Walker Magnetics SMART-D SERIES - Manual (Page 3)

O.S. WALKER Co., Inc. SMART-D Control
SMART D MANUAL DD14511L Rev. L, March 30, 2011
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TABLE OF CONTENTS
1 INTRODUCTION...............................................................................................................................................................1-1
2 SAFETY INSTRUCTIONS ................................................................................................................................................2-1
2.1 G ENERAL S AFETY R ULES .............................................................................................................................................2-1
2.2 R ECOGNIZE S AFETY I NFORMATION ................................................................................................................................2-2
2.2.1 Ways to Avoid a Reduction of Holding Capacity................................................................................................2-2
2.3 A DDITIONAL W ARNINGS ................................................................................................................................................2-3
2.4 D ESIGNATED P ERSON ..................................................................................................................................................2-3
3 INSTALLATION INSTRUCTIONS....................................................................................................................................3-1
3.1 M OUNTING THE C HUCK C ONTROL & C ONNECTING E LECTRICAL P OWER ..........................................................................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 C ONTROL M OUNTING G UIDELINES ................................................................................................................................3-5
4 OPERATING INSTRUCTIONS.........................................................................................................................................4-1
4.1 I MPORTANT F ACTS ABOUT M AGNETIC H OLDING .............................................................................................................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 F ULL H OLDING .............................................................................................................................................................4-3
4.3 V ARIABLE H OLDING ......................................................................................................................................................4-3
4.4 R ESIDUAL H OLDING ......................................................................................................................................................4-3
4.5 R ELEASE .....................................................................................................................................................................4-3
4.6 C ONTROL P ROTECTION ................................................................................................................................................4-5
4.7 R ELEASE C YCLE S TEPS ................................................................................................................................................4-5
4.8 G ROUNDING & S HIELDING .............................................................................................................................................4-7
4.8.1 Current Sensing..................................................................................................................................................4-7
4.8.2 Part Release.......................................................................................................................................................4-7
4.8.3 Lockout ...............................................................................................................................................................4-7
4.9 C ONTROL O UTPUT V OLTAGE ........................................................................................................................................4-7
5 MAINTENANCE & TROUBLESHOOTING ......................................................................................................................5-1
5.1 I NSPECTION & M AINTENANCE ........................................................................................................................................5-1
5.2 H AVING A P ROBLEM WITH YOUR C HUCK C ONTROL ? .......................................................................................................5-1
5.3 C HUCK C ONTROL C ONNECTIONS ..................................................................................................................................5-3
5.4 R EMOTE I NTERFACE .....................................................................................................................................................5-4
5.4.1 Connections:.......................................................................................................................................................5-4
5.5 I NTERFACE ...................................................................................................................................................................5-4
5.6 S MART 75/100D P ANEL L AYOUT ...................................................................................................................................5-5
5.7 S MART 20/30/50D P ANEL L AYOUT ................................................................................................................................5-6
5.8 S MART 7/10/15D P ANEL L AYOUT ..................................................................................................................................5-7
5.9 S MART 3/5D P ANEL L AYOUT .........................................................................................................................................5-8
5.10 M AIN PC B OARD ........................................................................................................................................................5-9
5.11 S MART 75/100D W IRING ..........................................................................................................................................5-10
5.12 S MART 20/30/50D W IRING .......................................................................................................................................5-11