Tiyoda-Serec High-Performance Vapor Degreasing
Why are High-Performance Degreasers so Efficient? All High-Performance Degreasers are designed with the following special features which drastically reduce vapor emissions and the potential for fluid losses: Drop-Seal Cover: Much emphasis is generally placed on efficiency of operation, but a significant portion of the solvent losses take place when the machine is not being operated. The manner in which the top opening of a degreaser is sealed will greatly affect the downtime losses. Hinged covers seal well, but tend to create a vacuum as they are opened; dragging vapors out of the machine. Sliding covers open without disturbing the vapor zone, but generally do not seal well around the edges when they are closed. TCS has developed and patented a cover which will roll into position without disturbing the vapor zone, and then drop into place; sealing the work area from the atmosphere. This system has the sealing advantages of the hinged cover, but causes no dragout when it is opened. Welded Plumbing: Tests have shown that, regardless of the joint compound used, fluorinated solvent vapors have a tendency of seeping through even the tightest threaded fitting joints. As a result of these tests, and to eliminate the possibility of threaded joints loosening over time, all High-Performance Degreasers are designed with welded stainless steel plumbing. Where maintenance requirements dictate that a removable connection be made, only metal-to-metal compression fittings are used. Shut-Down Cooling Cycle: Upon Depressing the Power Off switch, a computer-controlled shut-down cycle will automatically be activated. During the shut-down cycle, the refrigerant in the primary cooling system is diverted from the primary cooling coil to cooling coils which are located within the liquid in the wash and rinse sumps. This feature is designed to cool the fluid in both compartments, causing an immediate reduction in vaporization of the solvent. The secondary refrigeration system continues to operate in its normal manner during the shut-down cycle, keeping the freeboard area cool. The computerized control system monitors the temperature in the sumps, and continues to operate the shut-down cooling cycle until the fluid has dropped to the desired temperature. Malfunction Reporting: Early and accurate detection of machine malfunctions are crucial in preventing long-term solvent losses. Software developed by TCS for the computerized central control unit, performs continuous diagnostic sensing and reporting of the functions which are crucial to the machine's efficient operation. In the event of a machine malfunction, the control unit will pinpoint the source of the problem, sound an alarm, and display a user-friendly, graphics-based malfunction window. The touch-screen malfunction window clearly explains the problem to the operator, and suggests the proper corrective action to be taken. Heating/Cooling System: Rather than incorporating a heat-pump combination for heating and cooling, High-Performance Degreasers maintain separate heating and cooling systems. By utilizing separate systems for heating and cooling, these systems produce much higher turnover rates than those associated with heat-pump systems. Higher turnover rates translate into cleaner rinse compartments and fewer rejected parts. In most applications, it also eliminates the need for a second rinse compartment, reducing the surface area of the vapor zone by one third. The smaller the surface area of the vapor zone, the lower the vapor losses. Additionally, this heating system offers versatility to change cleaning solutions at some point in the future. How Do They Work? High-Performance Vapor Degreasers are designed to accept nearly any non-flammable degreasing solvent. They can be utilized as either a single-solvent system or a co-solvent system. Single-Solvent Degreasing Systems Parts can be cleaned with the single-solvent degreasing method with either a pure solvent, or more commonly, with a solvent azeotrope. The workpiece is normally suspended in the vapors directly above the wash compartment, where it is exposed to the pure solvent vapors created by the boiling solvent. When the warm vapors touch the comparatively cool workpiece, a condensing action occurs which dissolves the contamination and flushes it away as it pours off the part. This cleaning action will continue until the workpiece and the solvent vapor have reached the same temperature. The workpiece is then immersed in the somewhat cooler rinse sump, where any residual contaminants left on the part are dissolved. For particularly stubborn contaminants, ultrasonics are added to this compartment. After immersion cleaning, the part is raised back into the vapor zone, where a final condensate rinse takes place.
Co-solvent degreasing is a unique combination of two distinct types of non-ozone-depleting cleaning agents.This system is most appropriate for applications where pure fluorinated solvents or their azeotropes are not aggressive enough to clean the workpiece. The cleaning process is similar to single-solvent degreasing, except that in the initial cleaning stage, the part is completely immersed in the wash compartment. A solvating agent in the wash sump dissolves contaminants from the workpiece. The liquid in the wash sump is constantly filtered to remove any solid particulate. Next, the part is immersed in the rinse compartment, which contains pure liquid solvent. It is then raised into the vapor zone, where it receives a final vapor rinse. Ultrasonics may 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 ratio of solvating agent to fluorinated solvent can be adjusted; enabling this cleaning system to meet nearly any cleaning requirement. Standard Features TCS High-Performance Degreasing Systems are designed to maximize cleaning effectiveness, operating efficiency, and dependability. We combine high turnover rates, continuous filtration, and ultrasonic cavitation in a design that ensures the most effective and efficient cleaning system available; and one that requires a minimum of floor space. If none of our standard models will meet the requirements of a specific application, we will be pleased to offer a custom-designed system that will. Construction: Completely constructed from heavy gauge, heli-arc welded, 300 series stainless steel; including the body, plumbing, structural frame, counter top, and exterior side panels. Heating System: Specially designed low watt-density stainless steel immersion heaters are utilized to ensure long heater life and minimal through-wall connections. Cooling Systems: The primary cooling system consists of a perimeter, multi-pass cooling coil which is located at the top of the vapor zone. The coil temperature can be maintained by an integral, direct-expansion refrigeration system, or by a separate refrigerated, recirculating water chiller. If chilled water is available at the installation site, the system can be designed to connect to the existing chiller. Regardless of which style is chosen, the coolant is constantly monitored, and any abnormality in temperature is reported immediately. The secondary cooling system provides additional efficiency. High surface-area secondary cooling coils are installed above the primary cooling coils, and are maintained at -10° to -20° F. A cold blanket of air is created at the top opening of the machine, which serves as a barrier to vapors that may have risen above the primary coils. Plumbing: As described above, stainless steel welded plumbing provides assurance that no vapors escape through the plumbing connections during downtime. Freeboard Ratio: Standard High-Performance Degreasers include freeboard ratios of between 1.20:1 and 1.5:1. If overall height is a concern, the generous freeboard area can be reduced, resulting in a slightly lower freeboard ratio. Drop-Seal Cover: TCS patented drop-seal cover produces a seal so tight, that a pressure-equalizing vent must be incorporated in order to prevent a vacuum from developing within the machine as it cools. Control System: All system functions are controlled through a graphics-based touch-screen, interfaced to the internal PLC. Proprietary software has been custom-designed to provide a user-friendly control package that is unparalleled in the cleaning equipment marketplace; making our comprehensive operations manual nearly superfluous. Secondary Containment: A secondary containment system provides assurance against undetected fluid leaks. Should the system develop a leak, the fluid will be contained in the integral secondary containment system, an alarm will sound, and the graphics-based control system will display a warning window which will inform the operator of the problem. Safety Controls: The PLC control system constantly monitors the machine operation, sensing for conditions that would result in vapor losses or system malfunctions. High vapor levels, low liquid levels, high cooling coil temperatures, even the ambient temperature within the master control box is continuously monitored and reported. Why Clean with Vapor? Although aqueous-based cleaning systems are effective in many applications, some aspects of aqueous-based cleaning can make it impractical or unusable for certain types of workpieces. Solvent degreasers can be used for removal of oil, flux, grease, wax and other stubborn solvent-soluble soils from nearly surface. Electrical and electronic subassemblies, intricate metal and plastic parts, and medical instruments, are routinely cleaned in vapor degreasers prior to assembly, inspection, or further processing. Because no water is used in the process, nearly any part can be cleaned in a solvent degreaser without concern for quality control issues like the effects of part oxidation, soap residue, water stains, and ineffective drying. |
High-Performance Vapor Degreasers are specially designed for use with the new generation of environmentally-friendly, non-ozone-depleting cleaning solvents. In order to make the use of these solvents economically feasible, a technologically advanced vapor degreaser — far more efficient than standard chlorinated solvent degreasers — is used. These technologically advanced degreasers were designed specifically to utilize the new solvents with the absolute maximum in vapor-retention efficiency. 
Single-Solvent Degreasing Systems
