Sometimes Plans Go Sideways – And That’s Okay

Published on by Brian FarnoLeave a comment

I often write and share personal experiences here. It’s kind of funny—if you had asked me 15 years ago whether I’d be writing regularly, I would have said, “Absolutely not.” That sentiment actually ties in well with today’s message.

Last night, I decided to tackle a maintenance issue on a 2014 Honda Pilot that’d been graciously loaned to us while we saved up for a newer vehicle for my wife. Her van’s transmission failed, and the cost to repair it just didn’t make sense. The Pilot has had a persistent clunking noise whenever it hits a bump. Upon inspection, I found both sway bar links were completely shot—the grease boots were torn, and the sway bar bushings were totally rotted. I had ordered the parts last winter with a few others, and I finally had time in my schedule to take care of them.

If you’ve ever worked on sway bar links, you know they usually don’t come off easily. Still, I kept a positive mindset and tried to remove the nuts holding the links in place—with zero success. So, out came the saw. I was able to cut the driver-side link out, and that’s when I should’ve realized things wouldn’t go smoothly.

My cut on the lower bolt was off and left too much of the stud. So, I grabbed another tool: the angle grinder. I’m not afraid to use the right tool—or to get rough when needed. With the sway bar supported and my hearing protection on, I went to work. It wasn’t a perfect job, but eventually I used a punch and hammer to knock out the remnants and moved on to the top mount. That one backed off halfway, then got cut at the threads and came right out. Thank goodness for sharp saw blades.

With the old link gone, I removed the deteriorated bushing and installed the new one without any trouble. Then came time to install the new sway bar link. These replacements were serviceable with grease fittings—a nice little upgrade for this older vehicle—so I had a good feeling they’d be the last ones it would ever need.

Oddly, the two new links (bought at the same time) came with different styles of lock nuts. One was slightly smashed into an oblong shape. The top nut went on snugly, but just as I was torquing it down, the Allen key recess began to round out. Not a huge deal, since I didn’t anticipate needing to take them apart again.

But the bottom stud and oblong retaining nut didn’t go so well. Halfway on, the nut tightened up severely, and the hex recess rounded out. All I could think was, “It shouldn’t be this hard.” I used the small wrench that came with the new links, and it popped loose—finally. Then I resorted to using vise grips on the flats.

Here’s where I made my mistake: I didn’t slide the grease boot out of the way and kept going. Just as I reached the last thread, the pliers slipped and pinched the brand-new grease boot. I still finished the installation—knowing I’d have to remove it again anyway—and wanted to make sure nothing else was out of alignment. At the time, I felt defeated by a simple task. This really shouldn’t have been so difficult.

In the end, I ordered another new sway bar link. It’s on the way, and I’ll attempt round two in 3–5 business days.

So, what’s the point of this story? Things don’t always go as planned. Sometimes it’s because you miss something or don’t trust your gut when something feels off. Other times, it’s stubborn determination to force something that just isn’t working. You can either dwell on it or take a breath, make a new plan, and keep pushing forward with the same energy.

I’ve seen this play out not just in car repairs, but in travel, my career, and life in general. When something doesn’t go right, it’s okay. Just adjust and move forward. It’s a mindset we bring to our work with customers at EXAIR.

That’s why our 30-day guarantee matters so much. If a recommendation didn’t work out, or testing pointed in one direction, but the results just weren’t there, we’ll help you rework the plan. We’ll back what’s already been done by covering any stock product with our 30-day guarantee and help chart a new path forward.

We’re not perfect, and we never claim to be. My plans don’t always work out either. But a failure doesn’t mean the end—it just means it’s time for a new plan of attack.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Big shout-out to my youngest daughter for snapping the photo of the passenger side and spraying down the rusted studs with Aero Kroil while I was at work, and she was enjoying summer break. It definitely pays to have your kids pitch in on these projects.

Keep Your Electronics Cool with EXAIR’s Cabinet Coolers: Cabinet Cooler® System Calculator

Published on by Jordan T ShouseLeave a comment

In today’s fast-paced industrial world, maintaining the performance and longevity of electronic equipment is crucial. Overheating electrical enclosures can lead to costly downtime, and premature component failure. Fortunately, EXAIR offers a reliable, efficient, and innovative solution with their Cabinet Cooler Systems. Paired with their intuitive Cabinet Cooler System Calculator, choosing the right cooling solution has never been easier. Let’s dive into what makes EXAIR Cabinet Coolers stand out and how the system calculator simplifies the selection process.

From right to left: Small NEMA 12, Large NEMA 12, Large NEMA 4X

EXAIR Cabinet Coolers are compressed air-powered cooling systems designed to keep electrical enclosures at optimal temperatures, even in the harshest environments. Unlike traditional air conditioners that rely on refrigerants and moving parts, these coolers use vortex tube technology to generate cold air from compressed air. This means no Freon, no maintenance headaches, and no risk of mechanical breakdowns—perfect for industries where reliability is non-negotiable.

Available in a variety of models, EXAIR Cabinet Coolers cater to different needs:

  • NEMA 12: Ideal for dust-tight, oil-tight indoor environments.
  • NEMA 4: Built for splash-resistant, indoor/outdoor use.
  • NEMA 4X: Corrosion-resistant stainless steel for food service or harsh settings.
  • Hazardous Location Models: Certified for explosive environments like Class I, II, or III areas.
  • ATEX:  Electrical enclosures located in ATEX Zones 2 and 22, for hazardous gases and dust.

Cooling capacities range from 275 Btu/hr for small panels to 5,600 Btu/hr for larger enclosures, with options for continuous operation or thermostat-controlled systems to save on air usage. Plus, they’re UL-listed, CE-compliant, and easy to install—typically in under an hour through a standard electrical knockout.

Launched as a do-it-yourself solution, the Cabinet Cooler System Calculator is a free, web-based tool available on EXAIR’s website under the Knowledge Base’s Calculator Library. It’s designed to provide instant feedback on the exact model you need, saving time and ensuring accuracy. Here’s how it works:

  1. Input Basic Information: Enter details like:
    • Enclosure dimensions (height, width, depth).
    • Current internal and external temperatures.
    • Maximum external temperature expected.
    • Desired internal temperature (typically 95°F for most electronics).
    • NEMA rating required.
    • Compressed air supply details (pressure and temperature).
  2. Heat Load Calculation: The calculator computes the internal heat load (from electronics inefficiency) and external heat load (from ambient conditions), factoring in variables like solar heat gain if applicable.
  3. Model Recommendation: Within seconds, it spits out the precise Cabinet Cooler model number—complete with cooling capacity in Btu/hr—and a link to learn more or order online.

Before the calculator, you’d fill out a Cabinet Cooler Sizing Guide and wait up to 24 hours for a recommendation. While that process still works (and EXAIR’s team responds promptly), the calculator delivers results in under 5 minutes. It’s perfect for engineers who want quick answers or companies facing urgent overheating issues. Plus, it’s packed with EXAIR’s decades of expertise, ensuring the recommendation compensates for non-optimal conditions like high air temperatures or low pressure.

In keeping with the understanding that we want to take your pain away quickly, not only can you get a recommendation for the right Cabinet Cooler system quickly, but we also keep all of our cataloged models on the shelf, ready for immediate delivery to your facility as quickly as the next day. Our customers have up until 2:00 p.m. Eastern time to get a recommendation and get an order in with us to be delivered the next day if the situation demands it.

EXAIR Cabinet Coolers are a proven, cost-effective way to protect your electrical enclosures from heat-related chaos. Paired with the Cabinet Cooler System Calculator, you’ve got a powerful duo that makes cooling simple, fast, and precise. No more guessing, no more delays—just cold air where and when you need it.

Ready to cool things down? Head to EXAIR.com, plug your specs into the calculator, and see the difference for yourself. Your electronics—and your bottom line—will thank you.

Jordan Shouse, CCASS

Application Engineer

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Twitter: @EXAIR_JS

Venturi Effect in Use

Published on by jasonkirbyLeave a comment

The Venturi effect describes the phenomenon where a fluid, such as air or water, accelerates as it passes through a constricted section, resulting in a decrease in pressure. This occurs because the fluid is drawn into the narrower area, and the increase in velocity leads to a corresponding drop in pressure. The effect is named after Giovanni Battista Venturi, who first articulated this principle in 1797.

A perfect example of the Venturi Effect can be found in our Air Amplifiers. Compressed air enters through the air inlet and flows into an annular chamber, where it is accelerated through a small ring nozzle. This high-velocity primary airstream follows the Coanda effect, guiding it toward the outlet. As a result, a low-pressure zone forms at the center, drawing in a significant volume of surrounding air into the primary flow. The mixture of the primary airstream and the surrounding air is then expelled from the Air Amplifier at a high volume and velocity.

The Venturi Effect is represented in amplification ratios. A ratio represents the relationship between two quantities, indicating how many times one value is contained within another. In the case of the Super Air Knife, this ratio illustrates the volume of ambient air that is drawn in alongside the primary flow of compressed air. With an impressive amplification ratio of 40:1, the Super Air Knife incorporates 40 parts of ambient air for every single part of compressed air, making it one of the most efficient air-operated knives available. This addition of mass enhances the device’s ability to deliver a powerful force, enabling it to perform more effectively in various applications.

The Venturi effect is integral to various EXAIR products designed for cooling, drying, and cleaning, alongside our vacuum generators. If your facility has a process that could benefit from an Intelligent Compressed Air solution, please reach out to us. We would be pleased to discuss your specific application and develop a solution that not only lowers your compressed air expenses but also enhances worker safety.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Advantages of EXAIR’s Cabinet Coolers: White Paper Recap

Published on by Tyler DanielLeave a comment

Summer has finally arrived in full force here in Cincinnati, Ohio after a much cooler than normal Spring season. Now that it’s officially summer, the weather has wasted no time with high temperatures here forecast to be in the mid-90s for the foreseeable future. For me, it’s great to finally be able to utilize the pool that we’ve been diligently maintaining for well over a month now. For the control panels installed throughout your facility, that’s a different story.

EXAIR manufactures a product called the Cabinet Cooler that is designed to rectify issues with overheating control panels. With the Cabinet Cooler installed and operating, you can completely eliminate production shutdowns due to heat, dirt, and moisture in the ambient environment. The systems are low cost and reliable, offering many advantages over other methods of heat mitigation such as heat exchangers, fans, and A/C systems.

Designed around Vortex Tube technology, the Cabinet Cooler is able to produce a stream of cold air from just a supply of ordinary compressed air. These products have absolutely no moving parts which allows us to operate 100% maintenance-free. Without any fans, condenser motors, evaporator blowers or compressors, there’s simply nothing to wear out or ever need to replace.

Most industrial environments are fairly harsh – Cabinet Coolers are not impacted at all by vibration or dirty conditions that can lead to refrigerant leaks and component failures in traditional A/C systems or heat exchangers. All of our Cabinet Cooler Systems come backed by a 5-Year Built to Last Warranty, with units still in service today after over 20+ years in operation. We even offer High Temperature Cabinet Coolers for ambient temperatures up to 200°F.

Installation couldn’t be simpler. The Cabinet Cooler installs in just minutes through a standard electrical knockout, compared to the hours necessary for a contractor to install a refrigerant-based system. Not to mention that those systems typically require a waiting period after shipping so the internal oils and lubricants can settle back into their proper reservoirs. Cabinet Coolers are ready to be installed the minute they arrive to your receiving dock.

Using clean, dry compressed air the Cabinet Cooler introduces clean, cold air directly into the panel. Warm air is purged through designed vents in the cooler itself, allowing you to completely seal off the panel from any ambient contaminants. There are no filters to replace, refrigerants to recharge or maintain, just set it and forget it!

The systems include a thermostat that’ll maintain a 35°C (or whatever temperature it’s set to) temperature inside of the panel at all times. When temperatures exceed the set point, a solenoid valve opens to supply air to the Cabinet Cooler. It’ll continue to operate autonomously, maintaining a safe operating temperature for your control panels when you need it most.

Register for an account on the EXAIR.com website today and check out our PDF Library where we have a complete White Paper published about the advantages of using a Cabinet Cooler this summer. Your facilities and maintenance teams will thank you!

Our complete line of Cabinet Cooler Systems is in stock and available to ship today. Input your conditions into our online calculator and get it on order ASAP!

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD