Non Hazardous Purge Cabinet Cooler System Keeps Enclosure Dust Free

A mining company has processing machinery operating in a poorly ventilated, dusty environment (actually, it’s a mine…as you might have guessed.) This machine’s control panel was supplied with filtered vents and fans to cool the electronic components inside. The filters clog regularly, and even though they checked them frequently, it’s not always frequently enough to prevent the drive from overheating.

Based on a referral they got from another one of their facilities, they called to get more information on a Cabinet Cooler System. For total dust exclusion, our Non-Hazardous Purge systems are ideal…they’re thermostatically controlled, so compressed air consumption is responsible and efficient, but they also provide a small, continuous flow, even when the thermostat set point temperature is attained, and the solenoid valve is shut. This keeps a low positive purge volume of clean, dry air in the enclosure.

EXAIR Non Hazardous Purge Cabinet Cooler Systems provide reliable and efficient cooling in the most aggressive environments.

The caller already had the data from our Cabinet Cooler Sizing Guide, so specification was quick & easy. A Model NHP4340 NEMA 12 Non-Hazardous Purge Cabinet Cooler System – 2,800 Btu/hr – w/Thermostat Control was ordered and installed the next day. We keep them in stock for situations just like this.

If you have heat issues with electrical & electronic equipment enclosures, give me a call.

Russ Bowman
Application Engineer
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Video Blog: Which EXAIR Air Knife Is Right For You?

The following short video explains the differences between the 3 styles of Air Knives offered by EXAIR – The Super, Standard and Full-Flow. All of these Models are IN STOCK, ready to ship, with orders received by 3:00 PM Eastern.

If you need additional assistance choosing your EXAIR Air Knife, please contact an application engineer at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

E-Vac for Epoxy Recycling

Recently, a manufacturer of custom magnetics called in about a special application. In the manufacturing of certain electronic systems, a very expensive, thick epoxy glue is used. They were exploring ways to be able to collect the excess after application.  They had used a system in the past and were looking to replicate it.  The previous system had an old boxy vacuum generator, and they asked us if we could provide a vacuum source that matched the performance specifications but in a more compact design.  After researching the specifications and a comprehensive comparison, we could offer the EXAIR model 810013 Inline E-Vac, generating up to 27 ” Hg of vacuum.  A basic sketch of the design concept is shown below-

Capture

By using the model 810013 to create a vacuum within the chamber, a strong suction can be generated at the tube inlet, strong enough to draw in the excess epoxy. The glue can be collected in the chamber for recycling and reuse, and because of the design, the glue does not pass through the E-Vac and cause any issues with build up or blockage that would hinder the performance, leading to the need to clean the unit.

In-LineE-VacFamily

The Many Sizes of E-Vac Models Available

EXAIR manufactures E-Vac’s for both porous and non-porous applications, as well as a line of Adjustable E-Vac Generators.  Smallest units use only 1.5 SCFM of 80 PSIG compressed air and the largest Adjustable E-Vac unit can pull 81 SCFM of air at open draw and 15″ Hg vacuum level setting.  With a wide range of sizes and types, there is a model available to meet your vacuum generation needs.

As a side note – the EXAIR Reversible Drum Vac, High Lift Reversible Drum Vac, Chip Trapper, and High Lift Chip Trapper all use this same basic principle of applying a vacuum to a chamber, but on a much larger scale, to turn a 5, 30, 55 or 110 gallon drum into an industrial liquid vacuum system.  The vacuum generating unit is of a different design, made specifically for the Industrial Housekeeping Products.

To discuss your process and how an EXAIR Intelligent Compressed Air Product can solve your toughest application issues, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Solving Static Problem in PET Plastic Thermoforming Application

PET plastic entering thermoforming machine to make cups

The image above shows a PET plastic sheet which is fed into a thermoforming machine. During thermoforming the plastic is made into drinking cups.  But, if the plastic enters the thermoforming machine with static present, the forming process cannot occur properly which results in defects.

The company in charge of thermoforming these cups reached out to the Application Engineering department at EXAIR in search of a solution to their problem. They had considered using Ion Bars, but were unsure if Ion Bars were the right solution.  So, we examined the process and the variables at play to determine the best path forward to remove this static.

The static in this application was present throughout the travel of the plastic sheet into the thermoforming machine. At EXAIR we always recommend to install any static eliminating solution at the last possible point before the static is causing a process disturbance, to ensure no static is regenerated.  Yes, a static charge has the potential to regenerate with friction, spearation or even simple contact with another surface. In the above example separation from the roll and friction upon the additional rollers could be a source of static. This meant finding a way to eliminate the static just prior to the sheet entering the thermoforming machine.

As it turns out, the thermoforming in this application can occur between 180-260°F, and this heat permeates from the machine to the area immediately outside of the plastic feed entrance. So, placing Ion Bars just outside of the machine, while potentially possible, would place them near temperatures at the high end of their operating temperature limits (maximum temperature for an EXAIR Ion Bar is 165°F).

However, just a couple of feet away from the machine this temperature dissipates significantly. So, if we could find a way to mount our solution 2-3 feet away and effectively eliminate static, we would have a viable solution.

That solution came in the form of Super Ion Air Knives. The Super Ion Air Knives provide the same static eliminating capabilities of an Ion Bar, but with an added benefit of transferring the static eliminating ions via a smooth and laminar air profile.  This allows for us to mount the Super Ion Air Knives a few feet away from the machine entrance, but to still effectively eliminate static.  At a distance of 12” away, the Super Ion Air Knife can eliminate a 5kV static charge in 0.18 seconds at an operating pressure of 80 PSIG, and in 0.60 seconds at an operating pressure of 5 PSIG.

Based on the width of 486mm, this customer opted for (2) 18” Super Ion Air Knives, model 111018, and (1) 230VAC power supply with (2) outlets, model 7907. By installing one Super Ion Air Knife on top of the plastic sheet, and one on the bottom, the static problem in this application is solved.

If you have an application in need of a static solution, contact an EXAIR Application Engineer. We’re here to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR.com

Think Of Quality And Service, Think Of EXAIR

As an Application Engineer at a direct sales manufacturing company, I get to talk to a LOT of people about potential uses for our quiet, safe, and efficient compressed air products. And, I’m happy to say, most of them I can even help with…even if the answer is “that’s just not gonna work.” Those are few and far between, however, and we can usually point someone in a better direction in those cases.

By the time we’ve “drilled down” into an application discussion far enough to make a product recommendation, we’ve got a pretty good feeling about it, and a vast majority of the time, our product solves the application in a big way. So big, in fact, that it makes them think of EXAIR again, and again.

Case in point: not long after I started here in 2011, I had the pleasure of helping someone out with some pick-and-place rigs on their packaging line…small products, bulk packaged for shipment to retail outlets. They used our Model 810003M E-Vac High Vacuum Generator and 900762 Small Round Vacuum Cups. Over the years, they’ve added some new products, and some more of the E-Vac pick-and-place rigs. It’s always good to hear from them, and I really believe the feeling is mutual.

EXAIR E-Vac Vacuum Generators provide a simple and reliable solution to pick-and-place applications.

Now, they want to automate a little clean-up operation where pilot holes are drilled in a plastic part, and are considering an intermittently operated vacuum. The concern is, if they use an electric powered one, the starting & stopping will take a toll on the motor. And they’re right.

So, the Model 6193-5 Mini Chip Vac System is up for consideration. Because it’s compressed air operated, constant starting & stopping is no problem…and, it’s generating vacuum immediately, so it’s ideal for quick bursts of cleanup suction action. No electric motor to burn out, no moving parts to wear – it’s a long term, maintenance-free solution.

Quiet and compact, the Mini Chip Vac is an ideal solution for a variety of industrial housekeeping needs.

If you’re an EXAIR engineered compressed air product user, I want to thank you for your business. If you’d like to discuss a particular compressed air product application (regardless of whether you’re a current user or not!) give me a call.

Russ Bowman
Application Engineer
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Many Ways to $ave on Compressed Air Costs

Using compressed air in the plant is common for many types of processes.  Typical uses are drying, cooling, cleaning and conveying. Compressed air does have a cost to consider, and there are many ways to keep the usage and the costs as low as possible.  The first step is to use an EXAIR Intelligent Compressed Air Product, which has been engineered to provide the most performance while using the least amount of compressed air. The next step is to control the use of the air, to only have it on when needed.

EXAIR offers the EFC – Electronic Flow Control.  It offers the most comprehensive method to maximize the efficiency of compressed air usage.  It combines a photoelectric sensor with a timing control that operates a solenoid valve to turn on and off the air as required. With 8 different program types, an on/off mode that works with any process can be programmed ensuring that the minimum amount of compressed air is used.  You can use the online EFC Savings Calculator to see how quickly the savings add up!

EFCp4

EFC – Electronic Flow Control

Another method would be to use a solenoid valve with some other method of control. Depending on the process, the solenoid could be energized via a machine control output, or as simple as an electrical push button station. EXAIR offers solenoid valves in a variety of flow rates (from 40 to 350 SCFM) and voltages (24 VDC, 120 VAC and 240 VAC) to match the air flow requirements of the products we provide, while integrating into the facility and available supply voltages.

For control of the Cabinet Cooler Systems, the ETC – Electronic Temperature Control, uses a thermocouple to measure cabinet temperature and cycle the system on and off to maintain a precise cabinet temperature, and provides a digital readout of the internal temperatures and on the fly adjustment.  Also available is the Thermostat Control models, which utilize an adjustable bimetallic thermostat to control the solenoid valve, also cycling the unit on and off as needed to maintain a set cabinet temperature.

ETC CC

ETC – Electronic Temperature Control

There are several manual methods that can be used to control the compressed air.  A simple valve can be used to turn the air off when not needed, whether at the end of the work day, at break time, or whenever the air isn’t required.  We offer several options, from a foot controlled valve, to a magnetic base with on/off valve, to a simple quarter turn ball valve.

footpedalvalve (2)dualstand (2) manual_valves (2)

 

To discuss your processes and how an EXAIR Intelligent Compressed Air Product can control the air supply and save you money, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Social Media Finds Lost Dogs, Helps Save Compressed Air

Lost Dog – Her name is Molly

 

The versatility of  social media is one of its greatest assets. If you have an interest in something you can most likely discover others with the same interests on one of the social media platforms. From Facebook, Twitter, blog posts, LinkedIn, Google+ and YouTube to Pinterest, Flickr, Instagram and Reddit – you will be hard pressed to NOT find something you are looking for.

The other day, we lost our dog, and it was a traumatic experience for us.  She saw some deer in the backyard; and in her crazed state, she knocked down the pet gate.  Molly went after the deer into the woods behind our place.  Being that it was raining and approaching the evening hour, I mentioned that when she gets done hunting, she will come back home.  We placed her bed and food onto the porch for when she returned.

The next day, Molly was not on the porch.  We were disheartened.  Being that I am a bit “old” school, we decided to print some flyers with Molly’s picture.  After I returned from work, we started in my neighborhood and worked our way out.  We drove to all the neighbors to see if they had seen her, and we stapled the flyers to telephone poles and community boards.  We were going at it for hours, and it seemed to be getting hopeless.  (Now, I would not have written this blog if it had a sad ending.)

As we continued to make our journey, I went up to a house and knocked on their door.  A gentleman answered, and I gave him the story of how our dog got out of her pen.  As I was still speaking, my significant other rolled down her window and shouted to me that she found Molly.  I was a little confused as I headed back to the vehicle.  She told me that a picture of Molly was on her Facebook.  (Of course Molly was making herself right at home as the picture showed her laying on a couch).  We were extremely happy that we had finally found her.  Apparently, a lady that found Molly posted her picture, and tagged her friends.  Her friends then sent it out to their friends, and before you knew it, we had her picture on Facebook.  With a friend request, we were able to receive her location and start our way to pick her up.  Believe it or not, Molly was over 2 miles away from our house.

Being curious, I looked at the timeline of the post.  I noticed that she posted the picture at 6:44 p.m., and we were looking at Molly at 7:28 p.m. that same day.  This was definitely much quicker and easier than hanging flyers and knocking on doors.  I was amazed at how fast and simple that this social networking reunited us with Molly.

This got me thinking about social media.  Facebook is the largest social network with almost 2 billion users throughout the world.  In looking at the nature of Facebook, it is more than reuniting with friends or finding lost dogs.  It also unites companies.  EXAIR has a Facebook page in which we post videos, photos, and blogs of compressed air solutions.  We can show you how to save money by using less compressed air with our products and how to solve every day problems with your compressed air system.  We would love to have you as a friend at www.facebook.com/exair.  We may not be able to find your dog, but we sure can share some stories, solve compressed air problems, and become good friends.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

 

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