| Warranty: | 1 Year |
|---|---|
| Application: | Petroleum Processing Industry |
| Cleaning Media: | Wet Cleaning |
| Automation: | Automatic |
| Cleaning Precision: | Precision Industrial Cleaning |
| Control: | PLC |
| Customization: |
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Audited Supplier Solvent Degreasing Ultrasonic Vapor Degreaser Machine uses boiling solvent, rather than water, for fast precision cleaning and remove of true oils from contaminated parts, vapor degreaser machine applies the principle of distillation and condensation to achieve high quality cleaning and quick drying, which have been around for long time, but, they doesn't mean they are all created equal, the significant advancements in cleaning solvent have brought increased solvent costs, therefore, vapor degreaser machine solvent recapture and vapor degreasing distillation has never been more important, ensuring the proper boiling heat capacity balanced with chilling capacity and free-board is a most for today's vapor degreaser machine, keepleader, we can provide reliable solution with proofread functionality
Solvent Degreasing Ultrasonic Vapor Degreaser Machine
01: Application
Solvent Degreasing Ultrasonic Vapor Degreaser Machine is conventional, but prevalent and reliable cleaning solution in almost any industry where precision cleaning is paramount to the manufactured parts, it is common in the automotive, aviation and aerospace and medical device manufacturing, jewelry manufacturing, and electronic assembly industries, various methods have been developed along the way to include vapor only cleaning, vapor-spray-vapor, liquid-vapor, boiling liquid-warm liquid-vapor, spray-under-immersion and vacuum degreasing,of note, ultrasonic cleaning can supplement nearly all of these methods
Solvent Degreasing Ultrasonic Vapor Degreaser Machine plays catching-eyes performance, in general, modern, nonflammable vapor degreaser machine cleaning fluids have low surface tension, low viscosity,high density and low latent heat,this means vapor degreaser machine cleans more easily, with less heating, fewer pumps, no air knives and so on, there is not water to heat, which save electricity, instead, the cleaning fluid heats to just above room temperature, which takes very little electricity in addition
011:The cleaning fluid moves by gravity, so there are no big pumps required to puch the cleaning fluid around, saving electricity
012: There are no blowers or air knives on vapor degreaser machine,which save electricity, the cleaning fluid is retained inside of vapor tank and the parts being cleaned come out dray, in fact, motorized fans and fume hoods are not recommended near vapor degreaser machine because it increase cleaning fluid losses, so electricity is saved there,too
013: No Stand-by mode required
014: there is no waste treatment required, which save electricity, because the vapor degreaser machine is automatically, inherently and continuously re-purifying and re-distilling the solvent
015: there is no humidity added to the factory environment, so air conditioning and environmental loads are reduced
02: Working Principle
Solvent Degreasing Ultrasonic Vapor Degreaser Machine gains another gratify because of simple operation, reliable working performance, inside the tank, liquid solvent is heated to a vapor which envelops the soiled parts suspended in the vapor zone of the vapor degreaser machine, as the vaporized/boiled solvent condenses when the parts at ambient temperature enters the vapor,dirt and contaminants are washed from the part and drained back into the liquid solvent solution in the boil sump of the vapor degreaser machine
In this process, parts are placed in a metal basket or holder that is lowered within the vapor degreaser machine, the basket remain above the boiling solvent but below the cooling coils, the vapor degreaser machine boils the solvent, solvent vapors rise but don't escape because there are trapped within the vapor degreaser machine via condensing coils blanket by a a large of refrigeration, the vapor then condenses on the surface of the parts dissolving the contaminants,as the solvent drips off the object it removes the soils with it, this is a closed-loop process, so the solvent is cycled
Over-and-over again, the vapors rise into the cold trap, condense into liquid, then run back down into the rinse sump/boiling sump, the rinse sump then over flow in the boil sump, if have not rinse sump, drip into the boiling sump directly. The soil stays in the boil sump and does not travel with the vapor, thus avoiding cross-contamination of both the parts and the rinse sum
03: Parameter
|
Description |
Solvent Degreasing Ultrasonic Vapor Degreaser Machine |
|
Model |
KLE-1024R |
|
Power Supply |
5KW |
|
Working Dimension |
300*380*380mm |
|
Solvent Capacity |
20~30L |
|
Distillation Rate |
70L/H |
|
Refrigerator |
3Hp |
|
Ultrasonic Power |
1200w |
|
Ultrasonic Frequency |
28Khz or 40khz |
|
Heating Power |
3800w |
|
Overall Dimension |
1.2*0.61*1.1m |
|
Weight |
188kgs |
|
Packaging Volume |
1.3CBM |
04:Salient Character
Free-board ratio of greater than 100% to eliminate diffusion losses
Refrigerated primary condensing coil to condense the bulk of the solvent vapors
Refrigerated sub-zero free-board condenser to provide a cold air barrier minimizing fugitive losses
Sealing cover to eliminate drafts and help seal the unit during periods of inactivity
Boiling sump construct level control to avoid dry heating
Distilling recovery and condensing dry take functional completion in a cycle
Extended bag filtering system is acceptable in a compacted construction
Chilling coils are connected with water chiller to barrier to environmental humidity
Stainless plumbing for solvent-wet areas
Future proofed design with five year manufacturer's warranty
Designed to use all types of non-flammable degreasing solvent including HFE,nPB
All machines manufactured by our family-owned factory
All stainless steel construction, traceability certification available
Specialized fabrication available required
Aluminum plate heating element for energy efficiency and longevity
Free-board dwell ensures completely dry components at end of process
Small footprint designed for clean room application
Easy to use, minimal operator training required
Intelligent ultrasonic agitation built in for deep penetration
