Lessons From Our Past

Published on by Brian FarnoLeave a comment

My first motorcycle was given to me by a friend of my brother who knew I just wanted to ride and, at the same time, knew I didn’t have the means to buy anything rideable. It came with some stipulations: there wasn’t a key, and it didn’t run. It was given to him by someone else, and the best part was that it actually had a service manual and a title.

1 – Camera phone / my first motorcycle

The bike was a 1984 Kawasaki KZ440 LTD. The issue was, rust in the gas tank had clogged the carb, and then it sat for years with the fuel in it. I had never attempted to rebuild a carburetor and had only heard horror stories. With my basic set of tools and the bike stored at my then-girlfriend’s house, I took the carbs off and figured, how hard could the repair be? I took everything apart, cleaned it all, or so I thought, put it back together, and it didn’t work. So then I took the carbs to a shop, and they warned me they couldn’t get them fully adjusted, but they were running. So I installed them back and found out I had to block off some of the intake, and it ran like a dream. Well, until you sat at idle, because then gas would leak out of the overflow onto the exhaust. I didn’t care, and I rode that bike for two years until the electric starter went out, and I worked on it continuously. Finally, I was able to purchase a fuel-injected bike and swore off carbs. Well, I was wrong. I now attempt to bring old equipment back to life for fun.

Well, last night, in between delivering the kids to Young Life and troubleshooting a car, I also had a carb off my dad’s John Deere 322 with electric choke. The tractor wasn’t running, he needed to get his garden tilled, and this tractor was the only way to do that. He brought me just the carb, and with this being a single-carb 3-cylinder motor, it is pretty simple. Having access to a friend with an ultrasonic cleaner makes it even easier. I opened the carb up and left the two halves fully assembled, then into an ultrasonic cleaner that was filled with piping-hot water and dish soap. No harsh cleaners; from shared experience of others, I have found that good old dish soap and hot water are all that is needed most of the time to clean these parts up.

That is some dirty water, and it had only been about 15 minutes in the cleaner.

After about 45 minutes in the cleaner, I took it out and checked all the jets with a light and a carb brush. Everything looked clean, I went and picked up some new bolts to hold the halves together, and sent them back home with my dad. He called me the next day and gave me the good news that the tractor ran better than it ever has.

All cleaned up, new bolts, and ready for testing.

The entire process made me realize that a carburetor is not far off from a couple of EXAIR products that we offer for refurbishment. Some of the products that we frequently refurbish for some customers are the EXAIR Air Knives and the Reversible Drum Vacs. These refurbishments are often the result of the environment and a failure in the filtration of the compressed air. The best part is that we will evaluate the products for free, determine if they can be repaired or refurbished, and then provide a quote for the process all within a few days of the item getting here. We also offer free videos of how to do things like clean the RDV for free through this blog.

Obviously, at some point, the filter and/or pretreatment for this compressed air supply failed and was not monitored. You can see the outline of the patented shim on the throat of this Super Air Amplifier.

Take this Super Air Amplifier, for instance. The system came in for the issue of underperformance, and we had already discussed with the customer how their filtration had failed about a year ago. They wanted to see what could bring this unit back to life. As soon as we saw pictures of it, we knew that the plenum was clogged up with debris.

If you have any EXAIR product that you think is not performing at an optimal level, please contact an Application Engineer today. If the product cannot be refurbished or repaired, we will give you a replacement option as well. The best part is, stock products ship the same day on orders received by 2 PM ET.

1 – Kris Krug – Camera phone / my first motorcycle – retrieved from https://commons.wikimedia.org/wiki/File:Kawasaki_Z440_LTD.jpg, 8/17/2005

Sound Power vs Sound Pressure

Published on by Al WooffittLeave a comment

Noise levels or sound levels are an important consideration in many industrial settings. Noise exposure can cause irreparable damage if the necessary safety precautions are not taken. OSHA standard 29 CFR – 1910.95 (a) addresses this very concern.

But when discussing sound levels, there are two terms that frequently come up – Sound Power, and Sound Pressure. So, what’s the difference?

Sound Power (measured in watts) refers to the rate at which sound energy (measured in decibels) is emitted, reflected, transmitted, or received over time. On the other hand, sound pressure is the local pressure change from ambient atmospheric pressure caused by a sound wave. From these definitions, we can see that sound power is what creates the sound wave, while sound pressure is the result of what we perceive after the sound wave reaches our ears.

