3-2646-13 - Thermal Arc WC-100B Plasma Controller

Advanced Plasma Welding Control

The Thermal Dynamics WC-100B Welding Console (SKU: 3-2646-13) is a specialized control unit engineered to facilitate the Plasma Arc Welding (PAW) process. Designed as an interface between a standard DC Constant Current (CC) power source and a plasma welding torch, the WC-100B provides the critical regulation required for high-precision joining applications. Unlike standard Gas Tungsten Arc Welding (GTAW), the plasma process requires the management of two distinct gas flows—the orifice (plasma) gas and the shielding gas—as well as a dedicated pilot arc circuit. This console integrates all these functions into a single, rugged industrial enclosure.

Technically, the WC-100B features an internal pilot arc power supply. This circuit establishes a low-current arc between the tungsten electrode and the copper nozzle within the torch, ionizing the gas before it reaches the workpiece. This non-transferred arc allows for reliable arc transfer to the workpiece without the risk of tungsten contamination or the need for high-frequency noise during the weld cycle. The console includes a high-frequency generator solely for initiating this pilot arc, ensuring a clean start every time. The front panel is equipped with dual flowmeters, allowing the operator to independently adjust the flow rates for the plasma gas (which shapes the arc) and the shield gas (which protects the weld pool), ensuring optimal process stability.

The unit is designed for versatility and safety. It includes interlock circuits that monitor coolant flow and gas pressure, automatically shutting down the system if parameters fall outside safe operating limits to prevent torch burnout. The WC-100B is compatible with a wide range of thermal arc and third-party DC power supplies, making it a cost-effective solution for facilities looking to add plasma welding capabilities without investing in a dedicated, integrated plasma power source. It is particularly well-suited for automated setups where arc consistency and depth-to-width ratios are critical.

System Integration

Integrating the WC-100B into an existing weld cell involves connecting it to the DC output of a power source, a water cooler (essential for the high-energy density of plasma torches), and the requisite gas supplies. The console manages the sequencing of these elements, providing a centralized control point for the operator. Its robust construction ensures it can withstand the rigors of industrial environments, from aerospace clean rooms to heavy fabrication shops.