Jorc is an independent manufacturer of products that are used to remove condensation from a compressed air system. Their experience in this business has led to a unique approach to solving the problems associated with compressor condensation.

The company has been successful because they deliver value to the customer by providing quality products at affordable prices. Our research found that they are able to combine technology and common sense to create reliable drains with practical features.

This special drain makes it possible for you to manage the condensation in your compressed air system without wasting compressed air. It has several exclusive benefits that eliminate the common problems caused by compressor condensate and the shortcomings of existing drains. These include the following:

• The Smart Guard is the only drain to use radio wave signals and a special transducer to measure the presence of condensate. It opens the valve when condensate is present and has a safety setting that closes the valve before wasting compressed air.

• The Smart Guard measures for condensation, volumetrically, 50 times per second. This continuous monitoring makes it possible for fast discharge of up to 20 gallons an hour for a 100 psi system, 30 gallons an hour for a 230 psi system. The large dumping capacity makes it possible for you to use this drain in most applications which eliminates the need for multiples sizes and types of drains.

• The Smart Guard is the only drain with a clear bowl so you can easily monitor the performance of the drain. This means you can see the cycling of the drain and investigate if the bowl stays full of condensate.

• The Smart Guard is the only drain without moving parts or sensors in the condensation. This eliminates maintenance.

• The Smart Guard uses a large orifice (4.5 millimeters) for the discharge of the condensation. This makes it possible for the drain to handle the larger contaminants often found in condensation without the constant clogging.

The Smart Guard can handle the condensation produced by the majority of compressed air systems used in industrial plants. You can simplify the operation by installing one on all drain points. This includes the aftercooler separator, receiver tank, air dryer, in-line filters and at drain points in the piping.

Potential Savings

The Smart Guard will quickly pay for itself when you replace your existing drains. The following explains:

• The Smart Guard is only $250! This is about 50% less than you will pay for the automatic (zero air loss) drains sold by the brand names in this industry. In fact, the price is compatible with what you would pay for some timer and float operated drains.

• Another area for saving money is the ability to recover energy costs and money previously spent on drain maintenance. Other drains will cause you to spend time and money to monitor and maintain and, in most cases, will waste compressed air. See Condensation Facts for more details on the shortcomings of other drains.

• Savings will also come from the elimination of condensation in your compressed air system. A consistent supply of dry air will reduce the equipment problems that lead to production downtime and poor quality.

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Jorc has an extensive group of products that can handle any condensation related problem with prices that will save you money. The following are a few examples:

TEC 44

The TEC 44 was designed to drain the applications with large contaminants in the condensation such as the deliquescent dryer. This type of dryer produces an aggressive condensation mixture because of the tablets used in the drying process.

The TEC 44 is a timer drain with a motorized ball valve to handle the heavy duty contaminates that pass through a deliquescent dryer. It has a micro processor, easy touch buttons for adjusting cycles and a battery for power failure back up.

This drain is priced at $250 and is a must for any application with heavy duty contamination.

Electronic Auto Drain (EAD)

The EAD is a timer drain that was designed for those customers that are not concerned about the energy cost of the air lost during drain cycles. It is mass produced with some unique benefits over the low priced timer drains on the market.

The EAD has a larger discharge orifice (4.0 millimeters) than the similar drains sold by the brand names in this industry. It also uses seals that are compatible with the use of synthetic lubricants in the compressor. This drain is very easy to install and requires no maintenance.

The EAD is priced at $70.00 which is favorable to any budget.

Air Saver

A compressed air system that is turned off at the end of a work day will waste the air that was stored in the receiver tank(s). It will simply leak out through the compressed air distribution system.

The Air Saver is a valve that can be installed between the receiver tank(s) and the air distribution system. It can be programmed to open at the start of your work day and close at the end of the work day.

This saves you the cost of producing an extra tank(s) of compressed air each day. The specific amount of recoverable energy cost will depend on the amount of air in the tank(s) and the KW power rate.

The Air Saver is priced at $129.00.

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The right information and the right drains will help you manage the condensation in your compressed air system. Consider the following offer:

• Would you like some help determining the type and size of drain that would be best for your application? If so, you can get some free advice from the consultants associated with CompressorWise.com.

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Condensation is the moisture that drops out of an air flow as it cools. The condensation in a compressed air system is a constant threat to cause expensive problems. The following are a few examples:

• Moisture washes lubrication from air tools and production equipment causing downtime and maintenance.
• An inconsistent supply of dry air causes production quality problems.
• Excessive rust and scale often forms in the air distribution system.
• Water can back up into the compressor and wreck the machinery.
• Air dryers can become overloaded.
• In-line filters can be destroyed.

The problems get worse if you operate lubed reciprocating or oil flooded rotary screw compressors – which is just about everyone. Compressor oil makes its way into the distribution system with the compressed air. The mixture of oil, water, dirt and heat tends to build up a sludge that will ultimately jam or clog production equipment, air tools and drains.

The situation is further complicated by climate and seasonal weather changes. This is because the amount of condensation generated will change according to changes in the temperature and the relative humidity of the inlet air.

Consider that a 200 horse power compressor operating in a climate of 60 degrees F with 40% relative humidity will generate approximately 50 gallons of condensate a day. However, that same compressor operating in a climate of 90 degrees F with 70% relative humidity will generate approximately 260 gallons of condensate a day.

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The typical compressed air system is designed to remove condensation at strategic locations. This means there are drains at the aftercooler separator, receiver tank, air dryer, in-line filters and at drain points in the piping. The following explains the shortcomings of the drains being used in industrial plants.

Manual Drains

These drains are valves that have to be opened manually to dump the condensation. Judging how often and when to drain each point manually is a complicated process.

Some operators solve this problem by leaving the valve partly open at all times. This constantly drains the condensation and wastes compressed air in the process.

The energy cost to produce compressed air will vary depending upon the KW power rate. However, even a small continual leak will waste several hundred dollars in annual energy costs.

Float Operated Drains

These drains use a float mechanism in a housing to automate the dumping of the condensation. The outlet valve is controlled by a float that rises as the housing is filled with the condensate.

This style of drain has a built in problem that is magnified in a lubricated compressed air system. The contaminants in the condensate will affect the performance of the internal components. The float mechanism tends to jam either in the open or closed position.

Unless operators check the valve’s performance regularly, they will not realize that the drain has stopped working. Of course, if the float has stuck in the open position, the air blast will be audible.

There is no easy way to monitor the performance of this type of drain which increases the risks of condensation problems. In addition, the internal parts will require more maintenance because they are in constant contact with the condensation.

Timer Drains

These drains utilize an electronic timer to activate a valve that dumps the condensation. These drains are inexpensive and popular because many vendors who make, package or service air equipment include timer drains with their products.

You can adjust the drain cycles by setting the number of cycles per hour and the length of time the valve will stay open during each cycle. The idea is to set the timer for a long enough period to completely drain the condensation without setting it long enough to waste compressed air.

This means that the settings will have to be adjusted to compensate for climate and seasonal changes. It requires considerable time, manpower and expertise to successfully manage this process.

The reality is that many timer drains are operated at the initial factory settings. This practice will waste compressed air every cycle.

Some operators fear the consequences of too short an open time. They will set the open time to the longest setting and select a frequent cycle setting to make sure that the system drains completely which will waste compressed air every cycle.

The problem with timer drains is that they waste air every cycle unless perfectly set to match current conditions. In addition, the compressor controls will respond to the loss of air by loading the compressor to fill what is really an artificial demand for compressed air.

Electronic Sensor Drains

These drains are very expensive in comparison to the other types of drains. They have electronic sensors monitoring the level of condensation within a housing.

One sensor signals a valve to dump the condensate when the housing is full of condensation. Another signals the outlet valve to close before completely draining the condensate to avoid wasting air.

The housing makes it difficult to monitor the performance of the drain. In addition, it possible for foam to develop within the housing. This can cause the sensor to detect condensation which activates false signals that will lead to wasting compressed air and over working the components.

The sensing devices are in constant contact with the contaminants found in compressor condensation. This will damage the reliability of the drain and increase maintenance.

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Why are Jorc drains priced so much lower?

Their philosophy is to deliver value to their customers. They believe this is best accomplished by providing an economical price on drains that work. This makes it possible for anyone to afford the top products that help manage compressor condensation.

Why does Jorc make timer drains?

Saving energy is not the top priority for everyone. In those cases, they want to provide the option of a timer drains with affordable prices.

What is the purpose of installing a strainer before drains?

A strainer is supposed to keep the largest contaminants from reaching the condensation drain. Some people use them to redirect the condensation when they have to do maintenance on a drain.

Does Jorc recommend strainers be used with their drains?

A strainer is not required when using a Jorc drain. The orifice in their valves are larger than those used by the brand names in this industry.

Why do drains with large ˝" connections clog?

It is not the size of the connection but the size of the orifice inside the valve that determines the size of the drain outlet. A drain with a larger outlet will be less likely to clog.

What is the best way to make sure a drain is working?

The consultants associated with CompressorWise.com recommend that you install a by-pass valve ahead of the condensation drain. That gives you a way to see if there is any condensation in the air line. It also makes it easier to do maintenance on drains.

What maintenance is required for the Smart Guard?

The Smart Guard Drain was designed with a large orifice and that will keep maintenance to a minimum. Jorc recommends that the inside of the monitoring bowl be cleaned a couple of times a year, especially if the compressors are lubricated. This must be done without the use of solvents which are harmful to the clear Lexan bowl.

Can the Smart Guard be used on every application?

The only location where the Smart Guard should not be used is on a drain for a deliquescent dryer. A special drain is needed to handle the aggressive contamination that can come from this type of dryer. Jorc recommends their TEC 44 drain – see Other Products for more details.

What can be used to handle applications with more than 20 gallons of condensation each hour?

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Jorc has proven the ability to deliver unique products at remarkable prices. This gives you the power to solve the problems caused by compressor condensation and save money in the process.

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