Yet to complete my compressor setup (95% complete), as it will be used at a different location, comprises of a 5 Hp Curtis Masterline compressor (18-21 cfm) 80 gallon tank, temporary hookup.
Compressor running, showing 21.2 amps on ammeter
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http://s852.photobucket.com/albums/ab84/pcmeiners/?action=view¤t=DSC_00640001.jpg&newest=#!oZZ1QQcurrentZZhttp%3A%2F%2Fs852.photobucket.com%2Falbums%2Fab84%2Fpcmeiners%2F%3Faction%3Dview%26current%3DDSC_00600001-1.jpg
Manufacturer's specs...
http://www.fscurtis.com/products/reciprocating-compressors/ml/index.htm
Modifications.........................................................
Removed the original small 10 micron air intake filter, created a 1” manifold to use with two larger intake filters (2 micron), 4 times total the original filter size, less intake loss, less filter changes.
http://www.ecompressedair.com/filtration/filter-assemblies/air-intake-filter-assemblies.aspx
Purchased a Hoffman enclosure (8”x10”x4”) for power contactor, added on/off switch, hour meter, and LED Ammeter (Ebay. Choose to install the ammeter as it is cool, and a friend’s compressor burnt through 3 motors, and consumed twice the normal current for months at his business before his issue was solved.
The LED display ammeter is similar to the Ebay link below. If anyone wants an LED ammeter, get one rated to the highest load at motor can pull (complete short, motor in flames draw). Aside from the meter you will need a small voltage supply, I used a small power supply from a laptop computer, just about any power supply will do.
With an ammeter you can tell a good deal about a compressor's health, once you have a baseline during normal operations. Baseline would be current draw with compressor belt off, startup current, current use at specific pressures, current draw just before a filter change, current draw during utility voltage drops ect; once you have a baseline, if the current draw deviates you need to look for a cause.
http://www.ebay.com/itm/Three-In-On...269?pt=LH_DefaultDomain_0&hash=item2a15e1125d
DIY compressor
Intercooler…
Intercooler between the first and second stage, consisting of an Allison DB-1290 (24.0 x 19.0 x 1.5 Overall size), with two coalescent filters (all 1” piping); cooler is mounted in front of the belt guard. The intercooler cools the air from the first stage (approx 275° F ) to ambient room temperature, resulting in roughly 15-20% more efficiency as the air is denser entering the second stage, and roughly a 50% moisture drop out. Two coalescent filters where installed just below the Allison cooler, the second small filter was installed in case the main water filter’s automatic drain fails, as water entering the second stage could cause severe damage; on a low humidity day (37% for summer in NYC is low), 10 minutes running (timed), approx. 1/2 cup of water/oil drops out; on a high humidity day over 1 cup will drop out in that time. Allison cooler picked up on Ebay for $40.00 delivered (I was lucky); most of the filters/valve/gauges ect. purchased on Ebay.
Shows DB1290 intercooler and auto drains...
http://s852.photobucket.com/albums/ab84/pcmeiners/?action=view¤t=DSC_00640001.jpg
Used as an aftercooler off the second stage, this unit would drop the temperature of the air entering the receiver to ambeint temperature, dropping most of the moisture out. Again, some sort of automatic water removal would be needed, as extended compressor use with a cooler such as this would produce far more water than normal. Approx water drop out on a humid summer day with extended use, such as car painting about 1 gallon.
http://www.makcotransmissionparts.com/DB-1290.html
Pick up db 1292 on Ebay for a friend with a 15 hp compressor
http://www.makcotransmissionparts.com/DB-1292.html
Moisture, page 26..
http://www.pneumatic-source.com/articles/pneumatictechnician.pdf
Efficiency, intercooler…
http://books.google.com/books?id=NG...sult&ct=result&resnum=10#v=onepage&q=&f=false
DIY compressor
Aftercooler….
Consists of two Thermal Transfer Products, tube heat exchangers mounted on a rectangular mounting made with 1 1/2" angle iron. The first is an air to air exchanger, (Ebay for $30.00) which cools the second stage compressor output from approx 275° F to ambient room temperature. The output of the first exchanger goes to a second (water to air) heat exchanger, water supplied by city or well water approx 50-55, which drops out most of the remaining moisture. I may place a refrigeration dryer unit after this. Aftercooler system has it own set of moisture coalescence filters.
