Products Built to Last and Maintenance Free

As an avid outdoors man, I have learned a lot about myself during these days of quarantine and social distancing; mainly I don’t quarantine very well. With all the climbing gyms closed, traveling strongly discouraged, and social distancing in place my  lifestyle has been brought to a grinding halt much like many of us. opening up, which will be good for all of us. 

So, in place I have taken upon myself to learn a new hobby that I can do solo and safely. In the past weeks I have spent learning about mountain biking and all that comes with it. This includes the maintenance required to work on a bike, specifically the front derailleur which controls the front major gear changes (and gets damaged if crashed). Realigning the front derailleur is one of the hardest fixes that one can do on a bike as it has three different adjustments that need to be made at the same time. Thus, I embarked on a week long project of learning how to make the adjustment and man was it frustrating.

Performing tricky maintenance can be one of the most frustrating and stress inducing things when all you really want is for something to work without any hassle. Whether its hours just trying to figure out what the issue is or actually fixing it, let’s be honest, it never goes as planned. The same can be said for maintenance on things such as compressors, cars, and production equipment. Here at EXAIR we strive to eliminate this frustration and hair pulling maintenance and replace it with maintenance free products.

EXAIR’s lines of compressed air products such as our Vortex Tubes, Super Air Amplifiers, and Super Air Knives have no moving parts. No moving parts means no wear down parts and no wear down parts means little to no maintenance. Besides the occasional air filter element change out or something getting lodged inside the product EXAIR’s compressed air products will run almost indefinitely as long as they are supplied with a source of compressed air, typically run through a standard 5 micron filter separator. 

Although you cannot really prevent dirt from collecting in a filter separator (that is, in fact what they are meant to do) you can prevent dirt, dust, and debris from getting into your products by using one of EXAIR’s Filter Separators. Filter Separators remove water condensate, dirt, dust, and debris from your compressed air line before it enters your compressed air product. This prevents the particles from disrupting small air outlets or lodging in the small pathways inside our compressed air products and keeps the product running like new.

All in all, maintenance is not fun to have to deal with and can be costly at times. By using EXAIR’s engineered compressed air products you can eliminate at least one thing to worry about on your list of maintenance that needs to be performed. With a little bit of preventive measures you can keep our products running like new for years and years.

If you have any questions or want more information on any EXAIR’s of our products, give us a call, we have a team of application engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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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

EXAIR’s Cabinet Coolers Eliminates Worry of Shutdowns

316SS Electrical Panels

A food and beverage company had 316SS NEMA 4X (IP66) electrical panels inside their facility.  The reason for the stainless-steel construction and NEMA 4X or IP66 rating was for the periodic washdowns with an aggressive cleaner.

This particular company had a bottling process and inside each panel, sensitive electrical components would control the operation of the system.  The panels were fitted with Freon type air conditioners to keep the electrical components cool.  One day, they had an A/C unit that failed, and it shut down their system for half a day.  For a bottling company, a shutdown for this long stopped many bottles from being processed which costed much money from loss of production.

They had four panels that were setup similar right next to each other.  They were fitted with 1,700 BTU/hr freon system on each panel.  In this situation, one of the refrigerant compressors failed.  They had to hire a mechanical serviceman with a license to work on Freon systems.  Because of the length of time to get their system restarted, they were losing money every minute.  This emergency call really hindered the entire bottling process.  In fear of another shutdown, they contacted EXAIR to see if we could help them.

Even with constant maintenance, the life span of a Freon system is only around five years.  (It can be even shorter if preventative maintenance is not scheduled regularly). Any mechanical system with moving parts will wear out and fail.  EXAIR Cabinet Coolers use the power of a Vortex Tube which only needs compressed air to generate cold air.  With no moving parts to wear or unsafe Freon to leak, they are designed to keep your electrical components cool and operating for a very long time.  Trying to predict failures with refrigerant systems is very difficult to determine; but, with the EXAIR Cabinet Cooler Systems, it takes that worry away.

EXAIR NEMA Type 4X Cabinet Cooler System

EXAIR Cabinet Cooler Systems are manufactured in a variety of options and types to meet different application requirements.  For the food and beverage company above, I recommended the model 4830SS-316 Cabinet Cooler System to replace each of the A/C refrigeration systems.  The model 4830SS-316 would meet the cooling requirement with 2,000 BTU/hr capacity, the NEMA 4X (IP66) rating of the panel, and the 316SS construction to withstand washdowns.  The complete system includes the Cabinet Cooler, a filter, cold air distribution kit, a thermostat and a solenoid valve.  The thermostat is preset at 95 deg. F (35 deg. C), and it operates a solenoid valve to only turn on when cooling is needed.  EXAIR has this model in stock as well as many others for quick delivery, reducing any downtime.  After the installation of the Cabinet Coolers onto the panels, the worry of production stoppage due to a failure with an A/C system was alleviated.

Maintenance departments have many concerns in keeping a system running smoothly and uninterrupted.  Why add additional worries with coolant based panel coolers?  If you have electrical panels that can stop your operation like the bottling company above, an EXAIR Cabinet Cooler will be a reliable solution.  You can fill out the Cabinet Cooler Sizing Guide and an Application Engineer can determine the best model for you.

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

Order An Industrial Vacuum System Through 5/31/18 And Receive A Free Vac-u-Gun

From now through May 31, 2018, we are offering a FREE Vac-u-Gun with any order for one of our Industrial Housekeeping Vacuum Systems. The Vac-u-Gun is a multi-purpose tool that can be used to vacuum or transfer material from one location to another or it can be used as a powerful blow gun to clean debris off of the surface of a part or workstation. There is no electricity required to operate and no moving parts to wear out, providing for a safe, maintenance free operation.

Change from a vacuum gun to a blow gun in a matter of seconds!

When choosing one of our vacuums, selection can be simplified depending on what type of media you are needing to pickup. Our systems are going to be either solids handling or liquid handling.

Our Chip Vac Systems are the ideal choice when looking to vacuum dry or damp debris left over from machining operations and delivers them to a standard open top steel drum. For more abrasive material, such as sand or steel shot used in sandblasting processes, the Heavy Duty Dry Vac provides superior wear resistance due to it’s proprietary hardened alloy construction.

If you are looking to vacuum liquids we offer our Reversible Drum Vac and High LIft Reversible Drum Vac providing higher suction lift, up to 180″ H2O.

Our Chip Trapper and High Lift Chip Trapper are also used in liquid applications but these systems incorporate a filter bag inside the drum to capture any suspended solids in the liquid so only clean fluid is pumped back into the reservoir or tank.

In dusty applications we offer the Heavy Duty HEPA Vac which uses the same vacuum as the HD Dry Vac but this system provides a higher level of filtration meeting HEPA requirements of 99.97% filtration at the 0.3 micron level.

All of these products are In-Stock, Ready To Ship.

To take advantage of the offer, you need to order using the promotional Model number. Ordering is easy – you can email the order to orders@exair.com or place your order online at www.EXAIR.com. If you’d rather place your order over the phone or have any technical questions about our products, you can call us at 800-903-9247 and one of our reps will be happy to assist.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN