Stay Set Hoses & Magnetic Bases – Precise Positioning for your Blowoff Application!

sshapp2

Once you’ve selected an engineered compressed air nozzle for your blowoff application, you’ll likely need a solution to mount and position it as well. In some applications you may be able to simply replace the old solution with a similar thread, but if the installation is a bit more complex, or if it is a new installation entirely, you’ll need a means to do so. Here’s where EXAIR’s Stay Set Hoses and Magnetic Bases come into play.

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EXAIR’s Stay Set Hoses are available from 6”-36” in length with ¼ NPT male threads on each end, or a ¼ NPT male on one end and 1/8 NPT female on the other. The Stay Set Hoses are rigid and allow you to maintain precise positioning of the blow off nozzle. The hoses have “memory” and will not creep or bend. They’re easily repositioned as well, making them an ideal solution for applications that may require moving them around due to varying parts.

Stay Set Hoses can also be installed on any Soft Grip Safety Air Gun. Simply adding a suffix to the end of the any of the Soft Grip Air Gun model numbers will come with the Stay Set Hose installed. For example, the gun below is a Model 1230-36SSH. A Model 1230 Safety Air Gun, with a 36” Stay Set Hose installed. Having a Stay Set Hose on your air gun can allow you to reach into tight or awkward places that a traditional air gun won’t permit.

1230-6SSH
Model 1230-36SSH

In addition to the Stay Set Hoses, EXAIR also has Magnetic Bases available as well. The powerful magnet permits both horizontal and vertical mounting. A manual valve is also included that will allow you to vary the force and flow. Magnetic bases are available with one or two outlets and can be combined with any of our nozzles and Stay Set Hoses to create your own customized blowoff system.

1122_9412
(2) 2″ Flat Super Air Nozzles w/ Dual Magnetic Base and 12″ Stay Set Hose

No matter the application, EXAIR has a solution for your blowoff. Give an Application Engineer a call today and we’ll help you determine EXACTLY what you’ll need with all parts available from stock!

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

Flat Super Air Nozzle: Build Your Own System Overview

Flat Nozzle Blow-off Kit

EXAIR manufactures a variety of nozzles that are OSHA safe, high quality, and very efficient.  In this blog, I would like to discuss the features and benefits of the EXAIR Flat Super Air Nozzles and how to build a system to fit your application.

The EXAIR Flat Super Air Nozzles are manufactured to blow a wide forceful stream of air.  Their patented design creates a high velocity, laminar air stream with minimal air consumption and low noise.  They come in two sizes; 1” (25mm) and 2” (51mm), and EXAIR stocks them in two different materials, zinc-aluminum alloy and 316 stainless steel.  With a metal construction, breakage is not a concern and performance is not sacrificed even in the harshest of environments.  I have seen many plastic flat nozzles that were broken in applications.  The noise level was loud, and compressed air was wasted.  The unique patented shims inside the EXAIR Flat Super Air Nozzles give three improvements to the design and function.   First, they come in different thicknesses to create a wide range of forces.  In conjunction with a regulator, you can “dial” in the correct amount of force from a breeze to a hurricane without overusing your air compressor.  The patented design also allows an even force across the entire width of the air nozzle.  Lastly, they help to entrain the free ambient air; so that less compressed air is required.  The high efficiency design will save you money.  The EXAIR Flat Super Air Nozzles are effective in uniform blowing; efficient; and superior in quality and durability.  You can watch a video blog on the importance of using our patented shim.

(Click on photo to go to blog)

To show the different types and styles of Flat Super Air Nozzles that EXAIR stocks, you can correspond to the model number make-up sheet below.

To give force adjustments to the individual Flat Super Air Nozzles, EXAIR offers a way to change the thickness of the shim to better suit your application.  You can increase or decrease the force of the nozzle by just removing two screws and changing the shim inside.  This is a unique feature as most competitive flat nozzles do not allow you to do this.  EXAIR offers different thicknesses of the patented shims in our Shim Sets.  The chart below corresponds the appropriate Shim Set to the Flat Super Air Nozzle.

Flat Super Air Nozzle to Shim Set Chart

What can make the Flat Super Air Nozzles even better?  More flexibility.  The Stay Set Hoses can add that flexibility to the Flat Super Air Nozzles.  They are designed to manually position the Flat Super Air Nozzle to accurately target the air stream.  They allow maneuverability to locate the nozzle at different heights or angles; and once positioned, the Stay Set Hose will hold the nozzle in place.  They come in different lengths from 6” (152mm) to 36” (914mm).  We carry two different styles of connections to adapt to any of the Flat Super Air Nozzles.  You can select the different lengths of Stay Set Hoses (SSH) to the Flat Super Air Nozzle by the model number make-up sheet below.

To build your system even further, EXAIR also can offer a Magnetic Base to your Stay Set Hoses and Flat Super Air Nozzles.  The Magnetic Base has a powerful magnet on the bottom to securely attach the blow-off nozzles vertically or horizontally.  This feature is great if you need to move the nozzles to different areas in your application.  EXAIR manufactures a one-outlet and a two-outlet design.  Each outlet has a ¼ turn valve to manually turn on or off the nozzle and only require one air supply inlet.  To add this product to the Flat Super Air Nozzle with the Stay Set Hose, you can use the model number make-up sheet below.

With the EXAIR Flat Super Air Nozzles, you can take advantage of the durability, safety, and efficiency for your blow-off device.  In addition, you can build a system that will best suit your requirements.  You can add different lengths of Stay Set Hoses and/or different Magnetic Bases.  With these combinations grouped into one model number and in stock for quick shipments, it makes it simple to purchase from EXAIR.  Just to let you know, they also come with a 30-day unconditional guarantee to try them out.  If you need any help in building your optimum blow-off system, you can speak to an Application Engineer at EXAIR.  They will be happy to assist you.

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

Eliminating False Image Readings Using The Gen4 Stay Set Ion Air Jet

I was recently contacted by a medical device manufacturer who was interested in implementing a Static Eliminator in their production process. They have a manually operated vision station where a plastic substrate, about the same size as a credit card, is placed into a nest then a small amount of liquid is deposited onto the surface. An operator takes a picture of the liquid and substrate and the image is analyzed. The part is stationary in the nest until the image is taken.  When the station is done, the plastic part is manually removed from the nest.

After some internal testing, they determined that static build up on the plastic part was causing the liquid to move, or “bounce” as they placed it, which was leading to a significant drop in their manufacturing yield due to faulty readings. The cycle time from taking the initial  image and the analysis results is roughly 2 seconds so they were needing something that would quickly remove the charge on the plastic part.

The customer was able to email some photos and after further review, EXAIR recommended they use our Gen4 Stay Set Ion Air Jet in the process. The Gen4 Ion Air Jet is a compact ionizer delivering a quiet, focused ionized air stream to quickly eliminate the static charge on the surface of a material or object. Operating at 20 PSIG, the Gen4 Ion Air Jet is capable of dissipating a 5kV charge in 0.45 seconds while maintaining a low sound level of only 67 dBA. The Ion Air Jet entrains ambient air at a rate of 5:1 and the airflow can be adjusted from a “blast” to a “breeze” simply by increasing or decreasing the inlet pressure. The Gen4 Stay Set Ion Air Jet includes our 12” Stay Set Hose which holds position until it is physically repositioned and a magnetic base for easy installation.

If you have an application that requires a concentrated, ionized airflow or for help with selecting the best product to fit your need, give me call at 800-903-9247 for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

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.

Blowoff Systems Makes it Easy to Clean Extrusions

A metal cutting facility would cut pieces of aluminum extrusions, bars and cylinders to specific lengths as requested by their customers.  They used a variety of different types of cutting equipment depending on the size and profile, but every cutting machine would use coolant. At the end of the cutting process, they would run the parts through a washing system to remove any coolant and then through an inkjet marking system.  They would print the corresponding tag information on the top of each product.

The surface had to be dry or the ink would run and become illegible.  To try and speed up the drying process, they attached four soft copper tubes to blow compressed air along the top of the parts.  They flattened the ends slightly to give a wider blowing area as well as to direct the air into the T-slots of the extrusions.  The customer liked the flexibility of the copper tubes as they would need to change the position often to fit the appropriate size and profile.

The problem that they had with their setup was that the blowing was too loud and it used a large amount of compressed air.  They found EXAIR which looked to have a better solution to blow off the water from the product.

Blow Off Application

The customer gave some additional details on their process.  They could cut a wide range of diameters from 2 inches (51 mm) to 12 inches (305 mm) within their bar and cylinder stock.  They also would cut square and rectangular extrusions that had a variety of profiles and dimensions.  They requested a flexible product that could conform to the different sizes and types and also be adjusted manually for optimum blowing positions.

1122-9412 Blowoff Kit

EXAIR offers a great product line that would fit their requirements for this application, the Blowoff Systems.  With their requested specifications, the flat blowing pattern and flexibility, it directed me to the model 1122-9412 Blowoff Kit.  This kit comes with a Magnetic Base, Flat Super Air Nozzles, and flexible Stay Set Hoses.  The model 1122-9412 has two 2” Flat Super Air Nozzles which will give a wide blowing area.

The Magnetic Base contains two outlets with shut off valves on each port to allow for an easy way to turn off a nozzle when not needed for the smaller products.  Between the Magnetic Base and the 2” Flat Super Air Nozzle, a 12” (305mm) long Stay Set Hoses connects them together which will allow for precise blowing and maneuverability.

By installing two pieces of the model 1122-9412 to his system, the customer was able to remove the four pieces of the copper tubing which were loud and inefficient.  The noise level dropped to 77 dBA with the 2” Flat Super Air Nozzles which was a relief, and they realized that the air compressor was working less.  By adding the Blowoff Kits to their system, they now had a flexible, efficient and effective way in drying the products prior to printing.

With the customer above, they saw much improvement in blowing off the water which kept the ink jet printing process from running or smearing.  If you need flexibility in your blowing application, EXAIR offers a variety of kits with different types of nozzles to accommodate the best blowing feature for your application.  If you would like to discuss these options, you can contact an EXAIR Application Engineer, and they will be happy to help.

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

EXAIR Safety Air Gun Accessories Improve Effectiveness and Safety

Safety Air Gun with accessories

EXAIR offers 5 different styles of Safety Air Guns; Precision, VariBlast, Soft Grip, Heavy Duty and Super Blast.   You can read more about the different styles of Safety Air Guns from a previous EXAIR blog “Not All Compressed Air Guns Are The Same” written by Justin Nichol. I will be targeting the accessories that can enhance the features of the EXAIR Safety Air Guns. These additions will make the Safety Air Guns more dynamic without sacrificing safety, efficiency, or durability.

Precision Safety Air Gun with Chip Shield
eg. 1408SS-CS

Chip Shields:

OSHA 1910.242(b) requires chip guarding when compressed air is used for cleaning. EXAIR offers Chip Shields with our Safety Air Guns to meet this requirement. They are made from a polycarbonate disc which is practically unbreakable and protects the operator from any blow back of metal shavings or coolant. They come with a durable rubber grommet that squeezes onto the extensions and can be adjusted to maximize protection. We offer Chip Shields for the Precision, VariBlast, Soft Grip, and Heavy Duty Safety Air Guns with or without aluminum extensions.

Heavy Duty Safety Air Gun with extension.
eg. 1350-72

Extension Pipes:

For those far away targets and hard-to-reach areas, EXAIR offers aluminum extension pipes to attach to the Safety Air Guns. They can range from 6” (15 cm) to 72” (183 cm) in length. This light-weight and durable material allows for easy handling to reach high above your head or to span across unsafe areas. With the EXAIR air nozzles at the end, the blowing force is not sacrificed as the back pressure will generate a high velocity air stream. The aluminum extensions are offered with the Variblast, Soft Grip, and Heavy Duty Safety Air Guns. The Super Blast Safety Air Guns has the option for two different lengths of extensions, 3 feet (91cm) and 6 feet (183 cm).

Soft Grip Safety Air Gun with Stay Set Hose.
eg. 1210-6SSH

Stay Set Hose:

In certain situations, you may need a way to blow air around a corner or in a tight space. The Stay Set Hose gives you that possibility of manually adjusting or re-adjusting the nozzles to target the correct areas. The hose has a “memory” function, and it will not creep or droop until you physically move it again. They come in lengths from 6” (15cm) to 36” (91cm), and they are offered with the Soft Grip and the Heavy Duty Safety Air Guns.

Coiled Hose

Coiled Hoses:

To get the proper amount of compressed air from the piping system to the Safety Air Guns, EXAIR offers a series of Coiled Hoses. They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters). They have swivel fittings to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking at the ends. 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 of 1/8” NPT, ¼” NPT, and 3/8” NPT. They can be used with our Precision, VariBlast, Soft Grip, and Heavy Duty Safety Air Guns. With the proper size, the Coiled Hoses can connect easily to the Safety Air Guns and supply the required amount of air with a minimal amount of pressure drop.

Regulator and Filter

Filter Separators/Regulators:

To improve the use of the Safety Air Guns, EXAIR offers a series of filters and regulators. The filters will remove dirty particles and liquid water from the compressed air that can affect the performance of the Safety Air Gun as well as contaminate the surface that you are cleaning. The regulators can control the amount of air pressure used for the Safety Air Gun; making them even more efficient. The idea for compressed air savings is to use the least amount of compressed air to do the job. If you only need 40 PSIG (2.8 Bar) to blow off an area, then you can save almost 40% of your compressed air as compared to doing that same job at 80 PSIG (5.5 Bar). The combination of a filter and regulator will allow you to control the proper amount of clean dry air to be used.

