Accessories, Don’t Forget About Accessories!

Accessories

I went to the auto parts store to replace my brakes on my vehicle.  They asked me if I needed some Anti-squeak grease for my brake hardware.  It made me think about the accessories that EXAIR sells.  I could have used my own kind of grease which may not be able to hold up to the heat, but for a few dollars more, I wanted to go with the item that the experts would suggest.

In this blog, I would like to turn your attention to the accessories that support our Intelligent Compressed Air® Products.  EXAIR products use compressed air to coat, conserve, cool, convey and clean.  To maximize the performance and/or ease installation it is important to have the controls and options, and EXAIR offers these items as Accessories.

Pneumatic applications come in many variations and forms, and Accessories can help you to adapt to your application and to remove “guess work”.  They can make installation easier, add flexibility, and give you peace of mind.

Here are the different categories and explanations for each item that EXAIR recommends for our products with their defined functions.  They can help you in different areas to enhance your EXAIR product experience.

Automatic Drain Filter Separator (left,) and a Pressure Regulator (right.) Oil Removal Filters (optional; center) are also available if needed.

Filters/Regulators:

  • Filter Separators remove bulk liquid and contamination from the compressed air stream. EXAIR stocks a range of sizes from ¼” NPT ports to 1 ¼” NPT ports.  They use a 5-micron filter and a mechanical baffle to remove slugs of liquid from your compressed air system.  Most Filter Separators have an auto-drain to automatically remove the buildup of liquid inside the bowl.   I would consider the Filter Separator as a minimum level of protection required to protect your EXAIR product installations.
  • Oil Removal Filters remove very small particles of dirt and oil from the compressed air; making it even cleaner. The 0.03-micron media of the Oil Removal Filter will “coalesce” the fine liquid particles into large droplets.  Thus, allowing gravity to remove oil vapor from the compressed air stream.  EXAIR offers different sizes ranging from ¼” NPT to 1 ½” NPT ports.  As a note, Oil Removal Filters are great for removing very fine particles, but if you have a system with lots of water, I would recommend a Filter Separator upstream of the Oil Removal Filter for optimal filtration.
  • Regulators control the amount of air pressure being supplied to your EXAIR product. This is important if you are trying to save compressed air, control the force produced by an Air Knife, or convey material slowly.  EXAIR, being a leader in compressed air savings, recommends to use the minimum amount of air pressure to do the job.  This will save compressed air and save you money.  Regulators have a characteristic called “droop”.  Droop is the amount of air pressure that it drops downstream when you start flowing compressed air.  If the regulator is not sized properly, you can “starve” your pneumatic components, causing loss of function.  EXAIR properly sizes our regulators in our kits to make sure that you won’t “starve” your application.
  • Mounting Brackets for the regulators and the filters to help support them to a wall or structure are available. To connect filters and regulators together without a pipe nipple, we also have Coupling Kits for sizes up to ¾” NPT.  And for combination kits which includes a filter and a regulator, we offer the Mounting Bracket and Coupling Kit together for a set.

Silencing Mufflers:

  • Reclassifying Mufflers are designed to have two functions. They can cut noise levels by 35 dB and remove oil mist from the exhaust air.  Cylinders and valves that exhaust pressurized air may have oil in the line to keep the seals from sticking.  When exhausted, it can create a fine mist which is dangerous for operators.  The Reclassifying Mufflers can reduce the loud noise as well as collect any contamination from the exhaust air.
  • Sintered Bronze Mufflers are simple in design, cost effective, and easy to install. They have a minimal back pressure to not restrict operations of the pneumatic device.  They come in sizes from #10-32 thread to 1-1/2 NPT.  For a quick and simple way to reduce noise, the Sintered Bronze Mufflers are in stock for fast delivery.
  • Straight-Through Mufflers offer a way to reduce noise levels without worrying about clogging. They have an aluminum shell lined with sound absorbing foam, and they can reduce the noise level by 20 dB.  EXAIR offers them with two ports from ¼” NPT to ¾” NPT.  This can allow you to connect other items like blowing hose kits while reducing noise.
  • Heavy Duty Mufflers have an outer aluminum shell with an internal stainless steel screen that can protect the components from environmental contamination, and can also keep contaminant like rust from being ejected at high speed into the work area. They have a typical noise reduction of 14 dB.

Pneumatic Valves:

  • Manual Valves allow for operators to turn on and off their system by hand. The full-flow ball valves range from ¼” NPT to 1 1/4” NPT in size and will not restrict flow.  EXAIR also offers a manual foot pedal valve for hands-free operations.  This ¼” NPT foot valve has a 3-way operation and works great if the operator has to use both hands in their process.
  • Solenoid Valves are a way to turn on and off the supply of compressed air electrically for automated systems. We offer solenoids in three different voltages; 110Vac, 240Vac, and 24Vdc.  EXAIR has a large range of flows with ports ranging from ¼” NPT to 1” NPT.  All models are UL listed and are CE and RoHS compliant.

Hardware:

EXAIR’s Swivel Fitting Family
  • Swivel Fittings are a great way to securely install and aim EXAIR nozzles. They are dynamic as they can be adjusted and set to a flow direction with 50-degrees of movement.  They are made from 303SS or 316SS for corrosion resistance with ports ranging from 4mm to 1” NPT.
  • Compressed Air Fittings are a nice arrangement to connect different compressed air items together. We offer a range of hex and close nipples, couplings, reducers, tees, elbows, crosses and bulk head fittings.  If you need a quick way to connect directly to your pneumatic system, we may have it on the shelf.

    Model 9043
  • Magnetic Bases are designed for a solid mount to steel surfaces and for easy portability of your blow-off system to different locations. It has a 100 lb. (45.5Kg) pulling force to keep the blowing device attached firmly until you want to move it.  They can be mounted in a vertical or horizontal position.  EXAIR offers a single outlet Magnetic Base (for one blow-off device); a dual outlet Magnetic Base (for multiple blowing products); and a single outlet Swivel Magnetic Base (to offer more flexibility to orientation).  The bases come with a ¼ turn shut-off valve to easily turn on and off the compressed air to the EXAIR products.
  • Receiver Tanks are used to store compressed air. They can be used at the air compressor or as secondary reservoirs for intermittent demand.  They help your compressed air system with pressure variations and high demand loads.  EXAIR offers a model 9500-60 Receiver Tank that has a 60 gallon capacity and is rated to 200 PSIG.  It meets the ASME pressure vessel code.

    Universal Air Mounting Kit
  • Universal Air Knife Mounting System gives you a way to mount the EXAIR Super Air Knife, Full-Flow Air Knife, and Standard Air Knife. This kit is used to position your air knife securely and precisely.  It comes with a bracket and an articulated arm that can reach up to 30” (762mm).  You can orientate the air knives in any position to maximize the effectiveness.

    Plumbing Kits
  • Plumbing Kit, or PKI, is a great tool for longer Super Air Knives to help attach your compressed air system. They are designed to help lessen the time for install as well as to properly supply compressed air equally along the entire length, specifically for 24” (610mm) and longer.  We can offer the Plumbing Kit separately if you find that it could benefit your fabricators during installation.
  • Coupling Kits are designed to attach Aluminum and Stainless Steel Super Air Knives if you need to extend past the 108” (2,743 mm) width. Coupling Kits will mount the air knives together end to end.

Hoses:

  • Conveying Hoses are used with our Air Operated Conveyors or Line Vacs. The hoses are made from a durable PVC semi-flexible hose with six different diameters from ¾” I.D. up to 3” I.D.  The conveyance hoses can slip easily to the ends of the Line Vacs or to tubes for an easy transition.  EXAIR can cut-to-length Conveying Hoses up to 50 feet (15m); in increments of 10 feet (3m).
  • Coiled Hoses get compressed air from the piping system to the EXAIR product. They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters).  They have swivel fittings at the end to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking.  The coiled design makes it easy to reach around the work area and retract back to the substation.  This will help to keep the hose off the ground where potential dangers could occur.  We offer 3 different connection sizes; 1/8” NPT, ¼” NPT, and 3/8” NPT.
  • Compressed Air Hoses is another way to supply EXAIR products. They are useful if you need to reach from overhead sources or around equipment.   They are made from a reinforced synthetic rubber in 3/8” I.D. and 1/2” I.D. diameters.  We can make specific lengths up to 50 feet (15m).  They are rated for 250 PSIG (17 bar) air pressure, and the hose material works well for long-lasting protection against ozone, weathering and temperatures up to 158oF (70oC).  They come standard with two male ends in ¼” NPT or ½” NPT.
  • Stay Set Hoses give you that possibility of manually adjusting or re-adjusting Super Air Nozzles. The hose has a “memory” function; so, it will not creep or droop until you physically move it.  They work well to direct air flows in unique ways at specific target areas.  They can be used with Super Air Nozzles, Safety Air Guns and Blow-off Kits.  The Stay Set Hoses come in lengths from 6” (15cm) to 36” (91cm), and they are offered with ¼” NPT male on both ends or with a 1/8” NPT female and a ¼” NPT male connections.  These hoses are rated for 250 PSIG (17 bar) and are made from reinforced synthetic rubber.

Temperature Accessories:

  • The ETC, or Electronic Temperature Control, is a digital temperature controller with a LED screen for precision monitoring and adjusting temperatures in a Cabinet Cooler System. The controller has easy-to-use buttons to raise or lower the desired internal cabinet temperature.  Once set, the ETC will hold the temperature to +/- 1 oF (+/- 0.5 oC).  The LED displays the internal temperature for continuous monitoring.  The ETC comes complete with the controller and a solenoid valve in two different voltages, 120Vac and 240Vac.
  • The thermostat is a way to control a solenoid valve electrically to turn on/off a Cabinet Cooler System at a set temperature. It is preset at 95°F (35°C), but it can be adjusted to other desired temperatures.  It has an accuracy to hold the set temperature within +/- 2 °F (1 °C).  It can handle voltages from 24V to 240V, AC (50/60 Hz) or DC.  They are UL Recognized and CSA certified.

In today’s fast-paced world, there is a need to get your devices operating correctly and as quickly as possible.  EXAIR Accessories can do that.  Not only will you have confidence, as you are using the items recommended by the EXAIR experts, but you won’t have to worry about your system “squeaking” to a halt.  Like with my brakes above; I was happy to use the recommended grease to end any annoyance with my braking.  If you would like to discuss the proper options with your EXAIR products, an Application Engineer will be happy to help you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

How to Calculate and Avoid Compressed Air Pressure Drop in Systems

EXAIR has been manufacturing Intelligent Compressed Air Products since 1983.  They are engineered with the highest of quality, efficiency, safety, and effectiveness in mind.  Since compressed air is the source for operation, the limitations can be defined by its supply.  With EXAIR products and pneumatic equipment, you will need a way to transfer the compressed air from the air compressor.  There are three main ways; pipes, hoses and tubes.  In this blog, I will compare the difference between compressed air hoses and compressed air tubes.

The basic difference between a compressed air hose and a compressed air tube is the way the diameter is defined.    A hose is measured by the inner diameter while a tube is measured by the outer diameter.  As an example, a 3/8” compressed air hose has an inner diameter of 3/8”.  While a 3/8” compressed air tube has an outer diameter that measures 3/8”.  Thus, for the same dimensional reference, the inner diameter for the tube will be smaller than the hose.

Why do I bring this up?  Pressure drop…  Pressure Drop is a waste of energy, and it reduces the ability of your compressed air system to do work.  To reduce waste, we need to reduce pressure drop.  If we look at the equation for pressure drop, DP, we can find the factors that play an important role.  Equation 1 shows a reference equation for pressure drop.

Equation 1:

DP = Sx * f * Q1.85 * L / (ID5 * P)

DP – Pressure Drop

Sx – Scalar value

f – friction factor

Q – Flow at standard conditions

L – Length of pipe

ID – Inside Diameter

P – Absolute Pressure

 

From Equation 1, differential pressure is controlled by the friction of the wall surface, the flow of compressed air, the length of the pipe, the diameter of the pipe, and the inlet pressure.  As you can see, the pressure drop, DP, is inversely affected by the inner diameter to the fifth power.  So, if the inner diameter of the pipe is twice as small, the pressure drop will increase by 25, or 32 times.

Let’s revisit the 3/8” hose and 3/8” tube.  The 3/8” hose has an inner diameter of 0.375”, and the 3/8” tube has an inner diameter of 0.25”.  In keeping the same variables except for the diameter, we can make a pressure drop comparison.  In Equation 2, I will use DPt and DPh for the pressure drop within the tube and hose respectively.

Equation 2:

DPt / DPh = (Dh)5 / (Dt)5

DPt – Pressure drop of tube

DPh – Pressure Drop of hose

Dh – Inner Diameter of hose

Dt – Inner Diameter of tube

Thus, DPt / DPh = (0.375”)5 / (0.25”)5 = 7.6

As you can see, by using a 3/8” tube in the process instead of the 3/8” hose, the pressure drop will be 7.6 times higher.

Diameters: 3/8″ Pipe vs. 3/8″ tube

At EXAIR, we want to make sure that our customers are able to get the most from our products.  To do this, we need to properly size the compressed air lines.  Within our installation sheets for our Super Air Knives, we recommend the infeed pipe sizes for each air knife at different lengths.

There is also an excerpt about replacing schedule 40 pipe with a compressed air hose.  We state; “If compressed air hose is used, always go one size larger than the recommended pipe size due to the smaller I.D. of hose”.  Here is the reason.  The 1/4” NPT Schedule 40 pipe has an inner diameter of 0.364” (9.2mm).  Since the 3/8” compressed air hose has an inner diameter of 0.375” (9.5mm), the diameter will not create any additional pressure drop.  Some industrial facilities like to use compressed air tubing instead of hoses.  This is fine as long as the inner diameters match appropriately with the recommended pipe in the installation sheets.  Then you can reduce any waste from pressure drop and get the most from the EXAIR products.

With the diameter being such a significant role in creating pressure drop, it is very important to understand the type of connections to your pneumatic devices; i.e. hoses, pipes, or tubes.  In most cases, this is the reason for pneumatic products to underperform, as well as wasting energy within your compressed air system.  If you would like to discuss further the ways to save energy and reduce pressure drop, an Application Engineer at EXAIR will be happy to assist you.

 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

EXAIR Hoses and Tubes are Great Accessories

EXAIR offers different styles of hoses and tubes as accessories to our product lines.  They are built and designed to easily fit with our products as well as being sized correctly to not affect performance.  It simplifies the use, setup, and integration of EXAIR products in your facility.   You do not have to determine the proper diameters, pressure ratings, or end fittings to best fit the EXAIR products to maximize their performance.  Also, having these items available from one source minimizes the number of purchases and vendors necessary for a complete and working solution. In this article, I will go over the different hoses and tubes that EXAIR can provide.

Conveying Hoses:

The hoses above are used with our Air Operated Conveyors or Line Vacs.  The Line Vacs are designed to move product from point A to point B.  If the Line Vac is the “vehicle”, the Conveyance Hose is the track.  The hoses are made of a durable PVC semi-flexible hose with 6 different diameters from ¾” I.D. to 3” I.D.  The conveyance hose can slip easily onto the EXAIR non-threaded style of Line Vacs.  EXAIR can cut-to-length Conveying Hoses up to 50 feet (15m); in increments of 10 feet (3m).

Coiled Hoses:

To get compressed air from the piping system to the Safety Air Guns, we offer a series of Coiled Hoses.  They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters).  They have swivel fittings to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking.  The coiled design makes it easy to reach around the work area and retract back to the substation.  This will help to keep the hose off the ground where potential dangers could occur.  We offer 3 different connection sizes of 1/8” NPT, ¼” NPT, and 3/8” NPT to attach right to the Safety Air Guns.  With the proper size, the Coiled Hoses can supply the required amount of compressed air with a minimal amount of pressure drop.

Compressed Air Hoses:

If you need a compressed air line to reach from overhead or around equipment, the EXAIR Compressed Air Hoses would work with these applications.  They are made from a reinforced synthetic rubber in 3/8” I.D. and 1/2” I.D. diameters.  We can make specific lengths up to 50 feet (15m).  They are rated for 250 PSIG (17 bar) air pressure, and the hose material works well for long lasting protection against ozone, weathering and temperatures up to 158oF (70oC).  They come with two male ends in ¼” NPT or ½” NPT.

Stay Set Hoses:

The Stay Set Hose gives you that possibility of manually adjusting or re-adjusting Super Air Nozzles.  The hose has a “memory” function, and it will not creep or droop until you physically move it.  They work well to direct air flows in specific target areas.  They can be used with Super Air Nozzles, Safety Air Guns and Blow-off Kits.  The Stay Set Hoses come in lengths from 6” (15cm) to 36” (91cm), and they are offered with ¼” NPT male on both ends or with a 1/8” NPT female and a ¼” NPT male connections.  These hoses are rated for 250 PSIG (17 bar) and are made from reinforced synthetic rubber.  If positioning is required for accurate blowing or re positioning for different areas, the Stay Set Hose would be a nice addition to your equipment.

Vacuum Tubing:

For our E-Vac product line, EXAIR offers vacuum hoses to connect the E-Vac vacuum generators to the suction cups.  They are made from polyurethane in ¼” O.D. and 3/8” O.D.  The tubing is very flexible for moving product, and they can resist the vacuum pressures created by the E-Vac.  They slip easily into our Push-In Connectors to quickly attach vacuum cups to the E-Vac system.  EXAIR can sell both types of tubing up to 50 feet (15m) in increments of 10 feet (3m).

Hoses and tubes may seem like simple things, but EXAIR already did all the research in determining the best material and correct size for optimum performance.  You can leverage this information to save you time and money when using EXAIR products in your application.  If you need help in selecting the correct model, you can contact an Application Engineer.  We will be happy to help you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Proper Supply Line Size And Fittings Provide Peak Performance

Many times when we provide the air consumption of an EXAIR product, we get a response like…. “I’ve got plenty of pressure, we run at around 100 PSIG”. While having the correct pressure available is important, it doesn’t make up for the volume requirement or SCFM (Standard Cubic Feet per Minute) needed to maintain that pressure. We commonly reference trying to supply water to a fire hose with a garden hose, it is the same principle, in regards to compressed air.

When looking to maintain an efficient compressed air system, it’s important that you use properly sized supply lines and fittings to  support the air demand (SCFM) of the point-of-use device. The smaller the ID and the longer the length of run, it becomes more difficult for the air to travel through the system. Undersized supply lines or piping can sometimes be the biggest culprit in a compressed air system as they can lead to severe pressure drops or the loss of pressure from the compressor to the end use product.

Take for example our 18″ Super Air Knife. A 18″ Super Air Knife will consume 52.2 SCFM at 80 PSIG. We recommend using 1/2″ Schedule 40 pipe up to 10′ or 3/4″ pipe up to 50′. The reason you need to increase the pipe size after 10′ of run is that 1/2″ pipe can flow close to 100 SCFM up to 10′ but for a 50′ length it can only flow 42 SCFM. On the other hand, 3/4″ pipe is able to flow 100 SCFM up to 50′ so this will allow you to carry the volume needed to the inlet of the knife, without losing pressure through the line.

Pipe size chart for the Super Air Knife

We also explain how performance can be negatively affected by improper plumbing in the following short video:

 

Another problem area is using restrictive fittings, like quick disconnects. While this may be useful with common everyday pneumatic tools, like an impact wrench or nail gun, they can severely limit the volumetric flow to a device requiring more air , like a longer length air knife.

1/4″ Quick Connect

For example, looking at the above 1/4″ quick disconnect, the ID of the fitting is much smaller than the NPT connection size. In this case, it is measuring close to .192″. If you were using a device like our Super Air Knife that features 1/4″ FNPT inlets, even though you are providing the correct thread size, the small inside diameter of the quick disconnect causes too much of a restriction for the volume (SCFM) required to properly support the knife, resulting in a pressure drop through the line, reducing the overall performance.

If you have any questions about compressed air applications or supply lines, please contact one of our application engineers for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN