Miller KG000000 Owner's manual

Brand: Miller

Model: KG000000

Type: Owner's manual

This manual is also suitable for

PAC PENDANT CONTROL

Processes

Description

Plasma Arc Cutting

Remote Pendant Control

OM-149 701B October 1996

PAC Pendant Control

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www.MillerWelds.com

OM-149 701 Page 1

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1. GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various la-

bels, 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 nameplate of this unit uses international symbols

for labeling the front panel controls. The symbols also

appear at the appropriate section in the text.

B. Safety

The installation, operation, maintenance, and trouble-

shooting of arc welding equipment requires practices

and procedures which ensure personal safety and the

safety of others. Therefore, this equipment is to be in-

stalled, operated, and maintained only by qualified per-

sons in accordance with this manual and all applicable

codes such as, but not limited to, those listed at the end

of Plasma Arc Cutting Safety Precautions in the power

source Owner’s Manual.

1-2 SAFETY ALERT SYMBOL AND SIGNAL

WORDS

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 instruc-

tions.

This safety alert symbol is used with the signal

words WARNING and CAUTION to call atten-

tion to the safety statements.

WARNING statements identify procedures or

practices which must be followed to avoid seri-

ous personal injury or loss of life.

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 equip-

ment.

SECTION 2 – SPECIFICATIONS

2-1/2 in

(64 mm)

2-3/4 in

(70 mm)

5-1/2 in

(140 mm)

ST-150 802-A

Figure 2-1. Dimensions

2-1. DESCRIPTION

This unit is a Remote Pendant Control for Plasma Arc

Cutting (PAC) power sources equipped with remote ca-

pabilities at an internal terminal strip. When properly

connected to the power source, this unit provides re-

mote contactor and thickness output control. This unit is

equipped with a 20 ft (6.1 m) interconnecting cord.

WARNING: Read and follow all safety infor-

mation in the cutting power source manual

before using this control.

OM-149 701 Page 2

SECTION 3 – INSTALLATION

3-1. CONNECTING THE PENDANT CONTROL

(Figures 3-1 And 3-2)

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down power source, and disconnect in-

put power employing lockout/tagging proce-

dures before inspecting, maintaining, or serv-

icing.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

The Pendant Control must be internally connected to

the power source terminal strip 1T. To make connec-

tions, proceed as follows:

A. Connections For 750 And 1500 Models (Figure

3-1 And Figure 6-1)

IMPORTANT: When the Remote Pendant Control is

connected to the power source, the Thickness Output

Control on the power source front panel is inoperative.

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 ter-

minals 9 and 10, and reconnect jumper link be-

tween 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. Connect the Pendant Control brown thickness

potentiometer maximum side lead (Point-A) to

terminal 7 on 1T.

7. Connect the Pendant Control red thickness po-

tentiometer wiper contact lead (Point-B) to termi-

nal 8 on 1T.

8. 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.

SB-129 411

Detector Lead

Torch Switch

N.O. Output Sensor

Command Ref.

Remote

Jumper Common

Panel

Signal Ground

Work (+) Output Terminal

Gas/Input Conductor

Pilot (+)/Coolant In

Connector

Work

Torch

Cable

Shield Cup

Detector Leads

1 And 2

Torch Switch

Leads 3 And 4

Terminal

Left Front

Corner Of Unit

Connection

Label

Torch (-)/Coolant

Out Connector

Reconnect Jumper

Link Between

Terminals 8 And 9

For Remote

Strip 1T

Cable

Operations

IMPORTANT: Torch coolant connections

shown apply to 1500 models only; terminal

strip 1T connections are the same for 750

and 1500 models.

Figure 3-1. Power Source Remote Connections And Information (750 And 1500 Models)

OM-149 701 Page 3

SA-127 362

S-0186

12345678910

TORCH

SAFETY TRIGGER

CURRENT

FEEDBACK

REMOTE

CONTROL

FOR

REMOTE

FOR

PANEL

JUMPER MUST

BE HERE

Work (+) Output

Terminal

Torch (-)/Coolant

In Connector

Connection Label

Torch Cable

Strain Relief

Lower Front Panel

With Access Door Open

Gas/Air Output

Connector

Pilot (+)/Coolant

Out Connector

Torch And Remote

Interface Control

Terminal Strip 1T

Figure 3-2. Power Source Remote Connections And Information (1500D Models)

B. Connections For 1500D Models (Figure 3-2 And

Figure 6-1)

1. Open power source lower front panel access

door and locate terminal strip 1T.

2. Disconnect jumper link connected between ter-

minals 9 and 10, and reconnect jumper link be-

tween 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 po-

tentiometer 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.

C. Connections For 1000 And 1250 Models

(Figure 3-3 And Figure 6-1 )

1. Remove power source left side panel, and locate

terminal strip 1T.

2. Route Pendant Control cord through the third

opening in the power source front panel below

where the torch and work cable are routed.

3. Disconnect jumper link connected between ter-

minals 9 and 10, and reconnect jumper link be-

tween 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. Connect the Pendant Control brown thickness

potentiometer maximum side lead (Point-A) to

terminal 7 on 1T.

7. Connect the Pendant Control red thickness po-

tentiometer wiper contact lead (Point-B) to termi-

nal 8 on 1T.

8. 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.

OM-149 701 Page 4

Torch

Switch

N.O.

Output

Sensor

Command

Ref.

Remote

Jumper

Common

Panel

Signal

Ground

S-169 259

Ref. ST-159 466-C / Ref. ST-150 802-A

+10 Volts DC

Wiper

GND

Terminal

Strip 1T

Connection

Label

Jumper

Link

Black Lead

White Lead

Brown Lead

Red Lead

Green Lead

Figure 3-3. Power Source Connections And Information (1000 And 1250 Models)

OM-149 701 Page 5

SECTION 4 – OPERATOR CONTROLS

Thickness

Output Control

Torch Output

Control Switch

Leads

ST-150 802-A

Figure 4-1. Pendant Control

4-1. TORCH OUTPUT CONTROL SWITCH (Figure

4-1)

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. 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.

4-2. THICKNESS OUTPUT CONTROL (Figure

4-1)

The Thickness Output Control provides a means of se-

lecting the desired output within the entire range of the

power source. The scale surrounding the control is cali-

brated in percent (0-100) and should not be read in in-

ches. Rotating the control clockwise increases the out-

put of the power source.

A. For All Models Except 1500D

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. For 1500D Models

When the Remote Pendant Control is connected to the

power source, the Thickness Output Control on the Re-

mote Pendant Control functions as a fine output adjust-

ment of the Thickness Output Control on the power

source front panel. For example, if the Thickness Out-

put Control on the power source is set at mid-point posi-

tion, the Remote Pendant Control will provide fine ad-

justment of one half of the power source output. If full re-

mote 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

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 in-

put power employing lockout/tagging proce-

dures before inspecting, maintaining, or serv-

icing.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

1. Every six months inspect the Pendant intercon-

necting cord for damage to or breaks in the insu-

lation jacket. Repair or replace cord as

necessary.

2. Remove grease and grime from components;

moisture from electrical parts and cord.

OM-149 701 Page 6

5-2. TROUBLESHOOTING

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down power source, and disconnect in-

put power employing lockout/tagging proce-

dures before inspecting, maintaining, trouble-

shooting, or servicing.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

Troubleshooting to be performed only by quali-

fied persons.

It is assumed that the unit was installed properly accord-

ing 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

power source Owner’s Manual for possible problems

caused by power source malfunctions.

Use this information in conjunction with the circuit dia-

gram while performing troubleshooting procedures. If

the trouble is not remedied after performing these pro-

cedures, contact the nearest Factory Authorized Ser-

vice Station/Service Distributor. In all cases of equip-

ment malfunction, the manufacturer’s recommenda-

tions 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 inopera-

tive component.

SECTION 6 – ELECTRICAL DIAGRAM

Circuit Diagram No. SA-146 052-C

Figure 6-1. Circuit Diagram For Remote Pendant Control

OM-149 701 Page 7

SECTION 7 – PARTS LIST

Part

No.

Dia.

Mkgs.

Figure 7-1. Pendant Control042 585

Item

No. Description Quantity

1 097 922 KNOB, pointer .875dia x .250 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 146 235 PLATE, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 134 429 CASE SECTION, front/end 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 R1 035 897 POTENTIOMETER, C sltd sft 1/T 2W 1000 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 S1 150 080 SWITCH, tgl SPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 148 348 CASE SECTION, back/sides/end/baffle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 134 900 STRAIN RELIEF, cable flexible .270-.480 cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 175 284 CABLE, port No. 20ga 5/c (order by ft) 20ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146 112 BLANK, snap-in nyl .218mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-149 968-B

Figure 7-1. Pendant Control

BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.