BOLTR: Air Compressor Explained and Fixed.
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- čas přidán 4. 02. 2017
- I haven't had a compressor in the shop for a few months. So we have a look at how the compressor works and salvage good parts to build a new compressor system for the shop.
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✪►teespring.com/Shmoo◄✪ - Věda a technologie
One of my first jobs out of high school was welding at Campbell Hausfeld. you were definitely right not to try to repair that. The weakness on those compressor are the heads. I'm not sure how they test them now but the 20-plus years ago I was there we tested them in a "bomb box" They were pressurize to 350 psi. When the tanks fail they always blow the heads off. The larger tanks were Hydro tested. Tanks up to 30 gallons were tested under air pressure. When one of those tanks failed it would shake the whole building. -david
AvE glad to be able to contribute. Another thing that is kind of interesting about those tanks is the large spuds that's welded in there. In order for the tank to be a certified pressure vessel you have to have inspection holes that's why some of the holes have really big bushings in them. They double as inspection holes.
krap101 not really sure what you're asking tanks under 30 gallons were tested with air pressure. larger tanks were tested with water or Hydro tested it's really interesting to watch a tank fail under a hydro. It would make a really cool video to blow that tank up with water pressure!!
Gorilla Strength Equipment USA Oh, I was just wondering whether the air pressure check was a different requirement from hydro. I know most if not all high pressure gas tanks require hydro testing
krap101 At the time hydro was required one level of certification. They were trying to move smaller tanks over to hydro testing so they could increase the pressure in the tank but they were having a lot of trouble with it. The smaller tanks out sold the larger ones almost 7 to 1. Depending on the size of the smaller tanks each line would turn out 2400 tanks a shift. Hydro testing was a huge bottle neck on production. Just dumping the water from 2400 30 gallon tanks would take forever.
It's been a long time since I was there but at that time 110 psi was the max pressure of the smaller tanks. I see some of them now at 175 psi. I'm guessing they are Hydro testing them. I don't recall the pressure limits and required testing for each. It's hard for me to imagine them hydro testing each of those but they may.
@ Krap101: These are low pressure. Low pressure requires only proof testing. Basically pressurize and prove it doesn't leak, distort or rupture. The manufacturer likely has an exemption/special provision to do air testing for expedience compared to draining the water and then drying the inside of the tank. The tank still experiences the same stresses as it would with water, the only difference is the vastly increased safety precautions required when using air. I intentionally ruptured a 2.5lb fire extinguisher cylinder at 900psi inside a cage and barely got wet while hydro testing it. A local dive shop had a reserve scuba tank about the same size rupture at about the same pressure. It was in a tub of water to cool it, the tub was destroyed, the wall damaged, ceiling tiles in pieces for a 8ft radius and the guy filling it couldn't hear right for hours after due to the shockwave. Hydro is way safer.
High pressure is another animal. All high pressure tanks need to be hydro tested. There are certain cases where the testing interval can be extended but there are requirements for tank specification, what it contains and how often its filled. But basically all high pressure tanks require hydrotesting unless its military.
That moment when he opens up his drawers full of adapters for both hydraulic and copper.
Your jaw drops and you realize your hard as frig!
Hmm. My forehead just wrinkled as I realized I had no clue what any of that shit was for. God I suck.
Never been so jelous of another mans junk drawers. Would kill to have that much quality junk in my drawers!
My step-father has two 40L tubs full of copper and brass fittings that he's 'collected' over about 50 years. Not organised in any way, mind you.
"There's no way he could have THAT much fitt- JESUS CHRIST ON A STICK."
One man's junk..
AvE's 'junk drawers have more fittings than some professional shops! :o
I just wanted to say that while only having a minor interest in this kind of stuff, your drive to educate and entertain makes your videos some of my favorite on CZcams. Thank you for all that you do!
No homegamer has this many fittings in their homegamer shop. This dude takes home the spoils of mine contracting war!!!
its if left on the floor of a job site ,then its free to take home lol
no matter how long you work in the same shop, you know when that compressor kicks in, your jumping out your fuckin skin.
I had a crappy old compressor that didn't have a start stop solenoid, just used to keep pumping, the relief valve was so big and worn it was like an elephant blowing rasphberries at random intervals, scarred the shite out of me everytime!
haha i'm not the only one?
fpdiscopenguin You know, I have never jumped because of either of my compressors starting. What does make me jump every damn time is the frigging unloader valve on my 80-gallon compressor -- does it every single time and always sounds like a line or hose just busted! I do not have that issue with my wimpy little 6-gallon pancake compressor, but the 80-gallon one absolutely startles me.
My compressor, long story short, is half a century old. I don't use it too often, but godamn when that relief valve opens up...Took out a window, once.
It happens you never know when the thing kicks on it will get you once in awhile
Mate.... Your Aussie safety tag is spot on. Pissed myself laughing.
Hands down the best video I've watched of yours thus far. Seen over 20 in the last 6 months. I love how you take us through the entire system. Loved the clear explanations and additional things to know in case A, case B, etc. Would love to see more like this.
"Now this is the thing that goes in the thing that goes in the thing."
I love you, man! Strictly platonic like.
The upload rate is still crazy. Love it!
when i was an apprentice, my boss asked me to strip a compressor to prove that i could, i fucked every single piston ring, as did the other apprentice when he did his. I spent a fortune on new parts (on company dollar mind) and re built mine proper, the other lad just left the rings out.
MY boss didnt like me much and decided that the machine that was knocking its bollocks out was the one i rebuilt. So i asked him to show me which machine was bad, and to run them both.
Thats where my letter stamping came into its own, i unbolted my machine and under neath was a date of repair and my name - stamped in a nice neat row.
Dont know why i felt the need to share this but yeah, basically bosses are arseholes and always leave a tell tale of your work someplace incase some shit like that happens.
For anyone wondering, those grabby test probes are Fluke AC220s. $28 on Amazon. I just went and found them and put them on my list.
Damn you AvE I said "good enough for the girls I go out with" to my girlfriend.
Braeden Hamson hahaa I got one worse... I said that on a job site in front of my girlfriends father 😂👎🏼
Hey Chris, Funny I have the same exact air compressor been going strong for over 18 years and yes it developed the same exact crack/leak in the same exact place, how about that! Confession, I purged the tank and tig welded it up, don't tell the wife... Very nice collection of fittings, Great video buddy!
Cheers,
Ray
Ray Caniglia did you... did you just expose AvE's real name?!
gnaeiuopl Ooooops, my bad...
All the Chris's I ever met were very flamboyant
Yeah must be his blog/CZcams name, he couldn't have near the knowledge he does if he was a Chris. Ask me, I should know...
Dogurasu same lol
I was so happy to see you grab some 7014 rods because I thought I was the only one that uses them for patch work. but I love the videos learn so much and I love how you just love what you do I've learned so much thanks for everything it truly means alot.
Just fixed my compressor, motor was sparking like mad, with lots of brush material to go, bearings were fine but motor was straining to get up to set psi. Called Canadian Tire, got a new motor and piston pump assembly for $55 bucks...good for another 20 years hopefully. Great vids, I learn something new every vid. Thank you Ave. Cheers
Nice one! Now you can build a smoker out of the old tank...or use it as the torso for the fabled bar tending robot.
ASKARIwest or an oil fueled blast furnace
what is this hydroolik bar tending robot I keep hearing about? I've seen every video on the channel and haven't seen much but a mention.
Pete Lorenz- same here, I'm fishing for more info but Ave hasn't taken the bait.
you have to be a patreon is the gist i get.
Ever since I started watching this channel few years back, I started marking things that were fucked with the good ol' "NFG".
I just checked and it's been almost 3 FUCKEN YEARS dude!
my dad used to use "RS" for RAT SHIT
Matthew McLaren I always knew what nfg meant.. heard it said from time to time but now I actually write it on things ,I have even put it on survey notes and reports without thinking about it.
funshootin1 I like it cause it explains its self and people in the know, know what it means.
Matthew McLaren yep I write NFG on all things I find broken
Glad to see your channel growing like crazy. It's well deserved.
Very good info. I need to do almost exactly the same thing. Happy to see you getter done. Just one caveat, you are one of the few people in the world that could slide open a drawer and find exactly what you need. I dub thee "Knight of the Drawers"
You got your Aussie tag perfect well done! Sincerely - An Aussie.
When you have too many beers do you tag yourself out?
You tie the tag to your tackle and keep drinking, that way when you stumble into bed at four in the morning on a Monday wreaking of turps and Lamb Kebab ya'sheila doesn't waste her time trying one on.
DrFuNK Sometimes when you have too many beers someone else tags you out.
Or if you get the Mounties involved it might be more of a lock out tag out when you wake up in the drunk tank.
God, I can't believe how much I can learn for this one man.
Holy hell - what was that. I couldn't take my eyes off of it. I don't know what I just saw, but I will remember it forever!
great, pressure vessel paranoia triggered on a Sunday evening. I gotta go back to my pressure vessel building/testing job in less than 12 hours..
how long did it take to acquire those fittings using the ol lunch box?
Ozzy ô never ask a man such questions!
As for "things that usually go wrong", with the single phase piston compressors I've used, I tended to get through two pump units for every one pressure switch and motor start capacitor. I've killed a lot of compressors and either I've got lucky with the centrifugal switch or unlucky with every other component, but never yet had a problem with one. Three phase compressors seem to last longer, and in my experience generally have a two stage pump instead of a twin cylinder single stage pump that the smaller single phase ones have.
Where I used to work we had 4 medium sized compressors, around the 200l tank with 4-5kW motor sort of thing. Small by industrial standards but bigger than most people would have at home. We needed 3 compressors to be in use, and the 4th one was the spare that I was always fixing. The heaviest use one was around about 1200 hours per year use, but in the UK you don't seem to be able to get good quality piston compressors - they're all crap up until you spend a huge amount of money on a screw or vane compressor.
In contrast, we had two (lower pressure admittedly, about 4 bar) vane compressors that had run extremely well in well over 30k hours use each. The only spare part I'd fitted was an oil pump on one of them.
Black cap is start and the grey is PFC. Great vid!
Rich.
When the Olympics came to Salt Lake City in 2002, I learned two new languages so I could better mix with the tourists - Australian and Canadian.
I gotta say, I feel a lot better about my stick welding after watching this video.
Small nylon line from check valve to pressure switch is the unloader line to drain air pressure from the line going from the exhaust valve of the compressor to the check valve when the PS shuts off, to enable zero back pressure (on the compressor) starts when the tank is at the kick in pressure. The pressure switch senses tank pressure through the fitting, usually 1/4" NPT, on its bottom. Great video as usual. Michael from Colorado
Man I love your videos!!! I always learn so much!! thanks for taking the time to explain how things chooch and letting us homegamers into your empire of dirt.
look at all those fittings! The neighbors must be bugging you all saturday long
Your Australian is on point.
czcams.com/video/VYH2Kw04QQA/video.html
Humor, learning and mo' powa. AvE your channel is the best!
That was one of the better explanations of the start and run capacitors on a motor.
@8:00 got the capacitors mixed up! Silver is run, black is start
"What we have is a bomb" lol
As a born and bred Aussie ave your lingo is spot on love ya vids so entertaining and informative
We Aussies are so proud of you. You getting our lingo correct
Ave if I wanted to send you something really cool to take apart howes would one does that ?
Pretty good explainin' but what you called a sense line was the unloader line. You didn't mention anything about unloading the head so the motor can start.
Yeah I caught that too
The best Aussie I have seen in ages
Very cool, this is exactly what my Sunday project is about (running an old air condition compressor) and I started to not understand anymore what I was looking at.
You forgot to tell us about the unloader valve. It releases the pressure in the line, when the tank is full. That way the motor can start easier on restart and not stall out (burning up the start capacitor in the process).
He did cover the "blow off valve" = Pressure relief valve. (Safety)
The valve that dumps the head pressure when the tank reaches "full" is known as the unloader because it "unloads" the pressure from the pump piston(s) & output line.
Bmp, I was a little lost in translation.
5:56 Pretty sure THAT IS NOT A SENSE LINE - that's the unloader line. (That's where the blast of air comes from when it stops normally) Sense is the main entry on the switch base (to the diaphragm).
The pressure switch is not just electric, it's a pneumatic switch as well. When the pressure is great enough, the power to the motor is switched off AND the air from between the pump and the tank check value is vented to atmosphere.
This is so when the pump starts again, the cylinder isn't already under pressure - causing the electric motor to stall before it gets a chance to get some momentum.
ISSUES WITH THE UNLOADER MECHANISM CAN BURN OUT MOTORS. (Particularly a problem with those single phase motors and their low torque start capacitor setups)
This is why you don't turn running compressors off & on again at the power... and why the human on/off switch built operates the air & power switching.
Jup, you are right Ivan! That's where the springs are for, setting the cut in and cut out pressure (hysteresis) for starting the motor.
And some compressors utilize a special check valve without an unloader line to the pressure switch. Called an Air Genie, these have a spring loaded check valve that senses flow...well, all check valves sense flow..anyhow, when the pressure causes the switch to stop flow of pixies to the motor, the check valve closes to isolate the tank AND a bleed port opens to vent pressure betwixt the compressor and Air Genie. This way the compressor starts up without pressure load.
We need an AvE translation manual :D
LMAO figures
Found it.....freaking hilarious :D
Was going to ask a question about power factor around 4 minutes, then you pretty much answered my question. You'd be a good teacher if they let them speak freely
Another.pleasant Sunday afternoon
in west London, with a vijeo from AvE.
Got some CK screwdriver bits that have
lasted better than most others over the
years, surprised to see the corners round
off like that. Great you've got over the
400tho subs mark.
An old wise electrician once told me to always avoid bad touching ;)
There's old electricians, and there's bold electricians. But there's no old, and bold electricians.
Same for pilots.
I've got a few things with the same tag 😂😂
as a aussie id have to say you tag out, was spot on for your SWMS and even used spot on Australian
Cody sent me and I must say Im not disappointed. Great video, you earned yourself a sub very easily, good sir. :)
I'm an hvac welder everything I do is pressure lol and only 150lbs for a compressor is cake
chris jones in the states you can't weld compressed air tanks it's illegal UNLESS a certified welder does the job and then OSHA recertifies the tank on smaller tanks like this it's not worth it
Benny CompTech if I'm an hvac welder that would mean I'm certified
Benny CompTech I don't know how much fear AvE would need of osha showing up in his home jobber shop....
chris jones oil + oxygen + heat = no garage door
Leahcim Michael lol. it would be cleaned out prior to any repair lol
As a wee laddy back in Texas I did a 3rd world fix on a propane tank. The purge was not as good as it should have been - I wouldn't call the result an "explosion" per se, more of a giant belch and fart of flame that sheared off one eyebrow , some hair and half my ginger mustache. Some how I survived my youth. Since your compressor reciprocates do you figure that was a fatigue crack?
The dreaded heat affect zone - no PWHT for danged ole consumer goods. Good call on no fixy fixy -there's a time and place to chase crack and another time to walk away.
Didn't know anything about compressors and now I know something. Thanks!
You were right that you got the start and run capacitors mixed up. The run cap does allow a higher power factor but it does this by creating an additional offset phase, so the motor essentially runs as a two phase motor.
what the hell was that magic libation he sprayed on there some sort of weird clear on spray paint? went on clear and dried white. That's new to me
It's part of a crack finding kit. First you spray on a cleaning solvent to remove dirt and oil from the surface you are testing. They you spray on a red die penetrate and let it soak into the surface for a few minutes. Then wipe off the excess die from the surface. Finally you spray on a developer (goes on clear and dries to a white powder) which draws out any remaining dye that is hidden in cracks. The dye then stains the white powder showing you where the crack is. Simple, no?
simple enough thanks for the explanation.
That is some really helpful stuff. It is called liquid penetration dye testing. I or inspectors test some welds that I make with that same fluid. It is great for parts too large to x-ray or when hydro testing is not practical. Sometimes parts will be tested with die/pen process before being steam tested as to help keep steam testers safe. It works great to find cracks on aluminum heads or other engine parts. I general it is just really great stuff that is easy to learn to use and not to expensive. It is for more than cracks it will show any defect that is open to the surface.
If interested Kieth Fenner has a great video on how to use the stuff.
