AP-25 Plasma System AP-25 PLASMA THERMAL SPRAY SYSTEM
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1 AP-25 PLASMA THERMAL SPRAY SYSTEM AP-25 Plasma System We set ourselves the challenge of producing a simple yet flexible, high tech system our customers can rely on. The result is the new 25-Series equipment from FST. Introduction The 25-Series is a result of carefully listening to our customers and combining their comments with our years of experience in system design and manufacturing. We can now offer a system that delivers advanced features with a traditional feel while adopting the latest technology to ensure the best quality coatings in a safe and economical manner. The challenge with the 25-Series was to design a system at a lower cost whilst retaining the use of high quality materials and components to maintain the longevity and reliability common across other FST systems. The 25-Series for example continues with its use of high quality stainless steel fittings throughout, we ve compromised on cost, not on our principle of quality throughout. A high definition touch screen provides the operator with easy access to important information including stored recipes, process parameters, pressures and flow rates, safety alarms and warnings. The powder feeder is also started and stopped via the touch screen. The main parameters (argon, nitrogen and hydrogen flows and carrier gas flow) are manually adjusted which makes the system operation intuitive, robust and user friendly. As with our successful 50-Series equipment, we have incorporated remote diagnostic capabilities using ewon technology (optional). This provides FST with remote access to the system which can reduce down time and service costs. Among other features, the multi-language AP-25 Plasma system provides the operator with warnings and alarms (shut down) in the event of parameters drifting out of range. E-stop integration is a standard safety feature. A typical AP-25 Plasma System consists of the following main components: AP-25 Controller ips80 or ips50 Power Supply Jam Box Plasma Torch incl. hoses & cables Powder feeder December Series Page 1 of 6
2 The i makes the Difference We understand that not all customers have the same needs or processing requirements when it comes to thermal spray. To help address this situation, the AP-25 is being offered in two variants. The AP-25 PLASMA The AP-25i PLASMA The Plasma Torches FST offers a complete range of both OD and ID plasma torches. This allows the customer to select the proper torch for the application. The AP-25 allows the operator to setup more than one plasma torch in the torch selector section the software. Within this section operational limits can be set protect each individual plasma torch. The standard AP-25 uses mass flow meters while the AP-25i uses mass flow controllers. The difference with the AP-25i is that parameters are closed-loop controlled and safeguarded. With the AP-25 the parameters are only safeguarded. OD Plasma Torches 3MB 9MB F4 SG kw 80 kw 55 kw kw ID Plasma Torches 3MBT F & kw Min. diam.: 4 Length: 18, 24, 26 Angle: 90º, 30º 25 kw Min. diam.: 3 Length: 18, 20, 24 Angle: 90º, 45º 40 kw & 20 kw Min. diam & 1.5 Length: 12, 24 Angle 60º, 45º December Series Page 2 of 6
3 Operator Interface The clear user interface combines a 12 high definition touch screen with large on/off controls as well as parameter control dials. The operator interface is simple but effective, providing a user friendly system that can be adapted to any production environment. Large and robust control dials (together with clear information on the touch screen for all critical parameters) makes the system easy to use. This minimizes the potential for operator error. Parameter storage, cooling information and powder feeder integration allows the operator direct control and feedback from a very intuitive system. The system and the process are protected through pre-set limits along with a range of warnings and alarms. Emergency-stop buttons are standard. The system has a multi-language interface. Many languages can be provided. Just ask your FST representative about our language capabilities. Values can very be set in either metric or imperial units, depending on your local requirements, by simply selecting the preferred unit. An alarm page displays and stores system warnings and alarms. These alarms provide the operator and FST engineers with important feedback and information in troubleshooting scenarios. Remote access Remote access is optional with each AP-25 system via ewon. ewon technology allows FST service engineers secure access to the system for remote diagnostics and / or service. ewon utilizes standard Ethernet protocols; however, Cellular (3G) and Wi-Fi connectivity are also available. Advantages Faster response times, reducing downtime Cost reduction by reducing service intervention calls Secure connection by using ewon technology December Series Page 3 of 6
4 AP-25 Plasma Jam Box A separate Jam-Box Module is supplied with the system. The Jam Box provides a convenient way to integrate incoming power, cooling water and process gas feeds with the torch hose/cable set. The Jam Box also houses the torch ignition module. Jam Boxes are normally mounted inside the spray booth. Plasma Power Supply The AP-25 is supplied with your choice of either a 600 or 800 A power supply: ips50-eco 600 A, 80 VDC ips80-eco 800 A, 80 VDC Either ips-eco power supply in combination with the AP-25 ensures that your plasma spray equipment performs with outstanding process stability and coating reproducibility. With the secondary chopped technology used, the FST power supplies will provide both excellent operational and cost efficiency. The stability of the plasma process begins with the quality of the power supplied to the spray system. Both the ips50-eco and ips80-eco produce a near perfect direct current waveform with a low ripple. This acts to stabilize the plasma spray process, which improves coating repeatability and increases gun consumable service life. Both the ips50-eco and ips80-eco are very efficient, with a power factor cosγ >0,95 that reduces overall power consumption. The ips- ECO series is the ideal choice for powering the AP-25 plasma spray system December Series Page 4 of 6
5 The Powder Feeder The AP-25 Plasma system is supplied with a PF-50 powder feeder. Utilizing proven technology and electrical controls, the PF-50 is inexpensive and reliable. The heart of the electrical controls is the digital closed-loop controller which offers precise and consistent wheel speed. The PF-50 is fully integrated and controlled via the AP-25. (feeder on/off, disc speed and carrier gas flow). The PF-50 offers a variety of features, including: Plasma & HVOF capable 15 rpm motor (32 rpm available) Closed-loop wheel speed control 6,2 bar (90 psi) maximum operating pressure 3,3 l (205 in 3 ) hopper volume Remote control +/- 2% feed accuracy Alternative feeders: FST-10C/FT, FST-20C/FT Features Summary Easy to use modern technology and process visualization... but with a traditional feel Remote access through the use of ewon (optional) for remote troubleshooting / service and software updates Available in AP-25 and AP-25i configurations allowing the choice between mass flow meters (parameter safeguarding) or mass flow controllers (closed-loop control and safeguarding) E-Stop and external e-stop integration Metric or imperial unit display Parameter storage Multi-language selection Multiple voltage: VAC, 50/60 Hz for worldwide usage. CE conformity. UL conformity upon request Powder feeder integration Integrated compressed air valve (optional)for cooling air jets (on / off) Automatic torch ignition Warning alarms to ensure the safe operation of the AP-25 Assembled using only first class materials to ensure product reliability December Series Page 5 of 6
6 SPECIFICATION Description Value 1 Value 2 Voltage VAC VAC (other voltages available) Frequency 50/60 Hz Current 150 A (ips80) Argon Flow 100 nlpm 212 scfh Argon Pressure 6 8 bar psi Argon Purity % (Grade 4.8) Nitrogen Flow 100 nlpm 212 scfh Nitrogen Pressure 6 8 bar psi Nitrogen Purity % (Grade 4.8) Hydrogen Flow 20 nlpm 42 scfh Hydrogen Pressure 6 8 bar psi Hydrogen Purity % (Grade 4.8) Air Pressure 6 8 bar psi Air Quality dry and oil-free Cooling Water Flow l / min gal / min Cooling Water Inlet Temperature ºC ºF Cooling Water Inlet Pressure 9 15 bar psi Cooling Power kw Btu / min Cooling Water Conductivity <5 µs Cooling Water Hardness <10 ppm Exhaust Air Flow (minimum) m 3 / hr 5900 ft 3 / min Ambient Temperature ºC ºF Humidity <75%, non-condensing December Series Page 6 of 6 Flame Spray Technologies B.V. Flame Spray Technologies Ltd. Flame Spray Technologies Flame Spray Technologies The Netherlands (Head Office) United Kingdom Poland France Tel: Tel: Tel: Tel: Fax: Fax: Fax: france@fst.nl info@fst.nl uk@fst.nl info@fst.nl Flame Spray Technologies, Inc. Flame Spray Technologies United States Middle East Tel: Tel: Fax: Fax: info@fstincusa.com fstme@emirates.net.ae Flame Spray Technologies Pte Ltd. Singapore Tel: info@fst.sg 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.
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