EXAIR Digital Flow Meters

A topic that we’ve talked about here on the EXAIR blog discusses the costs of compressed air and how to use it more efficiently. How can you determine the costs of your compressed air? The first step you’ll need to take is to put a number to how much compressed air you are currently using. In order to do that you’ll need a measurement tool such as the EXAIR Digital Flowmeter.

EXAIR Digital Flow Meters

The Digital Flowmeter is available from stock for use on Schedule 40 pipe with sizes ranging from ½”-4” I.D. Sizes up to 8” for Schedule 40 and ¾”-4” for copper pipe are also available. Metric sizes are also available for 25mm, 40mm, 50mm, 63mm, 76mm, and 101mm. With a digital readout display, it’s easy to accurately monitor your compressed air usage throughout the facility. Creating a baseline of your usage will allow you to understand your compressed air demand, identify costly leaks, and replace inefficient air products.

The Digital Flowmeter installs in minutes with help from a drill guide and locating fixture to assist in mounting the Digital Flowmeter to the pipe. Two flow sensing probes are inserted into the drilled holes in the pipe. The meter then seals to the pipe once tightened. There is no need to cut, weld, or do any calibration once it is installed. With blocking rings also available, installation can be permanent or temporary. Below is a easy to follow video on how to install EXAIR’s Digital Flow Meter!

The newest addition to this product line is the Digital Flowmeter with wireless capability. Using a ZigBee® mesh network protocol, data is transmitted to an Ethernet connected gateway. This allows you to mount the Digital Flowmeter in areas that you may not be able to easily access and wirelessly monitor and graph the usage with the EXAIR Logger software. Take a peek at this video blog for a demonstration of the use of a wireless Digital Flowmeter software to compare an open pipe to an engineered Air Nozzle.

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Wireless output gives you the freedom to track air usage data from any computer!

In addition to communicating wirelessly with the gateway, the Digital Flowmeters can “piggyback” off of each other to extend their range. Each meter has a range of 100’. Using multiple Digital Flowmeters within the same ZigBee® mesh network, data can be passed from meter to meter to extend the distance over which the meters can operate. These can be installed on each major leg of your compressed air system to continuously monitor usage throughout the facility.

If you’d rather go with a hard-wired data collection method, the Digital Flowmeter is also available with a USB Data Logger. Simply remove the Data Logger from the Digital Flowmeter and connect it to the USB port of your computer. The data can then be viewed directly in the accompanying software or exported into Microsoft Excel.

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Add a Data Logger for easy Value Tracking

Two special flow meter options we now offer are the Pressure Sensing Digital Flowmeters, and the Hot Tap Digital Flowmeters!

Pressure Sensing Digital Flowmeters help by generating a pressure and consumption profile of a system can help to pinpoint energy wasters such as timer-based drains that are dumping every hour versus level based drains that only open when needed. Hot Tap Digital Flowmeters offer a way to install a flow meter on a pipe that is currently under pressure. It uses a series of valves and mufflers to maintain a safe working environment for the installer.

If you’d like to get a clear view of your compressed air usage, give us a call. An Application Engineer will be happy to work with you and get the proper Digital Flowmeters installed in your facility!

Jordan Shouse
Application Engineer

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EXAIR Wireless Digital Flow Meters Monitor Compressed Air Use

Would you like the ability to monitor your plants compressed air usage from one convenient location?  If the answer is yes, EXAIR has just the solution to fit your needs, EXAIR’s Digital Flow Meter with Wireless Capability.

Wireless capability is an option for EXAIR’s Digital Flowmeter’s.  It is the efficient way to monitor your compressed air consumption wirelessly utilizing the ZigBee® mesh network.  This is accomplished by a module located within the meter that transmits data to an ethernet connected gateway.  Each meter has a range up to 100 feet (30 meters), however the ZigBee mesh network protocol is very versatile as it allows data to also be transmitted from meter to meter, effectively extending the distance over which the system can operate.  So large facilities with great distances to cover are not a problem.

Digital Flowmeter w/ Wireless Capability, Gateway, and Drill Guide Kit

The Digital Flowmeter with Wireless Capability is offered in a kit with a wireless output flow meter, wireless to ethernet gateway, drill guide, power supplies for each component, and ethernet cable for gateway connectivity.  These kits are best suited for new installations.  They are also available without a gateway if you are simply adding an additional meter to a pre-existing Gateway in your plant.  EXAIR simplifies this process by configuring each gateway to communicate with the flowmeter to provide the necessary communication for monitoring your system.  Models from 1/2″ to 4″  iron pipe are in stock. 5″, 6″ iron pipe,  copper pipe ranging from 3/4″ to 4″ diameter and aluminum pipe from 25mm to 101mm diameter are available with short lead time as a special product offering.  Each digital flowmeter is calibrated for the pipe size to which it is mounted and the large digital display shows air use in either SCFM or Cubic Meters per Hour.

Setting up the EXAIR Digital Flow Meter with Wireless Capability is super easy.  After the meter is installed download the graphing software from our website and install on your computer.  There is also a video tutorial posted in the previous blog from Tyler Daniel, Video Blog: EXAIR’s New Wireless Digital Flowmeter Installation.

The Digital Flowmeter with Wireless Capability is designed for permanent or temporary mounting to the pipe.  It requires the user to drill two small holes through the pipe using the optional drill guide which includes the drill bit and locating fixture.  The two flow sensing probes of the flowmeter are inserted into these holes.  The unit seals to the pipe once the clamps are tightened.  No cutting, welding, adjustments or calibration are needed, ever!  If the unit needs to be removed, blocking rings are available for the 1/2″ to 4″  iron pipe sizes from stock with other sizes available on short lead time as special orders.

If you have questions on Digital Flowmeter’sDigital Flowmeter’s with Wireless Capability or need expert advice on safe, quiet and efficient point of use compressed air products give us a call.   We would enjoy hearing from you!

Jordan Shouse
Application Engineer

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6 Steps to Air Savings: Step 1 – Measure!

Six Steps to Optimizing Your Compressed Air System

If you’re a follower of the EXAIR Blog, you’re probably well aware that compressed air is the most expensive utility in an industrial environment. The average cost to generate 1000 Standard Cubic Feet of compressed air is $0.25. If you’re familiar with how much air you use on a daily basis, you’ll understand just how quickly that adds up. To make matters worse, many compressed air systems waste significant amounts of compressed air just through leaks. According to the Compressed Air Challenge, a typical plant that has not been well maintained will likely have a leak rate of approximately 20%!! Good luck explaining to your finance department that you’re carelessly wasting 20% of the most expensive utility. Step 1 of the 6 steps to optimizing your compressed air system is to measure the air consumption to find sources that consume a lot of air.

In order to have an understanding of your compressed air usage across various processes and in your entire facility, you have to measure. Without a measurement of usage, there’s no way to determine your actual costs or evaluate opportunities for savings. To do so, EXAIR offers a range of Digital Flowmeters in sizes from as small as ½” Schedule 40 iron pipe and up to 4” Schedule 40 pipe from stock. Larger sizes and pipes calibrated for use on copper or metric pipe are also available.

The Digital Flowmeter provides a digital readout of the exact amount of compressed air being used. Many companies will install the DFM on each major leg of their air distribution system to allow for constant monitoring and provide a benchmark of compressed air usage.

Each meter has a built in LED display that provides the volume of air moving through the pipe in SCFM, m3/hr, or m3/min. Two small probes are inserted into holes in the pipe (drill guide kit w/ drill bit included) to detect the airflow. The unit seals to the pipe once the clamps are tightened. (If the DFM ever needs to be removed, EXAIR also offers blocking rings to seal off the holes) No cutting, welding, adjustments or calibrations are ever required.

In addition to the standard Digital Flowmeter itself, it’s also offered with wireless capability to transmit the data back to your PC, or via USB Data Logger. Both of these options will allow you to track usage over time and upload that data into an Excel spreadsheet.

EXAIR’s Digital Flowmeter w/ USB Data Logger

If you’re “flying blind” when it comes to understanding your costs of compressed air in your facility, this is the first step. Contact an EXAIR Application Engineer today to get started. We’ll be happy to help you identify areas where you could take advantage of simple savings.

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

EXAIR Digital Flow Meters

Information is important to diagnose wasteful and problematic areas within your compressed air system. To measure air consumption, flow meters are used to find the volume or mass of compressed air per unit of time. Flow rates are very useful data points to find problems like leaks, over-use in blow-offs, waste calculations, and comparison analysis.

There are many different types of flow meters. Many of them entail a breakdown of your current compressed air lines by cutting, welding, or dismantling for installation. This will add cost in downtime and maintenance staff. But, not with the EXAIR Digital Flowmeters. In this blog, I will share the features and benefits of the Digital Flowmeters including options for you to start measuring and optimizing your compressed air system in Step 1.

Digital Flowmeter

Overall, it only takes a few minutes to install and start measuring. The installation kit comes with a drill bit and a drill guide to properly locate the two holes on the pipe. The Digital Flowmeter uses a clamp to mount to the pipe and to seal the area around the probes. Once it is powered, the unit is ready to measure the air flow inside the pipe with a large LED display. The display can be customized to show flow readings in three different units; SCFM, M3/hr or M3/min; and, it can display the Daily Usage and Cumulative Usage. This will require that the compressed air line is discharged, or pressure free. However, there are Hot Tap digital flowmeters available for installing on pressurized compressed air lines.

To get started, the EXAIR Digital Flowmeter is a thermal dispersion device that can accurately measure compressed air flows. They use two sensing probes for comparative analysis. One probe is a temperature sensing probe, and the other is a flow-sensing probe. By comparing these, the Digital Flowmeter can measure precisely the mass air flow without needing to be recalibrated. They are a cost-effective, accurate, and simple way to measure compressed air flows.

EXAIR stocks a large volume of Digital Flowmeters to ship same day for U.S. and Canadian customers. We also offer a 30-day unconditional guarantee to try them out. We stock meters for pipe diameters from ½” NPT to 4″ NPT Schedule 40 black pipe. EXAIR can also offers flow meters up to 8″ NPT black pipe; copper pipes with diameters from 3/4″ to 4″, and aluminum pipes with diameters ranging from 40mm to 101mm. If you have another type of piping for your compressed air system, you can give us the material, O.D. or I.D., and wall thickness. We may still be able to get a Digital Flowmeter for you.

For measuring, all the units come standard with a 4 – 20mA analog output. Per your request, we can change this signal to a serial output for RS-485 or Ethernet connections. What more can we offer with the EXAIR Digital Flowmeter? Options. Options upgrade the flow meters to better suit your application. Here is a list below:

Digital Flowmeter w/ Wireless Capability, Gateway, and Drill Guide Kit

Wireless Capability: Our latest Digital Flowmeter now has wireless capabilities. They use a Zigbee® communications to pick up flow readings from other flow meters and the Gateway. The Gateway can detect over 100 Digital Flowmeters in your facility. From the Gateway, the information is transferred through a LAN. You can record and analyze the flow information from each meter on the network with our EXAIR® Logger Software. You can set limits to send warnings when your compressed air system is using too much or too little of compressed air. This technology makes it very easy for measuring your compressed air system in the entire facility without having to be there.

When you need to analyze your pneumatic components, flow is an important point in diagnosing the overall “health” of your compressed air system. The EXAIR Digital Flowmeter can give you that important data point. With optimization, you can cut your energy consumption, improve pneumatic efficiencies, and save yourself money. This blog is an overview of Step 1 of six steps. 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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Twitter: @EXAIR_JS