MAKESafe Tools PTC Series User manual

Power Tool Control
PTC Series
Note: The image above represents one particular configuration of this product though this manual
can be used for all product configurations.
COPYRIGHT © 2021 BY MAKESAFE TOOLS, INC
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR
FORM WITHOUT THE WRITTEN APPROVAL OF MAKESAFE TOOLS, INC.

Warning
You have just purchased a safety device and this manual contains critical safety instructions on
the proper setup, operation, maintenance, and service of this safety device. Keep this
document readily available, refer to it often, and use it to instruct other operators.
Failure to read, understand and follow the instructions in this manual may result in property
damage and/or serious personal injury - including amputation, electrocution, or death. The
owner of this device is solely responsible for its safe use.
The manufacturer will not be held liable for injury or property damage from negligence, failure
to adhere to this documentation, improper training, device modifications or misuse.
Warning
This safety device is intended to be installed as a retrofit to a very specific class of power tool.
Read and understand the intended use and limitations of this device before installing it.
The manufacturer has made reasonable attempts to test and describe this device’s
compatibility with different power tools but cannot certify or guarantee its compatibility with any
one power tool. It is the responsibility of the owner of this device to follow the guidance
provided below to determine compatibility.
Warning
All induction motors, such as those running power tools, have inherent limitations on their
maximum number of starts per hour and their minimum rest time between starts, as described
in NEMA MG 10, Table 8. Motor braking contributes additional heat to the motor and can
significantly impact these values. Reduce allowable startups per hour by a factor of 0.5 and
increase rest time between starts by a factor of 1.5, until such time that a more precise factor
can be determined by the operator for a specific tool and set of conditions.
Warning
When this device is in braking mode, it delivers high voltage direct current to your tool. If you
operate the tool switch during braking, you will destroy or significantly reduce the life of your
tool switch while also increasing the risk of electrical fire. Never operate your tool switch during
braking and always cover the tool switch as described in the instructions below.
Warning
RISK OF ELECTRIC SHOCK
DISCONNECT ALL SOURCES OF POWER PRIOR TO SERVICING THIS DEVICE.
Important!
Retain this manual and include it with the original user manual for the machine on which this
device is installed.
MAKESafe Tools, Inc. | Copyright 2021 | Last Updated 1/4/22 Page 1

Table of Contents
Table of Contents 2
Introduction 3
Application 3
Compatibility 3
Glossary 3
Specifications 3
Device Diagrams 4
Compatibility Checklist 5
Recognizing Existing Controls 6
Installation 6
Occupational Safety Standards 7
Normal Operation 8
Inspections & Maintenance 8
Troubleshooting 8
Service 11
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Introduction
Application
The MAKESafe Power Tool Control is a
safety device that provides accidental
restart protection, on/off control, and
emergency stop functions to stationary
power tools and machinery.
Compatibility
This safety device is not compatible with all
power tools. Please complete the included
compatibility checklist below before
installing this device.
Glossary
●Power Tool - the tool or machinery that
you intend to use this product with.
●Control Panel - The provided remote
enclosure with start, stop, and e-stop
buttons.
●Business End - The part of the power
tool that performs an operation on a work
piece (i.e. saw blade, grinding wheel,
etc.).
Specifications
PTC-V120-P1
PTC-V240-P1
PTC-V240-P3
Rated Input Voltage
120 VAC
1 PH, 60Hz
(50 Hz options available)
240 VAC
1 PH, 60Hz
(50 Hz options available)
240 VAC
3 PH, 60Hz
(50 Hz options available)
Rated Horsepower (UL508)
1.5 HP
3.0 HP
5.0 HP
Rated Current (UL508)
20 A
17 A
15 A
Approvals
UL508: Industrial Control Devices
CSA #14-13: Industrial Control Equipment
LISTING NUMBER: E114885
Control Voltage
5 VDC
Control Current
< 100mA
Dimensions
(main enclosure)
7.25” L x 5.0” W x 2.22" H
(185 mm x 127 mm x 57 mm)
Dimensions
(standard control panel)
3.0” x 2.0” x 0.9” in.
(76.20 mm x 50.80 mm x 22.86 mm)
Weight
3 lbs
(1.4 kg)
3.3 lbs
(1.5 kg)
Rated Output Voltage (motoring)
120VAC
240VAC
240VAC
Plug & Receptacle Type
NEMA 5-15
(custom and international
options available)
NEMA 6-15
(custom and international
options available)
NEMA L15-20
(custom and international
options available)
Notes:
1. Suitable for connection in the field to a branch circuit rated not more than 20 amperes and
capable of delivering not more than 5,000 rms symmetrical amperes.
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Device Diagrams
Main Enclosure
7.25” L x 5.0” W x 2.22" H
(185 mm x 127 mm x 57 mm)
Control Panel
3.0” x 2.0” x 0.9” in.
(76.20 mm x 50.80 mm x 22.86 mm)
Control Panel (Industrial)
3-Button Control Panel
*All dimensions are for enclosure and do not include dimensions of buttons, plugs, and cable
glands.
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Compatibility Checklist
Getting Ready
This safety device is meant to be installed and used in conjunction with a power tool. Prior to
completing the compatibility checklist, collect the following items:
● The MAKESafe Power Tool Control.
● The power tool you intend to use with this product with.
● The instruction manual and specifications sheet for your power tool.
As the owner of this safety device and your pre-existing power tool, it is your responsibility to
complete this compatibility checklist before installing this safety device. If you cannot complete the
checklist, do not install the device.
Checklist
For More Information
❏Confirm that the voltage, number of phases, and
frequency of your power tool match the voltage,
number of phases, and frequency indicated on the
product.
This is typically marked on the motor
itself and on the top of the product.
❏Confirm the motor horsepower on the power tool is
rated at or below the horsepower rating of your
product.
This is typically marked on the motor
itself.
❏Confirm the power tool contains only a simple on/off
switch and no other digital electronics, emergency
stop switches, reversing switches, or other motor
controls.
See section titled Recognizing
Existing Controls
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Recognizing Existing Controls
The MAKESafe Power Tool Control is designed for use on tools with a simple on/off switch and no
pre-existing electronic controls. If your power tool has any other controls, electronic indicators,
digital displays, starters, dials or variable controls, magnetic switches, or variable frequency drives
- do not install the MAKESafe Power Tool Control. If you have questions about compatibility,
contact MAKESafe Tools for assistance.
Installation
You can find a video companion for these installation and calibration instructions on our website at
www.makesafetools.com.
1. Unbox the product and inspect the device and shipping containers for any damage that may
have been incurred during shipping.
2. Plug your control panel into the product by inserting the silver connector on the control panel
cable into the mating connector on the product. The connector will only fit in one orientation
so rotate it gently until it snaps into place. Once mated, manually screw the control panel
connector clockwise to lock it in place. Hand-tighten the connector until snug (do not use
tools to tighten).
3. Plug your power tool into the power tool receptacle on the product. It is important to plug
your tool into the product before plugging the product into the wall.
4. Once your power tool is plugged into the product, plug the product into a power outlet.
5. Mount the control panel to your power tool in a convenient to access location.
6. Turn the on/off switch on your power tool to the ‘on’ position. Note that the power tool
switch must now remain in the ‘on’ position at all times. To prevent tampering or otherwise
being turned ‘off’, cover the power tool switch. If this device is being used in a workplace,
refer to the Occupational Safety Standards section for further information.
7. Now that you have completed the installation, proceed to the Calibration section to calibrate
your device.
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Occupational Safety Standards
ANSI B11.19-2010, Performance Criteria for Safeguarding, states the following:
Code Excerpt
(Requirement)
Code Excerpt
(Explanatory Information)
Relevance & Applicability*
“The user shall ensure that
guards are installed,
maintained, and operated
so as to protect against:
unauthorized adjustment
or circumvention;”
(ANSI B11.19-2010 7.2.6)
“Guards installed in such a
manner that tools are
necessary for their
adjustment or removal
may satisfy this
requirement.”
“Examples of some types
of fasteners that should
not be used are: slotted or
Phillips head screws; wing
nuts; Magnets; latches and
hasps; hooks and eyes.”
(ANSI B11.19-2010
E7.2.6)
After the installation of the
MAKESafe Power Tool
Control is complete,
MAKESafe Tools
recommends the following
in order to comply with
ANSI B11.19 7.2.6:
1) Cover the tool switch on
your power tool to prevent
tampering and to maintain
its ‘on’ position. Use
fastening means to comply
with provided explanatory
information.
2) Use a plug lockout
enclosure or other
fastening means to
prevent the unauthorized
unplugging of the power
tool from the MAKESafe
Power Tool Control.
*It is the end users responsibility to read and interpret all occupational safety requirements along
with their local authority having jurisdiction. Interpretations provided here are the opinion of
MAKESafe Tools.
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Normal Operation
The MAKESafe Power Tool Control is designed to make normal operation of the device simple
and straightforward. To operate your power tool with the MAKESafe Power Tool Control installed,
follow the procedure below:
1. Turn on your power tool by using the green start button on the control panel.
2. Use your power tool.
3. Press the red stop button on the control panel to stop your tool.
4. If the emergency stop is activated, release the emergency stop button by rotating it
gently clockwise.
Inspections & Maintenance
MAKESafe Tools recommends the following inspections:
1. At the beginning of each shift, cycle the tool through the complete on/off cycle and
visually verify proper operation.
Troubleshooting
Problem
Solution
My tool will not start. Every time I
try to turn my tool on, the product
makes a clicking noise, and the
tool fails to start.
You may have engaged low voltage protection. This
can happen due to low service voltage or under-rated
conductors. Do not use this device with an extension
cord.
My tool will not start.
You may have blown the device’s internal fuse.
Unplug the device from the wall and remove the cover
using a phillips screwdriver. Remove the fuse and test
for continuity. If the fuse is blown, first identify the
source of the fault. Contact MAKESafe Tools, Inc. for
fuse replacement specifications. This device does
not use a standard fuse.
Be sure to replace the cover before plugging in the
device.
I don’t know what’s happening
and I need help.
Please contact MAKESafe Tools at:
[email protected] or [phone].
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Service
If you have any questions or your device needs service, please contact us.
[email protected]
[phone]
www.makesafetools.com
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