VIXEN HORNS VO4830AC 3 Gallon Aluminum Air Tank with 200 PSI Air Compressor Onboard Air System Installation Guide

VIXEN HORNS VO4830AC 3 Gallon Aluminum Air Tank with 200 PSI Air

Compressor Onboard Air System

BEFORE BEGINNING YOUR INSTALLATION

Read through the instruction guide before getting started with the installation. Professional installation is recommended for this product.

CONTENTS

• 200 PSI Air Compressor (Silver)
• 3 Gallon Aluminum Air Tank (Silver)
• 240 PSI Pressure Gauge
• 170-200 PSI Pressure Switch
• 250 PSI Safety Valve
• 1/4″ NPT Wing Style Drain Valve
• 1/4″ NPT Compression Fitting for 1/4″ OD Air Line
• 1/4″ OD Nylon Plastic Hose (6 Feet)
• 3/8″ OD Nylon Plastic Hose (10 Feet)
• Intake Air Filter with Remote Installation Kit
• 40A In-line Fuse with Waterproof Holder
• Liquid Thread Sealant (10ml)
• Mounting Hardware

The specific voltage requirement for this onboard air system is 12 volt DC, therefore installation must be done to a DC power source of 12 volts.

SAFETY INSTRUCTIONS

• Do not attempt to disassemble, repair or customize this product.
• Avoid setting up any parts of this product where there is a risk of falling off or risk of coming in contact with water.
• Avoid reaching out to touch or pick up any fallen or water-submerged parts.
• Never leave this product unattended during use.
• Intended for use by adults only.
• During and immediately after use, avoid touching any part of the compressor with bare hands as it is very hot during such periods.
• Avoid use of products near flames, explosive materials, aerosol products, or oxygen devices.
• Be sure to pump nothing other than atmospheric air.
• It is important to determine the maximum air pressure for any tool or attachment before using it.
• Air sprayer or nozzle should always be pointed away from any part of the body.
• The compressor has Thermal Overload Protection, if this protection activates, cut off the source of power and let the unit cool down for about 30 minutes. This will reset the system and allow you to safely resume use of the air compressor.
• Make sure your battery ground is detached and the tank has no pressure before you begin the installation.
• Employ equipment for eye protection during drilling operations.

PLANNING YOUR INSTALLATION

• Before beginning the installation, determine each component’s spot.
• Confirm you have the proper length of airline and wire.
• The power wire to the compressor should be kept short.
• To power up the air compressor, make sure you use a 12-gauge wire or thicker.

COMPRESSOR

MOUNTING

• Determine a dry place to mount your compressor. If you have chosen to install in the engine compartment, you should mount it as close to the front as possible to allow for maximum flow of air around the compressor and also to avoid heat from the exhaust. IMPORTANT: Never attach the compressor to any plastic or other flexible material.
• For optimal results, the compressor should be placed as close to the battery as possible. This will reduce the amount of wiring needed.
• Avoid placing compressors near flammable liquids.
• Make sure your placement allows for the airline to be routed from the air inlet of the compressor to the remote inlet air filter. The Remote Inlet Air Filter should be placed somewhere dry and not prone to getting wet.
• Mark the spots for the holes with the mounting base as a guide and then drill. Make sure the compressor is secured.

BRAIDED HOSE INSTALLATION

• Connect the stainless steel braided hose of the compressor to the tank inlet port.
• IMPORTANT: The tank inlet port must be 3/8″ N.P.T. (National Pipe Thread).

REMOTE AIR FILTER INSTALLATION KIT
Only use if you need to move the compressor’s air intake to an area other than where the compressor was installed.

• A. Braided Hose Bracket with Self-Anchoring Pin (1 pc)

• B. 3/8″ NPT Female x 3/8″ Barbed Tube Fitting (1 pc)

• C. 3/8″ NPT Male x 3/8″ Barbed Tube Fitting (1 pc)

• D. 3/8″ OD Air Line (1 pc)

• E. Air Line Clips (3 pcs)

• F. Air Line Clips Screws (3 pcs)

• G. Remote Inlet Air Filter with Filter Element (1 pc)

• H. Remote Filter Holder with Self-Anchoring Pin (1 pc)

• I. Filter Elements (2 pcs)

• J. Remote Filter Holder Screws (2 pcs)

  • 10 feet of the airline is enclosed for attaching the remote air filter.

  • Find an installation location for the remote air filter, ensuring that the location is dry and far from a heat source.

  • Use a hose cutter, a razor blade, or a sharp knife when trimming the airline. A clean, square cut is optimal.
    IMPORTANT: Do not use wire cutters or scissors to cut the air line, these tools may flatten or crimp the air line causing it to leak.

  • Place the airline onto the barbed fittings or at least, until it covers two ridges and starts routing the airline.

AIR TANK

MOUNTING

• Find a convenient mounting location in your vehicle for the air tank. Ensure ports are reachable before drilling any holes.
• Mark the location of holes using the mounting brackets of the air tank as a template, and then drill to size.
• Using the mounting hardware provided, secure the air tank. IMPORTANT: Do not mount on a flexible material.
• The installation location of your tank’s accessories depends on your air system’s configuration.

PORT LOCATIONS AND THREAD SIZE (NPT)

PRESSURE SWITCH RATING

• The included pressure switch has a rating of 170 PSI ON, and 200 PSI OFF. When the air pressure in the air tank is below the preset ON pressure (170 PSI), the compressor will automatically turn on and will start pumping air into the tank. When the pressure reaches the cut-OFF pressure (200 PSI), the compressor will be automatically shut off.

AIR PRESSURE GAUGE

• In one of the Air Tank’s 1/4″ NPT ports, using the thread sealant provided, install the air pressure gauge.
• The side or top of the tank is the best location to use to prevent condensation from entering the gauge.
• Dropping or disturbing the product can affect the product’s accuracy.
• For best results, the air gauge should be installed perpendicular to the ground, with the zero facing the bottom.
• To tighten the pressure gauge into the air tank, place a wrench over the square wrench flats to turn the gauge. This is the proper way to avoid air leakage or damage.

SAFETY VALVE

• Your system comes with a safety valve designed specifically to release pressure from the air tank automatically if 250 PSI is exceeded. This will help prevent an accident in case of pressure switch failure.

DRAIN VALVE

• This valve helps you drain the water that can collect in the air tank after long periods of use.

REMOVING CONDENSATION:

• To remove any condensation that has accumulated inside the tank, bleed the tank’s pressure until it ranges from approximately 5 PSI to 20 PSI.
• Remove the drain valve found at the tank’s bottom to drain the water from the tank. After draining the accumulated condensation, reinstall the drain valve.
• IMPORTANT: Draining the system regularly will extend the life of the air tank.

THREAD SEALANT

• Your system includes Premium Thread Sealant, make sure to use it on all thread connections to ensure proper air sealing.

ELECTRICAL CONNECTION

• The red wire of the compressor should be connected to (+) 12-volt power source.
• IMPORTANT: To prevent the compressor from overrunning and possible damage due to an air leak, connect the compressor’s red wire to a power source in the vehicle that only gets power when the vehicle’s ignition is on. Recommended connection points are windshield wiper motor, blower motor or an accessory terminal on the fuse panel. Make sure to use wire that is as heavy as the wire of the compressor.
• Attach the black wire to any of the Pressure Switch’s connections located on the air tank.
• The remaining Pressure Switch connection should be attached to the ground. Secure the end under any metal body or to the negative side of the vehicle’s battery. The ground connection should be rust and paint-free. Your compressor is now set for use and will turn on automatically when air pressure in the air tank falls. When air pressure reaches maximum PSI, it will turn off. If the compressor fails to reach the maximum air pressure of the tank, which is the Pressure Switch’s cut-off pressure, check all air connections for leaks. While the compressor is pumping, use soapy water or any bubble solution to perform this check. In case the leak remains after tightening, re-apply thread sealant.
• CAUTION: Never touch fittings, braided hose or the air compressor with bare hands either during or shortly after use.

ON-BOARD SYSTEM/TRAIN HORN WIRING DIAGRAM (FOR REFERENCE ONLY)

MAINTENANCE

• Make sure that electrical and fitting connections are regularly inspected, cleaned, and tightened when needed.
• Make sure mounting screws are regularly tightened if needed.
• Drain weekly, to avoid excessive buildup of condensation.
• The compressor features a washable air filter which should be cleaned using any mild form of liquid soap every two months if it gets dusty. Just remove the front cover of the filter’s housing to reach it. Replacement time frames depend on the operating environment and how often it is used.
• Clean dirt and dust from the heat spreader and motor housing of the compressor.
• The motor of the air compressor has a maintenance-free lasting lubricant. DO NOT LUBRICATE.

SOLUTIONS TO COMMON ISSUES

Issue: Compressor inoperable.

• Solution 1: Check all switches to make sure they are ON.
• Solution 2: Check the fuse; if blown, disconnect the compressor from power and replace the fuse.
• Solution 3: Allow compressor to cool off for 30-60 minutes.
• Solution 4: Check the pressure switch, and replace if damaged or inoperable.

Issue: Excessive moisture in the safety valve.

• Solution 1: Depressurize and drain the tank.
• Solution 2: Relocate the compressor to a drier location.

Issue: Continual cutting-off of Thermal overload protection.

• Solution 1: Relocate the compressor to a drier, cooler location.
• Solution 2: Replace the compressor.

Issue: Excessive vibration or noise

• Solution 1: Tighten system components.
• Solution 2: Replace the compressor.

Issue: Loss of pressure of tank when the compressor is shut off.

• Solution 1: Tighten the drain cock.
• Solution 2: Examine air and check valves and replace if damaged or leaking.
• Solution 3: Use soap and water solution on air connections, and tighten connections or repair leaks where needed.
• Solution 4: Replace the safety valve, it may be defective.

Issue: The compressor runs continuously and has low airflow.

• Solution 1: Decrease the frequency of use.
• Solution 2: Use soap and water solution on air connections, and tighten connections or repair leaks where needed.
• Solution 3: Clean or replace the air filter element if it is clogged.
• Solution 4: Replace compressor.

Issue: Safety valve trips repeatedly due to overuse

• Solution 1: Replace the pressure switch.
• Solution 2 : Replace the safety valve.

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