05:Operative guidelines
The utmost in Solvent Degreasing Ultrasonic Vapor Degreaser Machine to perform best effects with sufficient knowledge upon optimizing a vapor degreaser machine process,it is prominent to note the following
This should be performed on easy different part you clean, this will help you develop standard operation procedures that your operators can follow
A subset of this process is to develop a program for each different soil on the parts, as an example, you may be a contract manufacturer that utilizes a large number of solder pastes and fluxes depending on the requirements and call-outs of your customer, determine, by the construction of the parts, which of the various cleaning options you can or cannot, utilize based on the sensitivity of the components, for instance, what is allowed by the customer, immersion (boil or clean/cold sumps), ultrasonic, spray wand usage, etc? Some customers may leave it up to you to determine the best and most efficient method while others will tell you what is not allowed or not recommended due to the sensitivity of the components, for instance, radio frequency components generally cannot withstand the aggression of an ultrasonic process due to their sensitive frequency operation
As our example, we will use a basic PCB to be de-fluxed with no sensitive component restriction, however, also assure the customer has specified that there will be no immersion such as vapor zone cleaning, but spray wand usage is ok
Hopefully, your chemical manufacturer has performed cleaning trials on these test board and has provided you with a general guideline for vapor zone cleaning only, use these setting as a starting point, if this has not occurred, you will need to start from scratch
051:Optimize for maximum condensation
Run the test board with a standard vapor zone cycle time to assure that maximum condensation has occurred ( when condensation stops, the part and the vapor have reached the same temperature and will be essential dry), record this time, as this point, cleaning has ceased, remove the part following the withdrawal procedure and inspect for cleanliness, if there is remaining flux residue, the cycle must be repeated, re-inset the part next to the cold condenser to chill it as much as possible, the goal is to obtain a wide temperature delta between the part and hot vapors (record this length of time for future reference), again, low the part into the hot vapors, and record this time (it will probably vary a lot from the first cycle). go through the withdrawal procedure and again inspect the piece, if it meets the cleanliness requirement, you are done, if not, repeat the cycle until clean. Verify the vapor zone cleaning procedure based on the specific validation plan
052: Evaluate supplemental cleaning steps
Since there was no restriction on wand usage, test this along with the times recorded for vapor zone cycles
Start by using the wand (record the time of spraying) prior to the vapor zone cleaning and see it that makes an improvement
Increase the spray time a bit prior to vapor immersion to see if cleaning improves, if not, start decreasing the times to find the maximum cleaning effect in the shortest amount time time
Also, try the wand spray in the same manner at the end of the vapor cycle times
Record all of these spray wand variations and times for later compilation
The idea behind this simple example is to increase cleaning performance in a timely manner, in turn, this increases throughout, decrease solvent loss and operates the unit in an efficient manner
For each cleaning option/variable you try if the option does not increase cleaning performance or reduce time, discard it, at each stage of experience, go back and re-verify each option/variable until you are convinced that the process is operating flawlessly and with maximum performance
Obviously, you can see that if you have multiple parts and soils, this can take a long period of time to set up you cleaning programs, or schedules, however, one done, you operators will have a clear step-by-step recipe for the variations in parts and soils, each time a new one is added, the variation process must be repeated and an addendum made to the program to follow, clearly logging these standard operation procedures also allows for smoother technician turnover and increased product consistency over time
Essentially, any time the upstream process changes, the cleaning department should verify what, if any changes should be make to account for this, this will give your process team members confidence that the cleaning method was validated by a strict set of rules and the most efficient method was chosen to both meet customer performance standards and streamline production time efficiency, it is well worth the time spent in optimizing the recording the process, your customers and team members will appreciate the results
Solvent Degreasing Ultrasonic Vapor Degreaser Machine gains superior characteristics of 1st: super fast, cycle time of about 5 to 6 minutes;2nd: hand warm, clean and dry end result; 3rd: based on non-flammable solvents;4th: no risk of corrosion, because no water is used; 5th: small footprint, take up little space; 6th: environmentally friendly; 7th: optionally manually or fully automated, 8th: options of mechanical control and intelligent controlling system: 9th: appended spray wand,multi-sumps and auto lifting system are all optional
Solvent Degreasing Ultrasonic Vapor Degreaser Machine has benefits of #1: superior cleaning performance and effectiveness #2: No dependence on manual cleaning #3: prevents cross-contamination #4: repeatable #5: quick, no extra drying process required #6: recycle solvent from one part to another
Ultrasonic solvent vapor degreasers
KEEPLEADER designed and built ultrasonic solvent vapor degreaser years of trouble-free operation, our machine is configured to operate with Chlorinated solvent to remove heavy grease, oils and compounds from heavily soiled industrial parts, or with the new ultrasonic, spray cleaning bends uses in precision cleaning applications, solvent cleaning must meet recent safe guidelines and include innovative features, like sealing covers, automated shut-down cycle, and early malfunction detection, all designed to make operating with the new solvent cost-effective and trouble-free
01: How ultrasonic vapor solvent degreaser work?
Solvent degreaser involves the exposure of cleaning parts to pure solvent vapors released by a boiling solvent, the cleaning parts usually suspended in the vapor zone above the boiling sump, when the vapor touch the comparatively cool cleaning parts, condensing action occurs which dissolves the contamination and flushes it away. And dripping into the boiling sump, because the boiling temperature of solvent is fixed, so the cleaning parts always touched the clean solvent, until the temperature of vapor is the same as cleaning parts, the cleaning action is stopped, this is basic cleaning schedules, the solvent cleaning machine often equipped with spraying cleaning, ultrasonic agitation, is usually used chlorinated solvents and new fluorinated solvent and other zoetrope
02: What's application of the ultrasonic solvent degreaser?
Although water-based cleaning machine are effective in many applications, some aspects of aqueous-based cleaning can make it impractical and unusable for certain cleaning application, So, solvent cleaning comes into the practice by its special performance, which can well clean petroleum basked oil, grease, wax and other stubborn solvent soluble soil from any non-porous surface, solvent cleaning is also very useful at precision, it is also very effective at precision-cleaning highly sensitive parts contaminated with dust, fingerprints, and other air-borne contaminants, vapor degreaser is commonly used to clean, machine parts, electrical and electronic subassemblies, intricate metal and plastic components, artificial joints, lenses, and a wide variety of other products prior to further processing, assembly, inspection, or packaging, nearly any part can be cleaned in a solvent degreaser without concern for quality control issues like part oxidation, effective drying and water spots
03: Safety controls and Solvent detention system
All of ultrasonic vapor degreaser must be designed with consideration of guidelines for safety and solvent detention
031: Safety controls
Each solvent degreaser, there is float switch to detect the chemical level, if the safe level is not reached, the heating will be stopped, buzzer sounds up and inducting light is lighted to remind the operators to fill the solvent, the machine is also equipped with circuit protection of overheating, compressor fault and other automated controlling for safety purpose
Solvent retention systems
The most importance of solvent degreaser is the detention design of solvent efficiency, tries to reduce the leakage of solvent, and recycling the dirty solvent, is not only a safe principle but also the environment orientation, several factors involved in overall efficiency of the solvent degreaser
032: The primary cooling coils
A multiple pass perimeter cooling coil is used as heat exchanger to condense the vapors, creating a sustainable vapor zone, the primary coil must be maintained at the temperature that will cause the vapors to readily condense, this function can be performed by directly refrigerating the coil, or by passing chilled water through it
On refrigerated system: multiple condensing coils mounted perimeters above the primary coils directly, which is continuously detained the vapors to avoid the leakage and quick drying
On water-cooled system: water-cooled vapor degreasers, a coolant flows through the primary cooling coil, if a constant supply of cool water is available, the system can operate a water along, more commonly however, to save water and to assure constant temperature, a combination of coolant and water is circulated through a refrigerated water chiller, the water chiller may be dedicated entirely to one degreaser, or it many be serving the cooling requirements of other equipment simultaneously, water-cooled degreaser that are connected to a water chiller perform as efficiently as refrigerated system
033: Secondary cooling system:
The secondary cooling system consists of an additional cooling coil that is mounted directly above the primary cooling coil and maintained at sub-zero temperatures, creating a cold blanket of air, which further reduces solvent consumption, the safety guidelines call for freeboard chiller on vapor degreasers containing trichloroethylene, perchloroethylene, give that a properly-designed freeboard chiller will reduce evaporative losses by 30% to 45%, the cost of a freeboard chiller can easily be justified as a solvent-saving measure with a short payback period
034: Freeboard ratio
Freeboard is the area within tank above the vapor zone, the freeboard ratio compares the width of the top opening of the tank to the freeboard height, the height of the area above the top of vapor zone, higher freeboard ratios have been demonstrated to aid in solvent retention, freeboard rations between 1.25 to 1 and 1.5 to 1 are offered
035: Automated slide cover
Unlike common sliding cover that leave gaps around their perimeter, this unique cover is designed to roll into place and seal the work chamber from the atmosphere, virtually eliminating evaporative losses during downtime
04: Vapor spray degreaser
Ultrasonic solvent degreaser of spraying at KEEPLEADER has one compartment cleaning system, with the vapor zone located directly above the boiling solvent, this unit is designed for cleaning application that require suspension in pure solvent vapors only, typically, the cleaning parts are lowered into the vapor zone and held there until condensation ceases, if necessary, it is then sprayed with freshly distilled solvent to remove oil, chips, solder flux or other soils, spraying the cleaning parts also cools it slightly, causing the vapor to begin condensing on the cleaning parts again, once condensation ceases again, as the cleaning parts are then raised into the freeboard area where it is held until it is dry
05: Immersion/vapor spray degreaser
Parts contaminated with particular stubborn soils or very high-weight parts that reach the vapor very quickly may not be completely cleaned in the initial vapor stage when a vapor immersion is not adequate for a particular cleaning application, an immersion/vapor spray design is suggested, the cleaning circle of the immersion vapor spray unit is similar to that of vapor spray unit, except that after the vapor stage, the part is immersed in the warm liquid solvent sump, this step provide additional cleaning and also lowers the temperature of the cleaning parts, after the liquid immersion stage, the cleaning parts are then raised back into the vapor zone to allow for final vapor rinse prior to removal from degreaser
06: ultrasonic immersion/vapor spray degreaser
Ultrasonic degreasing offers advantages for the most stubborn contaminants and is commonly used for cleaning application like those listed below
Stubborn organic soils such as mold release agents wax and impregnated grease
Excessive particulate contamination on the cleaning parts
Inaccessible surfaces, blind holes and intricate passageways on the cleaning parts
Critical cleaning of high-reliability components such as printed circuit boards and hybrid/microcircuits
The ultrasonic vapor degreaser incorporates the same features as the immersion/vapor spray degreaser with the addition of ultrasonic agitation in the liquid rinse sump, the cleaning cycle remains the same, with the cleaning parts being suspended in the ultrasonic sump for the required time
07: Co-solvent degreaser
KEEPLEADER standard two-compartment degreaser is configured as single-solvent, cleaning parts can be cleaned with the single-solvent degreasing method with either a pure solvent, or more commonly, with a solvent zoetrope, in a single solvent system, the cleaning parts are normally suspended in the vapor directly above the wash compartment, where it is exposed to the pure solvent vapors, generated by the boiling solvent below when the warm vapors touch the comparatively cool cleaning parts, the vapors condense into liquid and dissolves the contamination on the part surface, the contaminant is then and flushed away as it pours off the part, this cleaning action continues until the cleaning parts and the solvent vapor have reached the same temperature, the cleaning parts are them immersed in the somewhat cooler rinse sump, where any residual contaminants left on the part are dissolved, for particularly stubborn contaminants, ultrasonic are added to this compartment, after immersion cleaning, the cleaning parts are raised back in the vapor zone, where a final condensate rinse takes place
Co-solvent degrease sometimes called dual solvent degreaser, operate somewhat different the use unique combination of two distinct types of non-ozone depleting cleaning agents
Operate somewhat differently, they use a unique distinct types of non-ozone depleting cleaning agents, this system is sometimes used for flux removal, and is most appropriate for applications where pure fluorinated solvents or their zoetrope are not aggressive enough to dissolve the contaminant, the cleaning process is similar to single-solvent degreasing, except that in the initial cleaning stage, the cleaning parts are completely immersed in the wash compartment, a solvating agent in the wash sump dissolves contaminants from the cleaning parts, the liquid in the wash sump is constantly filtered to remove any sold particulate, the parts are then removed from the wash chamber and immersed in the rinse compartment, which contains pure liquid solvent, it is then raised in the vapor zone, where it receives a final vapor rinse, ultrasonic many be provided in either or both compartments, depending on the cleaning application, additionally, the solvating agent can be specifically formulated for the contaminant being removed and the ration of solvating agent to fluorinated solvent can be adjusted to affect the temperature and effectiveness of the wash compartment, because the system uses two chemistries with different boiling temperatures, its operation tents to be somewhat more complicated that that of a single-solvent machine and it normally supplied with an upgraded control package
Attn: MS Helen
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