 

All of our Safety Air Guns are fitted with our engineered Air Nozzles  which make them OSHA compliant for noise and dead-end pressure. With the accessories, you can optimize the use of the Safety Air Guns to better fit your application. If you need help in determine the correct Safety Air Guns and accessory items, you can contact an Application Engineer for help. If you are within the U.S. or Canada, you can take advantage of our 30-day unconditional guarantee to trial any of our stocked Safety Air Guns.

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

Not All Compressed Air Guns Are The Same

If you work in an industrial plant or manufacturing environment, chances are you use some type of compressed air gun for cleaning parts, work areas, etc. Many air guns purchased through large industrial suppliers are a common choice due to the cost of the gun but as the saying goes – “you get what you pay for”. These types of guns may be cheap to purchase but they are also made cheap and have parts that can break easily, like the trigger or nozzle. In many cases, the nozzles on these guns are also in violation of OSHA requirements, producing dangerous discharge pressures and loud noise levels, which can lead to costly fines or potentially deadly injuries.

EXAIR offers 5 different styles of Safety Air Guns that not only eliminate these concerns, but also provide a more efficient operation, which can reduce energy costs. All of our Safety Air Guns are fitted with our engineered Air Nozzles  which meet OSHA Standard 1910.242(b) for 30 PSI dead end pressure, as they provide a relief or safe path for the air to exit if the nozzle were to be blocked or pressed against an operator’s body so the exiting air pressure will never reach 30 PSIG. They are also engineered to entrain surrounding air across the profile of the nozzle, which produces a smoother airflow, ultimately reducing wind shear, resulting in much lower sound levels, meeting OSHA Standard 29 CFR 1910.95(a).

 

 

The Precision Safety Air Gun body is made of a durable high impact, glass reinforced nylon, providing for a lightweight, ergonomic operation. These guns feature a curved extension, ideal for delivering a powerful stream of air in hard to reach areas, like clearing debris from drilled holes. All of the nozzles used with these units are either 316ss construction for durable, corrosion resistance or PEEK plastic for non-marring applications. The air inlet is 1/4 FNPT and there is a convenient hanger available for safe storage.

 

 

 

Our NEW VariBlast Compact Safety Air Guns are ideal for light to medium duty processes, featuring a variable flow trigger to achieve different force levels ranging from 2.0 ounces up to 1 pound, depending on the nozzle. The body is cast aluminum and there are (2) 1/4 FNPT air inlets available, 1 on the bottom and 1 on the back of the gun, as well as a storage hanger, for easy installation. Nozzles are available in zinc aluminum alloy, 303ss, 316ss and PEEK plastic. These guns are available with aluminum extensions from 6″ up to 72″.

 

 

The Soft Grip Safety Air Guns are commonly used in long-term use applications as they feature a comfortable grip and long trigger which helps to reduce hand and finger fatigue. The cast aluminum construction is well suited for more rugged environments and again, features a hanger hook. These guns can be fitted with aluminum, stainless steel or PEEK plastic to meet the demands of a variety of applications and are available with 6″ – 72″ aluminum extensions for extra reach or Flexible Stay Set Hoses , allowing the user to aim the airflow to a specific target area. The air inlets for these guns are going to be 1/4 FNPT.

 

 

 

EXAIR’s Heavy Duty Safety Air Guns deliver higher force and flows than other air guns, as these units feature a 3/8 FNPT air inlet, which maximizes the compressed air flow to the engineered Super Air Nozzle. Like the Soft Grip, the durable cast aluminum body is designed for use in tough industrial processes, and the ergonomic and comfortable trigger are ideal for hours of use. Aluminum extension are available, again in lengths from 6″ up to 72″, but feature a larger diameter for optimal flow and superior durability.

 

The Precision, VariBlast, Soft Grip and Heavy Duty Safety Air Guns are ALL available with an optional, polycarbonate Chip Shield to protect personnel from flying chips and debris, further meeting OSHA Standard 1910.242(b) for the safe use of compressed air.

 

Lastly we offer our Super Blast Safety Air Guns. The Super Blast Safety Air Guns are ideal for wide area blowoff, cooling or drying a part, as well as long distances. They feature a comfortable foam grip and spring loaded valve that will shut off the airflow if the gun is dropped. These units use our larger Super Air Nozzles and Super Air Nozzle Clusters, providing forces levels from 3.2 lbs. up to 23 lbs. Depending on which nozzle is fitted on the assembly, air inlets will range from 3/8 FNPT up to 1-1/4 FNPT. Aluminum extensions are available in 36″ or 72″ lengths.

 

 

For help selecting the best product to fit your particular application, please contact one of our application engineers for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN