Glaston FC1000
Page 02 Glaston Comprehensive expertise in safety glass processing Glaston s heat treatment product line provides safety glass processing technology and services for the architectural, automotive, furniture, and domestic appliance and solar industries. During our over 40 years of operation, we have delivered close to 3,000 safety glass machines to more than 90 countries. We provide technology for flat glass tempering, glass bending & tempering, glass bending and flat glass laminating. The competitive edge of our glass processing machines is reliability of operations, flexible capacity, energy efficiency, and a high-quality end product. We are part of Glaston Corporation, a global company developing glass processing technology for architectural, appliance, automotive and solar applications. Glaston s portfolio ranges from pre-processing and safety glass machines to related services. Glaston s customer service network is the largest in the industry, with over 20 locations around the world, and provides services for all glass processing needs with a coitment over the lifecycle of your processes. Glastonishing! We are changing the way the world sees glass. Leading glass processing technology partner Glaston s heat treatment product line provides safety glass processing technology and services for the architectural, automotive, furniture, and domestic appliance and solar industries.
Page 03 Glaston FC1000 High-tech solution for ultimate Low-E glass quality Circulated air convection system on top and bottom of glass Glaston FC1000 is the result of continuous development work with our renowned Glaston FC500. Equipped with new technological advances, FC1000 meets the most stringent demands for flatter and iridescence-free glass. In addition, FC1000 provides a significant increase in energy efficiency and Low-E glass tempering capacity. These profitable benefits come with the new Glaston Chinook Pro convection system with circulated air on top and bottom of the furnace. FC1000 can also be equipped with our brand-new intelligent online assistance system, GlastonInsight. Using an accurate temperature scanner and the online quality measuring system, GlastonInsight helps you raise your glass quality to an excellent and more uniform level, minimizing waste for higher production efficiency. ENERGY EFFICIENCY Air circulation on the top and bottom of the glass decreases energy consumption significantly. ULTIMATE GLASS QUALITY New technological improvements throughout the entire tempering line noticeably raise glass quality. INCREASED LOW-E PRODUCTION New Glaston Chinook Pro convection system provides increased Low-E production. Glaston FC1000 Glaston FC1000 Glaston FC1000 Glaston FC1000 energy consumption. available in the market. safety and heat treated glass helps decrease production costs and GlastonAir produces the thinnest The unique air flotation technology float glass. quality, which is comparable safety GLass Thinnest The key to choosing the FC series furnace is its ability to provide glass tempered produces GlastonAir value chain efficiency toughened quality, particularly on high-specification solar control products and being able to future-proof our business by having the ability to toughen the next generation of coated glass products. Gordon Dickson, Managing Director, Ravensby Glass, UK Record-breaking quality
Page 04 Glaston ULTIMATE QUALITY FC1000 Ultimate quality with accurate heating control Glaston Chinook Pro Precisely designed air blow FC1000 with the new Glaston Chinook Pro convection system transfers the heat more accurately and uniformly than conventional convection systems. The accuracy is achieved with an extreme air volume, which is blown on the top and bottom of the glass at low pressure. On the upper glass side, the air is blown through optimally placed hole nozzles. Below the glass, the air blow happens through multiple divided segments. Ultimately, this convection design results in a uniform heat transfer that ensures the best possible quality for all glass types and thicknesses, and especially for Low-E glass. Multiple divided segments for easier heating control Controlling the temperature of furnace rolls is challenging in any system where air is circulated on the bottom of the glass. FC1000 is designed with air blown through multiple divided small segments, which eliminates this challenge and helps maintain excellent heating accuracy. Automatic roller heat control eliminates heat disturbance Glaston is the only one in the market that measures the temperatures of furnace rolls to control roller heat efficiently. FC1000 uses an automatic roller heat control (RHC) system to eliminate any roller heat disturbance during the heating process. The system transmits roller heat information to the control system and automatically adjusts the bottom heat level to balance the roller temperatures. The RHC system ensures that temperatures at each point of every roller are the same for better glass quality. Varying heating angles with shifted heating modules The heating modules on the upper side of the glass are shifted in parallel to the glass flow. This means varying the heating angles, and thereby minimizing iridescence, which is also known as anisotropy or strain pattern. The heating modules are easily serviceable from below, thus ensuring quicker maintenance times.
