Product Data Sheet

SmartArc Advanced Electric Wire Arc

Thermal Spray System
The SmartArc™ is a state-of-the-art, ­advanced When used with Oerlikon Metco’s extensive portfolio of high
electric wire arc spray system for high productivity quality wire arc materials, SmartArc delivers superior coat-
that produces repeatable coatings of unsurpassed ings, at high deposition rate, and with ease.
quality.
1 General Description
A premium system, SmartArc has innovative engineering that The high power capacity (400 A) allows SmartArc to deposit
ensures it will produce highly reliable electric wire arc spray coatings from both hard and soft wires very quickly and eco-
coatings, while being cost-effective and having outstanding nomically. Hard wire coatings produced using the SmartArc
ease-of-use and serviceability. system have excellent bond strength, high hardness, low
­porosity and are easily machined. When soft wires are used,
With applications in a wide variety of industries, SmartArc is exceptionally high coatings rates of up to 32 kg/h (70 lb/h)
the answer for swift, cost-effective thermal spray coatings for are possible.
wear protection, restoration of component dimension and
corrosion protection. Some examples of applications where SmartArc incorporates a leading-edge gun head design that
SmartArc produces excellent value are: delivers low-turbulence, nearly laminar air flow. This results in
nn Industrial rollers used in printing and textiles, paper and high deposition rates, very dense, low oxide coatings and a
pulp production, embossing and steel manufacturing, reduction in consumables and maintenance. Voltage mea-
nn Automotive mufflers and exhaust pipe seam welds, surement is at the gun for reliable coating results.
nn Aviation and aerospace components requiring bond coat-
ings and machinable restoration coatings, A unique feature of SmartArc is load-sharing; a patented mo-
nn Hydroelectric turbine parts for power generation, tor control method that provides “push-pull” coordination of
nn Aluminum extrusion mills, the wire feed stock. As a result, wire feed is very smooth, al-
nn Tube mill weld seams. lowing wire conduit cables of up to 15 m (50 ft). This allows
the SmartArc PPG gun to be mounted on a robot or other
gun manipulation equipment for added precision and auto-
mation. When the gun “pull” motor, that acts as the master
feed motor, needs assistance, SmartArc senses the load and
has the console motor “push” harder to ensure highly con-
sistent wire feed.

Truly automated, SmartArc incorporates rugged and reliable

PLC (programmable logic control) computer technology for
its advanced feature capability and provides diagnostics
tests that are easily interpreted by the operator.

SmartArc PPC Console and 350RU Power Supply

(shown with optional Power Supply Truck) SmartArc PPG Wire Arc Spray Gun

DSE-0055.6 – SmartArc
© 2015 Oerlikon Metco 1
Two gun models are available for the SmartArc system. The
PPG gun (CE-conformant) is a machine-mount push-pull de-
sign. The PPGH hand-held model offers an optional gun
handle that incorporates an integrated, system-wide E-stop
and wire speed control, on the handle. (Not for sale in
CE-conforming countries)

Wire Feed and Clamping Mechanism

Drive Unit

Gun Handle PPGH

Contact Tips

Locating Ring

Air Cap Body

Air Cap Insert

Arc Shield

DC Power/Air Cables
(PPG Machine Mount Gun)

Lower Cover

Cable Cover Tool Post

SmartArc PPG Gun – Main Parts Overview (PPG Machine Mount Gun)

2 Features and Benefits

nn Modular design allows for superior flexibility in work nn Voltage measurement at the gun ensures repeatable
­c­onfigurations. coating results.
nn Advanced controls deliver outstanding spray process nn Low turbulence, near laminar air flow for fast spray rates
­reliability. of very dense, low oxide coatings.
nn Unique load-sharing control method produces “pushpull” nn Fixed position gun contact tips assure consistent, repeat-
action for smooth and consistent wire feed and allows able coatings.
long distances between the controller and the gun. nn Quick release wire connector and pull action at the gun
nn PLC (programmable logic control) automation ensures allows fast and simple changeover of wire feedstock.
coating reliability and simple operation. nn Machine-mount and hand-held gun options are available
nn Diagnostic system provides ease of use and reliable for production flexibility.
­results. nn Machine-mount guns can easily be mounted on a robot
nn Spray hard, soft or cored wires with equal ease (with or other gun manipulators for precision and production
­optional hardware for soft wires). automation.
nn High power allows spraying of even the hardest wires nn Relocation of the coaxial power cables improves gun
quickly. ­balance on hand-held guns.
nn Adjustable, air-actuated clamp makes feeding of hard, nn Controller, power supply and gun conform to CE
soft or cored wires far more reliable. standards.

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3 Accessories and Options
Oerlikon Metco offers a selection of options and accessories Air Caps:
for the SmartArc system and gun for complete operating nn Fine Spray Air Cap: for smooth coating surfaces (stan-
flexibility. For a complete list of optional parts and spare dard-factory equipped)
parts, please refer to the parts lists section of the reference nn Fan Air Cap: for large and wide surface areas
manual. nn High Velocity Air Cap: for narrow spray patterns
nn High Profile Air Cap: for rough surface finishes
Power cables, control cable packages, interconnecting ex- nn Focused Air Cap: for narrow spray patterns at higher
tension cables, air supply cables and wire feed cables are ­deposit efficiencies
available in various lengths to suit specific application needs.
Extension Modules:
Hardware Kits: Extension modules in several lengths are available:
SmartArc systems and guns are factory equipped to spray nn PPGT-190: 305 mm (1 ft), 90° spray angle
1.6 mm (14 gauge) hard wires. Oerlikon Metco has gun nn PPGT-290: 610 mm (2 ft), 90° spray angle
­hardware options to accommodate different wire materials
including: For more information on these extension modules, please
nn 1.6 mm (14 gauge) soft wires ­refer to the SmartArc PPGT datasheet DSE-0054.
nn 1.6 mm (14 gauge) aluminum wires
nn 2 mm hard wires Spool Holders:
nn 2 mm soft wires The SmartArc comes factory equipped with standard,
nn 2 mm aluminum wires ­dorn-style plastic spools holders.
nn 2.3 mm (11 gauge) soft wires nn Wire Baskets: an optional conversion kit is available to
for use with wire basket spools
Customers may need to change console or gun drive rollers
for softer wires. Proper configurations are listed in the Please note that adapters for hasp-style spools are not
SmartArc instruction manual. ­available for the SmartArc.

PPG51845 Handle: Power Supply Truck:

Optional handle for PPG or PPGH guns with wire speed con- Using this optional hand truck, the entire SmartArc system
trol, spray on/off and E-stop. Not CE-conformant. (power supply and console) becomes portable. It is an ideal
accessory for on-site use and in shops where the system is
used in several locations.

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4 Technical Data

4.1 Dimensions

300 mm x 100 mm (12 in x 4 in)

150 mm (6 in)
278 mm (11 in)

(PPG)
1460 mm (57.5 in)

(PPGH)
1067 mm (42 in) 565 mm (22.25 in) 390 mm (15 in) 112 mm (4.5 in)

4.2 Specifications

350RU Power Supply

Input Amperage 82 / 72 / 41 / 36 A
Input Voltage 208 / 230 / 400 / 460 VAC
Input Frequency 50 / 60 Hz
Output Voltage 10  to 46 VDC (100 % duty cycle)
Output Amperage 80  to 400 A (100 % duty cycle)
Weight 174 kg 383 lb
Maximum Ambient Temperature 40 °C 104 °F
PPC Console
Air Pressure 2.4 to  4.2 bar 35 to  60 psi
Air Flow 58 to 105 m3/h 2200 to  4000 ft3/h
Weight 130 kg 290 lb
Gun
Wire Size (hard wires) * 1.6 mm 14 gauge
Models (specify when ordering) PPG machine-mount, with tool post
PPGH hand-held
Weight PPG 6.3 kg 14 lb
Weight PPGH 5.4 kg 12 lb

* as equipped at factory; options are available or different configurations

Information is subject to change without prior notice.

DSE-0055.6 – SmartArc www.oerlikon.com/metco

© 2015 Oerlikon Metco [email protected]