Lol 90 amps for 3/32 6011 is like toasting bread for 5 minutes
Maybe 70 would be better
Trevor Emmett yup maybe 60 on a 1/8 thick pressure Vessel..you dont wont to blow a hole in that wimpy shell..
Clearly neither of you have welded lots of thinwall. Straight polarity my brothers. That is the answer to the question
@@Hollowminder 7018 rod after drilling both ends of the crack. 125 gallon air compressor at 175 psi. I've also made my own hydraulic fittings by welding 2 pieces together. Run them to 5500psi in track hoes
Serviced an old one a whole back, interesting learn. Nice vid!
your Aussie slang "and this is from an Aussie" is perfect!
Why not just smoosh some JB Weld on the inside of your leaky seam?
What do you think about oil less air compressors? I call garbage.
SD Customs They're fine for a small job site portable compressor up to about 4cfm. For running air nailers and stuff They're much lighter to move around and fairly inexpensive. But, for something that you're gonna park in your garage, buy the biggest thing you can possibly afford with an actual oiled crankcase. 2 stage is preferred so that you can get some real air pressure ,150-175psi, and some real cfms. I'd recommend at least a 5hp 220 volt, with a 60 gallon tank if you can afford it.
SD Customs i got a craftsman 30 gal last year for $20 and the cylinder had de-chooched along with the compression ring. got a repair kit for all of $30 and sold the thing for $200.
at the same time I decided to check out my many years old long suffering contractor compressor and discovered it was in immaculate condition.
the rungs were the same teflon material but the cylinders were different and I think that made all the difference. the Cman was chintzy stamped metal with visible waves even in the new one, the contractor was a nice cast or pressure molded piece with a coating and it barely showed any scuffing at all where even the best sections of the C mans bore were rubbed raw.
I take it then that like most things it depends on the manufacturer, oil less can be good...or it can be junk.
They're good for paint sprayers.
Good for spraying things you don't want oil in.
As a diver i love them.
that is an Australian standard recognized tag out tag, well done for using proper procedure!
I always wondered what that capacitor on the start winding was for. Well, now I know it, thanks a lot for the explanation!
Btw, I appreciate the amount of videos!
why did you use glue sticks?
I have a shop where the compressed air tanks are inspected by the state every 5 years. I have had the same inspector everytime and he has some *very* scary stories about air tank explosions. The most memorable one involved a car wash where the air pump wore out and was consuming oil. Instead of repair or replace the pump they kept pouring oil into it. The pump was running so hot the oil caked in the HP line running into the tank (plus the tank was full of oil vapor) making a restricted orifice..... One day... BOOM! Destroyed the compressor shed, blew out a block-wall, launched the pump unit over 200 feet away, killed 1 and injured 4 people. The inspector had pictures and it was truly scary how violent it was. Mind you, it *was* a bomb but the idea that something like that can happen is sobering.
I'm thinking, since this is in his house and he has a wife and child, he doesn't want to Mickey Mouse the compressor to save a couple of Canadian Pesos.... Some things are worth doing correctly. This is one of them.
That's why it's important to maintain your compressor, I don't think i've ever heard of a air compressor exploding that was functioning correctly, it's always overpressure that does it.
After seeing his welds, yea, i wouldn't trust myself to weld a air tank either. Besides, if you have other tanks laying around, why not use em?
For me, I make sure my tank stays drained, and my blowoff valve works (I test it occasionally) and don't worry too much about it. I've never heard of a air tank exploding that wasn't over pressurized, seen dozens that leak @ 125psi, but never explode.
I've done weld repairs on air tanks at a shop that built them... but the shells were a lot thicker than that Campbell Hausfeld ever thought of being. The prep work was what took most of the time.
Greetings from Alberta! Thanks for the morning video ,
how did you survie for months with out a compressor? I lost a belt on my 3 stage 120 gal at home, had too wait 3 days for the replacement... I could be found hiding in the corner of the shop in the fetal position.
Heyya... I inherited a big box of assorted pipe fittings a few years ago. In it, were a dozen or more of these things; some brass, some stainless, no two quite the same length, taper, or diameter. Did image searches, looked through pipe-fitting catalogues, asked my facebook horde, etc. At best, some guessed check valves, or pipe flaring bits. Might you, or your horde know what these bullet-shaped turned metal parts are?
bonmot.ca/~nevin/wtf.JPG
Nevin Williams It looks like a homemade metric bubble flare swaging tool for setting the bubble.
those are mushroom tips.
