December 1991 FORM: OM-149 701
MODEL: PAC Pendant Control
OWNER’S MANUAL
MILLER ELECTRIC Mfg. Co.
A Miller Group Ltd., Company
P.O. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
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 equip-
ment. 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 PRINTED IN U.S.A.
OM-149 701 – 12/91
Before unpacking equipment, check carton for any
damage that may have occurred during shipment. File
any claims for loss or damage with the delivering car-
rier. Assistance for filing or settling claims may be ob-
tained from the distributor and/or the equipment manu-
facturer’s Transportation Department.
When requesting information about this equipment, al-
ways provide the Model Designation and Serial or Style
Number.
Use the following spaces to record the Model Designa-
tion and Serial or Style Number of your unit. The infor-
mation is located on the rating label or nameplate.
Model
Serial or Style No.
Date of Purchase
RECEIVING-HANDLING
TABLE OF CONTENTS
Section No. Page No.
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Safety Alert Symbol And Signal Words 1. . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS
2-1. Description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION
3-1. Connecting The Pendant Control 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATOR CONTROLS
4-1. Torch Output Control Switch 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Thickness Output Control 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1. Maintenance 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Troubleshooting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAMS
Diagram 6-1. Circuit Diagram 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – PARTS LIST
Figure 7-1. Pendant Control 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 Section 1 – Safety Rules For Plasma Arc Cutting
(PAC) 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 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 thick-
ness output control. This unit is equipped with a 20 ft.
(6.1 m) interconnecting cord.
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 Diagram 6-1)
IMPORTANT: When the Remote Pendant Control is con-
nected 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
1
2
3
4
5
6
7
8
9
10
11
Detector Lead
Torch Switch
N.O. Output Sensor
Command Ref.
Remote
Jumper Common
Panel
Signal Ground
1T
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 T1
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
Diagram 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.
OM-149 701 Page 4
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)
ON
OFF
MOMENTARY
The TORCH OUTPUT CONTROL switch has three po-
sitions; 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 re-
turns to the OFF position.
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
When the Remote Pendant Control is connected to the
power source, the THICKNESS OUTPUT CONTROL
on the power source front panel is inoperative. The Re-
mote Pendant Control THICKNESS OUTPUT CON-
TROL provides complete control of the minimum to
maximum output of the power source.
B. 1500D Models
When the Remote Pendant Control is connected to the
power source, the THICKNESS OUTPUT CONTROL
on the Remote Pendant Control functions as a fine out-
put adjustment of the THICKNESS OUTPUT CON-
TROL 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
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 neces-
sary.
2. Remove grease and grime from components;
moisture from electrical parts and cord.
OM-149 701 Page 5
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. In all cases of equipment malfunction, the
manufacturer’s recommendations should be strictly fol-
lowed.
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 nec-
essary.
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 DIAGRAMS
Circuit Diagram No. SA-146 052-B
Diagram 6-1. Circuit Diagram
OM-149 701 Page 6
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 052 246 CABLE, pwr No. 20ga 5/c (order by ft) 20ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
4
7
8
56
ST-149 968-B
Figure 7-1. Pendant Control
BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.
Notes
Notes
/