When To Use The High Lift Reversible Drum Vac vs. The Reversible Drum Vac

One of my favorite TV shows growing up was Home Improvement with Tim Allen. One of the most memorable parts of the show was when Tim’s character would always state that when doing a job you need … MORE POWER!!!

In real life and within a production environment this is not always true. More often than not more power equals waste and inefficient use of the resources at hand. I know, I sound a lot like Tim Allen’s counterpart in the show, Al Borland. Well, the truth is, Al was usually right.  Here at EXAIR, we offer two different types of Reversible Drum Vac, the standard unit and the High Lift RDV.

The Reversible Drum Vac System converts a drum and dolly into a mobile pumping system.

The standard RDV will pull up to 96″ of water column when in suction mode. This is ideal for water-soluble coolants or other water-based rinses. The unit is paired with a 10′ vacuum/discharge hose to ensure optimal performance. The RDV will fill a 55-gallon drum with water in 90 seconds or less when operated at 80 psig inlet pressure. It will then empty the same drum even faster by discharging liquid at up to 166″ of water column displacement. To do both of these operations, fill or empty the drum the RDV will utilize 19 SCFM of compressed air. This is easily supplied within most industrial applications where that amount of compressed air usage can be overlooked.

EXAIR’s High Lift RDV makes cleaning out pits up to 15′ deep easy and fast.

If Binford manufactured a compressed air liquid vacuum, it would be the High Lift Reversible Drum Vac. This is the, “More Power” version of the RDV and can pull up to 180″ of water column when in vacuum mode. This can pull water-soluble coolants up to 15 feet below grade for those large machining centers that sit over the top of a coolant pit or those large footprint machines where a 20′ hose is needed to reach into and around the parts of the machine to where the coolant or liquid is housed. Another application would be for oil-based coolants or other petroleum-based oils/higher viscosity fluids. This will still discharge liquids at 166″ of water column when in positive displacement. The unit will outperform its predecessor and that comes with higher utilization of compressed air. While operating at 80 psig inlet pressure the unit will consume 43 SCFM of compressed air. This volume of air is still easily located within most industrial environments and is still less than the amount demanded by competitive units that do not offer the reversible feature of the High Lift Reversible Drum Vacs.

When it boils down to it, the High Lift Reversible Drum Vac will perform every task of the standard Reversible Drum Vac and will perform the vacuum portion of those tasks all faster due to the higher level of vacuum. When this higher level of vacuum isn’t needed, when the sump is at ground level and the coolant or liquid is around the viscosity of 50 weight motor oil or thinner then the standard RDV will work ideal for the application and would be the most efficient method to get the job done. When the liquid is higher viscosity or below ground level trying to pull it up out of a pit then the High Lift Reversible Drum Vac is the ideal tool to get the job done. Again, Al Borland had it right, more power is not always needed, sometimes it is better to keep it efficient.

If you would like to discuss your liquid vacuum application or any point of use compressed air application, please contact us. (Heck, I’ll even talk about Home Improvement if you are a fan too.)

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Best of Home Improvement so 1 eo01 More Power – @shary h – https://www.youtube.com/watch?v=ts9UONUMlCg

Solving Performance Issues of Air Operated Industrial Vacuums

This blog will focus on the EXAIR Chip Vac, but the troubleshooting process and steps for achieving optimal performance are consistent among EXAIR’s entire line of air operated industrial vacuums.

There’s really not that much that CAN go wrong with an EXAIR Chip Vac System. They have no moving parts to wear or electrical components to burn out. As long as they’re supplied with clean air, they’ll run darn near indefinitely, maintenance free.

Murphy’s Law, of course, is still in full force, so if something CAN go wrong, it WILL go wrong.  The Chip Vac is, alas, no exception.  Good news is, because of the Chip Vac‘s simplicity, troubleshooting is simple as well.  The most common problems we see with ANY of our engineered compressed air products (not just the Industrial Vacuums) are related to compressed air supply:

  • New users might not consider the air demand required by a new product, and may provide an inadequate supply line.  The Chip Vac, for example, will consume 40 SCFM @80psig for rated operation, and will need a 1/2″ (inside diameter) hose to supply that, assuming a length of no more than 20ft.  Hooking one up to a common 3/8″ hose on a 50ft reel, for example, will “starve” the Chip Vac, resulting in degraded performance.
  • Also, the preferred method of connection is a hose with threaded fittings on the ends.  A local hydraulics/pneumatics shop can likely make these, while you wait.  Push-to-connect quick connect fittings are restrictive by nature, and should be avoided.  Quarter turn claw-type fittings are great…the main drawback (which can be solved with an upstream shutoff valve) is the line has to be depressurized to make or break the connection.
  • If you absolutely want to use a push-to-connect type, you can oversize it (use one made for larger hose with, say, 3/4 NPT fittings) and use bushing/adapters to get to your actual hose size.

    If you must use quick connects, the 1/4 turn claw type (left) is the least restrictive. Push-to-connects (center) are likely to starve your product, unless you oversize them (right) like we do in our Efficiency Lab.
  • Speaking of supply issues, make sure nobody’s bumped into a valve handle & partially closed it (I have,) ignored the maintenance schedule & didn’t change a clogged filter element (I have,) or ran something into a copper line hard enough to crimp it, but not rupture it (I haven’t…that was Tim, who, aside from this incident, was really pretty good with a forklift.)

The issues above apply to not only any compressed air system, but most fluid power/fluid handling systems.  Since this blog is about Chip Vac troubleshooting, let’s move on to some specifics.  If you’re sure you’re getting proper air supply to the Chip Vac (by the way, a pressure gauge right at the inlet – like the one that comes with our Premium Chip Vac System’s air hose – will eliminate any doubt,) then let’s look at some potential issues downstream:

  • Dirt & debris can collect inside the Chip Vac itself, obstructing the outlet holes, and lowering your vacuum flow.  You can disassemble and clean it pretty easily, though.
  • The Filter Bag can get clogged, especially if you’re vacuuming up a lot of dust or powdery materials.  If this happens, turn the Chip Vac off and shake the Filter Bag to dislodge the material, allowing it to fall back into the drum where it belongs.
  • Speaking of which, if you find that, all of a sudden, the Filter Bag is clogging, remove the drum lid and check for the Silencing Hose.  This serves two functions…the first is in the name (just a little discharge hose mitigates the sound level of the Chip Vac‘s exhaust flow.)  Secondly, it directs the vacuumed material positively into the drum, limiting the amount that is “dust-storms” in the upper area of the drum, where it’s more prone to make it into the Filter Bag.
Pro tip: check for the Silencing Hose when you remove the lid to empty the drum. DON’T throw the Silencing Hose in the trash.

I’m not going to unequivocally state that this is an all-inclusive list (see “Murphy’s Law,” above,) but these are the Usual Suspects if you’re just not getting the most out of your Chip Vac.  If you ever have any questions, though, give us a call.  We’re here to help.

Russ Bowman
Application Engineer
EXAIR Corporation
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Air Operated Industrial Vacuum Helps Reclaim Grass Seed and Save Thousands

A customer who produces bags of grass seed were experiencing a large amount of lost product due to spillage during the bagging process. Any spillage they would typically sweep up and throw away. This sweeping would take a good amount of time. Their goal was to determine a way to speed it up the cleaning and see if it was possible to reclaim the seed that was currently scrapped.

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EXAIR has a broad line of industrial vacuums for a variety of jobs. In this case we recommended our Chip Vac.

EXAIR’s Chip Vac is a compressed air operated industrial duty vacuum designed for vacuuming up dry (or mostly dry) products. The powerful vacuum is suitable for use with metal, wood, or plastic chips and is designed to thread into the 2” NPT bung on standard drum lids. The Chip Vac can handle dry or coolant soaked chips from fixtures, floors and work surfaces of machining centers, lathes, saws, mills, and a variety of other industrial equipment. It was also very suitable for this grass seed application.

Electrically powered vacuums or shop vacs are not designed to be operated in a rugged industrial environment. Filters clog, motors wear out, and you find yourself frequently replacing them. EXAIR’s Chip vac has NO moving parts to wear out, doesn’t require maintenance, and needs nothing but a source of compressed air to operate. In addition, the sound level produced is half of that produced by an electric vacuum.

Chip Vacs-all
From left to right: 5 gallon, 30 gallon, 55 gallon, and 110 gallon Chip Vacs are sized for any cleanup need.

Using the Model 6193 Chip Vac System they were able to reclaim lost product in and around the machines in less time and more efficiently.  While the recovered seed could not be used in their certified premium product, they were able to add it to the “contractors” blend. Saving them around $2,500 annually!

Don’t waste your time, get yourself a vacuum designed for the job. One that’ll last year after year! With these systems in stock, ready to ship with an order by 3:00 ET, a unconditional 30 day guarantee and backed up by our 5-Year Warranty, there’s no reason not to give one a try!

Jordan Shouse
Application Engineer

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Images Courtesy of Oregon Grass Seed Bag Creative Commons.

HEPA Vac Improves Cleaning Process AND Keeps Operators Safe!

On a recent visit with our Hungarian Distributor, I had the pleasure of visiting an automotive leather manufacturing plant. They process and cut to order a wide variety of different styles of leather used in the manufacturing of European automobiles. In one of their machines, a grinding process is performed that smooths out the cut edges of the material before they’re stitched together.

The grinding process itself is self-contained within the machine, but the significant amount of leather dust created needs to be periodically cleaned out. If not, it ends up accumulating on some of the internal components and increasing the downtime and maintenance required on the machine. Due to this, they implemented a 2x per shift cleaning operation.

The machine has several tight spaces inside where the dust accumulates. They’d shut off the machine and blow out the dust. Then, sweep up all of the dust into a dustpan and dump it in the trash. This entire process took approximately 30 minutes each time for 1-hr/shift. With three shifts operating 24/7, that’s 3-hrs/day of lost production time for this particular cleaning process, still less than what they were experiencing as a result of the machine downtime when they weren’t regularly cleaning it.

HDHEPAVac559

However, the primary concern of theirs was that they were now blowing dust all over the shop causing a potential health hazard to their operators. They wanted a solution that would allow them to clean the machine, without presenting an additional hazard. We tested with a Mini Chip Vac first, but the dust was a bit too fine and was still passing through the filter bag.

For fine dusts such as this, the Heavy Duty HEPA Vac is the more suitable option. After testing the Heavy Duty HEPA Vac, it was clear that this was the solution they were hoping for. The high-powered vacuum made quick work of the dust inside, while keeping it contained inside of the drum by the HEPA filter.

They still need to stop and clean the machine out 2x/shift, but now the process only took 10 minutes. They reduced their overall downtime on this machine per day by 2/3 to just 1hr, while keeping their operators safe. While this wasn’t the reason for looking at new solutions, it was definitely an added benefit. If you’re looking for a maintenance-free vacuum system for cleaning up in your facility, EXAIR has a wide range of Industrial Housekeeping solutions available from stock.

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

Effectively and Efficiently Remove Chips and Debris from Blind Holes

I was recently contacted by an automotive parts manufacturer that was looking for a solution for cleaning out blind holes in a variety of machined parts. After discussing the application, we settled on a 1697SS-6-CS VariBlast Compact Safety Air Gun with Pico Nozzle, 6” Extension, and a Chip Shield. The small M5 nozzle at the tip of the gun allowed them to insert it inside of the hole and dislodge the hard-to-reach chips inside of the holes.

1697SS VariBlast Compact Safety Air Gun

This worked very well for removing the chips, but they were encountering an unexpected issue as these chips were now getting lodged in other areas of the part as they were ejected. They then had to visually inspect the entire part after each blowoff to ensure that everything was completely removed.

What they thought to be an ideal solution, ended up not being the best fit. They gave us a call back to inquire about an alternative solution. We offer another product, the Deep-Hole Vac-U-Gun, that is capable of both removing chips and debris from blind holes and also vacuuming it away simultaneously.

This addresses the problem of dislodged chips being caught elsewhere on the parts. Fortunately, EXAIR offers an unconditional 30-day guarantee for all stock products. They were able to return the previously purchased gun and apply the credit towards the purchase of the Deep Hole Vac-u-Gun system.

The Deep Hole Vac-u-Gun is a low-cost solution to quickly remove chips and contaminants from grooves, containers, and drilled holes. In applications where simply blowing the debris out of the hole isn’t suitable, simply position the Deep Hole Vac-u-Gun over the hole and press the trigger. A small blow tube (3) dislodges and lifts the chips while the large suction tube (5) vacuums them away. The operator is then protected from flying debris since the contaminants are then contained within the suction tube and directed into a filter bag or other container with the included vacuum hose.

Sometimes we don’t always get it right on the first try. But, with the ability to take advantage of the 30-day guarantee we’ll make sure to get the best product to you for your application. With same day shipments with orders received by 3:00 ET for stock products, EXAIR can get a solution out to you quickly!

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

Video: EXAIR Drum Vacs Selection For Solid Materials

EXAIR Corporation has engineered compressed air solutions for Industrial Housekeeping…among them, a full line of drum mounted vacuums for dry/solids cleanup.

If you’d like to find out more, please give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Compressed Air Vacuums and Their Advantages Over Electric Vacuums

EXAIR‘s line of Industrial Housekeeping Products consist of liquid and dry vacuums that utilize compressed air to operate. They do not have loud electric motors which most ‘all purpose’ electric vacuums rely on.  In industrial settings with harsh conditions and rugged use, EXAIR’s Industrial Housekeeping Products are better suited for the everyday wear and tear of typical manufacturing, commercial and construction environments.

When you look at EXAIR vacuums, you’ll notice there is not an electrical cord.  Because the EXAIR Industrial Housekeeping Products utilize compressed air for operation. This means they do not have the same maintenance issues of an electric motor which breakdown and fail when dirt, dust and temperature take their normal toll on moving parts. With EXAIR vacuums there are no moving parts: no motors to burn up, no bearings to wear out, and no impellers to clog in the vacuum units. They also run quieter than a typical electric vacuum.

They are maintenance free, just supply clean and filtered air, and they can operate for many, many years.

 

EXAIR’s liquid vacuums, there is a built in pressure/vacuum relief device and auto safety shut-off to prevent over-filling.

The Reversible Drum Vac is a two-way liquid pumping system, also made for mounting on standard steel drums…closed top drums, in this case.  They can fill or empty a 55 gallon drum in 90 seconds.  Options include 5, 30, and 110 gallon drum sizes, and a High Lift model – increased suction head for deep wells, underground tanks, or higher viscosity liquids, up to 1,400 cP.

hlrdvhowworks

The heart of our popular coolant filtration system: the EXAIR Chip Trapper.  A Filter Bag in the “fill” line traps chips, swarf, and shavings.  The liquid passes through, and is able to be immediately pumped back out.  Not only is coolant life extended, regular cleaning of the coolant sump prevents loss of coolant flow due to clogging of the supply lines.  The Chip Trapper is available in 30, 55, and 110 gallon sizes, and also in the High Lift version.

Chip Trapper Family
30 gallon, 55 gallon, and 110 gallon Chip Trapper

EXAIR’s dry vacuums provide many pickup and filtration options. They withstand harsh environments, have many filtration and power options and run quieter than electric vacuums.

The EXAIR Chip Vac and Heavy Duty Dry Vac is a powerful industrial vacuum for use on wet or dry chips. Both are for use with 30, 55, or 110 gallon drums, and the Chip Vac can also be used on a 5 gallon drum. The Heavy Duty HEPA Vac has the added benefit of the HEPA quality filter system.  Filtration per IEST-RP-CC-007 to 99.97% minimum filtration at the 0.3 micron level ensures performance meets the needed criteria.

The Chip Vac is also 50% quieter than a comparable electric vacuum at only 77 dBA!!

Chip Vacs-all
From left to right: 5 gallon, 30 gallon, 55 gallon, and 110 gallon Chip Vacs are sized for any cleanup need.

If you would like to talk about Industrial Housekeeping products or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact  myself or one of our Application Engineers we can help you determine the best solution.

Jordan Shouse
Application Engineer
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