Miller PAC PENDANT CONTROL Owner's Manual

December 1991
FORM: OM-149 701
MODEL: PAC Pendant Control
OWNER’S MANUAL
IMPORTANT: Read and understand the entire contents of both this manual
and the power source manual used with this unit, with special emphasis on
the safety material throughout both manuals, before installing, operating, or
maintaining this equipment. This unit and these instructions are for use only
by persons trained and experienced in the safe operation of welding equipment. Do not allow untrained persons to install, operate, or maintain this unit.
Contact your distributor if you do not fully understand these instructions.
ST-150 802-A
MILLER ELECTRIC Mfg. Co.
A Miller Group Ltd., Company
P.O. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
PRINTED IN U.S.A.
OM-149 701 – 12/91
RECEIVING-HANDLING
Before unpacking equipment, check carton for any
damage that may have occurred during shipment. File
any claims for loss or damage with the delivering carrier. Assistance for filing or settling claims may be obtained from the distributor and/or the equipment manufacturer’s Transportation Department.
When requesting information about this equipment, always provide the Model Designation and Serial or Style
Number.
Use the following spaces to record the Model Designation and Serial or Style Number of your unit. The information is located on the rating label or nameplate.
Model
Serial or Style No.
Date of Purchase
TABLE OF CONTENTS
Section No.
Page No.
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1.
1-2
General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
SECTION 2 – SPECIFICATIONS
2-1.
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
SECTION 3 – INSTALLATION
3-1.
Connecting The Pendant Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
SECTION 4 – OPERATOR CONTROLS
4-1.
4-2.
Torch Output Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thickness Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1.
5-2.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
SECTION 6 – ELECTRICAL DIAGRAMS
Diagram 6-1. Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
SECTION 7 – PARTS LIST
Figure 7-1. Pendant Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1.
GENERAL INFORMATION AND SAFETY
1-2
A. General
Information presented in this manual and on various labels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
The following safety alert symbol and signal words are
used throughout this manual to call attention to and
identify different levels of hazard and special instructions.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call attention to the safety statements.
The nameplate of this unit uses international symbols
for labeling the front panel controls. The symbols also
appear at the appropriate section in the text.
WARNING statements identify procedures or
practices which must be followed to avoid serious personal injury or loss of life.
B. Safety
The installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1 – Safety Rules For Plasma Arc Cutting
(PAC) in the power source Owner’s Manual.
SAFETY ALERT SYMBOL AND SIGNAL
WORDS
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equipment.
SECTION 2 – SPECIFICATIONS
2-1/2 in.
(64 mm)
2-3/4 in.
(70 mm)
5-1/2 in.
(140 mm)
2-1.
DESCRIPTION
This unit is a Remote Pendant Control for Spectrum
750, 1500, and 1500D model Plasma Arc Cutting (PAC)
power sources. When properly connected to the power
source, this unit provides remote contactor and thickness output control. This unit is equipped with a 20 ft.
(6.1 m) interconnecting cord.
ST-150 802-A
Figure 2-1. Dimensions
OM-149 701 Page 1
SECTION 3 – INSTALLATION
3-1.
CONNECTING THE PENDANT CONTROL
(Figures 3-1 And 3-2)
1.
Remove power source left side panel, and locate
terminal strip 1T.
2.
Route Pendant Control cord through the opening
in the power source front panel where the torch
and work cable are routed.
3.
Disconnect jumper link connected between terminals 9 and 10, and reconnect jumper link between terminals 8 and 9 on 1T.
4.
Connect the Pendant Control black contactor
switch lead to terminal 3 on 1T.
5.
Connect the Pendant Control white contactor
switch lead to terminal 4 on 1T.
6.
The Pendant Control must be internally connected to
the power source terminal strip 1T. To make connections, proceed as follows:
Connect the Pendant Control brown thickness
potentiometer maximum side lead (Point-A) to
terminal 7 on 1T.
7.
A. Connections For 750 And 1500 Models (Figure
3-1 And Diagram 6-1)
Connect the Pendant Control red thickness potentiometer wiper contact lead (Point-B) to terminal 8 on 1T.
8.
IMPORTANT: When the Remote Pendant Control is connected to the power source, the THICKNESS OUTPUT
CONTROL on the power source front panel is inoperative.
Connect the Pendant Control green thickness
potentiometer minimum side (ground) lead
(Point-C) to terminal 11 on 1T.
9.
Reinstall and secure power source left side panel.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
•
Shut down power source, and disconnect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other disconnecting device.
IMPORTANT: Torch coolant connections
shown apply to 1500 models only; terminal
strip 1T connections are the same for 750
and 1500 models.
Work (+) Output Terminal
Torch (-)/Coolant
Out Connector
Gas/Input Conductor
Pilot (+)/Coolant In
Connector
Work
Cable
1T
Detector Lead
1
2
3
4
5
N.O. Output Sensor
6
Command Ref. 7
Torch Switch
Reconnect Jumper
Link Between
Terminals 8 And 9
For Remote
Operations
Torch
Cable
Remote 8
Jumper Common 9
Shield Cup
Detector Leads
1 And 2
Panel 10
Signal Ground 11
Torch Switch
Leads 3 And 4
Connection
Label
Terminal
Strip T1
Left Front
Corner Of Unit
SB-129 411
Figure 3-1. Power Source Remote Connections And Information (750 And 1500 Models)
OM-149 701 Page 2
Work (+) Output
Terminal
Lower Front Panel
With Access Door Open
Gas/Air Output
Connector
Pilot (+)/Coolant
Out Connector
Torch (-)/Coolant
In Connector
Connection Label
Torch And Remote
Interface Control
Terminal Strip 1T
Torch Cable
Strain Relief
TORCH
SAFETY
1
TRIGGER
2
3
4
CURRENT
FEEDBACK
JUMPER MUST
BE HERE
REMOTE
FOR
FOR
CONTROL REMOTE PANEL
5
7
6
8
9
10
SA-127 362
S-0186
Figure 3-2. Power Source Remote Connections And Information (1500D Models)
B. Connections For 1500D Models (Figure 3-2 And
Diagram 6-1)
1.
Open power source lower front panel access
door and locate terminal strip 1T.
2.
Disconnect jumper link connected between terminals 9 and 10, and reconnect jumper link between terminals 8 and 9 on 1T.
3.
Connect the Pendant Control black contactor
switch lead to terminal 3 on 1T.
4.
Connect the Pendant Control white contactor
switch lead to terminal 4 on 1T.
5.
Connect the Pendant Control brown thickness
potentiometer maximum side lead (Point-A) to
terminal 10 on 1T.
6.
Connect the Pendant Control red thickness potentiometer wiper lead (Point-B) to terminal 8 on
1T.
7.
Connect the Pendant Control green thickness
potentiometer minimum side (ground) lead
(Point-C) to terminal 7 on 1T.
OM-149 701 Page 3
SECTION 4 – OPERATOR CONTROLS
Placing this switch in the OFF position deactivates the
torch. Pushing this switch to the MOMENTARY position
activates the torch; when the switch is released it returns to the OFF position.
Thickness
Output Control
Torch Output
Control Switch
4-2.
THICKNESS OUTPUT CONTROL (Figure
4-1)
The THICKNESS OUTPUT CONTROL provides a
means of selecting the desired output within the entire
range of the power source. The scale surrounding the
control is calibrated in percent (0-100) and should not be
read in inches. Rotating the control clockwise increases
the output of the power source.
A. 750 And 1500 Models
Leads
ST-150 802-A
Figure 4-1. Pendant Control
4-1.
TORCH OUTPUT CONTROL SWITCH (Figure
4-1)
When the Remote Pendant Control is connected to the
power source, the THICKNESS OUTPUT CONTROL
on the power source front panel is inoperative. The Remote Pendant Control THICKNESS OUTPUT CONTROL provides complete control of the minimum to
maximum output of the power source.
B. 1500D Models
ON
OFF
MOMENTARY
The TORCH OUTPUT CONTROL switch has three positions; ON, OFF, and MOMENTARY. Placing this
switch in the ON position activates the cutting torch.
When the Remote Pendant Control is connected to the
power source, the THICKNESS OUTPUT CONTROL
on the Remote Pendant Control functions as a fine output adjustment of the THICKNESS OUTPUT CONTROL on the power source front panel. For example, if
the THICKNESS OUTPUT CONTROL on the power
source is set at mid-point position, the Remote Pendant
Control will provide fine adjustment of one half of the
power source output. If full remote adjustment of the
maximum output of the power source is desired, the
THICKNESS OUTPUT CONTROL on the power
source must be set to the maximum position.
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1.
MAINTENANCE
Lockout/tagging procedures consist of padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other disconnecting device.
Usage and shop conditions will determine the frequency
and type of maintenance.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
•
Shut down power source, and disconnect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing.
OM-149 701 Page 4
1.
Every six months inspect the Pendant interconnecting cord for damage to or breaks in the insulation jacket. Repair or replace cord as necessary.
2.
Remove grease and grime from components;
moisture from electrical parts and cord.
5-2.
TROUBLESHOOTING
power source Owner’s Manual for possible problems
caused by power source malfunctions.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
•
Shut down power source, and disconnect input power employing lockout/tagging procedures before inspecting, maintaining, troubleshooting, or servicing.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other disconnecting device.
Troubleshooting to be performed only by qualified persons.
It is assumed that the unit was installed properly according to Section 3 of this manual, the operator is familiar
with the function of the controls, the power source was
working properly, and that the trouble is not related to
the cutting process. The following information is
supplied to diagnose and provide remedies for some of
the troubles that may develop in this unit. Check the
Use this information in conjunction with the circuit diagram while performing troubleshooting procedures. If
the trouble is not remedied after performing these procedures, contact the nearest Factory Authorized Service Station. In all cases of equipment malfunction, the
manufacturer’s recommendations should be strictly followed.
Problems with this unit fall into two categories: 1) front
panel components, or 2) the interconnecting cord and
connections.
If the controls do not function at all or improperly, the
connections may be loose or the cord may be damaged
internally, interrupting signals between the power
source and this unit. Check connections, and tighten if
applicable. Check continuity of cord, and replace if necessary.
If everything on the remote control functions except for a
particular switch or potentiometer, the problem is most
likely an inoperative component. Replace the inoperative component.
SECTION 6 – ELECTRICAL DIAGRAMS
Circuit Diagram No. SA-146 052-B
Diagram 6-1. Circuit Diagram
OM-149 701 Page 5
SECTION 7 – PARTS LIST
Item
No.
Dia.
Mkgs.
Part
No.
042 585
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
.............
.............
.............
. . . . . R1 . . . .
. . . . . S1 . . . .
.............
.............
.............
097 922
146 235
134 429
035 897
150 080
148 348
134 900
052 246
Description
Quantity
Figure 7-1. Pendant Control
. . . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . PLATE, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . CASE SECTION, front/end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . POTENTIOMETER, C sltd sft 1/T 2W 1000 ohm . . . . . . . . . . . . . . . . . . . . 1
. . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . CASE SECTION, back/sides/end/baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . STRAIN RELIEF, cable flexible .270-.480 cable . . . . . . . . . . . . . . . . . . . . . 1
. . . CABLE, pwr No. 20ga 5/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20ft
4
5
6
3
2
1
7
8
ST-149 968-B
Figure 7-1. Pendant Control
BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.
OM-149 701 Page 6
Notes
Notes