IN - LINE BRAZING M/C OPERATING 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 & 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 A/S 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 2050m/m width1850m/m length 3070m/m hight, including venting hood is less than 3550m/m

3-2. CONTROL UNIT We made several leaves of doors for the maintenance control, easily. The dimension is 960m/m width 600m/m lenght 1100m/m hight.

4. SPECIFICATION
4-1. CONBUSTION UNIT Heating of the part is accompolished both three lines using propane/oxygen 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 & 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, solidify the alloy. It will be helpful to get a good color of copper tubes after brazing. and will

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

-. 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 m/m 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 : -. Fuel Gas : 415V/ 3PH/ 50HZ LPG/OXYGEN

-. 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 600~2200m/m 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 9.4m/m dia is required for each combustion system (Note;3 supply lines required). The gas supply hould be between 1 - 1.5Kg/cm2. -. A water supply of at air curtain etc. least 9.4m/m dia is required for the water cooled burner tips and

-. A Nitrogen gas supply of at least 1/4" nipple is required for the gas flux supply. The pressure, over 0.5kg/cm2 is required. -. A compressed air pressure, over 5kg/cm2 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 & 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 0.5kg/cm2, 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 1kg/cm 2 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 don't 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 gas/oxygen 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 Check the piping and hoses leakage. Check the leakage of Gas Fluxer Check the Emergency Button. Pls remove dust or carbon adheres, gas flux residue to the burner nozzle Check the manual valve condition like gas, oxygen, nitrogen, gas flux, etc. Check water cooling line leakage. Check the main regulator (Gas, oxygen, nitrogen) Check the gas flux hose. MAINTENANCE TIME 1 DAY 1 DAY 1 WEEK 1 WEEK REMARK

1 WEEK 1 DAY 1 DAY 1 MONTH

9. OPERATION METHOD
1) Power S/W "ON" in the Control Box.

2) Select S/W "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 ON 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 S/W

(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 & Oxygen by Gas & Oxygen Auto Pressure Controller with digital guages after gas switch "ON". Be careful with back fire. Refer to "Back Fire Information"

(6) Conveyor S/W "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 S/W "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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 ITEM BURNER TIP BURNER TIP PIPE CONVEYOR MOVING MOTOR GAS PRESSURE S/W OXY PRESSURE S/W GAS FILTER PRESSURE SENSOR SOL V/V FLOW METER FLOW METER GAS CONTROL OXY CONTROL V/V V/V MAKER SKB SKB MOTOVARIO KONICS KONICS SUNG JIN SK(SENSYS) SK(ODE) KOREA FLOW METER KOREA FLOW METER SK(ODE) SK(ODE) SKB KOREA GAS SUNGRISA DRAGON DRAGON DONG GUNG DONG GUNG SMC
FINE SUNTRONICS FINE SUNTRONICS

SPEC & TYPE S1043 BR

Q' TY 100 100 1 3 1 1 4 6 3 2 3 3 4 1 3 3 3 1 1 2 1 1 1 1 1 1 1 1 10 2 2 1 2 4

8mm Dia.
NMRV063-1/50 3028(0.6) 3028(1.0) SJG-01 U5100 21A5KV45 PA 20 200L PA 20 100L 21A2KCV45-1X 21A2KCV30-05 SKACG100 GKL15 SR-9 DR-60-A100 DR-60-A025 C-200 2P220 AR30-03BG SN-M6H-CM MSF 150-24 32/15A 32/5A 33/10A 33/10A 32/10A 42-2KWA MY4N H.S. PARKER H.S. PARKER ST56B-3-110V SR30W2 SR30W2

GAS CONTROL DISPLAY GAS KEEPER FLAME ARRESTOR GAS REGULATOR GAS REGULATOR IGNITIOR ROD IGNITOR TRANSE AIR REGULATOR NOISE FILTER POWER SUPPLY GCP GCP GCP ABE ABE T/R RELAY FLEXIBLE HOSE FLEXIBLE HOSE SIGNAL LAMP LM BLOCK (TORCH MOVING) LM RAIL (TORCH MOVING)

HONEYWELL HONEYWELL HONEYWELL LS LS UNYOUNG HONEYWLL 1/2" 1500 1/2" 2000 Q-LIGHT THK THK

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

LM BLOCK (TORCH MOVING) LM RAIL (TORCH MOVING) TORCH POSITION SERVO TORCH UPDOWN SERVO SERVO DRIVE SERVO DRIVE AIR REGULATOR TOUCH PANEL INVERTER PLC POWER PLC CPU PLC BASE INPUT CARD OUTPUT CARD OUTPUT CARD TEMP. SENSOR SERVO SENSOR FLAME SENSOR BURNER CONTROLLER TEMP. CONTROLLER PANEL AIR-CON

THK THK MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI SMC MITHUBISHI MITHUBISHI MITHUBISHI MITSUBISHI MITHUBISHI MITHUBISHI MITHUBISHI MITHUBISHI

SR25W SR25W HC-KFS23G1 1/5 HC-MFS43BG1 1/20 MRJ2S20B MRJ2S40B AR30-03BG GT1572 FR-E740-0.75 Q61P Q03UD Q35B QX41 Q41P QY10 SH-N K32

4 4 1 1 1 1 1 1 2 1 1 1 1 1 1 1 6 1 1 1 1

OMRUNI HONEYWELL HONEYWELL AUTONICS DAEYANG

NPN C-7027 BC1000A0110U TOS B4RK4C SCA-500BR