Optimize Your Intelligent Compressed Air® Products with EXAIR’s Accessories

EXAIR offers a wide variety of various accessories that can help you to better control and fine-tune any of your compressed air operated products. Most of EXAIR’s line of Intelligent Compressed Air Products have no moving parts and require no maintenance. The caveat to the “no maintenance” aspect is proper filtration at the point of use. Many products have very tight orifices that could get clogged from any contaminants such as particulate, condensate, and lubricant. EXAIR recommends point of use filtration to be installed just upstream of any EXAIR Product for this purpose.

EXAIR has a line of Automatic Drain Filter Separators and Oil Removal Filters, available from stock, to make sure the quality of your air supply is sufficient for proper operation of any EXAIR product. Particulate filters remove any suspended solids from the airstream, ensuring the tight orifices in the products remain free of debris. If your system has residual oil, this should also be removed with a coalescing filter. Check out this short video from my colleague, Brian Farno, that demonstrates these filters in action:

Controlling your compressed air pressure at the point of use is an excellent way of minimizing your compressed air usage. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air at the point of use can often be overlooked. using them to minimize your pressure can result in dramatic savings to your costs of compressed air. As pressure and flow are directly related, lowering the pressure supplied results in less compressed air usage. EXAIR recommends operating your Intelligent Compressed Air Products at the minimum pressure necessary to achieve a successful application. If you notice a desirable result at a pressure of 60 PSIG, or even less, there’s no need to run full line pressure. In-line point of use pressure regulators are the simplest and most reliable way to allow you to dial down to the pressure to any compressed air operated product.

Taking this idea of minimizing air usage one step further, you can achieve even greater savings by simply turning the air off when not needed. The most basic option for turning off the air supply is a simple manual valve. EXAIR offers a range of various sized valves to allow you to do just that.

This process can also be automated as well. If you’d like to automate the control of your blowoff, EXAIR offers solenoid valves that can tie into your existing PLC and eliminate unnecessary air usage. For those that want a solution ready to go right out of the box, EXAIR’s Electronic Flow Controller utilizes a photoelectric sensor and solenoid valve tied to a timer that allows you to shut off the air supply when a part or component is not present. This can lead to dramatic air savings in many applications where parts are traveling along a conveyor.

Once you’ve selected an engineered compressed air nozzle for your blow off application, you’ll likely need a solution to mount and position it as well. Here’s where EXAIR’s Stay Set Hoses and Magnetic Bases come into play. EXAIR’s Stay Set Hoses are available from 6”-36” in length with ¼ NPT male threads on each end, or a ¼ NPT male on one end and 1/8 NPT female on the other. The Stay Set Hoses are rigid and allow you to maintain precise positioning of the blow off nozzle. The hoses have “memory” and will not creep or bend. They’re easily repositionable as well, making them an ideal solution for applications that may require frequent repositioning due to varying parts.

In addition to the Stay Set Hoses, EXAIR also has Magnetic Bases available as well. The powerful magnet permits both horizontal and vertical mounting. A manual valve is also included that will allow you to vary the force and flow. Magnetic bases are available with one or two outlets and can be combined with any of our nozzles and Stay Set Hoses to create your own customized blowoff system.

Regardless of your application, EXAIR has the products available from stock to help optimize your processes. These accessories allow you to help optimize the use of your blowoff products and ensure reliable, repeatable performance. If you’d like to discuss an application, give us a call.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

EXAIR E-Vac Vacuum Generator Accessories: Overview

Vacuum systems are becoming more and more prevalent within manufacturing day by day. Vacuum powered lifts can make it easy to lift and move small objects like tiny coins to heavy steel plates. Vacuum chucks hold work pieces that could be marred by jaws or vises. And sealed vessels can be pressure tested or tested for leaks by pulling a vacuum on them. It’s pretty simple to pick out which vacuum generator that you need, but what about the accessories? There are so many different accessories to choose from such as mufflers, suction cups, hose, valves, and connections. The following is a quick overview of the different accessories that you can get from EXAIR along with your E-Vac vacuum generator.

Vacuum cups for E-Vac generators

Suction cups are a very common accessory that you need when using a vacuum system. Vacuum cups allow one to create a seal on the surface of the object that you wish to pick up and is what allows the system to lift objects. We offer four different kinds of vacuum cups to choose from stock; available are small and large Round, Oval, and Bellow styles. Round cups are more suited to being used on smooth, flat surfaces. Oval cups provide the most vacuum due to the larger surface area making them ideal for lifting heavy loads. The Bellows style is best suited for textured or uneven surfaces; the folds provide a collapsible area that allows the cup to compress and seal on an uneven surface.

EXAIR’s Standard and Straight Through Muffler

Next up is the mufflers; they muffle the sound generated by the E-Vac and quiet a working vacuum generator. There are two different types of mufflers from EXAIR that are available; these are the Standard and the straight through mufflers. The Standard muffler is designed to be attached to the discharge end of an in-line E-Vac and has a closed end. These are best suited for applications that are free from dust and debris. The straight through muffler is open all the way through and are more suited to applications were dirt, dust and debris is present. The straight through style also offers the best sound level reduction, up to 26 dBA.

Lastly the E-Vacs have an NPT threaded connection that will allow for a suitable connector to be properly installed. From here different connectors can be used to attach the various amounts of vacuum cups. The connectors provided are Push-In Connector Type Fittings of assorted styles available with our polyurethane tubing to make the installation and plumbing a cinch.

If you have any questions or want more information on EXAIR’s E-Vacs and their Accessories. Give us a call, we have a team of application engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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Vortex Tubes – The Basics, And Beyond

The Vortex Tube might be just about the most interesting compressed air device around.  They have no moving parts, and they don’t need any but a compressed air supply, which they ‘split’ into a hot air stream, and a cold air stream.

EXAIR Vortex Tubes come in three sizes – Small, Medium, and Large – and 24 distinct Models across those three sizes.  They’re all in stock, along with Hot & Cold Mufflers (for sound level reduction,) Automatic Drain Filter Separators (to keep the air supply clean & moisture free,) Oil Removal Filters (to coalesce any trace of oil from the air supply,) and Solenoid Valves & Thermostats (to automate operation.)

From left to right; a few value added accessories for your Vortex Tube: Hot Muffler, Cold Muffler, Automatic Drain Filter Separator, Oil Removal Filter, and Solenoid Valve/Thermostat Kit.

The Vortex Tube, right out of the box, is easily adaptable to a wide range of cooling (or heating) applications.  If your needs are specific, though, we can customize a Vortex Tube to meet them:

  • Material of construction: our stock Vortex Tubes are made of 303SS and are equipped with a plastic Generator and Buna o-ring.
    • For high temperature (>125F ambient) applications, we can install a brass Generator and Viton o-ring, suitable for ambient temperatures up to 200F.
    • If the environment is particularly aggressive, or if industry codes (I’m looking at you, food & pharma) call for it, we can also make them out of other materials.  We’ve, for instance, made them out of 316SS, complete with material certifications, when needed.
  • Flow & temperature: the Hot Valve can be opened or closed to dial in a particular Cold Fraction (that’s the percentage of the supply air which is directed to the cold end.)  If you know what flow rate and temperature you want, we can replace the Hot Valve with a non-adjustable plug, so your Vortex Tube’s cold flow is only dependent on the compressed air supply temperature and pressure.
  • Accessories: if you’re looking for features like a magnetic base, or a flexible cold air hose, you might consider an Adjustable Spot Cooler.  If you like the idea of tool-free change of air flow/temperature, that’s definitely the way to go.  If you want those other options, and don’t mind using a screwdriver to adjust the Cold Fraction, those other options are compatible with any Medium Vortex Tube.

Model 3925 Adjustable Spot Cooler

These are just a few of the most common possibilities for customizing a Vortex Tube.  If you have a spot cooling application you’d like to discuss, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Compressed Air: Only as Intelligent as Your Accessories

How often have you seen a compressed air system functioning at 100% efficiency? Do you have the right accessories to provide a source of clean air at the proper pressure? Even with the right accessories, have they been maintained in good working order? Chances are that some of your components are in fact in need of attention such as a clogged filter, improper regulator or maybe undersized hoses. Your air compressor is only as intelligent as the weakest component in your system.

This is why you need to make sure all of your EXAIR accessories are properly fitted and located in the most efficient locations. Your compressor is capable of producing compressed air but your accessories will allow it to function the way it is meant to function. Using accessories and using them in the right manner is the intelligent choice, it will minimize your maintenance while increasing your energy efficiency for the life of your compressor. Let’s review a few of the most important compressed air accessories you should consider.

Filter Separators: Filters remove and separate water, dirt and scale from your compressed air system to keep your air clean and output pure. Clean air keeps your air products and machines more efficient and reduce the frequency of maintenance. Filter Separators will accumulate particulate matter naturally so they will need cleaned and/or replaced filter elements regularly depending on your operating environment. EXAIR provides Filter Separators and recommend they be installed prior to an Oil Removal Filter, pressure regulator or valve.

Filter Separators

Oil Removal Filters: Many air compressors use oil to lubricate therefore the risk of oil in your air lines is imminent. Although oil may not affect the compressed air system itself it can become a problem with products which do not require oil and have small air gaps. It can also be problematic if oil is blowing on to packaging or the final product. Keep this in mind and remember that oil should be removed from compressed air lines in certain instances. EXAIR’s oil removal filters will remove oil and solid particulate found in many compressed air systems.

Pressure Regulators: Regulators adjust the air pressure being supplied by your air compressor to the level that you require at the point of use. For instance your compressor generates 150 PSI but your compressed air product only requires 80 PSIG, the regulator can adjust the pressure to the desired setting and also relieve undue pressure on fittings, hoses and tools. Reducing pressure at the end-use product will also reduce the air consumption. Almost every compressed air application will use tools with varying pressure ratings making EXAIR Pressure Regulators a must-have accessory.

Hoses & Fittings: Hoses and fittings wear with time. Common issues are kinking, bending, leaks and contaminants, they should be checked often and replaced when required. Another common problem with hoses is that they are either too long and not as efficient or too short which can cause your employees reduced productivity. EXAIR offers STAY SET Hoses, Conveying Hose, Coiled Hoses and Compressed Air Hoses of different sizes and lengths. Our selection of compressed air fittings insures you can get all you need from one location.

Receiver Tanks: The use of receiver tanks can improve your overall system efficiency. Storage receivers can be placed near equipment that consume short duration of high flows of compressed air that might cause localized low pressure. EXAIR’s 60 Gallon Receiver Tank placed near the point of use can smooth out the high flows so as not to cause the start of an extra air compressor or cause localized low pressure.

If you would like more information regarding how proper use of EXAIR’s accessories can make your compressed air consumption more intelligent please contact me or any of our qualified Applications Engineers to discuss your applications.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK