P6906 Edition 3 April 1999 - Tool

03537495
Form P6906
Edition 4
April, 1999
OPERATION AND MAINTENANCE MANUAL
FOR
MODEL ESCB50 ELECTRIC SCREWDRIVER CONTROLLER
This Controller is designed for indoor use only, with Models ES45T, ES50T and
ES50TC Electric Screwdrivers,
Models ES45T, ES50T and ES50TC Electric Screwdrivers are recommended for
assembly applications where precise torque control is required.
IMPORTANT SAFETY INFORMATION ENCLOSED.
READ ALL THESE INSTRUCTIONS BEFORE PLACING TOOL IN SERVICE OR OPERATING THIS
TOOL AND SAVE THESE INSTRUCTIONS.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION
IN THIS MANUAL INTO THE HANDS OF THE OPERATOR.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
WHEN USING ELECTRIC TOOLS, BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE
FOLLOWED TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK AND PERSONAL INJURY,
INCLUDING THE FOLLOWING.
it to disconnect from receptacle. Keep cord from heat,
PLACING TOOL IN SERVICE
•
•
•
Always operate, inspect and maintain this tool in
accordance with all regulations (local, state, federal
and country), that may apply to hand held/hand
operated electric tools.
Inspect tool cords periodically and if damaged, have
them repaired by an authorized service facility.
Inspect extension cords periodically and replace if
damaged.
Do not remove any labels. Replace any damaged
label.
USING THE TOOL
•
•
•
•
•
•
Disconnect Tools when not in use, before servicing
and when changing accessories and bits.
When Tool is used outdoors, use only extension
cords intended for use outdoors and so marked.
Always wear eye protection when operating or
performing maintenance on this tool.
Power tools can vibrate in use. Vibration, repetitive
motions, or uncomfortable positions may be
harmful to your hands and arms. Stop using any
tool if discomfort, tingling feeling or pain occurs.
Seek medical advice before resuming use.
Guard Against Electric Shock. Prevent body contact
with earthed or grounded surfaces. For example;
pipes, radiators, ranges, refrigerator enclosures.
Don’t Abuse Cord. Never carry tool by cord or yank
•
•
•
•
•
•
•
•
•
•
oil, and sharp edges.
Keep work area clean. Cluttered areas and benches
invite injuries.
Consider work area environment. Don’t expose
power tools and chargers to water. Keep work area
well lighted. Do not use tool in explosive or
flammable atmospheres.
Keep bystanders and children away. Do not permit
unauthorized personnel to operate this tool, or touch
tool or cord.
Store idle tools. When not in use, tools should be
stored in a dry, high or locked up place, out of reach of
children.
Don’t force tool. It will do the job better and more
safely at the rate for which it was intended.
Use the right tool. Do not force a small tool or
attachment to do the job of a heavy–duty tool.
Do not use a tool for a purpose for which it is not
intended. Example: Do not use a screwdriver as a
drill.
Dress properly. Do not wear loose clothing or
jewelry. They can be caught in moving parts. Rubber
gloves and non–skid footwear are recommended when
working outdoors. Wear protective hair covering to
contain long hair.
This tool is not designed for working in explosive
atmospheres.
This tool is not insulated against electric shock.
The use of other than genuine Ingersoll–Rand replacement parts may result in personal injury, decreased tool
performance and increased maintenance, and may invalidate all warranties.
Have your tool repaired by a qualified person. This electric tool is in accordance with the relevant safety requirements.
Repairs should only be carried out by qualified persons using original spare parts, otherwise this may result in
considerable danger to the user.
Repairs should be made only by authorized, trained personnel. Consult your nearest Ingersoll–Rand Authorized
Servicenter.
Refer All Communications to the Nearest
Ingersoll–Rand Office or Distributor.
 Ingersoll–Rand Company 1999
Printed in U.S.A.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
•
USING THE TOOL (Continued)
•
•
•
•
•
•
•
•
•
•
Secure work. Use clamps or a vise to hold work.
Operators often need both hands to perform job
functions.
Don’t overreach. Keep proper footing, balance, and a
firm grip on the tool at all times.
Maintain tools with care. Keep tools clean for better
and safer performance. Follow instructions for
lubricating and changing accessories. Inspect tool
cords periodically and if damaged, have them repaired
by an authorized service facility. Inspect extension
cords periodically and replace if damaged. Keep
handles dry, clean, and free from oil and grease.
Remove adjusting keys and wrenches. Form habit of
checking to see that keys and adjusting wrenches are
removed from tool before turning it on.
Avoid unintentional starting. Don’t carry tool with
finger on switch.
Do not drop or abuse the tool.
Whenever a tool is not being used, position the
Power Switch to the “OFF” position and unplug the
power cord.
Stay alert. Watch what you are doing. Use common
sense. Do not operate tool when you are tired.
Check damaged parts. Before further use of the tool,
a guard or other part that is damaged should be
carefully checked to determine that it will operate
properly and perform its intended function. Check for
alignment of moving parts, binding of moving parts,
breakage of parts, mounting, and any other conditions
that may affect its operation. A guard or other part that
is damaged should be properly repaired or replaced by
an authorized service center unless otherwise indicated
elsewhere in this operation manual.
Have defective switches replaced by an authorized
service center.
•
•
•
•
•
•
Do not use the tool if the switch does not turn it on
and off.
Do not drop or abuse the screwdriver.
Whenever changing a bit, make certain the
Forward/Reverse Switch is in the “OFF” position
and the tool is unplugged.
Do not allow chemicals such as acetone, benzene,
thinner, ketone, trichloroethylene or other similar
chemicals to come in contact with the screwdriver
housing as damage will result.
Do not operate the Forward/Reverse Switch when
the motor is running.
Whenever a tool is not being used, move the
Forward/Reverse Switch to the “OFF” position and
unplug the screwdriver.
The use of any accessory or attachment other than
recommended in this manual can present a risk of
personal injury.
OPERATION
•
•
Do not drop or abuse the Controller.
Whenever a Controller is not being used, position
the Power Switch to the “OFF” position and unplug
the power cord.
MAINTENANCE
DO NOT ATTEMPT TO REPAIR THIS TOOL.
All repairs and maintenance of the Controller and its cord
must be performed by an authorized servicenter.
2
WARNING LABEL IDENTIFICATION
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
WARNING
WARNING
WARNING
Always wear eye protection
when operating or performing maintenance on this
tool.
Always turn off the electrical
supply and disconnect the
power cord before installing,
removing or adjusting any
accessory on this tool, or
before performing any
maintenance on this tool.
Always wear hearing
protection when operating
this tool.
WARNING
WARNING
Do not carry the tool by
the cord.
Powered tools can vibrate in
use. Vibration, repetitive motions or uncomfortable positions may be harmful to your
hands and arms. Stop using
any tool if discomfort, tingling
feeling or pain occurs. Seek
medical advice before resuming use.
WARNING
Do not use damaged, frayed
or deteriorated power cords.
WARNING
Keep body stance balanced
and firm. Do not overreach
when operating this tool.
WARNING
INDOOR USE ONLY.
PLACING TOOL IN SERVICE
GROUNDING INSTRUCTIONS
If your unit is for use on less than 150V, it has a plug that
looks like that shown in Figure A.
An adapter (see Figure B) is available for connecting
Figure A–type plugs to 2–prong receptacles. The green
colored rigid grounding strap must be connected to a
permanent ground such as to a properly grounded outlet
box as shown in figure C.
The tool should be grounded while in use to protect the
operator from electric shock. The tool is equipped with a
three–conductor cord and three–prong grounding–type plug
to fit the proper grounding–type receptacle. The green
(or green and yellow) conductor in the cord is the
grounding wire. Never connect the green
(or green and yellow) wire to a live terminal.
COVER OF GROUNDED
OUTLET BOX
GROUNDING
PIN
FIGURE A
FIGURE C
ADAPTER
FIGURE B
GROUNDING MEANS
(Dwg. TPD446–2)
For safe use of adapters, the outlet box must be grounded. If there is any doubt, have a qualified electrician check
connections.
Use only 3–wire extension cords that have 3–prong grounding type plugs and 3 pole receptacles that accept the
controllers plug. Replace or repair damaged cords.
3
Extension Cords
Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry
the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and
overheating.
The Table below shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the
next heavier gage. The smaller the gage number, the heavier the cord.
Volts
120V
Ampere rating
More than
Not more than
0
6
10
12
6
10
12
16
Total length of cord in feet
0 – 25
26 – 50
51 – 100
101 – 150
AWG
18
15
16
14
16
16
16
12
4
16
14
14
12
14
12
not recommended
MAINTENANCE SECTION
5
(Dwg. TPB865–2)
PART NUMBER FOR ORDERING
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover Mounting Screw (4) . . . . . . . . . . . . . . . . . .
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Cord Assembly . . . . . . . . . . . . . . . . . . . . . .
Cord Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Holder Assembly . . . . . . . . . . . . . . . . . . . . . .
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Washer . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Screw Lock Washer . . . . . . . . . . . . . . . . .
Ground Screw Nut (2) . . . . . . . . . . . . . . . . . . . . . .
Rubber Foot (4) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot Mounting Screw (4) . . . . . . . . . . . . . . . . . . . .
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer Mounting Screw (2) . . . . . . . . . . . . .
Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Block Mounting Screw (2) . . . . . . . . . . .
ESCB50–628
ESCB50–808
ESCB50–627
ESCB50–449UL
ESCB50–445
ESCB50–A705UL
ESCB50–638UL
ESCB50–301UL
ESCB50–810
ESCB50–812
ESCB50–811
ESCB50–740
ESCB40–730
ESCB50–672
ESCB50–325
ESCB50–672
ESCB50–813UL
ESCB50–814UL
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Circuit Board Mounting Bracket (2) . . . . . . . . . . .
Mounting Bracket Screw (2) . . . . . . . . . . . . . . . . .
Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board Mounting Insulator (4) . . . . . . . . . .
Circuit Board Mounting Screw (4) . . . . . . . . . . . .
Socket Assembly (2) . . . . . . . . . . . . . . . . . . . . . . .
Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Mounting Nut . . . . . . . . . . . . . . . . . . . . . . .
Pilot Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle Mounting Screw (4) . . . . . . . . . . . . . . .
Control Knob (includes setscrew) (2) . . . . . . . . . .
Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . .
Soft Start Potentiometer . . . . . . . . . . . . . . . . . . . . .
Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logoplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Warning Label . . . . . . . . . . . . . . . . . . . . . . . .
ESCB50–629
ESCB50–806
EC24N–B525
ESCB50–616
ESCB50–787
ESCB50–670
ESCB50–634
ESCB50–636
ESCB50–637
ESCB40–463
ESCB50–815
ESCB50–801
ESCB40–485
ESCB40–486
ESCB50–667
ESCB10–99
ESCB50–99UL
EC24N–98
MAINTENANCE SECTION
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
PART NUMBER FOR ORDERING
MAINTENANCE SECTION
Soft Start Potentiometer (32)
1.
Maintenance procedures have the potential for
severe shock hazard and should be performed by
qualified personnel.
2.
DISASSEMBLY
3.
Speed Potentiometer (31)
Always wear eye protection when operating or
performing any maintenance on this tool. Always
turn off the electrical supply and disconnect the
electrical cord before installing, removing or
adjusting any accessory on the tool or before
performing any maintenance on this tool.
1.
2.
Cover (1)
1.
2.
Using a miniature thin bladed screwdriver, unscrew
and loosen the setscrew in the Control Knob (30) of the
Soft Start Potentiometer. Remove the Knob.
Unscrew and remove the potentiometer nut and pull
the Potentiometer away from the Chassis (3).
Remove the heat shrink and unsolder the yellow and
orange wires. Important: Note the location of these
wires for reassembly purposes.
Using a phillips screwdriver, remove the four Cover
Mounting Screws (2).
Lift the Cover off the Chassis (3).
Using a miniature thin bladed screwdriver, unscrew
and loosen the setscrew in the Control Knob (30) of the
Speed Potentiometer. Remove the Knob.
Unscrew and remove the potentiometer nut and pull
the Potentiometer away
from the Chassis (3).
Important: Note the location of these wires for
reassembly purposes.
Power Cord Assembly (4)
Power Switch (25)
1.
1.
2.
3.
4.
Using a thin bladed screwdriver, loosen the right rear
screw in the Terminal Block (17) and remove the white
wire.
Remove the heat shrink from the Power Switch (25)
and unsolder the black wire from the Switch.
Loosen the two Ground Screw Nuts (12) and remove
the green ground wire.
Using a thin bladed screwdriver, pry the Cord Stop (5)
out of the Chassis (3) and remove the Cord Assembly.
2.
Pilot Lamp (27)
1.
2.
Transformer (15)
1.
2.
3.
Remove the heat shrink and unsolder the two yellow
wires from the red and brown leads.
Using a thin bladed screwdriver, loosen the three
screws at the front of the Terminal Block (17) and
remove the brown, grey and white wires.
Using a phillips screwdriver, remove the two
Transformer Mounting Screws (16).
2.
1.
2.
Unplug the two Socket Assemblies (24). Important:
Note the location of
the Socket Assemblies for reassembly purposes.
Using a phillips screwdriver, remove the two Mounting
Bracket Screws (20).
Fuse Holder (6)
1.
2.
3.
Loosen and remove the nut and washer of the Pilot
Lamp located on the back of chassis front panel.
Remove the heat shrink and unsolder the two wires on
the Pilot Lamps. Important: Note the colors and
location of these wires for reassembly purposes.
Receptacle (28)
Circuit Board (21)
1.
Using pliers, unscrew and remove the Switch
Mounting Nut (26).
Remove the shrink wrap and unsolder the two wires
from the Power Switch. Important: Note the colors
and location of these wires for reassembly purposes.
Insert a thin bladed screwdriver into the slots in the
fuse holder cap and rotate the cap counterclockwise.
Remove the cap and the Fuse (7).
Remove the heat shrink and unsolder the two wires
from the Holder.
Using a wrench, unscrew and remove the fuse holder
nut. Pull the Fuse Holder out of the Chassis (3).
7
Using a phillips head screwdriver, unscrew and remove
the four Receptacle Mounting Screws (29).
Remove the heat shrink and unsolder the five wires at
the Receptacle. Important: Note the color and
location of these wires for reassembly purposes. To
assist with reassembly, the plug face is numbered at
each jack position.
MAINTENANCE SECTION
ASSEMBLY
screwdriver, tighten the knob setscrew against the
shaft.
Soft Start Potentiometer (32)
Receptacle (28)
1.
2.
3.
4.
1.
Slip a small piece of heat shrink tubing (obtain from
nearest Radio Shack)
onto each of the five receptacle wires.
Pull the wires through the receptacle opening in the
front face of the Chassis (3) and solder each colored
wire to the same terminal it was removed from at
disassembly.
Slide the five pieces of heat shrink tubing over the
soldered connections and heat shrink the tubing.
Position the Receptacle against the face of the Chassis
with the number one jack at one o’clock and the
number five jack at eleven o’clock. Secure the
Receptacle by installing the four Receptacle Mounting
Screws (29).
2.
3.
4.
5.
Fuse Holder (6)
1.
Pilot Lamp (27)
1.
2.
3.
4.
Install the Pilot Lamp in the Chassis (3) and secure it
with the nut and
washer.
Slip a small piece of heat shrink tubing onto each of
the two pilot lamp
wires.
Solder each wire to the terminal it was removed from
at disassembly.
Slide the two pieces of heat shrink tubing over the
soldered connections
and heat shrink the tubing.
2.
3.
4.
2.
3.
4.
1.
2.
Slip a small piece of heat shrink tubing onto each of
the two power switch
wires.
Solder each wire to the terminal it was removed from
at disassembly.
Slide the two pieces of heat shrink tubing over the
soldered connections and heat shrink the tubing.
Position the Switch against the Chassis (3) and secure
it with the Switch
Mounting Nut (26).
2.
3.
4.
5.
Plug the two Socket Assemblies (24) into the Circuit
Board in the same location as when disassembled
Position the Board in the Chassis (3) and, using a
phillips screwdriver, install the two Mounting Bracket
Screws (20).
Transformer (15)
1.
2.
3.
Speed Potentiometer (31)
1.
Slip a small piece of heat shrink tubing onto each of
the two fuse wires.
Position the Fuse Holder against the Chassis (3) and
secure it with the washer and fuse holder nut.
Solder each wire to the terminal it was removed from
at disassembly.
Slide the two pieces of heat shrink tubing over the
soldered connections and heat shrink the tubing.
Circuit Board (21)
Power Switch (25)
1.
Slip a small piece of heat shrink tubing onto each of
the two potentiometer wires. Do not install the tubing
on the jumper wire.
Solder each wire to the terminal it was removed from
at disassembly.
Slide the two pieces of heat shrink tubing over the
soldered connections and heat shrink the tubing.
Position the Potentiometer against the Chassis (3) and
secure it with the washers and nut.
Slide the Control Knob (30) onto the shaft of the
Potentiometer and, using a miniature thin bladed
screwdriver, tighten the knob setscrew against the
shaft.
Slip a small piece of heat shrink tubing onto each of
the three potentiometer wires.
Solder each wire to the terminal it was removed from
at disassembly.
Slide the three pieces of heat shrink tubing over the
soldered connections
and heat shrink the tubing.
Position the Potentiometer against the Chassis (3) and
secure it with the washers and nut.
Slide the Control Knob (30) onto the shaft of the
Potentiometer and, using a miniature thin bladed
4.
5.
8
Position the Transformer on the Chassis (3) with the
side having three leads toward the Potentiometer side
of the Chassis. Using a phillips screwdriver, install the
two Transformer Mounting Screws (16).
Slip a small piece of heat shrink tubing onto each of
the two wires opposite the three lead side.
Solder the left yellow wire, when facing the front of
the Controller, to the exact same red wire it was
disassembled from in the Socket Assembly (24). Slide
the heat shrink tubing over the solder connection and
heat shrink the tubing.
Solder the right yellow wire, when facing the front of
the Controller, to the exact same brown wire it was
disassembled from in the Socket Assembly. Slide the
heat shrink tubing over the solder connection and heat
shrink the tubing.
When facing the front of the Controller and using a
thin bladed screwdriver, install the brown wire from
the Transformer into the right front connection on the
Terminal Block (17). Install the grey wire from the
Transformer into the center front connection.
MAINTENANCE SECTION
4.
Power Cord Assembly (4)
1.
2.
3.
Install the Cord Assembly and Cord Stop (5) into the
rear panel of the Chassis (3).
Slip a small piece of heat shrink tubing onto the black
wire of the Power Cord. Solder the black wire to the
terminal of the Power Switch (25) it was removed from
at disassembly. Slide the heat shrink tubing over the
soldered connection and heat shrink the tubing.
Install the green ground wire on the Ground Screw (9)
and tighten the Ground Screw Nuts (12).
When facing the front of the Controller and using a
thin bladed screwdriver, install the white wire from the
Power Cord into the right rear connection on the
Terminal Block (17).
Cover (1)
1.
Position the Cover on the Chassis (3) and secure it with
the four Cover Mounting Screws (2).
Wiring Diagram
9
(Dwg. TPD1112)
MAINTENANCE SECTION
TROUBLESHOOTING GUIDE
Trouble
Probable Cause
No power
Fuse
Power Switch
Power Cord
Transformer
Faulty braking
Speed control does not work.
Circuit Board
Circuit Board
Speed Potentiometer
Circuit Board
Soft start does not work.
Soft Start Potentiometer.
Circuit Board
Solution
Disconnect Power Cord. Replace fuse.
Disconnect Power Cord. Use ohmmeter to check
yellow and black leads at Switch. Reading should
be 0 to full scale when switched from on to off.
Use Voltmeter to check white lead at terminal
block and black lead at Switch. Reading should
be 115 VAC.
Use Voltmeter to check the two yellow leads from
the Transformer. Reading should be 24 VAC.
Replace the Circuit Board.
Replace the Circuit Board.
Disconnect Power Cord
Unplug the Socket Assembly (24) from the Circuit
Board. Using an ohmmeter, check the blue to
purple or blue to green leads at the Potentiometer.
Replace the Circuit Board.
Disconnect Power Cord. Unplug the Socket
Assembly (24) from Circuit Board. Using an
ohmmeter, check the yellow and orange leads at
the potentiometer by rotating the knob. Reading
should be 0 to 50 000 ohms.
Replace the Circuit Board.
SAVE THESE INSTRUCTIONS. DO NOT DESTROY.
10
NOTES
11
NOTES
12
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