APS Thermal Spray System - Systems & Equipment · PDF fileAP-50 | Thermal Spray System Added...

AP-50 | Thermal Spray System

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AP-50 APS Thermal Spray System

INTRODUCTION

The AP-50 is a stand-alone single process,

mass flow controlled (MFC) APS coating

system. Built using only state-of-the art

components and technologies, the AP-50 is

designed to be both reliable and functional

and to be used for every type of APS

application ranging from R&D, single piece

production to high volume production.

The AP-50 represents FST’s concept of

“Advanced Simplicity”. The combination of

sophisticated software with first class hardware

results in an exceptionally easy-to-use and

reliable system ensuring a consistent high

quality coating application without constant

operator intervention.

The system is built

around an intuitively

operated touch

screen panel,

which can be wall

mounted onto an

adjustable arm or

floor mounted on an

operator stand. The

high definition

touch screen makes all

process controls and monitoring

available to the operator’s fingertips.

The AP-50 can store up to 256 recipes.

The system is fully “closed loop”,

assuring a consistent coating quality

each and every time.

The AP-50 is engineered, designed and built to

be the safest APS system available on the

market today. This is achieved by using the

latest safety standards, modular construction

separating gasses from the electrical parts, the

use of only first class materials integrating PLC

controls and monitoring of all parameters such

as gas pressures and flows, water temperatures,

combustible and gas monitoring (H2, He). Safety

interlock integration and e-stops with external

equipment such as cooler and part- and gun

manipulation units come standard with the

system.

A multi-level monitoring and alarm system

notifies the operator of out-of-range conditions

and safely shuts down the system in critical

situations.

The built-in Remote Access (eWon) allows for

FST engineers to remotely analyse and

troubleshoot the customer’s controller via a

secure internet connection, thus reducing costly

service interventions and downtime

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The AP-50 has the ability to operate and

control most commercially available plasma

guns including:

• 3MB, 3MBT

• 9MB

• F4, F1

• SG100, 2086 Ext, 2700 Ext

The AP-50 is built to the highest standards

using the latest process control technology to

ensure optimum system performance. Its

modular construction incorporates unique

design features that make the AP-50 the most

user friendly and flexible plasma spray system

available. From standard core components,

each system is effectively custom built to meet

the individual customer demands.

OPERATOR INTERFACE

The operator interface consists of a Siemens

15” touchscreen display with sophisticated and

intuitive software. The software interface is

designed to be elegant and simple as possible;

however, it will display all relevant information

to the operator.

Entering parameter values is made quick and

easy. In case of multiple plasma guns (like

combining F4 and F1) selection of the plasma

gun automatically sets the operating gun limits,

thereby enhancing the safe operation of the

system.

A multi-level alarm system provides visual

notification to the operator on out of tolerance

parameters and critical issues/situations.

Multiple Language selection including English,

German and French are standard selectable

languages. Other languages can be provided

upon request.

Operating Values shown on touch screen can

be read and set in Metric or Imperial Units.

TRENDING, LOGGING & REPORTING

The Data Trending, Data Logging and the

Optional Data Reporting package are great

features of the AP-50.

Data Trending

Data Trending records and displays the most

important parameters that can be set and

monitored from the operator panel. The data

can be recalled on-screen. The parameters are

differentiated by different graph colours.

Data Logging

In addition to data trending, the software

provides data logging. Data logging records all

important process data directly onto an external

USB device, which then can be processed

using a PC. This process can be fully

automated. The USB device is connected via a

USB slot on the side of the TSP.

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Data Reporting (optional)

Data Reporting is an optional feature and allows

for off-line data analyses and reporting. Data is

automatically downloaded onto a PC, This

allows for personalized reporting and analysing,

and the storing of data on an available network.

Typically the Data Trending, Logging and

reporting is used for:

• Application and Spray parameter

development

• Quality and Process control

• Reporting required for the coating of critical

components

• Spray gun and system maintenance

• General system troubleshooting

• Operator training and qualification

REMOTE ACCESS

The Remote Access is a standard feature of AP-

50. Through the use of eWon™ a secure

Ethernet-based connection will connect the AP-

50 directly to a FST Service Engineer (3G

connection available optionally). The remote

access allows the FST engineer to troubleshoot

and diagnose system issues without being on-

site

The Advantages include:

• Faster response times to system issues

reduces downtime of system

• Reduction in costly service calls and

technical interventions

• Safe and secure, as the encrypted

connection must be initiated by the

customer

OTHER FEATURES

Recipe Management

The system allows for easy recipe selection,

modification and creation from the advanced

menu. All recipes can be backed up to a USB

device. Reloading of recipes is simple and fast.

User Levels

The system allows for multiple levels of User

Login giving people different access levels to

the system. The predefined Login Levels

include:

• Operator

• Quality

• Supervisor

• Service (FST Only).

Alarm Menu

The Alarm Page provides easy to understand

and well documented alarm registration,

including alarm history. Each alarm has a

remedy suggestion attached resulting in

improved service capabilities and reduced

down time.

Stop Watch Display

This feature provides the operator with a

function to display the current and last cycle

times. This is useful when running a series

production.

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Counter Menu

The system provides a listing of gasses and fuel

used. This provides a better understanding of

total consumption and the cost involved per part

and/or job.

Cooling Information

The system displays the actual cooling capacity

and heat loss to the cooling water. This

information shows the real-time power level of

the system directly to the operator.

Overview Menu

The system provides data on valves, sensors,

and safeties giving the service engineer a

detailed overview of the system status. This

feature helps to quickly locate any issue, thus

reducing costly down-time.

Master/Slave Integration (optional)

FST 50 series can be master/slave integrated

with the robot (ABB) part handling system. The

system can be operated in 2 different modes:

• Manual mode, where the AP-50 and robot

are operated independently. During

spraying, the operator can change the

spraying parameters manually and operate

the robot manually.

• Remote mode, where the robot is the

master and the AP-50 system is fully

controlled via the robot program (Plasma

start/stop, recipe selection or switch to a

different recipe, powder feed start/stop,

etc.)

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AP-50 Touch Screen Panel

The AP-50 Touch Screen Panel provides

access to all programming features and

displays all set and actual spraying parameters.

The displays are easy to follow and operate.

Different displays can be selected to enable the

operator to overview the entire process data.

The TSP is compact and can be wall mounted

or movable floor stand mounted.

AP-50 Electrical Control Module

The AP-50 ECM contains the PLC unit with

software used to control the system and all

related processes. Most process parameters

are closed-loop controlled for maximum coating

quality, reliability, repeatability and safety. Up to

256 spraying recipes can be stored in the PLC.

System status, alarm and safety features are

continuously monitored by the PLC controller.

The ECM is equipped with extra I/O terminals to

allow easy integration of peripheral equipment

such as powder feeders, dust collectors and

turntables.

AP-50 Gas Control Module

The AP-50 Atmospheric Plasma System is

supplied with a separate Gas Module. The gas

module contains the Mass Flow Controllers for

all the gases and all pressure sensors and

valves. Typically, the plasma gas module

includes Mass Flow Controllers for nitrogen,

argon, helium and/or hydrogen as the plasma

gases. (The required plasma gases need to be

specified). For safety reasons, the gas module

is continuously vented, preventing the

accumulation of gases and/ or fumes inside the

gas module. Furthermore, the Gas Module

cabinet is equipped with a hydrogen gas

sensor.

Gas Module also contains the gun cooling air

jets which are controlled (on/off) via the touch

screen controller.

All gas lines and fittings are manufactured from

stainless steel. Gas inlet pressures are

constantly monitored and the system will

generate a visual alarm if the gas pressures are

too low.

AP-50 Touch Screen Panel

AP-50 Electrical Control Module

AP-50 Gas Control Module

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Plasma power supply IPS-80

The secondary

chopped Power Supply,

in combination with the

AP-50 System, offers

the possibility of

operating different

plasma torches at a

high and constant

quality level. The

secondary chopped

technology guarantees

stable current and

homogeneous and

constant plasma over

the entire power range,

even at very low power

levels.

Highly efficient and heavy duty secondary

chopped (inverter) rectifier with the following

characteristics:

• Maximum output 80kW

(1000 ADC/80VDC or 800 ADC/100VDC)

• Duty Cycle 100%

• Electricity Supply filter in accordance with

“EMC” standards

The secondary chopped power supply

represents the latest technology for plasma

rectifiers. This technology provides substantial

advantages compared to conventional

rectifiers, such as:

• Unsurpassed plasma current stability (over

the entire power range).

• Ripple-free currents avoiding plasma power

fluctuations.

• High electrical efficiency (reductions in

power consumption of up to 40%).

Optionally the IPS50 PS (50 kW variant) can be

installed with the AP-50.

AP-50 Jam Box Module

A separate Jam Box Module is supplied with the

system and is used for cooling water and

plasma gas and electrical power integration.

The gun cables and hoses are connected to the

Jam Box. The Jam Box Module is usually

mounted inside the spray booth.

Next to water, gas and power integration, a

High-Voltage discharge unit is installed inside

the Jam Box. This High-Voltage unit is used for

the safe gun ignition. High Voltage Discharge is

the latest technology used to ignite a thermal

spray torch. FST does not use the older’ type of

high frequency ignition unit because of the

interference that may happen with surrounding

equipment such as robot controllers,

computers, etc.

The cooling water flow and water temperatures

are also measured in the Jam Box. In case one

of the measured process parameters operates

outside of the set tolerances, an alarm is raised.

This alarm can trigger a warning or a system

stop.

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FST 20C/FT Powder Feeder

The FST-20C/FT double powder feeder is one

of the easiest and most reliable powder feeders

in its class. Low maintenance requirements and

consistent powder supply to the plasma gun in

a manner that ensures high quality coatings day

in/day out.

The FST 20C/FT powder feeder can be used

with most powder based thermal spray

processes including plasma and HVOF. Its

proven design has become the standard in the

thermal spray industry. The FST 20C/FT feeder

offers unparalleled powder feeding accuracy

and repeatability (±2 gr/min).

The feeder operates in a volumetric principle

that directly controls the powder feed rate by a

variable speed powder wheel.

• Double powder feeder based on the

volumetric principle used for accurate and

homogeneous powder feed to the APS

torch.

• The powder feeder is integrated and

remotely controlled by the AP-50 system

• All powder feed carrier gases are mass flow

controlled.

• Powder feeder is equipped with two 1,5 liter

powder hoppers. 5ltr hopper are optional.

• Prepared for the upgrade with gravimetric

feeding (weight loss)

Note: PF-50 Powder Feeder can also be in

used with the AP-50

FST 20C/FT Powder Feeder

PF-50 Powder Feeder

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AP-50 Plasma System

The AP-50 System consists of the following

main components:

1. AP-50 System Touch Screen Panel (TSP)

2. AP-50 System Electric Control Module (ECM)

3. AP-50 System Gas Control Module (GCM)

4. AP-50 Jam Box

5. iPS-80 Power Supply

6. FST Powder Feeder

7. Plasma gun

8. Cooler – Pump Skid and e-Pure (optionally)

9. E-Stop

10. Tow (2) H2 Sensors (1x GCM, 1x Spray Booth)

11. Flow sensor GCM

12. Exhaust Flow Sensor

Note: for more technical details about our

systems, please do contact your local

FST sales representative or the FST

head office.

Hose & cables

a. H2 Gas Supply

b. Ar Gas Supply

c. N2 Gas Supply (optional)

d. He Gas Supply (optional)

e. Ar/N2 Gas Supply

f. Compressed Air Supply

A+B Electrical Control Cable ECM to GCM

C+D Electrical Control Cables ECM to PS

E Power Cables PS to JB, Neg

F Power Cables PS to JB, Pos

I Plasma Gas Hose GCM to JB

J Plasma Gas Hose JB to Plasma Gun

L Power/Water Cables JB to Plasma Gun Neg

M Power/Water Cable JB to Plasma Gun Pos

N Electrical Control Cable ECM to JB

O Electrical Control Cable ECM to PF

P Electrical Control Cable ECM to TCM

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SPECIFICATIONS

Description 3MB 9MB F4 SG-100

Gun Power 40KW 80KW 55KW 40-80KW

Power requirements (Gun limits set in system)

Voltage 380 - 400 VAC

480 VAC

380 - 400 VAC

480 VAC

380 - 400 VAC

480 VAC

380 - 400 VAC

480 VAC

Frequency 50 – 60 hz 50 – 60 hz 50 – 60 hz 50 – 60 hz

Current 160 Amp 160 Amp 160 Amp 160 Amp

Gas requirements

Argon 100 NLPM, 10 Bar 100 NLPM, 10 Bar 100 NLPM, 10 Bar 100 NLPM, 10 Bar

Nitrogen 100 NLPM, 10 Bar 100 NLPM, 10 Bar 100 NLPM, 10 Bar 100 NLPM, 10 Bar

Hydrogen 20 NLPM, 10 Bar 20 NLPM, 10 Bar 20 NLPM, 10 Bar 20 NLPM, 10 Bar

Helium 200 NLPM, 10 Bar 200 NLPM, 10 Bar 200 NLPM, 10 Bar 200 NLPM, 10 Bar

Carrier Gas (Ar/N2) 20 NLPM, 10 Bar 20 NLPM, 10 Bar 20 NLPM, 10 Bar 20 NLPM, 10 Bar

Plasma Gas Purity (min.)

Nitrogen 99,7% 99,7% 99,7% 99,7%

Argon 99,95% 99,95% 99,95% 99,95%

Hydrogen 99,995% 99,995% 99,995% 99,995%

Helium 99,995% 99,995% 99,995% 99,995%

Cooling Water requirements

Flow 15 - 20 l/min 15-20 l/min >9 l/min 30-40 l/min

Quality Conductivity

Quality ph Value

< 5 µS/cm

6,6

< 5 µS/cm

6,6

< 5 µS/cm

6,6

< 5 µS/cm

6,6

Inlet Temperature 15 to 25 °C 15 to 25 °C 15 to 25 °C 15 to 25 °C

Inlet Pressure 8 to 10 bar 8 to 10 bar 10 to 15 bar

Cooling Capacity Max 30 KW 50 kW 35KW 30-50KW

Other

Air Flow Exhaust >10.000 m3/hr >10.000 m3/hr >10.000 m3/hr >10.000 m3/hr

Ambient temperature 10 to 40 °C 10 to 40 °C 10 to 40 °C 10 to 40 °C

Humidity <75%, non-

condensing

<75%, non-

condensing

<75%, non-

condensing

<75%, non-

condensing

Powder Feeder

PF-50 Integrated,Recipe Integrated,Recipe Integrated,Recipe Integrated,Recipe

FST 10C/FT & 20C/FT Integrated,Recipe Integrated,Recipe Integrated,Recipe Integrated,Recipe

Other Upon request Upon request Upon request Upon request

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Description 3MBT F1 2086 2700

Gun Power 40KW 25KW 40KW 30KW

Min. Diameter 100 mm 75 mm 75 mm 40 mm

Length available 18”, 24” 18”, 20”, 24” 12”, 24” 12”, 24”

Angles available 30°, 90° 45°, 90° 45°, 60° 45°

Power Requirements (Gun limits set in system

Voltage 380 - 400 VAC

480 VAC

380 - 400 VAC

480 VAC

380 - 400 VAC

480 VAC

380 - 400 VAC

480 VAC

Frequency 50 – 60 hz 50 – 60 hz 50 – 60 hz 50 – 60 hz

Current 160 Amp 160 Amp 160 Amp 160 Amp

Gas requirements

Argon 100 NLPM, 10 Bar 100 NLPM, 10 Bar 100 NLPM, 10 Bar 100 NLPM, 10 Bar

Nitrogen 100 NLPM, 10 Bar 100 NLPM, 10 Bar 100 NLPM, 10 Bar 100 NLPM, 10 Bar

Hydrogen 20 NLPM, 10 Bar 20 NLPM, 10 Bar 20 NLPM, 10 Bar 20 NLPM, 10 Bar

Helium 200 NLPM, 10 Bar 200 NLPM, 10 Bar 200 NLPM, 10 Bar 200 NLPM, 10 Bar

Carrier Gas (Ar/N2) 20 NLPM, 10 Bar 20 NLPM, 10 Bar 20 NLPM, 10 Bar 20 NLPM, 10 Bar

Plasma Gas Purity (min.)

Nitrogen 99,7% 99,7% 99,7% 99,7%

Argon 99,95% 99,95% 99,95% 99,95%

Hydrogen 99,995% 99,995% 99,995% 99,995%

Helium 99,995% 99,995% 99,995% 99,995%

Cooling Water requirements

Flow 15 - 20 l/min 15 - 20 l/min 17 - 20 l/min 17-20 l/min

Quality Conductivity

Quality ph Value

< 5 µS/cm

6,6

< 5 µS/cm

6,6

< 5 µS/cm

6,6

< 5 µS/cm

6,6

Inlet Temperature 10 to 25 °C 10 to 25 °C 10 to 25 °C 10 to 25 °C

Inlet Pressure 8 to 10 bar 10 to 15 bar 8 to 12 bar 8 to 12 bar

Cooling Capacity Max 30 KW 20 kW 30 KW 20 KW

Other

Air Flow Exhaust >10.000 m3/hr >10.000 m3/hr >10.000 m3/hr >10.000 m3/hr

Ambient temperature 10 to 40 °C 10 to 40 °C 10 to 40 °C 10 to 40 °C

Humidity <75%, non-

condensing

<75%, non-

condensing

<75%, non-

condensing

<75%, non-

condensing

Flame Spray Technologies B.V. Flame Spray Technologies Ltd. Flame Spray Technologies

The Netherlands (Head Office) United Kingdom France

Tel: +31 26 3190140 Tel: +44 2921 660511 Tel: +33 660 479051

Fax: +31 26 3190141 Fax: +44 2921 660811 [email protected]

[email protected] [email protected]

Flame Spray Technologies, Inc. Flame Spray Technologies

United States Middle East

Tel: +1 616 9882622 Tel: +971 50 6171749

Fax: +1 616 9882629 Fax: +971 439 473 54

[email protected] [email protected]

Flame Spray Technologies

Poland

Tel: +31 26 3190140 Fax: +31 26 3190141 [email protected]

Flame Spray Technologies Pte Ltd.

Singapore

Tel: +65 644 982 38

[email protected]

www.fst.sg

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The information contained in this document is offered as a guide only. It does not form any part of any sales contract as guaranteed performance of the delivered product. Although

the information and suggestions in this brochure (“information”) are believed to be correct, Flame Spray Technologies makes no representations or warranties as to the completeness

or accuracy of the information. The information is supplied upon the condition that the persons receiving the information will determine its suitability for their purposes. This document

and the information contained herein is the property of Flame Spray Technologies and shall not be used, disclosed, forwarded or reproduced in whole or in part by the recipient for

any other purpose. Copyright © 2014 Flame Spray Technologies.


DIMENSIONS AND WEIGHT

Description Dimension (LxHxW) Weight

AP-50 Touch Screen 600 x 300 x 100 mm approx. 15 kg (excl. toolpost)

AP-50 Electric Module 1000 x 760 x 300 mm approx. 100 kg

AP-50 Gas Module 1000 x 760 x 300 mm approx. 150 kg

AP-50 Jam Box 600 x 760 x 350 mm approx. 45 kg

iPS-80 Power Supply 2000 x 800 x 600 mm 650 kg

FST 20C/FT Powder Feeder 600 x 1650 x 500 mm 120 kg

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