The first brand-new car I ever bought was a 1995 Ford Escort wagon. I was playing in a band pretty much every weekend (and the occasional weeknight), and my digital piano case fit perfectly in the back – I took it with me to make sure when I went to test drive it. Over eleven years, I put just shy of 200,000 miles on it, and, aside from gas, oil, and tires, had a little under $1,000 in repair costs.
There used to a legendary warning about not buying a car made on a Monday (since the auto workers were presumably recovering from the weekend) or a Friday (since they were equally presumably distracted by getting ready for the weekend). Some folks only buy a particular make of automobile (or shun another) because that’s the make their favorite race car driver (or least favorite) drives. I don’t know what day of the week that Escort was made, and I couldn’t tell you which race car drivers are loyal to the Ford Motor Company, but I CAN tell you that I followed the manufacturer’s recommended maintenance schedule to a “T”. And I’m pretty sure that had a LOT more to do with that little red wagon’s longevity than a bunch of auto workers’ attention to detail (or lack thereof) or who’s popular on the NASCAR circuit.
The same is true for many components that make up your compressed air system. You’re going to want to change the lubricating oil in your compressor on a regular basis (as recommended by the manufacturer) for the exact same reasons you change the oil in your car’s engine. You need to replace particulate elements in compressed air filters, same as you need to periodically replace your car’s air filter.
For point-of-use devices – like most EXAIR compressed air products – preventative maintenance largely comes down to replacing those particulate elements in your filters. Products like our Air Knives, Air Wipes, Air Amplifiers, E-Vac Vacuum Generators, Reversible Drum Vacs, and Vortex Tubes all have relatively small passages that the air has to flow through, so it’s critical to their performance to supply them with clean air. In fact, if you DO supply these products with clean air, they’ll run darn near indefinitely, maintenance free. That’s why all of our product Kits include a Filter Separator with a 5 micron particulate element, and a centrifugal element for moisture removal.
Good engineering practice calls for point of use filtration and moisture removal, such as that provided by EXAIR Filter Separators.
One question we get on a pretty regular basis is, how often do you have to change the particulate element in our Filter Separators. Good engineering practice calls for replacing that element when the differential pressure across the filter reaches 5psi. Now, you can measure the pressure on either side of the Filter Separator and change the element when the outlet pressure drops 5psi from the inlet. If you can shut down long enough to do so, that’s an efficient way to do it – that ensures you get the most ‘bang for your buck’ from that element.
Of course, those elements don’t cost all that much – but shutting down a production line, for even the few minutes it takes to replace an element, can get VERY costly. Facilities that run 24/7 will usually plan some downtime for periodic maintenance on SOMETHING…and they’ll just replace their Filter Separator’s particulate elements during those downtimes.
If you’ve got questions about getting the most out of our products – and, by extension, your compressed air system – give me a call.
Russ Bowman, CCASS
Application Engineer Visit us on the Web Follow me on Twitter Like us on Facebook
Reversible Drum Vac (left) and Chip Vac (right) – two EXAIR Industrial Vacuums
When selecting a vacuum, you want to take into account a variety of things other than the purchase price. You should consider reliability, safety, and the total cost of ownership. I had a customer contact me about our Chip Vac System. They were currently using an electric vacuum to clean up debris around their machine shop. I gave them the pros of using the Chip Vac System as compared to electric vacuums. They thought that it was too much money as compared to the electric version. In less than 6 months, this same customer contacted me again to purchase the Chip Vac System, as they had gone through two more electric vacuums in that time. I would like to share some of the features and benefits that I shared with the customer above to illustrate how the EXAIR Industrial Housekeeping Products are better than electric vacuums that you could purchase.
1. Reliability: The EXAIR venturi-type vacuum systems do not have any moving parts that can wear; so, they will last for a long time. We use compressed air to generate a powerful vacuum to pick up liquids and debris. We do not use electric motors with bearings that could lock up and fail. EXAIR offers different materials for different applications, like the heavy-duty version, which uses an abrasion-resistant material for sandblasting, glass, and garnet.
2. Safety: We cover two areas in this field. The first is the potential hazard of liquids and electricity. Our vacuums only use compressed air to generate a vacuum. Even though EXAIR products are not certified to be used with explosive materials, we are still able to remove the shock hazard for users when operating electric vacuums for liquids. The second safety concern is noise. Electric vacuums can be very loud. And when the motor bearings start to fail, they can become even louder. Loud noises can become an OSHA violation and may require hearing protection. With the EXAIR industrial vacuums, we are near 83 dBA in sound during operations.
3. Total Cost of Ownership: It is easy to run to your nearest hardware store to purchase a vacuum for your facility. The problem, like with the customer above, is that you will have downtime, multiple purchases, and frustration when using inexpensive electric vacuums. You may decide to go with a bit more expensive electric unit, only to find that it is extremely noisy. The total cost of ownership takes into account the safety, reliability, and purchase price over the years of operation.
EXAIR offers a wide range of packages and categories in our Industrial Housekeeping Products. Here is a short guide to the pneumatic vacuums that we manufacture.
EasySwitch® Wet-Dry Vac: Our newest vacuum line that can be used for both wet and dry materials. They come with a standard and a HEPA filter to contain the dry material inside the 55-gallon drum. The patent-pending lid has quick and easy access to remove or add the filter without tools or removing the lid. So, transitioning from a dusty to a liquid cleanup is quick and easy.
Chip Vac™ System: Like the name states, it is a great vacuum for cleaning up chips from a machining process. The vacuum generator uses a small amount of compressed air to create a powerful vacuum to remove the chips from the process or from the machine. We offer 5-gallon, 30-gallon, 55-gallon, and 110-gallon drum sizes. The material can be stored for recycling.
Heavy Duty Dry Vac™ Systems: A “big brother” to the Chip Vac System, it can handle heavy items like sandblasting material, garnet, sand, steel, etc. The vacuum generator is made from an abrasion-resistant, hardened material that can resist wear from these types of materials.
Heavy Duty HEPA Vac™ Systems: This vacuum uses the same vacuum generator as the Heavy Duty Dry Vac, but we replace the filter with a HEPA media. This media stands for High Efficiency Particle Air filter, which can remove particles down to 0.3 micron at a rate of 99.97%. So, if the material is very small and fine, this vacuum will keep the material inside the drum and not back into the atmosphere.
Chip Trapper Cut Away
Chip Trapper™ System: Designed and used by EXAIR. We are able to clean and change out the coolant system within our CNC machines quickly. Time is money, and when a CNC machine is not running, it is not making money. The Chip Trapper has a filtration system to clean the coolant from swarf and tramp oil. By using compressed air, we are able to aerate the coolant, which reduces bacterial growth and extends the life of your coolant. With a switch of a lever, you can return the fresh, clean coolant back into the sump. We offer different micron ratings with the filter bags to accommodate the type of CNC machine and fluid “cleanliness” required.
High Lift Chip Trapper™ System: Like its cousin above, it has a stronger vacuum generator to move thicker materials or retrieve coolant from sumps below floor level. It can move fluids up to 15 feet (4.5 meters). It will come with a longer vacuum hose to reach those distances.
Reversible Drum Vac™ System: This system is a great tool for transferring liquids. It has a two-way pump to bring the liquid into a 5-gallon, 30-gallon, 55-gallon, or 110-gallon drum, and with a turn of a knob, you can discharge the liquid from the drum. It has a safety valve for the drum and a shut-off valve to prevent overfilling. They can be used with closed-top or open-top steel drums, and they can fill a 55-gallon drum in 90 seconds.
High Lift Reversible Drum Vac™ System: Like its cousin above, it has a stronger vacuum to lift liquid from a farther distance or for fluids with viscosities up to 1400 CPS. It does come with a longer vacuum hose, which is great for any slip hazards that may occur. We only offer the 30-Gallon, 55-Gallon, and 110-Gallon versions.
Vac-u-Gun™: This is a hand-held vacuum system that works great for small jobs. The generator can be switched from a vacuum collection system to a blow-off system. In vacuum applications, we have a transfer hose to move material or a filter bag to capture debris. Or you can switch the generator around to make it a blow-off system to clean material from tables, electrical panels, or parts.
Deep Hole Vac-u-Gun™: EXAIR modified the Vac-u-Gun to do a unique job, clean out chips from blind holes and hidden contours. We blow a small amount of compressed air through a tube at the same time that we vacuum to draw and extract chips. We use a vacuum tube to help move the loose debris into a filter bag.
All the vacuums above only use compressed air for a reason. They may seem a bit “pricey” to some, but you will not be disappointed. These vacuums are built and designed for rugged industrial use with longevity, safety, and reliability in mind. Production is very important for manufacturing plants, and having a dependable vacuum will help keep production running smoothly. We can help reduce your headaches from purchasing multiple electrical units, like the customer above. If you would like to discuss your Industrial Housekeeping requirements, an Application Engineer at EXAIR will be happy to help you select the correct product.
Per the National Electrical Code (NEC) there are (3) classifications for areas that are defined as hazardous. They are Class I (gases & vapors), Class II (flammable dusts) & Class III (fibers), the focus of today’s Blog is on Class II locations.
Class II locations are those that are hazardous because of the presence of combustible dust. Note that the dust must be present in sufficient quantities for a fire or explosion hazard to exist. The fact that there is some combustible dust present does not mean a Class II hazardous location exists. Dust is defined as a combustible material that must exist as a finely divided solid of 420 microns (0.420 mm) or less. This will allow the dust to pass through a No. 40 sieve. Just as in Class I, Division 1 and 2, the subdivision of Class II into Divisions 1 and 2 identifies the likelihood that there is an explosion hazard.
Division 1 locations are defined as an area where the amount of combustible dust is either suspended in the air or accumulated on surfaces in a sufficient concentration to allow for ignition. The ignition could be caused by a failure or malfunction of the equipment in the classified area. Group E & F dust (see chart below) are considered conductive and could penetrate into electrical equipment such as electric motors, control panels, electrical panels, etc., and cause an electrical failure.
Group E dusts are metal dusts, such as aluminum and magnesium. In addition to being highly abrasive, and likely to cause overheating of motor bearings if it gets into them. Group E dusts are also electrically conductive and if they are allowed to enter an enclosure can cause an electrical failure.
Group F dusts are carbonaceous, the primary dust in this group is coal dust. Coal dust has a lower ignition temperatures than those in Group E. While Group F dust has a higher thermal insulating value than the layer of Group E. Therefore Group F requires more control of the temperature on the surfaces that the dust settles on. Group E dusts are semi-conductive, however if the voltages are 600 volts or less it is not generally considered a factor.
Group G dusts include plastic dusts, most chemical dusts and food-grain dusts. They are not electrically conductive. Generally these dusts have the highest thermal insulating characteristics and the lowest ignition temperatures. Therefore, the equipment used in Group G areas must have the lowest surface temperatures to prevent ignition of a layer.
Lastly, equipment rated for use in Classified Environments have a rating called the Temperature Code or “T-Code”. This is the temperature or temperature range that the rated device will operate normally and/or in a failed or failing state. Consider something as common as a light fixture, electric motors, etc., as they could become hot enough to cause ignition depending on the type of dust in the area. So be sure to check the “T-Codes” for every piece of equipment that will be used within a Classified Environment.
Handheld air guns are something that you can find in nearly any and all manufacturing facilities that have compressed air within them. Suppose they are not at every operator station because the machines don’t require compressed air. In that case, they are generally found at the very least within the maintenance department where they are continually keeping the facility functioning.
Don’t let this happen to your air gun…use an EXAIR Precision Safety Air Gun with a quiet, efficient Super Air Nozzle instead.
These handheld guns are easily overlooked for being safe and efficient for the operators to use. Often, the cheapest gun possible is also the most costly regarding ownership and operation. These are just a few of the reasons EXAIR designed the VariBlast Precision Safety Air Gun.
The ergonomic design fits well in any sized hand and the long trigger makes for easy use with up to the four-finger engagement. The integrated loop allows the tool to easily hang on a tether or hook near an operator station. The optional Chip Shieldadds additional protection for the operator and can be adjusted to any location along the extension. The extension pipe is offered in three different lengths, 6″ 12″, or 20″ overall length. Each one of these components is also field replaceable in the event one becomes damaged.
There are three different models of Super Air Nozzle available at the end of the extension in two separate materials. You can purchase the Atto, Pico, or Nano Super Air Nozzle in either stainless steel or PEEK thermoplastic for more sensitive applications. These nozzles coupled with our engineered valve design permit the user to vary the amount of air coming out of the gun by pulling the trigger to a higher flow or pulling it slightly and letting less volume of air through.
If you want to discuss whether the current air gun you use meets or exceeds OSHA standards and how much air it may use versus what an EXAIR VariBlast Precision can do for you, please contact an Application Engineer today.
