Compressed Air Digital Flow Meters Monitor Your System Demand

In the times we live in, efficiency is key. To offset the rising costs of goods, services, and energy we must be purposeful in lowering costs wherever we can. Every company has large utility expenses such as electricity, water, gas, sewer, waste, and recycling. Many companies have policies and systems in place to help control these expenses. One major utility that gets overlooked is your compressed air. Many companies just loop this expense into the gas and or electricity funnel and move on. But that can be a costly mistake. Assuming you utilize compressed air in your facility, it is most likely your 3rd-4th highest utility expense. The good news is there are many ways to make this utility much more efficient.

We have several EXAIR blogs on how to improve your compressed air efficiency from mitigating leaks, sizing pipe properly, flow control, pressure regulators, engineered nozzles and tools, and even receiver tanks. These are all very effective ways to reduce this expense. There is another tool that I would like to share with you; our Digital Flow Meters. What they are, how they work, and how they can save you money…

With a rough cost of $0.25 per 1000 SCFM, wouldn’t it be nice to know how many SCFM you are using? (Please click here for a great blog on how to calculate your SCFM cost) More importantly how much air are you wasting… Your compressor information already tells you how much air it is producing and with EXAIR’s Digital Flowmeter, you will know the exact amount of compressed air that is being used, making it very easy to identify loss. These losses are primarily found in leaks or inefficient air products. A best practice is to install one of these on each leg of the air distribution system and monitor and and benchmark the compressed air usage.

EXAIR Digital Flowmeter

The EXAIR Flowmeters work by measuring the temperature differential between two probes that are inserted into the compressed air pipes. One probe is kept warmer than the other, and the mass flow rate is determined by the amount of heat required to maintain the temperature differential. The flow rate, or SCFM is displayed on the large digital display

To install the Flowmeters, you will drill 2 holes into your pipe for the probes. Included with the meter is the drill bit and the Drill Guide to quickly install the meter. We have these available in many sizes from 1/2″ to 4″ iron pipe, We also offer these for Copper Pipes, and can make / calibrate them for many others, we will just need the information.

In addition to our standard version we offer several upgrades. One is a Data Logging version. You can download our software and then set the data logging to record from once a second for about 9 hours of data to twice a day for over 2 years worth of data. You simply plug the Data Log Stick this into your computer, download and repeat.

We also offer a wireless option that will run through a ZigBee mesh Network. A radio module within each meter transmits data to an ethernet connected gateway. You can also piggyback meter to meter to extend the range for this wireless solution. Each meter has a range of about 100 feet.

Many people ask if they have to shut down their system to install the Flowmeters. Understanding that this could cause systemic issues, we have a Hot Tap option that will allow you to install while the pipe is still under pressure. It incorporates 2 valves that the probes pass through as well as a muffler that collects the chips from the drilling process. This is only available on the 2″ or larger units.

Speaking of pressure, we also offer a Pressure Sensing Digital flow meter. On this, there is a pressure sensor that is mounted between the two flow sensor probes. The pressure is sent via a second milliamp output. The display can be configured to show either pressure or flow. You can set this to send alarms if the pressure falls under 50 psi. Also only available on 2″ pipes and above.

Finally, we also offer Block Off Rings. These are simply rings to block off holes where the flowmeter was, in case you need to use the same one in a different location.

Please fee free to reach out with any questions, or for more information. Let us help you save air and money…

Thank you for stopping by,

Brian Wages

Application Engineer

EXAIR Corporation
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Why use EXAIR’s Digital Flow Meters

Since air compressors use a lot of electricity to make compressed air, it is important to use the compressed air as efficiently as possible. EXAIR has six simple steps to optimize your compressed air system. Following these steps will help you to cut electrical costs, reduce overhead, and improve your bottom line. In this blog, I will cover the first step – Measure the air consumption to find sources that use a lot of compressed air.

Six Steps to Optimizing Your Compressed Air System

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.

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:

EXAIR’s Digital Flowmeter w/ USB Data Logger

USB Data Logger: This option allows for a recording of the flow information. With a software download, you can setup the USB Data Logger to record the flows from once a second (roughly 9 hours of storage) to every 12 hours. After the data points are recorded, you can then download the information into the software to review. Then the information can be uploaded into an Excel program to do further analysis.

Summing Remote: With compressed air pipes running along the ceiling and walls, reading the Digital Flowmeter may be difficult. The Summing Remote has a 50-foot (15 meter) cable to bring the LED display into viewing. The Summing Remote is powered by the Digital Flowmeter, and it can be positioned at eye level, inside managers’ rooms, or around large equipment for monitoring.

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.

Hot Tap DFM

Hot Tap Digital Flowmeter: This option is a great way to install a Digital Flowmeter to the pipe without shutting down the compressed air line. We offer this option for 2″ and larger flow meters for steel and copper pipes. It gives a quick and easy way to attach if you have a 24-hour operation or a critical process that needs to continue to run.

Pressure Sensing Port

Pressure Sensing Digital Flowmeter: If you would like to know the compressed air flow and the air pressure, this option will be able to do this. They are available with the Digital Flowmeters for steel and copper pipes that are 2″ and larger, and for the aluminum piping that is 50mm and larger. This option can display pressure units in either PSI or Bar right on the same LED display that shows the flow readings.

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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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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Twitter: @EXAIR_JS

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

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS