If at First You Don’t Succeed Try, Try Again!

Over the past few weeks I’ve been going back and forth with my phone provider over some technical issues I’ve been having with the device. After some troubleshooting, we were able to conclude that the antenna has likely become loose, leading to the phone periodically not receiving service. Naturally, we’re outside of the 1-Year “Warranty” period that covers a defective device. I paid my insurance deductible and received a “refurbished” phone the following day. Unfortunately, this refurbished phone was unable to take pictures with the front-facing camera. I know what you’re thinking, how on Earth can I take selfies without a front-facing camera? So it was back to the phone provider to get another replacement, fortunately this time they sent a brand new device.

There’s nothing more frustrating than trying to get something to work right out of the box, only to experience issues. Whenever a customer is having an issue with a particular product, there’s a certain progression that we go through in order to assess the problem and determine the root cause. In some cases it is something simple, others it can be a few individual problems that are compounding each other. I recently assisted a customer that was having problems with his 110 Gallon Reversible Drum Vac System. He was having difficulty pumping water out of a container and into the 110 gallon drum. He stated that he just received the unit and was unable to get it to work.

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EXAIR’s Reversible Drum Vac installed on a 110 Gallon Drum

This is a call that we get from time to time, and is generally remedied pretty quickly. Our first step is to check the air pressure at the inlet of the Reversible Drum Vac while it is operating. We recommend an inlet pressure of at least 80 PSIG for proper operation. By installing a pipe tee with a pressure gauge directly at the unit, we can not only verify the inlet pressure but also that the Reversible Drum Vac is being supplied with an adequate volume of compressed air. If the pressure on the gauge begins to decrease once the unit is in operation, we can conclude that the volume of compressed air to the Reversible Drum Vac is insufficient. This can be due to the use of restrictive quick disconnect fittings, improper line size, or a compressor that is undersized.

If the air supply is sufficient, we then inspect the system for vacuum leaks. If the drum does not have a complete seal, the system will not function. If there’s no vacuum leak and there is an adequate supply of compressed air, the Reversible Drum Vac likely needs to be cleaned. It took us a few tries to get there but through a little bit of trial and error, we were able to determine that this was exactly the case in this scenario. Even though the system was new, it had been supplied with compressed air that was not properly filtered. Some scale, rust and debris from the customer’s supply lines made its way into the body of the Reversible Drum Vac, impeding the flow of air. Here is a video that shows the cleaning procedure for the Reversible Drum Vac. Over time the Reversible Drum Vac can accumulate debris inside of the plenum chamber. Regular maintenance of the unit will ensure that it stays within specifications for when it’s needed most!

If you have an EXAIR product that’s not performing as well as it used to, give us a call. One of the Application Engineers will be able to walk you through the steps to ensure that you’re getting the most out of our products!

Tyler Daniel
Application Engineer
E-mail: tylerdaniel@exair.com
LinkedIn: @EXAIR_TD

EXAIR Air Guns Increase Safety And Reduce Air Use

Many times we receive calls from customers that fall right in line with our focus here at EXAIR  – providing Intelligent Compressed Air Products that improve overall safety for operators and plant personnel in industrial operations as well as reduce compressed air usage, ultimately lowering energy costs. Such was the case last week when I received an inquiry from a customer who was looking for a handheld device that could easily attach to their existing air hose to replace the loud and inefficient homemade air nozzles they are currently using to blow off steel chips and coolant from their saws and drills. Their current set up includes a combination of smashed air guns, similar to the one shown below, some small open tubes and cheap plastic nozzles. The blowoffs were working but their operators were starting to complain about excessive noise during operation and notice the compressor in the area was running continuously during the cleaning cycle. Their first proposed solution was to lower the supply pressure which did lower the sound level and air usage somewhat, but now the exiting airflow wasn’t powerful enough to clear the debris. After doing an internet search they decided to reach out to EXAIR for assistance.

crushed-gun

Crushed guns create high pitch wind shear and provide no relief path for the air to exit safely

All of the Safety Air Guns we offer utilize our Air Nozzles which are engineered to meet or exceed OSHA Standard CFR 29 – 1910.95(a) for allowable noise exposure levels. As the Standard reads, when employees are subjected to sounds in excess of 90 dBA, some type of engineered controls should be used to lower the sound to a permissible level. Prolonged exposure to excessive noise can result in serious health issues, like tinnitus or a constant ringing of the ears, as well as stress and reduced productivity. In addition, our engineered Air Nozzles cannot be dead ended, meeting OSHA Standard 1910.242(b). With the design of our Air Nozzles, there is always a safe path for the air to exit so the outlet pressure will not reach 30 PSIG if the nozzle exhaust were to be blocked or pressed against the skin.  Due to this design, our units are safe to operate at higher pressure, resulting in a high velocity, forceful airflow.

1210

Model 1210 – Soft Grip Safety Air Gun

For this application, I recommended the customer use our Model # 1210 Soft Grip Safety Air Gun. This particular unit incorporates our Model # 1100 Super Air Nozzle which produces a low sound level of 74 dBA, well within the OSHA guidelines, and consumes only 14 SCFM @ 80 PSIG while having the necessary power to solve their application.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Finding What You Want – A Black Friday Blog

In the United States, today is the day that we traditionally call “Black Friday” – the retail industry’s unofficial “start of Christmas gift shopping season” – where stores made a habit of opening up early with deep discounts on select items. Here’s the deal: these are SELECT items (that THEY select) and the hopes are, you’ll buy more stuff (that may or may not be on sale) while you’re there. If you know exactly what you want, it can be a good deal for you. If you don’t, it can be a good deal…for the store.

Although we don’t have Black Friday sales events (in fact, we – and I believe most others in the industry, are closed today,) it still makes good sense to know what you’re looking for before you start shopping.  Let’s consider something basic, like an air gun.

Left-right: Precision, Soft Grip w/Stay Set Hose, Heavy Duty w/Rigid Extension, & Super Blast Safety Air Guns. With so many to choose from, we've got the one you're looking for.

Left-right: Precision, Soft Grip w/Stay Set Hose, Heavy Duty w/Rigid Extension, & Super Blast Safety Air Guns. With so many to choose from, we’ve got the one you’re looking for.

Price: this can be a real two-edged sword…not much is cheaper than a commercial grade air gun that you can buy at just about any hardware store. But, they can use upwards of 50 SCFM.  By comparison, our Model 1210 Soft Grip Safety Air Gun uses only 14 SCFM (@80psig supply pressure.)  And in any typical industrial blow off application, it’ll do the exact same thing, and cost WAY less to operate.  Use this calculator to find out.

Sound level:  you won’t find a quieter blow off product on the market.  At 80psig, the 1210 Safety Air Gun is only running at 74dBA.  Others can be well over 100dBA…that’s up to 3 times as loud, and well in excess of OSHA’s limits published in Standard 29CFR1910.95(a).

Safety: OSHA also limits the dead-end pressure of compressed air blow off devices used for cleaning purposes, to 30psig.  Unless it’s fitted, or designed, with a relief feature, you can’t supply it with any more than 30psig compressed air…which won’t really do a lot, when you think about the jobs you want to use an air gun for.  Ours can’t be dead ended, so you can supply them with 80-100psig for strong performance AND safety…by design.

Durability: You get what you pay for.  Normally, I would say “’nuff said,” but for further proof of this, I submit this blog, from the archives, on our Durable, Safe, and Efficient Safety Air Guns.  ‘Nuff said (now, anyway.)

If you’d like to talk about your compressed air product application, and how an EXAIR Intelligent Compressed Air Product might be the solution you’re looking for, give me a call.

Russ Bowman
Application Engineer
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How To Not Use Any More Compressed Air Than You Have To

It should be no secret that EXAIR is all about compressed air efficiency. Our Super Air Knife is the most efficient (and quietest) blow off product on the market today. Our Application Engineering team is tech savvy, highly trained (continuously,) and dedicated to the goal of making sure you get the most out of our Intelligent Compressed Air Products and your compressed air system.  All of our products are engineered with efficiency and value in mind…and if it’s in the catalog, it’s right here in stock, so you can get it right away.  So that’s one way to not use any more compressed air than you have to…start saving it RIGHT NOW.

If you care about your compressed air use, you need one of these. Click here to get one sent to you today!

If you care about your compressed air use, you need one of these. Click here to get one sent to you today!

In addition to the highly efficient design of the Super Air Knife, we also help you to not use any more compressed air than you have to by offering them in any length you need.  We’ve got sixteen lengths in stock because, again, why wait to start saving?  We can also custom cut a Shim for any of those to get you just the air flow you need, or we can fabricate a custom length Air Knife if you’re space-limited.  You can have either of those in just three days.

Buy a Super Air Knife before December 31, 2016, and get a FREE Safety Air Gun!

A FREE Safety Air Gun is another great way to not use any more compressed air than you have to.

With sixteen stock lengths to choose from, product selection oftentimes comes down to which one(s) a user thinks will solve their application.  Such was the case just last week, when a major manufacturer of packing/shipping materials & supplies was building a new blow off station.  Based on their intended design, they ordered four Air Knives: (2) Model 110018 18″ Aluminum Super Air Knives, and (2) Model 110024 24″ Aluminum Super Air Knives.  I’ve written before about how something might have “looked good on paper,” and that’s what happened here…they found out that despite their design considerations, they just didn’t need all 24″ worth of air flow from two of those units, so they wanted to get two more 18″ Super Air Knives to replace them.  And it was an easy fix: this morning, we processed the order for (2) more 18″ Super Air Knives, and arranged for the return of the (2) 24″ ones…which we will issue full credit for, per the terms of our 30 Day Unconditional Guarantee.  They’ll start not using any more compressed air than they have to tomorrow, and it’s not costing them a dime.

You too, dear reader, can start saving quickly by calling me now to discuss your compressed air use, and which EXAIR Engineered Compressed Air Product is right for you.  Why wait?

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: www.exair.com
Blog: http://blog.exair.com
Twitter: https://twitter.com/exair_rb
Facebook: http://www.facebook.com/exair

Blowing Water from Hard-To-Reach Places

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Cables boxes stacked after leak testing

One of the areas of expertise for our Application Engineers is in compressed air blow off applications.  Finding the proper Air Knife, Super Air Nozzle, or Safety Air Gun to suit an application can be as simple as considering a few variables (such as the required force to blow off the item in question), or as complicated as examining tolerance specs within the application to determine whether our products are the right fit (hint: we have CAD drawings available on our site to help with this, too).

20161025_121205

These boxes needed a better way to remove water after submerged leak testing

Earlier this week I was contacted by an industrial service provider which performs leak testing on cable boxes.  The boxes (shown above) are submerged in water as part of an inspection process, and after this process is complete, the water needs to be removed.  The current method of drying the boxes is to allow the boxes to drip-dry, but this presents several problems.  Firstly, drip-drying does not remove all the water from the crevices of the heat sinks, and it leaves unsightly water stains on the outside of the boxes (a small problem, but something to be avoided, if possible).  But, most importantly, allowing the boxes to drip-dry creates a bottleneck in the testing process, reducing throughput due to increased time needed for drying.  So, the service provider reached out to EXAIR in search of a solution to easily, effectively, and quickly remove the water from the heat sinks of these cable boxes.

In order to determine the best solution, we discussed application parameters surrounding the process.  The most important aspect, after determining how much force is needed, was the degree to which the process is automated vs. manual.  Due to the manual nature of the process, a manual blow off would be most suitable, and we determined that the model HP1230 Soft Grip Safety Air Gun would be the best fit for this application.

Coupled with a model 9008 pressure regulator to allow for reduction in line pressure (if needed) this solution provides an efficient, safe, and repeatable means to blow off the water from these cable boxes.  If you have a similar blow off application, or would like to discuss another application, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Out Of This World

One of the best parts about being an Application Engineer at EXAIR is the vast array of applications that customers call in with.  Every time the phone rings, a chat notification pops up, or an email to Techelp comes in, another interesting application presents itself and the process of helping to provide a solution begins.

Recently, I worked with an Optical Scientist working on the next class of giant ground-based telescopes that promises to to revolutionize our view and understanding of the universe.  He made contact with us via chat and said that he had seen a special Safety Air Gun being used to blow off a telescope mirror at a different telescope site.  He said the unit had black plastic nozzles, which was preferred, because they would not scratch or damage the mirror glass. After receiving a photo of the unit, we were able to identify it as the model 1213-4-PEEK, Super Blast Safety Air Gun, with 4 PEEK Nozzles (PEEK  = Polyetheretherketone, a thermoplastic).

1213-4-peek_400w

Model 1213-4-PEEK Super Blast Safety Air Gun

The Super Blast Safety Air Gun is one of the EXAIR  High Force Safety Air Gun offerings that provide a strong blowing force with the added convenience of a comfortable soft grip and easy to operate spring-loaded manual valve that automatically shuts off should it be dropped.  The Super Blast Safety Air gun is ideal for long distance, wide area blowoff, cooling and drying applications.  In the case of the telescope mirror application, the mirrors are outside and subject to dust and bird and bat “deposits.”  After a thorough washing, the Super Blast Safety Air Gun provides the method for drying the mirrors. At 8.4 meters in diameter, a strong, far reaching blast of air is required to ensure complete drying of the mirror surface.

gmt-2015-mirrors1-medium

Array of 7 Mirror Surfaces

EXAIR offers a wide range of Safety Air Guns, from those offering small, precise blowoff of 2 ozs. up to large, strong blowing forces of 23 lbs.  To discuss your special blowoff, cooling or drying application, feel free to contact EXAIR and one our  Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Image Courtesy of “Giant Magellan Telescope – GMTO Corporation”

Controlling Supply Pressure, Controlling Flow

“What is the lowest operating pressure and what kind of force can I expect?”. This is common question we get at EXAIR and the simple answer – it depends. Okay, that’s not so simple and it does matter what EXAIR product you are considering.

Take for example some of the vortex tube based cooling products, like our Cold Gun for dry machining and Cabinet Cooler Systems to purge and cool electrical enclosures. These particular products are designed to operate at 80-100 PSIG for optimal performance and efficient cooling capacity. They can be operated at lower pressure but their effectiveness and performance are reduced.

Most other products, and the problem they are solving vary in the amount of pressure needed for success. In many cases, the simplest method would be to use a pressure regulator. By incorporating a pressure regulator in a blowoff application, for example using our Air Nozzles or Safety Air Guns,  adjusting the supply pressure is the easiest way to control the output velocity and force of the airflow. Many applications don’t require full line pressure to achieve the desired result and operating at lower pressure provides a way to reduce compressed air usage and lower energy costs.

Click on picture for more information

Pressure Regulator with gauge for simple supply adjustment

Another way some of EXAIR’s products allow for easy adjustment is by incorporating a replaceable shim. Take for example our Air Knives – All of our Air Knives are shipped from stock with a .002″ shim installed. We offer Shim Sets for our aluminum knives that include a .001″, .003″ and .004″ shim  that allows you to either reduce the gap and cut your air usage and force in half. By installing the thicker shims, you can increase these properties by 1.5 times for the .003″ shim or double by installing the .004″. For our stainless steel knives, we offer shim sets which include (3) .002″ which can best stacked to provide more force and flow.

sak-shims

Super Air Knife shims

Our Air Amplifiers feature patented shims that allow for the similar adjustments, resulting in large volumes of outlet airflow.

Super Air Amplifer w- shims

Super Air Amplifier and optional shim set

Our Air Wipes, which perform similar to our Air Knives but produce a 360″ ring of air to treat the surface of a hose , pipe, tube, etc. , are also shipped with .002″ shim installed with optional shim sets available.

gh_SAWshimsets_750x696p

Shims for our Super and Standard Air Wipes

We also offer replaceable shims for our 1″ and 2″ Flat Super Air Nozzles for those applications requiring more of a focused airflow that needs that extra bit of force, like when trying to blow heavy grit off of a chain or blow reject parts from a conveyor.

Model 1126 (Zinc Aluminum) or 1126SS (316SS) 1" Flat Super Air Nozzles (left) have replaceable shims (middle), same as Model 1122 (Zinc Aluminum or Model 1122SS 2" Flat Super Air Nozzles (right.)

1″ and 2″ Flat Super Air Nozzles provide laminar airflow that can be easily adjusted.

As you can see, there are some viable options to fine tune your EXAIR product to provide the optimal performance. If you need any assistance or would like to discuss the specifics of a particular application, give us a call.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

 

 

 

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