GMW 5203 User manual

GMW
955 Industrial Road, San Carlos, CA 94070 Tel: [phone] Fax: [phone]
Email: [e-mail] Web site: http:/ / www.gmw.com
GMW
USER’S MANUAL
MODEL: 5203
Projected Vertical Field Magnet
PROPRIETARY
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION
PROPRIETARY TO GMWASSOCIATES. IT MUST NOT BE REPRODUCED
OR DISCLOSED TO OTHERS OR USED IN ANY WAY EXCECPT FOR THE
INSTALLATION, OPERATION OR MAINTENANCE OF GMW ASSOCIATES
PRODUCTS.
File Name: M5203_G_Proj_Vert_Field_Magnet_Apr_2022.pdf Revision Date: April, 2022

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CONTENTS
1. SAFETY 3
Symbols Used In This Manual 3
Installation, Operation and Service Precautions 4
Lockout/Tagout Procedures 4 - 6
2. SPECIFICATIONS 7
General Specification 7
Model 5203 Electrical and Water Cooling Connections 8
11907-0224-0 - General Assembly 9
11907-0223-0 - Terminal Block Assembly 10
17907-0412-0 - Mounting Plate 11
3 WARNINGS 12 - 13
4 INSTALLATION 14
Site Considerations 14
Unpacking Instruction 15
Magnet Power Supply 15
AC Mains Connections 15
Magnet Power Connections 16
Magnet Interlocks 16
Interlock Testing 16
Magnet Cooling 17
5. OPERATION 18
General 18 - 19
Field Control Operation 19
6. MAINTENANCE 19
Cooling Circuit 19
Electrical Connections 19
Interlock Testing 19
Spare Parts and Consumables 19
7. STANDARD OPTIONS 20
Standard Pole Option 20
8. CUSTOM OPTIONS 21
Custom Pole Options 21
9. EXCITATION CURVES AND FIELD UNIFORMITY 22 - 36
10. TEST DATA 37

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11. SYSTEM DRAWINGS 38
13907-0025-1 - System Wiring , 5203, 1x BOP20-50, and PDU 39
13907-0026-1 - System Wiring , 5203, 2x BOP20-50, and PDU 40
1C907-5203-08 - Electrical Assembly, 5203 and IECO BPS 41
1D907-5203-08 - Electrical Wiring, 5203 and IECO BPS 42
1C907-5203-09 - Electrical Assembly, 5203, IECO BPS, and 5972 43
1D907-5203-09 - Electrical Wiring, 5203, IECO BPS, and 5972 44
12. ACCESSORY AND OPTIONS DRAWINGS 45
16907-0116-1, S1 - DC Cable, 5203, BOP20-50, and PDU 46
16907-0116-3, S1 - DC Cable, 5203, BPS85-70, and 5972 or IECO BPS 47
16907-0281-0 - Cable Assembly, Interlock Pigtail, 5972 or IECO BPS 48
11907-0620-0 - GMW RC-1920 Equipment Rack 49
13. Magnet Accessories 50
5972 Magnet Control 50
RC-1920 Equipment Rack 50
14. APPENDIX 51
Recommended Mains Connection 51
15. WARRANTY INFORMATION 52
INCLUSIONS
GMW 5972 Magnet Control Brochure
IECO BPS
Thermo Scientific Water Chemical Kit
Thermo Scientific Treated Water Instructions
ThermoFlex Preventative Maintenance

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1. SAFETY
1.1 Symbols Used In This Manual
Important information. This label indicates important information that must be read
and understood prior to operation.
Warning relating to the presence of magnetic field.
Warning relating to a trip hazard.
Warning relating to hot surfaces.
Warning relating to the potential for electrical shock.
Warning relating to the potential of injury due to lifting heavy weight.

