Air compressor fail!

[dreamingmuscle]

No explosion but it could have been costly.

I bought a Ingersoll Rand 60 gallon compressor last veterns day at Tractor Supply. 15% off for veterns made it a steal at $549.50

Anyway I didn't develop the habbit of switching it off when I leave for the day. I mean its not running when I walk out the door so out of sight out of mind right.

Well Tuesday around 3 my daughter calls and asked what's running in my shop and what ever it is, has been running most of the day. I said the fan maybe, it's plugged into the light switches so if the lights are on its on. Please check on it. She calls back and says the compressor is running and the garage is full of smoke.

Directed her to turn off the main breaker which is next to the man door and open the garage door to let the smoke out. I'm sure lucky and happy nothing caught fire. (A metal surround is in order.)

I'm guessing the air pressure had gotten low enough for it to cycle on and then the contacts welded them selves together. I couldn't even get it shut down by cycling the switch after I got home. Luckily the high pressure pop valve did its job.

My first thought was that a rubber airline busted causing it to have a run on. But they were all fine.

It still compresses air but not as quick, and it makes a squalling noise on shut down. The oil was clear but is now grayish with shinny tiny clitter.

Found my receipt and called the IR service center near me and explained my problem. They took my information and said it will take a week for the parts to come in and they'll call to scheduel a time to come repair it under warranty.

I'm going to have my daughter make me a sign or better yet have her paint a large reminder on the door to turn off the compressor and drain the lines.

 

[The Cobbler]

glad it wasn't worse.
there are a few recent threads on here about auto shut offs ofr compressors.

 

[BillK]

Could have been a lot worse. This is the reason I cringe every time I see a post where guys leave their compressors on 24/7 Mine at my business gets turned off every day when I walk out the door.

 

[OccupantRJ]

Exactly why my compressors are controlled by relays run through a master switch at the entry door. It is right alongside the light switches and controls the compressors, welding vent hood fan, hood light, ceiling fan. More functions can be controlled by adding onto the control circuit. One swipe going out the door gets the master and two light switches. I installed a grey color master switch to make it easy to spot.

 

[Mr_B]

Yeah relay controlled manual switch by door is good way go .
real bad habit leaving them on and unattended. can end in ashes ...

 

[Boilerhouse]

Yes, I turn my compressor off when I leave the shop. The home units are not rated to run 100% of the time, and I have heard that they can overheat to the point of causing a fire and burning the shop down. This story confirms that this is likely true.

 

[pepi]

Mine is 20 years, on 24 -7, do close a ball valve plumbed on the tank, isolating the compressor and shop feed. If I do forget it will cycle a few times a week, closing shop supply stops that. Compressor tanks do not leak it's the down stream side that does..

Just another way to skin the cat,

Pep

 

[Bad Eye Bill]

I have a switch similar to this for my compressor. There is also a pilot light wired to it right beside the man door. If light is on when I'm going out the door at the end of the day I turn around and go back and shut the compressor switch off.

 

[countryroad82]

Mines wired up to a light switch by the man door. After I walk in and flip the lights on, it's the next movement I make to turn on the compressor and it's the first thing I do when I go to leave the shop is to turn it off. Always been terrified of burning one up if a hose blew while I was gone.

 

[biggziff]

Mine is 20 years, on 24 -7, do close a ball valve plumbed on the tank, isolating the compressor and shop feed. If I do forget it will cycle a few times a week, closing shop supply stops that. Compressor tanks do not leak it's the down stream side that does..

Just another way to skin the cat,

Pep

Same here, but I am thinking of changing to an electronic valve at the compressor as I do forget to close the manual valve from time to time.

 

[strutaeng]

A fer years ago I recall there were a lot of problems with these compressors. Is it this one?
https://www.tractorsupply.com/tsc/p...stage-twin-cylinder-pro-air-compressor-60-gal

In my opinion 5HP and higher motors need a magnetic switch so that the pressure switch does not have to deal with the high arcing at the contacts. I know they make pressure switches rated for this, but that's just me.

 

[Spulen81]

I had the same thing happen with a newer 5hp rated switch but luckily I was in the shop when it happened.
I installed a magnetic starter and and a new pressure switch and like you forgot to turn it off sometimes. At some point the caps in the motor exploded and and the there was just a loud hum, dim lights and a smoke filled garage. Luckily my son heard the hum and called me.

 

[synchro7]

I worked with industrial motor controls for years. I set my 7.5 HP
up with a typical industrial preset holding circuit and a magnetic motor starter. An overload on the motor, a power bump or a simple push button shuts it down

 

[dreamingmuscle]

A fer years ago I recall there were a lot of problems with these compressors. Is it this one?
https://www.tractorsupply.com/tsc/p...stage-twin-cylinder-pro-air-compressor-60-gal

In my opinion 5HP and higher motors need a magnetic switch so that the pressure switch does not have to deal with the high arcing at the contacts. I know they make pressure switches rated for this, but that's just me.