What're they for? A google search gives me smoking paraphernalia.
Nevin Williams mushroom tips are for putting in mushroom tip receptacles.
side note: I don't actually know what it is. lol
Heh. #subtletroll
Aussie here, that tag's spot on. Another favourite of mine is "she's munted".
I'm so glad you stressed NOT WELDING PRESSURE VESSELS. Some people just don't understand!!!
Your Australian is spot on Ave!!
hello from ireland young man , love the videos
As a Aussie viewer myself I approve of your Australian keep it up
I'm watching this and thinking; My ruler and t-shirt should be here soon.... entertainment AND educational! can't get enough.
I've had the pleasure of seeing one of those large caps blow a few times on this glass polishing machine at my work. Blows the chinesium sub panel door right off the hinges every time. Quite a show though, the sound is unreal.
The black capacitor is the start cap. They are rated for a limited number of starts an hour or they overheat and can blow up. The 29 mfd cap can be in the circuit all the time.
As an Australian Tradesmen I can confirm this is indeed how we tag out equipment!
Love your lingo and channel peace from the uk
I love the rotating "blue shmoo" addition to the thumbnail in the notification for subscribers.....
as an Australian I approve and confirm your terminology is correct sir
I love the classical music in the newer videos!
Hi Ave, I would like to correct you on something I have also only recently learned. The 'sensing' line that runs to the switch unit is in fact a depressurizing line. The sensing goes via the big plug the switch is mounted to. It's purpose is to release the pressure in the cilinder so the motor does not have to push through a static spring basically at start. I found this out when building my own big compressor out of parts... the pumps would work fine first time but hum and smoke and not rotate after the first cycle, until I helped them. It is in fact the big PSHHH you tend to hear when the compressor reaches pressure. super cool vids man, very therapeutic to watch. by the way whatsup with the Feyenoord flag?
Hahaha that was my handwritting on that bag of dental burs i sent, now i know why youre fixing the compressor!
This video needs a part 2!
im an aussie and your correct on your tagging ....thats awsome cracked me up
bahahaha I know its just a video but I flinched and shut my eyes as you showed how to deal with the hole on the compressor
always learn something - thank you sir.
amazing and informative videos love em
Your videos are awesome so much learning.....
Useful video, like often. Just bought old ingersoll-rand compressor that needs a lot of work. Now i have some idea where to start :)
When I worked for the medical examiner collecing bodies I picked up a fellow who died in a welding accident when the vessel he was welding exploded. It was a large vessel, but the idea is the same. The ladder he was tied off to came clean off the vessel launching him straight up with it, and he landed on concrete still in his harness still attached to the blown off ladder.
While driving him to the morgue a news broadcast came on the radio and his death was included in the broadcast, along with the fact he had a wife and two kids. I'll never forget that one.
2:06 "due for it's quarter-century bit of attention" Your tongue in cheek realism kills me. I usually have the best intention in caring for my equipment and frequently realize when something breaks that I haven't done any PM in years.
10:14 yes you did get the caps in reverse the start cap is the black one and the oil filled cap (gray one) is the run cap. The oil keeps it cool since it's always in circuit.
As a general rule when working on capacitor start / capacitor run motors the start cap will have a higher capacitance than the run cap. The start cap also will blow if a bad centrifugal switch leaves it in circuit for too long since it's not rated for continuous duty like the run cap.
My Hazard Fraught compressor has a leak that I have located only as "near the pressure switch". I don't need air in the shop that often as I mostly do handloading and ham radio, but when I do need it badly enough, I just run the compressor long enough for the job, then shut it off and let it leak down. This video has inspired me to look closer and maybe actually fix the thing :) Maybe I can use my AvE ruler...
I have the exact compressor. Got it mid 90's. Your's looks like it's used everyday.
You've got the Aussie tagging system spot on.
Trouble is lately with the volume of precious personnel on site, we've had to substitute it with 'FINGERED' instead. . .
i'm from aus mate, you got your tag labeled correctly. good to see.
I do love the woodpecker approach to stick welding ,it never worked for me!