How to Install A Super Air Knife – From the Basic to the Creative

Occasionally, a caller will ask if we offer installation services for our products. They’re usually very pleased to learn that there’s not all that much to it.

Any of our Super Air Knives can use our Model 9060 Universal Air Knife Mounting Systems (shown below; one on a 12″, and four on a 108″ length) for easy installation and precise aiming.

The 9060 Universal Air Knife Mounting Systems are perfect for simple, fast installation and positioning.

Shorter lengths, like the Model 110006 6″ Aluminum Super Air Knife (below, left,) can be adequately supported by air supply piping.  We don’t recommend that with longer lengths (due to overhung load concerns) but even a Model 110018 18″ Aluminum Super Air Knife (below, middle,) can be supported by the supply pipe in a vertical position.  We even stock our 3″ Aluminum Super Air Knives with Stay Set Hoses & Magnetic Bases (below, right.)

Just a few more popular ways to install a Super Air Knife.

The Super Air Knife also has a series of 1/4″-20 tapped holes, 2″ apart, along the bottom of the body.  These are often used for installation & mounting as well, and we’ve seen some creative methods, for sure:

Yes, that’s a door hinge. No, it wasn’t my idea, but I kind of wish it was.

EXAIR Super Air Knives come in lengths from 3 inches to 9 feet long.  We stock them in aluminum, 303SS, 316SS, and PVDF.  If you need a custom length or material, though, we do those too.  We can even talk about the best way to mount it.  Call me.

Russ Bowman
Application Engineer
EXAIR Corporation
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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

Accessories and the Value Added

The word “accessory” can come with some baggage… it’s become synonymous with “add-on” and “up-sell,” and cost-mindful consumers may see them as just another way for a slick salesperson to make an extra buck. And frankly, they wouldn’t have that reputation if there wasn’t some truth to it.  The server at your favorite restaurant will offer appetizers, or recommend side dishes to go with your entree. If you go to buy a new car, you’ll get a pitch for a variety of aftermarket add-ons.  The paint counter folks at the hardware store always tell me what specific brush and/or rollers I should use with the paint I’m buying…and it’s never the 10-pack of economy brushes that costs less than the single, premium quality brush they recommend.  In all of these cases, these employees are trained, constantly encouraged, and hopefully rewarded on the success of these “up-sell” strategies.

Of course, my boys and I can devour even the largest plate of chili cheese nachos long before the rest of meal comes out.  My wife absolutely loves the remote starter function that the dealership installed on the new car she bought last year.  And, if you’ve ever painted a well-lit room, you know the difference between a $1 paint brush and a $10 paint brush.  So if my server gets a little bigger tip, my car dealer salesperson gets a little more commission, or the paint counter folks get a bonus, then it’s a win-win, as far as I’m concerned.

EXAIR carries a variety of accessories for our Intelligent Compressed Air Products.  Some aid in mounting & installation:

Clockwise from top: Universal Air Knife Mounting System, Stay Set Hoses, Cabinet Cooler Side Mount Kit, Mounting Brackets for Line Vac, Filter Separator, and Pressure Regulator, Swivel Fitting for Super Air Nozzle, Tool Holder for Industrial Vacuum Drums, Spray Nozzle Mounting Clip.

Others make it easy to ensure adequate supply conditions:

The performance of many EXAIR Intelligent Compressed Air Products can be altered by replacing the shim:

From left to right: Super Air Amplifier, Super Air Knife, 1″ Flat Super Air Nozzle, High Velocity Air Jets, and Air Wipe all feature replaceable shims to modify performance.

In addition to these product-specific accessories, EXAIR carries a complete line of:

Filter Separators are rated for air flow up to 400 SCFM; Oil Removal Filters, up to 310 SCFM.

*Filter Separators to remove water, dirt, and rust from your compressed air system.  Our Automatic Drain Filter Separators have a 5 micron particulate element, and a centrifugal vane to remove moisture.

*Oil Removal Filters with coalescing elements that remove any trace of oil, and also provide additional particulate filtration to 0.03 microns.

 

*Pressure Regulators, so you can “dial in” the performance you need, so you don’t overpower the application, or waste compressed air.  They come in sizes from 1/4 NPT to 1-1/4 NPT, and are rated for flows up to 700 SCFM.  A pressure gauge provides accurate indication of outlet pressure, and the adjustment cap can be removed to prevent tampering.

*Mounting Brackets and Modular Coupling Kits for our Filters and Regulators.  The latter are especially handy for easy, compact, and leak free installation.

*Silencing Mufflers to reduce work area noise from compressed air exhausting from pneumatic cylinders, valves, etc.  There are several styles to choose from, depending on your needs:

  • Sintered Bronze Mufflers are simple in design, with minimal back pressure restriction, and come in sizes from #10-32 thread to 1-1/2 NPT.
  • Straight-Through Mufflers offer noise reduction up to 20 dB, and come in sizes from 1/4 NPT (up to 22 SCFM) to 3/4 NPT (up to 73 SCFM.)
  • Heavy Duty Mufflers have an internal stainless steel screen that not only protects the exhausting components from environmental contamination, but also keeps air system contaminants from being ejected at high speed into the work area.
  • Reclassifying Mufflers are an upgrade to the Sintered Bronze Mufflers and provide the highest level of noise reduction – up to 35 dB.  They also trap oil mist, eliminating breathing hazards to personnel.

*We have manual ball valves (1/4 NPT to 1-1/4 NPT) and Solenoid Valves (120VAC, 240VAC or 24VDC) from 1/4 NPT to 1 NPT, and a Foot Valve, for hands-free operation.

*Swivel Fittings to securely install & aim many of our nozzles, from the Atto to the High Force 1 NPT Super Air Nozzles.  For a little more flexibility, Stay Set Hoses and Magnetic Bases can be used for Air Amplifiers, Super Air Nozzles, and even short Air Knives.

*12 ft Coiled Hoses (1/4″ or 3/8″ ID) and Compressed Air Hose (3/8″ or 1/2″ ID; up to 50ft lengths) can be provided with any Intelligent Compressed Air Product.  We also have a full supply of fittings (tees, elbows, nipples, couplers, reducers, etc.) and adapters to fit our Super Air Nozzles to your existing air guns or blow off devices.

*Receiver Tanks are used to store a ready supply of compressed air.  If you have an intermittent demand of sufficient size, it can cause a pressure transient in your system, which can drag down the ability to supply other points of use.  Installed near the point of intermittent demand, they prevent pressure & volume fluctuations, keeping the operators at all points of use happy.  Model 9500-60 Receiver Tank has a capacity of 60 gallons, is rated to 200psig, and meets ASME pressure vessel code.

In closing, let me offer the following advice that’s served me well over the years:

*Be mindful of the valued added by the accessories & add-ons you’re presented during a purchase of capital equipment…or anything else, really.  Don’t buy something you don’t need, but if you need it…well…it’s OK to buy it.

*Don’t skimp on quality.  Odds are, if an accessory is offered by the manufacturer of the product, it’s going to work well for you.  They should be able to tell you if it will or won’t if you discuss your needs with them.  I know I will if you call me to discuss a compressed air product application.

*Get the big plate of nachos, especially if you’re dining with teenagers.

Russ Bowman
Application Engineer
EXAIR Corporation
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The Case Is Mounting For Stay Set Hoses

So, you’ve selected a quiet, efficient, and safe EXAIR Super Air Nozzle for your blow off application – good call! – and now you’re thinking about how to install it.  Sometimes, it’s as simple as replacing whatever you’re using right now:

EXAIR Intelligent Compressed Air Products have common NPT (or BSP) connections, making for easy replacement of most any existing threaded device.

Or maybe you’re using an open end blow off…in which case, you’re just an adapter away:

EXAIR Super Air Nozzles are quick and easy to install on existing copper tube, via a simple compression fitting.

Perhaps, though, it’s a new installation, or the existing supply lines aren’t suitable for one reason or another.  In those cases, we’ve still got you covered…consider the EXAIR Stay Set Hose:

Precise aiming and location is a breeze with EXAIR Stay Set Hoses.

Available in a variety of lengths from 6″ to 36″, they’re positionable, and re-positionable with a simple bending action.  They won’t kink or easily fatigue like copper tubing.  The supply end is 1/4  MNPT, and you have your choice of 1/4 MNPT or 1/8 FNPT on the other end, depending on which Super Air Nozzle, Air Jet you need to use it with.

We also offer Blow Off Systems, which are a combination of a specific Air Nozzle (or Air Jet,) fitted to a Stay Set Hose:

Model 1126-9262, for example, is a Model 1126 1″ Flat Super Air Nozzle with a 9262 Stay Set Hose.

For added convenience and ease of installation, these products can also come with a Magnetic Base:

Mag Bases come with one or two outlets. Stay Set Hoses come in lengths from 6″ to 36″.

Stay Set Hoses are also available with a variety of our Soft Grip Safety Air Guns, and they make the GEN4 Stay Set Ion Air Jet one of our most popular Static Eliminator products.  They’ve even been successfully applied with small Air Amplifiers and Air Knives…with certain limitations (spoiler alert: trying this with a 108″ Super Air Knife is going to be a definite “no.”)

Model 110003 3″ Aluminum Super Air Knife with 6″ Stay Set Hose & Magnetic Base.

From the beginning in 1983, EXAIR’s focus has been on being easy to do business with, and that goes from our friendly customer service to our expert technical support to our 99.9% on-time shipments (22 years and running) to designing our engineered products and value-added accessories with efficiency, safety, and ease of installation in mind.  If you want to find out more, give me a call.

Universal Air Knife Mounting System Saves You Time & Money

Using EXAIRS Universal Air Knife Mounting System greatly ease’s the installation of all Air Knives (Except PVDF).  It will save you the time and expense of designing and fabricating your own mounting system which will maximize your uptime and keep your staff focused on key plant tasks!

Please note the table below that highlights the recommended number of the Universal Air Knife Mounting System to use for the various length of Air Knives.

Length Of Air Knife Number of UAKMS
3″ – 18″ 1
24″ – 54″ 2
60″ 3
72″ – 95″ 4
96″ – 108″ 5

If you would like to discuss Universal Air Knife Mounting System, Air Knives or any EXAIR compressed air product, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer

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Video Blog: EXAIR Swivel Fittings

A brief video showcasing the full EXAIR Swivel fittings offering. Each of the 9 Swivel Fitting models offers a 25° from center line adjustment for a total of 50° full range of adjustment. The Swivel fittings are an ideal accessory for a variety of EXAIR products.  For more product details see our product page.  For any questions or fitment suggestions contact an Application Engineer.

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

The Super Air Knife: It’s Super Easy To Install

One of the more commonly asked questions about one of our more commonly asked-about products is:

“How do you install a Super Air Knife?”

Well, I’m glad you (or, in this case, “they,”) asked! There are several options, and they’re all pretty simple:

The Universal Air Knife Mounting System – right out of the box, the 9060 Universal Air Knife Mounting System is ready to go. It gives you a complete range of motion, so changes to the angle, direction, and distance of the air flow to the target are quick and easy. Multiple systems provide secure support for longer Air Knife lengths.

The 9060 Universal Air Knife Mounting Systems are perfect for simple, fast installation and positioning.
The 9060 Universal Air Knife Mounting Systems are perfect for simple, fast installation and positioning.

The Air Knife Plumbing Kit – Air Knives 24″ and longer need to be supplied at multiple inlets.  A Plumbing Kit comes with everything you need to get that down to just one (lengths to 54″) or two (lengths to 108″) 1/2 NPT connections, saving you from hunting down the fittings and hose or tube, while ensuring you get sufficient air flow for optimum performance.

Plumbing Kits

The Super Air Knife Itself (part 1) – because the Air Knife cap & body are held together with a series of Stainless Steel cap screws, there’s a 1/4″-20 tapped hole, about 3/8″ deep, every 2″ along the bottom of the body. These are commonly used to install the Air Knife to an acceptable mount.

If you've got something to hold it to, mounting a Super Air Knife with 1/4"-20 fasteners is a snap!
If your equipment already has rails or a frame, mounting a Super Air Knife with 1/4″-20 fasteners is a snap!

The Super Air Knife Itself (part 2) – like I said above, when they get longer than 24″, an Air Knife needs to be supplied at both ends to ensure proper air flow across the entire length. There are MANY Super Air Knives installed over conveyor belts (a “textbook” application) that are simply supported by hard piping to both ends. The Air Knife is, essentially, as well supported as the piping.

Use the supply piping to adequately support longer lengths of Super Air Knives
Use the supply piping to adequately support longer lengths of Super Air Knives.

The Super Air Knife Itself (part 3) – I saved “part 3″ to talk about the 3” Super Air Knife specifically…see what I did there? These short, compact units can actually be supported and plumbed properly, using a Magnetic Base and a Stay Set Hose.

Install and reposition a 3" Super Air Knife using any steel surface with a Mag Base & Stay Set Hose.
Install and reposition a 3″ Super Air Knife using any steel surface with a Mag Base & Stay Set Hose.

If you’ve got an application for a Super Air Knife, we can help you get in installed, in a snap. Call me; let’s talk!

Russ Bowman
Application Engineer
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