Compressed Air Accessories for Clean Air, Quiet Air, and Adjustability

In this blog, I would like to turn your attention to our accessories that support our Intelligent Compressed Air® Products.  EXAIR products use compressed air to coat, conserve, cool, convey and clean.  To maximize the performance, it is important to have the controls and options to increase their “flexibility”.  EXAIR offers these items as Accessories.  Pneumatic applications come in many variations and forms, and Accessories can help you to adapt to your application and to remove any “guess work”.

Here are the different categories and explanations of each item that EXAIR recommends for our products.  With their defined functions, they can help you in different areas to enhance your pneumatic experience.

Filters/Regulators:

  • Filter Separators remove bulk liquid and contamination from the compressed air stream. EXAIR stocks a range of sizes from ¼” NPT ports to 1 ¼” NPT ports.  They use a 5-micron filter and a mechanical baffle to remove slugs of liquid from your compressed air system.  Most Filter Separators have an auto-drain to automatically remove the buildup of liquid inside the bowl.   I would consider the Filter Separator as a minimum level of protection required to protect your EXAIR products.
  • The Oil Removal Filters remove very small particles of dirt and oil from the compressed air; making it even cleaner. The 0.03-micron media of the Oil Removal Filter will “coalesce” the fine liquid particles into large droplets.  Thus, allowing gravity to remove it from the compressed air stream.  EXAIR offers different sizes ranging from ¼” NPT to 1 ½” NPT ports.  As a note, Oil Removal Filters are great for removing very fine particles, but if you have a system with lots of water, I would recommend a Filter Separator upstream of the Oil Removal Filter for optimal filtration.
  • Pressure Regulators control the amount of air pressure being supplied to your EXAIR products. This is important if you are trying to save compressed air, control the force, or convey material.  EXAIR, being a leader in compressed air savings, recommends to use the minimum amount of air pressure to do the job.  This will save compressed air and save you money.  Regulators have a characteristic called “droop”.  Droop is the amount of air pressure that it drops downstream when you start flowing compressed air.  If the regulator is not sized properly, you can “starve” your pneumatic component, causing loss of function.  EXAIR properly sizes our regulators in our kits to make sure that you won’t “starve” our product.
  • EXAIR also offers Mounting Brackets for the regulators and the filters to help support them to a wall or structure. To connect filters and regulators together without a pipe nipple, we also have Coupling Kits for sizes up to ¾” NPT.  And for combination kits which includes a filter and a regulator, we offer the Mounting Bracket and Coupling Kit together for a set.

Silencing Mufflers:

  • Reclassifying Mufflers are designed to have two functions. They can reduce noise levels by 35 dB and remove oil mist from the exhaust air.  Cylinders and valves that exhaust pressurized air may have oil in the line to keep the seals from sticking.  When exhausted, it can create a fine mist which is dangerous for operators.  The Reclassifying Mufflers can reduce the loud noise as well as collect any contamination from the exhaust air.
  • Sintered Bronze Mufflers are simple in design, cost effective, and easy to install. They have a minimal back pressure to not restrict operations of the pneumatic device.  They come in sizes from #10-32 thread to 1-1/2 NPT.  For a quick and simple way to reduce noise, the Sintered Bronze Mufflers are in stock for fast delivery.
  • Straight-Through Mufflers offer a way to reduce noise levels without worrying about clogging. They have an aluminum shell lined with sound absorbing foam, and they can reduce the noise level by 20 dB.  EXAIR offers them with two ports from ¼” NPT to ¾” NPT.  This can allow you to connect other items like blowing hose kits while reducing noise.
  • Heavy Duty Mufflers have an outer aluminum shell with an internal stainless steel screen that can protect the components from environmental contamination, and can also keep contaminant like rust from being ejected at high speed into the work area. They have a typical noise reduction of 14 dB.

Pneumatic Valves:

  • Manual Valves allow for operators to turn on and off their system by hand. The full-flow ball valves range from ¼” NPT to 1 1/4” NPT in size and will not restrict flow.  EXAIR also offers a manual foot pedal valve for hands-free operations.  This ¼” NPT Foot Valve has a 3-way operation and works great if the operator has to use both hands in their process.
  • Solenoid Valves are a way to turn on and off the supply of compressed air electrically for automated systems. We offer solenoids in three different voltages; 110Vac, 240Vac, and 24Vdc.  EXAIR has a large range of flows with ports ranging from ¼” NPT to 1” NPT.  All models are UL listed and are CE and RoHS compliant.

Hardware:

  • Swivel Fittings are a great way to securely install and aim EXAIR nozzles. They are dynamic as they can be adjusted and set to a flow direction with 50-degrees of movement.  They are made from 303SS or 316SS for corrosion resistance with ports ranging from 4mm to 1” NPT.
  • Compressed Air Fittings are a nice arrangement to connect different compressed air items together. We offer a range of hex and close nipples, couplings, reducers, tees, elbows, crosses and bulk head fittings.  If you need a quick way to connect directly to your pneumatic system, we may have it on the shelf.
  • Magnetic Bases are designed for a solid mount to steel surfaces and for easy portability of your blow-off system to different locations. It has a 100 lb. (45.5Kg) pulling force to keep the blowing device attached firmly until you want to move it.  They can be mounted in a vertical or horizontal position.  EXAIR offers a single outlet Magnetic Base (for one blow-off device); a dual outlet Magnetic Base (for multiple blowing products); and a single outlet Swivel Magnetic Base (to offer more flexibility to orientation).  The bases come with a ¼ turn shut-off valve to easily turn on and off the compressed air to the EXAIR products.
  • Receiver Tanks are used to store compressed air. They can be used at the air compressor or as secondary reservoirs for intermittent demand.  They help your compressed air system with pressure variations and high demand loads.  EXAIR offers a model 9500-60 Receiver Tank that has a capacity of 60 gallons, is rated to 200 psig, and meets ASME pressure vessel code.

 

Hoses:

  • Conveying Hoses are used with our Air Operated Conveyors or Line Vacs. The hoses are made from a durable PVC semi-flexible hose with six different diameters from ¾” I.D. up to 3” I.D.  The conveyance hoses can slip easily to the ends of the Line Vacs or to tubes for an easy transition.  EXAIR can cut-to-length Conveying Hoses up to 50 feet (15m); in increments of 10 feet (3m).
  • Coiled Hoses get compressed air from the piping system to the EXAIR product. They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters).  They have swivel fittings at the end to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking.  The coiled design makes it easy to reach around the work area and retract back to the substation.  This will help to keep the hose off the ground where potential dangers could occur.  We offer 3 different connection sizes; 1/8” NPT, ¼” NPT, and 3/8” NPT.
  • Compressed Air Hoses is another way to supply EXAIR products. They are useful if you need to reach from overhead sources or around equipment.   They are made from a reinforced synthetic rubber in 3/8” I.D. and 1/2” I.D. diameters.  We can make specific lengths up to 50 feet (15m).  They are rated for 250 PSIG (17 bar) air pressure, and the hose material works well for long-lasting protection against ozone, weathering and temperatures up to 158oF (70oC).  They come standard with two male ends in ¼” NPT or ½” NPT.

    Flexible and durable, EXAIR Stay Set Hoses come in lengths from 6″ to 36″.
  • Stay Set Hoses give you that possibility of manually adjusting or re-adjusting Super Air Nozzles. The hose has a “memory” function; so, it will not creep or droop until you physically move it.  They work well to direct air flows in unique ways at specific target areas.  They can be used with Super Air Nozzles, Safety Air Guns and Blow-off Kits.  The Stay Set Hoses come in lengths from 6” (15cm) to 36” (91cm), and they are offered with ¼” NPT male on both ends or with a 1/8” NPT female and a ¼” NPT male connections.  These hoses are rated for 250 PSIG (17 bar) and are made from reinforced synthetic rubber.

Temperature Accessories:

  • The ETC, or Electronic Temperature Control, is a digital temperature controller with a LED screen for precision monitoring and adjusting temperatures in a Cabinet Cooler System. The controller has easy-to-use buttons to raise or lower the desired internal cabinet temperature.  Once set, the ETC will hold the temperature to +/- 1 oF (+/- 0.5 oC).  The LED displays the internal temperature for continuous monitoring.  The ETC comes complete with the controller and a solenoid valve in two different voltages, 120Vac and 240Vac.
  • The thermostat is a way to control a solenoid valve electrically to turn on/off a Cabinet Cooler System at a set temperature. It is preset at 95°F (35°C), but it can be adjusted to other desired temperatures.  It has an accuracy to hold the set temperature within +/- 2 °F (1 °C).  It can handle voltages from 24V to 240V, AC (50/60 Hz) or DC.  They are UL Recognized and CSA certified.

In todays fast-paced world, there is a need to get your devices operating as quickly as possible.  With EXAIR Accessories, they can help you to do that.  Not only will you have confidence, as you are using the items from the manufacturer, but it will minimize downtime, setup, and malfunctions that can occur if using other types of accessories.  If you would like to discuss the proper options with your EXAIR products, an Application Engineer will be happy to help you.

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

Compressed Air Demand Preventative Maintenance

Preventative maintenance for compressed air demand products is a simple as keeping the compressed air clean and condensate free. It is simple because all it takes is a filter and keeping the filter element clean, just like you do for your home furnace and/or air conditioner.

I received a phone call from a customer that needed replacement elements for EXAIR filters.  They were using four different models of Filter Separators and Oil Removal Filters.  The filters had been in service for one year, and the internal elements needed to be changed.  They requested a quote to replenish the replacement elements that they stocked as a preventative measurement.  What an idea!

Majority of EXAIR products use compressed air for cleaning, cooling, conveying, static elimination, coating and more.  To help keep your EXAIR products running efficiently, it is important to supply them with clean, dry, pressurized air.  EXAIR offers a line of Filter Separators and Oil Removal Filters to supply quality air to your equipment.  In this blog, I will explain the two types of filters that we carry and the maintenance requirements.  The filters and preventative measures can play an important part in your compressed air system.

Filter Separators are used to remove bulk liquid and contamination from the compressed air stream.  They utilize a 5-micron filter with a mechanical separation to help remove large amounts of dirt and water.  This type of filter would be considered the minimum requirement for filtration.  Most of the Filter Separators come with an auto-drain to automatically dispense the collection of oil and water.  EXAIR offers a variety of port sizes and flow ranges to meet your pneumatic flow requirement.  For maintenance, the filter elements should be changed once a year or when the pressure drop reaches 10 PSID, whichever comes first.  I created a list in Table 1 showing the correct replacement element kits for each model number.  And for any reason, if the bowl or internal components get damaged, we also have Rebuild Kits as well.  Just remember, the air quality is very important for longevity and functionality for pneumatic products and even for EXAIR products.

The Oil Removal Filters can make your compressed air even cleaner.  They work great at removing very small particles of dirt and oil.  They are made from glass fibers and can remove particles down to 0.01 micron.  They are designed to collect small particles and to coalesce the liquid particles into a large droplet for gravity to remove.  Because of the fine matrix, Oil Removal Filters are not great for bulk separation.  If you have a system with lots of oil and water, I would recommend to use the Filter Separator upstream of the Oil Removal Filter.  As with the Filter Separator, the filter element should be changed once a year or at a pressure drop of 10 PSID.  EXAIR also offers a variety of port sizes and flow ranges.  Table 1 below shows the replacement Element Kits as well as the Rebuild Kits.  If the application requires very clean compressed air, the Oil Removal Filter should be used.

Table 1

By using EXAIR filters, they will clean your compressed air to prevent cross contamination, performance issues, and premature failures.  As an ounce of prevention, you can add the replacement elements in stock and enter them in your preventative maintenance program.  With clean quality air, your pneumatic system and EXAIR products will provide you with effective, long-lasting performance without maintenance downtime.  If you would like to discuss the correct type of filters to use in your application, you can speak with an Application Engineer.  We will be happy to help you.

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

Compressed Air Accessories – Filters and Regulators – The Rest of the Solution

IMG_5696
EXAIR Regulator with gauge and Filter/Separator

Many times in the stories that are written in our daily blogs, we espouse the many benefits of installing and using EXAIR made products into our many customers’ compressed air-based applications. From the guy who has a small shop in his home garage using our Atto Super Air Nozzle to much larger applications where customers use our 84” Long Super Air Knives to do such things as drying cast Acrylic Sheets used in tub and shower surrounds, the message is a very consistent one. Customers benefit by saving money, increasing the safety level of an application, reducing sound levels and improving productivity.  There’s no doubt that our customers will excel in these areas.

Knowing there is much more to a compressed air system than just point of use products, lets shed a little light on the other “parts” of a typical system set-up. Those would be the compressed air filter / separators and the pressure regulators that are a highly recommended part of a good installation. But why are they so highly recommended? What exactly is their role and why would anyone want or need to install them?

First, the blunt realities of compressed air and its relative “un-clean” condition once it arrives at the point of use. Since compressed air a utility that is produced in-house, the quality and quantity available will vary widely from facility to facility. And since it is not a regulated utility such as gas or electricity are, there are no universal minimums of quality that compressed air must meet before sent out to the distribution system. Yes, of course, companies are all the time getting better at this part, but many still operate with older, iron pipe systems that produce rust and scale which wreak havoc on the components within mechanical products that use compressed air as their power source. The point is that you are never sure of the quality of the air you will get at the point of use, so install a compressed air filter near that point to keep the debris out of your Air Knife, Nozzle, Line Vac or even other components like solenoid valves, air motors and the like. Believe me when I say it is much easier to un-screw a bowl from a filter housing and change an element than it is to disassemble an air motor or an 84” long Super Air Knife because rust migrated in from the pipes. So it is quite safe to say that an ounce of prevention in this case is worth a pound of cure!

Second, the discussion turns to the Regulator part of the equation. As many know, our products and those of other pneumatic product manufacturers have a certain set of specifications regarding performance at stated input pressures. But what if your application doesn’t require that “full, rated performance”? Maybe instead of needing two pounds of force, you only need one pound? In fact, if you provided two pounds of blowing force, you would end up “over-blowing” your target. By that, I mean you cause damage to the target or other surrounding items in the application. Or, perhaps blowing to hard (or sucking too hard in the case of a Line Vac or E-vac) might cause the vessel or the material you are picking up to collapse or deform (due to too much power).  There is also the concern about using more energy than one really needs to in order to achieve the desired effect in an application. In other words, if you can achieve your goals with only 40 PSIG, then why would you ever use 80 PSIG to accomplish the goal? By reducing your compressed air from 80 down to 40 PSIG, you can easily reduce the air consumption of the “engineered” solution by another 40% + …………that’s the cherry on top of the cake when you compare the benefits of simply “bolting on” the solution of an engineered air nozzle vs. an open pipe in the first place. Then there is the issue of taking advantage of the pressure differential (from 80 down to 40 PSIG) that creates a little bit more air volume capacity. At 80 PSIG, your compressed air to free air volume ratio is 6.4:1. At 40 PSIG, it is only 3.7:1. The net effect is you effectively have an overall larger volume of air at the disposal of the application which is always a good thing.

Regulating pressure is definitely warranted given the benefits that compliment the operation of the core EXAIR products.

If you need a deeper understanding about how EXAIR’s products can help your application, feel free to contact us and we will do our best to give you a clear understanding of all the benefits that can be had by our products’ use as well as proper implementation of accessory items such as compressed air filters and regulators.

Neal Raker, International Sales Manager
nealraker@exair.com
@EXAIR_NR
www.EXAIR.com 

Why 5 PSIG Matters

Last week I pointed out the important locations for measuring your compressed air system pressure throughout your compressed air system.   One of the critical points to measure system pressure was before and after each filter.  This leads into another question that I receive every once in a while, “How do I tell when the filter needs to be changed?”  The answer to this is easy, when you see more than a 5 PSIG pressure drop across the filter.  This means that the element within the filter has become clogged with sediment or debris and is restricting the volume available to your downstream products.

Filter
EXAIR 5 micron Auto Drain Filter Separator

 

This can lead to decreased performance, downtime, and even the possibility of passing contaminants through the filter to downstream point of use components.  In order to maintain an optimal performance when using EXAIR filter separators and oil removal filters, monitoring the compressed air pressure before and after the unit is ideal.

Replacement filter elements are readily available from stock, as well as complete rebuild kits for the filter units. Changing the filters out can be done fairly easily and we even offer a video of how to do it.

The life expectancy of a filter element on the compressed air is directly related to the quality of air and the frequency of use, meaning it can vary greatly.  If you tie a new filter onto the end of a compressed air drop that has not been used in years, you may get a surprise by the filter clogging rather quickly.   However, if you maintain your compressor and your piping system properly then the filters should last a long time. Generally we recommend checking your filters every 6 months.

If you have questions about where and why to filter your compressed air contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF