What’s So Great About Thermostat Control for EXAIR Cabinet Cooler Systems?

Published on by Russ BowmanLeave a comment

EXAIR Cabinet Cooler Systems are a durable & reliable way to protect electrical enclosures (and the components they contain) from heat damage. All you need is compressed air…

Compressed air goes in; cold air comes out of the Vortex Tube and is circulated through the enclosure. The Vortex Tube’s hot flow and the warm exhaust from the enclosure are vented through the Cabinet Cooler’s body.

…and as long as the cooling capacity of the Cabinet Cooler System is equal to or greater than the heat load of the enclosure, everyone’s happy, right?

Well, almost. I mean, it’s great that the vital components inside the enclosure aren’t getting too hot, but if it’s getting colder than it needs to be inside, then you’re using compressed air when you don’t have to. And compressed air is EXPENSIVE.

If you’re talking to an EXAIR Application Engineer about panel cooling, we’re going to talk about Thermostat Control too. We have two options for that:

Thermostat, optional Mounting Bracket & Locknut, and Solenoid Valve (120VAC, 240VAC, or 24VDC)

Thermostat Control consists of a bimetallic probe-type Thermostat, spliced in to the ‘hot’ lead of a Solenoid Valve that’s plumbing into the compressed air supply of the Cabinet Cooler. These come preset at 95°F (35°C), which is based on the 104°F (40°C) temperature limit published by many manufacturers of electrical & electronic components. The setpoint temperature CAN be lowered (at the factory or in the field) if any particular component(s) need a cooler environment to operate in. It can also be raised, if everything in the enclosure can handle a higher temperature. THAT can save a good amount of compressed air (which, again, is EXPENSIVE.)

Operation is pretty simple: when the temperature starts to rise inside the enclosure, two dissimilar metal strips that are bonded together inside the thermostat start to thermally expand. Because they’re made of different metals, they expand at different rates, which makes the strips bend until they contact. This completes the electrical circuit to the Solenoid Valve’s coil, opening the valve to start operation of the Cabinet Cooler. As the temperature subsides and cold air flows into the enclosure, the two metal strips contract & straighten out, detaching the strip and the contact, which causes the Solenoid Valve to close, until temperature rises to the setpoint again.

EXAIR’s ETC Electronic Temperature Control provides the same function, but with some notable advantages:

EXAIR NEMA 4X 316SS Cabinet Cooler System with Electronic Temperature Control is installed on a control panel in a pharmaceutical plant.
  • A Type J Thermo couple is wired to a solid state temperature controller to sense & control the temperature. It’ll hold +/- 1°F of the setpoint temperature, as opposed to the +/-2°F accuracy range for the bimetallic Thermostat.
  • The LED readout provides constant indication of the temperature inside the enclosure. Personnel can verify, at a glance, that proper cooling is being applied. This is of great benefit to users who regularly monitor & log readings like this on enclosures with critical equipment inside, like nuclear power plants.
  • Push button control allows for on-the-fly adjustment of the setpoint temperature. This, along with the +/-1°F accuracy range, allows users to precisely set the desired temperature to a point just slightly under the maximum rating for the electronics, which, as mentioned above, can result in a reduction in compressed air consumption and hence, operating cost.
  • There’s also a calibration offset feature, which is handy if the Cabinet Cooler System is being installed on an enclosure with other temperature sensing equipment. This uses the push button controls to match the displayed temperature on the ETC to that of the existing equipment. It can also be used to verify the calibration of the ETC, which is another great benefit to users responsible for maintaining critical equipment.

As an EXAIR Application Engineer, it’s my goal to help you get the most out of our products, and your compressed air system. A big part of that is making sure you don’t use any more compressed air than you have to. If you’re ready to start saving, give me a call.

Russ Bowman, CCASS

Application Engineer
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Differences Between an EXAIR Adjustable Spot Cooler and Cold Gun Aircoolant System

Published on by John BallLeave a comment
Adjustable Spot Cooler
Cold Gun Aircoolant System

Have you ever wondered about the differences between the Adjustable Spot Cooler and the Cold Gun? 

In their most basic form, these two items are very similar – both require a compressed air supply, both produce localized cold air flows, both have magnetic bases, and both have the same basic profile.  However, under closer scrutiny, we can see that the Adjustable Spot Cooler can pivot on its magnetic base.  It also has the ability to vary the cold fraction and thereby vary the cold outlet temperature and flow.  The Adjustable Spot Cooler is supplied with multiple generators which allow for control of the compressed air inlet flow – yet another way to vary the cooling capacity of the Adjustable Spot Cooler.

Model 3925 Adjustable Spot Cooler System has a Dual Outlet Hose Kit for distribution of cold air flow to two points.

These distinctions make the Adjustable Spot Coolers the most versatile spot cooler on the market.  They can be used in many applications in which the exact cooling capacity is not known, a target temperature is required, or if the application requires temperature variations.   For example, if a customer has an application where a specific temperature is required or if shrinking/expansion is critical, the Adjustable Spot Cooler can provide a solution unavailable with a Cold Gun.  EXAIR offers them with either a single outlet for direct cooling or a dual outlet to capture both sides. 

The Cold Gun, on the other hand, produces a preset volume at a specific temperature drop.  This is great for applications with steady heat loads like machining, grinding, or laser cutting; or for applications in which you need to be free from tampering.  The Cold Gun will produce consistent performance without any modification needed from the end user.  EXAIR offers two types, the Cold Gun Aircoolant System and High Power Cold Gun Air Coolant System, which gives twice the cooling capacity.  Both units can be purchased with a single outlet hose or a dual output hose. 

There are many applications for our Spot Coolers.  They help remove heat to extend tool life, and they can help eliminate coolant to improve production rates.  If you have an application where you need to remove heat and do not know which unit to select, an Application Engineer at EXAIR is here to help you. 

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

Precision and Control with EXAIR Internal Mix Atomizing Nozzles

Published on by Jordan T ShouseLeave a comment

When it comes to applying coatings, cooling, humidifying, or lubricating, precision atomization makes all the difference. EXAIR’s Internal Mix Atomizing Nozzles are engineered to provide fine, uniform spray patterns with exceptional control—helping manufacturers achieve consistent results while conserving compressed air and liquid.

Internal Mix Atomizing Spray Nozzles

How EXAIR Internal Mix Atomizing Nozzles Work

EXAIR’s Internal Mix Atomizing Nozzles mix compressed air and liquid inside the nozzle body. This design produces the finest atomization and is ideal when both air and liquid flow rates can be precisely controlled.

The result? A highly consistent spray pattern with optimized droplet size and coverage—perfect for applications requiring accuracy and repeatability.

Key Benefits

  • Fine atomization: Internal mixing produces a mist with smaller droplets for superior coverage and surface finish.
  • Flexible spray patterns: Available in round, narrow-angle, and flat fan patterns to suit a wide range of needs.
  • Precise flow control: Independent adjustment of air and liquid allows you to fine-tune performance for your exact process.
  • Durable construction: Built in stainless steel for long life and corrosion resistance, even in harsh environments.
  • Reduced waste: Delivers the right amount of liquid—exactly where it’s needed—minimizing overspray and product loss.

Applications Across Industries

EXAIR Internal Mix Atomizing Nozzles are used in a wide variety of industries and processes, including:

  • Coating and painting of parts or products
  • Cooling of molds, tooling, and components
  • Moistening of materials in paper, textile, or food processing
  • Lubrication in metalworking or cutting operations
  • Dust suppression in handling and processing operations
142 distinct models. 8 different patterns. Liquid flow rates from 0.1 to 303 gallons per hour. If you’ve got a spraying application, EXAIR has an Atomizing Nozzle for you!

Why Choose EXAIR?

With EXAIR, you’re getting more than just a nozzle—you’re getting a complete engineered solution backed by decades of experience in compressed air efficiency. Every nozzle is designed for reliability, ease of maintenance, and precise performance, ensuring a consistent spray every time.

Looking to improve your spray application efficiency?
Explore EXAIR’s Internal Mix Atomizing Nozzles and discover how precision atomization can enhance quality, reduce waste, and improve process control in your operation.

Jordan Shouse, CCASS

Application Engineer

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Compressed Air Savings Made Easy: Turn Off Air When Idle

Published on by Tyler DanielLeave a comment

Compressed air is often the most expensive utility in an industrial facility. The energy required to generate compressed air makes it a significant operational cost. That is why EXAIR focuses on providing products that help reduce overall compressed air consumption and improve efficiency throughout your processes.

The simplest way to save compressed air is to turn it off when it is not needed. While that sounds straightforward, many operations cannot rely on manually opening and closing a valve. For example, if parts move along a conveyor and need to be cooled, dried, or blown off, there are usually gaps between parts. Running a blowoff continuously during those gaps results in wasted compressed air. Reducing that unnecessary usage can significantly lower the load on your air compressor.

EXAIR’s Electronic Flow Control, or EFC, provides an easy way to automate these savings. The system uses a photoelectric sensor to detect when a part is present. When no part is in place, the EFC closes a solenoid valve to stop the compressed air. When the next part arrives, the air turns back on automatically. This ensures air is supplied only when it is actually needed.

To demonstrate the impact an EFC can have, here is a real example. A manufacturer of car bumpers was using a Model 112060 60 inch Super Ion Air Knife at 40 PSIG to remove dust before painting. The dust was clinging to the bumpers due to a residual static charge. They traveled at roughly 10 feet per minute and had one foot of spacing between each part. Each bumper was under the air knife for 10 seconds, followed by 6 seconds with no part present. Because the operation ran three shifts, the system used compressed air for a total of 1,440 minutes per day.

A 60-inch Super Ion Air Knife consumes 102 SCFM at 40 PSIG. Without any control system, its total usage was:

102 scfm x 1,440 minutes = 146,880 SCF

After installing the EFC, the air turned off during the 6-second gap. This reduced airflow by 37.5 percent. The new daily consumption was:

146,880 SCF x .625 = 91,800 SCF

Using the common estimate that compressed air costs $0.25 per 1,000 SCF, the daily savings from reducing 55,080 SCF of use came to $13.77:

55,080 SCF x ($0.25/1,000 SCF) = $13.77

Because this facility operated 24 hours a day, 7 days a week, the yearly savings reached $5,012.28:

$13.77 x 7 days/week x 52 weeks/year = $5,012.28

These savings easily paid for the EFC in less than six months. After that point, the system continued saving money every day with no additional effort.

EXAIR has EFC models in stock for applications using up to 350 SCFM. For higher flow rates, models with dual solenoids are available as well. If any of your processes involve intermittent compressed air use, we would be happy to evaluate the application and help you determine how quickly an EFC could begin saving you money.

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com