Page 05 Glaston ULTIMATE QUALITY Dense roller conveying system for greater glass flatness Slot nozzle design in chiller cuts iridescence remarkably Reaching the unreachable Iridescence no longer an issue FC1000 includes a new, dense roller conveying system to further minimize edge kink and glass waviness. This new system, together with Chinook Pro and RHC innovations, helps achieve exceptionally flat glass and expands your business to areas where glass distortion is not tolerated, such as with laminated glass applications and in the solar panel industry. Thanks to the flatter glass, decreasing the PVB thickness and getting rid of the clamping process in laminated glass applications is possible with FC1000. Depending on the glass type, the savings can be vast. The excellent flatness of the glass enables high-quality lamination, while extending the lifetime of the lamination. Glass iridescence has been long accepted as an inevitable feature of heat-treated glass. However, the requirements of reducing iridescence are growing among glass processors around the world. FC1000 is available with a brand-new slot nozzle design in the chiller to decrease differences in stress levels inside the glass. This design, together with the advanced convection nozzle distribution, shifted heating modules and divided heating segments, reduces iridescence radically. Since there are no coonly agreed on measurement criteria or mandatory standards for acceptable levels of iridescence, we have developed Glaston IriControL in joint cooperation with arcondur to meet this challenge. IriControL measures the iridescence level of the glass in real numerical values. This enables the evaluation of iridescence in a true and objective manner. With FC1000, the iridescence value of tempered glass is clearly over 90%, which is beyond the normal values of 70 85% achieved by standard furnaces. Glaston IriControL is available as an option or an upgrade for Glaston flat tempering furnaces. Left panel: no iridescence stripes. Iridescence value results of approximately 95%. Right panel: visible iridescence stripes. Iridescence value results of approximately 75%. Wider application areas with iridescence-free products 0 50%: visible marks 50 50 70%: marks can be easily seen The Glaston IriControL iridescence measurement system helps define which glass is acceptable in terms of iridescence. Based on the IriControL measurement results, FC1000 produces tempered glass with iridescence values clearly over 90%. This makes FC1000 a strong choice for producing glass for applications where iridescence is not tolerated, such as in glass facades and coercial glazings. 25 UNACCEPTABLE NOT GOOD Glaston IriControL 70 TOLERABLE 70 85%: normal market quality 90 0 Isotropy value VERY GOOD 90 100%: FC1000 EXCELLENT 100
Page 06 Glaston ENERGY EFFICIENCY FC1000 Circulated air on top and bottom of glass Remarkably lower energy consumption The new Glaston Chinook Pro convection system circulates air onto both glass surfaces and minimizes total energy consumption significantly.
Page 07 Glaston ENERGY EFFICIENCY Heating energy consumption close to absolute minimum FC1000 sets a new trend in power consumption and brings the total consumption close to the absolute minimum. This is thanks to the new Glaston Chinook Pro convection system, which circulates the air onto both the top and bottom surfaces of the glass. Large convection compressors and the heating of cold compressed air are not needed at all. Based on the principles of thermodynamics, FC1000 decreases total energy consumption significantly. High loading efficiency, decreased idle time As a result of the full-convection Chinook Pro system, FC1000 enables fast and efficient heating. This makes it possible to feed the line more frequently and with more glass per batch. The high utilization rate decreases idle time both in the furnace and quench. FC1000 minimizes waste heat and idle use of the blowers, therefore consuming less energy per square meter and providing considerable annual savings. Highest quality insulation As in every Glaston flat tempering machine, the opening line of the FC1000 furnace is placed above the rollers. This provides a more compact construction and decreased energy consumption with greater heat sealing. If the furnace opening line is situated in the middle of the drive system roller line, insulating material starts to crumble and crack in production, causing energy loss. FC1000 is equipped with the highest quality insulation materials for maximum durability. The intelligent split line design increases the insulating material s lifetime even further. Robust and reliable blower solution Higher capacity, decreased idle time & energy savings Quench blowers with a variable frequency drive (VFD) enables motor speed adjustment in between loads An integrated blower vibration measurement system for preventive maintenance
Page 08 Glaston INCREASED LOW-E PRODUCTION FC1000 The highest capacity for Low-E glass production True capacity increase in serial production The high production capacity of Low E glass is often expressed in theoretical numbers in the market. However, this does not take into account undesired production breaks that emerge from the need to tune the heating or unacceptable glass quality with high waste rates if tuning is neglected. FC1000 is developed to meet this challenge with the new high air volume Glaston Chinook Pro convection system. FC1000 eliminates the need to constantly fine-tune the process parameters and provides the highest realized capacity for Low-E glass production. It is an excellent choice for serial production. Increased production with more efficient heat transfer In addition to the unique Glaston Chinook Pro convection system, FC1000 is based on a highly efficient overall heating system and accurate heating control. The convection is produced with custoade, heavy-duty blowers that circulate air onto the top and bottom of the glass with an accurate temperature profiling. This combination provides the most efficient and uniform heat transfer to the glass and increases production capacity considerably. Easy and flexible operations, more freedom in loadings FC1000 with full-convection Chinook Pro provides fast heating times and high loading efficiency with flexible loading patters. As there is no need to break production for process fine-tuning, FC1000 makes running Low-E glass practically as easy as running clear glass. High air volume with Glaston Chinook Pro The new Glaston Chinook Pro convection system uses significantly more air volume than traditional compressed air and high pressure systems, leading to more uniform and efficient heat transfer, as well as increased Low-E glass production capacity.
Page 09 Glaston INCREASED LOW-E PRODUCTION Robust materials provide decades of reliability FC1000 is designed to perform as efficiently and reliably after decades as in the beginning. All materials and production techniques guarantee years of heavy-duty and carefree operation. The modular frame construction features a state-of-the-art design, which provides a durable platform for flat tempering operations. The best and most accurate production technologies are used, including precision machining, high-quality steel work and welding that comply with the most stringent quality standards and ensure minimal maintenance costs. Now with our own machine up and running, we have seen for ourselves that the furnace can produce the best glass around. Even when unpacking the six containers shipped from Finland, our guys said we had a Cadillac because all the elements were so sturdy and well crafted. Michelle Magyar, President, Mid-American Glass, USA.
Page 10 Glaston FC1000 Accurate operations through advanced automation icontrol The most dynamic automation system in the market Glaston s Automation family, icontrol, is based on extensive field studies among glass processors, including tempering line operators, factory managers and company owners. Being aware of the challenges that the operators face daily, Glaston has incorporated a unique, cutting-edge icontrol Dynamics automation system into the FC1000 furnace. Easy recipe management and fast furnace adjustment with automatic temperature profiles are some of the many features that make icontrol Dynamics arguably the best automation system in the market. The system includes extensive interfacing possibilities to other factory machinery and higher-level control systems to enable advanced automation. Choose the most suitable solution for your needs With the icontrol automation product family, you will have a reliable and intelligent tool to manage your business. icontrol Dynamics an intuitive, easy- to-use automation system (standard) icontrol Intelligence an extensive reporting system for operations management on top of icontrol Dynamics (option) icontrol Quantum an accurate, online glass measurement system ilook integrated seamlessly into icontrol Intelligence (option) icontrol ensures top user experience with a large 22-inch, ergonomically designed touch panel. All-inclusive reporting icontrol Intelligence and icontrol Quantum reporting packages include extensive reports of actual line usage at any given time with one click: Loads/hour, m 2 /hour Operator and shift performance indicators Loading efficiency Energy efficiency Furnace idle time, uptime Online glass quality measurement (icontrol Quantum ) Maintenance-related reporting: alarms, temperatures, trends icontrol Quantum icontrol Intelligence icontrol Dynamics
Page 11 Glaston GlastonInsight Intelligent online process optimization for greater performance FC1000 can be equipped with our new intelligent online process assistance system, GlastonInsight. The system gives operators proposals based on feedback on how to tune the heating to achieve the highest possible glass quality. Using an accurate temperature scanner and the online quality measuring system ilook, GlastonInsight helps you raise your glass quality to an excellent and more uniform level, minimizing waste for higher production efficiency. Any operator can be the best operator GlastonInsight visualizes the temperature distribution of each batch. It measures all glasses for roller wave and edge kink, and gives the operator recoended tuning options to optimize the tempering process. This enables every operator to achieve the ultimate glass quality. Up-to-date intelligence brings several benefits Real-time feedback on process optimization for better glass quality Less waste, higher productivity Easy operation, ideal in serial production GlastonInsight GlastonInsight An operator s best friend in serial production GlastonInsight is ideal when production volumes get as high as with FC1000. The system gives operators proposals on how to tune the heating to maintain consistent glass quality in serial production. GlastonInsight, icontrol Intelligence and icontrol Quantum all are Glaston s unique solutions for greater production management.
Page 12 Glaston FC1000 Ease of use with icontrol Dynamics Control your entire process with just one click! A well-designed automation system and user interface are top priorities nowadays in flat tempering production. Considerable efforts have been invested in FC1000 to ensure a wide scope of accuracy and adjustable performance by providing the top-of-the-line icontrol Dynamics automation system with the best PLC control in the market. Image 02 Top user-friendliness is achieved with a human machine interface (HMI) touchscreen and a multilingual user interface. Controlling the entire tempering production has never been easier than this. Image 01 Ease of use with automatic heating profile (DLP) FC1000 features the Dynamic Load Pattern Recognition (DLP) system. It contains an array of sensors at the entrance of the furnace to determine the size, shape and location of the glass. This data is used to generate an automatic heating profile for a specific load pattern. This greatly assists operators in their day-to-day activities and helps them use the most suitable heating setting for their production. DLP proves its value when enhanced automation and ease of use are needed to boost glass production. Image 01 Easy recipe management, a large 22-inch touchscreen system, and fast and easy furnace adjustment are some of the many features incorporated into the icontrol Dynamics operating system. Image 02 The icontrol Dynamics system includes extensive interfacing possibilities to other factory machinery and higher level control systems. This is achieved through OPC UA (open connectivity via open standards).
Page 13 Glaston /s Vibration monitoring Image 03 Image 04 Image 05 Time Image 03 The most sophisticated heating control possibilities with Glaston Chinook Pro convection system with air circulation on the top and bottom of the glass. Image 04 Advanced heater and convection nozzle design for the best heating uniformity and easy maintenance. Image 05 FC1000 includes intelligent control of blowers during the tempering process. In addition, quench blowers are equipped with a blower vibration measurement system, which monitors the blower condition and avoids unexpected breakdowns.
Page 14 Glaston FC1000 Innovative options for more enhanced production Ultimate quality Energy efficiency Increased Low-E production Optional features EXTENDED CAPACITY +RC350: Second heating chamber (type RC350 ) ACS: After-cooling system to increase heat strengthened and thick glass tempering capacity THIN GLASS TEMPERING* BOOST: Boost unit for tempering down to 2.8 or 3.15 glass (1 PTQ280/315: Full pass-through quench system for tempering 2.8 or 3.15 glass (1 IPT315: Integrated pass-through quench system for tempering 3.15 glass (1 (B): Readiness for boost unit (additional nozzles for quench) ~40 MPa HS HEAT STRENGTHENING HS10: Heat strengthening system for clear glass up to 10 (2 (requires Nxx cabinet) HS12 + INA: Heat strengthening system for clear glass up to 12 (2. Low-E (1 glass and ASTM C1048 heat strengthening of glass up to 10 (requires Nxx cabinet) QUENCH/COOLING SYSTEM SLOT: Slot nozzle design in chiller** N82/85: Noise reduction cabin around the chiller LpA = 82 or 85 db(a) *) Not available with the Slot option to quench **) For 4 and up 1) According to EN 12150 and ANSI Z97.1 standards 2) According to EN 1863 standard
Page 15 Glaston ~40 MPa HS Compressor HS: Heat strengthening system Quenching pressure Air icontrol Intelligence Cooling pressure Control valves BOOST: Thin glass tempering IPT: Integrated pass-through PATENTED PATENTED GlastonInsight AUTOMATION AND PROCESS CONTROL GlastonInsight : Intelligent online process assistance system icontrol Intelligence : Extensive process, production and maintenance reporting system includes IR scanner (SCA), quality reports (QMS), energy consumption and process/production efficiency measurement system icontrol Quantum : Online glass distortion monitoring system ilook integrated with icontrol Intelligence reporting package PPL: Peak power limitation system V: Additional process screen for unloading table QUENCH ACCESSORIES M: Cullet removal lifting conveyor with cullet container INSTALLATION AND SERVICES TURNKEY: Turnkey installation CARE: Glaston Care service agreement SPARES: Recoended spare part kits
Page 16 Glaston FC1000 Advantages at a glance Ultimate glass quality Accurate and uniform Glaston Chinook Pro convection with circulated air on top and bottom of the glass ensures the best possible quality for all glass types and thicknesses, especially Low-E glass New dense roller conveying system minimizes edge kink and glass waviness New slot nozzle design option in chiller reduces iridescence Energy efficiency Significant decrease in energy consumption due to effective air circulation Optimized inverter-controlled quenching system Excellent insulation Increased Low E production Increased Low-E production capacity thanks to the new Glaston Chinook Pro convection system Highly efficient heat transfer to top and bottom of glass More flexible and versatile loadings Standard features HEATING SYSTEM Chinook Pro: Glaston Chinook Pro convection system with circulated air on top and bottom of the furnace DH: Divided heating elements DLP: Dynamic load pattern recognition for automatic heating profiles RHC: Automatic roller heat control system QUENCH/COOLING SYSTEM Quench blowers (380/470/570) max. alt. 600 m according to EN 12150 and ANSI Z97.1 BMON: Blower vibration monitoring system with preset vibration limits to enable predictive maintenance of blowers HS8: Heat strengthening system with frequency converter(s) for tempering glass up to 19 S: Energy efficient blower system up to 19 tempering with frequency converter(s) VC: Cullet conveyor under quenching section
Page 17 Glaston Main dimensions of the Glaston FC1000 GLASTON FC1000 Total length Total width Total height Blower room L x W x H Loading area W x L Installed power (kw) Type Heating and drives Note: Blower room dimensions are indicative of and subject to factory layout. Dimensions for double chamber furnaces are given separately. Blower room dimensions may vary based on final quench configuration. Location of the blower room according to factory layout. Noise reduction cabin affects the total height of the line. 1) Note: Installed power for blowers in special conditions (temperature, humidity and altitude) to be given separately. Blower installed powers are based on 4 Low-E production according to EN 12150 and ANSI Z97.1. 2) Based on 5 Low-E production according to EN 12150 and ANSI Z97.1. Quench 1) 2136 18000 6300 3400 9000 x 6500 x 4000 2100 x 3600 821 2 x 250 (500) 1321 2448 23000 6600 3400 9000 x 6500 x 4000 2440 x 4800 1218 2 x 250 (500) 1718 2860 28000 7000 3400 9000 x 6500 x 4000 2800 x 6000 1683 2 x 315 (630) 2313 Total Technical capabilities of the Glaston FC1000 Energy consumption data 4) GLASTON FC1000 Capacity (loads / hour) per glass thickness, clear glass Capacity (loads / hour) per glass thickness, Low-E glass (0.02) GLASTON FC1000 Energy consumption (kwh/m 2 ) Type 3 3) 4 5 6 8 10 12 15 19 3 3) 4 5 6 8 10 Clear float glass Low-E glass (0.02) 2136 2848 32 26 21 17 13 10 8 6 5 25 21 17 14 11 9 2860 32 26 21 17 13 10 8 6 5 25 21 17 14 11 9 3360 - - 21 17 13 10 8 6 5 - - 17 14 11 9 4 2.8 3.2 6 3.5 3.7 10 5.6 5.8 Note: All capacities during one hour of operation at constant production. Capacities shown above are based on 65% loading efficiency and with glass size 865 x 1930 according to EN 12150 and ANSI Z97.1 standards. Final capacity depends on glass size, shape and edgework quality. Capacities for double chamber furnaces to be given separately. 3) 3 capacity depends on the blower/compressor combination. 4) Note: Energy consumption values are given with 65% loading efficiency with an ambient temperature of 25 C according to EN 12150 standard. Values are based on continuous production figures with FC1000 type 2448. DRIVE SYSTEM & CONVEYORS DR: Dense roller conveying system (not available for 28xx width) L: Loading and unloading conveyors with lifting tables SO 2 i: SO 2 interface (valves and piping) to provide a protective layer on the rollers MGS: Minimum glass size of 100 x 250 BB: Battery back-up system to empty the hot glass from the furnace in case of power failure ENVIRONMENTAL, HEALTH & SAFETY ECS: Emergency cooling system in case of glass breakage in the furnace PROJECT MANAGEMENT SV: Installation supervision and training AUTOMATION icontrol Dynamics : Most sophisticated control system in the market REMOTE: System for remote control
About Glaston Care : With the technician coming to our facilities twice a year, we re able to improve on our quality and our production. The agreement pays for itself every year. Mr. Michael Saroka, VP of Operations, Goldray Industries Ltd., Canada
Page 19 Glaston Glaston services for a lifetime Service agreements Spare parts Service work GlastonMove Training and consultation Software and machinery upgrades We are at your service Glaston provides global service network support to further promote your continuous production. For more opportunities, please contact your nearest Glaston office. www.glaston.net/services
Through vision, innovation and cooperation we are changing the way the world sees glass. Glaston is a global company developing glass processing technology for architectural, solar, appliance and automotive applications. Our portfolio ranges from pre-processing and safety glass machines to tools and services. We are dedicated to our customers continued success and provide services for all glass processing needs with a lifecycle-long coitment in mind. For more information, please visit www.glaston.net. Sustainable glass processing technology Glaston takes into account the entire lifecycle of its machines. One key issue is to design and manufacture the constructions to tolerate heavy use. Upgrades and relocations also extend the lifetime of the machine in the marketplace. Special attention has been paid to the recyclability of materials, particularly to wearing components and parts. NOTE: Images shown in this brochure are indicative and depend on the level of equipment. Models may differ from the pictures shown. 2014 Glaston Corporation Glaston FC1000 ENG printed 10/2014 Sektori/HKP