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1.2 Installation, Operation, and Service Precautions
During installation or servicing this magnet must be locked out following the
Lockout/Tagout procedure defined in section 1.3.
Hazardous voltages are present within this product during normal operation.
This equipment should never be operated with any covers removed or interlocks
defeated.
When operated at peak direct current of 63A the surface temperature of the coils
of
the electromagnet can rise as high as 80°C. Care must be taken not to touch
the coils for extended periods.
NEVER SERVICE ALONE. The output of this equipment and its DC Power Supply is capable of
delivering high voltages at high currents, and is potentially lethal. Do not perform service to this
equipment or its associated DC Power Supply unless another person is present who is capable of
rendering first aid.
1.3 Lockout/Tagout Procedures
Purpose:
To protect personnel and ensure that machines and equipment are isolated from potentially
hazardous electrical energy. Lockout or tagout must occur before employees perform service,
maintenance, or renovation. This is important where unexpected start-up could cause personal
injury, fire, or equipment damage.
Policy:
All equipment shall be locked out where possible. Where such control is not possible, equipment
may be tagged out-of-service. In all instances, equipment shall be made inoperable to protect
against possible operation where such operation may cause personal injury or damage. Employees
must not attempt to operate any switch or source of energy which is locked out or tagged out.
Procedures:
1. When working on systems which could accidentally be activated, the system shall be locked out
or tagged out by use of a safety lockout device and padlock. In addition, a tag shall be used to
identify the purpose of the shutdown, the employee involved, the date the unit was removed
from service, and when the system may operate again.
2. If more than one source of energy is present, all such sources must be locked out or tagged out.
Special procedures must be followed to ensure that the equipment is disconnected from an
energy management system or emergency generator system that may start or energize the
equipment.
3. A lockout is required on all systems where possible. A tagout is an acceptable means of
protection on systems which are less hazardous. An example of less hazardous is a device, if
started accidentally, would not cause personal injury.

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4. If more than one person is involved in the repair, each person shall install a lock and or tag to the
equipment energy source. An employee may not use the tag or lock of another employee.
5. After servicing, renovation, or maintenance is complete, the area must be checked for tools,
parts, removed guards, and assurance that no personnel are in the danger zone. Then the lockout
or tagout will be removed by the same employee who initially locked it out so energy may be
restored to the equipment.
6. If the employee who locked out or tagged out the equipment is unavailable, the supervisor may
remove the lock or tag if the following conditions are met:
1. Verification that the employee who applied the device has left for the duration of the shift
and is not at the job site.
2. Made reasonable efforts to reach the employee.
3. Inform the employee that the lock or tag has been removed and the system is no longer
de-energized, before the employee resumes work.
7. Employee's using lockout/tagout devices shall have training about this program, and shall have
annual retraining to ensure that the employee understands and follows this program. The
training and retraining shall be documented with the training records maintained by the training
coordinator.
8. Outside contractors are required to follow this policy or provide a similar policy that is in
compliance with Occupational Safety and Health Administration (OSHA) Standard 1910.147.
Under no circumstances are outside contractors authorized to remove a lockout/tagout device nor
are they allowed to energize a locked out/tagged out system.
Lockout/Tagout Procedures Checklist:
The following steps must be followed in sequence to properly lockout/tagout and re-establish
energy:
I. Understand the hazard:
Electrical
Electrical Shock and or burn could result from contact with the exposed conductors line
voltage or high voltage equipment. Flying parts or fire could result if this circuit were
shorted. Electricity should be controlled at the circuit breaker, main switch, or fuse box.
Mechanical
Equipment or machinery can inflict tissue or skeletal injury through crushing, laceration or
impalement. This can be controlled through the main electrical switch, plug, circuit breaker
or anti-motion pin.
Thermal
May cause burns or fires. It can be controlled by the main electrical switch, electrical plug
control, electrical circuit breaker, electrical fuse box, steam valve, fluid line valve or
shielding.

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II. Shutdown:
Know what type of energy the machine uses.
Identify its potential hazards.
Find the switches or other devices that control energy and need to be locked out.
Let employees know that you will be locking or tagging out the equipment and why.
Turn off the machine or equipment.
III. Isolate the source of energy
Electrical
•Locate the main switch box or circuit breaker.
•Open the breaker, open the switch or remove the plug.
•Attach a lockout enabling device if the circuit cannot otherwise accommodate a padlock.
•Place plug in a plug lock box.
Mechanical/Storage Potential Energy
•Lockout enabling device.
•Secure the energy controlling lockout by attaching a personal lock and completed tag to
the lockout enabling device. If more than one person will be performing the work, each
must apply their own lock to a multiple lock device.
•Release all stored energy.
•If there is a heat exposure, allow to cool.
Release from Lockout/Tagout
1. Inspect the surrounding area following completion of work for loose tools, parts, correct valve
settings, system integrity, and exposed conductors.
2. Check that all machine guards are in place and reconnected if applicable.
3. Notify others in the area that the equipment is about to be made operational and returned to
service.
4. Remove personal lock, tag, and lockout enabling device. This step must be performed by the
same person who applied the tag and lock.
Lockout/Tagout Training
The lockout/tagout program is designed to train employees on disabling powered equipment from
their power sources before beginning any servicing or maintenance work. Lockout/tagout
training is required for all employees who may possibly need to lockout and tagout equipment.
Employees will receive annual training in the following areas:
1. Recognition of applicable hazardous energy sources.
2. Methods and Means necessary for energy isolation and control.
3. Restrictions and limitations of lockouts.

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2. SPECIFICATIONS
2.1 General Specifications
Projected Field (X, Y, Z= 0, 0, 5mm)
at:
Max triangle wave current 100A, 945W Bz = ± 0.518T (5180G)
Max sinusoidal current 85A, 945W Bz = ± 0.476T (4760G)
Max DC current 63A, 945W Bz = ± 0.407T (4070G)
Coils (series connection)
Coil Resistance (20°C) 0.173 Ohm
Max Resistance (80°C) 0.240 Ohm
Max Power (water cooled @ 8 lpm) 63A/15V (945W)
Self Inductance (low field) 3500µH at 1 Hz
Self Inductance (high field) 895µH at 1 Hz
(The apparent inductance increases with
frequency due to eddy currents in the solid poles)
Water Cooling (18°C) 4.0 bar (60 psid), 8 liters/min (2.1 US GPM)
Over-temperature Interlock Selco UP62-080C thermostat
Contact rating 250VAC, 2.5A. Closed below 80°C
Water flow interlock GEMS FS-380. Closed above 1.5 US GPM
Dimensions Drawing 11907-0224-0_F
74.0 mm W x 74.0 mm D x 123.5 mm H
(2.91 inch W x 2.91 inch D x 4.86 inch H)
Mass 2.5 kg (5.5 lb)Pole Diameter
CAUTION The value of maximum coil resistance given should not be exceeded. At
this resistance the coils are at maximum safe temperature for continuous operation.

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2.2 5203 Electrical and Water Cooling Connections
DC Current The 5203 electromagnet is shipped with the power and water connections
between the junction box and the magnet head connected. In the event that
these connections are broken, the correct reconnections can be made by
referencing drawings 11907-0224-0_S2 and 11907-0233-0_S1.
Ground The coil cooling plates, the magnet body and the base plate are all earthed
through the power supply earth.
Interlocks The Model 5203 has a single thermostat, Selco part no UP62-080C. It is
(refer Section 8) located between the base yoke plate and the lower cooling plate. The
thermostat is normally closed, opening when the coil heatsink temperature
exceeds 80°C, ± 5°C. In addition, a water flow switch is located in the
junction box. This is normally open and will close once the flow rate rises
above 1.5 US GPM.
Water Clean, cool (16°C - 20°C) water at 8.0 lpm at 4.0 bar (60 psid) should be used
to cool the 5203 magnet. This can be provided by house water supply or from
a recirculating chiller. An appropriate recirculating chiller is the TF90 from
Thermofisher. The magnet is shipped with a cable junction box connected,
water connections should be made to the two connections on this junction
box. The flow direction is indicated on the side of the flow switch. Refer to
drawing 11907-0224-0_S2_F. If house water supply is used, an in-line 5
micron water filter should be used for the supply line to the magnet. Also,
10m of hose is provided to give two 5m lengths for connection between the
magnet and the recirculating chiller (if ordered), brass fittings on the chiller
are already provided. Note that 4 hose clamps have also been provided for
fitting these water hoses. The power cable that connects the power supply to
the magnet (16907-0116-1-S1_A) is also provided.
Outlet: 1/4 inch Swagelok
Inlet: 1/4 inch Swagelok
CAUTION Ensure that the high current connections are tight. Loose connections may
lead to oxidation and overheating. The field stability may be degraded and
the current terminations damaged.

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2.3 11907-0224-0 - 5203 General Assembly

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2.4 11907-0233-0 - 5203 Terminal Block Assembly

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2.5 17907-0412-0 - 5203 Mounting Plate

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3. WARNINGS
PERSONNEL SAFETY
The Model 5203 has a low level of fringe field. In operation the magnet
fringi
ng field can be in excess of 0.5mT (5G). This can cause malfunctioning
of heart pacemakers and other medical implants. We recommend that the
fringing field should be mapped and warning signs be placed outside the
0.5mT (5G) contour. Entry to this region of higher field should be restricted
to qualified personnel.
FERROMAGNETIC OBJECTS
During operation the magnet exerts strong magnetic attraction towards
ferromagnetic objects in the near vicinity. Loose objects can be accelerated
to sufficient velocity to cause severe personnel injury or damage to the coils.
Keep ferromagnetic tools clear.
ARCING
This magnet stores considerable energy in its field during operation. Do not
disconnect any current lead while under load or the magnetic field energy
will be discharged across the interruption causing hazardous arcing.
HIGH VOLTAGES and CURRENTS
Be aware that the AC mains input to the DC power supply and the output
to the electromagnet are high voltage. Follow lock-out / tag-out procedures
during all maintenance procedures. Verify that all electrical connections
are secure and properly strain relieved. Loose connections may overheat
and cause damage to equipment.
HOT COIL RESISTANCE
Do not exceed the maximum coil hot resistance given in the specifications or
coil overheating and possible damage may occur.

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SYSTEM INTERLOCKS
These should always be connected if the magnet is to be operated
unattended
to avoid the possibility of coil overheating caused by excessive
power dissipation or inadequate cooling.
WATCHES, CREDIT CARDS, and MAGNETIC DISCS
Do not move magnetically sensitive items into the close vicinity of the
magnet. Even some anti-
magnetic watches can be damaged when placed in
close proximity to the magnet during operation. Credit cards, hotel room
keys,
and magnetic disks are affected by magnetic fields as low as 0.5mT
(5G).
TRIP HAZARDS
Caution must be taken when moving around the magnet as there are
potentially cables and cooling hoses on the floor that will present a trip
hazard. It is highly advised that floor conduit be purchased that will cover
these items. This will also protect from potential damage.

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4. INSTALLATION
4.1 Site Considerations
The Model 5203 is not magnetically shielded. Ferro-magnetic material in the vicinity
of the magnet will modify the magnitude and uniformity of the central region
magnetic field. As a general rule avoid magnetic material closer than approximately 1
meter of the central region.
Background fields such as the geomagnetic field and alternating field from 60Hz power sources are
not shielded by the magnet and will add to the field produced by the magnet. If possible these
background fields should be measured and their effects evaluated before the Model 5203 magnet is
installed. It may be necessary to orient the Model 5203 axis to minimize the effects of external
fields, to relocate ac power sources or to install suitable magnetic shielding.
The 5203 Electromagnet features four M3 clearance holes in its base plate and should be securely
mounted to a stable foundation. Refer Drawing 17907-0412-0_C in section 4.6
The width of the working space in front of control cabinets and compartments should be the width of
the opening or 762mm (30 in.), whichever is greater. Where control equipment or devices are
mounted on or through the fixed area around the opening into the control cabinet or compartment,
the width of the working space in front of the control cabinet or compartment shall include the width
of the fixed area containing the control equipment and devices.
The working space height shall be clear and extend from the grade, floor, or platform to a height of
2.0 m (6 ½ ft). Within the height requirements of Section 11.5, other equipment associated with the
machine located above or below the control cabinet or compartment shall be permitted to extend not
more than 150 mm (6 in.) beyond the front of the electrical control cabinet or compartment.
The working space shall permit at least 90-degree opening of control cabinet and compartment doors
or hinged panels.
The main disconnect plug socket combination shall be marked “Main Disconnect. The Main
Disconnect should be located within sight from the operator station and be readily accessible. The
height of Main Disconnect must not be greater than 2m height from floor.
The switch rated plug/receptacle shall not be placed below 0.6m to be compliant with NFPA 79.
At least one entrance of sufficient area shall be provided to give access to the working space around
control cabinets or compartments and working space should not be used for storage.

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4.2 Unpacking and Damage Inspection
Caution: Take care when handling system. All movement, lifting and installation of
the 5203 Electromagnet must be under the supervision of an experienced person to
prevent the possibility of serious injury or damage to the electromagnet and associated
equipment.
To unpack the electromagnet please use the following procedure.
1. First remove the wire clips and screws from the ‘top crate cover’ of the shipping crate.
2. Remove the top crate cover and set it aside. Remove the protective foam packaging material.
3. Inspect the magnet and junction box to ensure that no damage has occurred during shipment.
If damage is evident report the damage in detail to the shipper for claim and simultaneously
notify GMW in case assessment of the damage must be made. If no damage is found proceed
with magnet unpacking and installation.
4. Carefully lift magnet, cables, hoses and junction box clear of the shipping crate.
5. All conductors of the same ac circuit routed to the same location shall be contained in the same
raceway. Conductors external to the electrical equipment enclosure(s) shall be enclosed in
raceways (ducts).
4.3 Magnet Power Supply
For full power operation, the 5203 Projected Vertical Field Electromagnet should have a power
supply with an output current rating of up to 63A for a DC field and 100A for a triangle wave
current. To provide a stable magnetic field the power supply should be operable in “current mode”
to deliver a constant set current with overall stability of approximately 1% of full-scale current.
It is essential that the power supply to have an interlock input that will inhibit its
output when the interlock circuit is
in an OPEN state. This is referred to as a
'NORMALLY CLOSED' interlock. A normally closed interlock will ensure that the
DC power supply will remain in an inhibited state should the interlock cable become
disconnected.
4.5 AC Mains Connections
Never connect or remove the AC Mains cables from the power supply without first
Locking-out and Tagging-out the AC Mains power source. In some cases, this power
source may be a locking NEMA plug, and in systems with higher current draw, it
should be direct wired into an appropriately fused, three phase disconnect box.
AC Mains connections should be made by a licensed electrician. Many facilities have
such personnel on site.
Please refer to the Power Supply Operators Manual for complete details on AC Mains
power connections.

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4.6 Magnet Power Connections
Never connect or remove cables from the magnet with the power supply energized.
The stored energy in the magnet can cause arcing resulting in severe injury or
equipment damage.
Follow the lockout/tagout procedure as described in Section 1, Lockout/Tagout prior
to connecting or removing the DC power cables.
The magnet is shipped with a power and interlock cable attached. The recommended current cable
for the 5203 is shown in Drawing 16907-0116-1-S1_A (section 12). Because the magnet stores a
significant amount of energy in its magnetic field, special care should be taken to ensure that the
current terminations are secure and cannot work loose in operation. Local heating at the
terminations can cause rapid oxidation leading to a high contact resistance and high power
dissipation at the terminals. If left unattended this can cause enough local heating to damage the
terminals and the coils.
4.7 5203 Interlocks
In the event of an interlock tripping it is strongly recommended that the root cause of
the trip be determined. In the event that the root cause cannot be determined please
contact Tom King ([email protected]) for technical support.
The Model 5203 has one Selco UP62-080C thermostat. It is located between the base yoke plate and
the lower cooling plate. The thermostat is normally closed, opening when the coil heatsink
temperature exceeds 80°C, ± 5°C.
The interlock circuit also includes a flow switch (GEMS FS-380) located at the junction box. This
flow switch is open for flow rates above 5.4 lpm (1.5 US gpm).
4.8 Interlock Testing
It is crucial that before general operation of the magnet system, that the interlock
circuits be tested. This test requires that the terminal cover be removed
from the
magnet while energized and therefore must be completed by a qualified electrician.
This test should be done with the magnet operating with a LOW power setting,
preferably less than 5 amps.
DO NOT AT ANY POINT TOUCH OR DISCONNECT THE MAGNET
POWER CABLES.
Thermal Switches: Carefully remove one of the temperature switch connections from the interlock
termination block. The power supply output MUST enter a disabled state. Reconnect the
connection and the power supply output should return to normal.
Flow Switch: Shut off the water supply to the magnet. The power supply output MUST enter a
disabled state. Restore the water supply and the power supply output should return to normal.
This interlock testing procedure should be carried out no less than every six months.

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4.9 Magnet Cooling
The Model 5203 can be operated up to an average coil temperature of 80°C. Assuming an ambient
laboratory temperature of 20°C and a temperature coefficient of resistivity for copper of 0.0039/°C,
the hot resistance of the coil should not exceed 25% more than the ambient temperature "cold"
resistance. The coil thermostat will open when any coil cooling plate temperature exceeds
approximately 80°C . Clean, cool (16°C 20°C) water at 8 l/min and 4 bar (60 psid) must be used to
cool the 5203 magnet.
The copper cooling tubes are electrically isolated from the coils to avoid electrochemical corrosion.
A 50 micron filter should be placed before the input to the magnet to trap particulates.
Configuration Suggestion: For continuous operation of the magnet it may be appropriate to use a
recirculating chiller to reduce water and drainage costs. The chiller capacity will depend on whether
cooling is required for the magnet alone or magnet and power supply.
Do not use corrosion inhibitors in high quality electrical systems since the water conductivity is
increased which can result in increased leakage currents and electrochemical corrosion.
Avoid cooling the magnet below the dew point of the ambient air. Condensation may cause
electrical shorts and corrosion.
During operation the resistance can be checked using a voltmeter across each coil. The voltage will
rise to a constant value once thermal equilibrium has been reached. If it is desired to save water, the
water flow may be reduced until the hot resistance is approached. NOTE: This adjustment must be
made slowly enough to allow for the thermal inertia of the coils.

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5. OPERATION
The 5203 electromagnet is water cooled and should not be operated without water.
Attempts to operate the magnet as an air cooled system will most likely result in
irreversible damage to the magnet.
This product is an electromagnet and creates significant magnetic fields both within
the magnet and in the surrounding area. Make sure that there are no ferromagnetic
items, tools or components loose in a 1 meter radius surrounding the magnet.
The Model 5203 is not a shielded electromagnet. In operation the magnet fringing
field can be in excess of 0.5mT (5G). This can cause mal
functioning of heart
pacemakers and other medical implants. We recommend that the fringing field should
be mapped and warning signs be placed outside the 0.5mT (5G) contour. Entry to this
region of higher field should be restricted to qualified personnel.
Do not move magnetically sensitive items into the close vicinity of the magnet. Even
some anti-magnetic watches can be damaged when placed in close proximity to the
magnet during operation. Credit cards, and magnetic disks are affected by magnetic
fields as low as 0.5mT (5G).
5.1 Initial Operation
The magnet system in its most basic configuration will consist of the electromagnet and a suitable
DC power supply. Options are available to improve usability by providing better feedback of the
magnet interlock status, computer control, and magnetic field monitoring and control.
1. Adjust the cooling water flow to approximately 8 liters/min (2.1 US gpm). For operation at
less than maximum power the water flow may be correspondingly reduced. Note that the inlet
water temperature will determine the actual flow rate required. The above specified flow rates
were determined with a water inlet temperature of approximately 18°C.
2. Set the DC power supply voltage and current controls to zero and switch on the power supply.
For maximum stability, the power supply should be operated in 'current mode', and most power
supplies will automatically switch modes depending on which control is set LOWER as the
lower control would be the limiting factor.
3. Switch on the DC power supply. To operate in the current mode, the voltage control must be
set to a sufficiently high level to allow the desired current to be set: With the current control at
its minimum, turn the voltage control up, and then adjust the current control to the desired
output. Should the current control stop responding, it is likely that the system has switched to
voltage mode. In that case, adjust the voltage control higher and then continue adjusting the
current control.
At this point the magnetic field should be checked to verify that the field being generated
corresponds correctly with data given for the Excitation Curve. Refer to Section 7 - 'Excitation
Curves' for excitation graphs that most closely resembles your magnet configuration.