Walker Magnetics IMI Smart-D Series User manual

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OperatiOns Manual
sMart-D series MicrOprOcessOr cOntrOlleD chuck cOntrOl
TOLL FREE: 800.WMAGNET
CONTENTS
P.O. #: Part #:Order #:
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
NEVER ATTEMPT TO OPERATE THIS CONTROL UNTIL YOU
HAVE READ AND UNDERSTAND THIS OPERATOR’S MANUAL

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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
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 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

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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 inefcient 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

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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 qualied personnel shall make adjustments within the control while it is
energized!
• Never operate the control and chuck until it has been veried 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)

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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.
Red Background, White Letters
This indicates a situation in which a
hazard is imminent and will result in a high
probability of serious injury or death.
These are
Hazard
Seriousness
Signal
Words
Orange Background, Black Letters
This indicates a potentially hazardous
situation, which could result in some
probability of serious injury or death.
Yellow Background, Black Letters
This indicates a potentially hazardous
situation, which could result in minor injury
or moderate injury.
2.2.1 Ways to Avoid a Reduction of Holding Capacity
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, at, 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 difculty holding a work piece, DON’T attempt to machine it! Call the
O.S. Walker Co. for advice at 1-800-962-4638.

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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.
• Modication 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 specic parts listed
in this manual and is able to verify the proper functioning of the specic replacement parts and the entire product after the
completion of the installation.
ELECTRICAL GROUNDING
Because the O. S. Walker Co. does not know the specics 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 cross-sectional 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 uid 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.

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3 INSTALLATION
• 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 qualied 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 fty (50) feet of the main control enclosure and away from exposure to any uids.
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 fty
(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.
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 qualied
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.

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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.
3.1.6 Transformer Wiring Diagram
Figure 3-2 Transformer Wiring Diagram

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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 owing 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 rst 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 rst 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.
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 specications must be met.
a. The air surrounding the panel on which the parts are located should not exceed 120° Fahrenheit.
b. The air temperature must be measured:
1) With the control in the Full holding position;
2) After the control has been in operation for 30 minutes; and
3) With the chuck holding the largest load to be used.

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2. When any control (power section) is to be placed in a secondary enclosure while still in its original enclosure, the following
specications must be met:
a. With the control (power section) mounted in its original enclosure and then mounted in a secondary
enclosure, the air surrounding the original enclosure should not exceed 104° Fahrenheit.
b. The air temperature must be measured:
1) With the control in the Full holding position;
2) After the control has been in operation for 30 minutes; and
3) With the chuck holding the largest load to be used.
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.
4.1 Important Facts about Magnetic Holding
Workpiece characteristics must be considered in order to determine the magnetic holding attraction that a magnetic chuck
can provide.
This is true for all magnetic chucks because they all operate using the same fundamental laws of physics. Magnetic power is
often pictured as lines of magnetic force owing from north to south pole. Anything that limits the ow of these magnetic lines
of force obviously reduces the magnets holding capacity. There are many important factors that limit the ow of these lines of
force.
4.1.1 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 the magnet and the workpiece limits the ow of magnetic lines of force and, thus,
reduces the holding capacity of a magnetic chuck.
• Magnetic Chuck Surface Condition -- The holding surface of a magnetic chuck must be clean, smooth, at, and
free of nicks or burrs in order to minimize the air gap between the chuck holding surface and the Workpiece. All Walker
chucks are designed with soft, low carbon steel magnetic poles in the top plate in order to maximize the holding capacity;
therefore, special care must be taken to protect these areas.
• Workpiece Surface Condition -- The holding capacity of the chuck will be reduced if certain surface conditions exist. A
rough surface nish on the workpiece creates an air gap as also foreign materials like dirt, paint, rust, paper, and rags.
4.1.2 Workpiece Thickness
The greater the number of lines of magnetic force owing 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 ow. After a certain
thickness of the workpiece, no additional lines of force will ow because the magnet has reached its full capacity.
• Thin workpieces mean less iron available, and thus fewer lines of magnetic force ow from the magnet into the
workpiece. Therefore, the chuck holding capacity is reduced.
• Typically, the minimum thickness of a workpiece required to reach full holding capacity is the same as the thickness
of the chuck major magnetic steel poles.
4.1.3 Portion of the Chuck Surface In Contact With the Workpiece
The full surface of the chuck top plate must be covered by the workpiece to achieve the maximum holding capacity.
The surface of the workpiece must contact equal areas of the chuck opposite polarity major magnetic poles to obtain
maximum holding force.