If you rely on compressed air for blow off, cooling, or ventilation, you already know the challenges: high energy costs, excessive noise, and inconsistent performance. That is where EXAIR’s Super Air Amplifiers can make a… More
Do I need a Gen4 Ion Air Jet or Intellistat Ion Air Nozzle?
EXAIR has been making a comprehensive line of Static Eliminators for decades. Like any air blowing application, the first consideration in selection is the size & shape of the airflow that’s needed to get the job done. If you’re looking for a tight, focused airflow, we have four products to choose from: a Gen4 Ion Air Gun or Ion Air Jet, or an Intellistat Ion Air Gun or Ion Air Nozzle. So, the next step in selection is whether you want something operated by hand, or mounted in place:
From there, it’s all about where you’re going to use it, and for what. First, let’s talk about the environment:
- First off, neither of these can be used around flammable materials or gases. If you need a static eliminator for those kinds of areas, call us and we’ll provide some leads based on your specific requirements.
- If you’re going to use it in a laboratory or cleanroom environment, the Intellistat Ion Air Nozzle is the clear choice, hands down. It has an ISO 14644-1 Class 5 Cleanroom classification. The stainless steel mounting bracket makes installation & positioning quick & easy.
- For more industrial environments, consider the compact and rugged construction of the Gen4 Ion Air Jet. They have 1/8 NPT threads for the compressed air connection, and a 5ft cable to attach to the Power Supply. We can also provide them with Stay Set Hoses & Magnetic Bases for ease of mounting & positioning.
Then, details about the nature of the application will be considered:
- To prevent nuisance shocks to personnel that have to handle the material, you can likely use either. The Gen4 Ion Air Jet DOES have a faster static dissipation rate: 0.18 seconds to dissipate 5,000V, but the Intellistat Ion Air Nozzle can dissipate the charge from 5,000 to 500V in 0.6 seconds. Either way, you need at least 2,000-3,000V for a noticeable ‘zap’ so if the charge is EXTREMELY high, AND you don’t have any more than a second or two, then we can make a case for the Gen4 Ion Air Jet. Otherwise, the environment is the deciding factor.
- If you need to get the static charge to as low of a level as possible, the balanced ionized air stream from the Intellistat’s +/- 30V offset means it can reliably reduce the static charge to 100V or less, regardless of the material and where it falls on the triboelectric series. This is going to be especially important when you’re trying to prevent damage or faulty operation of sensitive electronics, for instance.
- Some applications require not only ionized air, but a fairly strong flow of it. We did an Efficiency Lab test for a snack food maker recently where they need to blow open a plastic bag with a gusset on the bottom and set it upright on a conveyor. They also need it to remain open so they can fill it, so they need ionized air to remove static charge. The Intellistat Ion Air Nozzle blew the bag open and dissipated the static charge just fine, but it didn’t have the flow & force necessary to expand the gusset so the bag would sit upright. The Gen4 Ion Air Jet did it every time, though.
No matter what you need to remove static from, EXAIR can help. If you’d like to discuss your application and product selection, give me a call.
Russ Bowman, CCASS
Application Engineer
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Cabinet Cooler Accessories: Adding to Efficiency and Effectiveness
Accessories can add much needed enhancements to assist in making your application as efficient and effective as possible. The same is true when it comes to our Cabinet Cooler Systems. Among the most essential accessories for our products are compressed air filters and regulators, which we highly recommend using with all our offerings, as well as with other brands. The Filter Separator effectively eliminates water, dirt, and rust from your compressed air system, while its 5-micron filter element prevents contaminants from clogging or damaging your equipment. For even more precise filtration, an Oil Removal Filter should be installed downstream of the Filter Separator; this filter utilizes a 0.03-micron element to remove oil and solid particulates. Additionally, our Pressure Regulators allow you to set the desired operating pressure, and we advise maintaining the minimum pressure necessary for optimal performance. This not only conserves air consumption but also fine-tunes the efficiency of EXAIR products in various applications.
A Cold Air Distribution Kit is an additional accessory available with our Cabinet Cooler Systems that enhances their efficiency. This kit features a length of flexible vinyl tubing designed to channel cold air for optimal circulation or to target specific hot spots. It also includes tubing connectors and adhesive-backed clips to secure the tubing in place.
Solenoid valves and thermostats are effective tools for conserving compressed air. Cabinet Cooler Systems equipped with thermostat control utilize a solenoid valve and thermostat to regulate the flow of compressed air, activating it only when cooling is necessary. The thermostat is preset to 95°F (35°C) and typically maintains a temperature within ±2°F (1°C) inside the cabinet. Solenoid valves are available in various voltage options, including 120V at 60Hz, 110V at 50Hz, 240V at 50/60Hz, and 24VDC. All solenoids are CSA Certified and either UL listed or recognized.
EXAIR’s Side Mount Kits facilitate the installation of cooling systems on the sides of electrical enclosures, particularly beneficial in scenarios where vertical or top mounting is impractical. It is important to note that NEMA 4 and 4X Cabinet Cooler Systems must be installed in a vertical orientation. These kits preserve the NEMA ratings for both large and small enclosures classified as Type 12, 4, and 4X, and they fit into standard electrical knockouts measuring 1-1/2 NPS. The Side Mount Kits designed for NEMA 12 Cabinet Cooler Systems are constructed from aluminum, while those intended for NEMA 4 and 4X systems are made from either Type 303 or Type 316 stainless steel.
If you have questions about the Cabinet Cooler Systems accessories, or anything regarding EXAIR and our products, please do not hesitate to reach out.
Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk
Dynamic Viscosity and Kinematic Viscosity
Dynamic viscosity is the frictional force between the liquid layers. It is measured with a viscometer that uses mechanical rotational resistance to discs that are placed in the fluid. They have the units of Centipoise (cP) or Pascal-second (Pa-s). Kinematic Viscosity removes the density to see how the behavior of the fluid flows. This type of viscosity is measured with funnels or tubes to see how long gravity will pull the fluid through under its own weight. The units for this type of viscosity are Centistokes (cSt) or M2/sec. Both types of viscosities are easily changed with temperature. To convert the kinematic viscosity to dynamic viscosity, you only need to divide the dynamic viscosity by the fluid’s density in grams per cubic centimeter (g/cm³), reference Equation 1. Because the density changes with temperature, the conversion is fluid specific. Why do I bring this up? If you are looking to transfer different fluids, EXAIR has a solution for you.
Equation 1:
Kinematic Viscosity = Dynamic Viscosity / density
Not all liquid vacuums are the same. Have you seen motor burnout, loud noises, single directional flow, and potential electrical hazards? EXAIR manufactures a pneumatic venturi pump to remove all those issues, the High Lift Reversible Drum Vac System. It does not have any moving parts to wear; a two-way action to fill or expel liquid from standard drums; and is quiet. They only use compressed air to generate a powerful vacuum to lift liquid into a drum; and with a simple twist of the knob, it will push the liquid out. And by using compressed air, no electricity is required, making it safe to use. They work great for fluid transfers or liquid spills, and the High Lift Reversible Drum Vac can fill a 55-gallon (208L) drum in 85 seconds from 15 feet of lift. And with the powerful vacuum pressure, it can move thick liquid with viscosity up to 1400 Cp through 20 feet (6m) of hose. How can this product be useful for you? If you work with liquids in a cistern, underground tanks, higher viscous fluids, or pits, EXAIR has a product for you; the High Lift Reversible Drum Vac System. They are reliable and simple to use, and that is why it was awarded the 2015 Product of the Year by Plant Engineering. In this blog, I will go over the specifications and packages that EXAIR offers.
The High Lift Reversible Drum Vac pump has stainless steel construction for corrosion resistance. It comes with a built-in safety relief valve to avoid over pressurizing and an internal float to stop any over-filling of the drum. The air consumption is only 43 SCFM (1,218 SLPM) at 80 PSIG (5.5 Bar), and it has a quiet noise level of only 83 dBA. Systems are available in 30-, 55- and 110-gallon capacities (114L, 208L, and 418L respectively) in different packages.
The standard package will include the two-way pump assembly, shutoff valve, 20′ (6m) vacuum hose, a 90° quick release elbow, a standpipe, and an aluminum chip wand. The standpipe is cut to length for the properly sized drum (the drum is not included in this option). The standpipe extends inside the drum to remove as much liquid as possible when emptying.
The Deluxe package will include all the items shown above in the Standard package and adds a drum dolly, ABS spill recovery kit, (2) extension wands, crevice tool, skimmer tool and a magnetic toolholder.
The Premium package will include all the items in the Standard package and adds the drum with lock ring and lid, drum dolly, ABS spill recovery kit, (2) different lengths, aluminum crevice tools, skimmer tool, a magnetic toolholder and a 20′ (6m) compressed air hose.
With the relationship between dynamic and kinematic viscosities, you can determine the best EXAIR Industrial Housekeeping Product to transfer or discard. If you have any questions about the High Lift Reversible Drum Vac System, you can contact an Application Engineer at EXAIR. We will be happy to help you.
John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb
Extend Refractory Life with an Unusual (and Practical) Cooling Fix
How an EXAIR Super Air Amplifier can reduce hot-spot damage and save thousands in unplanned downtime.
Hot spots on refractory walls are common in high-heat operations, but premature refractory failure need not be. If you can quickly pull heat out of a problem area (without touching the lining), you can reduce thermal stress and keep your furnace running longer.
Figure 1. Targeted, non-contact cooling helps stabilize refractory hot spots before they become cracks or spalls.
The problem: localized hot spots
During heat cycles, refractory walls rarely heat perfectly evenly. Burner impingement, scale buildup, airflow changes, and normal process variation can create concentrated hot spots. Left unchecked, these areas run hotter than the surrounding area, accelerating wear that shows up as cracking, spalling, and ultimately downtime.
The solution: EXAIR Super Air Amplifier
A Super Air Amplifier converts a small amount of compressed air into a high-velocity, high-volume stream of ambient air. Aimed at a hot spot, the airflow impinges on the outside surface of the refractory to carry heat away quickly without contacting or mechanically disturbing the lining.
Because cooling is targeted and non-contact, it can reduce peak temperatures and thermal gradients in critical areas. The result: less thermal stress, slower localized erosion, and a better chance of getting maximum life from your refractory lining.
The payoff: more uptime and real savings
Even small gains in living life matter. Extending a campaign by days, or even hours, can help you delay an early reline, reduce emergency maintenance, and keep the furnace in production when it counts.
In many operations, that additional runtime translates into thousands of dollars savedthrough fewer relines, less lost production, and more predictable maintenance planning.
A simple cooling upgrade with a significant impact.
The EXAIR Super Air Amplifier is a dependable, low-maintenance solution for addressing refractory hot spots, protecting your furnace investment, and improving your bottom line. If hot spots are shortening your lining life, it’s worth considering as part of your standard operating response.
Neal Raker, Application Engineering Manager
nealraker@exair.com