Month: August 2013

Computer Problems? We Solve Them! (Well, Just This Once…)

Published on by Russ BowmanLeave a comment

computer problems

OK; so it wasn’t an actual “computer problem” that you call your company’s IT folks for.  This particular caller was having a problem with an enclosure-mounted computer…seems that when they started up their newly installed EXAIR Cabinet Cooler System, the computer wouldn’t boot, and showed indications of hard drive failure.  When they shut off the Cabinet Cooler System, the computer would resume normal operation.

Over the years, we’ve heard of this happening a handful of times, but, much to our collective frustration, did not have a definitive answer.  Among the issues we’d encountered:

A few years ago, a user who was experiencing this same problem fixed it by removing the Cabinet Cooler from the enclosure, mounting it remotely, and running the Cold Air Distribution Hose through the knock-out that was formerly occupied by the Cabinet Cooler.  One thought was that the air flow through the Vortex Tube was producing a harmonic frequency vibration that interfered with the computer’s operation.  Another was that the slight pressure buildup might be the culprit.

Another user suspected the Solenoid Valve (part of the Thermostat Control) might have been causing electrical interference.  That case went cold, unfortunately…they elected to return the Cabinet Cooler System under our 30 Day Unconditional Guarantee.

The current caller, though, was not so easily deterred.  Over the course of the last couple of weeks, he tried several things, including grounding the computer’s chassis, and installing a fiber mesh filter in the Cold Air Distribution Hose outlet, with varying degrees of success…the computer would now boot up, but it took longer than if the Cabinet Cooler System wasn’t running.

Then, they tried something that was rather “out of the box” – a 25ft length of rubber air hose was installed in place of the PVC Cold Air Distribution Hose (which only 2-3 feet long.)  The computer booted up and ran normally.  This got us thinking about the one from a few years back, where we suspected that the internal enclosure pressure, however slight, might have caused the problem.  It started to make sense: the line loss through the additional length of hose could be resulting in a lower pressure…less air going in, with the same capacity for air going out (this enclosure wasn’t completely air tight.)

So, now we knew WHAT the fix was, but we weren’t 100% about WHY, and you know THAT didn’t sit well…not with this group, anyway.  Our Senior Application Engineer, Joe Panfalone (you may also know him as #dearjoe if you follow him on Twitter – @EXAIR_JP – and if you don’t, you should) was first to strike paydirt on this, when he found the following:

HDD article

Source: http://en.wikipedia.org/wiki/Hard_disk_drive

It stands to reason that if low pressure won’t lift the flying head, then high pressure will lift it too far – not causing the physical damage described in the article, but instead causing the failure to operate correctly.  Problem solved?  We thought so.  For further verification, we also received a report from our customer that, after replacing the Hard Disk Drive with a Solid State Drive (which is impervious to changes in pressure), the original Cold Air Distribution Hose was able to be reinstalled, and everything is working fine.

Now, I’m not inclined (or authorized) to say that EXAIR’s Application Engineering Department is now ready to tackle your computer problems, but  I guess the point I’d like to make here is this:  If you’ve got an issue with a system that has an EXAIR product in it, we don’t stop with what we know about our gear. We want to make sure you’re getting the most out of our products, even (especially?) if that means getting  “out of the box.”

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: www.exair.com
Blog: http://blog.exair.com/
Twitter: twitter.com/exair_rb
Facebook: http://www.facebook.com/exair

High Temperature Cabinet Cooler Keeps Laser Measurement System Cool on Steel Slab Production Line

Published on by Neal RakerLeave a comment

slab cutting

Large steel slabs are cast, sized and cut to length in order to ready them for various types of secondary processing such as rolling, forging, machining, etc. The measurement and cutting functions of the steel slab process are controlled by various lasers focused on different features of the slab to provide for non-contact measurement due to the extreme high temperature conditions that are present.

slab measurement with laser

The electronics that are used as part of the laser measuring equipment can withstand temperatures up to about 60°C (140°F). The areas in a steel slab casting line where the laser electronics are located will usually exceed this temperature quite easily.

One of our customers was utilizing a protective box for his equipment that had a Peltier type cooling system integrated within. The cooling system would work for only a short while as the cooler would become clogged with dust and debris from the operation. This condition would lead to overheating and failure of the measuring equipment.

The customer came to EXAIR for a solution. He wanted to keep his existing enclosure and simply add an EXAIR Cabinet Cooler System to the box to replace the function of the original cooling module. The Cabinet Cooler System would be able to deliver significant cooling power for the application and provide a positive pressure on the enclosure to keep dust and debris from getting inside. Best of all, the Cabinet Cooler System is not affected by debris accumulation on the outside of the cabinet.