Yeah thats the one. It runs quite and puts out a good amount of air for the money. I've been happy with it till now.

 

[dreamingmuscle]

Mine is 20 years, on 24 -7, do close a ball valve plumbed on the tank, isolating the compressor and shop feed. If I do forget it will cycle a few times a week, closing shop supply stops that. Compressor tanks do not leak it's the down stream side that does..

Just another way to skin the cat,

Pep

Thats what I figured. Who cares if it cycles now and then. No use is abuse right?

Well all well and good till the switch fuses shut and it doesn't cycle back off while your gone. I learned this the hard way.

 

[Bert_]

Another idea would be to wire in a max run timer (one shot). Could set it so if it doesn't cycle off after an hour or two it would time out. Common set up for feed lines in hog barns. Turning power off and on will reset it.

I have a switch similar to this for my compressor. There is also a pilot light wired to it right beside the man door. If light is on when I'm going out the door at the end of the day I turn around and go back and shut the compressor switch off.

Probably just a generic picture but the pictured switch is a 30 amp and only good for 3hp. Anyone with a 5-10hp would need a 60A switch.

 

[Bad Eye Bill]

Yeah, you're right Bert. I just googled the pic and didn't even look at the amp rating.

Good catch.

 

[ZRX61]

Ball-valve on the tank outlet & service disconnect for the power. Both were always shut off when I left the garage.

 

[Kevin Essiambre]

Another idea would be to wire in a max run timer (one shot). Could set it so if it doesn't cycle off after an hour or two it would time out. Common set up for feed lines in hog barns. Turning power off and on will reset it.





Probably just a generic picture but the pictured switch is a 30 amp and only good for 3hp. Anyone with a 5-10hp would need a 60A switch.

Except that the max HP rating on that one (and the 30 amp one on my compressor) is 7.5 HP. It's printed on the door of that one.

We only have a 5HP motor.

We also have a overload and starter combo wired in too. Makes starting it really easy. Just push the start button.

Sent from my SM-G920W8 using Tapatalk

 

[NC Rick]

Thanks for posting this. I have an old ingersol rand compressor which I was given in the 80’s and rebuilt. It has been in my (new) shop, switched on for 23 years. I shut it off when we go on vacation for a few weeks but never otherwise. It’s a 5hp 80 gallon unit with a magnetic starter with heaters. I may have to rethink this policy.

 

[Norcal]

Ball-valve on the tank outlet & service disconnect for the power. Both were always shut off when I left the garage.

Service disconnect? A service disconnect is a disconnect for service entrance conductors.

 

[RVDan]

My compressor won't run unless the lights are on. Eliminates getting woken up in the middle of the night. Unless I leave the lights on.

A good security measure too, if someone should turn the lights on the compressor will kick on and wake me.

 

[bts]

I don`t know why I started doing it but for the last 20 + years when I`m finished in the shed for the day I switch off the mains breaker. No power to shed at all.
Just seams to give me peace of mind.

 

[jmarkwolf]

Yes, I turn my compressor off when I leave the shop. The home units are not rated to run 100% of the time, and I have heard that they can overheat to the point of causing a fire and burning the shop down. This story confirms that this is likely true.

My buddy's dad burned their family home down while doing some pressure washing with an air compressor. He was at the far end of the house working on a long hose, didn't realize the compressor in the garage at the other end of the house had caught fire. By the time he investigated why the compressor had stopped working, the house was engulfed.

No one was hurt but a tragedy just the same.

 

[TractorJeff]

See!
24 posts on air compressors with the majority insisting on leaving it powered 24/7, WHY?
Are you Industrial/Commercial businesses where air is needed all hours?
You guys have grandiose fantasies of being powered up and ready to go!
WHY?
Is your time all that important that you need IMMEDIATE air?
Do you come racing in the driveway from work, jump out of the car running into the garage to grab an air tool expecting it to run immediately? Are your car tires flat everyday requiring over 100 lbs of air to refill them before you can race off to work?
Or
Are you so ingrained from Garage Journal fantasies that you are so important that common sense goes out the window?

 

[Showkey]

^^^^^^^. I would not assume any thing close of the majority of members leave their compressors powered up.

Also related .........Think many with knowledge and experience might close the water main ( flip the well power off) when they are on week long vacation ?

 

[TRWham]

Except that the max HP rating on that one (and the 30 amp one on my compressor) is 7.5 HP. It's printed on the door of that one.

We only have a 5HP motor.

We also have a overload and starter combo wired in too. Makes starting it really easy. Just push the start button.

Sent from my SM-G920W8 using Tapatalk

That picture is likely of a 3 phase switch, where 30 A would be good for 7.5 hp. A single phase 7.5 hp motor is sized for 40 A full load current at 220-240 V and needs more than a 30 A switch.

 

[Bert_]

That picture is likely of a 3 phase switch, where 30 A would be good for 7.5 hp. A single phase 7.5 hp motor is sized for 40 A full load current at 220-240 V and needs more than a 30 A switch.

^This

Most 30A switches are 7.5hp on 240V 3Ø and 3hp on 240V 1Ø.

60A switches are 10hp 1Ø and 15hp on 240V 3Ø.

That said I have seen a lot of 5hp motors wired to 30A fused disconnects and for the most part they work. Contacts tend to wear pretty fast if it's switched under a load.

If your doing a new install why do it the wrong way?

 

[Bad Eye Bill]

See!
24 posts on air compressors with the majority insisting on leaving it powered 24/7, WHY?
Are you Industrial/Commercial businesses where air is needed all hours?
You guys have grandiose fantasies of being powered up and ready to go!
WHY?
Is your time all that important that you need IMMEDIATE air?
Do you come racing in the driveway from work, jump out of the car running into the garage to grab an air tool expecting it to run immediately? Are your car tires flat everyday requiring over 100 lbs of air to refill them before you can race off to work?
Or
Are you so ingrained from Garage Journal fantasies that you are so important that common sense goes out the window?

Well I didn't count but it seems to me that the majority in this thread turn them off when they're not in the shop.

 

[Git]

I leave my compressor powered up 24/7, BUT I turn off the air at the tank with a motorized ball valve, It is also set to turn off automatically every night at 6 PM in case I forget

 

[JOE.G]

I turn the ball valve feeding the shop but leave the compressor powered on, If I shut the compressor switch off is that enough or do I need to completely cut the power at the breaker?

 

[sberry]

I turn the ball valve feeding the shop but leave the compressor powered on, If I shut the compressor switch off is that enough or do I need to completely cut the power at the breaker?

Once they are off they rarely fail "on" . Most problems are shutting off once they are running. With the 2 cases I had a motor problem came in to find breaker tripped.

 

[sberry]

See!
24 posts on air compressors with the majority insisting on leaving it powered 24/7, WHY?
Are you Industrial/Commercial businesses where air is needed all hours?
You guys have grandiose fantasies of being powered up and ready to go!
WHY?
Is your time all that important that you need IMMEDIATE air?
Do you come racing in the driveway from work, jump out of the car running into the garage to grab an air tool expecting it to run immediately? Are your car tires flat everyday requiring over 100 lbs of air to refill them before you can race off to work?
Or
Are you so ingrained from Garage Journal fantasies that you are so important that common sense goes out the window?

I am on 24/7. We usually don't go more than a few hours without using air.

 

[Showkey]

In a somewhat related story .......
Called on a dealer where the bulk oil tank stayed on ( engerized) over night. In the night the oil line failed at the overhead dispenser. 1500 gallons of new oil ended up on the shop floor.

The parts department was responsible for shutting down the system each day at closing. Someone forgot...........it never a problem until it’s problem.

 

[bts]

Most problems are shutting off once they are running.

A common cause of motor failure in this part of the world.
People shut off the compressor mid cycle by turning the power off at what ever socket its plugged into and not at the compressor. This means that the compressor heads are not bleed down so when the comp is started the motor is going against full load.
Had a client complaining that this was the second motor he had to be repaired. Turns out he had fitted a larger circuit breaker to stop the breaker tripping out all the time when he started the compressor. He use to turn it off and on several times a day to save power when it was not being used. He was not happy with what I had to say, I never did see him again.

 

[exranger06]

^^^^^^^. I would not assume any thing close of the majority of members leave their compressors powered up.

Also related .........Think many with knowledge and experience might close the water main ( flip the well power off) when they are on week long vacation ?

I went on a week long vacation 2 months ago. I strongly considered turning the well pump off before leaving, but I knew my mom would be stopping in almost every day, checking on the house, getting the mail, and doing a little yard work for me and she would probably need to use the water at some point. So I left it on. If the house was going to be empty the whole week with no one stopping by, I would've turned it off. I also unplugged most of the appliances and electronics before leaving, so they didn't use any electricity (parasitic load) and so they wouldn't be damaged if there was a lightning strike while we were gone.

As far as my air compressor goes, I haven't finished wiring or plumbing it up, but I plan on installing a toggle switch in the garage that's hooked up to the control side of the magnetic starter. The swich has a pilot light to tell me when it's on. It'll get turned om only when I'm using the compressor, and turned off when I'm done working in the garage.

 

[bubinga]

Subscribed

 

[Tinkerman66]

I have a switch similar to this for my compressor. There is also a pilot light wired to it right beside the man door. If light is on when I'm going out the door at the end of the day I turn around and go back and shut the compressor switch off.

Man, this is kind of scary. Here is my setup.

 

[sreeb]

If you are leaving your compressor on 24/7 so you always have air in a home environment, you need to take a few hours and fix your leaks.

 

[larry4406]

Mine is energized 24/7 but I shut the ball valve off at the tank. I like the motorized ball valve concept tied to lighting and a backup timer.