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INSTRUCTIONS
PARTS MANUAL
PLASMA HEIGHT
for WPD-2100 Pendulum Weaver
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
AND
CONTROL
AVC-2060
A DIVISION OF WELD TOOLING CORPORATION
PHONE: 412-331-1776
CANONSBURG, PENNSYLVANIA
http://www.bugo.com
LIT-AVC-2060-IPM-1120
15317-9564 USA
FAX: 412- 331- 0383
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Summary of Contents for Bug-O Systems AVC-2060
- Page 1 Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. LIT-AVC-2060-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. EQUIPMENT DAMAGE POSSIBLE. ELECTRIC SHOCK can kill. 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.
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Page 4: Table Of Contents
6 ..Sensor Options for Plasma Power Sources 6-9 ..Setup 10 ..AVC-2060 Plasma Height Control / Exploded View / Parts List 11 ..AVC-2051-10 MDS AHC 10' (3.0 m) Remote Control 12 ..CAS-1500-18 Height Slide Assembly / Exploded View / Parts List 13 .. -
Page 5: Introduction
“ok to move” signal and automatically shuts off when voltage drops too low (generally below 36 volts). The AVC-2060 Plasma Height Control is available as original equipment or as a retrofit unit designed to provide automated height control on the BUG-O Modular Drive Systems (MDS) with a Pendulum Weaver (WPD-2100). -
Page 6: Sensor Options For Plasma Power Sources
SETUP AVC-2060 Plasma Height Control This is available as original equipment or as a retrofit unit designed to provide Plasma Height Control on BUG-O Modular Drive Systems (MDS) with the Pendulum Weaver (WPD-2100). - Page 7 SETUP, CONT’D. AVC-2055 MDS AHC Control Box This mounts directly on top of the MDS Drive. Align the socket on the top of the MDS Drive with the plug on the bottom of the AHC Control Box and seat it firmly and secure in place with the four (4) screws, one (1) in each corner.
- Page 8 SETUP, CONT’D. Plug in MDS System with AHC Inspect the power cord before each use. Do not use if damaged. Plug in the machine to a power outlet of the appropriate voltage. Power ON the MDS System with AHC CAUTION: machine may start moving as soon as it is powered “ON.” Use the power switch on the MPD-1000 Drive Unit to turn the power “ON”...
- Page 9 SETUP, CONT’D. Plasma Source, Cutting Torch, and PHC Setup Manual – Automatic Up – Down JOG Toggle Switch Toggle Switch Volt Dial AVC-2051-10 Remote Control 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.
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Page 10: Avc-2060 Plasma Height Control / Exploded View / Parts List
AVC-2060 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 CAS-1500-18 Height Slide Assembly 18" CAS-1558... - Page 11 AVC-2051-10 MDS AHC 10' (3.0 M) REMOTE CONTROL 2,10 ITEM PART NO. DESCRIPTION AVC-2045-M AVC Pendant, Male End BUG-9676 Dial Counter CAS-2045-F CAS Pendant, Female End CAS-2052 Guard CWO-6335 Toggle Switch, DPDT, On-None-On FAS-0525 Soc Hd Cap 8-32 x 1/2 MUG-1199 Toggle Switch, DPDT, On-Off-On PLT-1001...
- Page 12 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 13 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 14 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 15 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 16 AVC-2055 CONTROL BOX / EXPLODED VIEW 16,24 20,23 18,24 18,19,24 9,10...
- Page 17 AVC-2055 CONTROL BOX / PARTS LIST ITEM PART NO. DESCRIPTION MDS-1058 Mounting Panel MDS-1057 Rear Panel PCB-1036 Connector 50-Pin, M PCB-1070 MDS AHC Break Out Board PCB-1035 Connector 50-Pin, F CAS-2056 Front Panel MUG-1156 Panel Connector, 4-T, F CAS-1780 DC Speed Card w/ 1770 Interface BUG-9677 Potentiometer, 10k Ohms BUG-5759...
- Page 18 AVC-2050-PL-ID CONNECTION DIAGRAM...
- Page 19 AVC-2050-PL-RV CONNECTION DIAGRAM...
- Page 20 AVC-2050-PL-PS CONNECTION DIAGRAM...
- Page 21 AVC-2055-WD CONTROL BOX / WIRING DIAGRAM / PARTS LIST PART NO. DESCRIPTION CAS-1780 DC Speed Card with CAS-1770 Interface BUG-9856 Panel Connector, 2-T, F MUG-1156 Panel Connector, 4-T, F CAS-1060-PL Control Board, Plasma CAS-2058 MDS AHC Wiring Harness PCB-1070 MDS AHC Break Out Board PCB-1036 Connector 50 Pin (M) w/ Ribbon to Socket PCB-1035...
- Page 22 AVC-1002-WD WIRING DIAGRAM...
- Page 23 CAS-2058 MDS AHC WIRING HARNESS / WIRING DIAGRAM / ELECTRICAL COMPONENT CHART PART NO. DESCRIPTION CNN-012C 12 Position Housing w/ Pins BUG-9677 Potentiometer, 10K OHMS CNN-0228 Housing 8 Pin...
- Page 24 AVC-2051-10-WD MDS AHC 10' (3.0 M) REMOTE CONTROL / WIRING DIAGRAM / PARTS LIST PART NO. DESCRIPTION CWO-6335 Toggle Switch, DPDT, On-None-On MUG-1199 Toggle Switch, DPDT, On-Off-On CON 5468 50 Position D-Ribbon, Female, Gold CON 5467 50 Position D-Ribbon, Male, Gold POT 5483 Potentiometer...
- Page 25 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 26 WARRANTY MODEL ___________________________ SERIAL NO. _______________________ Limited 3-Year Warranty 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.
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