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The 50 Series Equipment Advanced Simplicity
March-2015
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The 50 Series
Introduction of the 3rd Generation 50 Series Equipment
Further development of the successful 2nd Generation 50-Series Equipment
First 50-Series Equipment installed in 1997, and still in operation every day.
Proven performance. More than 120 50-Series systems operational worldwide including: Siemens, Aquamarine, Flame Spray, CTS, Chromalloy, GE, WGHITT, TST, Wamar, Brenco, Woodgroup, GE, etc.)
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System Configurations
HV-50 • HV-50/JP-5000 • HV-50/Jet Kote • HV-50/DJ-2600
AP-50 • AP-50 Ar/H2 • AP-50 Ar/N2/H2 • AP-50 Ar/N2/H2/He • iPS-80 (80KW) or iPS-50 (50KW)
MP-50 • Combination of the above • Incl. Flame Powder
Powder Feeders • FST 10C/FT • FST 20C/FT • PF-50
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ALL SYSTEMS STANDARD:
Mass Flow Controlled Remote access Multiple language software Multiple gun technology Stainless steel hard plumbing CE Conformity Gun limits safeties Parameter safeties Recipe saving
•Multi-process •Integration M/S or I/O •E-Stop Integration •Data logging •Closed loop parameters
Turn Key
•Plasma / HVOF •I/O integration •M/S integration •Data logging •Modular Contruction •Stainless Steel Internals
MP-50
•Plasma process •I/O integration •Data logging •Stainless Steel Internals
•Modular design
AP-50
•HVOF Process •I/O integration •Data logging •Modular design •Stainless Steel Internals
•Mobile version
HV-50
•HVOF Process •I/O integration •Data logging •Ethanol based •Highly efficient •Ultra High Pressure
•Modular design •Mobile version
eGun system
System Portfolio
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•Volumetric feeding •Fully controlled via 50-Series equipment
•One hopper 1.5, 2.5, 5 Ltr. •Optional heater blanket
FST 10
•Volumetric feeding •Fully controlled via 50-Series equipment
•Two hoppers 1.5, 2.5, 5 Ltr. •Optional heater blanket
FST 20
•Volumetric feeding •I/O Controlled •Hopper 3.3 tr. •Std. Heater blanket •Easy cleaning •High pressure
PF-50
Powder Feeder Portfolio
POWDER FEEDER OPTIONS FST 10 / 20:
Mass Flow controlled Mass View controlled Flow Tube controlled Gravimetric feeding Laser version High pressure version
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System Levels
25-Series 50-Series 100-Series Operating Menu (Basic) √ √ √ Operating Menu (Operator) √ √ Settings Menu √ √ √ Recipe Menu (20) √ √ √ Recipe Menu (256) √ √ Alarm Menu (Basic) √ √ √ Alarm Menu (Solutions) √ √ Pre-Settings Menu √ √ √ Consumption Page √ √ Remote Access (eWon) √ √ Data Trending √ √ Data Dump √ √ Data Logging incl Report √ User Level Setting √ √ Service Page √ √ I/O Integration √ √ √ Master/Slave Integration √ (Optional extra Price) √ Downloadable Information √ Surface Temperature Sensor √ (Optional extra Price) Barcode Reader √ (Optional extra Price) Part Cooling Jet Torch as Parameter √ Torch Cooling Jet Part as Parameter √
06-0
6-20
14
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AP-50System Configuration
1. AP-50 Touch Screen
2. AP-50 Electric Module
3. AP-50 Gas Module
4. AP-50 Jam Box
5. iPS80 Power Supply
6. Powder Feeder
7. Plasma Torch
8. Water Cooling Unit
9. E-Stop
10.H2 Sensor Gas Module
11.H2 Sensor Spray Booth
12.Flow Sensor
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HV-50/JP-5000 System Configuration
1. HV-50 Touch Screen
2. HV-50 Electric Module
3. HV-50 Gas/Fuel Module
4. Cooling Unit
5. Powder Feeder
6. HV-50 Jam Box
7. Hoses & Cables HVOF Torch
8. HVOF Torch
9. E-Stop & Flow Sensor
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50-Series key features
Latest Graphical Touch Screen provides clear and user friendly control and monitoring.
PLC controlled for maximum reliability
Closed loop all parameters
Integration with powder feeding systems
Integration with handling systems
Monitoring peripheral equipment
Remote access via eWon
Data trending and logging
Self diagnostics systems
Safety measures
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Heart of the system – PLC with software and communication with the sub components.
System status and all alarms and safety measures are constantly monitored
Improved remote access using the Service Page
50-Series Electric Module
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Dedicated gas module for each process
High precision MFC for all the gases
Pressure sensors, valves and switches
Carrier gas control
Cooling air control
Supply pressure monitoring
Forced air circulation
50-Series Gas Modules
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Latest Generation Siemens Simatic S7-1200 PLC Great performance and reliability
Modular, compact, versatile and powerful
providing the ideal fit to the 50 series
requirements
New FST PLC software
Latest generation Siemens HMI Panel Comfort Panel TP1200
High Performance, robustness
Designed to reliably work with PLC S7-
1200 Series
50-Series Technology Used
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Bronkhorst MFC’s for all process gasses
In-line filter, pressure sensors, valves etc.
Stainless Steel tubing inside gas module
Gas Line in straight line for easy access and maintenance, and improved gas flows to torches
Calibration connections
Forced air circulation including flow sensor
50-Series Gas Modules
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Connection modules for guns
Integration of the electric power, water and process gases
Ignition devices for APS and HVOF guns
Cooling water pressure, flow and temperature monitoring
Back flash valves for HVOF guns
Jambox / Water Switch Module
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Heavy Duty Secondary Chopped 80 kW Rectifier (1000 Amp, 80 V). Also available in a 50KW version.
100% Duty Cycle for the entire power range
No disturbance or contamination back into the electrical supply net
Higher electrical efficiency; up to 40% in power savings!
More stable plasma and less plasma power fluctuations, especially for low power applications (ID coatings)
iPS-80 PowerArc™ Power supply
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Longer hardware (nozzles/electrodes) lifetimes and more homogeneous coating quality
Controlled soft ignitions reducing nozzle/electrode wear
No HF disturbance with other components such as robots, PC’s, etc
Access to individual power modules inside the power supply
iPS-80 PowerArc™ Power supply
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Operator Interface New design, New Software
Mounted on a toolpost
New generation of Siemens touch 15” screen
Data trending & logging
Multilevel password
Up to 250 recipes can be stored
Saving recipes via USB Port
Export recipes
Remote Diagnostics
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15” Touch Screen operation with several main and sub menu’s for easy programming and operator friendly control. Storage of 250 recipes. Possibility of multi-level pass word protection.
The Software
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The Software: Operator Screen Screen
The Software; keeping simplicity and operator friendliness
Safety First
Menu Selection Buttons
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The Software: Operator Screen Screen
The Software; keeping simplicity and operator friendliness
Powder Feeder
Torch Selected
Integration – I/O
Start/Stop
Flow Read-out. Alarm 5% & 10%
Recipe Management
Cooling water information
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The Software: simplicity screen for operator easiness. Only displayed what is required.
The Software: Operator Screen
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Software Features
Idle Mode Data trending & Data logging Improved recipe management Recipes back-up to external USB device User levels Improved alarm page including alarm history Consumption page Improved remote diagnostics via internet using secure eWON
technology. Stop watches with current and last cycle time Displaying actual cooling capacity or heat losses to cooling water. Service page including actual status of all PLC signals Surface Temperature Sensor
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The Software: Data Trending
Important process data can be directly followed in real time
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The Software: Data Logging
Data Trending only displays the data
Data Logging records raw the data to an external USB device
Fully automatic between start and stop
Post processing in standard computer (Excel)
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The Software: Recipe Management
Easy select, modify or create new recipes
Call up from Recipe Page or from Operational Page
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The software: User Levels
4 different Service Level can be set
Operator, Quality and Supervisior are for the customer
Service is for the FST Technicials
Operator Quality Supervisor Service
Operating system X X X X
Recipe edit X X X
Settings edit X X
Logging edit X X
Service edit X
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The Software: Alarm Registration
Display of actual alarms including Alarm history
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The Software: Consumption Page
Shows the volumes of media used
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Improved Remote Access
Connect any Ethernet devices without the need to configure the gateway
Instant broadband connection across factory LAN. Easy to setup with no firewall issues.
Cloud based solution. One click to connect within fully secure VPN tunnel. Unlimited in time FREE service.
Fully secure SSL-based VPN tunnel.
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The Software: Maintenance Help
Providing detailed information on system status
For service & maintenance engineers
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Optional Features
IR sensor connected to 50 Series EM
Substrate temperature displayed on Touch Screen
Barcode Scanner
Master/Slave Integration robot/50series
Gun Air Jet & Part Cooling Air Jet as parameters
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The Software: Service & Settings
Setting of gun limits and other important system settings (FST Service Engineer Only)
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Integration with robotic handling systems, allowing I/O or master/slave (optional) operation
With robot as master, all process functions (plasma start, PF start, DC functions, recipe selection) are controlled by the robot with 50-Series as slave
Integration
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50-Series has a self diagnostics system continuously monitoring the status of the 50-series and peripherals
Gas modules are continuously vented
Combustible gases sensors in gas module(s) and inside the booth
Shut-off valves for combustible gases lines that automatically close when gas leak is detected
Monitoring and safe guarding the gas supply pressures
50-Series Emphasized on Safety
E-Stop buttons, robot teach pendant, robot controller and inside the spray booth, door switch
Monitoring device in ducting between the spray booth and the dust collector
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50-Series Emphasized on Quality!
The 50-Series has been designed with Quality in mind: • Use of only first class components
• Standard quality industrial parts and components
• Stainless Steel Piping
• User friendly software
• Remote diagnostics
• etc
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Thanks for your attention…