VIAIR 380C User manual

380C AIR COMPRESSOR KIT
PART NO. 38033
480C AIR COMPRESSOR KIT
PART NO. 48043
200 PSI COMPRESSORS - MODEL NUMBERS
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
380C
480C

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liquids.
- 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, 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an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
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WATERPROOF. Do not mount
compressor in locations where the unit is likely to come in contact with water.
5.Forremoteltermounting,selectcompressor’s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 the elements.
6.Youwillalsowanttoselectcompressormountinglocationwheretheleaderhosebracketcanbe
mounted to secure the leader hose.
7. If it is necessary to mount the air compressor further away from the battery, such as inside
 yourvehicleorinthebedofyourpickup,useaminimum8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
380C - 480C 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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.
6. VIAIRaircompressor(s)comeequippedwithheavydutyheatresistantleaderhose(s)with
 either1/4”or3/8”NPT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has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’s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
made properly.
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.Repairconnections
as needed.
(Fig. 1) 380C / 480C Compressor Installation Parts List:
A. HoseBracket(1pc)
B. MountingBolts(4pcs)
C.FlatWashers(8pcs)
D.LockingWashers(4pcs)
E.Nuts(4pcs)
F.3/8NPTFx1/2”BarbedFitting(1pc)(480C)
1/4NPTFx1/2”BarbedFitting(1pc)(380C)
G.3/8NPTMx1/2”BarbedFitting(1pc)(480C)
1/4NPTMx1/2”BarbedFitting(1pc)(380C)
H.RemoteMountFilterAirLine(1pc)(380C)
I. AirLineClips(3pcs)
J.Screws(3pcs)
K.RemoteInletAirFilterwithFilterElement(1pc)
USER MANUAL
380C - 480C COMPRESSOR KIT
C E
B
ADFG
I
J
K
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powertotheaircompressorOFF.Theautomaticthermaloverload
protector will automatically reset when internal temperature of the air compressor drops below
 safelevel.Afterallowingaircompressortocooloffforabout30minutes,youcansafelyresume
use of the air compressor.
5.Topreventdischargeofyourvehicle’sbattery,werecommendthatyoukeepthevehicle’sengine
running while using the air compressor.
6.ONLYOPERATETHEAIRCOMPRESSORINWELL-VENTILATEDAREAS.
7.Compressorperformanceisenhancedwhenoperatingcompressorwithvehicle’senginerunning.
MAINTENANCE & REPAIRS
1.Periodicallycheckallelectrical,ttings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,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apermanentlylubricated,maintenance-freemotor.
 Nevertrytolubricatethe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.The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
380C - 480C COMPRESSOR KIT
RELAY WIRING SCHEMATIC
Pressure Switch
86
Fused
12-Volt 30
To Ground
85
87 Compressor
(+) Lead
B
C
C
D
E
F
(Fig. 2) Compressor
Mounting Hardware
B.MountingBolt
C.FlatWasher
D.LockingWasher
E. Nut
F.VibrationIsolator
(Fig. 3) Leader Hose Bracket
L.HoseClamp
M.ClampReleaseTab
N.Self-AnchoringPin L
M
N

SPECIFICATIONS
•PartNo38033/380CAirCompressor(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 22Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 200PSI
Max.DutyCycle(@72ºF&100/200PSI): 100%/55%
MinutesOn/Off(@72ºF&100PSI): Continuous
Max.AmbientTemperature: 158ºF
Min.AmbientTemperature: -40ºF
Auto.ResetThermalProtection: Yes
Dimensions: 9”Lx4”Wx6.75”H
NetWeight: 8.75Lbs.
•PartNo.48043/480CAirCompressor(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 20Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 200PSI
Max.DutyCycle(@72ºF&100/200PSI): 100%/50%
MinutesOn/Off(@72ºF&100PSI): Continuous
Max.AmbientTemperature: 158ºF
Min.AmbientTemperature: -58ºF
Auto.ResetThermalProtection: Yes
Dimensions: 11.5”Lx4.3”Wx6.5”H
NetWeight: 11.05Lbs.
USER MANUAL
380C - 480C COMPRESSOR KIT

COMPRESSOR APPLICATION GUIDE
Toensurethatyougetthehighestlevelofsatisfactionfromyourcompressor’sperformance,referto
information below:
VIAIR COMPRESSOR REFERENCE CHART
COMPRESSORSERIES DUTYCYCLE WORKINGPRESSURE
100SERIES  15%  130PSI
200SERIES  20%  150PSI
275SERIES  25%  150PSI
280SERIES  30%  150PSI
325SERIES  33%  150PSI
350SERIES  100%  150PSI
380SERIES  100%  200PSI
400SERIES  33%  150PSI
450SERIES  100%  150PSI
480SERIES  100%  200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andatastandardambienttemperatureof72°F.DutyCycleiscommonly
expressedinpercentileas:
CompressorOnTime/(CompressorOnTime+OffTime)%
Asanexample,acompressorthatisratedfor25%dutycyclemeansthatcompressor
can be operated at:
100PSI@72°Ffor10MinutesONand30MinutesOFF
10Min.On/(10Min.On+30Min.Off)=10Min./40Min.
=25%DutyCycle
DUTY CYCLE REFERENCE CHART
DUTYCYCLE@100PSI/720F MINUTESON/OFF
15%    6Min.On/34Min.Off
20%    8Min.On/32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.
WIRE GAUGE GUIDE 12-VOLT:
USER MANUAL
380C - 480C COMPRESSOR KIT
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

380C - 480C COMPRESSOR KIT
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
airlinelter
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compressor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
PROBLEM: POSSIBLECAUSE(S) CORRECTIVEACTION

USER MANUAL
380C - 480C COMPRESSOR KIT
VIAIR CORPORATION
MANUFACTURER DEFECT WARRANTY:
VIAIRCorporationwarrantsthisproduct,whenproperlyinstalled
and/or under normal conditions of use, to be free from defects
in workmanship and materials for a period of one year from
provideddateofpurchase.Toreceiveawarrantyinspection,
pleasecontactVIAIRCorporation.Avalid,datedsalesreceipt
mustaccompanyyourrequest.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anRGAnumber,faxacopyofyour
receiptto(949)585-0188.
Forcompletewarrantydetails,visit:www.viaircorp.com/warranty
IMPORTANT:
THISWARRANTYCOVERSPRODUCTDEFECTSONLY;ITDOES
NOTCOVERINCIDENTALORCONSEQUENTIALDAMAGESAS
RESULTOFMISUSEORABUSE.
VIAIRCORPORATION
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