In Line Brazing

IN - LINE BRAZING MCOPERATING MANUAL

IN - LINE BRAZING SYSTEM

SERIAL NO 90896

1 SYSTEM DESCRIPTION 1 MODEL NO 300 IN-LINE BRAZER

2 GENERAL DESCRIPTION

In-Line Brazers are idel for mass production of similar assemblies like heat exchanger parts for R amp A Automotive radiator parts etc with linear movement of the assemblies a between the burner

units Of course the heat zone can be adjusted to various assembly height and width

3 BASIC MACHINE DESCRIPTION 3-1 MAIN BODY

The body will be made with all welded steel construction As you can see our drawing sheet

we made 8 leaves of doors at the front and back sides to give the AS convenience to you

Also we made 4 reinforced glasses doors in the upper front and back sides so that you can see

the brazing condition easily The body dimension is 2050mm widthtimes1850mm length

times3070mm hight including venting hood is less than 3550mm

3-2 CONTROL UNIT We made several leaves of doors for the maintenance control easily The dimension is 960mm width

times 600mm lenght times 1100mm hight

4 SPECIFICATION

4-1 CONBUSTION UNIT

Heating of the part is accompolished both three lines using propaneoxygen mixture

We use 100EA Burner tips(preheating 50EA main heating 50EA)

Each group of three lines is controlled form a separate mixer valve We attach each 3EA of gas and

oxygen Auto pressure controllers to make a easy to control gas amp oxygen amount

4-2 COOLING UNIT

We use two kinds of cooling methods water cooling and air cooling etc 1) Air Cooling Unit

Air cooling takes at air curtain below both heating zones to avoid a color change of end plate and

aluminum pin etc on heating

Another air cooling takes place at the upper side of the brazed assemblies after brazing and will

solidify the alloy It will be helpful to get a good color of copper tubes after brazing

2) Water Cooling

Water cooling takes place at each end of tips We made water cooling units for torch unit

Here are several advantages as follows

Water Cooling for burner tips 985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138985138

- Prevents overheating of burner tips

- Reduces back fires

- We can adjust the burner units to any directions So we can get more flexibility and good

brazed joints

- Gives longer life to burner tips

- We can get more uniform heating temperature

Countion Pls be careful for water freezing in the winter season At the case water cooling unit might be broken

4-3 PRODUCTION CAPACITY

This system includes a varible speed dirve with digital meter

The maximum conveyor speed will be 3000 mm per minute Normally our costomers set 1-2 meters

per minute depending on the items for brazing of 3-6 row heat exchangers

4-4 UTILITY REQUIREMENTS

- Electricity 415V 3PH 50HZ

- Fuel Gas LPGOXYGEN

- Compressed Air

- Water 10 Liters per minute plant water

4-5 OTHERS

- The capability of brazing 1 2 3 or 4 row heat exchanger coils

- Coils between 600~2200mm high can be brazed on this system

- An adjustable torch pattern for exact heat positioning including height width and engle of bruners

- Torch height positioning will be made automatically by servo motor system

- Torch widthes will be adjusted with servo motor moving unit

- Key components are made of durable stainless steel including heavy duty conveyor belt and

heat exhaust hood air cooling unit etc

- Full framed construction for easy of transport and relocation within your plant

- Jack screws for easy leveling of the machine

5 HOOK-UP FOR IN-LINE CONVEYOR BRAZING MACHINE

- An electrical power supply of 415Vac 3Ph 50Hz with proper grounding is required

- Exhaust Blower capable of moving 3875 CFM is required

- A propane supply line of at least 94mm dia is required for each combustion system (Note3 supply lines required) The gas supply hould be between 1 - 15Kgcm2

- A water supply of at least 94mm dia is required for the water cooled burner tips and air curtain etc

- A Nitrogen gas supply of at least 14 nipple is required for the gas flux supply The pressure over 05kgcm2 is required

- A compressed air pressure over 5kgcm2 is required for a air cooling

6 MACHINE ADJUSTMENTS

6-1 CONVEYOR SPEED

Conveyor speed is adjustable through the speed control located on your conveyor unit

Adjust to obtain desired speed for brazing

6-2 MANIFOLDS

To adjust the manifold height pls push teaching pendent The burner units will be up or

down by servo motor amp screw etc To adjust the manifold distance or degree you must do

by manual

6-3 GUIDE

To adjust X - Y you must do by manual

6-4 GAS FLUXER

- Pls connect nitrogen lines to a gas fluxer

- A nitrogen gas supply of 05kgcm2 at least is required

- It is recommended that an approved non-return check valve be installed in the gas line between

the outlet valve of the gas fluxer

- Do not operate gas fluxer with more than 20psig oxygen pressure or more than 1kgcm2 fuel gas

pressure

- Gas flux is a various flammable liquid and it should not be poured within 20 feet of an open

flame Use adequate ventilation

- Always keep refill valves closed except during flux transfer to prevent overfill gas fluxer

- Do dont operate th gas fluxer when the liquid gas flux has filled the sight glass

If overfilled pressure of the gas may force the liquid gas flux out through the hose and into the

tip making it impossible to operate Also never operate the gas fluxer unless sight shows some

liquid gas flux 7 BACKFIRE

1) The main reasons of backfire

- Uneven pressure of gas or oxygen

- Sudden pressure fluctuation by pipe clog

- Suddenly torch tip hole clog by some dirty things

- Burner tip over heating

- Some problem with the solenoid valve

- Remaining carbon residues in burner tip and gasoxygen pipe line after back fire

- In case that water cooling unit will not work 2) Checking points after back fire

- Check the inside of burner tips and remove the carbon residue

- Check the flame arrester and remove the carbon residue on parts specially stainless steel filter

- Check rubber hoses

- Check water cooling unit

8 DAILY MAINTENANCE

1 Check the piping and hoses leakage

2 Check the leakage of Gas Fluxer

3 Check the Emergency Button

4 Pls remove dust or carbon adheres gas flux residue to the burner nozzle it is very important

5 Check the manual valve condition like gas oxygen nitrogen gas flux etc

6 Check water cooling line leakage

7 Be careful for water freezing in winter season

CHECK POINT MAINTENANCE TIME REMARK

Check the piping and hoses leakage 1 DAY

Check the leakage of Gas Fluxer 1 DAY

Check the Emergency Button 1 WEEK

Pls remove dust or carbon adheres gas fluxresidue to the burner nozzle

1 WEEK

Check the manual valve condition like gas oxygen nitrogen gas flux etc

1 WEEK

Check water cooling line leakage 1 DAY

Check the main regulator (Gas oxygen nitrogen) 1 DAY

Check the gas flux hose 1 MONTH

9 OPERATION METHOD

1) Power SW ON in the Control Box

2) Select SW ON on the Operation Control Panel

3) Confirm The supply of Gas and Oxygen with light signals on the operation Control Panel

4) Confirm water flow for cooling with water flow switch

5) Pilot Switch ON After confirming above things Confirm pilot flame

If no flame you must try again

Then press torch ldquoONrdquo switch

6) Select line 1 or 2 3 after confirming pilot flame

(1) Line - 1 Pre Heating Line Flame ON

(2) Line - 2 Main Heating Line Flame ON

(3) Line - 3 Final Heating Line Flame ON

7) Manual

(1) Select manual SW

(2) Select Line 1 or Line 2 3

(3) Pilot Flame ON Confirm the pilot flame

(4) Torch ON after confirming the pilot flame

(5) Set a proper pressure for Gas amp Oxygen by Gas amp Oxygen Auto Pressure Controller with

digital guages after gas switch ON Be careful with back fire Refer to Back Fire Information

(6) Conveyor SW ON - Set a proper speed of the conveyor belt

(7) Supply coils for brazing

(8) In case of finishing the job just push Gas off switch and Pilot switch off

The flame will be gone

8) Auto

(1) Confirm Pilot Flame

(2) Selet line 1 or line 2 3

(3) Confirm the flame condition and conveyor speed

(4) Select Auto Mode

(5) The burners will be ON in case of sensing the coils

9) Adjust flame height with up or down buttons

10) Push emergency SW ON on the front and rear of the body unit and of the operation panel

in case that you need a urgent stop

11 OTHERS

11-1 Be careful for water freezing in water cooling line specially in winter season

Also we recommend that you make a continous water circulation during all day in order to

prevent water freezing in winter season

It is very important In case of water freezing in water cooling line the unit will broken and

the water cooling line might be cracked

11-2 Reduce water and moisture content in oxygen and gas Water and moisture in oxygen and

gas will react with gas flux They will make white powder in the gas mixed line and it will

make many kinds of problems

2 PARTS LIST

NO ITEM MAKER SPEC amp TYPE Q TY

1 BURNER TIP SKB S1043 BR 100

2 BURNER TIP PIPE SKB 8mm Dia 100

3 CONVEYOR MOVING MOTOR MOTOVARIO NMRV063-150 1

4 GAS PRESSURE SW KONICS 3028(06) 3

5 OXY PRESSURE SW KONICS 3028(10) 1

6 GAS FILTER SUNG JIN SJG-01 1

7 PRESSURE SENSOR SK(SENSYS) U5100 4

8 SOL VV SK(ODE) 21A5KV45 6

9 FLOW METER KOREA FLOW

METERPA 20 200L 3

10 FLOW METERKOREA FLOW

METERPA 20 100L 2

11 GAS CONTROL VV SK(ODE) 21A2KCV45-1X 3

12 OXY CONTROL VV SK(ODE) 21A2KCV30-05 3

13 GAS CONTROL DISPLAY SKB SKACG100 4

14 GAS KEEPER KOREA GAS GKL15 1

15 FLAME ARRESTOR SUNGRISA SR-9 3

16 GAS REGULATOR DRAGON DR-60-A100 3


18 IGNITIOR ROD DONG GUNG C-200 1

19 IGNITOR TRANSE DONG GUNG 2P220 1

20 AIR REGULATOR SMC AR30-03BG 2

21 NOISE FILTER FINE SUNTRONICS SN-M6H-CM 1

22 POWER SUPPLY FINE SUNTRONICS MSF 150-24 1

23 GCP HONEYWELL 3215A 1



26 ABE LS 3310A 1

27 ABE LS 3210A 1

28 TR UNYOUNG 42-2KWA 1

29 RELAY HONEYWLL MY4N 10

30 FLEXIBLE HOSE 12 times 1500 HS PARKER 2


32 SIGNAL LAMP Q-LIGHT ST56B-3-110V 1

33 LM BLOCK (TORCH MOVING) T H K SR30W2 2

34 LM RAIL (TORCH MOVING) T H K SR30W2 4

35 LM BLOCK (TORCH MOVING) T H K SR25W 4

36 LM RAIL (TORCH MOVING) T H K SR25W 4

37 TORCH POSITION SERVO MITSUBISHI HC-KFS23G1 15 1

38 TORCH UPDOWN SERVO MITSUBISHI HC-MFS43BG1 120 1

39 SERVO DRIVE MITSUBISHI MRJ2S20B 1



42 TOUCH PANEL MITHUBISHI GT1572 1

43 INVERTER MITHUBISHI FR-E740-075 2

44 PLC POWER MITHUBISHI Q61P 1

45 PLC CPU MITSUBISHI Q03UD 1

46 PLC BASE MITHUBISHI Q35B 1

47 INPUT CARD MITHUBISHI QX41 1

48 OUTPUT CARD MITHUBISHI Q41P 1

49 OUTPUT CARD MITHUBISHI QY10 1

50 TEMP SENSOR SH-N K32 1

51 SERVO SENSOR OMRUNI NPN 6

52 FLAME SENSOR HONEYWELL C-7027 1

53 BURNER CONTROLLER HONEYWELL BC1000A0110U 1

54 TEMP CONTROLLER AUTONICS TOS B4RK4C 1

55 PANEL AIR-CON DAEYANG SCA-500BR 1

IN - LINE BRAZING SYSTEM

SERIAL NO 90896

1 SYSTEM DESCRIPTION 1 MODEL NO 300 IN-LINE BRAZER

2 GENERAL DESCRIPTION

In-Line Brazers are idel for mass production of similar assemblies like heat exchanger parts for R amp A Automotive radiator parts etc with linear movement of the assemblies a between the burner

units Of course the heat zone can be adjusted to various assembly height and width

3 BASIC MACHINE DESCRIPTION 3-1 MAIN BODY

The body will be made with all welded steel construction As you can see our drawing sheet

we made 8 leaves of doors at the front and back sides to give the AS convenience to you

Also we made 4 reinforced glasses doors in the upper front and back sides so that you can see

the brazing condition easily The body dimension is 2050mm widthtimes1850mm length

times3070mm hight including venting hood is less than 3550mm

3-2 CONTROL UNIT We made several leaves of doors for the maintenance control easily The dimension is 960mm width

times 600mm lenght times 1100mm hight

4 SPECIFICATION

4-1 CONBUSTION UNIT





4-2 COOLING UNIT






2) Water Cooling







brazed joints











- Compressed Air


4-5 OTHERS


















6-1 CONVEYOR SPEED



6-2 MANIFOLDS



by manual

6-3 GUIDE


6-4 GAS FLUXER






pressure




















8 DAILY MAINTENANCE













1 WEEK


1 WEEK




9 OPERATION METHOD












7) Manual











8) Auto









11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1





























4-1 CONBUSTION UNIT





4-2 COOLING UNIT






2) Water Cooling







brazed joints











- Compressed Air


4-5 OTHERS


















6-1 CONVEYOR SPEED



6-2 MANIFOLDS



by manual

6-3 GUIDE


6-4 GAS FLUXER






pressure




















8 DAILY MAINTENANCE













1 WEEK


1 WEEK




9 OPERATION METHOD












7) Manual











8) Auto









11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1


































- Compressed Air


4-5 OTHERS


















6-1 CONVEYOR SPEED



6-2 MANIFOLDS



by manual

6-3 GUIDE


6-4 GAS FLUXER






pressure




















8 DAILY MAINTENANCE













1 WEEK


1 WEEK




9 OPERATION METHOD












7) Manual











8) Auto









11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1






























6-1 CONVEYOR SPEED



6-2 MANIFOLDS



by manual

6-3 GUIDE


6-4 GAS FLUXER






pressure




















8 DAILY MAINTENANCE













1 WEEK


1 WEEK




9 OPERATION METHOD












7) Manual











8) Auto









11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1






































8 DAILY MAINTENANCE













1 WEEK


1 WEEK




9 OPERATION METHOD












7) Manual











8) Auto









11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1






































1 WEEK


1 WEEK




9 OPERATION METHOD












7) Manual











8) Auto









11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1
































1 WEEK


1 WEEK




9 OPERATION METHOD












7) Manual











8) Auto









11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1



































7) Manual











8) Auto









11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1




































8) Auto









11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1































11 OTHERS









2 PARTS LIST











METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1





































METERPA 20 200L 3


METERPA 20 100L 2
















26 ABE LS 3310A 1

27 ABE LS 3210A 1













































Documents

In Line Brazing