VACUUM FURNACE

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VACUUM FURNACES FOR HEAT TREATMENT

Vacuum soldering furnaces VTG-100

 

Vacuum soldering furnaces.

 

Soldering of metal is performed when the brazing material comes in contact with diffusion metal components during the vacuum heat treatment. Finished products are bright and clean.Furthermore, vacuum soldering of parts is an environmentally friendly process. In the absence of oxygen flux for soldering is required, the final product does not contain pores and is not oxidized. Vacuum soldering furnace offers one of the most reliable methods of connection products, having a number of advantages. These furnaces are particularly recommended for manufacturers of tools and complex parts.

 

The use of furnaces:

  • Aerospace.
  • Satellite connection.
  • Electronics.
  • Medicine.
  • Nuclear fusion and splitting.

The advantages of the presses:

  • Flux-free soldering.
  • No hazardous gases and toxic wastes.
  • Uniformity of temperature.
  • Uniformity of temperature.
  • Excellent air tightness and reliability.
  • Synchronicity of vacuum brazing and heat treatment.

 

VTG-100VACUUM FURNACE SPECIFICATION compartment, horizontal type, double-walled, water-cooled, the inner and outer wall made of steel SUS # 304.
Material of the heating element graphite
The maximum temperature of the furnace 1,350℃
Temperature uniformity 600 ~ 1,250℃ ±5℃
Capacity of the furnace chamber 100 kg
Effective dimension 300х300х600 mm
hardening rate in the gas stream 1,093℃→250℃,20 min.
hardening environment nitrogen or argon, the maximum pressure of 6 bar, rotatable through 360 degrees, the presence of gas supply tubes.
Control system display panel with touch controls, and the main memory controller, programmable logic controller, PID temperature controller.
Vacuum system a mechanical pump, a Roots vacuum pump, a vacuum thermocouple.
Additional settings cooling water or liquid supply system in case of emergencies, compressed air.
The effective area of the furnace (h×W×L) 300 × 300 × 600 mm

COMPONENTS OF VTG-100 VACUUM FURNACE

1.

Vacuum chamber - 1 pcs.

  • Cylindrical, horizontal type.
  • With double walls from Stainless steel SUS # 304
  • The space between the walls is filled with cooling water, forming a system of forced cooling.
  • Cover with hydraulic type automatic shutter, with a protective sealing ring .
  • Supports batch processing products.
2.

The components of the vacuum chamber:

  • Vacuum system.
  • hardening system.
  • System of compressed gas partial pressure.
  • Wiring.
  • Electrodes Wiring.
  • holes for pressure sensors.
  • Thermocouples Wiring.
3. Channel for the temperature uniformity test.
4. Protective casing for electrodes.
5. Circulating water pipe with water flow sensor.
6. The heat exchanger in the form of ribbed copper pipes with maximum efficiency.
7. high-speed fan with a powerful drive motor.
8. Split heat exchanger of main thermal cameras, easy in operation.
9. Design module for a cooling fan with drive motor facilitates their immediate dismantling of the furnace back.
10. heat shield of removable type, easy to operate.
11. The heating elements and electrodes made of graphite, easy in operation.
12. Rack zone.
13. Support stabilizer of horizontal type.
14. Cargo truck.
15. Primary thermostat, alarm system in case of overheating thermocouples.

 

VTG-100 VACUUM FURNACE HEATING SYSTEM
1. heating element:
  • graphite electrodes.
2.

heat shield:

  • Type: removable, easy in operation.
  • Material: Carbon fiber and a layer of graphite.
  • Case: stainless steel SUS # 304.
3. The system of forced water cooling of electrodes with water flow sensor.

 

Hardening system:

  • The inert gas is nitrogen or argon.
  • Maximum operating pressure: 6 bar.
  • Gas hardening Pressure: 700 Torr ~ 6 bar.
  • Gas exhaust overpressure fan.
  • Modules for cooling fan with a drive motor of removable type.
  • Cooling Fan power: 60 hp, 2P.
  • Cooling gas (nitrogen). Gas flow rate: 1.8 m3 at pressure of 8 bar.
  • The heat exchanger in the form of ribbed copper pipes with a maximum efficiency.
  • Safety valve.

 

Control system

    I. The display panel with touch control (interface) FUJI color display with touch screen (or a device of similar quality).

    • Graphic display with malfunctions warning system.
    • Panel user-friendly, easy to use.
    • It displays the heating program, the hardening process.
    • It displays the status of pipes and valves.
    • Displays I / O.
    • Displays information about the maintenance schedule.
    • Displays manual.

    II. Programmable logic controller: Mitsubishi A1S- PLC (or a device of similar quality).

    • It combines the functions of the monitor and control procedures.
    • Programs and correct the faults.
    • It provides reliability.

    III. Temperature control: Yamatake-honeywell DCP-551 (or a device of similar quality).

    • high precision, error of ± 0.1% Automatic function for PID regulation.
    • Saves a set of 99 programs, each program supports 99 levels.
    • It provides 16 regimes of sequence control.
    • It provides reliability.

    IV. Registrar: ChION 6 pen (or a device of similar quality).

    • Registers temperature signal.
    • Registers a vacuum pressure signal.
    • Registers high pressure signal.
    • It provides reliability.

    V. Thermocouples: Type-S, 2 pcs.

    • Each heater is controlled by a thermocouple, completed with voltmeter and ammeter.
    • Thermocouples are sealed with a safety mechanism.
    • The drive cooling fan: set with an ammeter.
    • Power supply: set with an ammeter.
    • The control unit: with sound warning, light alarm system and a vent hole at the top.
    • Wiring in a protective casing provides a link between the control units, furnace and a supporting device (cable rack).
    • The analog signal with low voltage.
    • The second output of the transformer: water cooling cable is used.
    • Adjustment bar and partial pressure control: the needle valve, the switch, the flowmeter.
    • Pneumatic system: mounted pressure sensor.
    • The valve of the gas pressure: functional unit.
    • Programmable logic controller: graphical representation of the process.
    • Power Requirements: 3 phase 380h, 80kW, 50hz.

     

    Vacuum system

    1. Mechanical pump           pumping rate of 45 m3 / h.
    2. Roots Vacuum Pump         pumping rate of 250 m3 / h.
    3. Vacuum Pirani.
    4. Roots backing line vacuum solenoid valve.
    5.

    Vacuum valve

    With Bellows Seal

    6. Preliminary valve with position sensor.
    7. Mechanical pump with forced cooling and water flow sensor .
    8. Limit pressure 10-3 torr
    9. The amount of vacuum leaks below 1×10-4 torr•l/sec.


    NOTE.

    The sphere the customer’s responsibility is to provide the following parameters:

    1. Pressure of the cooling water 2~3 kg/сm2.
    2. Cooling water consumption 80~150  L/min.
    3. Emergency water supply direct water supply to the cooling system.
    4. Compressed air 80~100 psi (5kg/сm2).
    5. Total area 3 × 4 m.
    6. Flow rate of cooling gas (nitrogen) 1.8 m3 at a pressure of 8 bar.
    7. Power consumption 3 phase 380h, 80kW, 50hz.

     

    ACCEPTANCE TESTS

    1. The amount of vacuum leaks below 1×10-4 torr / sec.
    2. Pumping speed to 10-2 for 20 minutes.
    3. Temperature 1050 ° C accuracy ± 5 ° C.
    4. Ultimate vacuum 10-3 torr (under empty, clean, dry box furnace)
    5. Quenching rate in gas stream from 1093 ° C to 250 ° C preferably for 20 minutes (at empty chamber).
    6. Guarantee one year. 
    7. Manual operation of the furnace and tools two copies.

     

    ALTERNATIVE ENERGY SUPPLY

    1. power 3 phase, 380h/50hz,  80 kW.
    2. Compressed air 80-100psi (5kg/сm2).
    3. Cooling water water pressure 3.5 kg/сm2.
    4. Water consumption 150  L/min.
    5. Argon 100 psi.
    6. Total area 3 x 4 m.

            

    COOLING SYSTEM

    The following characteristics of the coolant and recommendations are in the responsibility of the Customer:

    • The level of pH 7.0 - 8.0.
    • Conductivity 900 - 1200 md mo / cm.
    • Number of suspended solids 10 ppm.
    • The measuring device and the corrosion inhibitor (test for phosphate at the range of 15 ~ 20 ppm).
    • The biocide to prevent the formation of algae.

    Additional expenses:

    • Painting.
    • The outer shell of the vacuum chamber and other components of the vacuum furnace must be securely primed and coated with factory type paint.
    • Components of the vacuum furnace are subjected to coloration only after dismantling.

    Documentation:

    • Two copies of manual for operation and maintenance of the vacuum furnace.
    • Two copies of the manufacturer's process instructions to components of the vacuum furnace.
    • One copy of the list of recommended spare parts.

     

    SUPPLY

    Electricity

    • The total connected load is 100 khA with a maximum current amplitude. This rate can be changed depending on the additional equipment requirements for engine performance.
    • Incoming line voltage: 380 h / 3 phase / 50 Hz or on demand.

    Water consumption

    • 80 l / min and 60 PSIG, 85 ° C (with supply in time heating) of 150 l / min and 60 PSIG, 85 ° C (with supply during heating)

    Air

    • 60PSIG (filter rigging, regulator, lubricator)

    Inert gas

    • A minimum of 25 PSIG with a 1 pneumatic pipeline from the reservoir of the Customer to pneumatic tanks.

     

    Security, alarm devices, safety interlock

    • Posters should be hung to warn staff of the dangers in order to prevent the incidence of work-related injuries.
    • Lifting, transport devices to move products and equipment, they must be equipped with mechanical brake system in order to avoid accidents.
    • All basic alarms and safety interlocks should be included to the control circuit. hisual alarms should just indicate failure or malfunction of the equipment in emergency situations. The visual signals must be accompanied by beeps. To restore a failed hardware configuration, the resumption of its settings must be carried out manually.
    • Activation of safety devices and emergency lock must be accompanied by light indication.
    • Pneumatic and electrical circuit must be reliably fixed to avoid accidental breaks.
    • In the event of a power failure, all vacuum valves should be closed automatically, preventing the zone heating and heat treatment of the injury.
    • Electric control cabinet must be equipped with emergency stop equipment.

     

    Installation and testing before shipment

    • The equipment of vacuum furnace will be fully assembled at the factory in accordance with the assembly drawing.
    • Each element of the furnace runs a complex testing procedure. The customer has the right to participate in the process of testing the equipment before shipment.
    • Testing before shipment (similar to the acceptance tests).
    • Each component that will be subjected to a vacuum checked for any leakage before assembly. Check for vacuum leak all the equipment is carried out after the complete installation of the furnace. All deficiencies must be corrected before shipment.

     

    Dismantling and loading

    • After testing and approval of the vacuum furnace, the manufacturer produces the dismantling of the furnace by taking additional measures to ensure that the reassembly of equipment can be done quickly and easily.
    • All connection points for wires, cables, pipelines, water lines and air lines should be identified and labeled.

     

    The volume of installation works

  • The manufacturer is fully responsible for installation of the equipment.
  • In addition to the installation instructions described in the instruction manual, the buyer is given a set of photographs and a full installation drawings as tools for assembly.

 

Scope of work for putting the equipment into operation

  • Work on putting the equipment into operation is carried out by experts of the manufacturer of the equipment. The duties of an engineer of the manufacturer as part of training staff.
  • Duration of works on commissioning the equipment can take up to 10 days, taking into account the 40-hour workweek. Including the time spent on the arrival of a specialist to the object of installation. Monday is usually the starting point.

 

Acceptance tests

  • The standard testing procedure.
  • hisual inspection to check the conformity of the equipment.
  • Bringing the atmosphere of the vacuum chamber to a state of ultimate vacuum. When disabled the pump unit, magnitude leakage must be equal to less than 5 microns (5 x 10-3 torr l / sec.).
  • The vacuum furnace is filled with nitrogen while the pressure falls instantly. The time required to reach the value of 30 microns, 1 micron and 10-3 torr fixed.
  • Vacuum furnace chamber is filled with nitrogen. Chamber cover is held in the open state for a certain period of time and the pressure reduction performed for the second time.
  • Furnace cavity is filled with tubes of mild steel or other similar material. The temperature of 1050 ° C ± 5 ° C.
  • After testing the homogeneity of temperature furnace chamber is filled with nitrogen and hardening process is performed at a pressure of 6 bar.
  • If thermodynamic cycle at 1100 ° C is necessary, products for the heat treatment providing as well as the responsibility for the increased temperature regime is in the responsibility of the Purchaser.