Compressor intercooler - Flexible line from pump head?

[scoob8000]

I have a pretty run of the mill single stage 60 gal compressor. Years ago I made a intercooler from a old car oil cooler and some muffin computer fans. Plumbed it in with soft copper tubing and mounted it to the compressor.

The vibration of the compressor finally took it's toll on the cooler. It's starting to leak and some cracks are visible on the brazed joints.

For my new design I'm thinking of mounting the cooler setup on the wall right behind the compressor to save it from the vibration. But I'm stumped on how to stop the vibration transfer.

I was trying to think of hose to use from the compressor head to the cooler. Maybe some braided line like a water heater whip hose. Something that will stand up to the heat and vibration. Thoughts?

 

[Movover]

I have always heard of using hydraulic line in your chosen size, it takes the pressure and heat just fine

 

[Lucid Moments]

I have always heard of usig hydraulic line in your chosen size, it takes te pressure and heat just fine

That is what I use. No cooler on mine, but I use hydraulic hose between the compressor tank and hard line mounted to the wall. Been there about a year now and no issues.

 

[scoob8000]

Good deal guys. I've got some ideas now. Thanks

 

[matt_i]

If you visit something like a Parker Store there are very flexible hydraulic lines that are engineered to work on things like forklift masts where the hose is rolling over a guide-sheave every time the mast is moved. I can't quote a hose stock series right off but a hydraulics shop will know based on that application -- constant flexing.

I think the soft copper would work if you put a loop in each hose (think of a slinky but fewer coils). That compliance element (the loop) will eliminate the ability of a rigid straight line to transfer vibration. It could also trap water but I presume there's going to be plenty of flow to push it out.

 

[stonesfan68]

If you're going to use water heater lines then make sure that the line is rated for 300F+ and that the pressure rating exceeds that of your air compressor by at least 20%. If that line lets go then you don't want to be near it.

 

[Citation]

No reason to mount it on the wall vs the tank, just use some rubber fittings between the intercooler and the tank to isolate the vibrations. Adding a bit of mass to the intercooler side of things can help. As for the lines, I would just use the copper tube but with at least two turns to act as strain relief. As others indicated, the air coming out of the head is really hot, so you need something that is temperature rated. CAT compressors use a braided line. It looks like a teflon brake line setup but I really don't know. I'm not sure if hydraulic lines are really rated that high. Again, copper tube is easy and not too expensive.

 

[scoob8000]

I've actually thought about using just a longer length of copper tube. I have plenty from the first go-round. I think I used maybe 3 feet out of the 25ft coil.

I have my current setup mounted rigidly to the top of the compressor mounting plate with heavy angle. It vibrates a lot. I guess it wasn't too bad that the 25 year old cooler lasted me a couple years on the compressor.

 

[Citation]

I've actually thought about using just a longer length of copper tube. I have plenty from the first go-round. I think I used maybe 3 feet out of the 25ft coil.

I have my current setup mounted rigidly to the top of the compressor mounting plate with heavy angle. It vibrates a lot. I guess it wasn't too bad that the 25 year old cooler lasted me a couple years on the compressor.

I suspect if you could both brace the mount so it wouldn't shake so much and put the intercooler on rubber dampers to further isolate vibration you would be find. Seriously, if you got 25 years out of the first one then even a small improvement should help it last more than 25 years.

 

[scoob8000]

I suspect if you could both brace the mount so it wouldn't shake so much and put the intercooler on rubber dampers to further isolate vibration you would be find. Seriously, if you got 25 years out of the first one then even a small improvement should help it last more than 25 years.

I should say the cooler was 25 years old off a car that I scrapped. I've had it running on my compressor for another 5 years or so.

 

[ez-duzit]

The cooler can be properly mounted to the compressor and then plumbed with copper tubing. Here's how I did mine.

 

[TTA89]

I've seen people using some kind of PTFE hose that you can crimp your own connectors on to make whatever sizes you want. I'm trying to find some of that so I don't have to use copper, mostly because I've never used copper and don't have any other use for it and need a flexible line to connect to the wall.

 

[sweetk30]

my local hydro hose shop made me a ptfe lined s.s. braided hose made just for high psi and temps . cost me around 50 bucks with 1 fixed joint and 1 swivel end joint to make install batter . that was a 1/2" one for my 9cfm compressor . my 3/4" one for the 19 cfm compressor was just under 80 bucks .

there both doing just fine now and going good 3+ years .

 

[908Jim]

The cooler can be properly mounted to the compressor and then plumbed with copper tubing. Here's how I did mine.

That's a super clean install. Very nice!

 

[ez-duzit]

9--thank you.

 

[scoob8000]

The cooler can be properly mounted to the compressor and then plumbed with copper tubing. Here's how I did mine.

Very nice and clean. I think we have the same compressor. 60 gal porter cable from Tractor Supply?

 

[ez-duzit]

s--exactly, and thank you.

 

[Lucid Moments]

The cooler can be properly mounted to the compressor and then plumbed with copper tubing. Here's how I did mine.

It may just be my ignorance, but that seems like a really small cooler. Do you have any data on temp drop with that cooler? I have always thought a larger one would be needed to get enough water out of the air to be useful.

 

[ez-duzit]

...Do you have any data on temp drop with that cooler?...

Nope.

 

[The Cobbler]

hydraulic line or coiled soft copper would work, mount the cooler so it doesn't vibrate

 

[scoob8000]

It may just be my ignorance, but that seems like a really small cooler. Do you have any data on temp drop with that cooler? I have always thought a larger one would be needed to get enough water out of the air to be useful.

That looks roughly the same size as mine. Mine is about 5x10. But I have two screamer delta 120mm fans on it. The top fan exhaust temp is around 200-220, the bottom one is about 90. The line going into the cooler is too hot for my IR thermometer to read but line coming out of the cooler is 80-90ish. I forget the CFM of my fans, but the output pushing thru the cooler feels about like a hair dryer on high.

 

[TNToy]

I used hydraulic hose and a transmission cooler, plumbed into a DIY catch can, and then into the tank.

See posts 314+ in the aftercooler thread where I detail my installation:
https://www.garagejournal.com/forum/showpost.php?p=5307906&postcount=317

That install was posted in 2015. For five years I’ve run the worst and pickiest tools off of it. High demand tools like die grinders and sanders... and it also feeds the pickiest tools because I have both a plasma cutter and an HVLP paint gun that it regularly supplies.

In five years I have yet to see a single drop of water in my tank, much less at the tool. The cooler and catch can do their jobs well. I don’t have runs of plumbing helping me out, either. I run a 75ft hose reel straight off the side of the tank.

 

[scoob8000]

TNToy, Nice setup. And nice Dillon in the background.

That thread some years ago was my motivation to make a aftercooler/intercooler setup for my compressor.

I just did some digging in the attic and found a old AC condensor from a Honda I had ages ago. It's a stacked plate parallel flow job and even has the fan and shroud. Just need a 12v power source and adapt the 1/2" lines to match the 3/8" lines on my compressor.

 

[csp]

There are braided stainless flex lines that are specifically made for air compressor use.

One example: https://compressor-source.com/produ...-flex-hose-tubing?_pos=9&_sid=396cf7962&_ss=r

 

[Wrench97]

Trucks use PTFE Stainless steel braided off the air compressor to the dryer works well for the heat out of the compressor.