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Walker Magnetics
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SMART-D
User Manual
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Walker Magnetics SMART-D User Manual

OPERATOR'S MANUAL
AND
SAFETY INSTRUCTIONS
WITH INSTALLATION, TROUBLESHOOTING,
INSPECTION AND MAINTENANCE INSTRUCTIONS
SMART-D SERIES
Microprocessor Controlled
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.com
Never attempt to operate this control until you have read and understand this OPERATOR'S MANUAL
O.S. WALKER Co., Inc. SMART-D Control
SMART D MANUAL DD14511L Rev. L, March 30, 2011
O.S. WALKER Co., Inc. SMART-D Control
SMART D MANUAL DD14511L Rev. L, March 30, 2011
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 INSTRUCTIONS....................................................................................................................................3-1
3.1 MOUNTING THE CHUCK CONTROL & CONNECTING ELECTRICAL POWER..........................................................................3-1
3.1.1 Optional Remote Unit.........................................................................................................................................3-1
3.1.2 Main Chuck Control Unit ....................................................................................................................................3-1
3.1.3 Connecting the Chuck........................................................................................................................................3-2
3.1.4 Connecting the AC Input voltage........................................................................................................................3-2
3.1.5 575 Volt Controllers............................................................................................................................................3-2
3.1.6 Transformer Wiring Diagram..............................................................................................................................3-3
3.1.7 Connecting Optional Features............................................................................................................................3-4
3.1.8 Current Sensing..................................................................................................................................................3-4
3.1.9 Part Release.......................................................................................................................................................3-4
3.1.10 Lockout.............................................................................................................................................................3-4
3.1.11 Energizing the System .....................................................................................................................................3-4
3.2 CONTROL MOUNTING GUIDELINES ................................................................................................................................3-5
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.........................................................................................................................................4-2
4.1.3 Portion of the Chuck Surface In Contact With the Workpiece ...........................................................................4-2
4.1.4 Workpiece Material.............................................................................................................................................4-2
4.2 FULL HOLDING .............................................................................................................................................................4-3
4.3 VARIABLE HOLDING......................................................................................................................................................4-3
4.4 RESIDUAL HOLDING......................................................................................................................................................4-3
4.5 RELEASE .....................................................................................................................................................................4-3
4.6 CONTROL PROTECTION ................................................................................................................................................4-5
4.7 RELEASE CYCLE STEPS................................................................................................................................................4-5
4.8 GROUNDING & SHIELDING.............................................................................................................................................4-7
4.8.1 Current Sensing..................................................................................................................................................4-7
4.8.2 Part Release.......................................................................................................................................................4-7
4.8.3 Lockout...............................................................................................................................................................4-7
4.9 CONTROL OUTPUT VOLTAGE ........................................................................................................................................4-7
5 MAINTENANCE & TROUBLESHOOTING......................................................................................................................5-1
5.1 INSPECTION & MAINTENANCE........................................................................................................................................5-1
5.2 HAVING A PROBLEM WITH YOUR CHUCK CONTROL?.......................................................................................................5-1
5.3 CHUCK CONTROL CONNECTIONS ..................................................................................................................................5-3
5.4 REMOTE INTERFACE.....................................................................................................................................................5-4
5.4.1 Connections:.......................................................................................................................................................5-4
5.5 INTERFACE...................................................................................................................................................................5-4
5.6 SMART 75/100D PANEL LAYOUT...................................................................................................................................5-5
5.7 SMART 20/30/50D PANEL LAYOUT................................................................................................................................5-6
5.8 SMART 7/10/15D PANEL LAYOUT..................................................................................................................................5-7
5.9 SMART 3/5D PANEL LAYOUT.........................................................................................................................................5-8
5.10 MAIN PC BOARD........................................................................................................................................................5-9
5.11 SMART 75/100D WIRING..........................................................................................................................................5-10
5.12 SMART 20/30/50D WIRING.......................................................................................................................................5-11
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SMART D MANUAL DD14511L Rev. L, March 30, 2011
SMART 7/10/15D 115V WIRING................................................................................................................................5-12
5.13
5.14 SMART 7/10/15D 200V WIRING................................................................................................................................5-13
5.15 SMART 3/5D 115VDC WIRING .................................................................................................................................5-14
5.1 SMART 3/5D 230VDC WIRING ...................................................................................................................................5-15
5.2 ENCLOSURE DIMENSIONS FOR SMART-D CONTROLS .................................................................................................5-16
5.3 REMOTE ENCLOSURE DIMENSIONS .............................................................................................................................5-17
5.4 REMOTE WIRING CONNECTIONS .................................................................................................................................5-18
5.5 REPLACEMENT PARTS LIST.........................................................................................................................................5-19
6 RETURN AND REPAIR INSTRUCTIONS........................................................................................................................6-1
TABLE OF TABLES
TABLE 5-1 TERMINAL TB1 ......................................................................................................................................................5-3
TABLE 5-2 CONNECTOR - J4...................................................................................................................................................5-3
TABLE 5-3 CONNECTOR - J5...................................................................................................................................................5-3
TABLE 5-4 REMOTE TB = TBR (LOCATED IN REMOTE ENCLOSURE); J5 (LOCATED ON MAIN PC BOARD) ......................................5-4
TABLE 5-5 REPLACEMENT PARTS..........................................................................................................................................5-19
TABLE OF FIGURES
FIGURE 3-1 CHUCK CONTROL ENCLOSURE..............................................................................................................................3-2
FIGURE 3-2 TRANSFORMER WIRING DIAGRAM .........................................................................................................................3-3
FIGURE 4-1 RELEASE CYCLE VOLTAGE VS. RELEASE CYCLE TIME...........................................................................................4-6
FIGURE 5-1 SMART 75/100D PANEL .......................................................................................................................................5-5
FIGURE 5-2 SMART 20/30/50D PANEL ....................................................................................................................................5-6
FIGURE 5-3 SMART 7/10/15D PANEL ......................................................................................................................................5-7
FIGURE 5-4 SMART 3/5D PANEL .............................................................................................................................................5-8
FIGURE 5-5 MAIN PC BOARD..................................................................................................................................................5-9
FIGURE 5-6 SMART 75/100D WIRING....................................................................................................................................5-10
FIGURE 5-7 SMART 20/30/50D WIRING.................................................................................................................................5-11
FIGURE 5-8 SMART 7/10/15D 115V WIRING..........................................................................................................................5-12
FIGURE 5-9 SMART 7/10/15D 230V WIRING..........................................................................................................................5-13
FIGURE 5-10 SMART 3/5D 115VDC WIRING .........................................................................................................................5-14
FIGURE 5-11 SMART 3/5D 230VDC WIRING .........................................................................................................................5-15
FIGURE 5-11 REMOTE ENCLOSURE BB-8783........................................................................................................................5-17
FIGURE 5-12 REMOTE WIRING CONNECTIONS .......................................................................................................................5-18
O.S. WALKER Co., Inc. SMART-D Control
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SMART D MANUAL DD14511L Rev. L, 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 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-D Control
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SMART D MANUAL DD14511L Rev. L, 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 perform any machining of work pieces on the magnetic chuck with the control setting in the "Residual" mode.
• 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.
(In Canada call 905-643-3338; In Europe 31-4973-83835)
O.S. WALKER Co., Inc. SMART-D Control
CALL 1-800-W-MAGNET IN THE USA
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SMART D MANUAL DD14511L Rev. L, 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 workpiece must be low carbon steel such as AISI 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-D Control
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SMART D MANUAL DD14511L Rev. L, 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 replacement 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.
O.S. WALKER Co., Inc. SMART-D Control
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SMART D MANUAL DD14511L Rev. L, March 30, 2011
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-D Control
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SMART D MANUAL DD14511L Rev. L, March 30, 2011

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. Conduit and associated hardware for AC input, chuck output and remote.
3. Remote cable: 14-conductor #22 AWG shielded cable.
4. Chuck cable: Type SO or SJO cord with proper current rating.

3.1 Mounting the Chuck Control & Connecting Electrical Power

3.1.1 Optional Remote Unit

Select a location for mounting the remote unit. The remote unit should be mounted in a location that is both safe and convenient for the machine operator. Typically, it is mounted in close proximity to the machine controls. It is important to keep the remote unit within fifty (50) feet of the main control enclosure and away from exposure to any fluids.
It is recommended that shielded cable be used for the remote unit wiring and that the conduit be run six (6) inches from all other parallel conduit runs. The remote unit wiring must include a ground wire that is connected to the chassis of the remote control and to the chassis of the main enclosure. The length of cable that is used should not exceed fifty (50) feet. It is recommended to use 14 conductor #22 AWG shielded cable for connecting the remote unit.

3.1.2 Main Chuck Control Unit

Select a location for mounting the main chuck control enclosure. It must be located in a well ventilated area. To ensure proper operation, ambient temperature at the main chuck control location must not be higher than 104º Fahrenheit outside the enclosure.
O.S. WALKER Co., Inc. SMART-D Control
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SMART D MANUAL DD14511L Rev. L, March 30, 2011
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.
Figure 3-1 Chuck Control Enclosure
MAINTAIN A SIX (6) INCH SEPARATION BETWEEN PARALLEL RUNS OF REMOTE
CONTROL CABLE AND OTHER HIGH VOLTAGE WIRING.

3.1.3 Connecting the Chuck

The DC output to the chuck must include a ground wire that is connected to the safety ground lug on the chuck and to the chassis of the chuck control. It is recommended that the conduit for the DC output not be routed near high voltage AC wires. Many chucks are installed on machines with moving tables. Choose a means of wiring the chuck that allows adequate freedom of movement over the full range of table travel.

3.1.4 Connecting the AC Input voltage

The input transformer can be tapped for nine different input voltages; 208, 220, 230, 240, 380, 416, 440, 460 and 480 VAC. Refer to the transformer wiring diagram Figure 3-2 on the following page.
Note: that there are two (2) primary and two (2) secondary out put windings.

3.1.5 575 Volt Controllers

The transformer installed in Controllers designed to operate on 575 volts AC have a single primary winding. Refer to the transformer wiring diagram Figure 3-2 on the following page.
O.S. WALKER Co., Inc. SMART-D Control
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SMART D MANUAL DD14511L Rev. L, March 30, 2011

3.1.6 Transformer Wiring Diagram

O.S. WALKER Co., Inc. SMART-D Control
Figure 3-2 Transformer Wiring Diagram
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SMART D MANUAL DD14511L Rev. L, March 30, 2011

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.

3.1.8 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. The current sense relay is a “Form C” dry contact type. The connections are at J4: Pin 6 is common, Pin 7 is the N. O. contact, and Pin 8 is the N. C. contact. The rating of the contacts are 10 A @ 125 VAC, 5 A @ 250 VAC, and 5 A @ 30 VDC. See Figure 5-5 for locations.

3.1.9 Part Release

The part release relay energizes and de-energizes with the chuck. It is the same type as the current sense relay. The connections are at J4: Pin 3 is the common, Pin 4 is the N. O., and Pin 5 is the N. C. contact. See Figure 5-5 for locations.

3.1.10 Lockout

A Lockout feature is supplied with this control, which prevents anyone from accidentally changing the settings while machining is in progress. There are two connections for lockout. The first is to supply 115 VAC to J4, terminals 1 and 2. The second is to sink the positive voltage at J5, terminal 8. This is done using a dry contact connected to terminal 8 (lockout) and terminal 13 (GND) on J5*. See Figure 5-5 for locations.
* When using lock-out, JP2 jumper must be removed.

3.1.11 Energizing the System

Inspect the conduit and wire installation. Verify that all wiring connections are correct and secure, paying particular attention to the ground connections. Thoroughly read the "Operating Instructions" section 4 prior to energizing any equipment.
Close all breakers and disconnects upstream of the chuck control. Close the door (on models equipped with enclosures) and put the chuck control disconnect switch in the "ON" position. When power is first applied, the chuck control will initialize itself in the "Release Mode". The "Release" indicator light on the remote unit will be lit and the current sense relay open. The system is ready for operation. No power is applied to the chuck.
O.S. WALKER Co., Inc. SMART-D Control
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SMART D MANUAL DD14511L Rev. L, March 30, 2011
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