Table of Contents
Advertisement
Quick Links
INSTRUCTIONS
PARTS MANUAL
STANDALONE
PLASMA HEIGHT
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Number
Serial Number
Date of Purchase
Whenever you request replacement parts or information on this equipment, always supply the information
you have recorded above.
Bug-O Systems is committed to empowering our customers by providing operator
controlled mechanized solutions for their welding, cutting and custom applications.
280 TECHNOLOGY DRIVE
PHONE: 412-331-1776
AND
CONTROL
AVC-2100 SERIES
A DIVISION OF WELD TOOLING CORPORATION
CANONSBURG, PENNSYLVANIA
http://www.bugo.com
LIT-AVC-2100-IPM-1120
15317-9564 USA
FAX: 412- 331- 0383
Advertisement
Table of Contents
Summary of Contents for Bug-O Systems AVC-2100 Series
- Page 1 Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. LIT-AVC-2100-IPM-1120 Bug-O Systems is committed to empowering our customers by providing operator controlled mechanized solutions for their welding, cutting and custom applications. A DIVISION OF WELD TOOLING CORPORATION...
- Page 2 SAFETY PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. ELECTRIC SHOCK can kill. EQUIPMENT DAMAGE POSSIBLE. 1) The equipment is not waterproof. Using the unit in a wet environment may result in serious injury.
- Page 3 HIGH FREQUENCY WARNINGS SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA, TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY TO STRIKE AN ARC. WARNING: HIGH FREQUENCY CAN EFFECT MACHINE OPERATION AND THEREFORE, WELD QUALITY. Read the precautions below before installing and using the equipment. PRECAUTIONS: 1) Some plasma or welding cables are strong sources of high frequency interference.
-
Page 4: Table Of Contents
6 ..Specifications 7-9 ..Setup 10 ..AVC-2100 Series Standalone Plasma Height Control / Exploded View / Parts List 11 ..CAS-1500-18 Height Slide Assembly / Exploded View / Parts List 12 ..AVC-1550-PL-ID Volt Sensor Assembly, Internal Divider Model / Exploded View / Parts List 13 .. -
Page 5: Introduction
INTRODUCTION AVC-2100 Series are Standalone Plasma Height Controls that control the tip to work distance and maintain a constant voltage, which provides a more uniform result. Available in three models, by voltage. Plasma Height Control senses the actual voltage, compares this value to the set point, and raises or lowers the torch accordingly. -
Page 6: Sensor Options For Plasma Power Sources
SENSOR OPTIONS FOR PLASMA POWER SOURCES On/Auto Manufacturer Model Sensor Additional Connection Instructions Switch Option Position ESAB Cutmaster 82 with full- Auto Contactor wires plug into AVC-1550, which ®1 featured automation sends them to the plasma source. interface PCB option Hypertherm Powermax45 XP with... -
Page 7: Setup
SETUP AVC-2110 Control Box, Volt Sensing A clamp, BUG-5295 Rod Mount Assembly is provided mounted to the bottom of AVC-2110 Control Box. This Rod Mount requires a 7/8" (22.2 mm) diameter rod for mounting. Typically, user will mount the Control Box to the “Cable Mounting Assembly” already on the BUG-O. Consult with your Local Bug-O distributor or the factory for assistance if you require help with mounting the control box. - Page 8 SETUP, CONT’D. Installing the AVC-1550-PL-PS (applies to this model only) If you choose to install the AVC-1550-PL-PS yourself, you can use the connection diagram for AVC- 2050-PL-PS. The CAS-1530 wiring harness plugs into J1 on the PCB-1273. CAS-1529 is provided to plug into J3. The “Ok to move” signal drives a 12VDC relay on the PCB-1273. J3 includes diodes to avoid reverse polarity on the connection.
- Page 9 SETUP, CONT’D. Plasma Source, Cutting Torch, and PHC Setup Up – Down JOG Speed On – Off Toggle Switch Potentiometer Toggle Switch Manual – Automatic Pilot Light Volt Dial Toggle Switch AVC-2110 CONTROL BOX If using the -RV type sensor, make sure your power source uses a starting method that does not use high frequency such as blowback start or touch start rather than HF start or capacitive discharge, as that may cause premature failure, electromagnetic interference, or an unsafe condition.
-
Page 10: Avc-2100 Series Standalone Plasma Height Control / Exploded View / Parts List
AVC-2100 SERIES STANDALONE PLASMA HEIGHT CONTROL / EXPLODED VIEW / PARTS LIST For use with machine barrel plasma torch: Remove standard torch clamp from CAS-1500-18, mount clamp block sideways, and install BUG-5188. ITEM PART NO. DESCRIPTION BUG-2708 Clamp with 7/8" Rod (22.2 mm) CAS-1500-18 Height Slide Assembly 18"... -
Page 11: Cas-1500-18 Height Slide Assembly / Exploded View / Parts List
CAS-1500-18 HEIGHT SLIDE ASSEMBLY / EXPLODED VIEW / PARTS LIST F7,F9 ITEM PART NO. DESCRIPTION CAS-1512 Torch Mount Plate CAS-1509-18 18" Height Arm Mounting Bar CAS-1523 End Cap CAS-1505-18 18" Height Arm Assembly PWS-1028 Fixed Wheel & Leg Assembly CAS-1522 Mounting Plate CAS-1511 Steel Pinion... - Page 12 AVC-2110 CONTROL BOX, VOLT SENSING / EXPLODED VIEW 16,25...
- Page 13 AVC-2110 CONTROL BOX, VOLT SENSING / PARTS LIST ITEM PART NO. DESCRIPTION BUG-5295 Rod Mount Assembly CAS-1019 Rear Cover BUG-5001 (120 VAC) Transformer BUG-5002 (240 VAC) Transformer BUG-5003 (42 VAC) Transformer CAS-1770 Speed Control (Iron Rotor) CAS-1060-PL Control Board / Plasma MUG-1156 Panel Connector, 4T, F BUG-9628...
-
Page 14: Avc-1550-Pl-Id Volt Sensor Assembly, Internal Divider Model / Exploded View / Parts List
AVC-1550-PL-ID VOLT SENSOR ASSEMBLY, INTERNAL DIVIDER MODEL / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CAS-1525 AVC Voltage Enclosure CAS-1526 Sensor Legend Plate CAS-1532 AVC Harness Volt To Pwr CAS-1531 AVC Harness Volt To Bug CNN PLUG-2666 Hole Plug PWS-0305 Main Current Sense Harness PCB-1273-PL-ID... -
Page 15: Avc-1550-Pl-Rv Volt Sensor Assembly, Raw Voltage Model / Exploded View / Parts List
AVC-1550-PL-RV VOLT SENSOR ASSEMBLY, RAW VOLTAGE MODEL / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CAS-1525 AVC Voltage Enclosure CAS-1526 Sensor Legend Plate CAS-1532 AVC Harness Volt To Pwr CAS-1531 AVC Harness Volt To Bug CNN CRS-1598 Hole Plug PWS-0305 Main Current Sense Harness CAS-1527... -
Page 16: Avc-1550-Pl-Ps Volt Sensor Assembly, Power Source Model / Exploded View / Parts List
AVC-1550-PL-PS VOLT SENSOR ASSEMBLY, POWER SOURCE MODEL / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CAS-1524 Voltage Sensor Mtg STOF-2009 6-32 M/F Nylon WAS-0210 #6 SAE Flat Washer FAS-0112 Pan Hd Slt 6-32 x 1/4 Black WSH 5432 #6 Flat Nylon Washer PCB-1273 AVC Volt Sensor... -
Page 17: Avc-210X-Pl-Id Connection Diagram
AVC-210X-PL-ID CONNECTION DIAGRAM... -
Page 18: Avc-210X-Pl-Rv Connection Diagram
AVC-210X-PL-RV CONNECTION DIAGRAM... -
Page 19: Avc-210X-Pl-Ps Connection Diagram
AVC-210X-PL-PS CONNECTION DIAGRAM... -
Page 20: Avc-211X-Wd Control Box, Volt Sensing / Wiring Diagram / Electrical Component Chart
AVC-211X-WD CONTROL BOX, VOLT SENSING / WIRING DIAGRAM / ELECTRICAL COMPONENT CHART ELECTRICAL COMPONENT CHART ITEM POWER SOURCE DESCRIPTION 120 VAC 240 VAC 42 VAC BUG-2923 BUG-2952 BUG-2933 Circuit Breaker LINE BUG-9445 GOF-3115 BUG-9442 Power Cord (120V shown) BUG-1415 BUG-1428 BUG-1427 Pilot Light BUG-5321... -
Page 21: Avc-1002-Wd Wiring Diagram
AVC-1002-WD WIRING DIAGRAM... -
Page 22: Troubleshooting
TROUBLESHOOTING If your control board has jumper J5 on it, you can test your height control without cutting by following the steps below. If you have an older style control board without jumper J5, or if you prefer to test by cutting rather than opening the control box, skip this test and use the instructions for the cutting test. -
Page 23: Warranty
WARRANTY MODEL ___________________________ Limited 3-Year Warranty SERIAL NO. _______________________ DATE PURCHASED: ________________ WHERE PURCHASED: ______________ For a period ending one (1) year from the date of invoice, Manufacturer warrants that any new ma- chine or part is free from defects in materials and workmanship and Manufacturer agrees to repair or replace at its option, any defective part or machine.