Bug-O Systems AVC-2100 Series Technical reference manual

INSTRUCTIONS
AND
PARTS MANUAL
A DIVISION OF WELD TOOLING CORPORATION
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA
PHONE: [phone] http://www.bugo.com FAX: [phone]
STANDALONE
PLASMA HEIGHT
CONTROL
AVC-2100 SERIES
Please record your equipment identication 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.
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.

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. Do not touch equipment
when wet or standing in a wet location.
2) The unused connectors have power on
them. Always keep the unused connec-
tors covered with the supplied protective
panels. Operation of the machine without
the protective panels may result in injury.
3) Never open the equipment without rst
unplugging the power cord or serious
injury may result.
4) Verify the customer-supplied power
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist,
use International Electric Code (IEC)
950.
5) Never remove or bypass the equipment
power cord ground. Verify the equipment
is grounded in accordance with all appli-
cable local and national electrical safety
codes. If none exist, use International
Electric Code (IEC) 950.
READ INSTRUCTIONS.
Read the instruction manual before
installing and using the equipment.
1) Do not plug in the power cord without rst
verifying the equipment is OFF and the
cord input voltage is the same as required
by the machine or serious damage may
result.
2) Always verity both the pinion and wheels
are fully engaged before applying power
or equipment damage may occur.
3) Do not leave the equipment unattended.
4) Remove from the work site and store in
a safe location when not in use.
1) Never try to stop the pinion from moving
except by removing power or by using the
STOP control.
2) Do not remove any protective panels,
covers or guards and operate equipment.
MOVING PARTS can
cause serious injury.
FALLING EQUIPMENT
can cause serious
personal injury and
equipment damage.
Faulty or careless user installation is
possible. As a result, never stand or
walk underneath equipment.

3
PRECAUTIONS:
1) Some plasma or welding cables are strong sources of high frequency interference.
NEVER lay a plasma or welding cable across the controls of the machine.
2) Always physically separate the plasma or welding cable leads from the machine
cables. For example, the plasma or welding cable leads should NEVER be bundled
with a pendant cable or the machine power cord. Maximize the separation between
any machine cables and the plasma or welding cables.
3) Strictly follow the grounding procedures specied for the plasma or welding unit.
NOTE: Some plasma and welding units produce exceptionally large amounts of high
frequency noise. They may require a grounding rod be driven into the earth within six
feet (2 meters) of the plasma or welding unit to become compatible with an automatic
cutting or welding process.
4) If the high frequency is produced using a spark gap, adjust the points so the gap is as
small as possible. The larger the gap, the higher the voltage and the higher the inter-
ference.
5) Some plasma or welding units will inject high frequency interference into the AC
power line. Use separate power line branches whenever possible to power the
plasma or welding source and the machine. Do not plug them into the same outlet
box.
6) High frequency noise may enter the machine through the plasma or welding supply
remote contactor leads. Some plasma and welding sources can produce noise spikes
of up to several thousand volts. These sources are not compatible with automated
cutting and welding equipment. It is recommended that the remote contactor leads on
these plasma or welding sources not be connected to the machine. An alternate
solution is to purchase a separate remote contactor isolation box.
HIGH FREQUENCY WARNINGS
WARNING: HIGH FREQUENCY CAN EFFECT MACHINE
OPERATION AND THEREFORE, WELD QUALITY.
SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,
TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY
TO STRIKE AN ARC.
Read the precautions below before installing and using the equipment.

4
TABLE OF CONTENTS
STANDALONE PLASMA
HEIGHT CONTROL
INSTRUCTIONS AND PARTS MANUAL
Patents Pending
5 ......... Introduction
5 ......... Overview
5 ......... Available Models
6 ......... Sensor Options for Plasma Power Sources
6 ......... Specications
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 ........ AVC-1550-PL-RV Volt Sensor Assembly, Raw Voltage Model / Exploded View / Parts List
14 ........ AVC-1550-PL-PS Volt Sensor Assembly, Power Source Model / Exploded View / Parts List
15 ........ AVC-2110 Control Box, Volt Sensing / Exploded View
16 ........ AVC-2110 Control Box, Volt Sensing / Parts List
17 ........ AVC-210X-PL-ID Connection Diagram
18 ........ AVC-210X-PL-RV Connection Diagram
19 ........ AVC-210X-PL-PS Connection Diagram
20 ........ AVC-211X-WD Control Box, Volt Sensing / Wiring Diagram / Electrical Component Chart
21 ........ AVC-1002-WD Wiring Diagram
22 ........ Troubleshooting
23 ........ Warranty
PAGE
AVC-2100 SERIES

