1004SS Back Blow Air Nozzle Clean Inside Small Diameters

Model: 1004SS

A metal fabricator made stainless steel tubes with a ½” (13mm) inner diameter.  Their process started by cutting the tubes into 8” (203mm) lengths.  The tubes would go through a wash system, then to a honing machine.   Once the inner diameter was honed to the specific diameter and concentricity, the tubes would be washed again for packaging.  The honing machine used oil to accurately grind the inner diameter.  Since oil and water does not mix, they had to dry the I.D. before honing.  They contacted EXAIR to see if we could find a solution.

Back Blow Air Nozzle Family

For cleaning the I.D. of parts, EXAIR manufactures three different sizes of Back Blow Air Nozzles that are designed to clean inside tubing, pipes, hoses, and channels.  They can range from internal diameters from ¼” (6.3mm) up to 16” (406mm).  The 360o rear airflow pattern can “wipe” the entire internal surface without contacting the surface to remove water, coolant, chips, and debris.  In reviewing the inner diameter above, I was able to recommend a model 1004SS Back Blow Air Nozzle.  This 316SS robust designed nozzle can fit inside and clean tubes with internal dimensions ranging from ¼” (6.3mm) to 1” (25mm); perfect for the ½” (13mm) diameter tube.

Model: 1604SS-12-CS

The customer indicated to me that there was a rush to start this project.  EXAIR stocks thousands of cataloged items for same day shipping.  He asked if EXAIR had any other components to help them to expedite their drying process.  Well, of course we do!  Since the tube was 8” (203mm) long, EXAIR has extension tubes that are used with our VariBlast Compact Back Blow Safety Air Gun.  We have them ranging from 6” (152mm) to 72” (1829mm) in incremental lengths.  For this customer, I recommended the 12” (305mm) extension to reach through the tube.  And, since it was a manual operation, I also recommended the model 9040 Foot Valve.

Model 9040 Foot Valve

Their operator could place the tube over the model 1004SS Back Blow Nozzle and with the Foot Valve, turn on the compressed air to dry the tubes.  With the powerful air stream, the entire internal surface was dry for the honing process to follow.

If you need to clean the inside of tubes, hoses, pipes, etc., EXAIR has the perfect nozzles for you, the Back Blow Air Nozzles.  EXAIR can attach these nozzles to our VariBlast Compact, Soft Grip and Heavy Duty Safety Air Guns for easy-to-use operations.  For this customer above, they were able to use components to get the operation running the next day.  If you need more information, you can share your application with an Application Engineer at EXAIR.  We will be happy to help.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Accessories, Don’t Forget About Accessories!

Accessories

I went to the auto parts store to replace my brakes on my vehicle.  They asked me if I needed some Anti-squeak grease for my brake hardware.  It made me think about the accessories that EXAIR sells.  I could have used my own kind of grease which may not be able to hold up to the heat, but for a few dollars more, I wanted to go with the item that the experts would suggest.

In this blog, I would like to turn your attention to the accessories that support our Intelligent Compressed Air® Products.  EXAIR products use compressed air to coat, conserve, cool, convey and clean.  To maximize the performance and/or ease installation it is important to have the controls and options, and EXAIR offers these items as Accessories.

Pneumatic applications come in many variations and forms, and Accessories can help you to adapt to your application and to remove “guess work”.  They can make installation easier, add flexibility, and give you peace of mind.

Here are the different categories and explanations for each item that EXAIR recommends for our products with their defined functions.  They can help you in different areas to enhance your EXAIR product experience.

Automatic Drain Filter Separator (left,) and a Pressure Regulator (right.) Oil Removal Filters (optional; center) are also available if needed.

Filters/Regulators:

  • Filter Separators remove bulk liquid and contamination from the compressed air stream. EXAIR stocks a range of sizes from ¼” NPT ports to 1 ¼” NPT ports.  They use a 5-micron filter and a mechanical baffle to remove slugs of liquid from your compressed air system.  Most Filter Separators have an auto-drain to automatically remove the buildup of liquid inside the bowl.   I would consider the Filter Separator as a minimum level of protection required to protect your EXAIR product installations.
  • Oil Removal Filters remove very small particles of dirt and oil from the compressed air; making it even cleaner. The 0.03-micron media of the Oil Removal Filter will “coalesce” the fine liquid particles into large droplets.  Thus, allowing gravity to remove oil vapor from the compressed air stream.  EXAIR offers different sizes ranging from ¼” NPT to 1 ½” NPT ports.  As a note, Oil Removal Filters are great for removing very fine particles, but if you have a system with lots of water, I would recommend a Filter Separator upstream of the Oil Removal Filter for optimal filtration.
  • Regulators control the amount of air pressure being supplied to your EXAIR product. This is important if you are trying to save compressed air, control the force produced by an Air Knife, or convey material slowly.  EXAIR, being a leader in compressed air savings, recommends to use the minimum amount of air pressure to do the job.  This will save compressed air and save you money.  Regulators have a characteristic called “droop”.  Droop is the amount of air pressure that it drops downstream when you start flowing compressed air.  If the regulator is not sized properly, you can “starve” your pneumatic components, causing loss of function.  EXAIR properly sizes our regulators in our kits to make sure that you won’t “starve” your application.
  • Mounting Brackets for the regulators and the filters to help support them to a wall or structure are available. To connect filters and regulators together without a pipe nipple, we also have Coupling Kits for sizes up to ¾” NPT.  And for combination kits which includes a filter and a regulator, we offer the Mounting Bracket and Coupling Kit together for a set.

Silencing Mufflers:

  • Reclassifying Mufflers are designed to have two functions. They can cut noise levels by 35 dB and remove oil mist from the exhaust air.  Cylinders and valves that exhaust pressurized air may have oil in the line to keep the seals from sticking.  When exhausted, it can create a fine mist which is dangerous for operators.  The Reclassifying Mufflers can reduce the loud noise as well as collect any contamination from the exhaust air.
  • Sintered Bronze Mufflers are simple in design, cost effective, and easy to install. They have a minimal back pressure to not restrict operations of the pneumatic device.  They come in sizes from #10-32 thread to 1-1/2 NPT.  For a quick and simple way to reduce noise, the Sintered Bronze Mufflers are in stock for fast delivery.
  • Straight-Through Mufflers offer a way to reduce noise levels without worrying about clogging. They have an aluminum shell lined with sound absorbing foam, and they can reduce the noise level by 20 dB.  EXAIR offers them with two ports from ¼” NPT to ¾” NPT.  This can allow you to connect other items like blowing hose kits while reducing noise.
  • Heavy Duty Mufflers have an outer aluminum shell with an internal stainless steel screen that can protect the components from environmental contamination, and can also keep contaminant like rust from being ejected at high speed into the work area. They have a typical noise reduction of 14 dB.

Pneumatic Valves:

  • Manual Valves allow for operators to turn on and off their system by hand. The full-flow ball valves range from ¼” NPT to 1 1/4” NPT in size and will not restrict flow.  EXAIR also offers a manual foot pedal valve for hands-free operations.  This ¼” NPT foot valve has a 3-way operation and works great if the operator has to use both hands in their process.
  • Solenoid Valves are a way to turn on and off the supply of compressed air electrically for automated systems. We offer solenoids in three different voltages; 110Vac, 240Vac, and 24Vdc.  EXAIR has a large range of flows with ports ranging from ¼” NPT to 1” NPT.  All models are UL listed and are CE and RoHS compliant.

Hardware:

EXAIR’s Swivel Fitting Family
  • Swivel Fittings are a great way to securely install and aim EXAIR nozzles. They are dynamic as they can be adjusted and set to a flow direction with 50-degrees of movement.  They are made from 303SS or 316SS for corrosion resistance with ports ranging from 4mm to 1” NPT.
  • Compressed Air Fittings are a nice arrangement to connect different compressed air items together. We offer a range of hex and close nipples, couplings, reducers, tees, elbows, crosses and bulk head fittings.  If you need a quick way to connect directly to your pneumatic system, we may have it on the shelf.

    Model 9043
  • Magnetic Bases are designed for a solid mount to steel surfaces and for easy portability of your blow-off system to different locations. It has a 100 lb. (45.5Kg) pulling force to keep the blowing device attached firmly until you want to move it.  They can be mounted in a vertical or horizontal position.  EXAIR offers a single outlet Magnetic Base (for one blow-off device); a dual outlet Magnetic Base (for multiple blowing products); and a single outlet Swivel Magnetic Base (to offer more flexibility to orientation).  The bases come with a ¼ turn shut-off valve to easily turn on and off the compressed air to the EXAIR products.
  • Receiver Tanks are used to store compressed air. They can be used at the air compressor or as secondary reservoirs for intermittent demand.  They help your compressed air system with pressure variations and high demand loads.  EXAIR offers a model 9500-60 Receiver Tank that has a 60 gallon capacity and is rated to 200 PSIG.  It meets the ASME pressure vessel code.

    Universal Air Mounting Kit
  • Universal Air Knife Mounting System gives you a way to mount the EXAIR Super Air Knife, Full-Flow Air Knife, and Standard Air Knife. This kit is used to position your air knife securely and precisely.  It comes with a bracket and an articulated arm that can reach up to 30” (762mm).  You can orientate the air knives in any position to maximize the effectiveness.

    Plumbing Kits
  • Plumbing Kit, or PKI, is a great tool for longer Super Air Knives to help attach your compressed air system. They are designed to help lessen the time for install as well as to properly supply compressed air equally along the entire length, specifically for 24” (610mm) and longer.  We can offer the Plumbing Kit separately if you find that it could benefit your fabricators during installation.
  • Coupling Kits are designed to attach Aluminum and Stainless Steel Super Air Knives if you need to extend past the 108” (2,743 mm) width. Coupling Kits will mount the air knives together end to end.

Hoses:

  • Conveying Hoses are used with our Air Operated Conveyors or Line Vacs. The hoses are made from a durable PVC semi-flexible hose with six different diameters from ¾” I.D. up to 3” I.D.  The conveyance hoses can slip easily to the ends of the Line Vacs or to tubes for an easy transition.  EXAIR can cut-to-length Conveying Hoses up to 50 feet (15m); in increments of 10 feet (3m).
  • Coiled Hoses get compressed air from the piping system to the EXAIR product. They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters).  They have swivel fittings at the end to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking.  The coiled design makes it easy to reach around the work area and retract back to the substation.  This will help to keep the hose off the ground where potential dangers could occur.  We offer 3 different connection sizes; 1/8” NPT, ¼” NPT, and 3/8” NPT.
  • Compressed Air Hoses is another way to supply EXAIR products. They are useful if you need to reach from overhead sources or around equipment.   They are made from a reinforced synthetic rubber in 3/8” I.D. and 1/2” I.D. diameters.  We can make specific lengths up to 50 feet (15m).  They are rated for 250 PSIG (17 bar) air pressure, and the hose material works well for long-lasting protection against ozone, weathering and temperatures up to 158oF (70oC).  They come standard with two male ends in ¼” NPT or ½” NPT.
  • Stay Set Hoses give you that possibility of manually adjusting or re-adjusting Super Air Nozzles. The hose has a “memory” function; so, it will not creep or droop until you physically move it.  They work well to direct air flows in unique ways at specific target areas.  They can be used with Super Air Nozzles, Safety Air Guns and Blow-off Kits.  The Stay Set Hoses come in lengths from 6” (15cm) to 36” (91cm), and they are offered with ¼” NPT male on both ends or with a 1/8” NPT female and a ¼” NPT male connections.  These hoses are rated for 250 PSIG (17 bar) and are made from reinforced synthetic rubber.

Temperature Accessories:

  • The ETC, or Electronic Temperature Control, is a digital temperature controller with a LED screen for precision monitoring and adjusting temperatures in a Cabinet Cooler System. The controller has easy-to-use buttons to raise or lower the desired internal cabinet temperature.  Once set, the ETC will hold the temperature to +/- 1 oF (+/- 0.5 oC).  The LED displays the internal temperature for continuous monitoring.  The ETC comes complete with the controller and a solenoid valve in two different voltages, 120Vac and 240Vac.
  • The thermostat is a way to control a solenoid valve electrically to turn on/off a Cabinet Cooler System at a set temperature. It is preset at 95°F (35°C), but it can be adjusted to other desired temperatures.  It has an accuracy to hold the set temperature within +/- 2 °F (1 °C).  It can handle voltages from 24V to 240V, AC (50/60 Hz) or DC.  They are UL Recognized and CSA certified.

In today’s fast-paced world, there is a need to get your devices operating correctly and as quickly as possible.  EXAIR Accessories can do that.  Not only will you have confidence, as you are using the items recommended by the EXAIR experts, but you won’t have to worry about your system “squeaking” to a halt.  Like with my brakes above; I was happy to use the recommended grease to end any annoyance with my braking.  If you would like to discuss the proper options with your EXAIR products, an Application Engineer will be happy to help you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Compressed Air Accessories for Clean Air, Quiet Air, and Adjustability

In this blog, I would like to turn your attention to our accessories that support our Intelligent Compressed Air® Products.  EXAIR products use compressed air to coat, conserve, cool, convey and clean.  To maximize the performance, it is important to have the controls and options to increase their “flexibility”.  EXAIR offers these items as Accessories.  Pneumatic applications come in many variations and forms, and Accessories can help you to adapt to your application and to remove any “guess work”.

Here are the different categories and explanations of each item that EXAIR recommends for our products.  With their defined functions, they can help you in different areas to enhance your pneumatic experience.

Filters/Regulators:

  • Filter Separators remove bulk liquid and contamination from the compressed air stream. EXAIR stocks a range of sizes from ¼” NPT ports to 1 ¼” NPT ports.  They use a 5-micron filter and a mechanical baffle to remove slugs of liquid from your compressed air system.  Most Filter Separators have an auto-drain to automatically remove the buildup of liquid inside the bowl.   I would consider the Filter Separator as a minimum level of protection required to protect your EXAIR products.
  • The Oil Removal Filters remove very small particles of dirt and oil from the compressed air; making it even cleaner. The 0.03-micron media of the Oil Removal Filter will “coalesce” the fine liquid particles into large droplets.  Thus, allowing gravity to remove it from the compressed air stream.  EXAIR offers different sizes ranging from ¼” NPT to 1 ½” NPT ports.  As a note, Oil Removal Filters are great for removing very fine particles, but if you have a system with lots of water, I would recommend a Filter Separator upstream of the Oil Removal Filter for optimal filtration.
  • Pressure Regulators control the amount of air pressure being supplied to your EXAIR products. This is important if you are trying to save compressed air, control the force, or convey material.  EXAIR, being a leader in compressed air savings, recommends to use the minimum amount of air pressure to do the job.  This will save compressed air and save you money.  Regulators have a characteristic called “droop”.  Droop is the amount of air pressure that it drops downstream when you start flowing compressed air.  If the regulator is not sized properly, you can “starve” your pneumatic component, causing loss of function.  EXAIR properly sizes our regulators in our kits to make sure that you won’t “starve” our product.
  • EXAIR also offers Mounting Brackets for the regulators and the filters to help support them to a wall or structure. To connect filters and regulators together without a pipe nipple, we also have Coupling Kits for sizes up to ¾” NPT.  And for combination kits which includes a filter and a regulator, we offer the Mounting Bracket and Coupling Kit together for a set.

Silencing Mufflers:

  • Reclassifying Mufflers are designed to have two functions. They can reduce noise levels by 35 dB and remove oil mist from the exhaust air.  Cylinders and valves that exhaust pressurized air may have oil in the line to keep the seals from sticking.  When exhausted, it can create a fine mist which is dangerous for operators.  The Reclassifying Mufflers can reduce the loud noise as well as collect any contamination from the exhaust air.
  • Sintered Bronze Mufflers are simple in design, cost effective, and easy to install. They have a minimal back pressure to not restrict operations of the pneumatic device.  They come in sizes from #10-32 thread to 1-1/2 NPT.  For a quick and simple way to reduce noise, the Sintered Bronze Mufflers are in stock for fast delivery.
  • Straight-Through Mufflers offer a way to reduce noise levels without worrying about clogging. They have an aluminum shell lined with sound absorbing foam, and they can reduce the noise level by 20 dB.  EXAIR offers them with two ports from ¼” NPT to ¾” NPT.  This can allow you to connect other items like blowing hose kits while reducing noise.
  • Heavy Duty Mufflers have an outer aluminum shell with an internal stainless steel screen that can protect the components from environmental contamination, and can also keep contaminant like rust from being ejected at high speed into the work area. They have a typical noise reduction of 14 dB.

Pneumatic Valves:

  • Manual Valves allow for operators to turn on and off their system by hand. The full-flow ball valves range from ¼” NPT to 1 1/4” NPT in size and will not restrict flow.  EXAIR also offers a manual foot pedal valve for hands-free operations.  This ¼” NPT Foot Valve has a 3-way operation and works great if the operator has to use both hands in their process.
  • Solenoid Valves are a way to turn on and off the supply of compressed air electrically for automated systems. We offer solenoids in three different voltages; 110Vac, 240Vac, and 24Vdc.  EXAIR has a large range of flows with ports ranging from ¼” NPT to 1” NPT.  All models are UL listed and are CE and RoHS compliant.

Hardware:

  • Swivel Fittings are a great way to securely install and aim EXAIR nozzles. They are dynamic as they can be adjusted and set to a flow direction with 50-degrees of movement.  They are made from 303SS or 316SS for corrosion resistance with ports ranging from 4mm to 1” NPT.
  • Compressed Air Fittings are a nice arrangement to connect different compressed air items together. We offer a range of hex and close nipples, couplings, reducers, tees, elbows, crosses and bulk head fittings.  If you need a quick way to connect directly to your pneumatic system, we may have it on the shelf.
  • Magnetic Bases are designed for a solid mount to steel surfaces and for easy portability of your blow-off system to different locations. It has a 100 lb. (45.5Kg) pulling force to keep the blowing device attached firmly until you want to move it.  They can be mounted in a vertical or horizontal position.  EXAIR offers a single outlet Magnetic Base (for one blow-off device); a dual outlet Magnetic Base (for multiple blowing products); and a single outlet Swivel Magnetic Base (to offer more flexibility to orientation).  The bases come with a ¼ turn shut-off valve to easily turn on and off the compressed air to the EXAIR products.
  • Receiver Tanks are used to store compressed air. They can be used at the air compressor or as secondary reservoirs for intermittent demand.  They help your compressed air system with pressure variations and high demand loads.  EXAIR offers a model 9500-60 Receiver Tank that has a capacity of 60 gallons, is rated to 200 psig, and meets ASME pressure vessel code.

 

Hoses:

  • Conveying Hoses are used with our Air Operated Conveyors or Line Vacs. The hoses are made from a durable PVC semi-flexible hose with six different diameters from ¾” I.D. up to 3” I.D.  The conveyance hoses can slip easily to the ends of the Line Vacs or to tubes for an easy transition.  EXAIR can cut-to-length Conveying Hoses up to 50 feet (15m); in increments of 10 feet (3m).
  • Coiled Hoses get compressed air from the piping system to the EXAIR product. They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters).  They have swivel fittings at the end to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking.  The coiled design makes it easy to reach around the work area and retract back to the substation.  This will help to keep the hose off the ground where potential dangers could occur.  We offer 3 different connection sizes; 1/8” NPT, ¼” NPT, and 3/8” NPT.
  • Compressed Air Hoses is another way to supply EXAIR products. They are useful if you need to reach from overhead sources or around equipment.   They are made from a reinforced synthetic rubber in 3/8” I.D. and 1/2” I.D. diameters.  We can make specific lengths up to 50 feet (15m).  They are rated for 250 PSIG (17 bar) air pressure, and the hose material works well for long-lasting protection against ozone, weathering and temperatures up to 158oF (70oC).  They come standard with two male ends in ¼” NPT or ½” NPT.

