WELD TOOLING CORPORATION Bug-O Systems AVC-2050 Instructions And Parts Manual

Plasma height control for wpd-1100 linear weaver

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INSTRUCTIONS

PARTS MANUAL

PLASMA HEIGHT

for WPD-1100 Linear 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-2050

A DIVISION OF WELD TOOLING CORPORATION

PHONE: 412-331-1776

CANONSBURG, PENNSYLVANIA

https://www.bugo.com

LIT-AVC-2050-IPM-0425

15317-9564 USA

FAX: 412- 331- 0383

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Summary of Contents for WELD TOOLING CORPORATION Bug-O Systems AVC-2050

Page 1 LIT-AVC-2050-IPM-0425 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 280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA PHONE: 412-331-1776 https://www.bugo.com...
Page 2: Read Instructions
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
PLASMA HEIGHT CONTROL AVC-2050 FOR WPD-1100 PENDULUM WEAVER INSTRUCTIONS AND PARTS MANUAL TABLE OF CONTENTS PAGE 5 ..Introduction 5 ..Overview 5 ..Items Supplied 5 ..Specifications 6 ..Sensor Options for Plasma Power Sources 7-9 ..Setup 10 ..
Page 5: Introduction
INTRODUCTION The AVC-2050 is an Plasma Height Control (PHC) for the WPD-1100 Linear Weaver that controls the tip to work distance and maintains 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 CAS-1500-18 Height Slide Assem bly The Height Slide Assembly replaces the Welding Clamp originally supplied on the Linear Weaver. It mounts to the 7/8” (22.2 mm) diameter rod. (Remove CON-1020 Swivel Clamp and BUG-2708 Clamp and set aside for use when Plasma Height Control is not used.) Slide clamp on bottom of CAS-1500-18 Height Slide Assembly onto UNI-1036 Rackrider with Post and lock in position.
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: Verify Setup
SETUP, CONT’D. VERIFY SETUP Before striking an arc, take a moment to verify the machine is set up correctly. With the tractor “ON” and the Arc “OFF”, run the machine and verify it is moving in the intended direction. Verify cross arm is in the proper position as well as the Drive Unit travel speed.
Page 10 AVC-2050 PLASMA VOLTAGE 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 CAS-1500-18 Height Slide Assembly 18" AVC-2051-10 MDS AVC 10' (3.0 m) Remote Control AVC-2055...
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...
Page 22 AVC-1002-WD WIRING DIAGRAM...
Page 23 CAS-2058 MDS AHC WIRING HARNESS / WIRING DIAGRAM / PARTS LIST 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
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
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.