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.

Clean air is crucial for optimal pneumatics

Liquid water, water vapor, particulates and oil can all interfere with proper compressed air operation. Removing moisture and contaminants ensure that the system does not experience premature wear or damage.

For optimal pneumatics performance, it is usually necessary to reduce the pressure of air leaving the compressor and filter out water, oil and contaminants. For some applications, clean oil needs to be added to the air to lubricate downstream equipment. This unit shows, left to right, a combined filter/regulator for general filtration/air pressure regulation, a coalescing oil removal filter and a lubricator.

Pneumatics is a versatile, proven technology for powering or controlling the operation of an amazing number of applications, from neo-natal respirators to building-size industrial equipment. The range of pneumatics capabilities is illustrated by the variety of typical systems, their uses and requirements.

• General pneumatic circuits (e.g. directional control valves and cylinders in machine cleaning, air motors and high-speed tools)
• OEM machines
• Breathing air
• Heavy duty lubrication
• Direct injection lubrication, such as required for conveyor chains
• Oil-free applications like paint spraying or film processing
• Critical pressure control and instrumentation
• Motion control for industrial automation or equipment operation
• Continuous processes like those in paper mills or chemical plants

While the configuration of pneumatic components for each of these systems varies, they all require air of the proper quality, temperature and pressure to function most productively. The air leaving a compressor is hot, dirty and wet, and is generally at a higher pressure than desired. Before this air can be used, it needs to have contaminants removed, pressure reduced and, in many cases, oil added to lubricate downstream equipment. This article examines the first requirement: removing moisture and contaminants.

Liquid water
Air exiting the compressor outlet will contain water vapor, but as the air cools, the moisture condenses. The amount of water vapor in any given volume of compressed air is directly proportional to the air temperature and inversely proportional to the pressure, so there is more liquid water when the temperature is lowest and the pressure highest. This is the point where removing it is the most efficient. An aftercooler should be used to cool the air coming out of the compressor to within 8º C of the temperature of the water entering the after cooler for most efficient water removal.

At this point, the outgoing air should be piped to a receiver in the coolest location available, definitely not within the compressor house itself. Further cooling—and condensation—may occur in the distribution mains. These should be laid out with a pitch in the direction of air flow, so gravity and air flow will carry the water to drain legs. Except for these drain legs, all other air take-off points from the distribution mains should be taken from the top of the main to prevent water from entering the take-off lines.

As discussed earlier, water condenses (and is most efficiently removed) at high pressure, so anything that produces a pressure drop in the distribution system should be avoided. Filters should be located upstream of any pressure-reducing valves.

Maintaining consistent pressure also conserves energy, helping to control costs. Make sure to properly size piping and eliminate complex flow paths with undue bends.

Water can be removed using drip leg drains, automatic drain valves or filters. These devices should be located where liquid water is present in amounts large enough to be removed. Because air may cool as it passes through distribution mains and branch lines, it is more effective to install smaller individual filters as near to the actual point of air usage as possible, rather than rely on one large filter at the air receiver.

Water vapor
A system properly designed to remove liquid water will still not remove moisture from the air, and this moisture can condense later in the process. If the application requires complete freedom from water contamination, then the water vapor content must be reduced to the point that the dew point is lower than any temperature to which the air in the system will be exposed.

To remove water vapor from a compressed air system, air dryers must be employed. Dryers are most efficient at the lowest possible temperatures, and performance is diminished when air is contaminated by water, oil or water/oil emulsions, so dryers should always be used in conjunction with filters and coolers.

There are three types of dryers: refrigerant, regenerative adsorbent desiccant and deliquescent absorbent. (See Table 1, Dryer Comparison.) Here are some considerations for making the most cost-effective dryer choices.

Does your process truly require dry air? Air dryers are most commonly needed in general industrial applications where high ambient temperatures exist.

Do not specify extremely low dew points if the process does not warrant them.

Limit the volume of air being dried to that actually needed for the particular process, plus some capacity for expansion. For example, only one area of a process plan may require a dryer.

General recommendations for air drying can be difficult, since this depends on the temperature of the compressed air main adjacent to the operation, the level of pressure reduction and air flow rate. It also depends on the relative humidity and ambient temperatures of the local environment.

Solid particles
Particulates enter every compressed air system, either through ambient air intake, corrosion, or carbon build-up. Dirt particles can range in size from a fraction of a micron to several hundred microns, (See Table 2) but generally fall into two categories: coarse (40 microns and above) or fine.

Most normal airline filters will remove coarse particles. Fine filtration in the region of 10-15 microns is normally required for high-speed pneumatic tools or process control instrumentation. Filtration of 10 microns or finer is essential for air bearings and miniature pneumatic motors. Even finer filtration may be needed for paint spraying, breathing air or food-related applications. These require high efficiency (oil removal/coalescing) filters. Standard airline filters should be used as pre-filters to avoid overburdening the finer filters with coarse particles and triggering premature failure.

Oil as a contaminant
The principle source of oil contamination in a compressed air system is the compressor. Oil lubricates the compressor, but by the time it emerges with the compressed air, it has lost any lubricating capability and in fact is an aggressive contaminant that must be removed.

Normal airline filters will remove enough oil to leave the air suitable for most pneumatic tools and cylinders, but certain applications require completely oil-free air. Oil-free compressors eliminate oil but not water and dirt. So it can be more economical to use lubricated compressors with after coolers and standard airline filters and fit high efficiency oil removal filters only at the points in the system where oil-free air is absolutely required.

A general airline filter to remove water and large particles should always be located upstream from a coalescing filter to prevent clogging filtration media. On this general purpose/coalescing filter combination, when the filter elements become saturated to the point that air pressure drops, the green indicator on top shows red, signaling the operator that the element needs to be changed.

Oil in compressed air systems can exist in three forms, oil/water emulsions, aerosols or oil vapor. While emulsions can be removed by standard airline filters, more sophisticated filtration is required for aerosols or vapors.

Aerosols are small oil particles suspended in the air. Approximately 90% of these are between 0.01 and 1 micron—too small to be removed by the centrifugal action of standard airline filters. Special coalescing filters are required, and these should be protected against particulate and water contamination by airline filters mounted immediately upstream.

For most processes, removal of oil vapor is unnecessary, since quantities are minute. Exceptions include food or beverage processing, pharmaceuticals or breathing air applications.

The most common method of removing oil vapor is to pass the air through an adsorbing bed, usually comprised of activated carbon, after it has been through a pre-filter and a coalescing filter. Note: this system will not, as is sometimes thought, remove carbon monoxide or carbon dioxide.

Filter selection
Once all the contaminants have been considered, the degree of cleanliness of air for each part of the industrial plant or process can be determined. Table 3 shows the levels of contaminants allowed in each class of air quality as defined by ISO 8573. Employing the correct filters in the right locations can keep energy and maintenance costs to a minimum.

Table 4 shows typical air quality class requirements, and thus recommended filtration levels, for various applications. Also, selecting a filter rated for volume of air required is critical because undersized, inappropriate filters drive up energy costs.

When designing filtration to clean compressed air, be sure:

• The correct type of filter and element rating is selected for particle removal.
• Liquid removal is efficient and re-entrainment is not possible.
• It is easy to maintain the filters and remove liquid condensate.
• There is easy visual monitoring of condensate or filter elements for proper function or prompt maintenance. This may be a pressure drop device, liquid level indicator or transparent bowl.

With the system in place to remove contaminants from compressed air, designers can move on to the challenges of optimizing pressure and adding lubrication. Correct air preparation is the best way to get maximum performance from any pneumatically controlled system.

Norgren, Inc.

Compressed air filters feature top-load design

The Filtration and Separation Div. 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., Finite Filter Div.

Mid-Size Coalescing Filters Provide Dry Air

When clean, dry air is important to your manufacturing application, including a coalescing filter in your pneumatic system is an easy way to ensure proper air preparation. The Mid-Size Coalescing filter comes with a standard 6-oz aluminum bowl with an easy-read clear nylon sight glass, but can also be ordered with a larger 10-oz extended aluminum bowl. The extended bowl provides a higher flow filter element which can be used for longer periods before changing is necessary, saving maintenance time.

The Mid-Size Coalescing filter may be mounted inline or can be paired with other products in a modular fashion. It is available in 1/4, 3/8 and 1/2 port sizes and comes with NPTF port threads (standard) or BSPP threads (optional).

The filter has a differential pressure gauge and an internal automatic drain (optional manual drain models available). Its internal filter element is rated to 0.3 microns; an optional 0.01 micron-rated filter element is also available.

Clippard Releases New Full-line Catalog

Clippard Instrument Laboratory, Inc., manufacturer of the industry’s most complete line of miniature fluid power products, has just released the all-new 356-page catalog.

This full-line catalog includes features, specifications, technical drawings, color photographs, and application highlights throughout. Products can be found in six main categories, including Cylinders, Electronic Valves, Control Valves, Modular Valves, Fittings and Hose, and Air Preparation equipment.

Clippard Instrument Laboratory, Inc.
www.clippard.com/catalog