High Temperature Vortex Tube for Sensor Cooling

Last year I worked with a power company that was having issues with Position Feedback Sensors overheating causing erroneous readings and early failures.  The sensors were located above a steam turbine, and the ambient temperatures reached 128°F with spikes to 140-150°F.  The customer had called in looking for a way to keep the sensors cool, using minimal compressed air, and in a robust package.  After reviewing the details, we recommended the High Temperature Vortex Tube, model HT3210.  While using just 10 SCFM of 100 PSIG compressed air, the HT3210 provides 8 SCFM of cold air at a temperature drop of 54°F from the supply air temperature.  Bathing the sensor with this cool air keeps prevents it from heating up and has eliminated the bad readings and prevented the early failures.

The customer recently implemented the same fix for another set of sensors.

Plant Photo
Power Generation Process, with (3) Position Feedback Sensors
Sensor
Position Feedback Sensor

The High Temperature Vortex Tube is a special Vortex Tube offering from EXAIR that utilizes a brass generator and hi-temp seal for use in ambient temperatures up to 200°F.  Simply supply clean, dry compressed air, and get cold air starting at 50-54°F lower than the supply air temperature.  With sizes ranging from 2 to 150 SCFM, there is a Vortex Tube that will meet most applications.

Vortex tube
High Temperature Vortex Tube

If you have questions about the Vortex Tubes, or would like to talk about any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Twitter: @EXAIR_BB

EXAIR’s Adjustable Spot Cooler: A Versatile Tool for Your Cooling Needs!

 

If you’re looking at replacing messy coolant mist systems, look no further than the Adjustable Spot Cooler. EXAIR’s Adjustable Spot Cooler incorporates Vortex Tube technology to produce temperatures ranging from -30°F – +70°F. A Vortex Tube works by imparting a rapid spinning motion to the supplied compressed air. This airflow makes its way to the end of the tube where it is forced to abruptly change directions. It is during this change of direction that energy is given off in the form of heat. The hot air then exits the tube from the hot end, while cold air exits the other end of the tube. As the valve is opened to allow more air to exhaust from the hot end, the temperature at the cold end will decrease. At a sound level of just 73 dBA when operated at 100 psig and stock generator installed, this compact cooler will keep your operation cool, clean and dry without causing unnecessarily high noise levels.

3725
Critical tolerances are maintained on plastic parts using the Adjustable Spot Cooler

 

When looking at a Vortex Tube based solution, the variety of options can sometimes be daunting. This is where the versatility of the Adjustable Spot Cooler shines. Through a simple turn of the control knob, you can easily adjust the temperature and cold fraction of the unit. Additionally, the kits come with (2) extra generators (15-H and 30-H) that can be swapped out for the stock generator for more/less cooling power and air consumption. The 15-H generator will deliver up to 1,000 Btu/hr of cooling capacity and the 30-H will provide up to 2,000 Btu/hr of cooling capacity. We have (2) different kits available, the Model 3825 Single Point and the Model 3925 Dual Point Kit. The 3825 is recommended for use in applications where you’re cooling a small surface such as solder joints, hot melts, or drilled plastics. The 3925 system is better served when heat is generated over a larger surface area such as saw blade cooling. The kits use flexible Loc-Line hose to allow you to precisely position the cold airflow onto your target. The Adjustable Spot Cooler provides easy mounting with a swivel magnetic base, allowing you to mount the cooler directly at the most critical point that heat is being generated.

3825_3925 adj spot cooler

If you’re tired of cleaning up your coolant or have an application that requires dry machining, get one of the Adjustable Spot Cooler systems on order today. They’re in stock ready to ship!

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

Video Blog: Medium Vortex Tube Cooling Kit

EXAIR offers (3) Vortex Tube Cooling Kits, and the video below will provide an overview of the medium size offering, for refrigeration up to 2800 BTU/hr (706 Kcal/hr.)

If you have questions regarding Vortex Tube Cooling Kits or any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
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Twitter: @EXAIR_BB

Trouble Identifying an EXAIR part? Don’t worry, we’ve got you covered!

3240VT
EXAIR Model 3240H Vortex Tube with Hot Muffler Installed

 

Not a day goes by that we don’t receive a call from a customer that is having trouble identifying an EXAIR part. Due to the robust nature of our Vortex Tubes, they can be installed in applications for several years without any maintenance. When the time comes to expand that line, the labels may have worn off, the unit may be covered in grime or oil, or the personnel that originally ordered the product may no longer be with the company. In any case, one of the Application Engineers here at EXAIR will certainly be able to help!

I recently received an e-mail from a gentlemen in Indonesia who was suffering from that very problem. They had a Model 3240 Vortex Tube installed in a camera cooling application near a boiler. The engineer who designed the project was no longer with the company and they could not determine a Model number or when they had purchased it. They saw the EXAIR sticker, along with our contact information, and reached out for help. Vortex Tube’s come in different sizes, based on the available compressed air supply as well as the level of refrigeration needed. They’re available in (3) different sizes as well as Vortex Tubes for max refrigeration (R style generators) and Vortex Tubes for a maximum cold temperature (C style generators). In order to identify the Model number, you must look on the shoulder of the Vortex Tube generator. On it, there will be a stamp that indicates the generator style that is installed. In this case, the customer stated that there was a “40-R”, indicating to me that he had our Model 3240 Vortex Tube.

Our team of highly trained Application Engineers is here ready to assist you with any needs you may have regarding EXAIR products. With a little bit of investigative work, a quick discussion about the dimensions or a photo; we’re able to identify any of our products. If you’re considering expanding a current line into other parts of your facility, or perhaps adding a new location and need help identifying your EXAIR products; give an Application Engineer a call and we’ll be sure you get the right products on order!

Tyler Daniel

Application Engineer

Twitter: @EXAIR_TD

E-mail: tylerdaniel@exair.com

A Solution for This and a Solution for That – Solving Problems Throughout the Plant

EXAIR’s 15 extensive product lines solve problems in production processes everyday. From cooling to laser lens protection (as you will see below) to static elimination, general shop housecleaning, conveying and air conservation –  we would like to help solve your problems.

Last week, I got an email from a customer.  It was late in the day, and I was spent from a busy day.  The customer was emailing for (2) reasons. First, they wanted to express their appreciation for our efforts several months ago regarding an application for a Vortex Tube. Over the course of a couple of weeks, we shared information and ideas back and forth regarding the Vortex Tube technology, how it works, and the various considerations when choosing the appropriate model.  They ended up purchasing a unit and put it into operation.  The application involved a plastic tubing cutting process and in this instance both the cold and hot air streams could be utilized to improve the process. The process involves heating up the material so it would lose its memory set, and then a cooling operation to improve the material cutting and handling.  Below is an excerpt from the recent email:

capture

How_A_Vortex_Tube_Works
The Vortex Tube takes in compressed air, and creates a Cold Stream and a Hot Air Stream

The second reason for the email was that he needed help with another application and based on the success of the initial collaboration, he knew he could trust in EXAIR to help find a solution that would work.  The new application involves protecting a camera lens from debris created during a wire cutting laser process. The lens is getting hit with spatter and damage is starting to occur. Our collaboration has begun, and we are looking at the Super Air Knife and Flat Super Air Nozzle as possible solutions, each of them providing a strong air flow to direct the debris away from the lens.

To discuss your application and how an EXAIR Intelligent Compressed Air Products can help your process, feel free to contact EXAIR and one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web
Like us on Facebook
Twitter: @EXAIR_BB

Video Blog: Adjusting a Vortex Tube

See how simple it is adjust the outlet temperature of an EXAIR Vortex Tube below zero degrees Fahrenheit.  Vortex Tubes  are a low cost, reliable maintenance free solution for many industrial spot cooling applications.

EXAIR Vortex Tubes are constructed of stainless steel to resist corrosion and oxidation for years of reliable, maintenance free operation. They are used to provide cooling for electronic controls, dry machining operations, cameras, sensors, CCTV, hot melt adhesives, soldering, brazing, gas sampling, heat seals, and environmental chambers.

There are many advantages when using Vortex tubes:

  • No moving parts
  • No electricity
  • No chemicals
  • Low cost
  • Maintenance free
  • Instant cold air
  • Easily adjusted for temperature

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

EXAIR’s Cabinet Cooler® Systems Withstand Every Environment

EXAIR’s second product to win Plant Engineering Magazine’s Gold Award for Product of the Year is EXAIR’s Dual 316 Stainless Steel Cabinet Cooler System.

EXAIR Cabinet Cooler Systems are used continuously in some of Industry’s harshest environment to protect crowded, overheated, and expensive electronic controls from heat failures and alarms.  Dual 316 Stainless Steel Cabinet Cooler Systems provide 5,600 BTU/HR of cooling through (2) electrical knockouts and a compressed air line.  The 316 Stainless Steel NEMA 4X Cabinet Cooler Systems are UL Listed for wash down environments for food service and pharmaceutical application.

Fans, air conditioners, and heat exchanges use ambient air and are susceptible to failure from dusty environments when the filters clog or mechanical components fail.  With no refrigerant, motors, or bearings, Cabinet Cooler Systems require no maintenance and can run for years or decades. Cabinet Cooler Systems prevent downtime on the most critical components in your facility.

These coolers are used to protect the most sensitive electrical components in the United States.  A customer disposes of chemical weapons and monitors the exhaust gases of their facility with electronic components mounted to the outside of the smoke stack. This enclosure is exposed to the elements and the heat of the desert sun. Any failure or alarm in the equipment forces the process to shutdown.  A Stainless Steel Cabinet Cooler System protects these electrical components from overheating.

CC_Apps_4up

Stainless Steel Cabinet Cooler Systems have been used on ships, power plants, medical device manufacturing facilities, and bakeries to keep heat out of their enclosures.  They also feature an added benefit that fans, air conditioner and heat exchangers don’t.  The EXAIR Cabinet Cooler Systems apply a positive pressure to the enclosure to push out any dust that may otherwise gather inside your cabinet.  This positive pressure improves air flow and limits dust building up on electrical components.  When dust collects on components, it acts as an insulator trapping the heat against your critical controllers.  This trapped heat can lead to premature failure even with sufficient cooling inside the enclosure.

As this spring heats up and summer begins, keep the Cabinet Cooler System in mind as great solution to your over heating issues.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW