OPERATOR'S MANUAL AND SAFETY INSTRUCTIONS WITH INSTALLATION, TROUBLESHOOTING, INSPECTION AND MAINTENANCE INSTRUCTIONS SMART-D 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. SMART-D Control SMART D MANUAL DD14511L Rev.
TABLE OF CONTENTS 1 INTRODUCTION...............................................................................................................................................................1-1 2 SAFETY INSTRUCTIONS ................................................................................................................................................2-1 2.1 GENERAL SAFETY RULES ..........................................................................................................................
5.13 SMART 7/10/15D 115V WIRING................................................................................................................................5-12 5.14 SMART 7/10/15D 200V WIRING................................................................................................................................5-13 5.15 SMART 3/5D 115VDC WIRING .................................................................................................................................5-14 5.
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. • Repair of this chuck control should only be done by the O.
ELECTRICAL GROUNDING Because the O. S. Walker Co. does not know the specifics of each application and installation of these products and the electromagnetic device to which they are attached, it can only warn the installer and user that the electrically conductive body of the electromagnetic device MUST be connected to a proper electrical ground. According to ANSI/NFPA 79 1997(an American National Standard) "Electrical Standard for Industrial Machinery": • Section 19.
3 INSTALLATION INSTRUCTIONS • 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. The installation parts list below should aid in your planning. 1. Mounting hardware for the control and the remote. 2.
Three conduits must be routed from the main chuck control enclosure; remote control cable, AC input and DC output. Conduit sizing should be determined in accordance with all NFPA/NEC, state and local regulations by the qualified person installing the system. The remote control cable must be kept a minimum of six (6) inches from high voltage cables such as the AC input. The DC output also must be kept at least six (6) inches from high voltage AC wiring. Refer to Figure 3-1.
3.1.6 Transformer Wiring Diagram Figure 3-2 Transformer Wiring Diagram O.S. WALKER Co., Inc. SMART-D Control 3-3 SMART D MANUAL DD14511L Rev.
3.1.7 Connecting Optional Features SMART-D chuck controls are equipped with three optional features, Current Sensing, Part Release and Lockout. These features enable the chuck control to work with external equipment such as machine controls or a PLC. Refer to the "Operation" section 4 of this manual for using of these features. 3.1.
3.2 Control Mounting Guidelines 1. When any control (power section) is removed from its original enclosure or shipped without an enclosure and installed in a customer supplied enclosure, the following specifications must be met: a. The air surrounding the panel on which the parts are located should not exceed 120° Fahrenheit. b.
4 OPERATING INSTRUCTIONS The O. S. Walker Microprocessor Chuck Control, model SMART-D, uses a remote unit that can select the following functions: Full Holding; Variable Holding; Residual Holding; and Release. This control comes equipped with an adjustment for the number of pulses per Release cycle. It also has additional options, which are a Part Released feature, a Current Sense feature, and a Lockout feature. 4.
4.1.2 Workpiece Thickness The greater the number of lines of magnetic force flowing from a magnet into the workpiece the greater the effectiveness of the magnetic chuck. The thicker the workpiece, the more lines of magnetic force are able to flow. After a certain thickness of the workpiece, no additional lines of force will flow because the magnet has reached its full capacity. • Thin workpieces mean less iron available, and thus fewer lines of magnetic force flow from the magnet into the workpiece.
4.2 Full Holding (Green Push-Button) In the Full holding position, full output voltage is supplied from the control to the chuck as soon as this function is selected. The indicator light for the Full holding position is illuminated when this function is selected. NOTE: Full holding has equivalent holding force to 100% on the Variable holding control knob. 4.
The external adjustment for the number of demagnetization pulses per Release cycle is done using the full, residual, release pushbuttons, and the Variable potentiometer. To adjust the number of release pulses, the control must be "at the end of the release cycle". The procedure for externally adjusting the number of Release pulses is as follows: 1. Hold the Release button down and PRESS the Full button.
4.6 Control Protection If the control is switched into sudden high power operation with too large a load, the AC fuse may blow before the electronic protective circuits can function. If the chuck control is overloaded by a short circuit or a chuck too large for this control's rating, the control will sense this condition and will attempt to protect itself by flashing all the system indicator lights, and the control will not respond to any function selection.
Figure 4-1 Release Cycle Voltage VS. Release Cycle Time O.S. WALKER Co., Inc. SMART-D Control 4-6 SMART D MANUAL DD14511L Rev.
4.8 Grounding & Shielding The optional chuck control outputs for current sense and part released are isolated from the control circuit ground. All other chuck control electrical inputs and outputs, if connected to electronic equipment, must be isolated from the control's internal circuit ground, which 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.
5 MAINTENANCE & TROUBLESHOOTING 5.1 Inspection & Maintenance • Check the physical condition of the power cords, indicating lamps, switches and the control enclosure. If any indications of damage are observed, contact your supervisor. • Check the integrity of the enclosure by inspecting for dust, debris and fluid. • Keep the outside of the enclosure free of dust and debris. 5.2 Having a Problem with your Chuck Control? Problem 1.
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-D 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.
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5.4 Remote Interface 5.4.1 Connections: Table 5-4 Remote TB = TBR (located in remote enclosure); J5 (located on main PC board) TBR:1 to J5:1 TBR:2 to J5:2 TBR:3 to J5:3 TBR:4 to J5:4 TBR:5 to J5:5 TBR:6 to J5:6 TBR:7,14 to J5:7 TBR:8 NC TBR:9 to J5:9 TBR:10 to J5:10 TBR:11 to J5:11 TBR:12 to J5:12 TBR:13 to J5:13 5.
5.6 Smart 75/100D Panel Layout Figure 5-1 Smart 75/100D Panel O.S. WALKER Co., Inc. SMART-D Control 5-5 SMART D MANUAL DD14511L Rev.
5.7 Smart 20/30/50D Panel Layout Figure 5-2 Smart 20/30/50D Panel O.S. WALKER Co., Inc. SMART-D Control 5-6 SMART D MANUAL DD14511L Rev.
5.8 Smart 7/10/15D Panel Layout Figure 5-3 Smart 7/10/15D Panel O.S. WALKER Co., Inc. SMART-D Control 5-7 SMART D MANUAL DD14511L Rev.
5.9 Smart 3/5D Panel Layout Figure 5-4 Smart 3/5D Panel O.S. WALKER Co., Inc. SMART-D Control 5-8 SMART D MANUAL DD14511L Rev.
5.10 Main PC Board Figure 5-5 Main PC Board O.S. WALKER Co., Inc. SMART-D Control 5-9 SMART D MANUAL DD14511L Rev.
5.11 Smart 75/100D Wiring Reference documentation included for schematics. Figure 5-6 Smart 75/100D Wiring O.S. WALKER Co., Inc. SMART-D Control 5-10 SMART D MANUAL DD14511L Rev.
5.12 Smart 20/30/50D Wiring Reference documentation included for schematics. Figure 5-7 Smart 20/30/50D Wiring O.S. WALKER Co., Inc. SMART-D Control 5-11 SMART D MANUAL DD14511L Rev.
5.13 Smart 7/10/15D 115V Wiring Reference documentation included for schematics. Figure 5-8 Smart 7/10/15D 115V Wiring O.S. WALKER Co., Inc. SMART-D Control 5-12 SMART D MANUAL DD14511L Rev.
5.14 Smart 7/10/15D 200V Wiring Reference documentation included for schematics. Figure 5-9 Smart 7/10/15D 230V Wiring O.S. WALKER Co., Inc. SMART-D Control 5-13 SMART D MANUAL DD14511L Rev.
5.15 Smart 3/5D 115VDC Wiring Reference documentation included for schematics. Figure 5-10 Smart 3/5D 115VDC Wiring O.S. WALKER Co., Inc. SMART-D Control 5-14 SMART D MANUAL DD14511L Rev.
5.1 Smart 3/5D 230VDC Wiring Reference documentation included for schematics. Figure 5-11 Smart 3/5D 230VDC Wiring O.S. WALKER Co., Inc. SMART-D Control 5-15 SMART D MANUAL DD14511L Rev.
5.2 Enclosure Dimensions for SMART-D Controls SMART MODEL # WATTAGE CAPACITY STANDARD OUTPUT VOLTAGE 3D 300 115VDC 5D 500 115VDC 7D 750 115/230VDC 10D 1000 115/230VDC 15D 1500 115/230VDC 20D 2000 230VDC 30D 3000 230VDC 50D 5000 230VDC 75D 7500 230VDC 100D 10000 230VDC ENCLOSURE DIMENSIONS MSD3 MSD5 MSD7 MSD10 MSD15 MSD20 MSD30 MSD50 MSD75 MSD100 WIDTH (W) 12” 20” 24” 24” HEIGHT (H) 20” 30” 30” DEPTH (D) 8” 10” MTG. HOLE DIAMETER .44” MTG.
5.3 Remote Enclosure Dimensions Figure 5-12 Remote Enclosure BB-8783 O.S. WALKER Co., Inc. SMART-D Control 5-17 SMART D MANUAL DD14511L Rev.
5.4 Remote Wiring Connections Figure 5-13 Remote Wiring Connections O.S. WALKER Co., Inc. SMART-D Control 5-18 SMART D MANUAL DD14511L Rev.
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6 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 repairs 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. SMART-D Control SMART D MANUAL DD14511L Rev.
