Replace or "upgrade" my air compressor

[MyLilMule]

In my attached garage, I have a 3rd, maybe 4th hand air compressor. It's right below our bedroom. It's an older Craftsman that has a good airflow and capacity, the problem is, it's getting louder and louder. If I have a demand for air later in the day, it wakes up my wife. Not a good position to be in.

It could use a rebuild, but unfortunately, rebuild kits for these are no longer available. I feel like it's on its last legs, as a motor and pump anyway. I don't think the tank is in too bad of condition. Even though it doesn't get drained everyday, I do drain it every month or two. which is still bad, just not as bad as never.

I want to replace it or at least upgrade it with a new motor and pump, with something that is quieter. I see there are a number of "quiet" compressors on the market that are supposedly 70db, but which one to choose is something I could use your help with.

For those that have larger capacity (60 gallon and up) QUIET compressors, was it worth the extra money? What make/model do you have?

If I were up just upgrade the pump and motor (220 volt), are there any brands to stay away from or are ones to look into?

I don't have an endless budget, but I am willing to spend a little more if I can check a few of my boxes. I hope to add a plasma cutter to the arsenal, so having a good airflow rating and tank capacity is going to be imperative. Especially if a CNC plasma comes after.

I am looking for specific options or opinions on specific manufacturers, not generalized answers. I know what my options are, 1. Run it, 2. Replace it, 3. Upgrade it.

 

[ChazzC]

Can’t comment on good vs. bad brands, but have a third alternative for you to consider: use the tank as a down-stream reservoir - that way you get the large volume of air near the use points and can locate a new high output, small/midsize tank compressor in an out of the way location.

 

[Nesse1]

What is the compressor model number? I found some rebuild parts for similar compressors, but I can't tell if it would fit your unit.

This repair kit seems to fit several different versions of that same compressor. Is the pump made by DeVilbiss?

DeVilbiss Air Compressor Piston Cup / Cylinder Kit #0999A9

DeVilbiss K-0650 Air Compressor Piston Cup / Cylinder Kit includes the cylinder, piston ring, retaining screw, o-ring, and head o-ring to help repair your air compressor. Master Tool Repair offers technical expertise and live customer service and support to help you find the right part to fix...

mastertoolrepair.com

 

[tq60]

You can look for dental office compressor, used maybe

Or, locate a suitable compressor and motor unit that can be mounted someplace like in a box.

Plumb it into bigger unit for the tank.

If you do not need the volume most of the time, add a small compressor for the small use projects, fire up big one as needed.

Sent from my SM-G781V using Tapatalk

 

[j-becker]

I don't have a modern quiet compressor but went the other route and rebuilt an industrial compressor with a slow running pump (400-800 rpm). That turns out to be a bit quieter and in a more pleasing frequency than anything I had before (but I haven't measured the db so no idea how it stacks up in numbers). So it depends what route you want to go and how much you want to spend. The first thing you should look at when you think rebuilding is your tank: if it is rusting (likely) I would not start putting a different motor & pump on it. Overall, I would not put more money and time into a lower end compressor and rather buy a new one or rebuild something worthwhile (industrial).

The high-end Quincy (325 series pump) or Champion (R series pump) are I was looking for. They all run lower rpm and have pumps with valves that can be rebuilt and include unloaders and after coolers as standard features. I ended up rebuilding a smaller Champion HR3-30 (3hp/30gal) compressors because I got it cheap locally. I underestimated the time and cost necessary (I spend ~$800 in parts including a VFD to drive the 3ph motor) to get a good result and probably should have waited to find a 5hp model. Oh well, I am pleased with the end result and ended up with a compressor that costs new around $3-4000. Which is probably what you would need to spend on these kinds of compressors and pumps new (e.g. a Champion VRV5-80 is >$4000 new).

 

[Eddyde]

Lots of compressor experience here. IMHO those "oil free" pumps don't last. If you want quiet and high output, a rotary screw compressor is the ultimate way to go, though they are quite pricy. Next would be a low speed, 2 stage piston compressor with an oil filled crank case. Quincy is a good brand of this type. Either way if you want to use for plasma you'll need a good air dryer as well.
You can also abate the noise by lining the area surrounding the compressor, walls & ceiling with several layers of sheetrock and a sound absorbing material, high density fiberglass or mineral wool insulation, etc.

 

[mksj]

The oil free pumps do not last long and some can be quite loud/annoying higher pitch frequency. There are oil free dental types that can last longer, but also get quite expensive for a decent unit. I have a Champion HR55-8 which is a 2 stage low speed pump, it performs very well, but I would not consider it quiet but is tolerable. There are a series of piston light industrial compressors that are much quieter (quiet air series), mostly lower speed pumps with a muffled intake chamber. They are rated at around 62 DBA, Eaton and Emax are both well built. I also highly recommend buying a compressor with an after cooler, it significantly drops the air temperature and moisture. My Champion came with an after cooler and an automatic tank drain. My last compressor was a Curtis horizontal CA-5 with the ultrapack, but was a bit louder than my Champion. If you are going to use it to provide air for a plasma cutter table, you probably want a refrigeration unit, dual filter setup and a desiccant filter.

5HP Single Phase Vertical Silent Air System 80 Gal|Polar Air by Eaton Compressor

Eaton Compressor carries an impressive line of quiet air compressors, including this single phase 5 HP Quiet Air Compressor with 80 Gallon Tank.

eatoncompressor.com

5 HP Quiet Air Compressor with 30 CFM Dryer Package, Single Phase, 80 Gallon Tank, Vertical

Eaton Compressor carries an impressive line of quiet air compressors, including this 5 HP Quiet Air Compressor with 30 CFM air dryer package.

eatoncompressor.com

5 HP Air Compressor, 2 Stage, 80 Gallon, Vertical, Silent Air System

Industrial 5hp 2 Stage Pressure Lubricated 19 CFM 1 Phase 80 Gallon Vertical Silent Air System 42 x 34 x 75

emaxcompressor.com

5 HP Air Compressor, 80 Gallon, 1 Phase, Silent Air System

EMAX carries a wide select of quiet air compressors, including this 5 HP quiet air compressor with 80 gallon tank.

emaxcompressor.com

 

[MikeInOr]

I have a 7.5hp 80 gal 2 stag belt drive oil bath pump compressor in the shop for tools and a blast cabinet. I also have a California air 2010A 1 hp Ultra quiet compressor in the garage for tires and nail guns, brad nailers and staplers.

https://www.amazon.com/gp/product/B00TDNKBMC/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

The California air compressor is considerably quieter and good for most things other than high CFM tools. But the 2 stage belt drive oil bath compressor in the shop is MUCH quieter than any old Craftsman direct drive oil-less compressor. Generally the slower the compressor turns the quieter it will be.

I started with a medium sized belt drive compressor. It was too small for high CFM tools like a sander. It was also too big for carting around to the job for stuff like nail guns, brad nailers etc.

My 18 yo daughter loves to tell the story about the time when she was 5 and she followed the air hose running through the house, up the stairs ,to the kitchen and found me decorating her birthday cake with an air brush in the middle of the night.

 

[Nesse1]

I have a 7.5hp 80 gal 2 stag belt drive oil bath pump compressor in the shop for tools and a blast cabinet. I also have a California air 2010A 1 hp Ultra quiet compressor in the garage for tires and nail guns, brad nailers and staplers.

https://www.amazon.com/gp/product/B00TDNKBMC/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

The California air compressor is considerably quieter and good for most things other than high CFM tools. But the 2 stage belt drive oil bath compressor in the shop is MUCH quieter than any old Craftsman direct drive oil-less compressor. Generally the slower the compressor turns the quieter it will be.

I started with a medium sized belt drive compressor. It was too small for high CFM tools like a sander. It was also too big for carting around to the job for stuff like nail guns, brad nailers etc.

I also have an 80 gallon 2 stage monster, that sees duty mostly for media blasting, and a 5.5 gallon California Air Tools compressor for general garage use. The CAT unit is remarkably quiet, and mine is 6 years old at this point, and works like new. It's truly a joy to use.

 

[7milesup]

@MyLilMule
One thing you didn't mention is budget, which, when it comes to air compressors, is a huge consideration. I had a two-stage Sanborn compressor that lasted many, many years, but the pump was starting to get weak, and the tank actually got a pinhole in it. I was lucky it didn't explode. It was reasonably quiet too. I would recommend tossing your tank, too.
I replaced it with a Rolair. Acme Tools - Rolair. The thing is LOUD. Even though it is a two-stage oil-lubed pump, it gets really loud when the tank is approaching the shutdown pressure (120-ish). Dissapointingly it is a lot louder than my old Sanborn. The Eaton compressors that Mark linked are not particularly quiet either. I have a friend who has one.
I used an old A-coil from a house central air unit as a condenser to remove the water from my air lines. It worked very well, and plan on installing it on the Rolair.
I too have a small oilless compressor that is wonderful to use. Its main purpose is to run my nail gun for installing trim, although the other weekend we re-roofed a house and garage and it ran two guns just fine. Fortress Ultra Quiet.