MP-X APS Thermal Spray System
multi process HVOF and Plasma Spray (Swiss Made)
 
Main features MP-X APS

  • Modular design to separate functions and easy access to all modules
  • Closed loop controlled parameters for the coating process
  • Multiple process selection (APS / HVOF Process)
  • Multiple torch selection
  • HMI with 19“ Touch screen for user friendly access to the system 
  • Data trending / Data logging functions
  • PLC based Software for real time functions


MP-X Control Module            
Rittal Cabinet (600x2000x600mm)
Power supply Primary 100-230VAC Secondary: 24VDC / 20A

Frequency: 50/60 Hz Gas Analyzer for Hydrogen (H2) equipped with one sensor inside MP-X Gas Module APS and one sensor inside the spray booth.

Dual channel emergency-off system standalone or integrated to handling system. o Machine safety loop for all relevant process safeties.


CPU Siemens S7-315 2PN/DP 

ProfiNet: HMI (Human Machine Interface) / Data logging
ProfiBus: System control o Power supply for all MP-X components and all peripheral units.

MP-X Teach Pendant

  • Simatic HMI TP1900 Comfort Panel
  • Touch screen 19“ Widescreen-TFT-Display
  • 16 million Colors
  • Profinet Interface
  • USB Interface for Recipe and data logging 
  • Windows CE 6.0 o MP-X  User software (English)
  • Trending- and Data logging –
  • Functions:Gas flows ( Nominal- / Actual value with three different parameter settings)
  • All parameters in metric or imperial units
  • Wall or Cabinet mount

 

MP-X Gas Module APS
Rittal Cabinet

Three gas lines set up as:

  • Mass flow controller Argon (Ar)  (0.2..100 NLPM) 
  • Mass flow controller Nitrogen (N2)  (0.2..100 NLPM)  
  • Mass flow controller Hydrogen (H2)  (0.4..20 NLPM) 
  • Optional: Mass flow controller Helium (He) (4..200 NLPM)
  • Optional: Proportional valve for Air Jet (0..6 bar)  or Carrier gas selection for Argon (Ar) or Nitrogen (N2)


All gas line sare protected with gas filter 60µm / main valve / pressure switch / pressure regulator and a manometer.


Servicing and calibration : calibration interface“ is included. All tubing is stainless steel with Swagelok fittings (size 3/8“).


Safety Features MP-X Plasma gas module

  • Positive pressure electrical cabinet,, keeps explosive gases away from electrical  connections
  • Fan inside cabinet door
  • Roof ventilation 
  • Gas sensor for Hydrogen detection, alarms at 20% LEL Warning / 40% LEL Alarm


MP-X Gas Module HVOF
Rittal Cabinet (600x600x2000mm)

Two fluid lines set up as:

  • Mass flow controller Oxygen (O2)  24.to 1200 NLPM)
  • Coriolis(tm) flow controller Kerosene (JetA1)        (0..45 l/h)


All fluid lines are protected with gas filter 60µm / main valve / pressure switch / pressure regulator and a manometer. 

Servicing and calibration : calibration interface“ is included. All tubing is stainless steel with Swagelok fittings.

 Safety Features MP-X Plasma gas module

  • Positive pressure electrical cabinet,, keeps explosive gases away from electrical  connections 
  • Fan inside cabinet door 
  • Roof ventilation  
  • Gas sensor for Hydrogen detection, alarms at 20% LEL Warning / 40% LEL Alarm

 
JAM Box APS / Switching Box 
Rittal Cabinet (600x600x350)

Column base for easy installation

Water control unit (inlet/outlet temperature and water flow)

Water bypass for low power torches
Ignition  APS 42VAC / 55Hz / 9000VDC peak to peak
Plasma gas switch outside the cabinet

Shroud gas connections Ar/N2 outside cabinet

Protection sheet against electricity 

Gun hoses connection for standard Metco Type hose

Metco 9MBM hose adapters included

Power supply unit Vario TS 1000

  • Rittal Cabinet (800x600x2100)
  • Secondary chopped power supply  
  • Maximum Output 80kW (1000A/80VDC or 800A/100VDC)
  • Duty cycle 100%
  • Electricity supply in accordance with „EMV“ standards Linked with Profibus – Protocol to MP-X
  • Door safety switch 


MP-X Cables and Hoses Package
The MP-X is  supplied with all required cables, hoses and cable ducting:

  • Signal cable from control module to all sub-components  
  • Signal cable from Power supply to JAM Box
  • Power cable from Power supply to JAM Box
  • Gas hoses from gas drop point to Gas Modules APS & HVOF
  • Gas hoses from Gas Modules to JAM Boxes
  • Plasma power cables/ plasma gas hose to the gun


All cables and hoses in the MP-X system will be covered and shielded inside the cable duct. The cable ducts are covered .   Cable duct dimensions are between 100/200/300mm . 


All electrical and pneumatic connections inside the cabinet are placed in aluminium tubes.  

APS 9MB Plasma Gun

  • Universal Plasma Spray gun
  • Including nozzles / Electrodes based on your needs
  • Gun hose package from JAM box to the 9MB Gun
  • 1 Set Powder injectors as requested your application
  • Option cooling nozzles (Air Jet’s)
  • Powder hoses from feeder to 9MB gun 
  • Isolated gun holder for handling system


MP-X Twin Powder Feeder
Twin powder feeder with mass flow meter
0.4..20 NLPM Argon (Ar) / 0.28...14.28 NLPM Nitrogen (N2)

Fully integrated to MP-X Controller Nominal and actual value for:

  • Mass flow meters
  • Disc drive unit
  • Stirrer drive unit o Maxon drives with closed loop function


 

Safety Features:
Over-pressure safety valve 

Siphon unit under hopper interface

High pressure hoses for gas flow

 MP-X Software Description
Main screen:

  • Process selection APS 
  • E-Stop Signalisation


 

Main screen APS:
Three running modes:

  1. Manual
  2. Automatic-
  3. Remote –


Mode or User Selection:

  1. Operator
  2. Senior Operator
  3. Supervisor
  4. Administrator


Multiple Plasma Spray Gun selection:

  • F4
  • F1
  • F-100
  • F2
  • 3MB
  • 7MB
  • 7MST
  • 9MB
  • SG100
  • Any gun


Gas lines control:

  • Argon (Ar)
  • Nitrogen (N2)
  • Hydrogen (H2)
  • Helium (He)
  • Shroud Argon (Ar)
  • Shroud Nitrogen (N2)
  • Compressed Air


Powder feeder control:

  • Carrier gas
  • Disc speed
  • Stirrer speed for two lines


Power supply and JAM Box information’s:


Voltage [V]

Option Voltage at Gun [V]  

Actual power consumption [kW]

Water flow [l/min]

Water supply line [°C]

Water return line [°C]

Cooling power [kW]
Actual status system sequencer

Idle Mode feature

Door open signals

Recipe Status

Robot selected number (Remote Mode)

Recipe name (Automatic Mode)

Main screen HVOF process:
Three running modes: 

  • Manual
  • Automatic-
  • Remote – 


Mode or User Selection: 

  • Operator 
  • Senior Operator 
  • Supervisor 
  • Administrator 


Multiple HVOF Spray Gun selection: 
JP-5000

JP-5000 ST  


Gas and Liquid Fuel lines control:

  • Oxygen (O2)
  • Kerosene


Powder feeder control:

Carrier gas

Disc speed

Stirrer speed for two lines


JAM Box information:

  • Oxygen pressure 0..25 bar
  • Kerosene pressure 0..25 bar
  • Chamber pressure 0..16 bar
  • Actual power consumption [kW]
  • Water flow [l/min]
  • Water supply line [°C]
  • Water return line [°C]  
  • Cooling power [kW]


Actual status system sequencer

Idle Mode feature

Door signalisation

Recipe Status

Robot selected number (Remote Mode)

 Recipe name (Automatic Mode)

 

APS Gas lines:
Gas lines control for Argon (Ar) / Nitrogen (N2) / Hydrogen (H2) and

Optional Helium (He) o Optional for Air Jets 0..6 bar adjustable with proportional valve 

(Manual mode: selected value / Automatic or Remote mode: RCP value) o Interactive gas flow chart  o Carrier gas selection o Primary gas selection o Exhaust control (on/off / status)

 

HVOF JP Gas lines:
Gas lines control for Oxygen (O2) / Kerosene o Interactive gas flow chart o Pressure settings:
Oxygen pressure o Kerosene pressure o Chamber pressure 
Carrier gas selection
Exhaust control (on/off / status)

 

Power supply and JAM Box:
Current control (Nominal- /Actual- / Visual actual value / on / off / status o Spray gun ignition test o Power control function:

Power constant / current constant / Voltage adjustable (Hydrogen)
Power constant / Voltage constant / Current adjustable (I)

Power supply and JAM Box information’s as written in main screen

 

Powder feeder page:

  • Carrier gas control (Nominal- /Actual- / Visual actual value / on / off / status)
  • Disc drive control  (Nominal- /Actual- / Visual actual value / on / off / status)
  • Stirrer drive control  (Nominal- /Actual- / Visual actual value / on / off / status)
  • Carrier gas selection Argon (Ar) / Nitrogen (N2)
  • Exhaust and Chiller controls


Settings page:
Language selection: German / English         

Date and Time adjustment
Units selection: Metric or Imperial Units

Tolerance selection: Three different warning and alarm value ranges 

Conversion factors between Metric and Imperial Units

Actual selected gun settings

User administration / Login / Logout o Adjustments for Windows Settings Page

System running hours o Counter for sprayed parts

Counter for sprayed parts (can be reset) 

Ignition test and status Service Mode
Gas consumption, total value and reset value

 E-Pure “Water regeneration system”
The E-Pure water regeneration unit consists in particular of a filter, the circulation pump, the de-mineralization cartridge as well as a conductivity measuring device.

  • De-mineralization cartridge
  • Anions / Cations exchanger for complete softening of water. Removes all minerals, like lime etc. from the cooling water. Welded cartridge.
  • Complete de-mineralization means, all Anions and Cations are removed from the process water. The resin in the welded cartridge revokes the minerals.
  • Filter unit
  • Highly effective, wide micro-filter for the removal of susceptible fixed particles up to a size of 5µm.
  • Double layers Supor-diaphragm (hydrophilic of polymers), 5µm.
  • Supporting material poly-propylene. 
  • Conductivity measuring device
  • In-LINE measuring instrument with conductivity value indicator:  Range 0-199.9 µS/cm.
  • Timer
  • Automatic: 15 minute work, 15 minute break 
  • Manual:     Non-stop operation
bexxon global pte ltd Indonesia
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Swiss made HVOF Plasma Multi Process

World Class quality design and build