OPERATOR'S MANUAL AND SAFETY INSTRUCTIONS WITH INSTALLATION, TROUBLESHOOTING, INSPECTION AND MAINTENANCE INSTRUCTIONS SMART-C SERIES Microprocessor Controlled Chuck Control O.S. WALKER Rockdale Street, Worcester, MA 01606 (508)-853-3232 FAX (508)-852-8649 3508 Glenridge Drive, Chino Hills, CA 91709 (909)-597-4785 FAX (909)-597-0581 901 Arvin Avenue, Stoney Creek, Ontario, L8E5N9 Canada (905)-643-3338 In Canada: 1-800-267-4678 FAX (905)-643-6111 www.walkermagnet.com Email: info@walkermagnet.
O.S. WALKER Co., Inc.
TABLE OF CONTENTS 1 INTRODUCTION...............................................................................................................................................................1-1 2 SAFETY INSTRUCTIONS ................................................................................................................................................2-1 2.1 GENERAL SAFETY RULES ..........................................................................................................................
TABLE OF TABLES TABLE 5-1 CONNECTOR J8 (MAIN P.C. BOARD).......................................................................................................................5-7 TABLE 5-2 CONNECTOR J1 (MAIN P.C. BOARD).......................................................................................................................5-7 TABLE 5-3 CONNECTOR J4 (MAIN P.C. BOARD).......................................................................................................................
1 INTRODUCTION Thank you for purchasing this O.S. Walker Chuck Control. If used and maintained properly, it should serve you for many years. However, if installed and used improperly, it can be rendered inefficient and unsafe. Therefore, it is absolutely essential that anyone who uses this control or is responsible for its application be trained on how to use it correctly. Read this manual carefully to learn how to operate and maintain your chuck control.
2 SAFETY INSTRUCTIONS 2.1 General Safety Rules Following these simple rules can help to avoid accidents: • Never attempt to operate this control and your magnetic chuck until you read and understand this operator's manual. • Never disconnect a magnetic chuck from the control's DC power source while it is energized! Electrical arcing will occur and may cause serious injury or death.
2.2 Recognize Safety Information This is the safety alert symbol. When you see this symbol on your magnet or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices at all times. This indicates a situation in which a hazard is imminent and will result in a high probability of serious injury or death.
2.3 Additional Warnings • • • Disassembly or repair of this chuck control can result in reduced holding power and/or cause an unsafe condition. Therefore, any time the control is disassembled or repaired it should be thoroughly inspected and re-tested for proper electrical grounding and power output. Modification of any operating circuits and electrical safety grounding can reduce the chuck control's effectiveness and/or cause an unsafe condition.
3 INSTALLATION • All electrical chassis must be safety grounded. • Check that all sources of power are disconnected, locked out and tagged “Out of Service” prior to beginning installation. • Only qualified personnel should install this chuck control unit. Prior to beginning, thoroughly plan your installation. Read this manual completely. An installation parts list is included below to aid in your planning. 3.1 Control Mounting Guidelines 1.
3.1.1 Connecting Additional Features SMART-C chuck controls are equipped with two optional features; Current Sensing, and Lockout. These features enable the chuck control to work with external equipment such as machine controls or a PLC. 3.1.1.1 Current Sensing This control is equipped with a current sensing feature that monitors the current flowing to the chuck and indicates when this current has reached a predetermined value.
4.1.1 Surface Conditions Magnetic lines of force do not flow easily through air. They need iron in order to flow freely; therefore, anything that creates a space or an air gap between the magnet and the workpiece limits the flow of magnetic lines of force and, thus, reduces the holding capacity of a magnetic chuck.
4.1.4 Workpiece Material Low carbon steel such as SAE 1020 steel, are nearly as good conductors of magnetic lines of force as pure iron. However, many other alloys contain non-magnetic materials, which reduce the ability of magnetic lines of force to flow. An alloy such as SAE 300 series stainless steel is almost as poor a conductor of magnetic lines of force as air.
3. Once the number of desired Release pulses has been set, PRESS the Residual button. 4. The control is now ready for operation. NOTE: THE ADJUSTMENT WILL NOT OPERATE WITHOUT JP1 INSTALLED.ON THE MAIN BOARD. 4.3 Full Holding (Green Push-Button) In the Full holding position, full output voltage is supplied from the control to the chuck as soon as the button is pushed. The indicator light for the Full holding position is illuminated when this function is selected.
4.5 Residual Holding (Yellow Push-Button) The output of the control is reduced to zero when this function is selected. The control turns the chuck fully ON for a short period of time, thus leaving a recognizable residual holding power in the chuck; this is called True Residual. During this brief pulse, the indicator light, will be ON until another function is selected. 4.
Figure 4-1 Release Cycle Voltage vs. Release Cycle Time O.S. WALKER Co., Inc.
4.9 Grounding & Shielding All electrical chassis must be connected to a proper electrical ground. The control's internal circuit ground is connected to the AC safety ground (the green or green/yellow wire in the AC line cord). The base of the chuck is to be grounded to this point, as well as, through the ground wire of the DC chuck cable. All electrical chassis must be safety grounded. The chuck control's DC power output leads MUST BE SEPARATELY ROUTED from other 115V level power leads in the machine.
5 INSPECTION & MAINTENANCE 5.1 Daily Inspection • Check the physical condition of the power cords, indicating lamps, switches, and the control enclosure. If any deficiencies are observed, contact your supervisor or O.S. Walker. • Check the integrity of the enclosure by inspecting for dust, debris, and fluid. Make necessary repairs. • Keep the outside of the enclosure free of dust and debris. 5.2 Having a Problem with your Chuck Control? Problem 1. All the remote unit lights are flashing.
3. The fuse in the control unit blows when any of the control modes are selected. Excessive current draw is causing fuse to blow before electronic protective circuits have time to react. O.S. WALKER Co., Inc. SMART-C Control 5-2 BEFORE PROCEEDING, DE-ENERGIZE THE CONTROL UNIT. a) Visually inspect chuck cable and connections for pinches or other damage. b) Check chuck cable and connections for shorts with ohmmeter. c) Replace any questionable equipment.
5.2.1 Main Pc Board Figure 5-1 Main PC Board O.S. WALKER Co., Inc.
Figure 5-2 Transformer Wiring for Smart-3C & 5C O.S. WALKER Co., Inc.
Figure 5-3 Enclosure Dimensions for Smart-C Control O.S. WALKER Co., Inc.
Figure 5-4 Enclosure Assembly O.S. WALKER Co., Inc.
5.3 Chuck Control Connections 5.3.1 Model SMART-C Table 5-1 Connector J8 (Main P.C. Board) 1 2 3 GND CHUCK +DC CHUCK –DC Table 5-2 Connector J1 (Main P.C. Board) 1 2 3 GND AC HOT AC NEUTRAL Table 5-3 Connector J4 (Main P.C. Board) J4:1 J4:2 J4:3 J4:4 J4:5 J4:6 J4:7 J4:8 Lockout Signal Lockout Common Current Sense Common Current Sense NO Current Sense NC 5.3.2 Adjustments Number of Release Pulses (1-16) - Set to 8 pulses at factory (see Release 4.2) O.S. WALKER Co., Inc.
6 REPLACEMENT PARTS LIST 6.1 SMART-C Controls Table 6-1 Replacement Parts List DESCRIPTION Main PC Board Fuse F1 (panel) Transformer (T2) Ribbon Cable Switch Panel Membrane Assembly SMART 1C 39-DD14401 18-1124 N/A 10-5418 56-DD14591 PART NUMBER SMART 3C 39-DD14329 18-1219 12-0267 10-5418 56-DD14591 SMART 5C 39-DD14329 18-1219 12-0267 10-5429 56-DD14591 * Walker replacement parts may be installed by a **Designated Person.
7 RETURN AND REPAIR INSTRUCTIONS For warranty and non-warranty repairs on any part of your chuck system, contact O.S. Walker Company TOLL FREE at 1-800-W-MAGNET. A return authorization number will be issued along with any applicable packaging and shipping instructions. After receipt of the components to be repaired, O.S. Walker Company will perform an inspection and provide an estimate of the repair costs at no charge to the customer. Authorization from the customer must be obtained by O.S.
FOR FAST RESPONSE, CALL 1-800-W-MAGNET O.S. WALKER Rockdale Street, Worcester, MA 01606 (508)-853-3232 FAX (508)-852-8649 3508 Glenridge Drive, Chino Hills, CA 91709 (909)-597-4785 FAX (909)-597-0581 901 Arvin Avenue, Stoney Creek, Ontario, L8E5N9 Canada (905)-643-3338 In Canada: 1-800-267-4678 FAX (905)-643-6111 www.walkermagnet.com e-mail: info@walkermagnet.com O.S. WALKER Co., Inc.
