Thermal Dynamics PAK Master 150XL, Service Manual

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DESCRIPTION 3-4 Manual 0-2728
B. Input and Output Power
The unit converts AC input power to DC power for the
main cutting arc. The negative output is connected to
the torch electrode through the negative torch lead, and
the positive output connects to the workpiece through
the work cable.
C. Pilot Arc
When the torch is activated there is a 2 second (service
adjustable) gas pre-flow, followed by an uninterrupted
pulsed DC pilot arc established between the electrode and
tip. The pilot arc is initiated by a momentary high fre-
quency pulse from the Power Supply. The pilot creates a
path for the main arc to transfer to the work. When the
main arc is established, the pilot arc shuts off. The pilot
automatically restarts when the main arc stops, as long
as the torch remains activated.
D. Main Cutting Arc
The power supply converts the AC input power to DC
power for the main cutting arc. The negative output is
connected to the torch electrode through the negative
torch lead. The positive output is connected to the work-
piece via the work cable and clamp connection.
E. RF Shielding
Machine torch systems using CNC Interface Cables are
shielded to minimize radio frequency (RF) interference
which results from the high frequency arc initiation. These
shielded systems are designed with features such as a
wire for establishing an earth ground and shielded torch
and control leads. The CNC control signals are filtered
on an internal PC Board.
F. Interlocks
The system has several built-in interlocks to provide safe
and efficient operation. When an interlock shuts down
the system, the fault condition must be remedied and the
system recycled using the applicable control device.
1. Parts-In-Place (PIP) Interlock
The Power Supply has a built-in parts-in-place in-
terlock that prevents accidental torch starting
when torch parts are not properly installed. A flow
switch on the coolant return lead detects reduced
coolant flow caused by improper torch assembly.
If not satisfied, the switch interrupts power to the
tip and electrode.
2. Gas Pressure Interlock
A pressure switch acts as an interlock for the
plasma gas supply. If the plasma gas supply pres-
sure falls below minimum requirements the pres-
sure switch will open, shutting off the power to
the contactors, and the GAS indicator will go out.
When adequate plasma supply pressure is avail-
able the pressure switch will close, allowing power
to be resumed for cutting.
NOTE
There is no gas pressure interlock for secondary
gas.