Special Cabinet Cooler Options – High Temperature, Non-Hazardous Purge and Type 316 Stainless Steel

Recent blog discussions about the EXAIR Cabinet Cooler Systems have covered many topics including correctly sizing one, the NEMA ratings, and how-they-work.  In this blog I will review three special options that are available for the most extreme environmental conditions- high temperatures, dirty environments, and harsh or corrosive areas.

High Temperature – For enclosures that reside in high temperature ambient conditions such as near furnaces, boilers, or ovens, EXAIR offers a High Temp version, with special internal components designed to withstand the elevated temperatures.  Cabinets near sources of high heat certainly need to be kept cool, and the EXAIR High Temperature Cabinet Cooler is specially suited to for use in these locations.

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High Temperature Dual Cabinet Cooler System

Non-Hazardous Purge (NHP) – Cabinet Cooler Systems with this feature provide a continuous positive purge within the enclosure to prevent contaminants from entering through small holes or conduits.  Especially suited for dirty and dusty environments, the NHP Cabinet Cooler Systems provide a slight positive pressure inside the enclosure. This is done by passing 1 SCFM (28 SLPM) of air through the cooler when the the solenoid is in the closed position. When the thermostat reaches the set-point temperature and energizes the solenoid, the full line pressure of air is delivered to the Cabinet Cooler providing the full cooling capability, and still keeping the positive pressure.  When the internal temperature cools to the set-point, the solenoid closes and the system returns to the 1 SCFM (28 SLPM) of air flow condition.

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Non-Hazardous Purge Cabinet Cooler for Dirty, Dusty Environments

Type 316 Stainless Steel NEMA 4X Cabinet Coolers – For enclosures that are in food service, pharmaceutical, harsh, and/or corrosive environments, and any application where 316 stainless steel is preferred, the Cabinet Coolers are available in the Type 316 stainless material. The systems are UL Listed for wash down environments, ensuring the enclosure electrical contents remain cool and dry under any condition. Noted applications include on ocean going ships, power plants, medical device manufacturing facilities, and bakeries.

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Type 316 Stainless Steel NEMA 4X Cabinet Cooler System

Please note that the High Temperature, Non-Hazardous Purge and Type 316 Stainless Steel Cabinet Coolers are each available from stock!  No waiting for these special models.

To discuss your application and how a Cabinet Cooler System or any EXAIR Intelligent Compressed Air Product can improve your process, feel free to contact EXAIR, myself, or one of our other Application Engineers. We can help you determine the best solution!

Brian Bergmann
Application Engineer

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Super and Adjustable Type Air Amplifiers

The EXAIR Air Amplifiers are a powerful, efficient and quiet air mover, whose power can be harnessed for blowoff, cooling and ventilation applications. Using a small amount of compressed air, air amplifiers pull in large amounts of surrounding air to produce a high volume, high velocity outlet flow.  Quiet and efficient, output flows with amplification ratios of up to 25 times are possible. There are two types, the Super Air Amplifier and the Adjustable Air Amplifier.

The Super Air Amplifier, with sizes ranging from 3/4″ to 8″, has a patented design (patent #5402938) that uses a special shim to maintain critical position of the components parts. It is through this critical gap setting that a precise amount of compressed air is passed at exact intervals controlled by the shim toward the center of the of the Super Air Amplifier.  The jets of air create a high velocity flow across the entire cross sectional area, which in turn pulls in large amounts surrounding air, resulting in the amplified outlet flow.  Because the outlet flow remains balanced and minimizes wind shear, sound levels are typically three times lower than other types of air movers. The shims are available in thicknesses of 0.003″ (supplied as standard), 0.006″ and 0.009″, and changing to a larger shim will increase the force and flow of the outlet air. The 8″ Super Air Amplifier is supplied with a 0.009″ shim, with a 0.015″ shim available.

2″ Super Air Amplifier and Patented Shim Design

For high temperature applications (up to 700°F/374°C) a special 1-1/4″ High Temperature Air Amplifier is available, with performance equal to the 1-1/4″ Super Air Amplifier. Its surfaces are protected from heat stress by a mil-spec coating process. The High Temperature Air Amplifier is highly effective at pushing large amounts of hot air to areas that typically remain cool.

The Adjustable Air Amplifier, with sizes ranging from 3/4″ to 4″, does not use a shim, and has an infinitely adjustable air gap, which regulates the air consumption and outlet flow from a light breeze to a powerful blast. A highly effective air mover, it can be tailored to meet the exact air flow and force of your specific application. They are available in aluminum and in stainless steel (Type 303) for food service, higher temperatures (400°F/204°C) and corrosive environments.

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2″ Adjustable Air Amplifier, in Aluminum or Stainless Steel

Force and flow of the Adjustable Air Amplifier is changed by loosening the knurled lock ring and turning the exhaust end to open or close the gap.  Once the desired force and flow is achieved, the knurled ring can be tightened to lock the device at the current setting. Typically, an air gap of 0.002″ to 0.004″ provides the required performance.

The table below summarizes the key features of the Super Air Amplifier and Adjustable Air Amplifier.  Please contact an Application Engineer if you need assistance in making a selection.

Air Amp Selection Chart

Note that EXAIR can manufacture special Air Amplifiers to your specification including special flanged mounting style or with a PTFE plug to avoid sticky material build up.

To discuss your application and how a Super or Adjustable Air Amplifier or any EXAIR Intelligent Compressed Air Product can improve your process, feel free to contact EXAIR, myself, or one of our other Application Engineers. We can help you determine the best solution!

Brian Bergmann
Application Engineer

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EXAIR Vortex Tubes are for a Variety of Cooling Applications

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Cooling or Heating with the Vortex Tube

EXAIR Vortex Tubes are a low cost, reliable and maintenance free solution to a wide variety of industrial spot cooling problems.  They only requirement is a supply of compressed air as the power source.  Vortex Tubes have no moving parts and can produce temperatures that range from -50°F to +260°F (-46°C to +127°C).

Vortex Tubes produce two air streams one cold and one hot, the percentage of cold air flow from the inlet flow is referred to as the cold fraction.  The cold fraction is adjustable by the hot valve on the hot discharge side of the vortex tube.  Adjusting the hot valve results in both air temperature and air volume changes. The colder the air becomes, the volume of that cold air declines. So for very cold temperatures, a smaller volume of air is produced compared to a warmer air temperature.

For the vast majority of industrial cooling applications a larger volume of cool air will provide more efficient cooling than a lesser amount of very cold air.  Generally speaking the highest Btu/Hr values are in the 70-80% cold fraction range.

The exception to this would be in labs or special cases where the coldest temperatures are desired.  Adjusting a Vortex Tube is easy, simply insert a thermometer/thermocouple in the cold air exhaust and set the temperature by adjusting the valve on the hot end of the Vortex Tube.  You will know when you reach max refrigeration (80% cold fraction) as the cold air temperature will be 50°F (28°C) lower than the compressed air supply temperature.

EXAIR Vortex Tubes are constructed from stainless steel.  This ensures excellent wear resistance, corrosion resistance and assures years of reliable operation.  They are offered in 3 different size ranges (small, medium & large).  There are generators located inside the tube (user serviceable) that will change the volumetric flow.  The generators are available in a plastic construction or brass construction for high temperature applications.  The ranges 2 SCFM – 8 SCFM are designated as small Vortex Tubes, 10 SCFM – 40 SCFM are medium and 50 SCFM – 150 SCFM are large.  This feature allows you to customize or change your Vortex Tube for greater flexibility in a wide range of applications.

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Vortex generator

Large Vortex Tubes are specified when a high flow of cold air is needed. There are 16 models to choose from in total.  Capable of providing 3,400 BTU/HR up to 10,200 BTU/HR of cooling power.  These have been used to cool high heat loads that are centrally located or to help cool samples of gases for testing.

Medium Vortex Tubes are the most popular – there are twenty to choose from, depending on the cold air flow rate and temperature you’re looking for. These can produce temperatures as cold as -40°F (-40°C) when set to a 20% Cold Fraction (which is the percentage of total supply air that’s directed to the cold end) and cold air flows as high as 32 SCFM when set to an 80% Cold Fraction, which will produce a cold air temperature of about 20°F (-7°C). Some common uses are cooling ultrasonic welds and brazed joints.

The Medium Vortex Tubes are so popular, in fact, that they’re incorporated into our Adjustable Spot Cooler and Cold Gun Systems. They come ready-to-go with mufflers, cold air hose kits, and magnetic bases, so they couldn’t be easier to use.

Adjustable Spot Cooler

Cold Gun Lineup

Small Vortex Tubes are great when low flows (less cooling power) will succeed, or if compressed air supply is limited.  There are 12 models in total to choose from. These are specified for much smaller applications, like cooling the needle of a sewing machine, small drill bits, etc. You can also get one with a cold air hose & magnetic base…that’s the Mini Cooler System.

Mini Cooler

If you would like to discuss Vortex Tubes, Spot Cooling, efficiency of your compressed air usage, quieter compressed air products and/or any EXAIR product,  I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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High Temperature Vortex Tube for Sensor Cooling

Last year I worked with a power company that was having issues with Position Feedback Sensors overheating causing erroneous readings and early failures.  The sensors were located above a steam turbine, and the ambient temperatures reached 128°F with spikes to 140-150°F.  The customer had called in looking for a way to keep the sensors cool, using minimal compressed air, and in a robust package.  After reviewing the details, we recommended the High Temperature Vortex Tube, model HT3210.  While using just 10 SCFM of 100 PSIG compressed air, the HT3210 provides 8 SCFM of cold air at a temperature drop of 54°F from the supply air temperature.  Bathing the sensor with this cool air keeps prevents it from heating up and has eliminated the bad readings and prevented the early failures.

The customer recently implemented the same fix for another set of sensors.

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Power Generation Process, with (3) Position Feedback Sensors
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Position Feedback Sensor

The High Temperature Vortex Tube is a special Vortex Tube offering from EXAIR that utilizes a brass generator and hi-temp seal for use in ambient temperatures up to 200°F.  Simply supply clean, dry compressed air, and get cold air starting at 50-54°F lower than the supply air temperature.  With sizes ranging from 2 to 150 SCFM, there is a Vortex Tube that will meet most applications.

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High Temperature Vortex Tube

If you have questions about the Vortex Tubes, or would like to talk about 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.

Brian Bergmann
Application Engineer

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Air Amplifiers – Vent, Exhaust, Cool, Dry, Clean – With No Moving Parts!

As an Application Engineer, one of the interesting aspects of working with customers on applications is the varied types of solutions an EXAIR product can provide.  The Air Amplifier family – Super Air Amplifier, Adjustable Air Amplifier, and the special High Temperature Air Amplifier can be used in a wide variety of process and applications.  Below highlights several of those from past experiences.

A defense contractor was performing maintenance service on a Navy ship, and the ventilation system had to be shut down.  To keep the personnel cool and safe, an auxiliary ventilation was to be supplied.  Rather than use a cumbersome blower assembly, which has to mounted on the top deck, and ducted down to the lower decks, they chose to utilize (2) 4″ Super Air Amplifiers.  They are very portable and can be set up in minutes.  This solution provided the necessary air flow, providing a safe environment for the maintenance crew.

Super Air Amplifier
EXAIR Air Amplifiers use a small amount of compressed air to create a tremendous amount of air flow.

A light bulb manufacturer needed a better solution for a cooling operation.  During manufacturing of a mercury lamp, the bulb must be cooled from 700°C to 600°C in just 15 seconds.  The current method, an open brass pipe, was working but the noise level was too high (95 dBA.) The goal was to maintain the 15 second cooling time, but reduce sound levels to 85 dBA.  By utilizing (2) of 3/4″ Adjustable Air Amplifiers, the customer was able to maintain the cooling rate, and reduce the noise level down to 80 dBA, a 15 dBA reduction.

adjustable Air Amplifier
Adjustable Air Amplifier

A garbage collector presented a problem that needed a solution.  The garbage was incinerated and when the furnaces were first started up, there tended to be issues with getting the flue to draft properly.  Using the High Temperature Air Amplifier, the high velocity air flow and draw provided the needed draft until the stack warmed up and the natural draft would be established.  Since the unit is capable of handling temperatures up to 700°F, it was able to withstand the heat of the process after the compressed air was turned off.

These and other Applications for the Air Amplifiers and all other EXAIR products can be found on the EXAIR website on the Products page, under the Related Info section toward the bottom of each page.

If you have questions regarding Air Amplifiers or 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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High Temperature Capability

Last week, a customer called in to talk about their application.  After aluminum and steel machining operations, parts are run through a washer system. The drying portion utilized a Super Air Amplifier to dry the sides and a Super Air Knife to dry off the top. The wash temperature was running at 185°F.  The customer wanted to review the application and make sure the EXAIR products utilized in the process were rated to this temperature and to check on high the products could go, since the maximum possible temperature for the washer was listed as 250 °F.

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Drying Section – Utilizing EXAIR Air Amplifier (near top) and Super Air Knife

The Super Air Amplifier is rated to 275°, above the maximum possible condition.  The Super Air Knife was pre-installed with a stainless steel shim, enabling a maximum temperature rating of 400 °F. Both of the components are rated for temperatures in excess of the maximum possible washer temperature condition, and the customer felt confident with the system design.

EXAIR has several options in the Air Amplifier and Super Air Knife product families to allow for operation in high temperature applications.  For the Air Amplifier, the Super Air Amplifier and Aluminum Adjustable Air Amplifier have a maximum temperature rating of 275°F.  The Stainless Steel Adjustable Air Amplifier is rated to 400°F, and for the hottest of conditions, the High Temperature Air Amplifier is rated to 700°F.

Relating to Super Air Knife, the aluminum Super Air Knife is rated to 180°F.  With a stainless steel shim installed, the maximum increases to 400°F. The PVDF Super Air Knife, used in applications where chemical resistance is needed, can withstand temperatures up to 275°F. And for the most extreme temperature environments, the Type 303 and Type 316 Stainless Steel Super Air Knives are rated up to 800°F.

To discuss your application and how an Air Amplifier and Super Air Knife or any EXAIR Intelligent Compressed Air Product can help your process, feel free to contact EXAIR and one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Need A Flange? We Can Do That!

I recently had a customer call in that was trying to boost an exhaust on a hot operation that he had in his facility.   We discussed what kind of fumes he was trying to evacuate and it appeared at face value that a High Temp Air Amplifier would be the perfect solution for his application.

A Model 121021 1-1/4" High Temp Air Amplifier directs hot air to a rotational mold cavity for uniform wall thickness of the plastic part.
A Model 121021 1-1/4″ High Temp Air Amplifier directs hot air to a rotational mold cavity for uniform wall thickness of the plastic part.

Then the words that strike fear into some manufacturers came out.  The customer asks, do you have any way to put a 4 bolt flange onto the unit so I can mount it straight into my piping system?   My response, “All I need are the dimensions of the flange you need and we will see what is possible.”  After a few further questions and verification, we had a drawing  with dimensions of a Flanged High Temp Air Amplifier.  We sent the drawing to the customer for approval, and once approved, we began to manufacture the custom product and provided it to the customer.  This unit will allow the customer to easily boost the exhaust on his operation and will bolt straight into his piping so there are no worries on his end about exhaust gas escaping.  His 500°F air temperature of the gases are of no concern to this special as it carries with it the high temperature rating of 700°F.  The pictures below show the Special – Flanged High Temp Air Amplifier.

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The air inlet and side view of the Special High Temp Air Amplifier
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Here you can see the low pressure side (intake) of the Special High Temp Air Amplifier.
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The O.D. of the flanges was 6″ with 4 – 3/4″: bolt holes. The Bolt holes were not required to align with the opposing side.

If you think there is no way we can find a product that will fit your compressed air application, or adapt a product to fit then give us a call, you might just be surprised at what we can offer in a quick turn around.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF