What’s Wrong With My Reversible Drum Vac? Most Likely – Nothing.

If you need to clean up spills, pump out a sump, or basically just move liquid from one place to another, the EXAIR Reversible Drum Vac is what you’re looking for.  The Model 6196 Reversible Drum Vac System is all you need to turn a closed top steel drum into a powerful two-way pumping system. They’re reliable (no moving parts), durable (stainless steel construction), safe (no electricity), they install quickly, they’re compact, and portable. They’re also very low maintenance…in fact, if you supply the Reversible Drum Vac with clean air, it’ll run maintenance free, darn near indefinitely.

That’s not to say things can’t go wrong…Murphy’s Law still applies…but most anything that can go wrong with the EXAIR Reversible Drum Vac can be identified fairly easily, and remedied fairly quickly. Here’s a rundown of “the usual suspects:”

  • Vacuum leaks.  Even small leaks can be a big problem…a crack or split in the hose, a worn hose cuff, a damaged seal, even a hairline crack in the drum or lid…if air can enter anywhere other than the suction end of the hose, vacuum performance can suffer.  The first thing to do in most any troubleshooting procedure is a visual inspection, and the Reversible Drum Vac is no exception.  We stock the gaskets for the vacuum hose quick connect, as well as the drum lid seals.
Make sure the gasket is clean, in good condition                  The hose cuff should fit snugly on the quick connect
and properly seated.                                                                                             elbow’s barbs.
Pay particular attention to drum lid penetrations.               The drum itself can also be susceptible to corrosion.
All EXAIR Industrial Vacuum drum lids come with an EPDM seal glued in place. If it gets rolled (center) or damaged (right) it’ll need to be replaced to ensure optimal vacuum performance.
  • Compressed air supply, part 1. There are some tight passages in the  Venturi chamber inside the Reversible Drum Vac; this is how the vacuum is generated.  Any contaminants such as dirt or rust can accumulate in these passages, hampering the ability to draw its rated vacuum levels.
    Actual photos of dirt, debris, and contamination we’ve found in Reversible Drum Vacs sent in for Factory Refurbishment Service (ask an Application Engineer for details.)

    Use of a Filter Separator (like our Model 9004 Automatic Drain Filter Separator) with a 5 micron particulate element is recommended.  If the Reversible Drum Vac does get dirty inside, though, it can be cleaned pretty easily…here’s a video that walks you through the process:

  • Compressed air supply, part 2.  The Reversible Drum Vac will produce rated performance when supplied with compressed air at 80psig.  Make sure you can get enough air to it; if your supply line is too long and/or too small in diameter, you’ll get line loss…and poor performance. Use a 3/8″ ID compressed air hose, or a 1/2″ ID if it’s longer than about 10 feet, and avoid any restrictions like quick connect fittings.
  • Compressed air supply, part 3.  If you want to fill the drum a little faster, you can increase the supply pressure to 100psig or so.  Too high of a supply pressure can actually degrade vacuum performance, though.  Excessive pressure can create enough flow to overwhelm the Venturi, hampering its ability to generate vacuum.
  • Safety Shutoff Valve Float.  The Reversible Drum Vac provides overflow prevention via a plastic float that rises when the drum is full.  This breaks the vacuum so that no more liquid can be pumped into a full drum.  When the float rises, you’ll hear a change in pitch.  If you hear this, and the drum isn’t full, remove the Reversible Drum Vac from the drum lid and turn it upside down/right side up a few times.  The float should move freely, all the way from the bottom to the top of its chamber.  If it doesn’t, remove it and make sure the float, o-ring, and the inside of the chamber are clean.  Certain chemicals can cause the float and/or o-ring to swell, which will impede its free movement.  If the body of the Reversible Drum Vac is damaged (pro tip: don’t drop it) that can also cause the float to hang up and not work properly.
If the float doesn’t move freely, remove it (snap ring pliers not included,) clean and reassemble.

Like I said, these are just the first things you want to look for, and it’s highly likely you’re going to solve the problem before you reach the end of this list.  If your Reversible Drum Vac (or any EXAIR product) isn’t giving you the results you’re looking for, though, don’t hesitate to call an Application Engineer.  Chances are, the vacuum unit is just fine and just needs a fresh gasket, a little cleanup, or a new drum. We want to make sure you get the most out of our products.

Russ Bowman
Application Engineer
EXAIR Corporation
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Deep Hole Vac-u-Gun – Blow Chips Loose and Vacuum Them Away in One Step!

Last week, we looked at the Vac-u-Gun, and you can take a look at that blog here.

This week I wanted to present the Deep Hole Vac-u-Gun, a special iteration of the Vac-u-Gun, designed to provide a solution to the troublesome process of cleaning cavities and drilled holes.

The Deep Hole Vac-u-Gun is a low cost solution to quickly remove chips and debris from grooves and drilled holes where blow gun could create potentially hazardous flying debris. The Deep Hole Vac-u-Gun is simply positioned over the hole, and the trigger squeezed and then a small blow tube delivers a a stream of air to dislodge and lift the chips while the large suction tube vacuum them away. The operator is protected form flying debris since all chips and debris is contained within the clear suction tube. The device is capable of cleaning holes up to 1-1/4″ (32mm) diameter and 18″ (457mm) deep!

How does the Deep Hole Vac-u-Gun work?

dhvghowani
How the Deep Hole Vac-u-Gun Works

 


Compressed air, normally 80-100 PSIG (5.5 – 6.9 bar), flows through the inlet (1) into an annular plenum chamber (2) when the trigger is pressed. A small amount of air is injected into the blow tube (3) to provide agitation and lift to the chips or debris. The larger airflow is injected into the the throat of the gun through directed nozzles (4). The jets of air create the vacuum at the intake (5) which draws the material in and accelerates it through the unit. The chips, debris or other particulates can then be exhausted into a filter bag or hose attached to the Deep Hole Vac-u-Gun System.


 

We have found many applications where the Deep Hole Vac-u-Gun is beneficial- including removing chips and debris in:

Holes in fixtures, drilled plastics, T-slots’groove cleaning , coolant evacuation from parts, woodworking, tapped holes, cavity evacuation, and many more!

There are many advantages to the Deep Hole Vac-u-Gun, and some are:

Low cost, no moving parts/maintenance free, durable die cast construction, eliminates shock hazard – no electricity, meets OSHA pressure requirements, safe operation – no flying chips, lightweight and portable, and quiet.

The Deep Hole Vac-u-Gun uses less compressed air than ordinary blow guns, and the amplified output flow is 12 times the air consumption rate.

Deep Hole Vac-u-Gun Specifications

Note that the Deep Hole Vac-u-Gun should not be operated without a filter bag or vacuum hose attached to the exhaust.

There are three (3) Deep Hole Vac-u-Gun System options-

Deep Hole Vac-u-Gun Systems

The Model 6094 is the Deep Hole Vac-u-Gun only.

The Model 6194 comes with a reusable bag and clamp for debris collection.

The Model 6394 comes with the reusable bag and a 10′ (3m) section of vacuum hose for transferring the debris to a collection point.

If you have questions about the Deep Hole Vac-u-Gun or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Shot Blasting Media and Dust Problems Solved with EXAIR’s HEPA Vac

Heavy Duty HEPA Vac Family

Have you ever heard an electric vacuum toward the end of its life?  It gets an irritating high-pitch noise caused by the bearings going out.  A customer was hearing this annoying sound after only two months of use.   Their application was shot blasting metal parts.  The shot blast media was very dusty and carried everywhere around the room.  After use, they would use a shop vac to clean the machine and around the area.   When they started to hear that “moan” from their electric vacuum, they knew that they would have to purchase another unit.  Additionally, they noticed a lot of dust migrating into the work environment from the shop vac, creating a breathing hazard for the operators.  After their second electric vacuum failed, they started looking for a better choice.

Sand Blasting Equipment

When they contacted EXAIR about these issues, EXAIR had a great solution for them.  I recommended our model 6399, 55-gallon Premium Heavy Duty HEPA Vac System.  This system comes with a drum, drum dolly, heavy duty accessories, HEPA Filter, and a robust vacuum system.  The heavy-duty accessories are easy to use to vacuum in tight spaces.  The HEPA filter inside the drum has an efficiency of 99.97% at 0.3 micron.  So, the dust will remain in the drum and not migrate back into the ambient air.  The HEPA filter media is pleated to give a large surface area of 36.7 ft2 (3.4 m2).  Packed inside a supported cylindrical, it will allow for great amount of debris before changing.  With the shop vac above, the surface area of the filter was very small causing the filter to plug and under-perform.  The EXAIR Heavy Duty vacuum generator is made from a hardened-alloy steel construction which is very resistant to wear.  It does not have any moving parts or bearings to wear.  For this application, the generator is perfect for the shot blast media.  The Heavy Duty HEPA Vac only requires compressed air to operate, not an electric motor which can fail from dusty environments.  The Heavy Duty HEPA Vac System only has a decibel level of 82 dBA which makes it very quiet compared to shop vacs.  With clean compressed air as the engine for the vacuum, this system can last for years; not months.

When the company above started to use the Heavy Duty HEPA Vac, the first thing that they noticed was how quiet it operated.  That constant loud noise from their electric vacuum was gone, making it a better working environment for the operators.  They also noticed that the dust was not getting back into the environment, reducing the dust nuisance.  If you find that your electric vacuums are breaking down or you would like to reduce the noise levels, EXAIR has a large line of Industrial Housekeeping Products.  You can contact an Application Engineer to see if we have the right vacuum product for you.

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

Vac-u-Gun: Low Cost Vacuum, Blowoff and Transfer

What is the Vac-u-Gun?  It is a low cost solution to many types of cleaning operations within an industrial setting.  The Vac-u-Gun is a vacuum gun, a blow gun, and a transfer tool, all-in-one! It is lightweight, easy to use, has durable die cast construction, and best of all, no moving parts to wear out. Simply hook up to a compressed air hose, and get to work.

Vac u Gun Hose

The Vac-u-Gun contains a nozzle insert that dictates the direction of air flow and operation. By simply unscrewing the the cap, reversing the orientation of the nozzle insert, and re-installing the cap, the gun is changed from a vacuum device to a blowoff device, and vice-versa.

vac u gun orientation
Reverse the direction of the nozzle insert to change from vacuum to blowoff

The Vac-u-Gun can be used in three modes- Vacuum, Transfer and Blowoff-

Vacuum Mode – Vacuum shavings, absorbents, sawdust, or spills into a reusable bag, or into a receptacle via the vacuum hose. Why blow it off and the have to sweep it up later?

Transfer Mode – Transfer small parts, pellets, or trim over long distances, using the smooth bore vacuum hose.

Blowoff Mode – Blow chips, water, coolant, or scrap away from the work area. The large 1-1/4″ diameter outlet directs the air over a larger area in less time. The Vac-u-Gun uses less compressed air than an ordinary blow gun.

Vac-U-Gun Specifications

There are many advantages to a Vac-u-Gun, and some are:

Low cost, no moving parts/maintenance free, durable die cast construction, easy to switch form vacuum to blow mode, safe – no electricity, meets OSHA pressure requirements, lightweight and portable, versatile, and quiet.

Versatile!  In just seconds, the Vac-u-Gun can transform from a powerful, handheld vacuum tool into an efficient blow gun or transfer tool for lightweight materials. Each Vac-u-Gun System comes with the attachments needed to suit numerous industrial applications.

Three (3) Vac-u-Gun System options are available and shown below-

Vac-u-Gun System Options

All of the Systems include the Vac-u-Gun, brush, crevice tool, skimmer tool and (2) extension wands.

The Model 6192 Collection System also includes the reusable bag with clamp for debris collection.

The Model 6292 Transfer System also includes the vacuum hose, for transferring the debris to a collection point.

The Model 6392 All Purpose System also includes both the reusable bag and clamp and the transfer hose, providing the most versatility of all.

To view a video that shows the Model 6392 All Purpose System, and demonstrates how it works, please view the video below-

 

If you have questions about the Vac-u-Gun or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Reversible Drum Vac Quickly Empties Sump In Close Quarters

I had the pleasure of talking with an operator in a power generating plant recently. A small sump, in a hard-to-access location, needed to be emptied periodically, or it would overflow and make a big mess. They didn’t have room for a “great big” (his words) 30 or 55 gallon drum, and it was difficult to use an electric shop vac because there wasn’t an outlet nearby (it’s a very humid location in the steam plant) so they had to rig an long extension cord through a doorway and down to the lower mezzanine.

They DO have compressed air available…in fact, there was an unused port on a manifold that supplied other pneumatic equipment, right next to the sump. He thought it sounded like an ideal application for the Mini Reversible Drum Vac.

And it was. They put a Model 6196-5 Mini Reversible Drum Vac System on the floor, next to the sump, and empty it (usually 1-2 gallons) on the night shift. They also got a 6569-20 20ft Vacuum Hose, which they use to pump the drum contents into an internal drain system.

Reversible Drum Vac systems are available from 5 to 110 gallon capacity

No more hassles with the electric shop vac and extension cord. No more overflow messes. The most they have to do now is change to the 20ft hose when they empty the drum.

If you’d like to find out how an EXAIR Intelligent Compressed Air Product can make your life easier, give me a call.

EXAIR Industrial Vacuums: Dry Vacuums

Our Industrial Housekeeping vacuums utilize compressed air energy to create a powerful and effective vacuum capable of with standing the harshest of environments. These vacuums have no moving parts to wear out or replace, run quietly and are built to be placed upon your own drum or may be purchased with a drum.

EXAIR has three dry/solid vacuum systems available they are the Chip Vac, Heavy Duty Dry Vac and the Heavy Duty HEPA Vac.

The EXAIR Chip Vac picks up wet or dry chips and delivers them directly into an ordinary open-top drum.  The Chip Vac is used to clean chips from fixtures, floors and work surfaces of machining centers, lathes, saws, mills and other industrial equipment.  The Chip Vac is the ideal choice for quick and efficient cleaning.  The Chip Vac can also be used to vacuum wood or plastic chips and can be used occasionally for dusty materials since it incorporates a filter bag to keep the surrounding air clean.

The 30, 55 & 110 Gallon Chip Vac’s consume 40 SCFM @ 80 PSI while the 5 Gallon size consumes 33 SCFM @ 80 PSI.  All 4 models are rated at a super quiet 77 dBA!

chipvac_family
5, 30, 55, and 110 Gallon Chip Vacs

The Heavy Duty Dry Vac like the Chip Vac can attach to ordinary open-top drums.  Designed to withstand tough industrial environments the proprietary hardened alloy pump deliver powerful performance with superior abrasion resistance.  They are used for a wide variety of applications that include abrasive materials such as steel shot, garnet, metal chips and sand!  Please know that while very powerful it is still suitable for general applications such as vacuuming floors, machines, work stations and industrial equipment.

The 30, 55 & 110 Gallon Heavy Duty Dry Vac’s consume 68 SCFM @ 80 PSI and have a sound level of 82 dBA.

6397
Available in 30, 55 & 110 Gallon Sizes

Finally the Heavy Duty HEPA Vac has the added benefit of the HEPA quality filter system.  Filtration per IEST-RP-CC-007 to 99.97% minimum filtration at the 0.3 micron level ensures performance meets the needed criteria.  Like the Chip Vac and the Heavy Duty Dry Vac it will attach to ordinary open top drums as well.

The 30, 55 & 110 Gallon Heavy Duty HEPA Vac’s consume 68 SCFM @ 80 PSI and have a sound level of 82 dBA.

6399
Available in 30, 55 & 110 Gallon Sizes

When you look at the EXAIR vacuum producing units, you will notice there is not an electrical cord.  That is because the EXAIR Industrial Housekeeping Products utilize compressed air for operation, therefore they do not have the same issues with wear, breakdown and failures as electrical type vacuums. Quite simply there are no moving parts in the vacuum units to wear out or break.  They are maintenance free, just make sure the air supply is clean & dry, and they will operate for a long time due to the fact that there are no motors and bearings to wear out and no impellers to clog.

If you would like to discuss Industrial Housekeeping or any EXAIR product,  I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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EXAIR Industrial Vacuums: Heavy Duty Dry Vacs for Heavy and/or Abrasive Materials

A milling company contacted me for help to improve their scrapping operations.  They had 8 machining stations that were used to machine cast iron.  The chips were removed from the machines by a conveying system and dumped into a wheelbarrow next to each machine.  Throughout the day, the CNC operator would have to remove the wheelbarrow to the scrap recycling area.  The operator would then shovel the chips from the wheelbarrow into 55 gallon drums for storage.  The company had concerns with safety ergonomics, and they wanted to improve the efficiency of the operation.

I suggested the Heavy Duty Dry Vac.  The vacuum generator, which allows your material to flow through itself, is made from a hardened steel construction which is very resistant to wear and abrasion.  Since it is a Heavy Duty vacuum, it has a higher vacuum level to pick up heavier material at a faster rate (as compared to our standard duty Chip Vac).  With the cast iron chips having a bulk density between 130 – 200 lb/ft^3 (2082 – 3204 Kg/m^3), this was the right tool for the right application.

He purchased the model 6297, the Deluxe Heavy Duty Dry Vac System.  It included the 55 gallon lid vacuum system, heavy duty aluminum tools, drum dolly, 10 foot (3 meter) anti-static vacuum hose, and 20 foot (6.1 meter) compressed air hose.  Now, with their new product and new procedure, the CNC operator was able to place the Heavy Duty Dry Vac system onto a 55 gallon open drum, turn the unit on, and vacuum the cast iron chips from the wheelbarrow directly into a drum.  Once the drum was full, a simple switch of the lid assembly on to an empty drum keeps the process moving along with negligible downtime.

Heavy Duty Dry Vac in operation
Heavy Duty Dry Vac in operation

EXAIR was able to address both concerns.  It was faster, saving them down time and improving operation efficiency; and, it was safer, eliminating the need to shovel and improving health ergonomics.  Because of the wide range of products that EXAIR offers, we can help you with saving money and overall safety.  If you would like to discuss any of your issues with our Application Engineers, you can contact us at your convenience.

If you would like to discuss increasing the efficiency of your compressed air usage, quieter compressed air products and/or any EXAIR product,  I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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