Optimize Your Intelligent Compressed Air® Products with EXAIR’s Accessories

EXAIR offers a wide variety of various accessories that can help you to better control and fine-tune any of your compressed air operated products. Most of EXAIR’s line of Intelligent Compressed Air Products have no moving parts and require no maintenance. The caveat to the “no maintenance” aspect is proper filtration at the point of use. Many products have very tight orifices that could get clogged from any contaminants such as particulate, condensate, and lubricant. EXAIR recommends point of use filtration to be installed just upstream of any EXAIR Product for this purpose.

EXAIR has a line of Automatic Drain Filter Separators and Oil Removal Filters, available from stock, to make sure the quality of your air supply is sufficient for proper operation of any EXAIR product. Particulate filters remove any suspended solids from the airstream, ensuring the tight orifices in the products remain free of debris. If your system has residual oil, this should also be removed with a coalescing filter. Check out this short video from my colleague, Brian Farno, that demonstrates these filters in action:

Controlling your compressed air pressure at the point of use is an excellent way of minimizing your compressed air usage. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air at the point of use can often be overlooked. using them to minimize your pressure can result in dramatic savings to your costs of compressed air. As pressure and flow are directly related, lowering the pressure supplied results in less compressed air usage. EXAIR recommends operating your Intelligent Compressed Air Products at the minimum pressure necessary to achieve a successful application. If you notice a desirable result at a pressure of 60 PSIG, or even less, there’s no need to run full line pressure. In-line point of use pressure regulators are the simplest and most reliable way to allow you to dial down to the pressure to any compressed air operated product.

Taking this idea of minimizing air usage one step further, you can achieve even greater savings by simply turning the air off when not needed. The most basic option for turning off the air supply is a simple manual valve. EXAIR offers a range of various sized valves to allow you to do just that.

This process can also be automated as well. If you’d like to automate the control of your blowoff, EXAIR offers solenoid valves that can tie into your existing PLC and eliminate unnecessary air usage. For those that want a solution ready to go right out of the box, EXAIR’s Electronic Flow Controller utilizes a photoelectric sensor and solenoid valve tied to a timer that allows you to shut off the air supply when a part or component is not present. This can lead to dramatic air savings in many applications where parts are traveling along a conveyor.

Once you’ve selected an engineered compressed air nozzle for your blow off application, you’ll likely need a solution to mount and position it as well. Here’s where EXAIR’s Stay Set Hoses and Magnetic Bases come into play. EXAIR’s Stay Set Hoses are available from 6”-36” in length with ¼ NPT male threads on each end, or a ¼ NPT male on one end and 1/8 NPT female on the other. The Stay Set Hoses are rigid and allow you to maintain precise positioning of the blow off nozzle. The hoses have “memory” and will not creep or bend. They’re easily repositionable as well, making them an ideal solution for applications that may require frequent repositioning due to varying parts.

In addition to the Stay Set Hoses, EXAIR also has Magnetic Bases available as well. The powerful magnet permits both horizontal and vertical mounting. A manual valve is also included that will allow you to vary the force and flow. Magnetic bases are available with one or two outlets and can be combined with any of our nozzles and Stay Set Hoses to create your own customized blowoff system.

Regardless of your application, EXAIR has the products available from stock to help optimize your processes. These accessories allow you to help optimize the use of your blowoff products and ensure reliable, repeatable performance. If you’d like to discuss an application, give us a call.

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

O-Rings, Seals, Gaskets, Maintenace, Filtration – They All Matter

I’ve mentioned it before and I’ll say it again. You can’t teach experience. This was told to me by a mentor at a previous job and of course, younger me thought, “Yeah, yeah I know all I need to know.”  Well, younger me was an idiot and learned many things through experience. Sometimes I am still a slow learner and eventually, I remember those experiences and make decisions based on them. So what does this have to do with o-rings, seals, and gaskets?

I’m in the midst of a light construction project in my house and have reached a stage where some tools that I do not have would come in handy and make the job faster. Younger me would have justified purchasing a new one, experienced me understands a budget and reached out to my network of friends and a good friend said they had the tool I needed. This was a compressed air powered framing nail gun. Straight through nailing, no-problem, toe-nailing, no-problem, this thing won’t break a sweat and your arms will be stronger by the time you are done using it while your thumbs are screaming thank you for not smashing me a hundred times.

The Framing Nail Gun in question

This loan did come with two conditions, one was, he didn’t have any nails to give with it. This was not a problem as I wouldn’t expect a friend to give me free fasteners with a tool loan. The second is the one that concerned me, he said, it does leak a little air but it should still shoot just fine. After working in the compressed air industry for over a decade I have experienced this many times. At that point I knew if you could hear it, chances were it was a bad leak. Upon further inspection, there was a cylinder gasket and rubber spring that were in pieces.

Old Spring Bumper and Main Cylinder Gasket

Gasket pieces and dirty air can result in catastrophic failures.

Nothing that a trip to a local business couldn’t take care of.  A few new parts and discussion with their knowledgeable staff and I had the information needed to rebuild this nail gun to functioning status.

New vs. Old

Oddly enough, my experience and expertise with how the EXAIR products like the No-Drip Air Atomizing Liquid Spray Nozzles operate and how to rebuild them, provided a good foundation about how this tool worked. This repair ended up being very similar to the rebuild on a No-Drip Spray Nozzle.

This story is two-fold, filtration could have prevented a lot of the damage to this gun. This gun uses a good amount of air volume at an expedient pace so keeping it clean and clear of debris helps extend the lifetime of internal parts.  See my video on what happens without filtration below.

The second part is that maintaining and understanding processes to clean/rebuild are crucial to sustainable function of a machine. The cleaning process for this gun was fairly straightforward and using the correct lubricant for reassembly was another critical role. This culminated in a framing nail gun that can now be used to further my project and will more than likely live another decade before needing a rebuild again. That is if filtration and proper lubrication are followed.

Had I not obtained experiences throughout my career that helped me to understand how this tool functioned, the worth of a reliable network of vendors, and the necessity to complete tasks that take me out of my comfort zone I wouldn’t be in the place I am today. Because I have the experience and the network to ask for help it enables me to keep machines running that could have cost valuable production hours had this been a production environment.

EXAIR stocks rebuild kits, gaskets, shims, and parts for all of our product lines which may require a repair. For products which need to be cleaned in order to return back to new performance, we have the instructions or can do it for you here. From time to time they may need a repair or refurb in order to keep functioning at peak performance. If you want to build your trusted network or learn more about how to rebuild or clean EXAIR products, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Comparing the Different Styles of Compressed Air Filters

Most of EXAIR’s line of Intelligent Compressed Air Products have no moving parts and require no maintenance. The caveat to the “no maintenance” aspect is proper filtration at the point of use. Many products have very tight orifices that could get clogged from any contaminants such as particulate, condensate, and lubricant. EXAIR recommends point of use filtration to be installed just upstream of any EXAIR Product for this purpose.

There are three primary types of compressed air filters: particulate, coalescing, and adsorption. Each have their own inherent characteristics and can be used in conjunction with one another. Each style is used to handle a different form of contaminant that’s present within the distribution system of your compressed air supply.

9001
EXAIR Model 9001 Auto-Drain Filter

Particulate filters – Particulate filters are available with different filtering mechanisms that allow you to control the particulate size that will be filtered out. The higher the level of filtration, the greater the pressure drop you’ll experience at the outlet of the filter. Styles are also available with either a polycarbonate bowl or metal bowls, depending on the application and environment.

Any filter with a polycarbonate bowl should have a metal guard on the outside to provide protection for personnel should a failure occur. In these styles of filters, compressed air is forced through a filter element that blocks any particulate contained within the air supply.

These filter elements are generally a sintered bronze material with filtration levels from 40-5 micron possible. Over time, the filter elements can clog and increase the pressure drop at the discharge of the filter. They’re relatively inexpensive and should be replaced yearly to maintain optimum performance and mitigate pressure drop. They also remove liquid drops as well from the air supply, containing them within the bowl. Styles with both manual-drains and automatic-drains are available that will drain the bowl of excess moisture automatically through the bottom of the filter.

9005
EXAIR Model 9005 Oil Removal Filter

Coalescing Filters – The coalescing filter is used to remove very fine water vapor as well as any residual oil. These filters are highly recommended to be installed just prior to any dryer that contains a media that would be compromised by any lubricant passing through it. Coalescing filters utilize an element typically made up of glass fibers that “coalesce”, or combine, the fine water vapor and oil aerosols until the droplet size becomes large enough that it drops off into the bowl or filter housing. With a coalescing filter, the most common cause of pressure drop increase is due to particulate clogging the filter element. Because of this, a particulate filter should always be installed just prior to any coalescing filters.

Adsorption Filters – The final type of compressed air filter is the adsorption filter. Where the particulate filters can remove the majority of contaminants and the coalescing filters the residual oil, they are not capable of removing lubricant vapors or oil. That’s where the adsorption filter comes in. In addition to removing the finest oil vapors, they also can eliminate odors from the compressed air supply. The oil vapors and odors adhere to activated carbon within the filter, removing them from the air supply. These filters are commonly found within the food processing industry, where any contaminants in the air supply could impact the integrity of the product.

EXAIR has a line of Automatic Drain Filter Separators and Oil Removal Filters, available from stock, to make sure the quality of your air supply is sufficient for proper operation of any EXAIR product. Feel free to give us a call and any of our Application Engineers will be happy to assist you.

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

What’s The Big Deal About Clean Air?

Compressed air isn’t called manufacturing’s “Fourth Utility” (the first three being electricity, water, and natural gas) for nothing. Pneumatic tools are popular because they’re often so much lighter than their electric counterparts. Compressed air can be stored in receiver tanks for use when other power supplies are unavailable or not feasible. Many compressed air operated products can be made to withstand environmental factors (high/low temperature, corrosive elements, atmospheric dust, oil, other contaminants, etc.,) that would make electric devices very expensive, unwieldy, or impractical.

One of the most valuable considerations, though, is that your compressed air system is, by and large, under your control.  The type and capacity of your air compressor can be determined by your specific operational needs.  The header pressure in your supply lines is based on the applications that your air-operated devices are used for.  And the performance & lifespan of every single component in your compressed air system is determined by the care you take in maintaining it.

I covered the importance of compressed air system maintenance in a blog a while back…today, I want to focus on clean air.  And, like the title (hopefully) makes you think, it’s a REALLY big deal.  Consider the effects of the following:

Debris: solid particulates can enter your air system through the compressor intake, during maintenance, or if lines are undone and remade.  If you have moisture in your air (more on that in a minute,) that can promote corrosion inside your pipes, and rust can flake off in there.  Almost all of your air operated products have moving parts, tight passages, or both…debris is just plain bad for them.  And if you use air for blow off (cleaning, drying, etc.,) keep in mind that anything in your compressed air system will almost certainly get on your product.

Your compressed air system may be equipped with a main filter at the compressor discharge.  This is fine, but since there is indeed potential for downstream ingress (as mentioned above,) point-of-use filtration is good engineering practice.  EXAIR recommends particulate filtration to 5 microns for most of our products.

Water: moisture is almost always a product of condensation, but it can also be introduced through faulty maintenance, or by failure of the compressor’s drying or cooling systems.  Any way it happens, it’s also easy to combat with point-of-use filtration.

EXAIR includes an Automatic Drain Filter Separator in our product kits to address both of these concerns.  A particulate filter element traps solids, and a centrifugal element “spins” any moisture out, collecting it in the bowl, which is periodically drained (automatically, as the name implies) by a float.

Point of use filtration is key to the performance of your compressed air products, and their effectiveness. Regardless of your application, EXAIR has Filter Separators to meet most any need.

Oil: many pneumatic tools require oil for proper operation, so, instead of removing it, there’s going to be a dedicated lubricator, putting oil in the air on purpose.  Optimally, this will be as close to the tool as possible, because not all of your compressed air loads need oil…especially your blow offs.  If, however, a blow off device is installed downstream of a lubricator (perhaps due to convenience or necessity,) you’ll want to do something about that oil. Remember, anything in your system will get blown onto your product.

If this is the case, or you just want to have the cleanest air possible (keep in mind there is no downside to that,) consider an EXAIR Oil Removal Filter.  They come in a range of capacities, up to 310 SCFM (8,773 SLPM,) and the coalescing element also offers additional particulate filtration to 0.03 microns.

In closing, here’s a video that shows you, up close and personal, the difference that proper filtration can make:

If you’d like to discuss or debate (spoiler alert: I’ll win) the importance of clean air, and how EXAIR can help, give me a call.

Russ Bowman
Application Engineer
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