MP-100-APS. Flame Spray Technologies SprayTech. Multi-Process Thermal Spray Centre

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1 bv Impact 4, 6921 RZ Duiven P.O. Box 1027, 6920 BA Duiven The Netherlands Tel: Fax: Homepage: Inc Charlevoix Dr. SE Suite 203 I Grand Rapids, MI USA Tel: Fax: Homepage: MP-100-APS Multi-Process Thermal Spray Centre Introduction, the most innovative and responsive supplier of thermal spray equipment and consumables, introduces the MP-100 Multi-Process Thermal Spray Centre. It represents a new step forward in equipment design and has been developed to meet the increasing customer demands for better process control, system flexibility, safety features and the unnecessary duplication of system peripherals whilst at the same time offering truly outstanding value. FST Distribution/Agent COPIES IN PDF FORMAT ARE AVAILABLE, PLEASE CONTACT FLAME SPRAY TECHNOLOGIES TO RECEIVE A COPY. Fig.1 MP-100 Control Module 1

2 The MP-100 is built to the highest standards using the latest process control technology to ensure optimum system performance and therefore maximum coating quality. Its modular construction incorporates unique design features that make the MP-100 the most user friendly and flexible thermal spray system available. From standard core components, each system is effectively custom built to meet the individual customer demands. If the customer demands change in the future, the MP-100 can change with those demands by the addition of the relevant process control modules, e.g. a user initially utilising plasma spray technology could simply expand into HVOF technology by the addition of an HVOF process control module and the purchase of the associated gun hardware, without having to purchase a separate HVOF system. The MP-100 is capable of controlling and handling all key thermal spray processes including plasma, HVOF, combustion powder/wire and electric arc spraying. The modular and multi-purpose concept enables reliable integration of the MP-100 into automated coating facilities with high production rates. Extensive savings can be achieved in applications where more than one coating process is required. Effectively the entire coating process can be achieved in a one step operation without having to move components between spray booths. The MP-100 Multi-Process Thermal Spray Centre can support most thermal spray guns and powder feed units depending on customer specific or application requirements. The modern design of the MP-100 ensures that it can be easily integrated within existing coating facilities. The versatile control system combined with the benefits of advanced closed loop mass flow control technology, ensures the consistency of coating quality and accurate repeatability of process parameters. The MP-100 is completely operator friendly, utilising a colour Touch Screen that allows process visualisation during operation and programming. Up to 100 spraying recipes can be stored in the PLC. Fig. 2 MP-100 Plasma/HVOF diagram 2

3 Main features of the MP-100: Fully adaptable system capable of controlling all thermal spray processes Superb flexibility, reliability and performance at a sensible price Modular construction enables future expansion of a mono-process system into a fully integrated thermal spraying centre as user demands change Closed loop mass flow controllers for all process gases including carrier gas The MP-100 Controller can also control all system peripheral or auxiliary components, such as heat exchangers, dust collectors, etc. Fully compliant with all relevant CE directives Multiple gun technology; can handle most thermal spray guns including F4, F1, 3MB, 9MB, SG-100, plasma guns, liquid and gas fuel based HVOF guns such as JP5000, DJ, Jetkote and combustion guns including FWS20, 12E, 6PII Designed to integrate with a range of customer specified powder feeding systems The process controller is PLC based providing maximum reliability An MMI graphical Touch Screen control panel provides clear and user friendly access to process control parameters and monitoring functions Fig. 3 MP-100 wall mounted Touch Screen Controller All process control parameters are closed loop for maximum coating consistency 3

4 MP-100 Plasma System The MP-100 Plasma Spray System from Flame Spray Technologies is an advanced and reliable coating system that provides the repeatability and accuracy required in today s thermal spray production environment. The MP-100-APS System consists of the following components: The possibility to select multiple gun technology provides maximum coating flexibility. With the selection of the desired plasma gun, the MP-100 automatically sets the ignition values and operating limits. Also the cooling water pressure is automatically adjusted depending on the type of plasma gun. MP-100-F4 Plasma gun MP-100 Touch Screen Control Console (integrated in Electric Module or Wall mounted) MP-100 Control Module MP-100 Jam-Box Module MP-100 APS Gas Module MP-100 secondary chopped 100 kw Power Supply FST-10/MC or FST-20/MC Powder Feeder Cable and Hose Package Gun Consumable Package (100 hrs) Full Documentation, Manuals and Drawings Fig. 4 MP-100-APS Gun Selection Menu The MP-100 Plasma System can be equipped with most plasma spray guns, powder feeders and heat exchangers, depending on customer requirements. As a standard, the customer can already select from the Touch Screen operated system between 10 different plasma guns (including an Any Gun that can be completely self-configured). 4

5 MP-100-F4 Plasma Gun The MP-100-F4 Plasma Spray Gun is designed to provide high quality plasma coatings at power levels up to 55kW. Touch Screen Control Console The Touch Screen control panel provides all programming features and visualization of all set and actual spraying parameters. Different menu s can be selected to enable the operator to overview the entire process data. The Touch Screen control panel is compact and can be either mounted on the cabin wall or on the floor, using a tool post. Fig. 5 MP-100-F4 Plasma Gun When incorporated with the MP-100 Plasma System, the Plasma Gun can be utilized for extended periods of time with minimal maintenance. The MP-100-F4 Plasma Gun is available in different configurations (MB Machine Mounted, HB Hand Held, HBS Special, or VB VPS Gun). Fig. 6 Touch Screen Control Panel (Plasma) main page As an option, different data logging configurations are available to store and manipulate actual and set process values.. 5

6 MP-100 Control Module The Electrical Module contains the PLC unit (Siemens S7) and software to control all system modules. All process parameters are closed loop controlled for maximum reliability and repeatability. Up to 100 spraying recipes can be stored in the PLC. System status and all alarm and safety features are constantly monitored by the controller. MP-100 APS Gas Module The MP-100-APS system is supplied with a separate APS 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 can include Nitrogen, Argon, Helium and Hydrogen as the plasma gases. The control of the carrier gases (Argon) is included in the FST Powder Feeder. For safety reasons, the Gas Module cabinet is continuously vented and is further equipped with hydrogen gas sensors. Furthermore, all gas lines and fittings are manufactured from stainless steel. The Gas Module also controls the compressed air for component cooling. The cooling air can be switched on/off from the Touch Screen controller or via a robot program if integrated with a robotic system. Gas inlet pressures are constantly monitored and the system will give a visual alarm if the air or gas pressures are too low. Fig. 7 MP-100 Control Module Optional: Remote Diagnostics The MP-100 Control Module can use an integrated modem to enable remote diagnostics via telephone line or internet. In this way, FST has remote access to the MP-100 PLC for failure analyses, system errors and trouble-shooting. This feature can potentially safe extensive costs in detecting and correcting problems. Fig. 8 MP-100-APS Gas Module 6

7 Jam-Box Module A separate Jam-Box Module for water and gas integration and connection box for the Plasma gun. The cooling water flow is measured and water flow minimum value is monitored and integrated in the E-stop loop. Also measurement of water temperature supply and return line (also with limit set points) is included in this Module. The unit contains all required back-flash valves and a purging unit for clearing torch hoses. Usually the Jam-Box Module is mounted inside the spray booth, with water and power integration for Plasma Gun connection. The module includes a HF Ignition unit and High Frequency choke. This module also monitors the Plasma gas pressures and contains the measuring device for the Plasma voltage. Adapted for use with measurement of cooling water conductivity (optional). Heavy duty secondary chopped Plasma Power Supply The secondary chopped power supply, in combination with the MP-100 system, offers the possibility of operating different plasma guns at a high and constant quality level. The secondary chopped technology guarantees a stable current and homogeneous and constant plasma over the entire power range, even at very low power levels. This enables the use of the ID guns for coating of very small internal bores while maintaining a high coating quality and efficiency. Next to this, the secondary chopped technology provides a very high electrical efficiency compared to the conventional thyristor based power supplies. Fig. 10 MP-100 Power Supply Fig. 9 Jam-Box Module for Plasma 7

8 The MP-100 APS Power Supply is a heavy duty secondary chopped Rectifier with the following characteristics: Maximum output current: 1000 A DC Maximum output voltage: 100 V DC at 100% Duty Cycle Main Transformer: 3x400V - 3x90V, 50Hz Electricity Supply filter in accordance with EMV standards Powder Feeders offers a full range of powder feeders suitable for all thermal spray processes. For the MP-100-APS system the following powder feeder is recommended: Fig. 11 FST-20/MC Powder Feeder Other powder feeders are available upon request. FST-10 or FST-20 /MC Powder Feeder The FST powder feeders are a further development of the PT Twin type feeder. The base geometry of the powder hoppers and the complete powder feeding system is similar to the Twin feeders. The powder hoppers are therefore fully compatible and interchangeable with the PT systems. Different types of single (FST-10) or double (FST- 20) feeders are available. In combination with the MP-100 system, the carrier gases can be mass flow controlled. 8

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