Small, lightweight brushless DC compressor

The Thomas 2220 Series brushless DC oil-less air compressor is designed for medical and other applications requiring a compact, lightweight compressor with variable output. The 2220 is small (3.77-in. high x 2.64-in. wide x 4.70-in. long) and weighs only 1.48 lb. (0.7 kg). The compressor features an efficient variable speed motor that produces flow to 1.1 cfm (32.3 lpm) and pressure to 30 psi. (2.1 bar). In addition, the proven Thomas WOB-L piston technology combined with the enclosed crankcase design provides durable quiet—45 dB(A)—performance.

Thomas Div.

Finding and measuring pneumatic leaks

Leaks can be a significant source of wasted energy in an industrial compressed air system.

If compressed air were hydraulic fluid, leaks would be so visible that we would ensure their reduction. As it is, we accept a low level hiss in our work places as simply a ‘part of the job.’ At a price that is roughly comparable to that of domestic gas, this attitude costs industry dearly.

It is estimated by the U.S. Department of Energy that industrial energy usage is $1.5 billion per year; 20% to 30% of this amount is lost in air leaks. In addition to being a source of wasted energy, leaks can also contribute to other operating losses. Leaks cause pressure loss in systems, which can mean pressure is too low to the application leading to more reject product. Frequently the generation capacity is increased to compensate, rather than simply fixing the leaks.

Where to find leaks
Pipework—Aging pipework is a prime source of leaks. Replace any corroded pipework sections—for safety as well as energy saving.
Fittings, flanges and manifolds—Large leaks are often found at connection points, both in the main distribution system and in off takes. Sometimes when several snap connectors are used together to form manifolds they can be a source of leakage due to worn connectors and poorly jointed pipe work.
Flexible hoses and couplings—Leaks can be caused by damage to hose due to abrasion by surrounding objects, deterioration of the hose material and strain on the joint because the hose is too long or too short.
Old components not maintained; seals start to leak—Check all pneumatic components, e.g. old cylinders and regulators, for worn internal air seals which can cause large leaks.
Condensate drainage valves—Large amounts of air can be lost when drain valves are stuck open or even left open intentionally. These can often be found in remote parts of the system where condensate collects.
Systems left pressured when not in use—Where subsystems have a large amount of leakage, which cannot be avoided, e.g. presses and drop hammers, isolate them from the air supply when not in use. Simple shut-off valves or electrically operated soft start dump valves offer cost effective ways to isolate leaky systems, or areas of a plant when not in use.

Measuring the leakage
You can measure the base leakage easily using one of several methods. Install a flowmeter and pressure transducer in the compressed air feeding main (after any receivers). Connect the output of the flowmeter and the pressure transducer to a chart recorder and take readings over a representative period of time. Measure the flow from the compressor when the system is not working, e.g. at a weekend.

Use a compressor of known capacity to pump the system up to normal operating pressure during non-production hours. The compressor will unload at the operating pressure. As the system pressure drops due to leakage the compressor will load at its minimum running pressure. You can then estimate the leakage rate from the average loaded and unloaded times over a representative period.

Pump the system up to pressure and measure the time taken for the pressure to decay to the lower limit. If you know the total volume of the piping network and the receivers, you can calculate the leakage rate. Use a small flowmeter in branch lines to identify real problem areas.

Norgren Ltd.

Air is money—cutting pneumatics operating costs

Pneumatic installations frequently do not include any monitoring facilities—a serious error, as 79% of the costs of compressed air are accounted for by the electricity used for generation and preparation. Even if compressors, distribution systems, and pneumatic actuators are correctly dimensioned, leakage often causes losses of up to 600 lpm. What does it matter, it’s only air, users might think. But even a reduction of compressed air losses of 100 lpm saves up to $1,450 per year.

Potential for savings
However, users often fail to exploit this potential for savings due to lack of know-how. Furthermore, in many cases, the technical equipment necessary to localize losses is not available. Frequently, lack of time prevents the implementation of energy-saving measures. Festo Energy Saving Services can help to monitor and optimize compressed air consumption by simple means.

Reducing energy costs
As part of an efficient leak-management system, a specialist will check during operation the compressed air system in question for leaks and will record each leak together with all the associated technical data, such as details of the spare parts required. This documentation will then show all the required maintenance measures and list the long-term savings against the short-term repair costs.

Optimizing compressed air consumption
More and more industrial companies are using precise compressed air consumption data as the main criterion for the choice of new equipment. With a detailed compressed air consumption analysis, they can make savings of up to 50% more than with conventional methods. Even before commissioning, a compressed air consumption analysis can determine the precise compressed air consumption of an installation—both during normal operation and with machines at a standstill. It thus guarantees optimum dimensioning of the compressed air supply system and prevents unnecessary costs, which might be caused by an over-dimensioned compressed air distribution system.

Increasing service life
Any excesses or shortages in the compressed air quality, with regard, for example, to oil, water or dirt particles, will have a negative effect on the service life of the pneumatic components concerned, resulting increased energy and operating costs. The compressed air quality analysis offered by Festo Energy Saving Services measures the residual oil content and pressure dew point, identifies weaknesses and develops suggestions for improvements, for example filter changes at more frequent intervals. Optimized maintenance allows average savings of 35% to be achieved.

Saving compressed air
Ideally, savings measures should begin at the source of the compressed air, the compressors. An energy analysis of compressed air generation provides detailed consumption profiles for electricity and compressed air, together with data on pressure levels, better timing of compressor run times, and flexible operating scenarios. In this way it is possible to ensure optimum use of available compressor capacity. A measurement of compressed air delivery with machines at a standstill provides a mathematical indication of leakage losses and thus the possible savings in the compressed air system as a whole.

Energy monitoring
When an installation is optimized with Energy Saving Services, the aim is to avoid damage and breakdowns in advance. Festo offers various condition monitoring and diagnostic measures for this purpose. Through the continuous monitoring of critical components, it is possible to detect wear, pressure, and flow changes at an early stage and avoid the danger of machine downtime. If a breakdown nonetheless occurs, the diagnostic systems ensure that the cause of the trouble is quickly located.

Energy Monitoring GFDM is a complete system for the continuous monitoring of compressed air consumption and volumetric flow. Alternatively, installation operators can select a customer-specific condition monitoring system. Diagnostic systems are compiled from function modules in accordance with individual customers’ requirements. The available functions include not only consumption monitoring, but also time monitoring of actuators and valves, monitoring of vacuum applications, and detailed monitoring of actuators (e.g. force monitoring and fault detection).

Festo Corp.

 

Air regulator, filter regulator series have added features

Amherst, N.H.—ControlAir Inc. has announced a new Instrument Air Regulator and Air Filter Regulator series. The company has expanded its 330 instrument air filter regulator to include a regulator only version, larger porting sizes, and an automatic drain. The Type-330/340 Series was designed to withstand harsh environments while providing highly accurate pressure regulation and filtration.

The Type-330 Air Filter Regulator provides pressure regulation and filtration in an integral compact package. It is now available in 1/4-in. NPT porting for normal operation and 1/2-in. NPT porting for high flow requirements. The new automatic drain option prevents moisture from being retained in the unit and being carried downstream. The new Type-340 Regulator was designed to provide accurate, constant control under variable flow rates and supply pressures. It is also available in both 1/4-in. and 1/2-in. NPT porting.

The Type-330/340 Series offers a choice of three output ranges that provide precision control up to 120 psig (8 BAR). Maximum supply pressure is 250 psig (17 BAR). Two 1/4-in. NPT gauge ports are included. The Type-330 offers an optional automatic float operated drain with 1/8-in. NPT connection for piping away waste liquid. The units can be pipe, bracket or through body mounted. ATEX 94/9/EC approval II G D is also available.

The Type-330/340 Series is designed to provide instrument quality air to valves, pneumatic controllers, transmitters, transducers, valve positioners, air cylinders, and a wide range of pneumatic control systems. Applications include oil and gas processing, both on and offshore; food; pulp and paper; pharmaceutical processing; pollution control; wastewater treatment and research projects.

ControlAir Inc.

 

Energy isolation for washdown applications

Building on its rugged Stainless Steel L-O-X lockout and exhaust valve, ROSS Controls is now offering a control reliable energy isolation solution specifically designed for sensitive washdown applications. ROSS has assembled some of its most popular products into a fluid and particulate resistant stainless steel cabinet to meet the need for uncontaminated fluid power control in industries such as food, beverage and chemical processing,

The Control Reliable Washdown cabinet incorporates:

• A 316 Stainless Steel L-O-X lockout and exhaust valve (on the exterior)
• A combination filter/regulator for particulate removal and pressure control
• A Category-4 DM2 double valve with dynamic monitoring and memory for air entry control
• A ready-to-mount stainless steel cabinet with a sloped top to avoid liquid accumulation

The self-draining Stainless Steel L-O-X valve is mounted on the exterior of the cabinet for quick access. It offers an easy-to-identify shape, tamper-proof locking mechanism, a large exhaust port for rapid pressure relief and simple push/pull operation—all of which meet OSHA, ANSI and CSA requirements. Its durable fluorocarbon seals resist contaminant ingression which is important in applications requiring consistent protection.

Because each cabinet is designed to customer specifications, the double valve used can be Category 2, 3 or 4—whatever is dictated by the customer’s thorough risk assessment. Further modifications can be made, depending on the application’s specific needs. Optional stainless steel silencers and pneumatic energy release verification products are also available for additional safety enhancement.

To learn more about how ROSS’ Control Reliable Washdown cabinet can help you maintain a productive and contaminant free production line, contact your local ROSS distributor or download ROSS’ brochure or Catalog 104.

ROSS Controls

Festo introduces MS9 compressed air preparation unit

Hauppauge, N.Y.—Festo is now offering the latest addition to its MS-series air preparation units, the MS9 size, a unit with a 1-in. (25.4 mm) port capable of 600% higher flow rate than the smaller units in the series. The MS-series received Germany’s highest design award in 2010, and the product extension MS-9 is now available in the U.S.

The MS-series combines all of the standard functions of air preparation united into one product series: pressure regulators, on/off and soft-start valves, filters, dryers, sensors, and lubricators. The series includes function modules with integrated sensors and remote adjustability and the most advanced technology for air preparation—remote-controlled pressure monitoring for maximum process security. Pressure regulator units in the series have a fiber-reinforced rolling membrane, which dramatically increases flow rate and service life. As a result, pressure drops and regulation failures are reduced, allowing pneumatic systems to function more reliably.

Powerful addition to the series
The MS9’s sturdy construction makes it suitable for a wide range of uses in the automotive and food industries. Individual modules can be combined with each other, or with smaller modules to form customer-specific solutions. Colored connection components are used in the design to emphasize the modularity of the system.

With the introduction of the MS9 components, Festo has added a new option to its three existing sizes – MS4, MS6, and MS12. The MS9 size has a grid dimension of 3.5 in. (90 mm) and connection sizes from ½ to 1 ½ in. (12.7 to 38.1 mm). Filtration grades from 0.0015 in. (40 µm) to activated carbon filtration are available.

Modular and flexible
All modules can be replaced without disassembling the entire system. The same is true for the replacement of filter trays, which are first loosened via the blue interlocking switch and can then be removed individually. During system operation, the fill levels can be read directly
from the front through the sight glass. This saves time when installing, maintaining, and expanding the system. The MS series service unit has high flow rates and yet its design is space-saving and can be configured to meet customer needs.

Safety and remote maintenance
With MS Safety, the MS series also offers maximum safety as standard for man and machine. For example, the new MS9 units can be combined with the soft-start and quick exhaust valve MS6-SV. This reliably ensures rapid venting in the event of an emergency shutdown in safety-critical areas of the system.

Festo Corp.

Compressed air filters offer top-load design

The Filtration and Separation Division of Parker Hannifin has introduced a new line of “top-loading” compressed air filters. These filter housings are designed to make element change-out in even the most space-challenged environments faster and easier. The drain connections do not need to be disrupted during the change-out process.

The proprietary, patented element design will remove up to 99.995% of oil, water, and solids from compressed air and other gases. Other product features include robust aluminum construction, top threading element design for faster change-outs, coalescing design to continuously trap and drain liquids, and operation with minimal pressure drop.

Applications include protecting refrigerated dryers from oil contamination, cold coalescing, general industrial, and OEM requirements.

Parker Hannifin Corp., Filtration and Separation Div.

Festo launches push for greater compressed air efficiency

Compressed air preparation is not exactly a hot topic for plant operators. As a result, carelessly maintained compressed air systems waste energy and result in premature wearing of high-quality pneumatic valves and drives. Festo is now launching a push for greater compressed air efficiency.

Once it gets into the service units, this contaminated compressed air results in faster wearing of seals, oiled-up valves in the control section and dirty silencers. This decreases the availability of the machines and the service life of the pneumatic components and systems and increases the energy costs due to leakage and maintenance effort.

Help is available in the form of diagnostic tools, safety functions to ISO and ready-to-install system solutions that Festo combines in a customised and energy-efficient package as appropriate to the requirements of the compressed air systems. Even a few small tricks can together increase the efficiency of the system. These include switching off the air supply when the machines are at rest, when shifts end or during breaks. If greater pressure is needed at specific points in the compressed air network, it is often enough to use a pressure booster at this point instead of operating the entire network with a higher working pressure.

It’s all about the design
Installing a decentralised compressed air preparation system directly at the system reduces the risk of components being contaminated. Users should clarify the following questions when designing a decentralised compressed air preparation system:

• What is the maximum flow rate required?
• What connection sizes are required?
• Do all consuming devices need the same compressed air quality?
• What compressed air quality does the compressor actually provide?

Sensors add intelligence
Intelligent service units such as the MS series from Festo integrate flow and pressure sensors that detect unnecessary consumption in good time and enable preventative maintenance. They can also be remotely adjusted and monitored. In addition, they indicate the degree of contamination of the filters so that maintenance intervals can be scheduled. Also on board the MS series: the MS6-SV for safe pressurising and exhausting.

Pre-assembled solutions for compressed air preparation save users a lot of time and money. These individual solutions with their one part number simplify the design and purchasing process and are supplied ready to install directly at the system.

Don’t forget accessories
Compressed air system accessories such as tubing and fittings also deserve attention: tubing materials appropriate to the environment prevent chemical, physical and microbial damage. When it comes to tubing, it is important to have the correct lengths and diameters to minimise pressure losses as well as to cut them to length using suitable tools. Fittings with modern sealing rings and support functions ensure leak-proof and reusable screw connections.

Festo
Festo Didactic

Miniature pressure regulator provides accuracy, repeatability

ControlAir Inc. has introduced Type-90 Miniature Precision Air Pressure Regulator. This unit is designed to provide the highest level of regulation accuracy and repeatability available to valves and other automatic control equipment in a lightweight, compact housing. The Type 90 is suitable for applications that require exact pressure control and substantial flow capacity under variable operating conditions and limited space.

Features:
• High resolution adjustment of set pressure
• Precision control – highly accurate air pressure regulation in a small package
• Pressure ranges up to 120 psig (8 bar)
• Compact and lightweight
• Two gauge ports and reversible bracket – allow front or back mounting
• Superior flow characteristics – aspirator design provides excellent resistance to droop
• Low air consumption – means less cost over time to the operator
• Available in 1/8 NPT, BSP porting and manifold mounting

The Type-90 is suitable for any application that calls for accurately maintained output pressure under variable operating conditions. This includes applications such as diagnostic controls, precision fluid control, microfluidics, air gauging, gas mixing, calibration standards, air hoists, medical instrumentation, ventilators, gate actuators, roll loading, valve operators, cylinder loading and web tensioning.

The Type-90 Miniature Precision Air Pressure Regulator is available in 1/8 NPT & BSP porting and manifold mounting. Output ranges include 0.7-30 psig (0.05-2 bar), 1.4-60 psig (0.10-4 bar) and 1.40-120 psig (0.10-8 bar). Maximum supply pressure is 150 psig (10 bar). Two gauge ports and reversible mounting bracket allow front or back mounting. A wide temperature range of 0º to 160º F (-18º to 71º C). Flow capacity is 14 scfm at 150 psig (10 bar) supply with 120 psig (8 bar) output. Exhaust capacity is 7 scfm (200 Nl/min) with downstream 5 psig (0.4 bar) above set point. Air consumption is 6 scfh (170 Nl/hr). Effect of Supply Variation is less than 0.5 psig (.034 bar) for a 100 psig (6.9 bar) change. The Type-90 Miniature Precision Air Pressure Regulator weighs 0.35 lb (0.16 kg).

ControlAir Inc.

Membrane air dryers from Parker Hannifin

The Filtration and Separation Division of Parker Hannifin offers a complete line of Balston membrane air dryers specifically for use with Coordinate Measurement Machines (CMM).

Proven to be the best performing dryers for the most sensitive applications, Balston CM Series Membrane Air Dryers offer lower operating costs and better performance than both non-cycling and cycling refrigerant air dryers and eliminate downtime and costly repairs resulting from dirty, wet compressed air supplies.

Balston Membrane Air Dryers for CMMs offer a guaranteed dewpoint of 35° F and will remove compressed air contaminants down to 0.01 micron in size. Unsurpassed in performance and durability to dehydrate and purify compressed air, the Balston CM Series Membrane Air Dryers significantly outperform refrigerant air dryers in dewpoint reduction and are typically less expensive to operate.

The Balston CM Series Air Dryers are shipped complete to with prefilters, auto drains and membrane modules assembled for easy installation. The membrane module can be installed horizontally or vertically.

Parker Hannifin Corp., Filtration and Separation Div.