What Is the DES-CASE Connected Extended Series Breather?
The DES-CASE Connected Extended Series® (EX-4) is the market’s first connected desiccant breather, combining silica gel water adsorption with real-time IoT monitoring. It targets proactive water ingression control on gearboxes, hydraulic reservoirs, and storage tanks across industries including wind energy, mining, petrochemical, and aviation. The EX-4 is available with either a wireless module (DC-IL-EX-4) or a wired module (DC-IL-M8-EX-4).
Filter media is polyurethane and polyester. The hydrophilic agent is silica gel. All other wetted and structural materials are polycarbonate, nylon, polypropylene, PVC, Buna-N, silicone, and EPDM — compatible with all mineral oils, most synthetic oils, and diesel.
What Are the Core Filtration Specs of the EX-4?
The EX-4 filters to 3 μm absolute with a maximum water adsorption capacity of 27 fl. oz (798 ml). Operating temperature range is -4°F to 130°F (-20°C to 54°C). Maximum airflow at a differential pressure of 1 psi (0.07 bar) is 24 cfm (680 l/min).
Sizing guidelines from Des-Case recommend the EX-4 for:
- Gearboxes and storage tanks up to 1,000 gal (3,785 L)
- Hydraulic reservoirs up to 400 gal (1,514 L)
- Suction/return rates up to 180 gpm (680 l/min)
Des-Case notes that humidity level, frequency of airflow, ambient temperature, and chemical compatibility all affect proper sizing. Larger or special applications should be reviewed directly with Des-Case technical support.
How Does the Wireless Module Work?
The wireless module (DC-IL-EX-4) communicates with the sensor board via 13.56 MHz RFID and transmits data over Bluetooth 4.0 Low Energy (2.402–2.480 GHz) with a line-of-sight range of up to 100 ft (30 m). It is powered by three AAA 1.5 V DC alkaline batteries (max 1,200 mAh each), supplying 4.5 V DC at 30 mA operational current. Battery life expectancy is 2 years (use and temperature dependent).
Data is recorded every 60 minutes and the module stores 365 days of hourly data points. The companion app is compatible with Android OS 5.0+ and iOS 10.0+. The module carries an IP66 dustproof/waterproof rating and is rated for altitudes up to 5,000 meters. It is not rated for hazardous locations. Certifications include FCC, CE, REACH, RoHS, and Anatel.
How Does the Wired Module Differ from the Wireless Version?
The wired module (DC-IL-M8-EX-4) uses an M8, 4-pin male A-coding connector and communicates via RS485 Half Duplex rather than Bluetooth. Supply voltage is 9–28 V DC at 30 mA — suitable for integration into existing PLC or SCADA wiring infrastructure without battery replacement.
Like the wireless module, it uses 13.56 MHz RFID for sensor-board communication, stores 365 days of hourly readings, and carries IP66, FCC, CE, REACH, and RoHS certifications. The power/data cable is a 4-position connector with 3 m wire leads; the Connected Breather Cable Assembly is sold separately (IEC 61076-2-104 standard). The wired module is also not rated for hazardous locations.
Why Do Connected Breathers Extend Asset Life?
Des-Case states the connected monitoring capability can extend breather service life by up to 20% compared to unmonitored breathers. By providing 24/7 visibility into breather condition, maintenance teams can replace breathers based on actual saturation data rather than fixed intervals, reducing both over-servicing and catastrophic missed changes.
Additional operational benefits cited include:
- Remote monitoring of difficult-to-reach locations
- Real-time data access from anywhere via mobile app
- Shortened lube routes by eliminating unnecessary visual checks
- Proactive diagnostic tool for critical rotating assets
What Industries Use the DES-CASE EX-4 Connected Breather?
Des-Case identifies the following typical industries for the Connected Extended Series:
- Wind energy
- Aviation
- Storage
- Manufacturing
- Pulp and paper
- Petrochemical
- Mining
Summary
- The DES-CASE EX-4 filters to 3 μm absolute with a 27 fl. oz (798 ml) water adsorption capacity.
- The wireless module (DC-IL-EX-4) runs on three AAA batteries with a 2-year life expectancy and transmits via Bluetooth 4.0 LE up to 100 ft.
- The wired module (DC-IL-M8-EX-4) accepts 9–28 V DC and uses RS485 Half Duplex via an M8 4-pin connector.
- Both modules store 365 days of hourly data and carry an IP66 environmental rating.
- Connected monitoring can extend breather service life by up to 20% versus unmonitored breathers.
Products discussed in this episode
Browse all DES-CASE products on PE Energy Industrial Supply.
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