MAKESafe Tools PTB-V120-P1 User manual
Power Tool Brake
User Manual
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 12/29/21 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
Identifying Receptacles 6
Identifying Motor Type 6
Reverse-Threaded Spindles 7
Limitations of Operation 7
Recognizing Existing Controls 8
How to Check for a Magnetic Switch. 9
Installation 10
Occupational Safety Standards 10
Calibration 11
Normal Operation 12
Inspections & Maintenance 12
Troubleshooting 12
Service 15
MAKESafe Tools, Inc. | Copyright 2021 | Last Updated 12/29/21 Page 2
Introduction
Application
The MAKESafe Power Tool Brake is a
safety device that provides accidental
restart protection, motor braking, 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 brake with.
●Brake (noun) - The MAKESafe Power
Tool Brake.
●Brake (verb) - The act of decelerating a
power tool.
●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
PTB-V120-P1
PTB-V240-P1
PTB-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)
4.1” x 2.2” x 0.9” in.
(105 mm x 57 mm x 23 mm)
Weight
3 lbs
(1.4 kg)
3.3 lbs
(1.5 kg)
Rated Output Voltage (motoring)
120VAC
240VAC
240VAC
Rated Output Voltages (braking)
0 - 90 VDC
0 - 180 VDC
0 - 240 VDC
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. This device is only compatible with direct-powered induction motor tools. To verify
compatibility, see included compatibility guide
2. 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.
MAKESafe Tools, Inc. | Copyright 2021 | Last Updated 12/29/21 Page 3
Device Diagrams
Main Enclosure
7.25” L x 5.0” W x 2.22" H
(185 mm x 127 mm x 57 mm)
Standard 3-Button Control Panel
4.1” x 2.2” x 0.9” in.
(105 mm x 57 mm x 23 mm)
*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 Brake.
● The power tool you intend to use with this brake 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 your
brake.
This is typically marked on the motor
itself and on the top of the brake.
❏Confirm the motor horsepower on the power tool is
rated at or below the horsepower rating of your
brake.
This is typically marked on the motor
itself.
❏Confirm the power tool has the same plug and
receptacle type as your brake.
See section below titled Identifying
Receptacles. If you plan to hardwire
the device, you can ignore this
section.
❏Confirm the power tool uses an AC induction motor
for its motive force.
See section below titled Identifying
Motor Type
❏Confirm the business end of the power tool is not
mounted on a reverse threaded spindle or confirm
that you will operate the brake within the limits
described in the section Understanding
Reverse-Threaded Spindles.
See section titled Understanding
Reverse-Threaded Spindles.
❏Confirm the power tool contains only a simple on/off
switch (for plug-and-play installation) or contact
MAKESafe Tools for guidance on how to install the
brake on your particular machine.
See section titled Recognizing
Existing Controls
❏Confirm the power tool does not contain an integral
circuit breaker.
Review your tool manual and inspect
your tool to ensure there are no
integral circuit breakers.
MAKESafe Tools, Inc. | Copyright 2021 | Last Updated 12/29/21 Page 5
Identifying Receptacles
Plug & Receptacle Types
Single-Phase
120V
The most common type of plug
and receptacle that you will find in
most american homes and
businesses.
Single-Phase
240V
A common plug and receptacle
type for single-phase 240VAC
applications.
Three-Phase
240V
A common locking plug and
receptacle type for three-phase
240VAC applications.
Other
Many alternate configurations exist. If you need assistance determining machine
voltage or plug type, please contact MAKESafe Tools.
Identifying Motor Type
Power tool motors come in a wide variety of shapes, sizes, and types. The intent of this section is
to help you identify if your tool uses an AC Induction Motor.
You have an Induction Motor if …
● You see one or more external
capacitors on your motor. These often
appear as cylindrical or rectangular
lumps on the exterior of your motor (see
photos).
● You have a heavy stationary (not
“portable” or “jobsite”) power tool. Tools
like stationary band saws, table saws,
jointers, and disc sanders typically use
AC Induction Motors.
You do not have an Induction Motor if…
● Your tool is hand held. Tools like a
corded drill or angle grinder do not use
an AC Induction Motor.
● Your motor uses brushes. Brushes are
a common maintenance item on other
motor types. If your power tool manual
describes brushes, you see brush caps
on your motor (image below),or you see
sparking from your motor, your power
tool does not have an AC induction
motor.
(handheld power tools example)
MAKESafe Tools, Inc. | Copyright 2021 | Last Updated 12/29/21 Page 6
Reverse-Threaded Spindles
Reverse threaded spindles are common on some
types of power tools. “Reverse threaded” just
means that the torque of the motor in normal
operation puts force on the arbor nut to tighten
the “business end” onto the spindle. This is an
inherent safety measure in all power tools and
helps to make sure that cutting blades and
sanding/grinding surfaces don’t loosen during
normal operation.
When a motor brake is used to slow a machine’s
operation, the momentum of the “business end”
puts a loosening force onto the arbor nut. If this
force is sufficiently large, it can loosen or
unscrew the arbor nut. For this reason, you never
want to apply excessive braking torque to a
reverse threaded spindle. To prevent excessive
braking torque on reverse-threaded arbor tools,
adhere to the following operational limitations.
Limitations of Operation
If you have a machine with a reverse threaded spindle, ensure that you follow the rules and
limitations below. Failure to follow the limitations below may increase risk of injury.
1. Check tightness of arbor nut prior to
installation and as a regular
maintenance item.
Regularly check the tightness of your arbor
nut and compare to the listed torque
specifications in your tool manual. To
prevent loosening, use double-nuts or other
positive locking methods.
2. Calibrate braking torque to bring the tool
to stop in no less than two seconds.
When braking a tool with a reverse-threaded
spindle, never calibrate the brake to stop the
tool in less than two seconds. Refer to the
calibration section of this manual for a
discussion of how to calibrate your device.
3. Never use The MAKESafe Power Tool
Brake to brake high inertia
reverse-threaded loads, such as:
○ a lathe with a reverse-threaded
spindle.
○ A saw with a dado or other
non-standard blade installed.
The larger the business end, the more
loosening force will be applied during
braking. For example, a lathe with a
reverse-threaded spindle should never be
used with a motor brake. The chuck has
sufficient mass to unscrew itself from the
spindle during braking and is a severe
safety risk.
4. Always make sure that all power tool
wheel guards, blade guards, shields,
and other manufacturer-provided and
OSHA required guards are properly
installed and adjusted.
Power tools should never be operated
without manufacturer-provided and OSHA
required guards.
MAKESafe Tools, Inc. | Copyright 2021 | Last Updated 12/29/21 Page 7
Recognizing Existing Controls
The MAKESafe Power Tool Brake is designed for plug-and-play 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, electronic dials or variable controls, magnetic switches, or variable
frequency drives - additional wiring and consideration may be required. Contact MAKESafe Tools
for assistance and we’ll help you to determine the best way to proceed with the installation.
Tip:Some existing controls can be safely bypassed (as the function also exists in the Power
Tool Brake) but this should be confirmed by an expert on a case-by-case basis. Please call
MAKESafe Tools for assistance.
Warning: Below are some examples of existing controls that would prevent a plug-and-play
installation. If your machine has any of the following controls, please contact MAKESafe Tools
before proceeding with your installation:
Note: this is a list of examples but does not represent every possible control. If in doubt, contact
MAKESafe Tools.
Magnetic Switch
Note: Many of the switches
shown above could be a
magnetic switch or a simple
on/off switch as they look similar.
The following section provides a
simple procedure to determine if
your machine has a magnetic
switch installed.
Starter
Variable Frequency Drive (VFD), Inverter, or Electronic Speed Control
MAKESafe Tools, Inc. | Copyright 2021 | Last Updated 12/29/21 Page 8
How to Check for a Magnetic Switch.
If your power tool utilizes spring-loaded or momentary push buttons for start and/or stop
operations (as opposed to a toggle switch or other mechanical switch), follow the procedures
below to confirm that your power tool switch is not a magnetic switch.
Note: This evaluation is for power tools with relatively simply on/off controls and not for evaluating
larger control systems. Before proceeding, confirm that the working area is free of hazards and
that it is safe to operate the power tool.
Step 1: Turn the power tool ON.
Step 2: While the power tool is ON and running, remove power by unplugging the power tool or
by switching-off power at an electrical disconnect switch or circuit breaker.
Step 3: Count to 5 then restore power by plugging-in the power tool or by switching-on power at
the disconnect switch or breaker.
Evaluate:
● If the power tool automatically turns ON when power is restored, then your power tool
does not have protection from unintentional restarts. You do not have a magnetic
switch.
● If the power tool remains off when power is restored and requires manual turn-on to
restart, then your power tool does have protection from unintentional restarts. It is likely
that you have a magnetic switch or other type of control installed. Contact MAKESafe
Tools before proceeding with your installation.
MAKESafe Tools, Inc. | Copyright 2021 | Last Updated 12/29/21 Page 9
Installation
You can find a video companion for these installation and calibration instructions on our website at
www.makesafetools.com.
1. Unbox your new brake and inspect the device and shipping containers for any damage that
may have been incurred during shipping.
2. Find the braking torque adjustment and use a small flathead screwdriver to confirm that it is
turned counter-clockwise as far as it will go. This will set the braking torque to the minimum
for your first test. This only requires gentle turning force - excessive force on the adjuster can
damage the device.
3. Find the braking time adjustment and use a small flathead screwdriver to confirm that it is
turned counter-clockwise as far as it will go. This will set the braking period to the minimum
for your first test. This only requires gentle turning force - excessive force on the adjuster can
damage the device.
4. Plug your control panel into your brake by inserting the silver connector on the control panel
cable into the mating connector on the brake. 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).
5. Plug your power tool into the power tool receptacle on the brake. It is important to plug
your tool into the brake before plugging the brake into the wall.
6. Once your power tool is plugged into the brake, plug the brake into a power outlet.
7. Mount the control panel to your power tool in a convenient to access location.
8. 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.
9. Now that you have completed the installation, proceed to the Calibration section to calibrate
your device.
Occupational Safety Standards
ANSI B11.19-2010, Performance Criteria for Safeguarding, states the following:
Code Excerpt
(Requirement)
Code Excerpt (Explanation)
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 your
brake, MAKESafe Tools
recommends the following in
order to comply:
1) Cover the original tool switch
on your power tool to prevent
tampering and to maintain its
‘on’ position.
2) Use a plug lockout enclosure
or other fastening means to
prevent the unauthorized
unplugging of the power tool
from the brake.
*It is the end user's 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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Calibration
While the MAKESafe Power Tool brake is capable of stopping your tool instantly, this sudden
action should be avoided. The purpose of this calibration section is to find an optimal braking
setting for your power tool.
You have two means of adjustment on this safety device, described below:
Braking Torque
Controls how strong of a braking force
is applied to your motor during braking.
Braking Period
Controls how long the braking torque is
applied.
Notes on Calibration:
● The first calibration step will apply a very small braking torque for a very short time and may
not be noticeable. This is normal. Proceed with calibration, making only incremental changes
for each braking attempt.
● We recommend finding a braking torque and braking time combination that brings your power
tool to a complete stop in between one and three seconds. A good rule of thumb is to aim for
a braking time equivalent to or greater than the time it takes your tool to come up to speed
during normal operation.
● You will hear an audible buzzing sound during and after braking. This is normal. Calibrate the
device such that there is a buzzing sound for approximately 0.5 seconds after the tool has
come to a complete stop.
Making Adjustments:
Adjustments are made by inserting a small flathead
screwdriver into the holes on the side of the brake
enclosure and gently turning counter-clockwise (to
turn down) or clockwise (to turn up) the respective
setting. You will feel the adjustment hit a stop at the
maximum and minimum values. This only requires
gentle turning force - excessive force on the adjuster
can damage the device.
Calibration Steps:
1. Find the braking torque and braking time adjustment and use a small screwdriver to confirm
that it is turned counter-clockwise as far as it will go. This will set the braking torque and
braking time to the minimum for your first test. This only requires gentle turning force -
excessive force on the adjuster can damage the device.
2. Turn on your power tool by using the green start button on the control panel. It should start
normally.
3. Once your power tool has come up to speed, press the red stop button on the control panel.
This will immediately disconnect power from the tool and apply a braking torque for a set
period of time.
4. If this braking action does not bring your power tool to a complete stop, increase your braking
period or braking torque, making small incremental adjustments. Never turn an adjustment
more than 1/8 of a turn at any one time.
5. Repeat until you achieve the desired result.
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Normal Operation
The MAKESafe Power Tool Brake is designed to make normal operation of the device simple and
straightforward. To operate your power tool with the MAKESafe Power Tool Brake 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 and brake your tool.
4. If the emergency stop is activated, release the stop button by rotating it 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 that the tool is coming to a complete stop in the expected time.
2. Re-calibrate the device every time a blade or cutting tool is replaced, tooling is
changed, or a machine is serviced.
Troubleshooting
Problem
Solution
My tool will not start. Every time I
try to turn my tool on, the brake
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 power tool operates normally,
but when I try to brake the tool,
there is no braking action.
Your braking torque may be set too low. Ensure that
you have followed the instructions for installation and
calibration.
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:
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