110V Aux Air Compressor Install

Topic: 110V Aux Air Compressor Install (Read 3319 times) previous topic - next topic

110V Aux Air Compressor Install

August 04, 2017, 10:24:22 pm

In a recent thread, we discussed ways to integrate a 110V air compressor into the coach air system. Link to thread:

Pancake compressor (split from How long to build air pressure?)

Mark Duckworth blazed the trail with a very neat installation. I decided to try emulating his work, with a few modifications. Don mentioned the QC3 filter, and I liked the fact that it was a little less expensive than Mark's filter system, so I bought one. I also purchased the California Air Tools Model 2010A compressor from Walmart. Links to these items are in the earlier thread.

Don brought up the fact that the QC3 filter is supposed to be installed 30' from the compressor. I did some reading on the subject, and learned that Don's guess about the reasoning behind this requirement was correct. The air coming out of a compressor can get hot...sometimes VERY hot. How hot depends mainly on how hard the compressor is working. The heated air carries moisture, which will eventually precipitate out as condensation when the air cools. SO, the reason for having 30' of flow line between the compressor and the QC3 filter is to allow the air to cool. Only then can the desiccant in the filter do it's job.

In my installation, I attempted to provide a means to cool the air between the compressor and the filter. My flow line is a little short at about 22', but I tried to compensate for that shortcoming with my choice of material. I used 3/8" soft copper line, hoping that the metal would be effective at radiating the heat. As you will see, it actually works pretty good! The hot air exits the compressor, travels around the copper pipe loop, and then dumps into the aluminum compressor tank, where it is further cooled. Then and only then does it pass through the QC3 filter, and on to the coach wet tank. I can drain any condensate accumulation at three points: the compressor tank drain, the QC3 filter drain, and the OEM wet tank drain. I hope this will provide sufficiently dry and clean air to the coach system.

The compressor cooling loop seems to be working great! After 10 minutes of running the flow line coming out of the compressor is so hot that I can't touch it for more than a second. After going around my loop, the line going back into the tank is only slightly warm. The aluminum tank did not feel any warmer than ambient temp. I will take some readings with my infrared temp gun over the next few days, and report back with more "scientific" temperature data.

I timed the compressor to see how it performed. Starting with the coach air system completely empty, it takes the compressor 10 minutes to bring the system up to cutout at 120psi. When I use air out of the system, the compressor cuts in at 90psi, and then it takes 2 minutes to recover from 90psi back to 120psi. I feel this will be perfectly satisfactory for my anticipated usage.

Having this compressor installed means that whenever our coach is plugged into shore power (or on generator), the air system will always be at operating pressure. The leveling system will always be at travel pressure. The air step will work all the time. When starting the coach, I will have immediate throttle control and parking brake release pressure. Plus, as part of this project I added a neat little Northern Tool 25' pull-out air hose reel to my "tool chest compartment", so I will have convenient air pressure for filling bike/car/coach tires anytime I need it.

By the way, I left the 12V HWH compressor in place, and fully functional, so it will be available (if needed) when we are on inverter power.

I'll load some photos in 3 posts. Any questions, please ask. All comments, or suggestions for improvements, cheerfully accepted.

Re: 110V Aux Air Compressor Install

Reply #1 – August 04, 2017, 10:25:16 pm

More photos:

Re: 110V Aux Air Compressor Install

Reply #2 – August 04, 2017, 10:26:02 pm

Last set:

Re: 110V Aux Air Compressor Install

Reply #3 – August 04, 2017, 10:49:20 pm

Chuck,

I love it. Great job. Thanks for blazing the trail for me. My coach has the exact same layout so I'm pretty sure I'll be doing this same setup this winter.

One question. How's the noise level from that "quite" California Air Tools Model 2010A compressor?

see ya
ken

Re: 110V Aux Air Compressor Install

Reply #4 – August 04, 2017, 10:57:04 pm

Quote from: kenhat – August 04, 2017, 10:49:20 pm

How's the noise level from that "quite" California Air Tools Model 2010A compressor?

The noise level is not bad at all. Not totally silent, mind you. I could always hear our little HWH compressor when it was running, and I would say this new compressor makes only slightly more noise. I did do a little work on the rubber feet on the compressor to help reduce the sound. Added some additional damping in the form of some extra rubber pads and "bobbin" bushings I had on hand (photo below).

I also added some extra screws to the plywood platform it sits on. The platform was loose and rattling a little bit initially.

Standing in the bedroom, with the A/C units turned off, I can't hear the new compressor running. Of course, my hearing ain't perfect!

Re: 110V Aux Air Compressor Install

Reply #5 – August 04, 2017, 11:31:24 pm

Nice job

Re: 110V Aux Air Compressor Install

Reply #6 – August 05, 2017, 12:09:50 am

Sweet! So to get the 22' of copper before the dryer, you went around three sides of the compartment? Glad to hear that cools effectively.
Don

Re: 110V Aux Air Compressor Install

Reply #7 – August 05, 2017, 04:41:19 am

Glad to know that the copper line worked out. I like the quick connects between the compressor and the rest of the system. Should make future compressor servicing a breeze! Did you incorporate any of the OEM filters into your new system? Wondering in particular about a desiccant filter downstream of the QC3.

The lowered sound level you get from the CAT 2010A is an enticing upgrade!

Nice job!

Re: 110V Aux Air Compressor Install

Reply #8 – August 05, 2017, 07:33:47 am

Quote from: Don & Tys (AKA acousticart) – August 05, 2017, 12:09:50 am

So to get the 22' of copper before the dryer, you went around three sides of the compartment?

Correct. I actually could have made the copper loop almost twice as long, because the coil of tubing I had on hand was 50' when I started. I thought about making a few back and forth "zig-zags" on the ceiling of the compartment, but decided that would be unnecessary complication. As it turned out, the length I used is doing a satisfactory job - any more (IMO) would be overkill.

Re: 110V Aux Air Compressor Install

Reply #9 – August 05, 2017, 07:46:35 am

Quote from: Mark Duckworth – August 05, 2017, 04:41:19 am

Did you incorporate any of the OEM filters into your new system? Wondering in particular about a desiccant filter downstream of the QC3.

The QC3 is the only filter between the compressor and the OEM wet tank. It is marketed as a 3-stage combination particulate filter, oil separator, and air dryer. The replaceable desiccant cartridge is pretty big, so hopefully will be sufficient for this application and last a reasonable length of time. It has a replaceable "telltale" disc that is supposed to show when the desiccant is used up. Just have to wait and see how long it keeps working. Live and learn!

Re: 110V Aux Air Compressor Install

Reply #10 – August 14, 2017, 11:22:39 pm

For the one or two members who might actually be interested in this project, I have a few updates on my compressor install. I'm still messing with the details, and have made a few changes.

First thing I addressed was the drain valve on the compressor tank. Since I'm trying to remove as much water from the compressed air as possible, before it goes into the coach air system, I was not happy with the drain valve on the tank. It was coming out the bottom of the tank at a angle, I suppose to make turning the valve handle easier. Because of this, a good quantity of water would remain in the bottom of the tank that would (normally) never reach the drain valve. A decal on the tank says "tip tank to drain completely". Well, this wouldn't work for me because I have the compressor mounted in a "fixed" position, and because I want to be able to drain it while standing outside next to the bay door. So, I unbolted the tank, and added a couple metal brackets between the compressor frame and the tank. This repositioned the tank so the drain is pointing straight down. Problem solved! (Nylon ties on bottom brackets are temporary. I will eventually re-drill the brackets and use bolts.)

(Photos below show new drain valve orientation)

Re: 110V Aux Air Compressor Install

Reply #11 – August 14, 2017, 11:34:23 pm

Thanks,

When I install mine I will do the same. I am thinks about putting a spitter on at the install also.

Re: 110V Aux Air Compressor Install

Reply #12 – August 14, 2017, 11:36:07 pm

Next thing is noise. The compressor is quiet, but it still makes some noise, so I have been working to reduce it as much as possible. I'm trying two different approaches. First, I made up some fancy "vibration absorbing" feet for the compressor. I read about this stuff called Sorbothane, and decided to give it a try.

Sorbothane - Wikipedia

Isolate It: Sorbothane Vibration Isolation Circular Disc Pad .5" (1.27cm)...

Ordered two sets of 4 pads in different durometer ratings: 30 and 50. Made up 4 double-decker sandwiches using the pads and rubber spacers. Attached them to the compressor as shown:

As an Amazon Associate Foretravel Owners' Forum earns from qualifying purchases.

Re: 110V Aux Air Compressor Install

Reply #13 – August 14, 2017, 11:43:11 pm

The fancy feet made a BIG difference in the amount of perceived vibration coming from the compressor. But, there was still some undesirable noise, so I tried another step. I had some 4mil foil + butyl rubber vibration damping material left over from a car stereo project about 10 years ago. It's called "Audio Barrier", and is a Chinese ripoff clone of DynaMat Extreme. Dug it out and found it to still be in good condition, so I said "What the heck...". Coated the entire underside of the stairwell with it. Even if it doesn't really do anything, it looks kinda cool!

Re: 110V Aux Air Compressor Install

Reply #14 – August 14, 2017, 11:50:20 pm

Any input to the coaches air system must be dry air.

Not sure how you are entering the system so this is a general comment.

Wet air and cold puts ice into the brakes and corrodes things

Re: 110V Aux Air Compressor Install

Reply #15 – August 14, 2017, 11:54:31 pm

End result (so far) is I have got the noise heard inside the coach down to what I would call a acceptable level. I can still hear it running, but it is not something that will bother me. (We'll have to see what the DW thinks on our next trip.) The vibration level felt inside the coach, especially in the stairwell area, is down to almost zero. Sorbothane is doing it's job!

Standing outside the coach you can hear the compressor running, but it is just a low-pitched humming noise. Probably not even noticeable to a neighboring camper.

I am still thinking of other steps that I might take, but will leave it like this for now. Anybody else has any ideas, speak up. This has become a fun and entertaining "science project", trying to reduce the noise/vibration to the lowest level possible.

Re: 110V Aux Air Compressor Install

Reply #16 – August 14, 2017, 11:56:10 pm

Quote from: Caflashbob – August 14, 2017, 11:50:20 pm

Any input to the coaches air system must be dry air.

Thanks, Bob. If you feel like reading back over this entire thread, you will see that we are attempting to address that concern.

Re: 110V Aux Air Compressor Install

Reply #17 – August 15, 2017, 03:23:16 am

Chuck,

Love the ingenuity of repositioning the tank drain.

Great job on mitigating the sound as well. Sound is transmitted both mechanically and through sound waves. Mechanical coupling is when the sound source (compressor in our case) is physically vibrating the structure and resulting in sound transmission. The new feet address that. The more common transmission of sound is through the air --- it is of course how loudspeakers work. Unfortunately it's also how the annoying subwoofer 2 cars back at the stoplight works. That's where the sound absorption material works. Great job hitting both means of unwanted acoustical transmission.

Re: 110V Aux Air Compressor Install

Reply #18 – August 15, 2017, 08:17:55 am

Nice work Chuck, having a aux compressor for two years now I have always kind of lived with the noise, thanks for the great post will be making g some.changes to my system with your ideas, I really like your air line reel. Again great post.and thanks for sharing.

Re: 110V Aux Air Compressor Install

Reply #19 – August 15, 2017, 08:52:11 am

Quote from: Andy 2 – August 15, 2017, 08:17:55 am

I really like your air line reel.

Air hose reel is currently on sale at Northern Tool. I used the 1/4" x 26' "Mini" model ($25). I only need it for filling tires. They also have a somewhat larger (but similar design) 3/8" x 50' "Compact" model ($50). Mine seems to be working great mounted in a horizontal position.

I printed out the product page with the "online" sale price, and took it down to our local Northern Tool store. They were happy to sell me the reel for the sale price, no problem.

1/4in. Hose Reels | Air Hose Reels | Air Tools + Compressors | Northern Tool...

3/8in. Hose Reels | Air Hose Reels | Air Tools + Compressors | Northern Tool...

Re: 110V Aux Air Compressor Install

Reply #20 – September 01, 2017, 08:36:29 am

UPDATE -SAFETY NOTICE

I am sorry to report that my California Air Tools Model 2010A has died an untimely death. I wanted to get this info out to the Forum for anyone who has purchased this compressor (Craneman) or is thinking about buying one. I can no longer endorse this product.

The sad story: I went out to our coach yesterday morning, as usual. Going inside, I noted the air pressure gauge was down to about 60psi - not a good sign. For the last couple weeks, the compressor has been keeping system air pressure between 90 and 120psi. So I went outside and opened my "tool chest compartment" bay door, and was met with the distinctive aroma of burned electrical components. Unplugged the power cord, pulled all the junk out of the bay from the other side, and crawled in to take a look. Found the smoke had been let out of the compressor motor. Photos below. It must have been a quick death. Thankfully, there was no evidence of flame or prolonged combustion. Just the bad smell, and the streaks of black on the motor housing. I removed the compressor, and set up a fan blowing through the bay to air it out.

Can't tell why the motor failed. It was certainly not being over-worked - only ran 5 minutes at a time, several times a day (Yes, I have a pesky air leak that I cannot find - working on that). The compressor supposedly has a thermal fuse that would shut it down if it over-heated. I can only guess that there was a critical internal electrical failure of some sort. I was very lucky that there was no fire. I can envision other scenarios in which the consequences were much more serious. I hope I get the word out to other members before they suffer any similar problems.

So, what to do now. I can return the compressor to Walmart for a refund under their "90 Day Satisfaction Guaranteed" policy, so I'm not out any cash. I DO still want to pursue the objective of having a aux compressor permanently plumbed into the air system. I just need to find a SAFER, more reliable compressor. I will look into some other 110V compressors, or possibly a high performance 12V model like the one Don has.

Back to the drawing board!

Re: 110V Aux Air Compressor Install

Reply #21 – September 01, 2017, 10:14:39 am

Chuck,
It looks like the windings shorted out - probably due to the varnish being too thin. Manufacturing defect IMO.
I would try to contact the manufacturer. They might have a silent recall. If anything, it lets them know there's a problem; you could be the one in 10,000 that fails but there are probably more. The squeaky wheel does get the grease.

Re: 110V Aux Air Compressor Install

Reply #22 – September 01, 2017, 10:41:12 am

I feel for Chuck, one of my favorite things to do, is sit on the phone all day trying to get someone who knows what to do!

Re: 110V Aux Air Compressor Install

Reply #23 – September 01, 2017, 10:59:09 am

I think I would be inclined to give them another chance if they will exchange it for a new one. The company has a good reputation and you have everything in place for an easy change out... The safety issue is of concern of course, maybe install a circuit breaker right before that outlet.
Don

Re: 110V Aux Air Compressor Install

Reply #24 – September 01, 2017, 11:01:10 am

Quote from Chuck

(Yes, I have a pesky air leak that I cannot find - working on that)

YES; don't we all !!

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