J. Screws (3pcs)
K.RemoteInletAirFilterwithFilterElement(1pc)
(Fig. 2) Compressor
Mounting Hardware
B.MountingBolt
C.FlatWasher
D.LockingWasher
E.Nut
K. Vibration Isolator
280C Air Compressor Kit
USER MANUAL
ABCDEFG
I
J
K
(Fig. 3) Leader Hose Bracket
L.HoseClamp
M.ClampReleaseTab
N.SelfAnchoringPin
B
C
C
D
E
K
L
M
N
H

OPERATING INSTRUCTIONS
1. IMPORTANT:AlwaysoperatethecompressoratorbelowtheMAXIMUMPRESSURERATINGof
 thecompressor.PleaserefertoApplication&SpecicationsSectionsofthismanualfordetails.
2.AlwaysobservetheMAXIMUMDUTYCYCLEoftheaircompressor.RefertoCompressor
 ApplicationsandSpecicationsSectionsofthismanualfordetails.Operationexceeding
 maximumpressureratingsand/ordutycyclewillresultindamagetotheaircompressor.
3.YouraircompressorisequippedwithanAUTOMATICTHERMALOVERLOADPROTECTOR.
 Thisfeatureisdesignedtoprotecttheaircompressorfromoverheatingandcausingpermanent
 damagetoyouraircompressor.Thethermaloverloadprotectorwillautomaticallycutpowerto
 youraircompressorshouldtheinternaloperatingtemperatureoftheaircompressorriseabove
 safelevelsduringexcessiveuse.
4. Should at any time during use, your air compressor automatically shuts off; do not attempt to
restart the air compressor. Turn off power and allow unit to cool for about 30 minutes. This will
 allowtheThermalOverloadProtectortoresetsoyoucansafelyresumeuseoftheaircompressor.
5.Topreventdischargeofyourvehicle’sbattery,andenhanceperformance,keepthevehicle’s
engine running while using the compressor.
6.Onlyoperatecompressorinwellventilatedareas.
7. The use of a relay is strongly recommended for installation of this compressor, but is not included.
 (40-amprelayvalueorhigher).
MAINTENANCE & REPAIRS
1.Periodicallycheckallelectricalandttingconnections.Cleanandtightenasneeded.
2.Periodicallycheckallmountingscrews.Tightenasneeded.
3.Replaceairlterelementperiodically.Replacementfrequencydependsonoperatingfrequency
 andoperatingenvironment.Forfrequentuseindustyenvironments,werecommendthatyou
 replaceairlterelementatleastonceamonth.
4.Regularlycleandustanddirtfromcompressorcoolingnsandmotorhousing.
5.Youraircompressorisequippedwithpermanentlylubricated,maintenance-freemotor.
 Nevertrytolubricatecompressor.
6.AllrepairsshouldbeperformedbyManufacturerorManufacturer’sAuthorizedService
 Agenciesonly.
CAUTION:
Nevertouchtheaircompressororttingsconnectedtotheaircompressorwithbarehands
duringorimmediatelyafteruse.LeaderhoseandttingsconnectedtoLeaderHosewillbecome
veryhotduringandafteruse.Ifnecessary,wearheatresistantglovestohandlettings,airline,
and leader hose.
USER MANUAL
280C Air Compressor Kit
RELAY WIRING SCHEMATIC
Pressure Switch
86
Fused
12-Volt 30
To Ground
85
87 Compressor
(+) Lead

SPECIFICATIONS
280CAIRCOMPRESSORPARTNUMBERS:
•PartNo.28021/280CAirCompressor(CESpec.)
MotorVoltage: 12volts
Max.CurrentConsumption: 16amps
MotorType: Perm.Magnetic
HorsePower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72ºF&100PSI): 30%
MinutesOn/Off(@72ºF&100PSI): 13On/30Off
Max.RestartPressure: 200PSI
Max.AmbientTemperature: 158ºF
Min.AmbientTemperature: -40ºF
Auto.ResetThermalProtection: Yes
Dimensions: 7.1”Lx3.9”Wx6.3”H
NetWeight: 6.95Lbs.
USER MANUAL
280C Air Compressor Kit

USER MANUAL
280C Air Compressor Kit
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&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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.

TROUBLESHOOTING GUIDE:
Tank pressure drops when
compressor(s) shut off
1.Loosedraincock
2.Checkvalveleaking
3.Looseconnections
1. Tighten drain cock
2.Replacecheckvalveor
compressor
3.Checkallconnectionswith
soap and water solution
and tighten
Compressorruns
continuouslyandairow
lower than normal
1.Excessiveairusage
2.Looseconnections
3. Worn piston ring or inlet
valve.
4.Cloggedairlterelement
1. Decrease air usage
2.Checkallconnectionswith
soap and water solution
and tighten.
3.Replacecompressor
4.Replaceairlterelement
Compressorruns
continuously causing
safetyvalve(ifequipped)
to open
1. Faulty pressure switch
2.Defectivesafetyvalve
1.Replacepressureswitch
2.Replacesafetyvalve
Excessivemoisturein
discharge
1.Excessivewaterinairtank
2.Highhumidity
1. Drain tank, tilt tank to drain.
Draintankmorefrequently
2.Movecompressortoarea
with less humidity, or use
water separator
Compressorwillnotrun 1. No power, or power switch
in OFF position
2. Blown fuse
3.Motoroverheats
4. Faulty pressure switch
(if hooked up to a
pressure switch).
1.Makesurecompressor
switch is ON
2. Disconnect compressor
from power source, replace
fuse.(RefertoSpecications
section for correct
fuse amperage)
3.Letcompressorscoolofffor
about 30 minutes to allow
thermaloverloadswitchtoreset.
4.Replacepressureswitch
Thermaloverload
protector cuts out
repeatedly
1.Lackofproperventilationor
ambient temperature is too high
2.Compressorvalvesfailed
1.Movecompressortowell
ventilatedarea,orareawith
lower ambient temperature
2.Replacecompressor
Excessiveknocking
or rattling
1.Loosemountingbolts
2. Worn bearing on eccentric or
motor shaft
3.Cylinderorpistonringisworn
1. Tighten bolts
2.Replacebearingor
piston assembly
3.Replacepistonorcompressor
CAUTION: NEVER DISASSEMBLE COMPRESSOR WHILE
COMPRESSOR IS PRESSURIZED.
USER MANUAL
280C Air Compressor Kit
PROBLEM: POSSIBLECAUSE(S) CORRECTIVEACTION

280C Air Compressor Kit
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.
WIRE GAUGE GUIDE 12-VOLT:
AmpDraw Lengthofwirefrombatterytocompressor
10 15 20 25 30
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 86644
50 66442
60 64422
15EDELMAN•IRVINE,CA92618
TEL:(949)585-0011•FAX:(949)585-0188
www.viaircorp.com
Wiring Diagram:
(Fuse Not Included)
SINGLE “C” MODEL
COMPRESSOR WIRING DIAGRAM
15 Edelman
Irvine, CA 92618
949-585-0011
www.viaircorp.com
87
86
30
85
+-
Battery
To Keyed
Power Source
12V 40A
Relay
Fuse
Pressure
Switch
Rev.1
USER MANUAL