Last week, I wrote about what a great idea it is to use a thermostat with a Cabinet Cooler System. I’ll let another cat out of the bag right now and tell you that there are less expensive thermostats than ours. But just like the savings you might realize on the purchase by foregoing a thermostat, using a poorly specified thermostat can also be the last savings you see.
In a Cabinet Cooler System application, we’re refrigerating air. This makes for a cool, clean, and dry atmosphere for your electrical & electronic components to operate in.
Not all thermostats are designed to read air temperature – in fact, a LOT of common, commercially available thermostats are designed for use with liquid. Using these to control air temperature will lead to slow response times. That means one of two things will happen:
When the air inside the enclosure is cooled to the thermostat’s set-point temperature, it won’t shut off the compressed air flow to the Cabinet Cooler unit, resulting in unnecessary compressed air consumption. And that’s a shame.
When the air inside the enclosure is heated to the thermostat’s set-point temperature, it won’t start the compressed air flow to the Cabinet Cooler unit, resulting in a potential overheating of those expensive…or critical…or both…electronic components. And that’s a REAL shame.
This past weekend I cleaned out some storage tubs that have been in my basement since I moved in. Within these tubs and boxes were all of my notes from college, along with all of my text books. Being any form of an engineering major means you keep all notes and books from college (I think). Among them was the manual for my graphing calculator. Even though I don’t graph anything on my calculator from college anymore, it still sits on my desk here and I use it to tell me how much money I am saving customers when they install our products. Along with calculating which Cabinet Cooler System they need.
The truth is, I don’t even need the calculator on my desk when I am looking at how much money an EXAIR Electronic Flow Control can save a customer. That’s because there is a free easy to use calculator right on our website. This calculator is going to allow you to put in how much air you are using, the percent of time the unit is on, how much you paid for the EFC and the compressed air, then it gives you how much air and money you save. The EFC Calculator will even tell you how many days it will take to recoup the price of the EFC.
Let’s look at an example of a 60″ Super Ion Air Knife that was installed to clean off bumper covers before a paint line. Not only did the customer save money by using the Super Ion Air Knife rather than the drilled pipes, they saved additional air and money by turning the compressed air off when a bumper wasn’t present. The following figures show the amount of money and air saved by implementing the EFC.
The Super Ion Air Knife was operated at 40 psig inlet pressure, this utilizes 102 SCFM of compressed air.
The process ran for 24 hours a day which equates to 1,440 minutes. There is a six second gap between each bumper, this means that you can reduce the on time by 37.5% just by turning the air off between bumpers.
The average cost to produce 1,000 SCF of compressed air is $0.25. The calculator shows the results below which include the pay back time for the EFC purchase. (CLICK it for a larger image)
As you can see, it will take a mere 84 days to reach a return on the investment of the EFC. The chart below (CLICK to enlarge) shows the math and cost savings when you also account for the amount of air saved by using the Super Ion Air Knife.
So if you have an intermittent compressed air application, by all means give us a call. We’ll help you figure out how much you’ll save by installing the EFC.
The most popular use for our Electronic Flow Control units is for an intermittent operation for blow off. This would be jobs such as computer monitors that need the screen blown off as they are coming down a conveyor belt. While this is ideal for the EFC there are other ways you can use this compressed air saving device.
One way would be for part ejection. This would be a case where maybe some pieces are taller than others and so you want to blow off the tall parts into a bin. Simply set the sensor at the height just above the height for the short product and then every piece that is above that height will trigger the sensor and blow it off the line.
Another use would be to tell when a hopper that is being filled by a Line Vac is empty or over filled. You can adjust the sensor and the control module to sense that the hopper is empty and it will turn the compressed air on to the Line Vac to then feed the hopper. Then set the timer module so it will run for the length of time it takes to fill the hopper. The other way would be to place the sensor at the top of the hopper and have it sense when the pile of media has reached the full level.
As with many of the other EXAIR products the Electronic Flow Control offers a solution to more than just one application.
If the weatherman is correct, it is going to be a sizzling hot summer this year with the southern tier states experiencing triple digit temperatures and the rest of the nation in the 90’s.
When it gets hot, controls fail. When controls fail, production shuts down. When production shuts down, the boss yells at you. When the boss yells at you, you tell him where to go. When you tell the boss where to go, you get fired. Don’t get fired. Install an EXAIR Cabinet Cooler system.
EXAIR Cabinet Cooler systems incorporate a Vortex Tube to produce cold air from compressed air – with no moving parts. The compact Cabinet Cooler system can be installed in minutes through a standard electrical knockout. NEMA 12, 4, and 4X Cabinet Cooler systems that match the NEMA rating of the enclosure are available in many cooling capacities for large and small control panels.
EXAIR has a staff of engineers that will assist you in selecting the proper cooler.