    Flexible and durable, EXAIR Stay Set Hoses come in lengths from 6″ to 36″.
  • Stay Set Hoses give you that possibility of manually adjusting or re-adjusting Super Air Nozzles. The hose has a “memory” function; so, it will not creep or droop until you physically move it.  They work well to direct air flows in unique ways at specific target areas.  They can be used with Super Air Nozzles, Safety Air Guns and Blow-off Kits.  The Stay Set Hoses come in lengths from 6” (15cm) to 36” (91cm), and they are offered with ¼” NPT male on both ends or with a 1/8” NPT female and a ¼” NPT male connections.  These hoses are rated for 250 PSIG (17 bar) and are made from reinforced synthetic rubber.

Temperature Accessories:

  • The ETC, or Electronic Temperature Control, is a digital temperature controller with a LED screen for precision monitoring and adjusting temperatures in a Cabinet Cooler System. The controller has easy-to-use buttons to raise or lower the desired internal cabinet temperature.  Once set, the ETC will hold the temperature to +/- 1 oF (+/- 0.5 oC).  The LED displays the internal temperature for continuous monitoring.  The ETC comes complete with the controller and a solenoid valve in two different voltages, 120Vac and 240Vac.
  • The thermostat is a way to control a solenoid valve electrically to turn on/off a Cabinet Cooler System at a set temperature. It is preset at 95°F (35°C), but it can be adjusted to other desired temperatures.  It has an accuracy to hold the set temperature within +/- 2 °F (1 °C).  It can handle voltages from 24V to 240V, AC (50/60 Hz) or DC.  They are UL Recognized and CSA certified.

In todays fast-paced world, there is a need to get your devices operating as quickly as possible.  With EXAIR Accessories, they can help you to do that.  Not only will you have confidence, as you are using the items from the manufacturer, but it will minimize downtime, setup, and malfunctions that can occur if using other types of accessories.  If you would like to discuss the proper options with your EXAIR products, an Application Engineer will be happy to help you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Optimizing Your Current Compressed Air System Is Simple

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.

Digital Flowmeter with wireless capability

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.

Model # 9061 Ultrasonic Leak Detector

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.

Model # 9104 Digital Sound Level Meter

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.

 

Sizes from 1/4″ NPT up to 1-1/4″ NPT are available

A simple manual ball valve and a responsible operator can provide savings at every opportunity to shut down the air flow.

 

120VAC, 240VAC or 24VDC

 

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.

 

 

Model # 9040 Foot Valve

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.

 

EFC – Electronic Flow Control

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.

Model # 9500-60

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.

Pressure Regulators permit easy selection of the operating pressure

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.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

EXAIR Accessories – We’ve Got you Covered

When you work with us here at EXAIR, we strive to have all the ancillary items that you might need to make your installation a success, without having to find components at the last minute or perhaps using the wrong sized components. Each specific product line such as Super Air Knives or Line Vac air operated conveyors have specific accessories such as mounting brackets or plumbing kits which EXAIR has made to simplify the installation of those particular products. We also carry generalized accessories which work across all of the product lines so you do not have to use multiple vendors or purchase orders.

Silencing Mufflers – Per OSHA Standard 1910.95(a), a worker must not be exposed to sounds levels above 90 dBA for any eight hour shift of a 40 hour work week.  EXAIR offers several types of mufflers including – Reclassifying, Sintered Bronze, Straight-Through and Heavy Duty.  For reducing the noise associated with an EXAIR E-Vac Generator, Vortex Tube, Cabinet Cooler System, or the exhaust air from cylinders, valves and other air powered equipment, we’ve got a muffler that will help to keep the noise level at an acceptable level.

Mufflers

Solenoid and Manual Valves – 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. EXAIR carries a wide assortment of solenoid valves, with offerings in the NEMA 4/4X classification, and supply voltages of 24VDC, 120VAC, and 240VAC.  We also have manual ball valves from 1/4 NPT to 1-1/4 NPT and a foot operated valve, with 1/4 NPT connections.

Valves

Swivel Fittings, Stay Set Hoses and Magnetic Bases – To provide a great degree of flexibility for positioning an EXAIR Super Air Nozzle, Air Jets or Air Amplifiers, EXAIR offers several items.  The Swivel Fittings have 25 degree of movement from the center axis, providing a total of 50 degree of adjustability.  The position is locked in place and holds until adjustment is needed. For applications where frequent re-positioning of the air device is required, the Stay Set Hoses are ideal.  Simply mount the hose close to the application, bend it to the shape preferred, and because the hose has “memory”, it will not creep or bend.  Lastly, the Magnetic Bases are another option for flexible, movable installations.  The base has a on/off valve, and a powerful magnet to hold in any vertical or horizontal mounting arrangement.

Swivels, StaySets,MagBases2

 

Hoses – EXAIR can provide hoses for your application.  For the Line Vac air operated conveyor applications, we offer conveyance hose – a durable, clear reinforced PVC hose, in diameters of 3/8″ to 3″ ID, and lengths up to 50′. On the compressed air side, we can provide 12′ Coiled Hoses with 1/8, 1/4, and 3/8 NPT connections, and also 3/8″ and 1/2″ ID hose in lengths to 50′.

Hoses

Filter Separators, Oil Removal Filters and Pressure Regulators – Perhaps the most important accessories for use on a compressed air device are filters and regulators. Filtering the compressed air of dirt, debris, moisture and oil will help to prevent build up inside the EXAIR products, leading to longer service life, and less time spent cleaning, while providing optimum performance. Regulating the air pressure allows for tuning of the performance, using the proper amount of compressed air to obtain satisfactory results.

Filter and Regualtors

If you have questions regarding accessories for use with any EXAIR Intelligent Compressed Air® Product, 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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Twitter: @EXAIR_BB

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

Send me an email
Find us on the Web
Like us on Facebook
Twitter: @EXAIR_BB

 

 

Step on It – Improve Cycle Times by Using Your Foot

I visited a manufacturing plant that made die-cast components for an automotive company. One of the operations was to deburr an outer edge of the part with excess flashing formed.  The component is in a visible area to customers, and for cosmetic reasons, the flash had to be removed.  I listed the steps of the operation below:

  1. Grab metal part from bin and place part onto fixture.
  2. With both hands, hit dual operational buttons. (4 seconds)
  3. A cylinder would come down and pinch the edge of the flashing, removing it.
  4. Release buttons to retract the cylinder. (10 seconds)
  5. Inspect the part and place into finished bin. (3 seconds)
  6. With a compressed air gun, clean trimmed flash and debris from sharp edge of fixture (3 seconds)
  7. Repeat operation.

The complete operation took 20 seconds, and in an 8 hour shift, they could deburr 1,440 pieces a day.

1910 Blowoff Station
1910 Blowoff Station

My suggestion was to use our model 1910 Instant Blowoff Station. This Blowoff Station comes complete with a model 1100 Super Air Nozzle, a 12” Stay Set Hose, a Magnetic Base, a foot pedal valve, and two 10 feet (3 meters) compressed air lines.  EXAIR Blowoff Kits can be customized to suit your application. You may choose different nozzles, a single or dual port Magnetic Base, and different lengths of Stay Set Hoses.  It gives you the flexibility to match our products to your application.

In manufacturing, little processes like trimming, deburring, coloring, etc. for cosmetic reasons adds additional time and cost to the parts. Even though these steps can be quick, it can still add up to be significant time within the process flow.  By installing the EXAIR Blowoff Station, this manufacturer could combine two steps in the operation.  During the inspection of the part, the operator was able to press the foot pedal to blow off the sharp edge on the fixture. With the strong Magnetic Base and Stay Set Hose holding the nozzle at the correct location, it made this a hands-free operation.  They were able to save 3 seconds on each part.  It doesn’t seem like much time, but throughout a day, they were able to increase productivity by 17.6% (or it saved 17.6% on labor for a cosmetic procedure).

When it comes to removing debris, EXAIR has a great range of products. We can do it very efficiently, quietly, effectively, and even hands-free.  If you have any issues with added cost caused by visual defects, you can discuss your applications with one of our Application Engineers.

John Ball
Application Engineer
Email: mailto:johnball@exair.com
Twitter: @EXAIR_jb