5
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. It features motion based on the plasma source “ok to move”
signal and automatically shuts off when voltage drops too low (generally below 36 volts).
OVERVIEW
AVC-2100 Standalone Plasma Height Control is a retrot unit designed to provide Plasma Height
Control on BUG-O and other mechanized welding systems. CAS-1500-18 Height Slide Assembly
replaces the welding clamp originally supplied. It requires a 7/8" (22.2 mm) diameter rod for mounting.
Likewise the AVC-2110 Control Box is mounted on a 7/8" (22.2 mm) diameter rod. In both instances
BUG-O offers many different Torch Supports and Cable Anchor designs to accomplish proper mounting
of both units. Consult BUG-O “Supports and Accessories” or “Heavy Duty Tool Positioning System”
brochures for available mounting options.
AVAILABLE MODELS
AVC-210X-PL-?? Standalone Plasma Torch Height Control Consisting of:
CAS-1500-18 Height Slide Assembly
AVC-1550-PL-?? Arc Volt Sensor Assembly
AVC-211X Control Box, Volt Sensing
“X” based on Voltage the unit will operate on: “??” is the volt sensor option:
X = 0 for 120VAC/50/60 Hz/1Ph ID for use with Internal Divider
X = 2 for 240VAC/50/60 Hz/1Ph RV for use with Raw Voltage of blowback
X = 4 for 42VAC/50/60 Hz/1Ph start type sources
PS for installation inside the Power Source
for HF or capacitive discharge type sources

6
SPECIFICATIONS
Net Weight: 14.5 lbs (6.6 kg)
Travel: 13" (330 mm)
Carrying Capacity: 10 lbs (4.5 kg)
Operating Range: 36 to 300 Volts
Minimum Recommended Standoff: 1/8" (3.2 mm)
Sensitivity
Difference between DC cutting voltage and set point (ΔV)
ΔV > 32 32 > ΔV > 15 15 > ΔV > 3 3 > ΔV > 0.4 0.4 > ΔV
Nominal
Maximum
Slide Speed
24 in/min
(609 mm/min)
24 in/min
(609 mm/min)
1.55 in/min
per volt
(39.3 mm/min
per volt)
0.46 in/min
per volt
(11.8 mm/min
per volt)
slide may
not move
Nominal Time
to Reach 90%
Speed
0.2 seconds 0.2 - 2 seconds 2 seconds 2 seconds slide may
not move
SENSOR OPTIONS FOR PLASMA POWER SOURCES
Manufacturer Model
AVC
Sensor
Option
AVC
On/Auto
Switch
Position
Additional Connection Instructions
ESAB®1 Cutmaster 82 with full-
featured automation
interface PCB option
-ID Auto Contactor wires plug into AVC-1550, which
sends them to the plasma source.
Hypertherm®2 Powermax45 XP® with
CPC port and voltage
divider
-ID Auto Contactor wires plug into AVC-1550, which
sends them to the plasma source.
Hypertherm®Powermax65® with
CPC port and voltage
divider
-ID Auto Contactor wires plug into AVC-1550, which
sends them to the plasma source.
Hypertherm®Powermax85® with
CPC port and voltage
divider
-ID Auto Contactor wires plug into AVC-1550, which
sends them to the plasma source.
Hypertherm®Powermax105® with
CPC port and voltage
divider
-ID Auto Contactor wires plug into AVC-1550, which
sends them to the plasma source.
Hypertherm®Powermax125® with
CPC port and voltage
divider
-ID Auto Contactor wires plug into AVC-1550, which
sends them to the plasma source.
Hypertherm®Powermax1650®-RV Auto AVC-1002 will need to be installed and will
need to connect to J15 and J16. Contactor
wires will need to be connected to the AVC-
1550 and then AVC-1003 (sold separately) can
connect the AVC-1550 to the machine inter-
face connection for arc start and arc transfer.
Lincoln
Electric®3
Tomahawk1538®-RV On AVC-1002 will need to be installed and will
need to connect to the EL2 and OUT1. Con-
tactor wires will need to connect to the Toma-
hawk’s accessory connector. A competent
person must determine how to best make
these connections.

7
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.
CAS-1500-18 Height Slide Assembly
A clamp, CAS-1510 Dual Position Clamp Block is provided mounted to the bottom of the Height Slide
Assembly. This Clamp Block requires a 7/8" (22.2 mm) diameter rod for mounting. Typically, user will
mount the Height Slide Assembly to the welding group 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.
Position and clamp welding gun with CAS-1500-18 installed on Torch Mounting Group, secure torch in
the clamp located on the end of the Height Slide Assembly. Arrange cables so that they do not interfere
with the movement of the machine before securing the cable in the cable anchor at the rear of the
machine.
Install Voltage Sensor
Connect AVC-1550 type voltage sensor according to the connection diagram on page 15 of this
manual. The connections will vary based on whether you have a type -ID, -RV, or -PS sensor assembly.
Choose whether the AVC-1550 sensor will use “Ok to Move” signal or always provide
voltage.
The sensor can switch off its feedback based on a power source’s “Ok to Move” signal. On the AVC-
1550-PL-ID and AVC-1550-PL-RV, this is done with the “Auto/On” switch on the side of the box. In
the “Auto” position, the sensor will automatically switch feedback on or off based on the “Ok to move”
signal; in “On”, it will always provide feedback, although the control still has its own lower limit of about
36V below which it will not respond. On the AVC-1550-PL-PS, which gets installed inside the power
source, this is done with the CAS-1529 wiring harness (shown in the connection diagram for the AVC-
2050-PL-PS); the wires either need to connect to terminals provided by the plasma power source to
use the “Ok to move” signal, or shorted together if no such signal is provided by the power source. This
may have already been done for you if you ordered a system with the sensor installed.
On systems that provide an “Ok to move” signal, it is better to use it, since it will prevent the initial
open-circuit voltage before an arc is transferred from showing up on the feedback signal. If your power
source does not have an “Ok to move” signal, you’ll want to try to get the arc transferred as quickly as
possible to reduce the impact of the open-circuit voltage, and be prepared to use the manual jog switch
to correct movement due to that initial higher voltage.

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. J3 pin 1 is connected to the PCB-1273’s
+15V source through a diode and a 120 Ohm resistor, and pin 2 goes to the relay coil through another
diode; the other end of the relay coil is connected to the Bug-O machine’s common power return, which
is not isolated. This connection method will work for dry contact closure or optical isolators, provided the
polarity is respected (Pin 1 goes to the optical isolator positive terminal or sink and pin 2 to the optical
isolator negative terminal or source).
J2 does not need to be connected.
You will need to identify which contactor cable you need and how to wire it based on the plasma source
you are using. There are pins on J3 to take a trigger input in, but they only route the signal to J2 to go
back out to the power source, so that a single cable can be used between other AVC-1550 models and
the power source.
Plug in the AVC System
Inspect power cord before each use. Do not use if damaged. Plug in the machine to a power receptacle
of the appropriate voltage.
Power ON the Drive System with AHC
CAUTION: machine may start moving as soon as it is powered “ON.” Use the power switch on the
Drive Unit to turn the power “ON” and “OFF” to the machine. For operator safety, set the Drive Unit to
“OFF” before turning on the machine.
Position the Torch
Proper setup of the torch is critical to a successful operation. In addition to manually positioning the
torch within the clamp, the torch must also be properly set with respect to three mechanical controls:
The Torch Mounting Group, the Plasma Height Controller (PHC) and the motion control position.
Height Slide Assembly: The slide assembly has 13" (330 mm) of travel available. For best
results, position the slide assembly in the middle of the total range
before setting the torch. Use the torch manual jog switch (located
on AVC-2100 Control Box) to position the height slide.
Motion Control: Use the motion control system to position PHC so that the torch
is over its starting point. The operator can increase or decrease
travel speed using the motion control system.

9
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. If HF start or
capacitive discharged is used, use the -ID type sensor if your power source has an internal divider, or
the -PS type sensor if it does not.
To set your PLASMA HEIGHT CONTROL:
(Reference AVC-2110 Control Box)
y Connect voltage sensor to power source according to sensor wiring instructions.
y Set the height control (Manual - Automatic Toggle Switch) to manual mode.
y Conrm the switch on the height slide faces away from the work piece.
y Set the torch height manually (Up - Down JOG Toggle Switch) to where you want it.
y Make a small cut and record the volt reading from the power source.
y Now, dial this number, volt reading, into the Height Control (Volt Dial).
y Turn the height control (On - Off Toggle Switch) back on.
y Run the system and it should run at the same height and thus voltage.
Alternate Setup:
If you already know what voltage you normally use or have charts specifying a voltage that has worked
well for you in the past that gives you at least 1/8" (3.2 mm) of standoff, you can begin by entering that
voltage on the dial then testing. Adjust the voltage if necessary to account for tolerances in the height
control system.
If this does not work please consult “Trouble Shooting Page” in the back of this manual.
The operator can temporarily override Plasma Height Control using the manual jog switch on AVC-2110
Control Box. PHC resumes as soon as the jog switch is released. To disable the PHC, move the Manu-
al -- Automatic Toggle Switch on the AVC-2110 Control Box to manual.
SETUP, CONT’D.
Plasma Source, Cutting Torch, and PHC Setup
On – Off
Toggle Switch
Up – Down JOG
Toggle Switch
Speed
Potentiometer
Pilot Light Volt Dial Manual – Automatic
Toggle Switch

10
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 QTY PART NO. DESCRIPTION
1 1 BUG-2708 Clamp with 7/8" Rod (22.2 mm)
2 1 CAS-1500-18 Height Slide Assembly 18"
3 1 AVC-2110 Control Box, Volt Sensing
4 1 BUG-5188 Torch Holder Assembly
* 1 CAS-1553 Connecting Cable Hall Effect
*Not Shown
1
4
2
3

11
ITEM QTY PART NO. DESCRIPTION
1 1 CAS-1512 Torch Mount Plate
2 1 CAS-1509-18 18" Height Arm Mounting Bar
3 2 CAS-1523 End Cap
4 1 CAS-1505-18 18" Height Arm Assembly
5 2 PWS-1028 Fixed Wheel & Leg Assembly
6 1 CAS-1522 Mounting Plate
7 1 CAS-1511 Steel Pinion
8 2 CAS-1517 CAS Drive Motor Cover Mount Angle
9 2 CAS-1510 Dual Position Clamp Block
10 1 PRS-1025 Motor
11 1 CAS-1518 CAS Drive Motor Cover Panel A
12 1 CAS-1521 CAS Drive Motor Outer Cover
13 1 CAS-1519 CAS Drive Motor Cover Panel B
14 1 BUG-1034 Panel Connector, 4-T, M
15 1 CAS-1503-P Arm Cover
16 2 PWS-1029 Adjustable Wheel & Leg Assembly
17 1 UCW-0261-03-02-00-0 Quick Disconnect Clamp Assembly
18 1 BUG-2708 Clamp
19 4 GOF-3036 QD Female, Fully Insulated
20 2 GOF-3037 QD Male, Fully Insulated
F1 2 MET-0975-SS Flt Hd Soc Scr M6 x 14
F2 8 MET-0553-SS Soc Hd Cap Scr M4 x 10
F3 4 MET-0559-SS Soc Hd Cap Scr M4 x 20
F4 4 MET-0147-SS Pan Hd Phil Scr M3 x 16
F5 8 MET-0542-SS Soc Hd Cap Scr M3 x 8
F6 8 MET-0541-SS Soc Hd Cap Scr M3 x 6
F7 4 FAS-1305 Hex Nut 4-40
F8 4 FAS-1204 But Hd Sk Hd Scr 4-40 x 3/8
F9 4 WAS-0201 #4 Internal Star Lockwasher
* 1 CAS-1557 Control to Slide Cable 3ft
* Not Shown
CAS-1500-18 HEIGHT SLIDE ASSEMBLY / EXPLODED VIEW / PARTS LIST
F6
12
F5
11
13
1
F1
3
2
F7,F9
18
9
F2
15
16
F8
8
F4
710
6
F3
5
4
19
19
20
17
14

12
AVC-2110 CONTROL BOX, VOLT SENSING / EXPLODED VIEW
18
20
19
F1
22
17
21
F1
16,25
11
F2
4
3
23
F6
F5
2
1
15
26 14 13
12
9
24 10
F1
7
F3
F4
6
8
5

13
AVC-2110 CONTROL BOX, VOLT SENSING / PARTS LIST
* Item Not Shown
ITEM QTY PART NO. DESCRIPTION
1 1 BUG-5295 Rod Mount Assembly
2 1 CAS-1019 Rear Cover
3 1 BUG-5001 (120 VAC) Transformer
1 BUG-5002 (240 VAC) Transformer
1 BUG-5003 (42 VAC) Transformer
4 1 CAS-1770 Speed Control (Iron Rotor)
5 1 CAS-1060-PL Control Board / Plasma
6 1 MUG-1156 Panel Connector, 4T, F
7 1 BUG-9628 Cap & Chain Assembly
8 1 BUG-9856 Panel Connector, 2T, F
9 1 BUG-5323 SPDT, Toggle, On-Off-On
10 1 BUG-9677 Potentiometer
11 1 BUG-9676 Dial Counter
12 1 BUG-9621 Knob
13 1 POT 5483 Pot
14 1 BUG-1415 (120 VAC) Pilot Light
1 BUG-1428 (240 VAC) Pilot Light
1 BUG-1427 (42 VAC) Pilot Light
15 1 ABP-1069 Toggle Switch
16 1 CAS-2111 Front Panel, Hall Effect
17 1 FAS-3150 Nut, Cord Grip
18 1 BUG-9445 (120 VAC) Power Cord
1 GOF-3115 (240 VAC) Power Cord
1 BUG-9442 (42 VAC) Power Cord
19 1 BUG-5321 (120 VAC) Single Power Receptacle
1 BUG-9595 (240 VAC) Single Power Receptacle
1 BUG-5321 (42 VAC) Single Power Receptacle
20 1 BUG-2924 Reset Seal, Transparent
21 1 BUG-9446 Cord Grip
22 1 BUG-2923 (120 VAC) Circuit Breaker
1 BUG-2952 (240 VAC) Circuit Breaker
1 BUG-2933 (42 VAC) Circuit Breaker
23 1 BUG-1393 (120 VAC) Volt Trap
1 BUG-1563 (240 VAC) Volt Trap
1 BUG-1393 (42 VAC) Volt Trap
24 1 BUG-2626 SPDT, On-None-On
25 1 AVC-2113 Legend Plate, Volt Sensing
26 1 BUG-1415-A Speed Nut
F1 8 FAS-0114 Pan Hd Scr 6-32 x 3/8 Black
F2 2 FAS-0124 Pan Hd Scr 8/32 x 3/8, Di-Chrome
F3 8 FAS-0204 Rnd Hd Slt Scr 4-40 x 3/8 Zinc
F4 8 FAS-1305 Hex Nut 4-40
F5 2 FAS-1320 Hex Nut 8-32
F6 2 WAS-0221 #8 Internal Star Lock Washer
* 1 BUG-2005 Bug-O Label
* 1 BUG-9234 (120 VAC) Voltage Label
1 BUG-9233 (240 VAC) Voltage Label
1 BUG-9492 (42 VAC) Voltage Label
* 1 CAS-1010-WG Wire Group
* 1 CNN-0228 Housing 8 Pin

14
AVC-1550-PL-ID VOLT SENSOR ASSEMBLY, INTERNAL DIVIDER MODEL /
EXPLODED VIEW / PARTS LIST
ITEM QTY PART NO. DESCRIPTION
1 1 CAS-1525 AVC Voltage Enclosure
2 1 CAS-1526 Sensor Legend Plate
3 1 CAS-1532 AVC Harness Volt To Pwr
4 1 CAS-1531 AVC Harness Volt To Bug CNN
5 1 PLUG-2666 Hole Plug
6 1 PWS-0305 Main Current Sense Harness
7 1 PCB-1273-PL-ID PCB Board
8 1 FAS-0104 4-40 x 3/8 Pan Hd Screw
9 12 FAS-1305 4-40 Hex Nut
10 12 MET-0151-N *Pan Hd Slotted Screw
11 4 WAS-0201 #4 Internal Star Lockwasher
*Do not overtighten
1
2
3
4
5
6
7
8
9
10
11

15
AVC-1550-PL-RV VOLT SENSOR ASSEMBLY, RAW VOLTAGE MODEL /
EXPLODED VIEW / PARTS LIST
ITEM QTY PART NO. DESCRIPTION
1 1 CAS-1525 AVC Voltage Enclosure
2 1 CAS-1526 Sensor Legend Plate
3 1 CAS-1532 AVC Harness Volt To Pwr
4 1 CAS-1531 AVC Harness Volt To Bug CNN
5 1 CRS-1598 Hole Plug
6 1 PWS-0305 Main Current Sense Harness
7 1 CAS-1527 Raw Volt Sense Cable
8 1 PCB-1273-PL-RV PCB Board
9 1 FAS-0104 4-40 x 3/8 Pan Hd Screw
10 12 FAS-1305 4-40 Hex Nut
11 12 MET-0151-N *Pan Hd Slotted Screw
12 4 WAS-0201 #4 Internal Star Lockwasher
*Do not overtighten
1
2
3
4
5
6
7
8
9
10
11
12

16
AVC-1550-PL-PS VOLT SENSOR ASSEMBLY, POWER SOURCE MODEL /
EXPLODED VIEW / PARTS LIST
ITEM QTY PART NO. DESCRIPTION
1 2 CAS-1524 Voltage Sensor Mtg
2 16 STOF-2009 6-32 M/F Nylon
3 4 WAS-0210 #6 SAE Flat Washer
4 4 FAS-0112 Pan Hd Slt 6-32 x 1/4 Black
5 8 WSH 5432 #6 Flat Nylon Washer
6 1 PCB-1273 AVC Volt Sensor
7 4 FAS-1310 Hex Nut 6-32
8 1 CAS-1529 Ok To Move Harness
9 2 CAS-1530 Sense Harness
10 1 CAS-1528 AVC Voltage Leads
Note: Do not overtighten fasteners & standoffs
1
2
3
4
5
6
7
8
9
10

17
AVC-210X-PL-ID CONNECTION DIAGRAM

18
AVC-210X-PL-RV CONNECTION DIAGRAM

19
AVC-210X-PL-PS CONNECTION DIAGRAM

20
AVC-211X-WD CONTROL BOX, VOLT SENSING / WIRING DIAGRAM /
ELECTRICAL COMPONENT CHART
ITEM POWER SOURCE DESCRIPTION
120 VAC 240 VAC 42 VAC
CB BUG-2923 BUG-2952 BUG-2933 Circuit Breaker
LINE BUG-9445 GOF-3115 BUG-9442 Power Cord (120V shown)
PL BUG-1415 BUG-1428 BUG-1427 Pilot Light
REC BUG-5321 BUG-9595 BUG-5321 Power Receptacle (120V shown)
T BUG-5001 BUG-5002 BUG-5003 Transformer
VT BUG-1393 BUG-1563 BUG-1393 Volt Trap
CB1 CAS-1770 Speed Control (Iron Motor)
CB2 CAS-1060-PL Control Board / Plasma
CN1 MUG-1156 Panel Connector, 4-T, F
CN2 BUG-9856 Panel Connector, 2-T, F
PT1 BUG-9677 Potentiometer 10K
PT2 POT 5483 3-Turn 10k Ω Pot
SW1 BUG-5323 SPDT, Toggle, (ON)-OFF-(ON)
SW2 ABP-1069 Toggle Switch
SW3 BUG-2626 SPDT, ON-NONE-ON
ELECTRICAL COMPONENT CHART