EXAIR Digital Flowmeters With Wireless Capability

“You can’t manage what you don’t measure” is a well-known axiom in engineering & process improvement circles.  We talk to callers every day who are keen on conserving compressed air use in their facilities by making a few tweaks, considering a complete overhaul, or more often, some point in between.  Bottom line (literally) is, compressed air isn’t cheap, so small gains in efficiency can add up.  And large gains can be complete game-changers…following our Six Steps To Optimizing Your Compressed Air System has resulted in users being able to shut down 50 and 100 HP air compressors, saving thousands of dollar A MONTH in operating costs.

Step #1 is measurement, and that’s where the EXAIR Digital Flowmeter comes in.  They’re easy to install, highly accurate, extremely reliable, and available for just about any size pipe used for compressed air distribution.  They can output a 4-20mA signal straight from their PCB board, or serial comms (RS485) through an optional control board.  USB Data Loggers and Summing Remote Displays have proven to be value-added accessories for data management as well.

Summing Remote Display (left) for remote indication and totalizing data. USB Data Logger takes data from the Digital Flowmeter to your computer and outputs to its own software (shown above) or Microsoft Excel.

If you want to go wireless, we can do that too: using ZigBee mesh network protocol, a radio module is installed in the Digital Flowmeter with wireless gateway to transmit data to an Ethernet connected gateway.  The transmitting range is 100 ft (30 meters,) and the data can be passed from one radio module to another, allowing for multiple Digital Flowmeter installations to extend the distance over which they can communicate with the computer you’re using for central monitoring.  Advantages include:

  • Wireless monitoring of EXAIR Digital Flowmeters throughout your plant.
  • Prevents unwanted joining upon the network.
  • Monitoring software is included at no extra charge.
  • Measures & transmits both current air usage, and cumulative air usage data.
  • 128 bit encryption for wireless transmissions.
  • Comes configured & programmed, out of the box, available for installation on 1/2″ to 4″ SCH40 iron pipe, or 3/4″ to 4″ Type L copper pipe.
Digital Flowmeter w/ Wireless Capability, Gateway, and Drill Guide Kit

If you’d like to find out more about how easy it is to measure, manage, and optimize your compressed air usage, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Super Air Knife’s Adjustability and Flexibility = Success

The EXAIR Super Air Knife is the most efficient compressed air knife on the market. We know this because we’ve tested them, and our competitors’ offerings, for performance, using the same instruments, controls, and procedures. We’re not going to publish data that we can’t back up, and that’s a fact.

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EXAIR Super Air Knife removing moisture after a rinse on anodized parts.

They’re also ideally suited to a wide variety of applications – they come in lengths from 3 inches to 9 feet long (and can actually be coupled together for uninterrupted air flows of even longer lengths,) a variety of materials for just about any environment. But the best thing about our Super Air Knives is how you can adjust the air pressure and flow to complete a wide variety of tasks. You can adjust them in two different ways, Replacing or adding Shims, or regulating the incoming air pressure.

completeAirknifesets
Shims for the aluminum, 303 Stainless Steel, and 316 Stainless Steel Super Air Knives

Changing out your shim!

A larger shim gap will give you higher flow and force from your Air Knife. Honestly, the 0.002″ shim that comes pre-installed in all of our Air Knives is perfectly suitable for most blow off applications, and appropriate air supply conditions are the first thing you should check for before going with thicker shims, but if you do indeed need a boost, a thicker shim will indeed give you one…here’s a blog with the video to show you how it’s done:

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Video Blog: How to Change a Shim in a Super Air Knife
Filter Regulator
Regulator and filter

Another advantage to having a Pressure Regulator at every point of use is the flexibility of making pressure adjustments to quickly change to varying production requirements.  Not every application will require a strong blast sometimes a gentle breeze will accomplish the task.  As an example one user of the EXAIR Super Air Knife employs it as an air curtain to prevent product contamination (strong blast) and another to dry different size parts (gentle breeze) coming down their conveyor. For Performance at different supply pressures see the chart below.

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Super Air Knife Performance Table

EXAIR products are highly engineered and are so efficient that they can be operated at lower pressures and still provide exceptional performance!  This save’s you money considering compressed air on the average cost’s .25 cents per 1000 SCFM.

If you’d like to discuss altering the performance of your Super Air Knife, give us a call.

Jordan Shouse
Application Engineer
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Coandă Profiles

Here at EXAIR, Coandă is a household name that can be heard on any given day multiple times throughout the day. The Coandă effect is fairly easy to visualize with a ligthweight ball and some high velocity airflow. Take the video below for example. This 2″ Super Air Amplifier on a stand powered at 40 psig at the inlet easily lifts this hollow plastic ball and then suspends the ball due to the Coandă effect.

If you were able to see the airflow, you would see it impacting the surface of the sphere at all different points then following the profile of the sphere until it colides with itself and is forced to separate off the surface. The turbulent flow on the top is creating a downward pressure as well. The science behind this was all found and showcased by Henri Coandă. He showcased this with a propulsion device which used a domed hood with airflow to follow the curvature of the dome then exit off the sharp edge or where the separate air streams began to recombine causing a turbulent / low pressure area depending on the angle.

This stream of air following a surface begins to pull in all surrounding and impacted air molecules from around the stream which is called entrainment. This is a key factor for EXAIR products and one reason the Coandă profiles are a key characteristic to obtaining the peak performance and efficiency out of a compressed air product.

As the high velocity air stream exits the EXAIR model 1100 Super Air Nozzle the ambient air is entrained around the fins and angled surfaces of the nozzle.

Many EXAIR products utilize the Coandă principle to improve their efficiencies and performance. Below you can see the EXAIR product families containing Coandă profiles within their design which increases the ambient air entrainment resulting in an amplified air blowoff.

Super Air Wipes, Super Air Knives, Super Air Nozzles and Super Air Amplifiers use the Coanda principle to become some of the most efficient compressed air blowoff products available.

If you would like to discuss how the Coandă profile and EXAIR Intelligent Compressed Air Products® can help your process, please give us a call.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Compressed Air Pressure Regulators Conserve And Protect

Imagine you’re enjoying a nice shower. A cascade of warm water is soothing your body – and spirit – then, someone starts the dishwasher. Or a load of laundry. Or flushes the toilet. Suddenly, the “soothe” turns to “scald” or “freeze,” depending on whether you’ve been robbed of hot, or cold water.  So, what happened?

What happened is, all of those “loads” on your house’s water supply that can ruin your shower experience are controlled by simple on/off valves…they open to permit a certain amount of water FLOW to pass.  When the dishwasher starts, or someone decides to wash a load of whites, the HOT water from your nice warm shower is diverted, leaving a stream of cold water.  When a toilet flushes, or it’s a load of colors, the COLD water is diverted…and that’s not just unpleasant, but downright painful.  Either way, (in my house anyway,) a teenager is getting read the riot act.

The same phenomenon can apply in a compressed air system, if simple flow control valves are used to throttle the appropriate supply of air to a pneumatic device.  If someone, for example, hooks up an air gun to blow off their tools or parts, the valves on EVERYTHING else will need to be opened up some to keep those devices working the same.  In the case of an air gun like this, it usually happens too quick to make the necessary adjustments (by hand) and you’re probably left with a machine tripped off-line, or a ruined part.

Pressure Regulators can prevent this by keeping (or regulating) their downstream pressure to a set value.  If a load elsewhere in the system is activated, the Pressure Regulator opens up, automatically, to keep its output constant.  When that load is secured, the Pressure Regulator closes back down accordingly.  Either way, no single load affects the operation of any others.

That’s only half the value of the use of Pressure Regulators, though.  The other half is, well…the value.  Just looking at a typical function of many EXAIR Intelligent Compressed Air Products – blow off – they’ll all pretty much accomplish the task if you run them, unrestricted, straight off your header.  That’ll give you a good, strong blast of air flow…and it may be more than what’s required, and a waste of good air.  Pressure Regulators will prevent this by allowing you to “dial in” the supply pressure to whatever it takes to get the job done, and no more.

EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

Compressed air isn’t free.  Heck, it isn’t even cheap.  Don’t use any more than you have to, and get the most out of what you do use.  Pressure Regulators are one important step in doing this.  If you’d like to talk about optimizing your use of your compressed air system, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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