shop air system / upgrade yet again . . .

[sweetk30]

well Friday I went and picked up the other air compressor I purchased for the electric motor it had on it .

got a nice tank looks to be about 60 gal . guess I will add this in to the system for a 200 gal storage total .

the pump unit is a older IR t30 style model 234 looks to be 9cfm @ 175psi in the 3hp motor spec it would of had way back in the day . I am going to spin it with the old motor off my 2 stage and just get the correct pulley size to match the rpm . this will be a backup unit or what ever little jobs I would need it for .

next I setup both units to get a idea on layout . I think its tight but it would be so easy to just do a pair of new top plates to bolt down to these a hair bigger . this will also give me the chance to add in rubber for anti vibration between the plate and tank top plate .

funny thing . . . both magnetek motors . . . . old one is physically smaller than new . . . old draws 22 amps on spec tag . . . new BIGGER motor draws 20 amp

for now here is the stuff . . .

 

[JoshHefnerX]

You might have a problem.... lol

 

[sweetk30]

I like backup . . . .

and 2 comp in shop comes from my wrenching days . 1 shop I was at the most had 2 . 1 for every day and 2nd for CRAZY days or backup if other went down . we did swap them now and then for use to keep both tested and working . saved our arss a few times.

 

[sweetk30]

got to digging on pulley sizes and specs ( thanks to member on other site ) and the belt size my old 234 has is 1/2" 4L series wide . if used on the now more common 5/8" 5Lseries wide pulley the o.d. would have droped big time for the depth of the seating of the belt in the grove .

so I dug this handy chart up http://www.masterdrives.com/sheaves/...%20Sheaves.pdf

did my reading and I needed a pulley a bit bigger to get me back up in dia. . got 1 ordered and on its way today . ordered a bk series solid pulley .

next I ordered 2 new check valves . 1 - 1/2" 20cfm unit for the smaller tank/pump unit. 1 - 3/4" 30cfm unit for the bigger unit , and @ 5hp/16cfm or 7.5hp/27cfm I am covered.

also got me 2 new fresh pop off valves to replace the old ones . cheep insurance . .

just got to get my plate steel to fab up my new top plates . then some plumbing for the outlet of comp high side to tank check valve inlet.

 

[sweetk30]

got my check valves and pop off valves yesterday .

3/4" 30cfm check valve for big unit . and 1/2" 360cfm pop off valve

1/2" 20cfm check valve for little unit. and 1/8" 80cfm pop off valve .

also got my top plates today .

1/4" plate cut on flow jet . should give me the room I need to mount both better than tight package they are now.

 

[sweetk30]

bit of work today .

smaller 234 is what is getting more of my time since I know it was a good working pump / motor on each own last tanks.

I did swap side to side the pump / motor . I like it better this way I think .

pic of the setup with new top plate out of 1/4" steel . the spacing is a lot better I think . also setup the pump for the mounting bolts to weld to the top plate . then cut the old rock quarry conveyor belting I had for anti squeak / rattle pads for the pump . still got to do the motor pads yet . ( question in a few posts down yet. )

also scanning my local craigslist I found this pair of pics of how my older 234 would have looked back in the day . . .

then the 2545 unit

also today I got the old 80gal tank out of the corner and cut the screwed up mounting bolts off flush with the floor .

cleaned out the old mix-n-match of outlet line to dryer / filter ( nothing in its case ) and this let me turn the tank 90* and set it back in a bit more to open up a LOT more floor space .

the new top plate on this one also helped a lot . spacing is a lot better now.

and I let the blood out of the old pump . . . she was gray and black with clean oil on top . . . but turn by hand bench test pin pointed the problem why it was so hot / wouldn't get over 120psi the blow by in to the crank case was so bad it was almost ready to pop the filter out of the vent / fill port . ........ so glad I didn't waste money on parts for that pump .

 

[sweetk30]

found a reman kit for 15 shipped with help from member over on www.garagejournal.com for my main line regulator .

and even a brand new unit shipped for 50 bucks to add in to the second comp unit.

 

[sweetk30]

o. . . m . . . g . . .

so last sunday night placed order with amazon 2 adjustable electric motor plate mounts . clicked the prime trial with 2 day free ship . . . . . .

showed more than 4 in-stock and sold by amazon . took them 3 business days to ship them out . and as said 2 to get to me . W.T.F

so the box showed up today TRASHED 1lb extra tape ( thanks fedex ) so I take pics of the box before I open it . the bottom has some of the mounting studs blown out of it . and I open it to find no extra beefy anti blow threw packing . just 1 wrap of tiny bubbles wrap on 1 then other set on top and the shipping air filled bags and all of them popped ! ! !

the bottom one was set in the box with no chance ever of making it here with no damage as it was set in studs down = the bottom blow out .

well I get them both out and the threads on both units studs are boogered to the point they all need cleaned up BIG time but I said no when I found 1 of them that was on the bottom unit that went threw the box was bent more than 20* off its 90* from plate spec.

so I called them up and they said we can ship you a new set next day shipping for sat delivery no charge . . . . . we will see just how this plays out .

