Walker Magnetics CER User Manual
OPERATOR’S MANUAL
AND
SAFETY INSTRUCTIONS
WITH INSPECTION AND MAINTENANCE INSTRUCTIONS
CIRCULAR ELECTRIC LIFTING MAGNETS
MODELS: CER-5, CER-7, CER-9, CER-12, CER-16, CER-20
CER-20
CER-12
CER-5
WALKER
Always stay clear of
the load.
O.S. Walker Inc., CER Lift Magnet
O.S. WALKER
DANGER
Never lift loads over
people or in close
proximity to people.
I/R CER-7
Never attempt to operate this magnet
until you have read and understand
this Operator’s Manual.
1
CONTENTS
INTRODUCTION ................................................................................................................................... 2
SAFETY INSTRUCTIONS .................................................................................................................... 3
GENERAL SAFETY RULES ......................................................................................................................................3
UNSAFE LIFTING APPLICATIONS FOR YOUR MAGNET ...................................................................................... 4
RECOGNIZE SAFETY INFORMATION ....................................................................................................................4
WAYS TO AVOID A REDUCTION OF LIFTING CAPACITY .....................................................................................5
ADDITIONAL WARNINGS ........................................................................................................................................5
SAFETY PERSON ....................................................................................................................................................5
IMPORTANT FACTS FOR THE OPERATION OF LIFT MAGNETS .................................................... 6
RECOMMENDED LIFTING PROCEDURES ...................................................................................... 10
OPERATING INSTRUCTIONS ............................................................................................................11
MODELS: I/R-CER-5 thru I/R-CER-12 .................................................................................................................... 11
GUIDELINES FOR THE REDUCTION OF THE RATED LIFTING CAPACITY: ................................. 12
ADDITIONAL OPERATING INFORMATION ........................................................................................................... 12
LIFTING GUIDELINES (PLATE) .............................................................................................................................13
LOAD WEIGHT GUIDELINE ...................................................................................................................................15
DUTY CYCLE ..........................................................................................................................................................15
INSPECTION AND MAINTENANCE INSTRUCTIONS ...................................................................... 16
EVERY LIFT ............................................................................................................................................................16
WEEKLY ..................................................................................................................................................................16
DAILY.......................................................................................................................................................................16
SPECIFICATION & PARTS LIST ........................................................................................................ 17
REPAIRS .................................................................................................................................................................18
CER-5, 7 & 9 Replacement Parts List ..................................................................................................................... 19
CER-12 Replacement Parts List .............................................................................................................................. 20
CER-12 with PC Board Replacement Parts List ...................................................................................................... 21
I/R-CER-5 THRU 12 Replacement Parts List ..........................................................................................................22
CER-16 & 20 Replacement Parts List ..................................................................................................................... 23
INTRODUCTION
Thank you for purchasing this O.S. Walker Product. If used and maintained properly, it should
serve you for many years. Thousands of O. S. Walker lift magnets are in service today doing safe, fast,
and efcient magnetic material handling applications. It is often the only way for one person to load,
transport, and unload material.
O.S. Walker Products have proven to be among the best designed and safest in our industry.
However, if used improperly, any CER magnet can be rendered inefcient and unsafe. Therefore, it is
absolutely essential that anyone who uses this lifting magnet and 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
MAGNET. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH, TO YOURSELF
AND PEOPLE IN THE AREA.
THIS MANUAL AND SAFETY CD SHOULD BE CONSIDERED A PERMANENT PART OF
YOUR MAGNET AND SHOULD ALWAYS BE AVAILABLE TO ALL OPERATORS AND REMAIN
WITH THE MAGNET IF IT IS RE-SOLD.
To request additional copies of this manual #37-DD10505 call 1-800-962-4638 in the USA;
In Canada: 905-643-3338; In Europe: 31-4973-83835.
O.S. Walker Inc., CER Lift Magnet
2
SAFETY INSTRUCTIONS
GENERAL SAFETY RULES
Danger always exists when loads are transported by lifting devices, especially
when the equipment is not being used properly or is poorly maintained. Because accidents and severe bodily injury or death can result, special safety precautions apply
to the operation, inspection, and maintenance of the Walker Lift Magnets.
Following these simple rules can help to avoid lifting accidents:
DANGER
Always stay clear of the load.
Never lift loads over people or in close proxim-
ity to people.
Never attempt to operate this magnet until you
read and understand the Operator’s Manual.
Never use this magnet to lift, support or trans-
port people.
Never leave any lifted load unattended.
Never lift more than one work piece at a time
with this magnet.
Always make sure that the supporting struc-
ture and load attaching devices (i.e. crane,
chains and hook) are rated to support the
weight of the magnet and load.
Always make sure that the load’s weight and
dimensions are within the Magnet’s Lifting
Guidelines. These Guidelines are located in
the Operator’s Manual.
Always let those near you know that a lift is to
begin.
Remember, proper lifting knowledge and techniques are the responsibility of the operator. Be sure to read and understand the instructions and safety warnings contained in
this manual before using your magnet.
If you do not understand everything in this manual contact O.S. Walker for assistance
before using the magnet.
Call 1-800-W-MAGNET
(In Canada: 905-643-3338; In Europe: 31-4973-83835.)
O.S. Walker Inc., CER Lift Magnet
IN THE USA;
3
SAFETY INSTRUCTIONS
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 operat-
ing practices at all times.
DANGER
Red Background, White Letters
WARNING
Orange Background, Black Letters
CAUTION
Yellow Background, Black Letters
UNSAFE LIFTING APPLICATIONS FOR YOUR MAGNET
This indicates a situation in which a hazard
is imminent and will result in a high probability of serious injury or death.
This indicates a potentially hazardous situation, which could result in some probability of serious injury or death.
This indicates a potentially hazardous situation, which could result in minor injury or
moderate injury.
DANGER
Never lift any pipe, solid round or struc-
tural shapes with this magnet.
Never lift any castings that do not have
a machined at lifting surface for the
magnet. The location of the lifting surface should be such to permit the load
to remain level when lifted.
These Hazard
Signal Words
Deserve your
Full Attention
O.S. Walker can provide other type magnets for these applications.
For Model CER type magnets see Lifting Guidelines on Page 11.
DANGER
Never lift a load by its narrowest
dimension.
If you have any difculty lifting a load, DON’T LIFT IT!
WARNING
4
Call Walker for advice at 1-800-962-4638
O.S. Walker Inc., CER Lift Magnet
SAFETY INSTRUCTIONS
WAYS TO AVOID A REDUCTION OF LIFTING CAPACITY
DANGER
To Avoid any Reduction of Lifting Capacity:
The lifting surfaces of the magnet and the area of the load where the magnet will
be located must be clean, smooth, at and free of nicks and burrs.
The full area of the magnet’s lifting surface must be in contact with the load.
The load must be at least 1.0" (24.5 mm) thick for CER-5, 1.5” (38.1 mm) for CER-
7, 2” (51 mm) for models CER-9 through 12 and at least 2.5” (63 mm) for models
CER-16 and 20.
The load must be low carbon steel such as SAE 1020.
The magnet’s lifting surface must stay level and the contacting surface of the load
remain at.
The temperature of the magnet and/or the load must not be greater than 110°F
(43°C).
Repair of this magnet should only be done by the O. S. Walker Co. or a Qualied
Person.*
Do not exceed the magnet duty cycle. Exceeding the duty cycle will result in
reduced lifting capacity.
If you have any difculty lifting a load, DON’T LIFT IT! Call O. S. Walker for advice
at 1-800-962-4638.
ADDITIONAL WARNINGS
WARNING
Never lift loads with any dimension greater than
those shown in the LIFTING GUIDELINES.
Never operate damaged or malfunctioning mag-
nets.
Never remove or damage Operating and Warning
labels.
Persons using pacemakers or other medical de-
vices should not use this magnet until they have
consulted with their physician.
If your magnet was provided with a remote
control unit, NEVER place the control unit in a
position where the switch could be accidentally
turned to “OFF”, “DROP”, OR “LIFT”.
Disassembly or repair of this magnet can result in
reduced holding power and/or cause an unsafe
condition. Therefore, anytime the magnet is disassembled beyond the parts list shown in this manual,
the magnet must be re-tested for breakaway force
in accordance with the test described in ANSI/
ASME B30.20.
Modication of any operating mechanism or
structure of this magnet can reduce the magnet’s
effectiveness and/or cause an unsafe condition.
Repair or modication of this magnet should only be
done by O.S. Walker*.
WARNING
SAFETY PERSON
O.S. Walker recommends that a person be assigned to review all magnetic
handling applications for these magnets to ensure that safe practices and
procedures are being followed.
*Walker replacement parts may be installed by a **Designated Person.
** Designated Person - A person selected or assigned by the employer as being competent to
replace specic replacement parts listed in this manual and is able to verify the proper functioning
of the specic replacement parts and the entire product after the completion of the installation.
O.S. Walker Inc., CER Lift Magnet
5
IMPORTANT FACTS FOR THE
OPERATION OF LIFT MAGNETS
LOAD CHARACTERISTICS OTHER THAN JUST WEIGHT
MUST BE CONSIDERED IN ORDER TO DETERMINE
THE LOAD THAT ANY MAGNET CAN LIFT.
This statement is true for all lifting magnets because they all operate using the same fundamental laws of physics. Magnetic power is often pictured as lines of magnetic force owing
from north pole to south pole. Anything that limits the ow of these magnetic lines of force
obviously reduces the magnet’s lifting capacity. There are many important factors which limit
the ow of these lines of force.
1. LOAD THICKNESS
The greater the number of lines of magnetic force owing from a magnet into the load,
the greater the effectiveness of the magnet. The thicker the load, the more lines of magnetic force are able to ow. After a certain thickness of load, no additional lines of force
will ow because the magnet has reached its full capacity.
Thin material (load) means less iron available, and thus fewer lines of magnetic force
ow from the magnet into the load. Therefore, the lifting capacity of the magnet is
reduced. In some cases the magnet will attract more than one thin plate of material
when set on a stack of thin plates. DO NOT LIFT more than one plate at a time since
the lower plate may not be held sufciently.
The lifting guidelines provide the user with what minimum thickness of load is re-
quired to reach full lifting capacity. Below such thickness of load, the user must accept the reduced lifting capacity of the magnet as shown in the guidelines.
2. SURFACE CONDITIONS
Magnetic lines of force do not ow easily through air. They need iron in order to ow
freely; therefore, anything that creates a space or an air gap between a magnet and the
load limits the ow of magnetic lines of force and, thus, reduces the lifting capacity of a
magnet.
MAGNET’S LIFTING SURFACE CONDITION — The lifting surfaces of a magnet
must be clean, smooth, at and free of nicks and burrs to minimize the air gap between a magnet and the load. This magnet has been designed with soft, low carbon
steel lifting surfaces in order to maximize the lifting capacity; therefore, special care
must be taken to protect these surfaces. Follow the Inspection Instructions in this
manual. Attaching or welding other materials to the lifting surfaces in order to reduce
wear should not be done with this magnet because it will reduce the lifting capacity.
LOAD SURFACE CONDITION — Paper, dirt, rags, rust, paint, and scale act
the same as air. Also, a rough surface nish on the load creates an air gap between the magnet and load. Any of these conditions will reduce the magnet’s
lifting capacity.
O.S. Walker Inc., CER Lift Magnet
6
3. LOAD ALLOY
Low carbon steels, 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 ow into the load. An alloy such as
SAE 300 series of stainless steel is almost as poor a conductor of magnetic lines of force
as air.
Type 416 stainless steel is considered magnetic, but it contains enough chromium
so that a magnet can develop only one-half as much force on a type 416 stainless
steel load as it can on a SAE 1020 steel load. Also, because of the carbon content,
the force developed on cast iron is less than one-half of that developed on SAE 1020
steel. (Chilled cast iron further reduces the force to less than one-quarter.)
4. LOAD LENGTH OR WIDTH
As the length or width of a load increases, it ceases to remain at when lifted and the
edges begin to droop. This drooping or sagging of the load can create an air gap between
the load and the magnet. This is called peel. If this occurs, the lifting capacity of the magnet is greatly reduced.
For plate lifting, where drooping often occurs, rectangular shaped magnets must be positioned so that the length of the magnet is parallel to the width of the load.
5. POSITION OF MAGNET’S LIFTING SURFACE
As the position of the magnet’s lifting surface changes from horizontal to vertical, the lifting capacity of the magnet decreases. When the magnet’s lifting surfaces are vertical, the
lifting capacity of the magnet is minimum and dependent upon the coefcient of friction
between the magnet’s lifting surface and the load.
6. PORTION OF MAGNET SURFACE IN CONTACT WITH
LOAD
The full surface of the magnet must contact the load if the magnet is to achieve rated lift
capacity.
7. LOAD TEMPERATURE
The temperature of the load can cause damage to the magnet and, if high enough, can
even change the magnetic characteristics of the load. For Standard Lift Magnets, Walker
should be consulted if the load or air temperature exceeds 110° F (43° C).
O.S. Walker Inc., CER Lift Magnet
7
SAFETY
FOR FAST, EASY LIFTING WITH YOUR WALKER LIFT
1 NEVER
attempt to operate
this lift magnet until you
read and understand the
OPERATOR’S MANUAL &
SAFETY INSTRUCTIONS
(Manual #37-DD10505)
for CER Lifting Magnets.
MAGNET
2
Check the condition of the magnet prior to
every lift. WIPE clean the bottom of the magnet
and the area on the load where the magnet will
be located. File away burrs.
5 6
Check to be sure no one is near the load to be
lifted. Inform others in the area that a lift is to begin. Lift the load 2 to 3 inches (50 to 75 mm) and
then jar the load to insure that adequate holding
power is available.
ALWAYS STAY CLEAR OF THE LOAD.
If you have any difculty lifting a load, DON’T LIFT IT.
Ask your supervisor for help or call O.S. Walker Co.,
Inc., for advice at 1-800-W-MAGNET
8
When working in an area using lifting magnets, wear safety
glasses, work gloves, steel-toed shoes and a safety hat.
Lift and move the load SMOOTHLY. Avoid jarring
and swinging the load while it is in transit. KEEP
THE LOAD LEVEL. NEVER let the load come in
contact with any obstruction.
O.S. Walker Inc., CER Lift Magnet
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