This Is A Hold Up

To clarify, right off the bat:

  1. Nobody is getting robbed here.
  2. Nothing is being delayed, especially a shipment from EXAIR. If it’s in the catalog, it ships on time, 99.97% of the time, for 17 years & running. This has nothing to do with this blog; I just never get tired of bragging about that.

Today I wanted to write about installing EXAIR products, but hey, it’s Friday, so I thought I’d start with something that would get your attention. If you’re still reading, I guess it worked.

We talk to users…and potential users…all the time about how to install an Air Knife, Air Nozzle, Vortex Tube, etc. And the answer is…it depends. But, it’s almost always quick and easy.

Consider the EXAIR Super Air Knife. There are a few ways to hold one in place:
*There are 1/4″-20 tapped holes, every 2″ along the bottom. These can be used to bolt it to just about anything you want to bolt it to.
*The 1/4″-20 cap screws can also be replaced with fasteners of sufficient length to allow use of a bracket. In fact, this is what we use for…
*The Universal Air Knife Mounting System – it’s a quick and convenient way to support an Air Knife. It’s especially beneficial to precisely position the Super Air Knife for optimum performance.
*Last but not least, Super Air Knives 24″ and longer need to be plumbed to both ends for proper performance. If you hard pipe it in, it’ll be as well supported as the piping.

EXAIR Super Air Knives are easy to install, no matter what the length, or application.
EXAIR Super Air Knives are easy to install, no matter what the length, or application.

Then there’s our Super Air Nozzles:
*With standard, common NPT threads, these are easy to install anywhere you have an existing air line. You can get NPT adapters for darn near any threaded connection, off the shelf, from a friendly local air compressor or hydraulic/pneumatics shop.
*We’ve got Stay Set Hoses in lengths from 6″ to 36″ – these let you reposition the Air Nozzle at will. It’ll “stay set” until you bend it again.
*Our Swivel Fittings can be used with any of our Super Air Nozzles, as well as our Air Amplifiers, for sturdy, yet easily repositionable, installation.

EXAIR Swivel Fittings or Stay Set Hoses - no better way to optimize your air flow than aiming it where it needs to be!
EXAIR Swivel Fittings or Stay Set Hoses – no better way to optimize your air flow than aiming it where it needs to be!

We’re even committed to making our air preparation accessories easy to install…our Automatic Drain Filter Separators, Oil Removal Filters, and Pressure Regulators (up to 1/2 NPT) can be coupled via a modular block assembly that eliminates a threaded connection between them, and is ideal for close quarters.

EXAIR Model 9027 Oil Removal Filter, installed between Model 9004 Filter Separator and 9008 Pressure Regulator, using our Modular Coupling Kits
EXAIR Model 9027 Oil Removal Filter, installed between Model 9004 Filter Separator and 9008 Pressure Regulator, using our Modular Coupling Kits

That’s not even mentioning the products that are ready to install, right out of the box with a convenient Magnetic Base:

From left to right: EXAIR Mini Coolers, Cold Guns, and Adjustable Spot Coolers come with Magnetic Bases for instant installation.
From left to right: EXAIR Mini Coolers, Cold Guns, and Adjustable Spot Coolers come with Magnetic Bases for instant installation.

If you’d like to find out more about how easy it is to install an EXAIR Compressed Air Product, give me a call.

Russ Bowman
Application Engineer
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EXAIR’s 2015 Year End Review!

In case you were too busy to notice, it’s 2016!  With the start of the new year I would like to review just a few milestones EXAIR reached which will help continue to serve our customers and provide solutions to manufacturing problems. The year was extremely busy for us and so far, 2016 is looking to be even better.

Throughout the course of the last year EXAIR has released hundreds of new products. We continue to increase our Atomizing Spray Nozzle product line and we received the official patent on our No Drip Atomizing Spray Nozzles. The No Drip versions of our spray nozzles have a patented design which helps conserve precious liquids, including water, while also preventing drips which could affect your product finish.

Stay up to date with EXAIR Press Releases
Stay up to date with EXAIR Press Releases

Our new line of Back Blow nozzles have been created to clean the inside of pipe, tube, hose, channel or shafts and prevent the operator from pushing debris further inside by directing the airflow and debris back out toward the nearest end. We have also outfitted our air guns with these nozzles to provide an easy to activate and ergonomic solution. EXAIR also expanded our swivel fitting, air operated conveyor, industrial housekeeping and Cabinet Cooler product lines. See our website for more information on these products. These new stock products ship same day on orders received by 3 PM EST for orders within the United States.

Custom products helped solve problems for hundreds of customers with manufacturing solutions that just didn’t quite fit the bill of our off the shelf products. Since we are a manufacturer (located in Cincinnati, OH) we have the ability to modify stock products, create custom solutions, provide timely information and fast lead times for special products. We blog about specials a lot and we continue to help customers with custom fit products that will surpass their expectations.

With all of the new products and customs, we continued to achieve higher levels of shipping accuracy.  We now have a 20 year streak of shipping complete, on time, correct orders if over 99.9%! There are not many companies that I deal with on a personal level or through EXAIR which can claim their accuracy is this high.

When we weren’t shipping orders or helping customers with custom solutions we also managed to post more than 1 blog per business day, I don’t even want to count the thousands of other Social Media posts we have done, and released numerous videos of tips and tricks for many of our products.

The message I am trying to get across is that we press forward here at EXAIR.  We are constantly making moves and trying to ensure that we offer our customers every item they may need, in a timely manner, correctly, of high quality, and easy to do business with.

That is the only way that we can continue to be the best company for Intelligent Compressed Air Products!

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

 

Minor Adjustments, Advice From An Expert Source

It’s not every day that we hear a customer say that our products aren’t consuming ENOUGH air, but that’s exactly what happened to me yesterday. I received a call from one of our long-standing customers who was experiencing reduced air consumption with our Model # 3202 Vortex Tube. The Vortex Tube uses compressed air to create a stream of cold air and a stream of hot air, providing a temperature range from -50°F to +260°F and cooling capacity up to 10,200 Btu/hr. Also, these units have no moving parts and are virtually maintenance free, making them the ideal choice for a variety of industrial spot cooling applications.

Vortex Tubes

This particular customer has been purchasing this model for several years, so they are pretty familiar with the performance and operation of the unit. They advised they were used to seeing air consumption at approximately 60 liters/minute or 2 SCFM (exactly what the Model # 3202 is designed to consume at 100 psig inlet pressure) but were starting to experience about a 50% drop to 30 liter/minute or 1 SCFM. We discussed the common troubleshooting:

  • Low supply pressure? (measuring at the inlet of the Vortex Tube during operation)
  • Compressed air inlet temperature? (warmer than ambient air – reducing performance)
  • Reduced cold flow? (possible clog from contaminants in the compressed air supply)
  • Unit seeing any back pressure? (up to 2 PSIG is acceptable, 5 PSIG will reduce approximately 5°F)
  • Over-tightened Cold Cap or Cold Muffler? (is it too tight?)

The customer advised they were using a push-to-lock fitting, where they drilled out the center and then would install it in the Cold Cap of the Vortex Tube. Their operator would hold the body of the Vortex Tube, by the air inlet, then take a wrench and thread the fitting into the ¼” NPT female opening on the Cold Cap. Without realizing, the operator was also turning the Cold Cap which was causing it to become over-tightened.  This in turn would reduce the consumption of the unit because it would shrink the internal air chamber.

Vortex Tube Exploded View

 

I made the suggestion to my customer to slightly loosen the Cold Cap and see if that didn’t fix the consumption issue. They called me back about an hour later and were very pleased to advise that now the unit was “working great!”.

We want to help you maximize our products, while optimizing your compressed air system. If you have a similar performance issue or would like to discuss your application, please contact us.

Justin Nicholl
Application Engineer
justinnicholl@EXAIR.com
@EXAIR_JN

Customer Service?

Recently I was having some issues with my cell phone dropping calls and frequent undelivered texts, emails and voice-mails so I placed a call to my provider to see what could be done. From my previous experience with cell phone providers, I knew this was going to be a tedious process but was hoping for the best since I have been an 8+ year customer. So I contacted the company last week and explained my situation. They advised that the service in my area had been acting up and they would need to open a file on my line that could take 7 – 10 days before I would receive a response. The VERY next morning they called to tell me that there were issues with the coverage in my area but it had been resolved.

So as the week went by and I was still experiencing the same issues, I called the company back. This time I was transferred to the technical department so they could troubleshoot my device – after a 2 hour phone call, they could provide no reason as to why I was having issues and offered me no course toward a resolution. Now frustrated, I decided to visit their website and participate in their chat option to see if we could get to a resolution. No such luck, I now had to elevate the situation and speak to a manager.

funny-cell-phone

After 17 phone calls to customer service and a total of 5 online chats, I finally got the one person who was actually willing to help. After reviewing the notes on my account, she offered me a free upgrade, without extending my service contract, shipped the replacement phone for overnight delivery and waived the $40 activation fee for the new device. Of course I was pleased with this resolution but asked why it was necessary to jump through so many hoops about the same issue – “it really depends on who you talk to and if they want to do the work or not”. In my opinion, that’s a pretty sad approach toward servicing a customer.

At EXAIR, our main focus is customer service and we will make every attempt to provide assistance and handle your request(s) in a prompt and thorough manner.  The fact is, a sales person can sell just about anything once.  It is the service that you are provided – that installation and maintenance guide or 3D model that can be easily downloaded – that takes a company with amazing products over the edge.   We strive to ensure you have every possible way to reach our Application Engineers.  We are here to help you not only determine which product will work best in your application, but also to help you troubleshoot your existing product, determine what air savings you have gained from installing an engineered solution, as well as figure out ways to make your operating area a safer, quieter place for your employees.

Here are some very recent comments we have received from customers:

  • “Super fast service. EXCELLENT!” – Joe, industrial laser manufacturer
  • “I called your customer service line and Vikki Foley was very helpful and even though it was late Thursday afternoon, she sounds like she enjoys her job.” – Mark, rapid prototyping and product design company
  • “Fantastic service. Very fast responses and concise information.” – Chase, display technology manufacturer
  • “Russ Bowman was an excellent help. He was respectful and went out of his way to find information that I requested. Would definitely recommend working with Exair. Outstanding customer service!” – Kathryn, engineering consultant

We can’t ask for anything more than that. We want to do the work, we want to make it easy for you.

Please feel free to contact us – via phone @ 800-903-9247, by email techelp@exair.com or our online chat for assistance with your compressed air application today.

Justin Nicholl
Application Engineer
justinnicholl@EXAIR.com
@EXAIR_JN

 

 

 

 

Troubleshooting 101: Super Air Knife

Yesterday, I was working with a customer on troubleshooting a Super Air Knife. He had brought the knife into EXAIR’s demo room so I was able to verify a few items very easily.  When trouble shooting air knives there are no moving parts, so it is very small list of items to check.

  1. Check the Air Supply

  2. Check the plumbing

  3. Check the inside of the Air Knife for debris

The customer had a 36″ Super Air Knife ,and he was seeing some weak spots in the air flow as well as a gradient in flow from one side of the knife to the other.  The first thing I did was to install a pipe tee with a pressure gauge in both ports on the bottom of the knife.  This would allow me to monitor the pressure we were supplying to the knife to calculate the air consumption and ensure the our piping was not starving the knife for air.

IMG_3735

Feeding the knife with equal pressure from both sides, is necessary for any air knife 24 inches or longer. The customer immediately noticed that the flow from the knife lost any sort of gradient, once it was fed in (2) locations. Still the air knife exhibited a spot in the flow where air velocity significantly decreased.  Since we were getting correct pressure and supplying enough air, we decided to remove the cap from the Super Air Knife.  Under the cap we found a variety of debris and one dreaded piece of PTFE plumbing tape. The plumbing tape was suppose to prevent air leaks throughout the compressed air system, but a piece had become lodged in the air gap of the Super Air Knife preventing air flow through a small portion of the Super Air Knife.  As you can see, once we followed a few simple steps to ensure proper installation of the Super Air Knife, it was quick and easy to narrow down what caused the lack of performance. This is yet another reason to make sure you have clean and dry compressed air, as well as use a point of use filter separator.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

Always make sure you have good support.

There is nothing worse than buying something with great hopes that the device will help you achieve a goal only to find out it doesn’t work at all like you had hoped or like the advertisement said it would.  I take that back…  The only thing worse than this is to discover there is no technical support or information on the product and you are basically stuck with something that doesn’t work.   Other times you can make do with the performance but it just doesn’t do as good a job as you need it to.  I like to call these “Band aid fixes”.   (What is shown below is what I truly hope to be one of those fixes.)

Here at EXAIR I get quite a few calls where people have an application that kind of works but they could really use something that is going to be more effective.  This is where our team of Application Engineers comes in.  You see we not only help you choose the product that will work for your application but then if you get it in-house and it isn’t working as good as you hoped then you call back in and we give you full tech support of the products for free.  We’ll help you fine tune the applications as much as possible and if it still doesn’t work we will take the product back on our 30 day guarantee.

Everything you do is always better with the proper support or safety net.  Just like my brother in-law and I had a support vehicle when we went through Deal’s Gap.   The video from the support vehicle is below.  (It’s sped up due to the time constraints of YouTube.)

So if you need some technical support on your application or on our product, feel free to give us a call.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF