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Air Compressor Woes

Discussion in 'The Tool Shed' started by 62CheepJeep, Feb 17, 2019.

  1. Jun 28, 2019
    EMA

    EMA Member

    Lake Elsinore,...
    Joined:
    Feb 20, 2019
    Messages:
    82
    I don't know what make mine is... it is a " two-stage piston " old....and I mean OLD as in over 35 year old.
    That said... It sits on a 150 gallon tank ( original tank and compressor setup )...coupled in series with another 250 gallon upright tank.
    It was old when I purchased " used ".
    This is all connected with 2" piping.
    Adding " auto-drain valves at each bottom of each tank, ( VERY important as it reduces water condensation in the tanks that cause rust ) They can be manual, but daily drain them then.
    Then from the last tank I plumbed in 3/4" line into and around the shop.
    Takes about 30 minutes for it to come from say a low at 30 psi to the 135psi I have the pressure switch set to.
    I have run this system in 100+ degree weather...24hr/day cycles for the last 25+ years since I built it.
    On a system there are TWO issues I see that can KILL a compressor....
    1 ) Weekly...CHECK THE OIL....CHECK THE OIL...Number reason of compressor failures. ( Make sure...very important....make sure CORRECT oil is used..! )
    2 ) Install a " Strainer / Filter " BEFORE your supply line to your shop or tool...! ( If not...rust debris will get in your line disconnects and reduce if not stop air flow )( NOT TO BE CONFUSED WITH A " DRYER " )

    As for adding more capacity... It will take longer for the system to get up to max. and either shut off or "idle"...BUT...you will have longer "cycle" on & off times during use.
    I also do not use a "Dryer" as I don't use painting tools...just air tools of every kind...
    What is important... ) keep a small bottle of 30wt. oil around.... Before I use a tool... I add a couple drops in the air pipe before plugging the tool into the air hose.
    I have air tools that are again over 30+ years working fine..! My machines in the shop that use air....same..!
    Does not increase CFM...just reduces the "cycle times" during use.
    Another interesting point.... You will find less condensation in larger tanks during the rains than on a sunny day...watch your condensate drains..!
    Hope this helps,

    George
     
  2. Jun 28, 2019
    TexasBlues

    TexasBlues JEEP-Hockey-Holic

    Marietta, GA
    Joined:
    Jun 5, 2007
    Messages:
    529
    Thanks EMA

    i do, in fact, put oil in every tool i have before i use it... and i make sure to hit them occasionally when not in use... just to keep them lubed... a drop or 2 per

    good to know that i can combine the tanks for more capacity... i will also be using the MaxLine in the shop for routing...

    thanks for the info...

    got any photos?
     
  3. Jun 28, 2019
    Dave Deyton

    Dave Deyton Member

    Fuquay-Varina, NC
    Joined:
    Oct 12, 2003
    Messages:
    847
    I have seen many setups with an additional tank in series for more air storage.

    My Quincy has always provided plenty of air with the 80 gallon up right tank.

    The CFM makes the difference at 23 Cubic Feet of air per minute, I can make it come on more, but I can't make it run continuously, even sandblasting.
    I need to get an automatic drain, but I drain it daily.
    Thinking about using the Max Line Rapid Air lines system.
    For painting and plasma cutters Motor Guard makes a great filter.
    Dave
     
    TexasBlues likes this.
  4. Jun 28, 2019
    TexasBlues

    TexasBlues JEEP-Hockey-Holic

    Marietta, GA
    Joined:
    Jun 5, 2007
    Messages:
    529
    I have looked at some youtube vids on how to connect the tanks, but nothing really shows the HOW..

    i ASSUME i have to pull off the crappy motor from the other and just treat it like a standalone tank... downstream to allow for cooling as well as storage

    this should be interesting

    itll help with plasma cutter and airhogs

    thanks everyone
     
  5. Jun 28, 2019
    Admiral Cray

    Admiral Cray I want to do this again.. Staff Member

    Bainbridge...
    Joined:
    Sep 21, 2009
    Messages:
    204,347
    I have a stand alone 30 GAL storage tank on my system. It's at the end of the line and outside. It's just plumb in to the system with the input and output on the same pipe. The pipe runs up hill to the tank with a drop for draining...

    Works great... :D
     
  6. Jun 28, 2019
    EMA

    EMA Member

    Lake Elsinore,...
    Joined:
    Feb 20, 2019
    Messages:
    82
    Just make sure the air drawn from any tank is near the top of the tank.... The feed from the compressor to the tank feeds in at the bottom or near it if possible.
    Just a side note regarding the "autodrain systems" I have yet to locate one though that does not plug up often in the strainer section.
    The ones I have now...I removed the strainer.
    My goal was to remove water.
    If this is not done... You guessed it...clean out the debris DAILY....or manually drain off water DAILY....Hmmmmm.
    Catch-22..?
    What I did on my setup to help keep electrical usage down: Two motors... One 2-1/2Hp coupled with a "three-groove" to a smaller 1-1/2Hp..Third groove actually is the belt to the compressor.
    I have a relay timer ( I call it my Timer Flip-Flop relay box ).
    System starts on the 2-1/2Hp...runs for about 90 seconds....then puts power to the 1-1/2...and cut power off the 2-1/2Hp....
    When running this on a 24-7 basis....really does reduce shop load as it is powered on a Solar system during the day.
    My shop is full of major machines, Lathes, Mill, Hyd. Cross Saw...etc... so power is a concern as well.
     
  7. Jun 30, 2019
    fyrmn

    fyrmn Member 2023 Sponsor 2022 Sponsor

    High Desert AZ
    Joined:
    Apr 29, 2006
    Messages:
    198
    IMG_3574.JPG Here's an old one, still working
     
    TexasBlues likes this.
  8. Jun 30, 2019
    EMA

    EMA Member

    Lake Elsinore,...
    Joined:
    Feb 20, 2019
    Messages:
    82
    Yep.... If taken care of...they will outlast us... :)
    Checking the oil is the most important other than the second most failures...not draining condensate from the tank....
    I had one about a third of this one in size...mounted up in the ceiling...it was plumbed into the outside system.
    30 years later....it gave up since I could not get to the ceiling often....tank split open.
    I had this on a timer so that it kept the shop air up until morning when I would start the larger compressor.
     
  9. Jul 1, 2019
    TexasBlues

    TexasBlues JEEP-Hockey-Holic

    Marietta, GA
    Joined:
    Jun 5, 2007
    Messages:
    529
    thanks everyone...

    i will have a look tonite and see what it will take to get the old pump off and see if maybe its salvageable for something...

    else i will see what it will take (parts-wise) to feed it as a standalone tank downstream...

    could i feed it with maxline? i will have some left over and it would be a good way to burn up the additional material
     
  10. Jul 1, 2019
    TexasBlues

    TexasBlues JEEP-Hockey-Holic

    Marietta, GA
    Joined:
    Jun 5, 2007
    Messages:
    529
    Dave-

    i am using (or will be when installed) the maxline... rapid-air... whichever is the blue flex line

    i like it... will provide a clean install and i am planning on having my hose reel mounted to the ceiling to eliminate hoses in the floor...

    if i can do it, i also plan to install the 'holding tank' downstream from the new unit coming in the next couple weeks... from what i understand, doing it this way (downstream tank) provides an easy way to cool the air... it has a bottom drain and i have drops in my lines as well...

    let us know how yours comes out!

    i will do the same
     
  11. Jul 1, 2019
    EMA

    EMA Member

    Lake Elsinore,...
    Joined:
    Feb 20, 2019
    Messages:
    82
    When I built my shop I trenched also around the property and laid in "green" underground gas piping 3/4" to various locations.
    Other than having "air" to work air tools....Makes it easier to sweep around even the walkways around the house... :)
    I have also a line I installed into the garage along this line... since if working on the boat there makes air tool usage easier.... again
    Don't sweep anymore....just grab the floor wand...five minutes... :)

    George
     
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  12. Jul 1, 2019
    Dave Deyton

    Dave Deyton Member

    Fuquay-Varina, NC
    Joined:
    Oct 12, 2003
    Messages:
    847
    Thought about underground piping to other sheds. One I have the woodworking tools in. Been planning air line
    hook ups for a while now. I really need to start on that system. Since I'm generally the only one working in
    the shop, I haven't taken the time to do it.
    Since the tube comes in a roll, is it hard to straighten out so it looks decent?

    Dave
     
  13. Jul 2, 2019
    TexasBlues

    TexasBlues JEEP-Hockey-Holic

    Marietta, GA
    Joined:
    Jun 5, 2007
    Messages:
    529
    Dave-

    its a little cumbersome but can be done by hand... there is a tool you can buy that is a system of multi rollers thats lays it out nice and straight, but if youre going to bury it, hans straight should be fine...

    mine is hand straight and i have it on the walls... i think it looks fine, but popular mechanics or better homes, gardens and garages wont be handing ME a prize
     
  14. Jul 2, 2019
    Warloch

    Warloch Did you say Flattie??? Staff Member

    Falcon, CO
    Joined:
    Mar 4, 2003
    Messages:
    5,466
    I did mine mostly hand straight - toward the end of plumbing my shop I staggered some tube tacked to the table and ran it through that for a pretty straight setup on the longer runs I have. Course I bent them some putting the hooks up to hang it on :D
     
  15. Jul 6, 2019
    EMA

    EMA Member

    Lake Elsinore,...
    Joined:
    Feb 20, 2019
    Messages:
    82
    Ran all my underground lines using 3/4" Green " Gas Line " piping, 20-ft. lengths connected.
    In the shop & garage...3/4" Galvanized.... Ball valves every ten feet to double air disconnects... Blow-Down lines at each to the floor.
    Have an " Air Pressure " Monitor " Light " on the wall in the shop as one of my machines uses air-over-oil actuator cylinders...will jam if under 95psi....would not be a good day if I ran it under that.
    Later I am going to re-write the PLC and add a Pressure Sensor connected into the " Cycle Start " function.
     
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