After we made some calculations, we recommended that he use our High Temperature, NEMA 12 Cabinet Cooler Model HT4215 on the enclosure.

high-temp-cabinet-cooler

The end result is a cooling system that has high reliability and low maintenance concerns due to zero moving parts, low purchase price and which is not affected by dirt, dust and debris from the ambient environment. This is a common problem for both Peltier coolers and Freon based cooling systems as they rely on the principle of ambient airflow over a heat exchange surface which is exposed to the ambient environment. EXAIR Cabinet Cooler Systems are using filtered compressed air utility from the facility compressed air supply, which by comparison is many times cleaner and thus contributes to low maintenance aspect of our product.

If you are looking for a simple, low cost, ‘bolt on’ cooling solution for your high temperature application, give EXAIR a chance. We may very well have the solution you are looking for.

Neal Raker, Application Engineer
nealraker@exair.com

A Special Build

Published on by Lee EvansLeave a comment

machining

The number of calls and emails that come in every week always seem to have something new.  Looking through my emails this afternoon I saw an product integration walk-through for a Line Vac, but with a twist.  This particular application had been mimicked in another facility and in looking at the specs, the requested model didn’t seem to fit quite right.  After a few emails and a sketch of the installation, everything was worked out with a safety margin to ensure proper application performance.

I also noticed the telltale signs of summer, which was an abundance of Cabinet Cooler Sizing Guide assistance forms.  There were a number of others dealing with Cabinet Cooler Side Mount Kits, Air Nozzles, Air Knives, Reversible Drum Vacs, etc.  In short, there hasn’t been a shortage of fresh applications to keep me on my toes and asking questions.

One of the questions that stood out to me this past week was whether we are able to offer our Threaded Line Vac products with BSPP threads, and the answer is yes.  Unsurprisingly the request came from an overseas source, and also unsurprisingly we are stepping up to fill the need.  We pride ourselves on building reliable products and having them in stock, but we also pride ourselves in being able to step out of the production manufacturing zone and modify our designs when you need a custom solution.

If you’re involved with our product and see the need for a BSPP thread, or another modification to suit the market, drop me an email and I’ll see what we can do.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

EXAIR Receives Honorable Mention in Green Manufacturer Product Innovation Award

Published on by Kirk EdwardsLeave a comment

EXAIR’s model 1126, 1″ Flat Super Air Nozzle received an honorable mention from Green Manufacturer magazine for the 2013 Product Innovation Awards. This competition was open to technology developers and manufacturers who have introduced new products designed to ensure environmental sustainability between January 1, 2012 and April 1, 2013. Green Manufacturer magazine includes a diverse range of products from biological building materials to welding tools, each with a unique set of qualifications and applications.

The competition focuses on the greenness of the product and how sustainably it is manufactured, as well as the ecopractices of the company. The claims were verified through judging which relied on third party testing and certification, reports to published databases, provision of specific metrics/quantitative information, and customer testimonials with quantitative data.

IMG_3206
The award with the 1″ Flat Super Air Nozzles and shims

Our engineered air nozzles, when compared to open blow off or traditional commercial nozzle designs, reduce compressed air consumption and the associated costs of producing compressed air. The lower compressed air volume required from EXAIR’s engineered air nozzles results in less electricity to generate the compressed air. Engineered air nozzles also reduce noise pollution better than traditional solutions and reduce noise exposure levels for personnel.

The model #1126, 1″ Flat Super Air Nozzle is available in a zinc/aluminum alloy suitable for most environments or 316 stainless steel when a higher level of corrosion resistance is necessary. The zinc/aluminum alloy used for this nozzle generally requires less energy
than similar materials to transform into finished products, release no pollutants and no toxic residues during the work cycle, and are fully recyclable at the end of their useful lives.

EXAIR’s whole line of Flat Super Air Nozzles also utilize an internal shim which restricts large amounts of compressed use. The design entrains additional surrounding air in order to provide added volume and force for each application.

EXAIR also takes responsibility for our own processes and manufacturing facility by adhering to our own sustainability plan. This plan helps us reduce waste, recycle more material, reduce energy consumption, reduce water consumption, and keep our employees informed and responsible.

Thanks to Green Manufacturer magazine for recognizing our efforts to keep energy consumption low and sustainability high.

Kirk Edwards
Application Engineer
kirkedwards@exair.com