EXAIR 2″ Flat Super Air Nozzles – Little Things That Make a Big Difference

EXAIR 2″ Flat Super Air Nozzle vs. other nozzles

I recently purchased a dart board to hang on the wall in my basement.  The dart board had a nice wood case with doors.  It also had some beautiful woodwork engraved along the outside edges.  When it arrived, I was so excited I decided to put it on the wall right then.  The wood case had four predefined holes that were 16” apart (to fit onto studs).  I got my tape measure, determined the correct height, and marked the points onto the studs.  As I ran the screw into the wall, I was about halfway into the stud, and the head of the screw broke.  That is correct!!!  It twisted right off the shank.  I was not happy.  I spent good money on a very nice dart board, and the screws were low quality and not tempered correctly.  The screws are only a fraction of the cost of the dart board, but they created a huge headache.  Now, I had to get the screw out and find new better quality screws to continue the process.

As an International Application Engineer for EXAIR, I have been to many facilities throughout the world with large automation systems inside their manufacturing plants.  I always wondered how much money was needed for the capital purchase to get a system created, assembled, and operational.  On many occasions when the customers brought me to their problem areas, I would see the flat plastic “duck-foot” nozzles.  They would be broken, ineffective, and loud.  They were looking for a recommendation to replace these plastic nozzles.  I know that their automation system cost much more than my dart board; but, I can relate to their headaches.

When you have an automated system that costs thousands or hundreds of thousands of dollars, the last thing you want is for nozzles that cost pennies compared to the full system to cause you headaches and problems.  EXAIR has effectively addressed this issue with the model 1122/1122SS 2” Flat Super Air Nozzles.  They are made either from zinc aluminum or stainless steel, not plastic.  This makes them very strong and durable.  With its unique design, they utilize shims which can be easily changed for different force requirements.  For stronger blowing applications, EXAIR also offers this same design in a high power version, model HP1125/HP1125SS.

This makes the 2″ Flat Super Air Nozzle very versatile as you can purchase shim sets with different thickness in your kit.  Now you have more flexibility to “dial” in the correct performance for your application.  Another feature is the ability to draw in large amounts of ambient air to make them very quiet and efficient.  So, it will actually save you money by using less compressed air.  The sound level is only 77 dBA for the model 1122/1122SS, so it is not a noise nuisance.  They are OSHA compliant with noise level, 29CFR1910.95a, and  for dead-end pressure, 20CFR1910.242b.

Since the plastic nozzles break easily, they become very loud and unsafe for workers as they will not meet the OSHA standard.  If you need a durable, versatile, efficient, OSHA safe type of nozzle that will last a long time, the 2″ Flat Super Air Nozzle is an easy choice over the plastic types of nozzles.  If you need help with mounting or positioning the nozzles, we have a line of accessories that can help.  We offer the Stay Set Hose, Magnetic Base, and Swivel Fittings to make it easy to mount and direct the nozzle for optimum performance.

2″ Flat Super Air Nozzle

If you have an automated system that is being contracted or if you are a machine builder, you will want to consider the EXAIR brand for your blow-off, cooling, and coating applications. With the overall cost of the system, you would not want to use poor quality plastic nozzles to save a couple of dollars.  In the long run, it will actually cost you more with loss of production, very loud noises, and an unsafe work environment.  I may have only broken one screw in hanging a dart board due to poor quality, but I can also relate to the unhappy feeling you get when your system is not performing because of low quality nozzles.   If you would like to try out the EXAIR Flat Super Air Nozzles against a plastic nozzle, you can request an Application Engineer to help.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Replacing Blowers with Super Air Knives

Chain conveyor application in need of a blow off solution

The image above shows a chain conveyor with coated handles travelling along a production line. At this stage in their production, these handles have just left a washing station and need to be dried.  In order to finalize the drying process, some form of blow off is needed.

The existing blow off solution which could not effectively remove the water.

The existing blow off setup is shown above. This system utilizes two blower driven air knives to remove any excess water from the handles, but it is proving to be ineffective due to the turbulent nature of the airstream from a blower.  To combat this ineffectiveness, this production facility has placed an employee in front of the existing setup, using a compressed air blow off as a pretreatment procedure.

Personnel were added to this stage of production to provide a pre-blow off treatment.

Having a line operator stationed at this point was undesirable for this customer.  What this application needed was an efficient, productive, and repeatable blow off solution that would eliminate the need for redundant personnel at this stage of production and make the process fully automated. That solution was the EXAIR Super Air Knife.

By utilizing Super Air Knives, this customer was able to create an even and laminar sheet of air to dry these handles. The smooth profile of the airflow allows maximum velocity to be maintained at a further distance from the knife than the existing setup.  This translates to higher force at further distances, which in turn translates to proper part blow off and full automation of the process (the line worker was removed from the application), thus saving cost and eliminating an unnecessary safety risk.

With a required blow off width of ~40” in this application, using (2) model 110042 42” Aluminum Super Air Knives was a perfect fit. If you have a similar, redundant blow off operation in place and would like to make it more effective in terms of results and costs, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Non Hazardous Purge Cabinet Cooler System Keeps Enclosure Dust Free

A mining company has processing machinery operating in a poorly ventilated, dusty environment (actually, it’s a mine…as you might have guessed.) This machine’s control panel was supplied with filtered vents and fans to cool the electronic components inside. The filters clog regularly, and even though they checked them frequently, it’s not always frequently enough to prevent the drive from overheating.

Based on a referral they got from another one of their facilities, they called to get more information on a Cabinet Cooler System. For total dust exclusion, our Non-Hazardous Purge systems are ideal…they’re thermostatically controlled, so compressed air consumption is responsible and efficient, but they also provide a small, continuous flow, even when the thermostat set point temperature is attained, and the solenoid valve is shut. This keeps a low positive purge volume of clean, dry air in the enclosure.

EXAIR Non Hazardous Purge Cabinet Cooler Systems provide reliable and efficient cooling in the most aggressive environments.

The caller already had the data from our Cabinet Cooler Sizing Guide, so specification was quick & easy. A Model NHP4340 NEMA 12 Non-Hazardous Purge Cabinet Cooler System – 2,800 Btu/hr – w/Thermostat Control was ordered and installed the next day. We keep them in stock for situations just like this.

If you have heat issues with electrical & electronic equipment enclosures, give me a call.

Russ Bowman
Application Engineer
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Video Blog: Which EXAIR Air Knife Is Right For You?

The following short video explains the differences between the 3 styles of Air Knives offered by EXAIR – The Super, Standard and Full-Flow. All of these Models are IN STOCK, ready to ship, with orders received by 3:00 PM Eastern.

If you need additional assistance choosing your EXAIR Air Knife, please contact an application engineer at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

E-Vac for Epoxy Recycling

Recently, a manufacturer of custom magnetics called in about a special application. In the manufacturing of certain electronic systems, a very expensive, thick epoxy glue is used. They were exploring ways to be able to collect the excess after application.  They had used a system in the past and were looking to replicate it.  The previous system had an old boxy vacuum generator, and they asked us if we could provide a vacuum source that matched the performance specifications but in a more compact design.  After researching the specifications and a comprehensive comparison, we could offer the EXAIR model 810013 Inline E-Vac, generating up to 27 ” Hg of vacuum.  A basic sketch of the design concept is shown below-

Capture

By using the model 810013 to create a vacuum within the chamber, a strong suction can be generated at the tube inlet, strong enough to draw in the excess epoxy. The glue can be collected in the chamber for recycling and reuse, and because of the design, the glue does not pass through the E-Vac and cause any issues with build up or blockage that would hinder the performance, leading to the need to clean the unit.

In-LineE-VacFamily

The Many Sizes of E-Vac Models Available

EXAIR manufactures E-Vac’s for both porous and non-porous applications, as well as a line of Adjustable E-Vac Generators.  Smallest units use only 1.5 SCFM of 80 PSIG compressed air and the largest Adjustable E-Vac unit can pull 81 SCFM of air at open draw and 15″ Hg vacuum level setting.  With a wide range of sizes and types, there is a model available to meet your vacuum generation needs.

As a side note – the EXAIR Reversible Drum Vac, High Lift Reversible Drum Vac, Chip Trapper, and High Lift Chip Trapper all use this same basic principle of applying a vacuum to a chamber, but on a much larger scale, to turn a 5, 30, 55 or 110 gallon drum into an industrial liquid vacuum system.  The vacuum generating unit is of a different design, made specifically for the Industrial Housekeeping Products.

To discuss your process and how an EXAIR Intelligent Compressed Air Product can solve your toughest application issues, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Beat the Heat with EXAIR Cabinet Coolers!

As we begin to approach the heat of summer in the northern hemisphere, we begin to break out the flip-flops, swimsuits, and warm weather attire. If you’re not a fan of the warmer temperatures, this may not be your favorite time of year. For me, I can’t wait to spend some time outdoors and enjoy all of the activities that summer has to offer. Whether you like the heat or not one thing is certain, the electrical enclosures within your facility most certainly do not.

