AVC118

ARC VOLTATGE CONTROLLER

Instruction Manual
Revision 2.0A
Mar. 2012

1
Introduction
The AVC-118 is a voltage sensing torch height control system

that is designed for the CNC plasma cutting machines.

During cutting process, the cutting current always keep

constant, and the cutting arc voltage will be changed with the

height of torch. When the distance between the torch nozzle

and work piece increases, the arc voltage increases, on the

opposite, the arc voltage will decrease. AVC118 plasma arc

voltage torch height controller will detect the voltage changes,

then control the distance between cutting torch and work piece

via the lifting motor in order to keep the arc voltage within a

given range, so that the height of cutting torch is kept within a

corresponding range.

Specifications
Work power: DC24V10%, 3-5A.

The total power of the DC supply must be 10W bigger than the

power of the torch lifting motor.

Lifting motor: DC24V motor within the power of 60W.

Drive Mode: PWM (pulse width modulation).

Working Temperature: -10 - 60

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IHS (Initial Height Setup) mode:

Inductive proximity switch mode.

Torch tip ohmic contact mode, only be suited for the

plasma power which has less HF and HV interferences

and working in dry cutting condition.

Arc voltage divider ratio: 1:100.

Accuracy: 1V to 5V adjustable.

Outline: 240mm/210mm/60mm(L/W/H).

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Pictures

4
System connection

AVC118 Controller

CNC

SYSTEM

START
MOTOR

Torch ARC VOLT

L
I
Lifter
M
I
PLASMA
T

PRO SW

SHIELD

WORK PIECES
GROUND

AVC118 controller system connection

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Connectors

5 1 1 7 GND

9 6 1 5

Terminals outline

J1Connect to CNC controller.

J2Connect to DC24V power supply, lifting motor and limit

switches.

J3Connect to the proximity switch and plasma start switch.

J4Connect to the arc voltage sampling terminals.

J5Connect to the torch shield cap signal terminal.

GNDConnect to the system ground. The grounding cable

should be at least 4mm2.

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 TERMINALS DEFINITION
NAME TERMINAL SIGNAL FUNCTION

1 AUTO CNC AUTO THC Enable

2 UP CNC Torch Up Signal

3 DOWN CNC Torch Down Signal

4 START CUT CNC Start Cutting Signal

5 NC

6 MOTION Motion Enable to CNC

J1
7 NC

8 COM GND of Control Signals

9 NC

1 UP_LMT Upper Limit Switch

2 DOWN_LMT Lower Limit Switch

3 COM GND of Control Signals

4 MOTOR_1 Motor Terminal 1

5 MOTOR_2 Motor Terminal 2

J2
6 DC24V(+) Power Supply DC24V(+)

7 DC24V(-) Power Supply DC24V(-)

Power of the Proximity
1 PRO_VCC_12V+
Switch :+12V
2 PRO_SW_SIGNAL Proximity Switch signal in
GND of the Proximity Switch
3 PRO_GND_0V
Power: 0V
J3
4 PLASMA_START1 Plasma Start Switch Term.1

5 PLASMA_START2 Plasma Start Switch Term.2

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J4Arc voltage input.

Through this lock terminal, Connect the WORK terminal

inside the controller to the positive terminal of plasma

power, and connect the E-TRODE terminal to the

negative terminal of the plasma power.

AVC118 has been integrated an isolated arc voltage

divider, the divided ratio is 1:100. The arc voltage sense

wires should be at least 0.9 mm squared twisted pair

wire, rated 600V or greater. When connecting arc

voltage sense wires to the controller, please check the

arc voltage polarity carefully to ensure correct

connection, otherwise serious damage may occur.

J5SHIELD CAP.

Through this lock terminal, Connect the shield cap lead

line (as the Ohmic IHS sensing signal) to the SHELD

terminal.

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 J4 ,J5 connection illustration

J4 J5

E_TRODE: ARC VOLT- SHIELD: CAP SHIELD

WORK: ARC VOLT+ LEAD LINE

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CNC INTERFACE
J1: connected to the CNC control system.

Terminal description:

J1-1: AUTO

Auto height control enable signal from CNC to AVC118

controller. Default definition: HIGH level signal enable

auto control, LOW level signal disable auto control. This

definition can be reversed by demand when placing order.

J1-2: UP

Torch UP signal from the CNC. Active level: LOW.

J1-3: DOWN

Torch DOWN signal from the CNC. Active level: LOW.

J1-4: START CUT

Start cutting cycle signal from the CNC, this signal must be

maintained during the entire plasma cutting cycle. Active

level: LOW.

J1-5: NC

J1-6: MOTION

Motion enable signal output to the CNC system. This signal

is issued after the plasma torch ignition and the pierce

process has been completed. This signal indicates that the

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 CNC should begin the cutting motion. In case of serious

error occurred during the plasma cut, this signal will be

reset to high level. Active level: LOW.

Please refer to the MOTION signal interface circuit

illustration.

J1-7: NC

J1-8: CNC_COM

This is the common ground terminal of all above signals.

MOTION signal interface

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LIFTER MOTOR AND LIMIT SWITCH
Lifter motor

DC shunt motor, 24V DC, power within 60W.

Connected terminal: J2-4 and J2-5, if the torch up and down

direction is not corresponding to the controller, please

exchange the lead wires of the lifter motor.

Limit switch

J2-1: Connect to the terminal of normal open contact of the

upper limit switch.

J2-2: Connect to the terminal of normal open contact of the

lower limit switch.

J2-3: Connect to the terminals of common contact of the upper

and lower limit switches.

PLASMA START
Terminal: J3-5 and J3-5. Relay contact output, 10A/250V.

Connect to the start arc terminal of the plasma power source.

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Proximity switch IHS mode
Terminal: J3-1: +12V output, supply for proximity switch.

J3-2: proximity switch signal input.

J3-3: 0V, ground.

Proximity switch type:

NPN, normal open, sense distance 2mm.

If there is a short wire connected between terminal J3-2 and

j3-3, you should remove it before connecting the proximity

switch.

When more than one proximity switch used, the user can

design a proper interface board or refer to the simple series

connection illustration.

DC24V+

SIGNAL

DC24V-

Simple series connection illustration.

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Shield cap IHS mode
Terminal: J5.

Through this lock terminal, Connect the shield cap lead wire

(as the Ohmic IHS sensing signal) to the SHELD CAP terminal.

The Ohmic IHS sense wire should be at least 0.5 mm squared,

rated 1000V or greater.

SHIELD

CAP

Shield cap IHS illustration

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Operation mode
The AVC118 will work in auto mode after power on. This

means that the controller will take the responsibility to monitor

the arc voltage and modify the torch height correctly during

plasma cut. In case of needed, you can Press the

AUTO/MANU key to enter into manual operation mode, and it

is your responsibility to maintain the torch height correctly.

Operational keys
MEMU --- Menu key

ENTR --- Enter key.

UP --- Move the lifter upward while standby.

Increase the value while parameter setup.

Increase the given arc voltage while cutting.

Select previous items while menu operation.

DOWN --- Move the lifter downward while standby.

Decrease the value while parameter setup.

Decrease the given arc voltage while cutting.

Select next items while menu operation.

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Arc voltage setup
Press the MENU key once while standby, the controller will

enter into parameter setup interface, then press UP or DOWN

arrow key to select menu items, press the ENTR (enter) key to

setup working arc voltage when it displays Arc_Volt

information. Now the current arc voltage value will be

displayed on the LCD display and the cursor blinks, after that,

press the UP or DOWN arrow key to increase or decrease the

value of working arc voltage. Holding the UP or DOWN key for

about 2 seconds to increase or decrease the value

automatically and faster. Press ENTR key to confirm and exit

to menu item select interface. After all working parameters

have been setup properly, press the MENU key to return to

standby status while menu item select interface.

IHS time setup

The unit of the initial height setup (IHS) time is 10ms

(millisecond).

The procedure of the IHS time setup is the same as above.

Caution: if the IHS time is setup to zero, the controller will not

execute initial height setup procedure and will start arc directly.
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You have to setup the initial torch height manually when start

arc.

Pierce time setup

The unit of the pierce time is 0.1s (second).

The procedure of the pierce time setup is the same as

above.

Caution: if the pierce time is setup to zero, the controller

will not execute pierce procedure. The CNC controller should

take the responsibility of pierce procedure control.

IHS Test
Press the MENU key once while standby, the controller will

enter into parameter setup interface, then press UP or DOWN

arrow key to select menu items, press the ENTR (enter) key to

enter into IHS test interface when it displays Ihs_Test

information. Now the controller will ask you to press the ENTR

key again to confirm and start the IHS test procedure. Now

you can press the MENU key to exit or the ENTR key to start

the IHS test procedure, you can also press the UP or DOWN

key to enter into IHS_TIME setup procedure to modify the IHS

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time. During the IHS test procedure you can press the ENTR

key to stop the procedure manually. After the IHS test

procedure, press the MENU key to return to standby status

while menu item select interface.

Arc Test
Press the ARC_TEST key while standby, the controller will

enter into arc test interface, the controller will ask you to press

the ENTR key to confirm and start the arc test procedure. You

can press the ARC_TEST key to exit or the ENTR key to start

the arc test procedure. During the arc test procedure you can

press the ENTR key to stop the procedure manually. After the

arc test procedure, press the ARC_TEST key to return to

standby status.

Inner parameters configuration

Caution: All inner parameters should not need to be changed

after the controller had been installed and debugged properly

by the CNC cutting machine manufactory. They are only

provided to a trained engineer to optimize the technical

performance.
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 Press the MENU key once while standby, the controller will

enter into parameter setup interface, then press the UP and

DOWN arrow key at the same time for about 3 seconds, then

release the key, the controller will enter into inner parameters

setup interface.

Press UP or DOWN key to select the inner parameter

which you want to modify, press ENTR key once to edit

current parameter, and then press the UP or DOWN arrow key

to modify current parameter value, press ENTR key again to

return. Press the MENU key to exit to standby status after all

inner parameters have been setup properly.

MAX_PWMThe maximum PWM value of the lifting motor.

This parameter defines the maximum speed of torch

lifting motor.

Range:60-120default120.

MIN_PWMThe minimum PWM value of the lifting motor.

This parameter defines the minimum speed of torch

lifting motor.

Range:10-120default30.

IhsUPPWM: The IHS upward PWM value of the lifting

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 motor.

This parameter defines the upward speed of torch lifting

motor during initial height setup procedure.

Range: MIN_PWM-MAX_PWMdefault30.

IhsDN PWMThe IHS downward PWM value of the lifting

motor.

This parameter defines the downward speed of torch

lifting motor during initial height setup procedure.

Range: MIN_PWM-MAX_PWMdefault90.

U&D_ PWMThe upward and downward PWM value of the

lifting motor.

This parameter defines the speed of torch lifting motor

during manual torch height control.

Range: MIN_PWM-MAX_PWMdefault120.

ARC_TOLEArc voltage toleration range.

This parameter defines the maximum allowable positive

deviation from the given arc voltage. An arc voltage

deviation bigger than this value means that the torch is

cutting across a kerf, and the controller will disable

auto height control temporally to avoid the cutting torch

diving into the workpiece.

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 Range: 5-50V, default: 15.

BRAKE_EN: Motor reverse brake enable control.

0: disable motor brake.

1 : enable brake.

Default: 1.

AUTO_AMPAuto amplification value.

This parameter defines the sensitivity to the arc voltage

deviation. If this value is set too high, the lifter

positioning during auto height control will become

unstable and prone to oscillation. If this value is set too

low, the lifter positioning during auto height control will

become slow and inaccurate.

Range:1-20default10

UP_BRK_T: Upward move brake time.

This parameter defines the reverse brake time of the

lifting motor after an upward movement.

Unit: ms (millisecond)

Range: 0-100, default: 20.

DN_BRK_T: This parameter defines the reverse brake time

of the lifting motor after a downward movement.

Unit: ms (millisecond)
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 Range: 0-100, default: 20.

EMG_LFT_TEmerge lift time.

This parameter defines the time of torch emerge lifting

once a torch tip collision detected.

Unit: 10ms (millisecond)

Range: 5-50, default: 20.

EMR_LFT_PEmerge lift PWM value.

This parameter defines the speed of torch emerge lifting

once a torch tip collision detected.

Range: MIN_PWM-MAX_PWM, default: 100.

ADJ_RANGArc voltage intelligent adjustment range.

The AVC118 controller has an intelligent arc voltage

adjustment function.

Supposing the initial arc voltage is set too low, the

cutting torch will be also too close to the workpiece, and

the torch tip will be very easy to collide with the

workpiece, if a certain number of continue collisions

have been detected, the AVC118 controller will increase

the given arc voltage automatically to avoid subsequent

collision.

A similar situation will occur due to the wear out of the

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 torch nozzle during cutting. The intelligent arc voltage

adjustment function make it possible to cut the left part

of an whole job without collision temporally, but the user

should check the cutting torch immediately after current

job.

Range:5-50V, default:10.

ADJ_STEPArc voltage intelligent adjustment step.

This parameter defines the step value of arc voltage

while intelligent arc voltage adjustment occurs.

Range: 1-5V, default: 1.

INTEL_SG Arc voltage intelligent adjustment enable control.

0: disable this function.

1: enable this function.

default: 0.

ARC_ACCUArc voltage accuracy.

This parameter defines the arc voltage accuracy while

auto height control.

Range: 1-10V, default: 1V.

PIER_ENPierce enable control.

This parameter enables or disables the pierce function

of the controller.
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 0: Disable the pierce procedure.

1: Enable the pierce procedure.

default: 1.

FAIL_LFT: Torch lifting time after arc off.

Unit0.1second.

0: Disable torch lifting after arc off.

Range: 0-100, default: 10.

COL_STOP: Torch collision stop enable control.

Range: 0-1, default: 0.

0: Disable this function.

1: Enable this function.

If a certain number of continued collisions have been

detected, the controller will stop the plasma power and

disable the MOTION signal to the CNC system.

DELAY_INArc voltage delayed input time.

This parameter defines the time to be delayed from

starting arc to the arc voltage input to the controller

through the isolated relay. It is used to avoid the HV and

HF interferences from the plasma power while starting

arc.

Unit: 0.1 second.

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 Range:10-60default: 20.

DEFAULTRestore default value.

When this parameter is set to the value of 18 and press

the MENU key to exit, all inner parameters will restore

to the default value, and this parameter will restore to

zero itself.

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TROUBLE SHOOTING

Error Description Possible cause Corrective action

When power on, the 1The IHS proximity Reinstall The IHS
1 torch moves upward switch not installed proximity switch
continuously.(if the IHS properly. properly.
proximity switch is 2The IHS proximity Replace the IHS
used switch is faulty. proximity switch.
2 Arc voltage unstable Check the GND connection.
Check the pressed air filter of plasma.
Check the arc voltage divide board.
3 The controller does not AVC118 controller may Make the controller
respond the CNC not be at the standby return to the standby
signal. status. status.
4 Plasma arc transfer Check the work cable connection.
difficult. Check if the IHS height too high.
Check the torch consumable.
5 Torch diving to the CNC auto enable signal active too early.
workpiece just when The working arc voltage is set too lower.
the cutting machine Pierce time is set too long when cutting thin
start motion. workpiece.
6 Torch diving to the Arc voltage toleration range set too wide, the
workpiece when auto height control disable function did not
cutting torch across active.
kerf. Decrease the value of arc voltage toleration
range .

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