VIAIR 485HG User manual

Brand: VIAIR

Model: 485HG

Type: User manual

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an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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o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.Threadtapeisnotrecommended.

 Properlysealed,recommendedtorqueis12to15ft.lbs

USER MANUAL

485C-HG 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

 InstructionsincludedintheRemoteInletAirFilterPack.

6. VIAIRaircompressor(s)comeequippedwithheavydutyheatresistantleaderhose(s)with3/8"

 NPTttings.Thisleaderhoseisdesignedtoprolongthelifeofyourairline.

7. Selectproperlocationtomountleaderhosewithhosebracketprovided.Avoidlocationswhere

 leaderhosemaybecometangledwithwiresandotherhoses.

8. 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.

9.Toremovehosefromthehosebracket,simplypressdownonthehoseclampreleasetabto

 releasebracketclamp.(Fig.3)

10.Connectcompressor’spositiveleadwiretooneoftheleadsofyourpressureswitch.

11.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.

12.Alwayslocatefuseascloseaspossibletopowersource.

13.Beforeconnectingtopowersource,re-checktomakesurethatallconnectionsare

 madeproperly.

14.Connectandtestcompressorsystembyrunningthecompressorforashorttimetobuildup

 pressureinyourairtank.

15.Onceairpressurereachespresetcutoutpressureofyourpressureswitch,thecompressor

 willshuto.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) 485C-HG 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)

G.3/8NPTMx1/2"BarbedFitting(1pc)

H.RemoteMountFilterAirLine(1pc)

I. AirLineClips(3pcs)

J.Screws(3pcs)

K.RemoteInletAirFilterwithFilterElement(1pc)

L.3/8”PTFELinedLeaderHose(withseparateJIC/NPTttings&checkvalve)

USER MANUAL

485C-HG COMPRESSOR KIT

ADFG

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o,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o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

485C-HG COMPRESSOR KIT

(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

REDUCER

SPECIFICATIONS

•PartNo48550/485C-HGAirCompressor

MotorVoltage: 12-Volts

Max.CurrentConsumption: 23-Amps

RecommendedFuse: 30-Amps

MotorType: PermanentMagnetic

Horsepower: 1/4

Max.WorkingPressure: 200PSI

Max.DutyCycle(@72ºF&100PSI): 100%

Max.DutyCycle(@72ºF&200PSI): 50%

MinutesOn/O(@72ºF&100PSI): Continuous

Max.AmbientTemperature: 158ºF

Min.AmbientTemperature: -40ºF

Auto.ResetThermalProtection: Yes

IngressProtectionRating: IP67

USER MANUAL

485C-HG COMPRESSOR KIT

USER MANUAL

485C-HG 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 MAX.WORKINGPRESSURE

   (100PSI@72°F)

090SERIES  9%  120PSI

092SERIES  9%  120PSI

095SERIES  9%  120PSI

097SERIES  10%  130PSI

098SERIES  10%  130PSI

100SERIES  15%  130PSI

250IGSERIES  100%  150PSI

275SERIES  25%  150PSI

280SERIES  30%  150PSI

325SERIES  33%  150PSI

330IGSERIES  100%  150PSI

350SERIES  100%  150PSI

380SERIES  100% 200PSI

  *55%

400SERIES  33%  150PSI

420SERIES  33%  150PSI

444SERIES  100% 200PSI

  *50%

450SERIES  100%  150PSI

450IGSERIES  100%  150PSI

460SERIES  100%  150PSI

480SERIES  100% 200PSI

485SERIES  100% 200PSI

  *100%

*Duty Cycle at 200 PSI and 72°F.

ABOUT COMPRESSOR DUTY CYCLE:

Dutycyclereferstotheamountoftimeacompressorcanbe

operatedinagiventimeperiodat100PSI,andastandardambienttemperatureof72°F.Itis

commonlyexpressedinpercentageformat:Compressorontime÷(ontime+otime)=DutyCycle

ONE-HOUR DUTY CYCLE MINUTES ON /

(100PSI@72°F) MINUTES OFF

 9% 5Min.On/55Min.O

 10% 6Min.On/54Min.O

 15% 9Min.On/51Min.O

 20% 12Min.On/48Min.O

 25% 15Min.On/45Min.O

 30% 18Min.On/42Min.O

 33% 20Min.On/40Min.O

 50% 30Min.On/30Min.O

100%1HourRunTime

NOTE:Allcompressors,regardlessofrateddutycycle,requiresucientresttimeinbetweencycles

toallowforpartialorcompleteheatdissipation.Heatdissipationratesmayvarydependingon

ambienttemperaturesandoperatingconditions.

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-opressure

thancompressor’sratedworkingpressure.

485C-HG COMPRESSOR KIT

TROUBLESHOOTING GUIDE:

Tank pressure drops when

compressor(s)shuto

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o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

485C-HG COMPRESSOR KIT

Wiring Diagram:

(Fuse Not Included)

SINGLE “C” MODEL

COMPRESSOR WIRING DIAGRAM

15 Edelman

Irvine, CA 92618

949-585-0011

www.viaircorp.com

Battery

To Keyed

Power Source

12V 40A

Relay

Fuse

Pressure

Switch

Rev.1

AmpDraw

Lengthofwirefrombatteryto

compressor(infeet)

5 10 15 20

5 16 16 16 14

10 16 14 12 10

15 16 12 10 10

20 14 10 10 8

25 14 10 86

30 12 10 86

40 12 8 6 6

50 10 6 6 4

60 10 6 4 4

AMERICAN WIRE GAUGE GUIDE 12-VOLT:

40AmpRelay

USER MANUAL

15EDELMAN•IRVINE,CA92618

TEL:(949)585-0011•FAX:(949)585-0188

www.viaircorp.com

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.

ThisManualisproprietarytoVIAIR®Corporationandnoownershiprightsareherebytransferred.NopartoftheManualshallbe

used,reproduced,translated,converted,adapted,storedinaretrievalsystem,communicatedortransmittedbyanymeans,forany

commercialpurpose,includingwithoutlimitation,sale,resale,license,rentalorlease,withoutthepriorexpresswrittenconsentofVIAIR®.

VIAIR®doesnotmakeanyrepresentations,warrantiesorguarantees,expressorimplied,astotheaccuracyorcompletenessofthe

Manual.UsersmustbeawarethatupdatesandamendmentswillbemadefromtimetotimetotheManual.Itistheuser'sresponsibility

todeterminewhethertherehavebeenanysuchupdatesoramendments.NeitherVIAIR®noranyofitsdirectors,ocers,employees

oragentsshallbeliableincontract,tortorinanyothermannerwhatsoevertoanypersonforanyloss,damage,injury,liability,costor

expenseofanynature,includingwithoutlimitationincidental,special,directorconsequentialdamagesarisingoutoforinconnection

withtheuseoftheManual.

R1-032221

VIAIR 485HG User manual

VIAIR 485HG User manual

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