Last week I wrote about the Thermostat Options for Smart Cooling utilizing the EXAIR Cabinet Cooler Systems. You can see read that blog post here. Today we will touch base on the Side Mount Kits as an option to expand the flexibility for the installation and operation.
Sometimes there isn’t room above an electrical panel to fit the Cabinet Cooler, even though it takes just 5″ to 7.25″ of space above. In these cases, the Side Mount Kit is available to handle any of the Cabinet Cooler sizes and NEMA ratings. EXAIR offers (6) models of Side Mount Kits –
Model 4909 – For NEMA 12 Cabinet Coolers up to 550 BTU.hr (139 Kcal/hr), Aluminum construction
Model 4910 – For NEMA 12 Cabinet Coolers , 650 BTU//hr (165 Kcal/hr) and higher, Aluminum construction
Model 4906 – For NEMA 4 and 4X Cabinet Coolers up to 550 BTU/hr (139 Kcal/hr), Type 303 Stainless Steel
Model 4907 – For NEMA 4 and 4X Cabinet Coolers, 650 BTU/hr (165 Kcal/hr) and higher, Type 303 Stainless Steel
Model 4906-316 – For NEMA 4 and 4X Cabinet Coolers up to 550 BTU/hr (139 Kcal/hr), Type 316 Stainless Steel
Model 4907-316 – For NEMA 4 and 4X Cabinet Coolers, 650 BTU/hr (165 Kcal/hr) and higher, Type 316 Stainless Steel
The NEMA 4 and 4X Cabinet Coolers must be mounted vertically for the unit to properly resist the ingress of liquids and maintain the integrity of the cabinet NEMA rating.
The Side Mount Kits install into a standard electrical knockout (1-1/2 NPS) for easy installation.
If you have any questions about the Side Mount Kits, Cabinet Coolers and/or Thermostat Options 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.
A few weeks ago, we posted a blog discussing how artificial demand and leaks can lead to poor performance and expensive waste. Today, I’d like to review how following a few simple steps can help optimize your current compressed air system and reduce compressed air usage.
The first step you want to consider is measuring the air usage in the system. To do this, you want to start at the compressor and check individual leads to each drop point to a blowoff device, record your findings to track the demand. By measuring your compressed air usage, you can locate the source of high usage areas and monitor the usage on each leg of the system. If the demand exceeds the supply, there is potential for problems to arise, such as lowered pressure and force from compressed air operated devices leading to irregular performance.
EXAIR’s Digital Flowmeters are designed to measure flow continuously and accurately to give you real-time flow measurements of your compressed air system to help identify problems areas.
Step 2 is to locate the source of waste. Again, compressed air leaks can result in a waste of up to 30% of a facility’s compressor output. A compressed air leak detection and repair program can save a facility this wasted air. Implementing such a program can be used as a way for a facility to “find” additional air compressor capacity for new projects. Whenever a leak occurs, it will generate an ultrasonic noise.
Our Ultrasonic Leak Detector is designed to locate the source of ultrasonic sound emissions up to 20’ away. These ultrasonic sound emissions are converted to a range that can be heard by humans. The sound is 32 times lower in frequency than the sound being received, making the inaudible leaks, audible through the included headphones and the LED display gives a visual representation of the leak.
The 3rd step involves finding the source of noisy and wasteful blowoffs, like open pipes or homemade blowoffs, and replacing them with an energy efficient, engineered solution. By replacing these devices, you are not only reducing the amount of waste but also improving operator safety by complying with OSHA safety requirements.
EXAIR’s Digital Sound Level Meter is an easy to use instrument that measures and monitors the sound level pressure in a wide variety of industrial environments. The source of loud noises can be quickly identified so that corrective measures can be taken to keep sound levels at or below OSHA maximum allowable exposure limits.
The easiest way to reduce compressed air usage and save on operating expense is to turn off the compressed air to a device when it isn’t needed, step 4 in the process. Not only will this save money, in many cases, it can also simplify a process for the operator.
A simple manual ball valve and a responsible operator can provide savings at every opportunity to shut down the air flow.
For automated solutions, a solenoid valve can be operated from a machine’s control. For example, if the machine is off, or a conveyor has stopped – close the solenoid valve and save the air.
A foot pedal valve offers a hands free solution to activate an air operated device only when needed, such as being implemented in an operator’s work station.
For even more control, you can use a device like our EFC or Electronic Flow Control. This helps minimize compressed air usage by incorporating a programmable timing controlled (0.10 seconds to 120 hours) photoelectric sensor to turn off the compressed air supply when there are no parts present. It is suited for NEMA 4 environments and can be easily wired for 100-240VAC.
Step 5, intermediate storage. Some applications require an intermittent demand for a high volume of compressed air. By installing a receiver tank near the point of high demand, there is an additional supply of compressed air available for a short duration. This will help eliminate fluctuations in pressure and volume.
EXAIR offers a 60 gallon, ASME approved vertical steel tank with mounting feet for easy installation near high demand processes.
Many pneumatic product manufacturers have a certain set of specifications regarding performance at stated input pressures. In many applications, or in the case of using a homemade blowoff device like open pipe, these wouldn’t necessarily require the full rated performance of the device or full line pressure. Controlling the air pressure at the point-of-use device will help to minimize air consumption and waste, step 6.
By simply installing a pressure regulator on the supply side, you can start off at a low pressure setting and increase the pressure until the desired result is achieved. Not only will this help to conserve energy by only using the amount of air required for the application, it also allows you to fine tune the performance of the point-of-use device to match the application requirements.
If you have any questions, please contact an application engineer at 800-903-9247.
I had the pleasure of speaking with the Maintenance Manager at a manufacturing plant for a global automotive supplier earlier this week. They have a whole factory floor full of machinery that operates from PLC controls. The space is not climate controlled, and the temperature broke 100°F the day before. This triggered some high temperature warnings on several control panels, but that was the worst thing that happened…luckily.
It should go without saying that the automotive industry is a big deal in the United States…maybe even a bigger deal here in the Middle Atlantic region, and a HUGE deal for those of us within a few hour’s drive of Detroit, Michigan…the home of the Big Three. Disruptions in their supply chains can affect not only the final production of automobiles, but also other suppliers, vendors, and service providers in separate “links” of that chain. So, if my caller has a breakdown and can’t ship parts, many other suppliers’ lines may be slowed or stopped, because if Detroit can’t make cars without one supplier’s parts right now, they won’t need the others’ parts right now either. That means reliability is paramount.
This is a “textbook” situation for EXAIR Cabinet Cooler Systems. They’re installed in minutes, have no moving parts, and require only a supply of compressed air for operation. If that air is clean & dry, they’ll operate darn near indefinitely, maintenance free. Thermostat Control turns them off & on as needed. I’ve talked to more than a few users who were (pleasantly) surprised when a Cabinet Cooler System activated on the first hot day in the spring, after not seeing it come on at all, after that last hot day near the end of the previous summer.
Back to the situation at hand – the Maintenance Manager had gathered Sizing Guide data for a couple of enclosures. You can submit it through our website, or email it in, but it only takes a minute; we do it over the phone all the time. So I did, and quoted the appropriate Cabinet Cooler Systems, which were ordered soon after. They were installed the next day, with a promise of more to come.
A company had a process where they were etching metal components with an acid bath. The system consisted of four baths where the metal parts would be dipped. The four baths consisted of a wash, rinse, acid bath, and rinse again. The automated system was contained inside an enclosed booth; and, once the parts were placed inside a 24” (610mm) X 18” (457mm) basket, a sliding door was closed to initiate the operation. The timing sequence consisted of the basket being dipped into each bath for a certain length of time. Between each bath cycle, the basket would be raised above the solution, and an open pipe blow-off would remove excess liquid from the part with compressed air. They complained that the parts were not getting dry enough, and cross-contamination was causing process problems. The acid bath was becoming more neutral and the effectiveness of the etching was being sacrificed. The rinse water was becoming more “soapy” after the cleaning bath and more acidic after the acid bath. Overall, they had to replace every one of the bath solutions which caused shut-downs and extra expense.
From similar applications, I was able to recommend a great solution. Because of the acidic solution and corrosive environment, I recommended two stainless steel Super Air Knives, model 110024SS. They are manufactured in 303 stainless steel. EXAIR also offers 316 stainless steel as well as PVDF for more acidic or caustic etching. Instead of using the open pipes to blow off the parts, the customer could replace them with the Super Air Knives. They can easily be mounted above the front and back of the basket, blowing at a downward angle toward the dip tank. The two Super Air Knives would remove the liquid solution from the parts as well as the basket to put back into the same dipping tank. The more solution that is removed, the less liquid that will transfer from one solution to the next; thus, reducing cross-contamination dramatically.
After installing the model 110024SS Super Air Knives in their system, they started to see a vast improvement in their etching process. The etching acid was able to be used roughly 40% longer as compared to the prior method. As an added feature, the Super Air Knives decreased the time to blow off the parts as they can be adjusted for optimum cleaning. Less waste and faster production times were how the EXAIR Super Air Knives helped the customer above. If you have a similar application and want to discuss how we can improve your dipping process, please speak to one of our Application Engineers. We’ll be happy to help.
EXAIR’s Air Wipes provide a 360° uniform, high velocity airflow that adheres to the outside surface of a round part, such as pipe, hose, cable, etc., as it passes through the throat or center of the device.
In this short video, we show how to change the shim inside of an Air Wipe, letting you achieve an increase or decrease in outlet flow and force while maintaining the same operating pressure.
If you have any questions, please contact an Application Engineer at 800-903-9247.
Across the United States, we are gearing up for our traditional observance of Memorial Day, on Monday. A good many of us will be fortunate to enjoy an extra day off…EXAIR employees included; we’re closed Monday, May 28, for the holiday.
In the temperate climate of the mid-Atlantic region where I live, there’s going to be a LOT of landscaping and gardening going on. Those with swimming pools will be starting the chemical balancing game that, with any luck, they’ll win before Labor Day. As for me, my rest & relaxation game will be strong for most of the weekend.
Monday, though, my family and I will join many others from our community at our township’s Memorial Day parade. My son plays in the local High School Marching Band, and they will be leading it out with a grand display of brass and winds and drums and color guard and patriotic musical selections. Volunteers from a vintage military aviation museum at our local airport will conduct a “fly-over” that never disappoints. Members of other civic-minded groups will likewise join the parade. And we’ll all take time to remember those who gave their lives in service to our nation.
Whatever your plans are for this weekend, I join the rest of the EXAIR team in wishing for you a perfect blend of rest, relaxation, productivity…and remembrance.
Several years prior we had a customer that was using a block-type Air Wipe from a competitor to remove water from an extrusion. These air wipes were built using materials similar to UHMW and the 2 halves were hinged with air holes drilled into it. They were using these block air wipes on several lines and decided to try an EXAIR Super Air Wipe after contacting our Application Engineers. The interesting point was that it required 5 block type air wipes to equal the efficiency of 1 EXAIRSuper Air Wipe.
Since one EXAIRSuper Air Wipe equaled the performance of 5 of the competitor’s products it consumed less air, was less expensive and produced less noise. Also in space sensitive applications the EXAIR Super Air Wipe is much thinner than the block type. To highlight this the Super Air Wipe is 1.13″ thick on all 11 models that range from 3/8″ to 11″ throat diameter.
Another clear advantage is performance. The block air wipe performance can only be changed by altering the inlet air pressure while the EXAIRSuper Air Wipe can also be changed by adjusting the inlet air pressure or changing the air gap of the Air Wipe. Simply by changing out an internal shim, the air gap will allow more or less volume of compressed air at a given pressure. By changing shims and adjusting pressure, EXAIR Super Air Wipes provide the flexibility which leads to a successful application across industry.
Compressed air flows through an inlet (1) of the Air Wipe into an annular chamber (2). It is then throttled through a small ring nozzle (3) at high velocity. This primary airstream adheres to the Coanda profile (4), which directs it down the angled surface of the Air Wipe. A low pressure area is created at the center (5) inducing a high volume flow of surrounding air into the primary airstream. As the airflow leaves the Air Wipe, it creates a conical 360° ring of air that attaches itself to the surface of the material running through it (6), uniformly wiping the entire surface with the high velocity airflow.