01.20.150 ap-25 plasma system dec2015 - fst global … · the ap-25 plasma system is supplied with...

AP-25 PLASMA | THERMAL SPRAY SYSTEM

01.20.150 | December 2015 | 25-Series | of 6

Added value through know-how | www.fst.nl

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


SPRAYTECH | AP-25 PLASMA


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 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.

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.

OD Plasma Torches

3MB 9MB F4 SG100

40 kW 80 kW 55 kW 40-80 kW

ID Plasma Torches

3MBT F1 2086 & 2700

� 40 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. 2.75” & 1.5”

� Length: 12”, 24”

� Angle 60º, 45º




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




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.




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 in3) 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: 100– 240 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.

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


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.



SPECIFICATION

Description Value 1 Value 2

Voltage 380 - 400 VAC

480 - 500 VAC

(other voltages available)

Frequency 50/60 Hz

Current 150 A (iPS80)

Argon Flow 100 nlpm 212 scfh

Argon Pressure 6 – 8 bar 87 – 116 psi

Argon Purity 99.998% (Grade 4.8)

Nitrogen Flow 100 nlpm 212 scfh

Nitrogen Pressure 6 – 8 bar 87 – 116 psi

Nitrogen Purity 99.998% (Grade 4.8)

Hydrogen Flow 20 nlpm 42 scfh

Hydrogen Pressure 6 – 8 bar 87 – 116 psi

Hydrogen Purity 99.998% (Grade 4.8)

Air Pressure 6 – 8 bar 87 – 116 psi

Air Quality dry and oil-free

Cooling Water Flow 12 – 20 l / min 3.2 – 5.2 gal / min

Cooling Water Inlet Temperature 10 – 25 ºC 50 – 77 ºF

Cooling Water Inlet Pressure 9 – 15 bar 130 – 210 psi

Cooling Power 20 – 45 kW 1100 – 2500 Btu / min

Cooling Water Conductivity <5 µS

Cooling Water Hardness <10 ppm

Exhaust Air Flow (minimum) 10.000 m3 / hr 5900 ft3 / min

Ambient Temperature 10 – 40 ºC 50 – 105 ºF

Humidity <75%, non-condensing

01.20.150 ap-25 plasma system dec2015 - fst global … · the ap-25 plasma system is supplied with...

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