EXAIR’s Digital Flowmeters are the easy way for you to monitor your compressed air consumption and waste. They provide a digital readout of the compressed air being used, allowing you to identify costly leaks or inefficient air products throughout the plant. They’re available from stock in sizes ranging from 1/2″-4″ for use with Schedule 40 iron pipe. Additional sizes and pipe materials are available as well, contact the factory for assistance in these applications.
The display on the Digital Flowmeter can be customized to show different values, units of measure, default display setting, resolution, etc. Check out the video below to see which settings are available and how you can adjust the display on your Digital Flowmeter.
If you have any questions give us a call, start an online chat from our website or send us an e-mail.
EXAIR’s Digital Flow Meter offers an easy way to measure, monitor and record compressed air consumption. The Digital display shows the current amount of compressed air flow, allowing for tracking to identify costly leaks and/or inefficient air users.
How exactly does the Digital Flow Meter work? The unit falls under the category of Thermal Mass or Thermal Dispersion type flow meters. Below shows the backside of a unit.
Thermal mass flow meters have the advantage of using a simple method of measuring flow without causing a significant pressure drop. The EXAIR units have (2) probes that are inserted through the pipe wall and into the air flow. Each of the probes has a resistance temperature detector (RTD.) One of the probes measures the temperature of the air flow. The other probe is heated to maintain a preset temperature difference from the temperature measured by the first probe. The faster the air flow, the more heat that is required to keep the second probe at the prescribed temperature. From Heat Transfer principles, the heat energy input required to maintain the preset temperature is based on the mass velocity of the air. Using basic physical properties for compressed air, the volumetric rate can be determined (SCFM), and displayed.
It is important to note that the compressed air should be filtered to remove oils, and dried to remove water, as these liquids have different physical properties from air, and will cause erroneous readings.
If you have any questions about the Digital Flow Meter or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
“To measure is to know – if you cannot measure it, you cannot improve it.” -Lord Kelvin, mathematical physicist, engineer,and pioneer in the field of thermodynamics.
This is true of most anything. If you want to lose weight, you’re going to need a good scale. If you want to improve your time in the 100 yard dash, you’re going to need a good stopwatch. And if you want to decrease compressed air consumption, you’ll need a good flowmeter. In fact, this is the first of six steps that we can use to help you optimize your compressed air system.
There are various methods of measuring fluid flow, but the most popular for compressed air is thermal mass air flow. This has the distinct advantage of accurate and instantaneous measurement of MASS flow rate…which is important, because measuring VOLUMETRIC flow rate would need to be corrected for pressure in order to determine the true compressed air consumption. My colleague John Ball explains this in detail in a most excellent blog on Actual (volume) Vs. Standard (mass) Flows.
So, now we know how to measure the mass flow rate. Now, what do we do with it? Well, as in the weight loss and sprint time improvements mentioned earlier, you have to know what kind of shape you’re in right now to know how far you are from where you want to be. Stepping on a scale, timing your run, or measuring your plant’s air flow right now is your “before” data, which represents Step One. The next Five Steps are how you get to where you want to be (for compressed air optimization, that is – there may be a different amount of steps towards your fitness/athletic goals.) So, compressed air-wise, EXAIR offers the following solutions for Step One:
Digital Flowmeter with wireless capability. This is our latest offering, and it doesn’t get any simpler than this. Imagine having a flowmeter installed in your compressed air system, and having its readings continually supplied to your computer. You can record, analyze, manipulate, and share the data with ease.
Digital Flowmeter with USB Data Logger. We’ve been offering these, with great success, for almost seven years now. The Data Logger plugs into the Digital Flowmeter and, depending on how you set it up, records the flow rate from once a second (for about nine hours of data) up to once every 12 hours (for over two years worth.) Pull it from your Digital Flowmeter whenever you want to download the data to your computer, where you can view & save it in the software we supply, or export it directly into Microsoft Excel.
Summing Remote Display. This connects directly to the Digital Flowmeter and can be installed up to 50 feet away. At the push of a button, you can change the reading from actual current air consumption to usage for the last 24 hours, or total cumulative usage. It’s powered directly from the Digital Flowmeter, so you don’t even need an electrical outlet nearby.
Digital Flowmeter. As a stand-alone product, it’ll show you actual current air consumption, and the display can also be manipulated to show daily or cumulative usage. It has milliamp & pulse outputs, as well as a Serial Communication option, if you can work with any of those to get your data where you want it.
Stay tuned for more information on the other five steps. If you just can’t wait, though, you can always give me a call. I can talk about compressed air efficiency all day long, and sometimes, I do!
This year EXAIR has introduced the new Wireless Digital Flowmeter. This meter is capable of monitoring compressed air consumption and transmitting the usage data to your PC wirelessly using ZigBee mesh networking protocol.
Each meter has a range of 100′ and allows for multiple meters to be installed on the same network, “piggybacking” off of one another. As long as the next meter is installed within 100′ of the first, you will only require one ZigBee gateway.
The Digital Flowmeter is available from stock for use on Schedule 40 pipe with sizes ranging from ½”-4” I.D. Sizes up to 6” for Schedule 40 and ¾”-4” for copper pipe are also available. 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.
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.
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.
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!
This video highlights the value and benefits of an engineered blow off solution. We take a homemade open pipe blowoff and replace it with an EXAIR model 1100 Super Air Nozzle. This air nozzle is then controlled through our Electronic Flow Controller, allowing for intermittent On/Off of the compressed air flow. And, these solutions are wirelessly monitored via Zigbee network using our Wireless Digital Flowmeter. Implementing these solutions results in a compressed air reduction of over 90%!!!
Full calculations along with supporting flow values (pulled from the same data shown in the video above) are shown below.
The open pipe:
The first compressed air flow values to show up on the EXAIR Logger are for the open pipe blow off. At 1 BAR operating pressure, this “solution” consumes 22.3 SCFM of compressed air. At a cost of $0.25 for every 1,000 cubic feet of compressed air, this nozzle will cost $695.76 to operate 8 hours per day, 5 days per week, 52 weeks per year.
The engineered EXAIR Super Air Nozzle
Model 1100 EXAIR Super Air Nozzles consumes 4.7 SCFM at an operating pressure of 1 BAR – a reduction of 79% compared to the open pipe. These savings prove out in terms of operating cost as well – $146.64 per year, compared to $695.76.
The engineered EXAIR Super Air Nozzle with Electronic Flow Control (EFC)
By controlling the “ON” time for this application with an EFC, we are only blowing for 32% of the time for each minute of operation which changes the required compressed air flow from 4.7 SCFM to a peak value of 1.5 SCFM. This control saves an additional 68% of compressed air flow. And, these savings are compounded by eliminating the need for constant compressed air flow. Total annual operating cost for the EXAIR 1100 Super Air Nozzle with Electronic Flow Control is just $46.80.
Implementing an engineered solution can have a TREMENDOUS impact on energy costs and operating costs in your facility. Compressed air is the most expensive utility to produce and consume, making the impact of proper solutions of high value to any business. Let us help you utilize engineered compressed air solutions in your facility by contacting an EXAIR Application Engineer today.
For over 34 years, EXAIR has been the industry leader in providing Intelligent Compressed Air Products to the industrial marketplace. While much of our focus is to ensure our products are engineered to provide optimal performance, we are also dedicated to manufacturing products that meet a wide range of standards and directives to promote safety in relation to plant personnel.
For instance, all of our compressed air operated products meet or exceed OSHA Standards 29 CFR 1910.242(b), requiring that the outlet pressure of an open pipe, nozzle, air gun, etc., when used for cleaning purposes, must remain below 30 PSI when dead-ended against the skin, as well as Standard 29 CFR 1910.95(a) as a way to protect workers from job related injuries related to dangerous sound levels of 90 dBA and higher.
Many of our products are also CE Compliant, meeting the mandatory requirements for products intended to be sold in the European Economic Area or “EEA”. For example our Electronic Flow Control and Electronic Temperature Control (ETC) meet the EU (European Union) Low Voltage Directive 2006/95/EC.
EXAIR electrically powered devices, like our Static Eliminators and Digital Flowmeters for example, comply with the “Restriction of Hazardous Substances” or RoHS Directive 2011/65/EU, including the amendment outlined in the European Commission decision L 214/65.
We are also committed to providing material that supports the conflict mineral free rule to help aid in the relief of illegal trade of exotic materials, like tungsten, gold, tin and tantalum in the DRC region. Using the CMRT 4.20 template, we document our supply resources to ensure we provide conflict free products, as outlined in Section 1502 of the Dodd-Frank Wall Street Reform and Consumer Protection Act.
Lastly, the European Union introduced the REACH program – Registration, Evaluation, Authorization and Restriction of Chemicals, as a method to register chemical substances being imported into the EU to protect people and the environment, per Regulation (EC) No 1907/2006 Title I, Article 3. Also noted in the program, Title II, Article 7, they state that any product with a substance intended to be released under normal operating conditions, must be registered for quantities totaling more than 1 metric ton per year. Since EXAIR products do not intentionally release or contain any such substances, registration to meet the program is not required.
If you have any questions about any of these Standards or Directives or about which EXAIR products comply, please feel free to contact an application engineer for assistance. We’d be happy to help!