Dirty Coolant in, Clean Coolant Out – EXAIR’s Chip Trapper Extends Coolant Life

In a machine shop one of the most dreaded tasks is always cleaning out the coolant sumps of the CNC machines. Over time, chips and shavings can make their way up into the coolant lines resulting in a clog. The coolant flow slows down or stops entirely, resulting in premature wear of expensive cutting tools, imperfections in the parts, or unacceptable product finish. When this occurs, if it is even noticed right away, the machine has to be stopped and valuable production time must be spent identifying the location of the clog and removing it.

Another problem, one anyone working around CNC machines can attest to, is the rancid coolant smell that is a result of bacteria building up in the stagnant cutting fluid. Regularly cleaning this oil can reduce this smell, prevent premature tool wear or costly shutdowns, as well as extend the overall life of your coolant.

ctrhlctr_heroi_770x620

There are some machines out there capable of cleaning the oil and removing any chips or shavings, but these tend to be very expensive and not very effective. We tested a few different methods here at EXAIR in our machine shop. As a result of these tests we determined that the best foot forward would be to develop something ourselves. Enter the EXAIR Chip Trapper. Using either a standard or High Lift Reversible Drum Vac to provide the vacuum source, the Chip Trapper is capable of filling or emptying a 55 gallon drum in less than two minutes. It is able to pick up both the liquid coolant as well as any chips or shavings that are suspended in the coolant. The liquid is forced through a filter bag inside of the drum which contains any solid materials while allowing the coolant to filter out into the drum. Switching the knob on the Reversible Drum Vac and the directional flow valve to empty will allow the clean coolant to be pumped back out of the drum and reused.

After implementing the Chip Trapper in our own shop, we were able to increase the life of the coolant by 6x. In addition to the increased coolant life, a process that used to take up to 2 hours per machine now takes less than 10 minutes. The Chip Trapper quickly and easily pays for itself.

The Chip Trapper is available in either 30, 55, and 110 gallon systems. It’ll also come with (2) 5 micron filter bags, other filter bags are also available ranging from 1 micron up to 200 micron filtration. Using a simple detergent, the filter bags can be washed out, cleaned, and reused multiple times. With no motors or impellers to clog or wear out, as well as no electricity requirement or shock hazard, the Chip Trapper comes with our standard 5-year Built to Last Warranty. Do yourself (and your machine operators) a favor and get a Chip Trapper on order today. They’re in stock, ready to ship and start saving you time and money!

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

Product Overview – High Lift Reversible Drum Vac

Are you needing to move a thick fluid, move liquid farther or higher? Do you have a below grade sump or pit you’re looking  to empty? Then EXAIR has the solution for you, enter the High Lift Reversible Drum Vac. Like the standard Reversible Drum Vac, the High Lift RDV is a compressed air operated, liquid only vacuum with no moving parts or motors that can fail,  like those in traditional electrically powered vacuums. What separates the High Lift RDV from the traditional version is the higher vacuum it achieves which allows you to lift liquids up to 15′, move liquids up to 20′ and handle fluids with viscosity as high as 1400 centipoise.

The High Lift Reversible Drum Vac is a high powered vacuum able to lift liquids up to 15′ and fill a 55 gallon drum in less than 85 seconds!

The High Lift Reversible Drum Vac features a two-way pump constructed of stainless steel and a built-in safety relieve valve to avoid over pressurizing or over-filling the drum. Air consumption is minimal, at 43 SCFM @ 80 PSIG, while maintaining a low noise level of only 83 dBA. In “empty” mode, the HLRDV achieves a flow rate of 30 gallons per minute (water) to quickly empty the drum.

Systems are available in 30, 55 and 110 gallon capacities in 3 different variations:

The Standard Systems include the High Lift Reversible Drum Vac, shutoff valve, 20′ vacuum hose, standpipe, 90° quick release elbow and aluminum chip wand.

Model # 6195, 6195-30 and 6195-110

Deluxe Systems include all of the items shown above in the “Standard” System and adds a drum dolly, ABS plastic spill recovery kit, (2) extension wands, crevice tool, skimmer tool and a magnetic tool holder.

Model # 6295, 6295-30

And Premium Systems include all of the items in “Deluxe” Systems and adds the drum with lock ring and lid, heavy duty aluminum tools and 20′ compressed air hose.

Model # 6395, 6395-30, 6935-110

Do You Need 30 Days for Testing?

Not long ago while checking out of a motel my laptop bag that was attached to the handle on my suitcase fell forward and the impact shattered the screen on the laptop.  Upon turning the computer on I realized that a new screen was in order.

I waited until I arrived at home and found what I thought to be the correct monitor and quickly ordered it.  It arrived two days later and I painstakingly took the laptop apart and exposed the mounting frame.  The removal of the broken screen and the installation of the new was not too difficult but the cable connector was less than robust and was very tight.  Carefully I worked it back and forth and it came free.

Installation and reassembly went quickly and then I powered up the machine.  I was only greeted with a series of very loud and annoying beeps.  At that point I shut it down and called the company I purchased the screen from and described the issue.  They determined that the resolution of the screen was incorrect for my laptop and that I needed a different model.  They said I could return the incorrect one and upon inspection receive a credit less the return shipping.  At that point I ordered the correct screen and packaged up the wrong one and dropped it off at the parcel delivery service.

The new model arrived and it installed easily and worked perfectly.  I waited patiently and never did see a refund so I called the company and they said that it was an oversight on their end and that it would be corrected within 48 hours.  Sure enough they issued the credit and money was credited back to my account with one exception, the 40% restocking fee!

I can tell you that EXAIR is not that way!  If you order the wrong item or are not satisfied for any reason and the item was purchased within the last 30 days we will facilitate the return and ZERO restocking fee. There are a multitude of reasons our customers would want to take advantage of our 30 day guarantee and we make it a simple transaction if you need to take advantage of it too. Testing is one reason a customer would use this 30 days, other customers may have ordered incorrectly or released product inadvertently, they may have wanted a small sample for a meeting or demonstration at a customers location.

30 day money back guarantee
EXAIR Guarantee

If you want to discuss any EXAIR product, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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EXAIR Industrial Housekeeping Vacuums – A Look at the 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 electric motors which most ‘all purpose’ vacuums rely on.  In industrial settings with harsh conditions and rugged use, the Industrial Housekeeping Products are ideally suited for the everyday wear and tear.                               6091   6095.jpg

The heart of the EXAIR liquid type vacuums, like the Reversible Drum Vac, the High Lift Reversible Drum Vac, and the same range in the Chip Trappers is shown here. Installing onto an any closed head, 30, 55, or 110 gallon drum creates a high powered vacuum.  It can fill a 55 gallon drum in less than 2 minutes.  Then, with the turn of a knob, the the same pump quickly empties the drum. Useful for refilling coolant sumps, vacuuming floor spills, or transferring contaminated liquids to filtration tanks in minutes.  Flow rate can be controlled with the knob.  The Chip Trapper has an internal filtration system to separate the chips from the coolant, allowing for disposal of the solids, and for pumping of the clean coolant back into the sump.

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5, 30, 55, and 110 Gallon Reversible Drum Vacs – A size to Meet Most Any Requirement

Also available are the dry/solid type vacuum systems, the Chip Vac, Heavy Duty Dry Vac and the Heavy Duty HEPA Vac which use the vacuum units shown below.6093                                                                    6097

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.

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5, 30, 55, and 110 Gallon Chip Vacs

When you look at the vacuum producing units, you’ll notice there is not an electrical cord.  Because the EXAIR Industrial Housekeeping Products utilize compressed air for operation, they do not have the same issues with wear, breakdown and failures as electrical type vacuums. There are no moving parts in the vacuum units to wear out or break.  They are maintenance free, just supply clean, dry air, and they will operate for a long time. For the the liquid type systems, there is a built in pressure/vacuum relief device and auto safety shut-off to prevent overfilling.

There are no motors and bearings to wear out and no impellers to clog.  The Chip Vac is 50% quieter than a comparable electric vacuum.  Safety is a top priority, and the use of the unit on wet floor and spills is not an issue.

If you would like to talk about Industrial Housekeeping products 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.

Brian Bergmann
Application Engineer

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Liquid Handling With Compressed Air: An Overview

There are some very good reasons to consider an EXAIR compressed air operated Industrial Housekeeping Product for liquid applications:

*Durability. No moving parts means nothing to wear or get damaged.
*Safety. No electricity means no dragging an energized cord through a wet area.
*Convenience. All you need is a supply of compressed air.
*Reliability. If you supply it with clean, dry air, it’ll run darn near indefinitely, maintenance free.

Depending on the needs of the application, we have different models to choose from:

Reversible Drum Vacs

If you’ve got a closed top steel drum that’s in good condition, look no further than the Reversible Drum Vac System.  It comes with everything you need to turn that drum into a powerful, 2-way liquid pumping system.  This is great if you just need to park the drum in one spot and suction out a sump or tank on a regular basis, using its 10 foot Vacuum Hose & Suction Wand.  They’re in stock for your existing 30, 55, and 110 gallon drums.  A 5 Gallon Mini Reversible Drum Vac System is also available; it includes the drum as well.

Reversible Drum Vac Systems come in sizes from 5 to 110 gallons.

If you’d like a little mobility, and a way to clean up floor spills, then the Deluxe Reversible Drum Vac System might be what you’re looking for.  It adds a Drum Dolly and our Spill Recovery Kit…it consists of a floor-length wand and a dual squeegee tool.  It also comes with a set of plastic tools (crevice tool, small skimmer, and two 20″ extensions) and a Tool Holder with clips for the tools, and magnets to attach to the drum.  We keep them in stock for your existing 30 and 55 gallon drums.  It also comes in the 5 Gallon Deluxe Mini Reversible Drum Vac System (drum included.)

 

Deluxe Systems add a Spill Recovery Kit, and a Dolly for your drum.

For a complete system, the Premium Reversible Drum Vac Systems have everything you need for most any liquid drum transfer job: they add a drum, lid & latch ring, as well as a compressed air supply hose & shutoff valve, and an upgrade to Heavy Duty Aluminum Tools.  They’re available with 30, 55, or 110 gallon drums; in stock.

Premium Reversible Drum Vac Systems come with everything you need, right out of the box.

Any of the 30, 55, or 110 Gallon systems are also available with our High Lift Reversible Drum Vac.  These provide for increased performance with more viscous liquids, and/or when the liquid needs to pumped from a depth of up to 15 feet.  They are outfitted identically to the standard Reversible Drum Vac Systems, except they come with a 20 foot Vacuum Hose.

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

As versatile as the Reversible Drum Vacs are, we also incorporate them into another 2-way pumping system, designed to help you get maximum life and performance from machine tool coolant and cutting oils:  The award-winning Chip Trapper Systems.

The vacuum hose (1) is attached to the barbed connection of the Chip Trapper (2). The directional flow control valve on the top of the drum (3) and knob on the pump (4) are set to the “fill” position. The air supply valve is opened to permit compressed air at 80-100 psig (5.5-6.9 BAR) to flow through the pump which pulls the liquid through the hose, then into the reusable filter bag (5). When all liquid is in the drum, the air supply is turned off. The filtered liquid can then be pumped out by setting the directional flow control valve on top of the drum and the knob on the pump to the “empty” position. Once the air supply valve is opened, the air pushes the liquid back through the hose while all solids remain in the reusable filter bag.

Powered by the Reversible Drum Vac, the Chip Trapper System draws the incoming liquid into the drum through a Filter Bag, which retains (or “traps”) any particulate as the drum fills with liquid.  Then, the freshly filtered liquid can be immediately pumped back out, while the particulate remains in the bag.  Once the bag is full, simply remove the drum lid, unhook the bag, empty it out, and return it to service.  The Chip Trapper System comes with two Filter Bags, in fact, so you can clean one while you use the other.  They are available, from stock, in 30, 55, and 110 gallon sizes.  They are all three available in High Lift configuration as well, with a 20 foot Vacuum Hose.

If you’d like to find out more about safe, reliable and effective liquid handling with EXAIR’s compressed air operated Industrial Housekeeping Productsgive me a call.

Russ Bowman
Application Engineer
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Order An Industrial Vacuum System Through 5/31/18 And Receive A Free Vac-u-Gun

From now through May 31, 2018, we are offering a FREE Vac-u-Gun with any order for one of our Industrial Housekeeping Vacuum Systems. The Vac-u-Gun is a multi-purpose tool that can be used to vacuum or transfer material from one location to another or it can be used as a powerful blow gun to clean debris off of the surface of a part or workstation. There is no electricity required to operate and no moving parts to wear out, providing for a safe, maintenance free operation.

Change from a vacuum gun to a blow gun in a matter of seconds!

When choosing one of our vacuums, selection can be simplified depending on what type of media you are needing to pickup. Our systems are going to be either solids handling or liquid handling.

Our Chip Vac Systems are the ideal choice when looking to vacuum dry or damp debris left over from machining operations and delivers them to a standard open top steel drum. For more abrasive material, such as sand or steel shot used in sandblasting processes, the Heavy Duty Dry Vac provides superior wear resistance due to it’s proprietary hardened alloy construction.

If you are looking to vacuum liquids we offer our Reversible Drum Vac and High LIft Reversible Drum Vac providing higher suction lift, up to 180″ H2O.

Our Chip Trapper and High Lift Chip Trapper are also used in liquid applications but these systems incorporate a filter bag inside the drum to capture any suspended solids in the liquid so only clean fluid is pumped back into the reservoir or tank.

In dusty applications we offer the Heavy Duty HEPA Vac which uses the same vacuum as the HD Dry Vac but this system provides a higher level of filtration meeting HEPA requirements of 99.97% filtration at the 0.3 micron level.

All of these products are In-Stock, Ready To Ship.

To take advantage of the offer, you need to order using the promotional Model number. Ordering is easy – you can email the order to orders@exair.com or place your order online at www.EXAIR.com. If you’d rather place your order over the phone or have any technical questions about our products, you can call us at 800-903-9247 and one of our reps will be happy to assist.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Simplifying Plastics Machining Using The Cold Gun And Chip Vac

I was recently contacted by a plastics manufacturer who was needing some solutions for problem areas in their production processes. The company imports their machines from overseas and they are outfitted with a coolant based, quench system for the tooling. They were wanting to get away from using coolant as the parts were absorbing liquid, causing them to swell, not to mention the mess they were creating, requiring more time and labor to dry and clean the parts manually.

For the first application, replacing the messy misting system, I recommended the customer use our Cold Gun System, Model # 5215. The Cold Gun uses Vortex Tube technology to produce a cold air stream 50°F lower than the incoming compressed air supply temperature. For example, if your supply air was ambient 70°F, you would effectively see 20°F air at the exhaust. This clean, cold air stream can be easily directed to the needed area to prevent any warping or other damage related to heat, while also blowing away the machined fines.

Model # 5215 – includes the Cold Gun, Single Point Hose Kit, 3/8″ Cone Nozzle, 1-1/4″ Fan Nozzle and Filter Separator

The second part of the process involved the recovery of the plastic scrap and chips created during the machining process. Once again, EXAIR has the ideal solution with our Chip Vac, Industrial Vacuum. The Chip Vac creates a powerful vacuum, with no moving parts or motors to wear out, making them virtually maintenance free. The Chip Vac is designed to vacuum dry or wet chips and collect them in a standard, open-top steel drum. Systems are available in 5, 30, 55 or 110 gallon capacities.

From small area clean up to larger scale processes, the Chip Vac has you covered

To discuss how EXAIR products might help improve your machining process, give us a call at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN