For most industrial enclosure cooling applications, a temperature of 95°F (35°C) is sufficient to be below the rated maximum operating temperature of the electrical components inside the cabinet. So, it is important to turn the cabinet… More
Comparing the Different Styles of Compressed Air Filters
Most of EXAIR’s line of Intelligent Compressed Air Products have no moving parts and require no maintenance. The caveat to the “no maintenance” aspect is proper filtration at the point of use. Many products have very tight orifices that could get clogged from any contaminants such as particulate, condensate, and lubricant. EXAIR recommends point of use filtration to be installed just upstream of any EXAIR Product for this purpose.
There are three primary types of compressed air filters: particulate, coalescing, and adsorption. Each have their own inherent characteristics and can be used in conjunction with one another. Each style is used to handle a different form of contaminant that’s present within the distribution system of your compressed air supply.
Particulate filters – Particulate filters are available with different filtering mechanisms that allow you to control the particulate size that will be filtered out. The higher the level of filtration, the greater the pressure drop you’ll experience at the outlet of the filter. Styles are also available with either a polycarbonate bowl or metal bowls, depending on the application and environment.
Any filter with a polycarbonate bowl should have a metal guard on the outside to provide protection for personnel should a failure occur. In these styles of filters, compressed air is forced through a filter element that blocks any particulate contained within the air supply.
These filter elements are generally a sintered bronze material with filtration levels from 40-5 micron possible. Over time, the filter elements can clog and increase the pressure drop at the discharge of the filter. They’re relatively inexpensive and should be replaced yearly to maintain optimum performance and mitigate pressure drop. They also remove liquid drops as well from the air supply, containing them within the bowl. Styles with both manual-drains and automatic-drains are available that will drain the bowl of excess moisture automatically through the bottom of the filter.
Coalescing Filters – The coalescing filter is used to remove very fine water vapor as well as any residual oil. These filters are highly recommended to be installed just prior to any dryer that contains a media that would be compromised by any lubricant passing through it. Coalescing filters utilize an element typically made up of glass fibers that “coalesce”, or combine, the fine water vapor and oil aerosols until the droplet size becomes large enough that it drops off into the bowl or filter housing. With a coalescing filter, the most common cause of pressure drop increase is due to particulate clogging the filter element. Because of this, a particulate filter should always be installed just prior to any coalescing filters.
Adsorption Filters – The final type of compressed air filter is the adsorption filter. Where the particulate filters can remove the majority of contaminants and the coalescing filters the residual oil, they are not capable of removing lubricant vapors or oil. That’s where the adsorption filter comes in. In addition to removing the finest oil vapors, they also can eliminate odors from the compressed air supply. The oil vapors and odors adhere to activated carbon within the filter, removing them from the air supply. These filters are commonly found within the food processing industry, where any contaminants in the air supply could impact the integrity of the product.
EXAIR has a line of Automatic Drain Filter Separators and Oil Removal Filters, available from stock, to make sure the quality of your air supply is sufficient for proper operation of any EXAIR product. Feel free to give us a call and any of our Application Engineers will be happy to assist you.
Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD
The Scientific Legacy of James Clerk Maxwell
On June 13, 1831 at 14 India Street, in Edinburgh Scotland James Clerk Maxwell was born. From a young age his mother recognized the potential in James, so she took full responsibility of his early education. At the age of 8 is mother passed away from abdominal cancer, so his father enrolled him in the very prestigious Edinburgh Academy.
James was fascinated by geometry at a early age, many times learning something before he was instructed. At the age of 13 he won the schools mathematical medal and first prize in both English and poetry. At the age of 16 he starting attending classes at the University of Edinburgh, and in 1850 he enrolled at the University of Cambridge.
The largest impact he had on science were his discovery’s around the relationship between electricity, magnetism, and light. Even Albert Einstein credited him for laying the ground work for the Special Theory of Relativity. He said his work was “the most profound and the most fruitful that physics has experienced since the time of Newton.”
Maxwell also had a strong interest in color vision, he discovered how to take color photographs by experimenting with light filters.
But here at EXAIR we are very interested in his work on the theory that a “friendly little demon” could somehow separate gases into hot and cold flows, while unproven in his lifetime, did actually come to fruition by the development of the Vortex Tube. Which does just that.
So here’s to you, James Clerk Maxwell…may we continue to recognize your brilliance, and be inspired by your drive to push forward in scientific developments.
Jordan Shouse
Application Engineer
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Twitter: @EXAIR_JS
Photo credit to trailerfullofpix & dun_deagh
Applications for Vortex Tube Spot Cooling
The EXAIR Mini Cooler family is one of the many vortex tube based Spot Cooler products that EXAIR offers. This is the smallest of the group coming in at 550 BTU/hr of cooling capacity. The Mini Cooler Systems are available in two options.
- The Single Point Outlet option will give you ten inches of flexible cold outlet to easily position the cold air stream near the target point.
- The Dual Point Outlet option gives ten inches of 1/4″ flexible outlet that then splits to two separate four inch lengths of 1/4″ flexible cold outlet hoses.
- Both include point or flat fan tips for the cold air outlets
- Both include a manual drain filter separator
- both include the swivel magnetic base with 100 lb. pull magnet.
The single point hose kit is ideal for small diameter milling or drilling applications where the cold air can cover the contact area of the cutter. It can also be used on soldering, industrial sewing, ultrasonic welding, or even small punching applications to list just a few.
The dual point hose kit is ideal for two separate small diameter cutters, one larger diameter cutter, rotary style knives where there material is being slit, or larger diameter multi-point ultrasonic welders/punches.
When using the Mini Cooler the adjustable cold outlet stays in place and can easily bend around fixtures, spindles, welding horns, or dye aligning pins. The swivel magnetic base gives additional adjustment at the base of the cooler to aid in the versatility of this product. To further the adjustability of the cooler the operating pressure can easily be adjusted to lower or raise the cooling capacity of the Mini Cooler to meet the demands of the precise application.
If you believe you have an application that would benefit from the use of a Mini Cooler, or you are unsure which product would be ideal for your application please contact an Application Engineer. we are all here, willing to help however possible to get your application improved in both safety and efficiency.
Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF
Compressed Air Accessories for Clean Air, Quiet Air, and Adjustability
In this blog, I would like to turn your attention to our accessories that support our Intelligent Compressed Air® Products. EXAIR products use compressed air to coat, conserve, cool, convey and clean. To maximize the performance, it is important to have the controls and options to increase their “flexibility”. EXAIR offers these items as Accessories. Pneumatic applications come in many variations and forms, and Accessories can help you to adapt to your application and to remove any “guess work”.
Here are the different categories and explanations of each item that EXAIR recommends for our products. With their defined functions, they can help you in different areas to enhance your pneumatic experience.
Filters/Regulators:
- Filter Separators remove bulk liquid and contamination from the compressed air stream. EXAIR stocks a range of sizes from ¼” NPT ports to 1 ¼” NPT ports. They use a 5-micron filter and a mechanical baffle to remove slugs of liquid from your compressed air system. Most Filter Separators have an auto-drain to automatically remove the buildup of liquid inside the bowl. I would consider the Filter Separator as a minimum level of protection required to protect your EXAIR products.
- The Oil Removal Filters remove very small particles of dirt and oil from the compressed air; making it even cleaner. The 0.03-micron media of the Oil Removal Filter will “coalesce” the fine liquid particles into large droplets. Thus, allowing gravity to remove it from the compressed air stream. EXAIR offers different sizes ranging from ¼” NPT to 1 ½” NPT ports. As a note, Oil Removal Filters are great for removing very fine particles, but if you have a system with lots of water, I would recommend a Filter Separator upstream of the Oil Removal Filter for optimal filtration.
- Pressure Regulators control the amount of air pressure being supplied to your EXAIR products. This is important if you are trying to save compressed air, control the force, or convey material. EXAIR, being a leader in compressed air savings, recommends to use the minimum amount of air pressure to do the job. This will save compressed air and save you money. Regulators have a characteristic called “droop”. Droop is the amount of air pressure that it drops downstream when you start flowing compressed air. If the regulator is not sized properly, you can “starve” your pneumatic component, causing loss of function. EXAIR properly sizes our regulators in our kits to make sure that you won’t “starve” our product.
- EXAIR also offers Mounting Brackets for the regulators and the filters to help support them to a wall or structure. To connect filters and regulators together without a pipe nipple, we also have Coupling Kits for sizes up to ¾” NPT. And for combination kits which includes a filter and a regulator, we offer the Mounting Bracket and Coupling Kit together for a set.
Silencing Mufflers:
- Reclassifying Mufflers are designed to have two functions. They can reduce noise levels by 35 dB and remove oil mist from the exhaust air. Cylinders and valves that exhaust pressurized air may have oil in the line to keep the seals from sticking. When exhausted, it can create a fine mist which is dangerous for operators. The Reclassifying Mufflers can reduce the loud noise as well as collect any contamination from the exhaust air.
- Sintered Bronze Mufflers are simple in design, cost effective, and easy to install. They have a minimal back pressure to not restrict operations of the pneumatic device. They come in sizes from #10-32 thread to 1-1/2 NPT. For a quick and simple way to reduce noise, the Sintered Bronze Mufflers are in stock for fast delivery.
- Straight-Through Mufflers offer a way to reduce noise levels without worrying about clogging. They have an aluminum shell lined with sound absorbing foam, and they can reduce the noise level by 20 dB. EXAIR offers them with two ports from ¼” NPT to ¾” NPT. This can allow you to connect other items like blowing hose kits while reducing noise.
- Heavy Duty Mufflers have an outer aluminum shell with an internal stainless steel screen that can protect the components from environmental contamination, and can also keep contaminant like rust from being ejected at high speed into the work area. They have a typical noise reduction of 14 dB.
Pneumatic Valves:
- Manual Valves allow for operators to turn on and off their system by hand. The full-flow ball valves range from ¼” NPT to 1 1/4” NPT in size and will not restrict flow. EXAIR also offers a manual foot pedal valve for hands-free operations. This ¼” NPT Foot Valve has a 3-way operation and works great if the operator has to use both hands in their process.
- Solenoid Valves are a way to turn on and off the supply of compressed air electrically for automated systems. We offer solenoids in three different voltages; 110Vac, 240Vac, and 24Vdc. EXAIR has a large range of flows with ports ranging from ¼” NPT to 1” NPT. All models are UL listed and are CE and RoHS compliant.
Hardware:
- Swivel Fittings are a great way to securely install and aim EXAIR nozzles. They are dynamic as they can be adjusted and set to a flow direction with 50-degrees of movement. They are made from 303SS or 316SS for corrosion resistance with ports ranging from 4mm to 1” NPT.
- Compressed Air Fittings are a nice arrangement to connect different compressed air items together. We offer a range of hex and close nipples, couplings, reducers, tees, elbows, crosses and bulk head fittings. If you need a quick way to connect directly to your pneumatic system, we may have it on the shelf.
- Magnetic Bases are designed for a solid mount to steel surfaces and for easy portability of your blow-off system to different locations. It has a 100 lb. (45.5Kg) pulling force to keep the blowing device attached firmly until you want to move it. They can be mounted in a vertical or horizontal position. EXAIR offers a single outlet Magnetic Base (for one blow-off device); a dual outlet Magnetic Base (for multiple blowing products); and a single outlet Swivel Magnetic Base (to offer more flexibility to orientation). The bases come with a ¼ turn shut-off valve to easily turn on and off the compressed air to the EXAIR products.
- Receiver Tanks are used to store compressed air. They can be used at the air compressor or as secondary reservoirs for intermittent demand. They help your compressed air system with pressure variations and high demand loads. EXAIR offers a model 9500-60 Receiver Tank that has a capacity of 60 gallons, is rated to 200 psig, and meets ASME pressure vessel code.
Hoses:
- Conveying Hoses are used with our Air Operated Conveyors or Line Vacs. The hoses are made from a durable PVC semi-flexible hose with six different diameters from ¾” I.D. up to 3” I.D. The conveyance hoses can slip easily to the ends of the Line Vacs or to tubes for an easy transition. EXAIR can cut-to-length Conveying Hoses up to 50 feet (15m); in increments of 10 feet (3m).
- Coiled Hoses get compressed air from the piping system to the EXAIR product. They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters). They have swivel fittings at the end to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking. The coiled design makes it easy to reach around the work area and retract back to the substation. This will help to keep the hose off the ground where potential dangers could occur. We offer 3 different connection sizes; 1/8” NPT, ¼” NPT, and 3/8” NPT.
- Compressed Air Hoses is another way to supply EXAIR products. They are useful if you need to reach from overhead sources or around equipment. They are made from a reinforced synthetic rubber in 3/8” I.D. and 1/2” I.D. diameters. We can make specific lengths up to 50 feet (15m). They are rated for 250 PSIG (17 bar) air pressure, and the hose material works well for long-lasting protection against ozone, weathering and temperatures up to 158oF (70oC). They come standard with two male ends in ¼” NPT or ½” NPT.
Flexible and durable, EXAIR Stay Set Hoses come in lengths from 6″ to 36″. - Stay Set Hoses give you that possibility of manually adjusting or re-adjusting Super Air Nozzles. The hose has a “memory” function; so, it will not creep or droop until you physically move it. They work well to direct air flows in unique ways at specific target areas. They can be used with Super Air Nozzles, Safety Air Guns and Blow-off Kits. The Stay Set Hoses come in lengths from 6” (15cm) to 36” (91cm), and they are offered with ¼” NPT male on both ends or with a 1/8” NPT female and a ¼” NPT male connections. These hoses are rated for 250 PSIG (17 bar) and are made from reinforced synthetic rubber.
Temperature Accessories:
- The ETC, or Electronic Temperature Control, is a digital temperature controller with a LED screen for precision monitoring and adjusting temperatures in a Cabinet Cooler System. The controller has easy-to-use buttons to raise or lower the desired internal cabinet temperature. Once set, the ETC will hold the temperature to +/- 1 oF (+/- 0.5 oC). The LED displays the internal temperature for continuous monitoring. The ETC comes complete with the controller and a solenoid valve in two different voltages, 120Vac and 240Vac.
- The thermostat is a way to control a solenoid valve electrically to turn on/off a Cabinet Cooler System at a set temperature. It is preset at 95°F (35°C), but it can be adjusted to other desired temperatures. It has an accuracy to hold the set temperature within +/- 2 °F (1 °C). It can handle voltages from 24V to 240V, AC (50/60 Hz) or DC. They are UL Recognized and CSA certified.
In todays fast-paced world, there is a need to get your devices operating as quickly as possible. With EXAIR Accessories, they can help you to do that. Not only will you have confidence, as you are using the items from the manufacturer, but it will minimize downtime, setup, and malfunctions that can occur if using other types of accessories. If you would like to discuss the proper options with your EXAIR products, an Application Engineer will be happy to help you.
John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb
Video Blog Cooling Comparison: EXAIR’s 2″ Super Air Amplifier vs. Fan
EXAIR‘s line of Adjustable and Super Air Amplifiers are the ideal solution for cooling hot parts. Using a small amount of compressed air, they’re designed to entrain massive amounts of free ambient air from the environment. This free air mixes with the primary air stream, achieving entrainment ratios of up to 25:1!
To demonstrate the dramatic difference between the Super Air Amplifier and a standard fan, I created a side-by-side video of the two. Using the 2″ Model 120022 Super Air Amplifier at just 40 PSIG (9 SCFM air consumption) check out just how effective we were at cooling down a stainless steel block:
When fast cooling of a hot part is necessary, look no further than EXAIR’s Adjustable and Super Air Amplifiers. They’re all in stock and can ship same day to the US & Canada with an order placed by 3:00 ET!
Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter:@EXAIR_TD
Engineered Air Nozzles vs. Commercial vs. Open Air Line
How much does your compressed air cost? If you don’t know, there are some handy tools, like this one, that will help you calculate it precisely. For estimating purposes, the U.S. Department of Energy estimates that compressed air costs about $0.25 per 1,000 Standard Cubic Feet of mass to generate. Again, this is an estimate based on different electric power consumption costs from around the country, varying efficiencies of different types & sizes of air compressors, etc., so, as the automobile folks say, “your mileage may vary.”
Regardless of whether you calculate it exactly or just estimate it, it’s going to come as no surprise that it isn’t cheap. That’s why efficient use HAS to be taken seriously. Luckily, there are steps you can take (six, specifically, see below,) that can help.
This is a common inquiry here at EXAIR Corporation. It’s not hard to find a blog about them -like this one, or this one, or even this one. Before we go any further….yes, this is ANOTHER one.
I recently had the pleasure of helping a caller who was using the male ends of pneumatic quick connect fittings to blow off steel tubes:
They were operating these, for the most part, 24/7, as their production was continuous, although there were actually spaces between product at times. They were using over 74 SCFM…that’s 750,000 Standard Cubic Feet of compressed air PER WEEK, or over 39 MILLION SCF per year…over $9,700.00* in generation cost. After a brief discussion, they ordered & installed two Model 1101 Super Air Nozzles, which threaded right in to their existing fittings:
Not only were the Super Air Nozzles markedly quieter (sound level went from 90dBA to 72dBA,) air consumption was reduced to just 20.90 SCFM…a 72% reduction, which translates to an annual cost savings of over $7,000.00*. But wait…there’s more.
See, that was just “step 3” – they also installed a solenoid valve in the supply line, actuated from their process control. This turns off the compressed air in between cycles, roughly estimated at about half the time. This gets them additional savings of almost $1,400.00* per year. But wait (again)…there’s STILL more.
This is one of five lines that were (mis)using the pneumatic fittings. With the dramatic improvements of the first line, they ordered Super Air Nozzles for the remaining four. So, to recap…an investment of $440.00 (2019 List Price for the Model 1101 is $44.00,) plus their solenoid valves, they’re saving almost $42,000.00* per year in compressed air generation costs.
*using the DoE thumbrule of $0.25/1,000 SCF referenced in the first paragraph.
Engineered compressed air products like the Super Air Nozzles are a clear winner all day, every day, over any open-end type device. If you’d like to find out how much EXAIR’s Intelligent Compressed Air Products can save you, give me a call.
Russ Bowman
Application Engineer
EXAIR Corporation
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Happy Independence Day From EXAIR!
Summer is my favorite time of year. Warm weather, hanging out by the pool, and enjoying the outdoors (weather permitting of course). It’s also the time of year when my favorite holiday occurs, Independence Day. EXAIR will be closed on July 4th in celebration of Independence Day. On this day 243 years ago the Declaration of Independence was adopted, marking the official legal separation of the Thirteen Colonies from Great Britain.
Although today we celebrate on July 4th, Congress actually voted to declare independence two days earlier on July 2nd. If it were up to John Adams, that would be the date we commemorate to this day. He wrote in a letter to his wife that this would be the most memorable day in the history of America, to be celebrated by pomp and parade, games, sports, guns, bells, bonfires, and illuminations from one end of this continent to the other. In protest of July 4th being designated a federal holiday, he was reported to turn down invitations to appear. Coincidentally, both he and Thomas Jefferson both passed away on July 4, 1829 on the 50th anniversary of the adoption of the Declaration of Independence.
I imagine the celebrations looked quite a bit different back then, but today many of us will spend time with our family and friends enjoying some BBQ. Parades and firework shows are also in abundance as we celebrate together as a country in unison.
“America was not built on fear. America was built on courage, on imagination and an unbeatable determination to do the job at hand.” – Harry S. Truman
The very same can be said of EXAIR, built on the courage, imagination and determination of our late founder Roy Sweeney. Without his willingness to take risks and build his version of the American Dream, we would have never come to be.
So while we celebrate, hot dog in hand, take a moment to reflect on what it means to be an American. Enjoy your right to life, liberty, and the pursuit of happiness. To all of my fellow Americans on behalf of EXAIR, Happy Birthday to US!
Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD
Photo courtesy of Andy Morffew via Creative Commons License