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but on a good note I did get the 1 small unit all done today with using 1 of the mounts for all my layout work as a template . so when the new show up in better condition I hope it should be bolt on / tighten belt / plug in / fire up .

ahhhhhhhhhhh I hate it when people don't do what they say they can do or will do .

and I did get a new power switch for the smaller unit with a unloader valve port to add in to the system since it didn't have one before on the old setup mix-n-match it was .

got her all rubber mounted also . rubber between old/new top plates . rubber between pump/motor & new top plate . will even be doing it between the floor to tank mount feet .

 

[sweetk30]

few box pics of packaging short falls .

and 2 of the small unit ready for a TEST FIRE

sat we be digging out the BIG boy and get him all done up .

 

[JoshHefnerX]

That's definitely some fantastic packaging right there... could have just slapped a shipping sticker on it and sent it...

 

[sweetk30]

got the little guy done and running today .

0psi in a 60 gal tank . then stops filling @ 140psi time is 8:30 sec . I don't think that's to bad a job . she is a bit LOUD on the intake pulse's got a idea to cure that tho . and swung here over in the corner for now and hooked up to the shop lines .

 

[sweetk30]

then I finished up the BIG boy to the point I just need a high pressure line from pump to tank inlet / and power to motor just need to get a cord .

here is the rubber sandwich I did for both . rubber between old top plate to new 1/4" 6 pads total . 4 pads between adjustable electric motor mount and top plate . then 2 strips between pump and top plate .

 

[JoshHefnerX]

You can make an intake muffler out of some pvc and you can dampen the pulses on the intake with them. Built one for mine and it was noticeable. Or you can pipe the intake outside...

 

[sweetk30]

ya was thinking muffler and pipe the intake to a different section of the shop . I was thinking the big unit is 1.25 inch inlet port were the filter screws on . so I would do 2" grey or white conduit and tee them together and run 1 massive filter/muffler combo . kind of like a air line setup for the output but for the input.

cant do the outside option as I am north east . lots of rain / snow / humid days . . . this would build up so much moisture I would then definitely need a dryer system

 

[sweetk30]

BIG boy is up and running good I think .

got the electric finished on it . all parts mounted up . had a braided Teflon air hose spec hose made for pump to tank .

80gal tank 0psi-175psi 6min 45sec .

 

[JoshHefnerX]

The fan on that big 2-stage isn't very large, does it produce decent flow? Mine's got a big fan/flywheel on it. Blows a decent amount of air across the heads but it still gets pretty warm.

 

[sweetk30]

that's a 18" flywheel on the big one.

and guy on othersite said by my time to full fill from zero I am at around 18.9cfm . just a hair above spec of 16 cfm .

 

[sweetk30]

the more I test and tweek a few things . . . . . the more I LOVE the big 2545 pump . its so nice to have a real pump . no more cheepy junk .

the noise level is decent but not bad at all for this unit .

 

[sweetk30]

.
got a size refrence pic today for some of you on the BIG pump . note the can of brake parts cleaner center top of pump .



also got a 1/2"x50ft flexzilla hose with 4 Milton G type ends for it to match the flow . this will let me use the gun I have had for some time but unable to for hose/cfm limitations. 3/4" impact gun built in ir plants but painted green and labled bosch . note the reducer bushing . I tried to make it work with reg hose and fittings . . . didn't wana play ball.



and last I come up with a pair of names for the small guy and the BIG guy . . .

 

[sweetk30]

so today I got the end of the 2nd line redone so make it a zone off section . it now can free flow from BIG FRANZ comp down to end of line 2 and stop . or if valve is open it can fill the storage tank at the end of the line . also if need be valve open and its a balance tank for the system now.

this new addition let me redo the end to also let the SMALL HANS feed both ways . he can do line 2 back shop back to the splitter and also go to line 1 front shop . but if zone valve at end of line 2 is off it will only feed the paint booth . and also the storage tank can be used if the valve is open for the tank .

also got 2 cans of black on the tank to freshen the looks up a LOT . and pressure washed / scrubbed / purple powered the inside of the storage tank a few times . she had a lot of oil / water / small amount of rust smuts inside . for as old as the tank is I am shocked how SOLID it still is . tag on the side says Westinghouse 1950 air brake service . she is only 60 gal but you HAVE to use a engine hoist to move it around the shop ! ! ! the newer 60 gal SMALL HANS tank before anything on it was hand cart easy all over the shop .

had to make the storage tank line go up/over/down the garage door . got slope in the crossover line and a valve drop on both sides for crap removal . going to do a small flex hose from har . just have to make a shelf over the tank to store firewood on then were done and ready for action .