I did not go with refrigeration dryer directly, as the compressor output temperature is much higher than the recommended input temperature of a refrigeration unit, cost to run such a unit increases with input temperature. Water cost to run my unit should be small as the first heat exchange removes the most heat, using a small 4 amp 12v blower. The first stage is air cooled, was not necessary, as the water cooled stage could do the job, but the air to air unit was purchased on Ebay for very little, and I figure the air cooling is cheaper than the added water cost. Along with the aftercooler I have a control box which supplies 12/24vdc, for the blower, a 1" asco water valve (opens when compressor starts), for the use of solenoid valves to dump water from the coalescence filters if need be.
Aftercooler assembly, to be attached at my new shop...
http://s852.photobucket.com/albums/ab84/pcmeiners/?action=view¤t=DSC_00680001.jpg&newest=1
Air cooled exchanger, equal to but not model k-1024, designed to reheat cooled compressed air,
http://www.thermaltransfer.com/pdf/individual/K.pdf
AB-405-B4-0, water cooled....
http://www.thermaltransfer.com/pdf/individual/_AB.pdf
On my compressor setup, I used 1”copper L pipe for the following reasons…
Ease of installation, smooth inside surface of pipes, especially fittings. Since I was not able to obtain/use all optimal fittings such as long radius elbows, and used branch flows in tees (not recommended), I increased the recommend pipe size of ¾” to 1”, which dropped the friction loss and pressure loss, pressure loss by a factor of 4. Had to debate the use of solder, as the heat output of my two stage compressor, said to be approx 275° F, (silver content solder melts approx. 425). Be aware single stage compressor output temperature is considerably higher.
As is, using the calculator below, for 110 feet of pipe in my system, including the piping in my intercooler and aftercooler, gives me a 0.4 psi pressure loss, a friction loss of 0.02, not including a .40 and .5 micron filters, which both should total a .8 PSI loss, as they are also oversized.
Great little pressure/friction loss calculators….
http://www.freecalc.com/gasfram.htm
http://www.kaeser.com/Online_Services/Toolbox/Pressure_drop/default.asp
On the tank, I removed the two 2" ports caps on the back side of the horizontal tank, added reducers to port down to 1" pipe for the intake from the compressor output, and output from the tank. The original input from the compressor had a very restrictive intake checkvalve, looks like 1/2", tank output was also restrictively small. On Ebay I purchase 6' of 1" stainless braid/teflon flex hose and fittings, used for vibration isolation on all three ports, though with the low rpm of the compressor, vibration is low, (not in place yet). Teflon is needed on the compressor output due to the high temperature. Input to the tank equipped with a 40 micron filter, output has a 5 micron filter and a high flow regulator. Replaced the Square D pressure switch with a Bradley 836t-t253j. Picked up four used Barry Stabl-Levl SLM-6A anti vibration mounts, hockey pucks will be sufficient.
Purchased Teflon flex from this seller, guy sells smaller pieces/sizes
http://cgi.ebay.com/1-STAINLESS-STE...0?hash=item1e51344ed3&_trksid=p3286.m20.l1116
Check valves....
My first choice for a compressor discharge check, high flow, dampening..
http://www.kingstonvalves.com/23/Products/17/2/parts_details.aspx
Next best...
http://www.amazon.com/gp/aag/main?i...etplaceID=ATVPDKIKX0DER&seller=A17VS4Z36UDX1I.
I milled out the check valve seats on these .
http://ubw.thomasnet.com/viewitems/industrial-lift-check-valves/model-53-lift-check-valve?
or on ebay
There is a concept copper is better to use on piping then steel pipe as it has better cooling ability, not true. Copper along with aluminum fins yes, drawn tubing no.
Copper conducts heat better then steel pipe but conduction and radiation are different metal characteristics. Comparing copper to steel (cold rolled), the steel is equal, if not better as a heat radiator. Copper is just easier to assembly and has less friction
http://www.optotherm.com/emiss-table.htm
Overall cool/fun to build, but costly in both time and money.