Walker Magnetics SMART-B User Manual

OPERATOR'S MANUAL

AND

SAFETY INSTRUCTIONS

WITH INSTALLATION, TROUBLESHOOTING,

INSPECTION AND MAINTENANCE INSTRUCTIONS

SMART-B SERIES

Microprocessor Controlled

Chuck Control

O.S. WALKER

Rockdale Street, Worcester, MA 01606 (508)-853-3232 FAX [phone]

3508 Glenridge Drive, Chino Hills, CA 91709 (909)-597-4785 FAX [phone]

901 Arvin Avenue, Stoney Creek, Ontario, L8E5N9 Canada (905)-643-3338

In Canada: 1-800-267-4678 FAX [phone]

www.walkermagnet.com

Email: [e-mail]

Never attempt to operate this control until you have read and
understand this OPERATOR’S MANUAL.

O.S. WALKER Co., Inc. SMART-B Control

SMART B MANUAL DD-14283J Rev I, October 29, 2008

O.S. WALKER Co., Inc. SMART-B Control

SMART B MANUAL DD-14283J Rev I, October 29, 2008

TABLE OF CONTENTS

1 INTRODUCTION...............................................................................................................................................................1-1

2 SAFETY INSTRUCTIONS................................................................................................................................................2-1

2.1 GENERAL SAFETY RULES .............................................................................................................................................2-1

2.2 RECOGNIZE SAFETY INFORMATION................................................................................................................................2-2

2.2.1 Ways to Avoid a Reduction of Holding Capacity................................................................................................2-2

2.3 ADDITIONAL WARNINGS................................................................................................................................................2-3

2.4 DESIGNATED PERSON ..................................................................................................................................................2-3

3 INSTALLATION................................................................................................................................................................3-1

3.1 CONTROL MOUNTING GUIDELINES ................................................................................................................................3-1

4 OPERATING INSTRUCTIONS.........................................................................................................................................4-1

4.1 IMPORTANT FACTS ABOUT MAGNETIC HOLDING .............................................................................................................4-1

4.1.1 Surface Conditions.............................................................................................................................................4-1

4.1.2 Workpiece Thickness.........................................................................................................................................4-1

4.1.3 Portion of the Chuck Surface In Contact With the Workpiece ...........................................................................4-1

4.1.4 Workpiece Material.............................................................................................................................................4-2

4.2 RELEASE .....................................................................................................................................................................4-2

4.3 FULL HOLDING .............................................................................................................................................................4-3

4.4 VARIABLE HOLDING......................................................................................................................................................4-3

4.5 RESIDUAL HOLDING......................................................................................................................................................4-4

4.6 CONTROL PROTECTION ................................................................................................................................................4-4

4.7 RELEASE CYCLE STEPS................................................................................................................................................4-4

4.8 GROUNDING & SHIELDING.............................................................................................................................................4-6

4.9 CONTROL OUTPUT VOLTAGE ........................................................................................................................................4-6

5 INSPECTION & MAINTENANCE.....................................................................................................................................5-1

5.1 DAILY INSPECTION........................................................................................................................................................5-1

5.2 HAVING A PROBLEM WITH YOUR CHUCK CONTROL?.......................................................................................................5-1

5.2.1 Main Pc Board....................................................................................................................................................5-3

5.3 CHUCK CONTROL CONNECTIONS ..................................................................................................................................5-7

5.3.1 Model SMART-B.................................................................................................................................................5-7

5.3.2 Adjustments........................................................................................................................................................5-7

6 REPLACEMENT PARTS LIST.........................................................................................................................................6-1

6.1 SMART-B CONTROLS..................................................................................................................................................6-1

7 RETURN AND REPAIR INSTRUCTIONS........................................................................................................................7-1

O.S. WALKER Co., Inc. SMART-B Control

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SMART B MANUAL DD-14283J Rev J, March 30, 2011

TABLE OF TABLES

T

ABLE 5-1 CONNECTOR J8 (MAIN P.C. BOARD).......................................................................................................................5-7

TABLE 5-2 CONNECTOR J1 (MAIN P.C. BOARD).......................................................................................................................5-7

TABLE 6-1 REPLACEMENT PARTS LIST ....................................................................................................................................6-1

TABLE OF FIGURES

F

IGURE 4-1 RELEASE CYCLE VOLTAGE VS. RELEASE CYCLE TIME............................................................................................4-5

FIGURE 5-1 MAIN PC BOARD..................................................................................................................................................5-3

FIGURE 5-2 TRANSFORMER WIRING FOR SMART-3B & 5B........................................................................................................5-4

FIGURE 5-3 ENCLOSURE DIMENSIONS FOR SMART-B CONTROL................................................................................................5-5

FIGURE 5-4 ENCLOSURE ASSEMBLY........................................................................................................................................5-6

O.S. WALKER Co., Inc. SMART-B Control

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SMART B MANUAL DD-14283J Rev J, March 30, 2011

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. Failure
to do so could result in serious injury, or even death, to yourself and others.

This manual should be considered a permanent part of your control and should always be
available to all operators and remain with the control if it is re-sold.

NOTE: Before using this chuck control, record this data from the nameplate for future use
in obtaining service.

MODEL NO._____________, PART NO._____________, SERIAL NO. __________

To request additional copies of this manual, call 1-800-962-4638 in the USA;

In Canada: 905-643-3338; In Europe: 31-4973-83835

O.S. WALKER Co., Inc. SMART-B Control

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SMART B MANUAL DD-14283J Rev J, March 30, 2011

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.

• Only qualified personnel shall make adjustments within the control while it is
energized!

• Never operate the control and chuck until it has been verified that a proper
electrical ground for the control and Chuck has been established.

• Never operate damaged or malfunctioning controls or magnetic chucks.

Remember, proper knowledge and techniques in the use of this equipment are the
responsibility of the operator. Be sure to read and understand the instructions and safety
warnings contained in this manual before using your chuck control and magnetic chuck.

If you do not understand everything in this manual contact O.S. Walker for assistance before
using the equipment.

CALL 1-800-W-MAGNET IN THE USA

(In Canada call 905-643-3338; In Europe 31-4973-83835)

O.S. WALKER Co., Inc. SMART-B Control

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SMART B MANUAL DD-14283J Rev J, March 30, 2011

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.

Red Background, White Letters

This indicates a potentially hazardous
situation, which could result in some
probability of serious injury or death.

Orange Background, Black Letters

This indicates a potentially hazardous
situation, which could result in minor injury or
moderate injury.

Yellow Background, Black Letters

2.2.1 Ways to Avoid a Reduction of Holding Capacity

These are
Hazard
Seriousness
Signal
Words

To Avoid any Reduction of Holding Capacity:

• The holding surface of the chuck and the contact area of the workpiece where it will
contact the chuck must be clean, smooth, flat, and free of nicks and burrs.

• The surface of the workpiece must contact equal areas of the chuck's opposite polarity,
major magnetic poles.

• The load must be low carbon steel such as SAE 1020.

• The chuck control must provide "FULL" power to the chuck, that is, maximum output

voltage.

• The workpiece thickness must be at least equal or greater than the width of the chuck's
major magnetic poles.

• The temperature inside the chuck control enclosure must not be greater than 104°
Fahrenheit (40° Celsius), nor the temperature of the chuck must not be greater than
110° F (43° C).

• Repair of this chuck control should only be done by the O. S. Walker Co.*

If you have any difficulty holding a work piece, DON'T attempt to machine it! Call the O.S.
Walker Co. for advice at 1-800-962-4638.

O.S. WALKER Co., Inc. SMART-B Control

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SMART B MANUAL DD-14283J Rev J, March 30, 2011

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. S. Walker Co.*

2.4 Designated Person

* 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 specific parts listed in this manual and is able to verify the proper functioning of the
specific replacement parts and the entire product after the completion of the installation.

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 Equipment Grounding: The machine and all exposed noncurrent-carrying
conductive parts, material, and equipment, including metal mounting panels that are likely to
become energized and are mounted in nonmetallic enclosures, shall be effectively grounded.

• Section 19.2.4 Grounding Conductors: It shall be permissible to use machine members or
structural parts of the electrical equipment in the grounding circuit provided that the cross­sectional area of these parts is at least electrically equivalent to the minimum cross-sectional
area of the copper conductor required.

• Section 19.6.1 Continuity of the Grounding Circuit: The continuity of the grounding circuit
shall be ensured by effective connections through conductors or structural members.

• Section 19.6.3 Continuity of the Grounding Circuit: Moving machine parts, other than
accessories or attachments, having metal-to-metal bearing surfaces shall be considered as
bonded. Sliding parts separated by a non-conductive fluid under pressure shall not be
considered as bonded.

PRIOR TO ENERGIZING THE ELECTROMAGNETIC DEVICE, CHECK ALL THE ELECTRICAL
CONNECTIONS AND CONFIRM THAT THE METAL BODY OF THE ELECTROMAGNETIC
DEVICE IS ELECTRICALLY GROUNDED.

O.S. WALKER Co., Inc. SMART-B Control

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SMART B MANUAL DD-14283J Rev J, March 30, 2011