Miller KB000000 Owner's manual

Brand: Miller

Model: KB000000

Category: Welding System

Type: Owner's manual

This manual is also suitable for

PAC PENDANT CONTROL

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

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 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)

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-149 968-B

Figure 7-1. Pendant Control

BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.