CC_Actionshot

EXAIR’s Cabinet Cooler Systems were designed specifically to rectify these issues within your facility. Utilizing Vortex Tube technology, the Cabinet Cooler produces cold air from an ordinary supply of compressed air. This cold air keeps the enclosure free of debris and moisture and is easily installed in minutes through a standard electrical knockout. Here is a short video that shows just how simple it really is. The Cabinet Cooler Systems are available with Nema 12 (IP54) ratings and are also available in Aluminum, 303 Stainless Steel, and 316 Stainless Steel construction for Nema 4 (IP66) rated enclosures. For systems that are not able to be mounted on top of the cabinet, we also have Side Mount Kits available in Aluminum, 303 Stainless, and 316 Stainless.

These systems are available with cooling capacities of anywhere from 275-5,600 Btu/hr. To make things much easier for you, we offer a Cabinet Cooler Sizing Guide that will allow us to recommend the most suitable model for your cabinet. With a few quick measurements, we’ll be able to determine the exact heat load that we’ll need to dissipate and offer you a quick and easy solution. If you’re experiencing heat related issues somewhere within your facility or remember the troubles that they caused you last year, contact an Application Engineer today and we’ll see to it that this summer your cabinets remain cool!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

The Victory is in Solving the Problem, No Matter the Size

I had an engineer from a welding company contact me about his application.  He was already using three EXAIR Super Air Knives for a cooling application.  He had the Super Air Knives mounted in a linear fashion, two model 110018 18″ Super Air Knives and a model 110012 12″ Super Air Knife. His system was designed to operate the different Super Air Knives to cool the corresponding tubes length after a welding operation.  (He purchased the EXAIR Super Air Knives because he wanted the best air cooling capacity with the highest efficiency.)

Super Air Knife

Because it was an automated system, timing was critical.  The system was designed to operate one 18″ Super Air Knife for an 18″ welded tube.  For a 36″ long tube, they would turn on both the model 110018 Super Air Knives.  For their longest tube, they would activate all three Super Air Knives to cool the 48″ welded seam.  The engineer was extremely happy with the effectiveness and the consistency of the Super Air Knives that he was able to create a timing sequence in his automated operation for a repeatable and reliable cooldown of the welds.

So, why did he decide to contact EXAIR? I was thinking the same thing when he was giving high praises about the EXAIR Super Air Knives.  It was because of their compressed air system.  In another section of the plant, they would use large air vibrators to break loose powder from a hopper.  These vibrating devices would use a large quantity of compressed air when they were turned on.  During this time, the compressed air system would drop in pressure throughout the plant. This would change the amount of compressed air available for his application; affecting his timing sequence to get adequate cooling.

EXAIR Digital Flowmeter

Since that the engineer was happy with the efficiency and quality of our Super Air Knives, it was an easy decision for him to contact EXAIR about the Digital Flowmeters. He wanted to measure the amount of air flow to each Super Air Knife and continuously monitor the system for any low-flow conditions.  Since he was supplying the Super Air Knives with ½” NPT piping, he requested the model 9090 ½” Digital Flowmeter for each Super Air Knife.  I explained that the EXAIR Digital Flowmeters are very accurate and easy to install.  They have different ways to monitor the compressed air flow; 4 – 20 mA analog output, serial connection, or a Datalogger.  Since his PLC system had an analog reader, our Digital Flowmeters could supply the analog signal for flow measurements.   Currently the PLC was operating the solenoids to turn on and off sections of the Super Air Knives to cool the desired length of welds.  Now, he was looking to measure the amount of air flow with the PLC to verify that they did have adequate compressed air flow to the Super Air Knives.  If the flow was not sufficient, then he could trigger an alarm to delay the welding operation.  So, when the vibrators went offline, then they could restart their operation.

EXAIR routinely maximizes compressed air efficiency in an effective manner and I recommended, as an alternative, that he could use one 1½” Digital Flowmeter, model 9094, to monitor the air flow to all three Super Air Knives.  This would save him a lot of cost for his project in purchasing one larger Digital Flowmeter instead of three smaller ones.  Also, with the resolution of the flow meter and his ability to utilize the 4 – 20 mA analog signal, he could easily determine the required flow to one Super Air Knife, two Super Air Knives, or all three.  In the end, he was quite impressed with my recommendation to keep his system operating, even during times of depletion in his compressed air system.

At EXAIR, our first priority is to help the customer to correct their compressed air issues.  For this engineer, he was able to mount one Digital Flowmeter to monitor the compressed air flow to all three Super Air Knives. If you need real solutions to your compressed air applications, you can contact an Application Engineer at EXAIR, and perhaps we can also reduce your project cost in the process.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

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