A good way of conceptualizing this is to imagine a light bulb. Light bulbs use electricity to produce light, which means the power needed (also measured in Watts) to make the bulb shine is similar to sound power. The brightness of the light produced (measured in lumens) corresponds to sound pressure. Sound pressure is essentially what we hear or refer to as sound. This is what gets measured because it can be harmful to our hearing. If the sound pressure is too high and the ear is exposed for too long, it can lead to permanent damage, hence OSHA’s regulation mentioned above. This regulation is the result of testing performed to determine what time thresholds at which permanent damage to human hearing will occur due to exposure over a period of time. The higher the sound pressure level, the less exposure time necessary to produce irreparable damage. Within this regulation is included a time weighted chart that OSHA follow for noise exposure issues that serve as the metric by which they determine if a company is in compliance. If not, they may recommend engineering changes, work process changes or require the use of PPE (hearing protection) if the other types of controls cannot be implemented.

If you would like a way to measure noise levels in your facility, EXAIR has the perfect product – EXAIR’s Digital Sound Level Meter. We have a video blog covering its benefits and operation here.

Generally speaking, compressed air-generated noise within a facility can be rather prevalent and loud. So, if you would like to discuss how EXAIR’s quiet and efficient compressed air products can help reduce noise levels in your facility, then give us a call!

Al Wooffitt
Application Engineer

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EXAIR Leads Industry in Standards Compliance

Published on by Tyler DanielLeave a comment

EXAIR prides itself in offering products with high-performance and peak efficiency. All EXAIR products are manufactured to meet the strict requirements of a variety of different standards, ensuring that you receive a reliable, high-quality product that WILL perform to the specifications we publish.

Safety is a top priority for most companies. EXAIR’s line of Intelligent Compressed Air Products meet or exceed the strict safety standards set forth by both OSHA and the European Union. EXAIR products comply with OSHA 29 CFR 1910.242(b), the standard implemented to ensure safe operation of compressed air blowoff devices, and the EU General Product Safety Directive (2001/95/EC).

 Additionally, they comply with the noise limitation requirements set forth under 29 CFR 1910.95(a) and the EU Machinery Directive (2006/42/EC). From the Optimization product line, EXAIR’s Electronic Flow Control and the Electronic Temperature Control meet the low voltage standards of EU Low Voltage Directive (2006/95/EC). A CE label is placed on all products that comply with applicable directives.

A more recent edition to the EXAIR line of Cabinet Coolers has been our UL HazLoc and ATEX lines for maintaining safe operating temperatures for control panels in hazardous areas or ATEX Zones. In these spaces, it’s critical to have a product that’s designed for safe operation to alleviate any risks for fire or explosion due to combustible materials or vapors that may be in the atmosphere.

In the assembly of electrical products there can be hazardous materials used during production. The Restriction of Hazardous Substances, also known as RoHS or (2002/95/EC), restricts the use of materials such as: lead (Pb), mercury (Hg), cadmium (Cd), hexavalent chromium (CrVI), polybrominated biphenyls (PBB), polybrominated diphenyl ethers (PBDE), and four different phthalates. The electrical portions of EXAIR’s Static Eliminators, Electronic Flow Control, Electronic Temperature Control, Digital Flowmeter, solenoid valves, and thermostats all comply with the amendment outlined in the European Commission decision L 214/65.

EXAIR is also committed to providing products that are conflict mineral free. In support of Section 1502 of the Dodd-Frank Wall Street Reform and Consumer Protection Act, EXAIR complies with the conflict minerals rule to curb illicit trade of tin, tantalum, tungsten and gold in the DRC region. Using the CMRT 4.20 template, we’re able to document our supply chain to ensure our materials are not being sourced from places that could finance conflict in the DRC and surrounding countries.

According to regulation (EC) No 1907/2006 Title I, Article 3, paragraph 3, the European Union enacted legislation requiring substances and chemicals imported into the EU to be registered to ensure a high level of protection for human health and the environment. Per Title II, Article 7, paragraph 1, articles must be registered when a substance is intended to be released during normal conditions of use that would exceed 1 metric ton per producer per year. Since EXAIR products do not contain substances that are intentionally released, registration is not required.

If you’re looking to maintain compliance in your industry, EXAIR products have you covered. If you have any questions about these standards of compliance feel free to reach out to us. Our team of Application Engineers have years of experience in industry and are waiting to take your call.

Tyler Daniel

Application Engineer

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD

Starting a Leak Prevention Program: Maximize Efficiency and Savings

Published on by Jordan T ShouseLeave a comment

Compressed air systems are the unsung heroes powering countless processes across all industries. However, they come with a hidden cost: leaks. Even the most well-maintained systems experience some level of leakage, often wasting 20-30% of a compressor’s output, according to the Compressed Air Challenge. This inefficiency translates directly into higher energy bills, increased compressor wear, and unnecessary maintenance expenses. The good news? You can take control of these losses by implementing a Leak Prevention Program. Let’s dive into how to establish such a program and why it’s a game-changer for your bottom line.

Compressed air isn’t cheap—it’s often one of the most significant energy expenses in a facility. When leaks go unchecked, you’re not just losing air; you’re losing money. A single leak can cost thousands of dollars annually, depending on its size and your energy rates. For example, at $0.07 per kWh, a leak as small as 1/8 inch can waste over $2,933 worth of compressed air per year. Multiply that by dozens of leaks across a system, and the financial impact becomes staggering. Beyond the dollars, leaks force compressors to run longer and harder, shortening their lifespan and driving up maintenance costs. A Leak Prevention Program isn’t just a nice-to-have—it’s a strategic necessity for operational efficiency and sustainability.

EXAIR provides resources and tools to help you design and execute an effective Leak Prevention Program. Here’s a step-by-step approach to getting started:

  1. Establish a Baseline – Before you can measure improvement, you need to know where you stand. Document your current compressed air usage by tracking compressor run times, energy consumption, and system pressure. This baseline serves as your reference point to quantify savings once leaks are addressed. To measure the total volume of air, you can implement the EXAIR Digital flow meter.
  2. Identify Leaks – Here’s where EXAIR’s Ultrasonic Leak Detector (Model 9207) shines. Leaks produce high-frequency turbulence—ultrasonic “white noise” that’s inaudible to the human ear but easily detectable with the right technology. This handheld, high-quality detector converts these ultrasonic signatures into audible sounds through headphones and displays intensity on an LED screen, allowing you to pinpoint leaks up to 20 feet away. Whether it’s a faulty fitting, a worn valve, or a cracked pipe, the detector’s precision ensures you won’t miss a thing—even in noisy industrial environments.
  3. Document and Prioritize – Once leaks are identified, record their location, size, and estimated cost. There are two main approaches: the Seek-and-Repair method, where leaks are fixed immediately, or the Leak Tag method, where leaks are tagged and logged for scheduled repairs. For larger facilities, a master leak list can streamline tracking and ensure accountability. Prioritize repairs based on leak size and accessibility—tackling the biggest offenders first maximizes early savings.
  4. Repair and Verify Fix the leaks using appropriate methods—tightening connections, replacing seals, or upgrading components. After repairs, use the Ultrasonic Leak Detector again to confirm the fixes hold. This verification step ensures your efforts translate into real results.
  5. Track Savings and Optimize Compare your post-repair compressed air usage to your baseline. The reduction in energy costs, compressor runtime, and maintenance needs will reveal the program’s ROI, then you can turn your leak prevention program into a continuous improvement process.

The EXAIR Ultrasonic Leak Detector is an important building block for this program. Its ability to detect leaks quickly and accurately sets it apart from rudimentary methods like listening for hisses (which only catches the worst offenders) or using soapy water (impractical for large systems). The detector’s portability and ease of use mean your team can cover an entire facility efficiently, even during normal operations. Its directional sensitivity zeros in on leak sources, minimizing guesswork and downtime. With minimal training, your staff can become proficient, making it a practical investment for any operation.

Compressed air leaks will rob your system of its capacity, compressor life, and electrical cost.  It is important to have a leak preventative program to check for leaks periodically as they can happen at any time.  The EXAIR Ultrasonic Leak Detector and the Digital Flowmeters will help you accomplish this and optimize your compressed air system.  Once you find and fix all your leaks, you can then focus on improving the efficiency of your blow-off devices with EXAIR products like Super Air Knives, Super Air Nozzles, and Super Air Amplifiers, and save yourself even more money.  This blog is an overview of Step 2 of the Six Steps to Optimization. You may have more questions; and, that is great! You can find them in other EXAIR blogs, or you can contact an Application Engineer at EXAIR.

Jordan Shouse
Application Engineer

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Air Leak Photo Courtesy of the Compressed air Challenge