Undersized Regulators Create Performance Problems with Compressed Air

“I have a Cabinet Cooler installed on my panel but it isn’t getting the temperature down cold enough. Can you quote me for a duplicate system to install on this panel?” This was a recent inquiry from a customer regarding an electrical enclosure that they had installed in their plant. The Cabinet Cooler was producing cold air, but not enough to keep the cabinet at their desired temperature. It would seem logical that they need additional capacity, right? While that could be the case, in this instance it most definitely was not.

When we get questions like this, we first want to take a closer look at the current installation. The cooling capacity for each system is published in our catalog. BUT, in order to rate a cooling capacity for any type of cooling system, some assumptions must be made. All Cabinet Coolers are specified with 70°F compressed air fed to the Cabinet Cooler at a pressure of 100 PSIG. In addition, each cooler has a specified volume of air that it must utilize in order to produce that rated cooling capacity. If any one of those parameters change, so does the overall cooling power.

In this particular case, the customer had installed a non-EXAIR pressure regulator just upstream of the cooler. Upon looking at the specifications for this regulator, it was found that the overall volume of air it can deliver was just 10% of the overall volume needed to produce the rated 1700 Btu/hr. They didn’t need another Cabinet Cooler System, they just needed to remove that restriction! Upon learning that it needed 100 PSIG, they removed the regulator and supplied full line pressure. No more heat alarms for that shift!

CC undersized valve

Rather than purchasing and installing an unnecessary system, they were able to get back up and running just by removing the problem upstream. At EXAIR, we want to make sure that you’re getting the most out of our products. Just because you call and inquire about a new purchase doesn’t necessarily mean that you need it. We’re here to help you determine if something is afoul with the current setup and make sure you have all of the knowledge necessary to rectify it.

We’re right in the middle of summer, and boy is it hot out there. If you have panels that are overheating and creating problems for you in your processes, give us a call. With Cabinet Cooler Systems ready to ship same day from stock (with properly sized regulators) you can have it fixed by tomorrow.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Video Blog: Filter/Separator and Pressure Regulator Mounting and Coupling Kit Installation

Using EXAIR mounting and coupling kits you can assemble EXAIR Filters and Regulators into one plug and play assembly. Follow along with the video posted below to complete this task!

If you need a deeper understanding about how EXAIR’s products can be applied and help your process or product, feel free to contact us and we will do our best to give you a clear understanding of the benefits when using our engineered compressed air products. We can also explain proper implementation of accessory items such as compressed air filters and regulators.

Jordan Shouse
Application Engineer

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Save Compressed Air Energy with Pressure Regulators

Why should you consider a Pressure Regulator when designing your compressed air system? As many know, our products and those of other  product manufacturers have a certain set of specifications regarding performance at stated input pressures. But what if your application doesn’t require that “full, rated performance”? Maybe instead of needing two pounds of force, you only need one pound? Sometimes more force does not produce the desired result for an application. By that, I mean you cause damage to the target or other surrounding items in the application. Or, perhaps blowing too hard (or vacuuming too hard in the case of a Line Vac or E-vac) might cause the vessel or the material you are picking up to collapse or deform (due to too much power).

Regulators catalog
EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

There is also the concern about using more energy than one really needs to in order to achieve the desired effect in an application. In other words, if you can achieve your goals with only 40 PSIG, then why would you ever use 80 PSIG to accomplish the goal? By reducing your compressed air from 80 down to 40 PSIG, you can easily reduce the air consumption of the “engineered” solution by another 40% or more.  Once you have installed engineered air nozzles to reduce compressed air on blow off applications, a pressure regulator can fine tune the pressure to save even more energy.

Regulator Internal
Regulator Internals

Then there is the issue of taking advantage of the pressure differential (from 80 down to 40 PSIG) that creates a little bit more air volume capacity. At 80 PSIG, your compressed air to free air volume ratio is 6.4:1. At 40 PSIG, it is only 3.7:1. The net effect is you effectively have an overall larger volume of air you can use for other applications in your facility. By reducing compressed air pressure of your demand applications, you may be able to reduce over all compressor discharge pressure. Reducing compressor discharge pressure by 2 PSIG also reduces required input power by 1 percent – so keep your pressure as low as possible!

Regulating pressure is definitely warranted given the benefits that compliment the operation of the core EXAIR products.

If you need a deeper understanding about how EXAIR’s products can help your application, feel free to contact us and we will do our best to give you a clear understanding of all the benefits that can be had by our products’ use as well as proper implementation of accessory items such as compressed air filters and regulators.

Jordan Shouse
Application Engineer

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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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