INSTALLATION, OPERATION, & MAINTENANCE

MANUAL FOR MAGNAFLUX® EQUIPMENT

D-2000 SERIES

Magnaflux
3624 W. Lake Avenue
Glenview, IL 60026
Phone: 847-657-5300
Fax: 847-657-4791
E-mail: [email protected]
 TABLE OF CONTENTS
GENERAL SAFETY INSTRUCTIONS
SECTION 1 - EQUIPMENT SPECIFICATIONS ........................................................................................ 1-1
Scope of this Manual ............................................................................................................................ 1-1
Purpose of the Equipment ..................................................................................................................... 1-1
Equipment Characteristics .................................................................................................................... 1-1
Equipment Specifications ..................................................................................................................... 1-3
SECTION 2 - INSTALLATION and STORAGE ......................................................................................... 2-1
General .................................................................................................................................................. 2-1
Installation ............................................................................................................................................ 2-1
Preparation for Storage or Shipment................................................................................................... 2-12
SECTION 3 - OPERATING INSTRUCTIONS ............................................................................................ 3-1
Operating Controls and Indicators ........................................................................................................ 3-1
Daily Start Up and Operation Check List ............................................................................................. 3-4
Piece Part Set-up ................................................................................................................................... 3-7
Magnetizing Procedures........................................................................................................................ 3-8
Demagnetization ................................................................................................................................. 3-10
Shutdown ............................................................................................................................................ 3-11
Emergency Shutdown ......................................................................................................................... 3-11
SECTION 4 - MAINTENANCE ..................................................................................................................... 4-1
General .................................................................................................................................................. 4-1
Daily Operator Maintenance ................................................................................................................. 4-1
Weekly Operator Maintenance ............................................................................................................. 4-2
Monthly Operator Maintenance ............................................................................................................ 4-2
Periodic Internal Maintenance .............................................................................................................. 4-2
Operational Checkout Procedures......................................................................................................... 4-5
Initial Set-up ......................................................................................................................................... 4-5
Circular (Contact) and Longitudinal (Coil) Magnetization Check ....................................................... 4-7
SECTION 5 – TROUBLESHOOTING ......................................................................................................... 5-1
Demagnetization Adjustment ................................................................................................................ 5-1
Troubleshooting Guide ......................................................................................................................... 5-3
SECTION 6 – DRAWINGS & SPARE PARTS LIST .................................................................................. 6-1
SECTION 7 – HOOD INSTALLATION ....................................................................................................... 7-1
 GENERAL SAFETY INSTRUCTIONS

This manual provides information on how to install, operate, and maintain your Magnaflux
magnetic particle inspection machine.

Read these instructions carefully before operating or servicing your machine.

· Only trained personnel should operate or service this machine. Be familiar with your facility and local
procedures as well as Lock Out/Tag Out requirements before working with this machine.

· Read this entire manual before operating this machine.

· Wear safety glasses that conform to ANSI Standard Z87.1 while operating this machine.

· Do not wear loose clothing or jewelry while operating or servicing this machine.

· Inspect the machine daily for unsafe conditions; replace any worn or broken parts (see Section 4).

· Keep all unauthorized personnel away from the machine operating area.

· According to the American Conference of Governmental Industrial Hygienists (ACGIH) recommendations,

inspectors with pacemakers should avoid exposure to D.C. fields over 10 gauss; or 60 cycle A.C. field over
1.0 gauss. There are a variety of pacemakers with different susceptibilities to magnetic fields. Wearers
should discuss pacemaker limitations with their physicians and learn more exactly what they should avoid,
and whether they should be exposed to magnetic fields before operating this equipment.

· When you are finished operating the machine, turn off all power.

· This machine was designed to help the end user comply with ASTM E-1444-11. Calibration frequency is
dictated by this standard.
 SECTION 1: EQUIPMENT SPECIFICATIONS

SCOPE OF THIS MANUAL

This manual provides essential information required for installation, operation, and maintenance of standard
Magnaflux D-2000 Series Stationary Magnetic Particle Inspection Machines.

PURPOSE OF THE EQUIPMENT

The equipment is used to inspect ferromagnetic parts by means of the magnetic particle inspection method.
Magnetic particle inspection (MPI) is a non-destructive method for revealing surface, and, under certain
conditions, sub-surface discontinuities. It consists of three basic operations:

1. Application of magnetic particles.

2. Establishment of a suitable magnetic field.

3. Inspection and evaluation of particle accumulations.

Discontinuities may exist in raw material from which parts are made, or, they may occur during processing or
fabrication of the parts, or, they may exist as cracks due to excessive service stresses. Discontinuities are
considered defects if their existence is detrimental to the usefulness of the part. Magnetic particle inspection can
readily and reliably locate discontinuities revealing manufacturing and/or service-induced defects.

EQUIPMENT CHARACTERISTICS

Stationary magnetic particle inspection units consist of a processing station and an integral power pack. The
power pack provides low-voltage, high-amperage 3-phase full wave direct current for magnetization and reversing
3-phase full wave direct current for demagnetization.

The output current levels are governed by 2 separate current control potentiometers. Selection of Contacts or Coil
operation is provided by push buttons on the Operator Control Panel. A push button on the Operator Control
Panel, or a push bar, initiates the timed magnetizing current “shot.”

A digital ammeter provides a reading of the magnetizing current. The reading is held until the next current “shot”
is initiated. The wet bath is contained in a tank that runs the full length of the machine. A pump re-circulates and
agitates the particle in bath and provides flow to the hand held spray nozzle or the Optional Auto-bath nozzles.
Grilles cover the tank, provide a work surface, and prevent parts from falling into the tank.

The air-operated headstock and fully adjustable locking tailstock provide the necessary clamping force to assure
good electrical contact with the part.

1- 1 -
Parts clamped between the headstock and tailstock for circular magnetization may also be magnetized
longitudinally with the coil while clamped in the headstock and tailstock.
The bath is charged with magnetic particles. An ultraviolet black light causes the coated particles to glow,
revealing flaws in the part being tested.

Pertinent data (e.g., the unit’s serial number, electrical specifications, and duty cycle rating) may be found on the
Magnaflux Data Plate, located on the headstock end of the unit.

1- 2 -
EQUIPMENT SPECIFICATIONS

CONVENIENCE OUTLETS 2 each 115 volts AC, 5 ampere (for Black Light)
COMPRESSED AIR (¼” NPT pipe connection) 60-100 psig

Input Specifications
The equipment can be fused based on less than the maximum amperage draw due to the duty cycle. Refer to NEC
Code Section 630.31 Ampacity of Supply Conductors and Table 630.31(A) (2) Duty Cycle Multiplication Factors
for Resistance Welders (NPFA National Electric Code 2011).

Table 1-1. Electrical Input

Model Input Volts Load Recommended Line Recommended

Series AC Phase (Amperes) Fuse (Amperes) Wire Size (AWG)
208 3 160 125 2
D-2060
230 3 160 125 2
(SEE MOD 6
AC ON 380 3 100 80
415 3 90 70 6
NEXT
PAGE) 460 3 80 60 6
575 3 70 60 6

Table 1-1. Electrical Input

Model Input Volts Load Recommended Line Recommended

Series AC Phase (Amperes) Fuse (Amperes) Wire Size (AWG)
208 3 400 300 0
D-2100
230 3 400 300 0
(SEE MOD
AC OPTION 380 3 245 200 2
ON NEXT 415 3 220 175 2
PAGE) 460 3 200 150 4
575 3 160 125 4

1- 3 -
Table 1-1. Electrical Input

Model Input Volts Load Recommended Line Recommended

Series AC Phase (Amperes) Fuse (Amperes) Wire Size (AWG)
208 3 425 300 0
MOD 2.5 &
230 3 400 300 0
MOD 4 AC
380 3 245 200 2
(Optional)
415 3 225 175 2
460 3 200 150 4
575 3 160 125 4

Table 1-1. Electrical Input

Model Input Volts Load Recommended Line Recommended

Series AC Phase (Amperes) Fuse (Amperes) Wire Size (AWG)
208 N/A N/A N/A N/A
MOD6 AC
230 3 575 350 2/0
(Optional) 0
380 3 350 200
415 3 325 200 0
460 3 300 150 2
575 3 200 100 2

1- 4 -
Output Specifications
*All contacts current ratings are based on the maximum current through a
2000 amp/100 mv shunt.

*Some coils may be capable of handling more current but these levels are based on the duty cycle of the unit.
Table 1-2. Magnetization and Demagnetization Output
Maximum Current
(Amperes)*
Model Current
Series Mode Average (DC) Peak Control Demag
D-2060 Contacts 6000 6000
Continuously Reversing
12” Coil 4600 4600 Variable Decaying DC
16” Coil 4400 4400 In all cases
20” Coil 4200 4200
25” Coil 4000 4000

Maximum Current
(Amperes)*
Model Current
Series Mode Average (DC) Peak Control Demag
D-2100 Contacts 10000 10000
Continuously Reversing
12” Coil 5800 5800 Variable Decaying DC
16” Coil 5200 5200 In all cases
20” Coil 5000 5000
25” Coil 4700 4700

Table 1-3. Duty Cycle

Model Series Seconds “On” Seconds “Off”

D-2060 SERIES
At Maximum Output 0.5 10
At 1000 A. Output 0.5 5

D-2100 SERIES
At Maximum Output 0.5 20
At 1000 A. Output 0.5 5

1- 5 -
 Dimensions and Capacities
Table 1-4. Part Weight Capacity

Maximum Load

Description Pounds Kilograms

Using contact pad mounted v-blocks to support part 300 136

Using contact pad mounted v-blocks to support part (with rotating heads) 70 32

Using rail mounted steady rests to support part 1500 680

Equipped with heavy duty frame option and rail mounted steady rests to support part 4000 1814

Table 1-5. Part Length Capacity Table 1-6. Recommended Bath Level

Model No. Length Model No. Gallons Liters

D-2*** 54" (137 cm) D-2*** 20 75

D-2***L 102" (259 cm) D-2***L 32 122

D-2***XL 146" (370 cm) D-2***XL 55 209

Table 1-7. Machine Weight

Approximate Weight (Dry) Approximate Weight (Crated)

Model No. Pounds Kilograms Pounds Kilograms

D-2*** 1600 726 1875 850

D-2***L 1825 828 2100 952

D-2***XL 1925 873 2200 998

Table 1-8. Overall Dimensions

1- 6 -
 Description D-2*** D-2***L D-2***XL

Basic Unit (No Hood)

Length 84½ (215cm) 132½(336cm) 176½(448cm)
Depth 41(104cm) 41(104cm) 41(104cm)
Height 60¼(153cm) 60¼(153cm) 60¼(153cm)

Basic Unit (With Optional Hood)

Length 86(218cm) 135(336cm) 178(452cm)
Depth (Hood Opened) 50(127cm) 50(127cm) 50(127cm)
Depth (Hood Closed) 73(185cm) 73(185cm) 73(185cm)
Height (Hood Opened) 120(305cm) 120(305cm) 120(305cm)
Height (Hood Closed) 89½(227cm) 89½(227cm) 89½(227cm)

1- 7 -
PAGE LEFT BLANK
INTENTIONALLY

1- 8 -
 SECTION 2: INSTALLATION AND STORAGE

GENERAL

This section contains information required for unpacking, inspecting, and setting up the magnetic particle
inspection unit. Information for preparing the inspection unit for shipment and storage is also included.

INSTALLATION

Location of Unit

Consider the following requirements before selecting a permanent location for the inspection unit:

1. A power source of the proper voltage, frequency and phase (as designated on the Magnaflux Data Plate
located on headstock end of inspection unit) capable of providing current per the nameplate.

2. A compressed air supply capable of providing minimum 60-100 psig at 5 cubic feet per minute.

3. A minimum of two feet is required at both ends and the rear of the inspection unit to ensure adequate
space for servicing and ventilation.

4. A firm, reasonably level floor capable of supporting the inspection unit and the materials awaiting
inspection.

5. Adequate space to accommodate a black light inspection canopy (Optional), material storage, material
movement and access to the materials.

Unpacking

No special unpacking process is necessary. Observe normal precautions to prevent damage to inspection unit,
and adhere to standard practices for the removal of crating material, protective barrier materials and
preservatives.

Visually inspect the machine and Optional accessories for any apparent shipping damage, and to ascertain that
all accessories ordered have been received. If shipping damage is found, please contact the freight company
to report the damage before contacting Magnaflux Customer Service via phone at 847-657-5300, or via e-mail
at [email protected].

Leveling

Check the tailstock rails for true level, shimming the legs as required. When the inspection unit is level,
secure it to the floor with a bolt through each leg.

2-1
Electrical Connections

The inspection unit as supplied is internally wired for operation from a power source as designated on the
Magnaflux Data Plate (located on headstock end of inspection unit). When connecting the unit all local codes
should be followed. External wiring directions for operation on the designated voltage are as follows:

1. Open rear panel located on the headstock end, or Optional disconnect, to gain access to input power
terminal block.
WARNING: Turn off and lock-out the external disconnect switch (not normally supplied) before opening
the rear panel. Failure to disconnect incoming power could result in severe electrical shock
or death.

2. Connect external power source to the terminal block on the rear of the inspection unit, or the top
connectors in the Optional disconnect. Refer to Table 2-2 for recommended dual-element time delay fuse
size and power source conductor size.
WARNING: Magnetic particle baths can carry electrical current. Since operators will come in
contact with the bath during operation, proper grounding of the inspection unit is
essential. Failure to ground the inspection unit properly may result in an electrical
shock hazard. Check the ground connection with an ohmmeter. A reading of 0 ohms
denotes an acceptable ground connection.

Figure 2-1 Figure 2-2

In Figure 2-1 above, the rear headstock side panel has been removed. This is the location for the
electrical connection. Figure 2-2 above is a closer view of where the connection is located. The black wires
on the right side of the High Voltage label in Figure 2-2 would be the wires that the customer installs.

2-2
 Figure 2-3
In Figure 2-3 above, the copper lug shown is the ground lug. The top punch out hole in the frame is for the
customer to run the wires through and connect to the terminal block located behind the High Voltage label.

Table 2-2. Recommended Fuse Size

D-2060
Voltage Fuse Line Wire Ground
wire

208 125 4 Same as

230 125 4 Line
380 80 6
415 70 6
460 60 6
575 60 6
D-2100

Voltage Fuse Line Wire Ground

Wire

208 300 0 Same as

230 300 0 Line
380 200 2
415 175 2
460 150 4
575 125 4

2-3
Table 2-2. Recommended Fuse Size
MOD 4AC (Optional)
Voltage Fuse Line Wire Ground
wire

208 300 0 Same as

230 300 0 Line
380 200 2
415 175 2
460 150 4
575 125 4
MOD 6AC (Optional)

Voltage Fuse Line Wire Ground

Wire

208 N/A N/A Same as

230 400 2/0 Line
380 300 0
415 250 0
460 225 2
575 200 2

Air Supply

Connect a 60-100 psig compressed air supply to the Pressure Regulator Valve (Item 7, Figure 2-9). Adjust the
pressure regulating knob until the air pressure gauge indicates 40 psi. Figure 2-4 and 2-5 below show this
regulator on the headstock end of the machine.

Figure 2-4 Figure 2-5

2-4
The air connection is required to operate the pneumatic headstock and pneumatic contactor, which is shown
below in Figure 2-6.

WARNING: If air is not connected to the machine, severe damage can occur.

Figure 2-6

Pump Connection

WARNING: Pump should not be run dry. Be sure to fill the tank with oil or water bath prior to
plugging in the pump.

After the tank is filled with oil or water bath, and the proper amount of magnetic particles, plug the pump in
to the outlet located on the operator’s end of machine. Figures 2-7 below shows the pump as it is shipped and
normal operation. Figure 2-8 shows the housing removed, which would be required to do any maintenance.

Figure 2-7 Figure 2-8

2-5
 FIGURE 2-9

Item 1 Foot Switch Item 6 Head Stock Pressure Regulator

Item 2 Push Bar Item 7 Air Input
Item 3 Power Indicator Item 8 Head Stock Needle Valve (speed adjust)
Item 4 Magnetic Current Button Item 9 Hand Hose
Item 5 Control Cabinet (see Figure 2-12) Item 10 Tail Stock Lock Ratchet

NOTE: Adjustment of the pressure regulator for higher or lower pressures will also result in higher or lower
clamping forces. Proper adjustment assures proper clamping force without distorting the test part.
Too low of pressure can cause arcing on the part at high amperage.

2-6
Inspection Hood installation
(Optional)

1. Refer to Section 7.

Black Light Installation

(Optional Accessory)

1. Secure the black light mounting bracket with three screws, lock washers, and flat washers through holes at the
tailstock end of the inspection unit.

2. Install the transformer by sliding bottom tabs through slots on mounting bracket.

3. Plug black light cord into the BLACK LIGHT outlet on either end of the inspection unit. Test ground fault
interrupt for proper operation.

4. If using the optional 600086 BLACK LIGHT with the integral mag shot button, plug the mag shot cable into
the REMOTE MAG socket conveniently located on either end next to the BLACK LIGHT outlets.

Adjustment of Magnetizing Shot Duration

The duration of the magnetizing shot is set at 0.5 seconds from the factory.

1) Figure 2-10 shows the PLC, while Figure 2-11 shows the port cover open on the PLC. Adjust the top
small potentiometer behind the communication port cover on the PLC. The range is from 0.5 to 5
seconds. Use caution not to exceed the duty cycle of the unit when adjusting the timer. With the screw
turned all the way counter clockwise, that equals 0.5 seconds. If the screw is turned all the way
clockwise, that equals 5 seconds. A shot timer (Magnaflux Accessory Part #622901) should be used to
provide the actual shot time that has been set.

Figure 2-10 Figure 2-11

2-7
 1

2
MAGNETIZING AMPERES X 1000

3 4

5 5
4 6 4 6

3 7 3 7

2 8 2 8

1 9 1 9

0 10 0 10
CONTACTS COIL
CURRENT CONTROL CURRENT CONTROL

5 6 7 8 9 10

PUSHBAR LIGHT COIL AUTO BATH DEMAG

11 12 13 14 15 16

PUMP FAN CONTACTS AUTO MAG MAG

FIGURE 2-12
CONTROL PANEL
Key

Item 1 Digital Ammeter Item 9 Auto-bath Select Button (Optional)

Item 2 Current Assurance Indicator Item 10 Demag Select Button
Item 3 Contacts Current Adjust Item 11 Pump Activate Button
Item 4 Coil Current Adjust Item 12 Hood Fan Button
Item 5 Push bar ON/OFF Button Item 13 Contacts Select Button
Item 6 Hood White Light Button Item 14 Spare (reserved for options)
Item 7 Coil Select Button Item 15 Auto-mag Select Button (Optional)
Item 8 Mod AC (Optional) Item 16 Mag Button

2-8
NOTE: The following procedure should be performed by a qualified maintenance technician.

Ammeter Accuracy Verification

1. With the unit electrically installed, the compressed air supply connected, and the inspection hood
installed, connect the foot switch or the Optional palm buttons to the FOOT SWITCH outlet on the
left side of unit. This outlet is the bottom one shown in Figure 2-13 below. In Figure 2-14 below it
shows all the outlets.

Figure 2-13 Figure 2-14

2. Unlock and position tailstock where the digital test meter kit shunt can be supported by the tailstock and
headstock shelves. Lock tailstock.

3. Position the digital test meter kit shunt (Magnaflux Accessory Part #622350) as shown in Figures 2-15
and 2-16 on the following page, and specified in Table 4-5, between the headstock and tailstock.

2-9
 Figure 2-15 Figure 2-16
4. Connect the shunt cable leads to the shunt terminals and the test meter shunt input as directed in the test
kit instructions.

5. Check that the pressure gauge indicates 40 psi.

6. Turn on disconnect switch; digital ammeter and power indicator will light.

7. If equipped with the AUTOBATH option, toggle AUTOBATH and PUMP push-buttons to off.
If equipped with the AUTOMAG option, toggle AUTOMAG to off by pressing and holding the AUTO
MAG button until the light goes dim, then releasing.

8. Depress the foot switch or the Optional palm buttons to firmly clamp the shunt in position between the
headstock and tailstock.

9. Electrically connect the digital test meter kit to the unit per the instructions furnished with the test meter.

10. Press CONTACTS push-button to on.

12. Set the CONTACTS CURRENT CONTROL to 1/3 full scale and lock to prevent accidental change in
setting.

13. Press MAG push-button. After the timed “shot,” both the unit’s digital ammeter and test kit ammeter
should display within +/- 5% or 50 Amps.

14. Press AC (MOD AC Optional) and set digital test meter to AC and repeat step 13.

Coil Ammeter Accuracy Verification

1. This unit is designed with one meter. The feedback circuit to the meter comes from the same source as
the contacts. If the meter is accurate in the contact mode, the meter is considered calibrated for the all
modes.

2-10
Preparation of Bath

WARNING: Never operate the pump without bath in the tank. Operation of the pump without bath
may overheat the pump seal.

1. Be certain that the drain cock at the rear of the unit is closed.

2. Agitation system is checked for leaks prior to shipment with light oil. If using water bath, carefully
clean the entire system with liquid detergent solution and re-circulate, followed by a thorough water rinse.
If using oil bath, flush system with light oil (Specification MIL-L-15016) such as Magnaflux Carrier II.

3. Prepare bath according to the manufacturer’s recommendations and any applicable specifications. For
proper particle agitation, DO NOT EXCEED VOLUME RECOMMENDED IN TABLE 1-6.

4. Press PUMP push-button to on. The push-button is dimly lit when off and brighter when on. Allow the
bath to agitate and circulate through the system.

Table 2-5. Recommended Bath Concentration

Magnaglo® Magnaflux® Water Conditioners

14A MG-410 20B 7C WA-2B WA-4

Recommended Concentration 1 Part to

Ounces/Gallon 1/6 1/10 1½ 1¼ 1_ 100 parts
Grams/Liter 1.25 0.75 11.25 9.4 10.0 water

Settling Volume (ml/100 ml bath) 0.15-0.25 0.05-0.15 0.15-0.25 1.1-1.7 N/A N/A

Use Centrifuge Tube Part # 8493 507923 8493 2461 N/A

Checking Bath Concentration Using Settling Test

NOTE: The settling test applies to both oil and water suspensions. As water evaporates more quickly
than oil, water baths generally require more frequent maintenance. Check applicable
specifications for test frequency.

1. Allow the pump to thoroughly agitate the suspension for at least fifteen minutes to assure uniform particle
distribution.

2. Run the suspension through a hand hose and nozzle for at least one minute to assure the suspension in the
hose is fresh and agitated.

2-11
3. Using the hand hose, fill the centrifuge tube with agitated solution to 100 ml.

4. Place the centrifuge tube in its stand (Magnaflux Accessory Part #1837A), and allow the suspension to
settle for thirty minutes (water baths) or sixty minutes (oil baths) in a vibration-free location.

5. Observe the total level of settled particles. Graduations read directly in milliliters (ml). If a contaminant
layer is present, subtract from the total level to obtain magnetic particle concentration.

6. Illuminate the centrifuge tube and suspension with a black light (Optional). Fluorescence in the liquid or
presence of a non-fluorescent particle layer indicates a solution breakdown, and requires replacement of
the tank solution.

7. If the solution concentration is outside the range of the manufacturer’s recommendations or applicable
specifications, adjust the amount of liquid or particles as required. Repeat steps 1 through 6 to verify
concentration.

8. Return the contents of the centrifuge tube to the tank and clean the centrifuge tube prior to the next test.

PREPARATION FOR STORAGE OR SHIPMENT

Limited Storage

When the inspection unit will not be used for a period up to 30 days, it should be serviced as follows:

1. Open the Auto-bath valve (Optional).

2. Open the drain cock at the rear of the inspection unit, drain all bath solution into a suitable container and
discard the used solution.

3. Remove and clean the grilles, agitator vee, and pump; then, replace these back on the unit, and close the
drain cock. The tank and hand hose can be cleaned using compressed air.

4. Open the valve (turn clockwise) at the bottom of the regulator/gauge/filter bowl, and blow out. Then,
shut off the air supply to the machine.

5. Place the CURRENT CONTROLS to the 0 positions. Disconnect power from the inspection unit by
placing the external disconnect switch in the off position.

6. Disconnect the foot switch or palm buttons (Optional), and the black light (Optional). Pack and store in a
plastic bag or carton on the grilles.

7. Cover the tank with paper, cardboard or plastic to prevent the accumulation of dust, dirt or other
contaminants. Close the hood (Optional) curtains for added protection.

2-12
Long Term Storage and/or Shipment
1. Open the Auto-bath valve (Optional).

2. Open the drain cock at the rear of the inspection unit, drain all bath solution into a suitable container and
discard the used solution.

3. Remove and clean the grilles, agitator vee, and pump; then, replace these back on the unit, and close the
drain cock. The tank and hand hose can be cleaned using compressed air.

4. Open the valve (turn clockwise) at the bottom of the regulator/gauge/filter bowl, and blow out. Then,
shut off the air supply to the machine.

5. Lock the tailstock assembly close to the headstock.

6. Place the CURRENT CONTROLS to the 0 position.

7. Disconnect power from the inspection unit by placing the external disconnect switch in the off position.
Disconnect the three conductors from the terminal block. Disconnect the ground conductor from the
brass grounding screw.

8. Disconnect the foot switch or palm buttons (Optional) and the black light (Optional). Pack and store in a
plastic bag or carton on the grilles.

9. Support the hood (Optional) at both ends and then remove the hardware securing the hood to the
inspection unit frame. Lower the hood and pack separately. Install the removed hardware back in the
frame.

10. Remove the mounting screws and shims securing the inspection unit to the floor.

11. Use the original shipping materials if possible. If the original packaging is not available, fabricate a
shipping container with sufficient blocking, bracing, and bolting to protect the contents during shipment
and long term storage. For overseas shipping, the shipping crate must be lined with sealed case liners.
For commercial level packing, fabricate a shipping container in accordance with Consolidated Freight
Classification Rules that will insure safe transportation to the point of delivery. Estimated shipping
dimensions and weight are listed in Tables 1-7 and 1-8. Mark the crate(s) clearly to identify the contents
and denote which side is to be up.

2-13
PAGE LEFT BLANK
INTENTIONALLY
 SECTION 3: OPERATING INSTRUCTIONS

OPERATING CONTROLS AND INDICATORS

All controls and indicators are illustrated in Figure 2-9.

WARNING: Do not operate this machine until you are familiar with all the electrical and mechanical
controls. Check controls for proper functioning before operating machine.

Foot Switch (1) (Without Autobath): Activates headstock clamping.

· Press once and release; part is clamped.
· Press again and release; part is released.

Foot Switch (1) (With Autobath): Activates headstock clamping, bath application, and mag current.
· Press once, and release, part is clamped; bath cycle begins.
· When bath cycle is finished, a mag shot is fired, then, the part is automatically unclamped.
· If Auto-bath push-button is off (dimly lit), the foot switch will only activate the headstock clamping.

Foot Switch (1) (With Auto-Mag): Activates headstock clamping, when released, activates mag shot.
· Press once and hold; part is clamped.
· Release; part is “magnetized,” then unclamped.

Push Bar (2): Enables/Disables the Push Bar

· With PUSHBAR switch “on” (light on), pressing Push Bar (2) from any position, activates the mag
shot. With PUSHBAR switch “off”, Push Bar (2) is inoperative.
· On longer machines, a second Push Bar is provided on the tailstock end of the machine for operator
convenience.

Power Indicator (3): Lights to indicate power to machine.

Mag Current Push-button (4): Initiates a magnetizing current “shot” each time push-button is de-
pressed.

Control Cabinet (5): Contains all of the Operator Controls and Pushbuttons. See Figure 2-12.

Headstock Pressure Regulator Valve (6): Controls amount of clamping force. Set at 40 psig for normal
operation.
· Reduce pressure to avoid damaging fragile parts, but clamp firmly enough to assure good electrical
contact.

Air Input (7): Air fixture on head stock end of unit for Air Supply Input.

Speed Control Needle Valve (8): Controls speed of clamping air cylinder in headstock. Has no effect on
clamping force.
· Slower clamping speed allows operator greater flexibility in positioning large, heavy or awkwardly
shaped parts.

3-1
· Faster clamping speed improves productivity for simple, repetitive parts.

Hand Spray Nozzle (9): Dispenses magnetic particle bath solution.

Tailstock Locking Ratchet (10): Locks tailstock in position.

Options not Illustrated

Tailstock Crank: Moves tailstock along rails.

Bath Applicator Pressure Regulator Valve: Controls the speed of the bath applicator (with Auto-bath
option).
· Set at 40 psig for normal operation.

Bath Applicator Ball Valve: Controls the flow of bath to the bath applicator (with Auto-bath option).

Palm Buttons (Optional): Used in place of foot switch, to activate headstock clamping, bath application
(Auto-bath option), and Mag Current (Automag option).
· Press both buttons simultaneously; hold for full extended stroke of bath applicator and release; part is
clamped and cycle begins
-If Auto-bath (Optional) push-button is off (dimly lit), the palm buttons will only activate the headstock
clamping.

Z-Axis Auxiliary Contacts (Optional): Selects output to auxiliary connections. Controlled by

CONTACTS potentiometer.

3-2
See Figure 2-12

Digital Ammeter (1): Displays the amount of current passed through the circuit.
· A reading of 3.25 equals 3250 amperes.
· A reading of 0.95 equals 950 amperes.

Green Current Assurance Light (2): Indicates current is flowing through circuit.

Current Controls (3 & 4): Control amount of current for each circuit.
· Set to desired level and lock to prevent accidental change in setting.

NOTE: The following push-buttons are dimly lit when off and bright when on.

Pushbar (5): Activates the push-bar(s) to fire a mag shot.

Light (6): Turns on/off the white light in the hood (Optional).

Coil (7): Selects coil output.

MOD AC (Optional) (8): Toggles the output from DC to AC.

Auto-bath (Optional) (9): Enables the Auto-bath (Optional) on/off.

Demag (10): Selects a demag cycle. Button is bright when “Demagnetizing,” and returns to dim when
demagnetizing cycle is complete.

Pump (11): Toggles on/off bath circulating pump motor.

NOTE: Do not run pump dry.

Fan (12): Toggles on/off fan in hood (Optional).

Contacts (13): Selects contacts circuit.

Spare (Optional) (14): Selects selected option (such as AUXILIARY output connection).

Auto Mag (Optional) (15): Selects Auto Mag (Optional). To select, press and quickly release button. To
de-select, press and momentarily hold button until light goes dim, then release.
When Auto-mag is “on”, press and hold foot switch until ready to mag. Part will
clamp. When ready to mag, release foot switch, and part will be “magnetized”, then
automatically unclamped.

Magnetize (16): Initiates a magnetizing current “shot” each time switch is depressed. Locked out during
demagnetizing.

3-3
 Figure 3-1 AUTOBATH (Optional)

Autobath Retracted Limit Switch (1): Initiates a magnetizing current “shot” when the bath applicator
reaches the switch position, on its return stroke.

Autobath Extended Limit Switch (2): Controls the extended length of the bath applicator.
· Loosen set screws and adjust position for length of part being inspected.

Bath Application Solenoid (3): Turns the bath on when applicator is extended, off when retracted.

DAILY START UP AND OPERATION CHECKLIST

All controls and indicators are illustrated in Figures 2-9 and 2-12.

1. Turn on external disconnect switch. Digital Ammeter and power indicator will light.

2. Check for proper volume of bath; see Table 1-6 in Section 1.

3. Press PUMP push-button to turn on and allow bath to circulate for a minimum of 15 minutes.

4. Check for proper magnetic particle concentration in bath; see Table 2-5 in Section 2.

5. Allow black light to warn up for approximately 5 minutes.

3-4
6. Check UV output of lamp using Magnaflux black light meter. Measure intensity 15" from the lens; clean
lens or replace bulb if reading is less than 1000µW/cm².

WARNING: Lens on the black light may be extremely hot. Let the unit cool before cleaning or replacing
bulb.

7. Set Pressure Regulator Valve to 40 psig.

WARNING: Lowering air pressure setting may be required for small part to prevent damage.

8. If equipped with Auto-bath (Optional), toggle the Auto-bath push button, and the PUMP push-button to
off. If equipped with the Auto-Mag (Optional), toggle Auto-Mag to off by pressing and holding the
Auto-Mag push-button until light goes dim (approximately 0.3 seconds), then releasing.

9. Check operation of headstock clamping cylinder by depressing and releasing Foot Switch or Optional
Palm Buttons.

10. Adjust Speed Control Needle Valve on headstock for desired clamping speed.

11. Press CONTACTS push-button to on.

12. Set CONTACTS CURRENT CONTROL to 2.

13. Check for magnetizing current between contacts.

a. Place a suitable part between headstock and tailstock contacts.

b. Place a piece of insulating material, such as a thick piece of cardboard, between headstock contact
and the end of the part.

c. Depress and release Foot Switch or Optional Palm Buttons to clamp part.

d. Depress MAG push-button while observing Digital Ammeter.

· The current assurance light should not light.
· The Digital Ammeter will reset to zero.

f. If there is any indication of current on the ammeter, an electrical short exists. For corrective action,
refer to Section 5 for Troubleshooting..

g. Place a minimum 1" diameter test bar between headstock and tailstock contacts.

h. Depress and release foot switch or Optional Palm Buttons to clamp test bar.

i. Depress MAG Current push-button while observing ammeter.

· The magnetizing current flowing through the test bar should appear on the Digital Ammeter.

3-5
 · The Green Current Assurance Light on the Ammeter should light indicating current flow through the
test bar.
. MOD AC (Optional) repeat step i. with AC selected.
. Z-Axis (Auxiliary Optional) repeat step i. with Z-Axis selected and load connected to AUX terminals.

14. Depress and release foot switch or Optional Palm Buttons to release the part.

15. If equipped with Auto-bath option, check as follows:

a. Press Auto-bath push-button and PUMP Push-button to on.

b. If equipped with foot switch, follow steps 13 and 14, keeping in mind that the foot switch is
depressed, and released to clamp the part, then the bath applicator will extend to apply bath. When
extend limit is reached, it will retract and mag shot will occur, and bath will turn off.

c. Part will then unclamp signifying that the Auto-bath cycle is complete.

d. If equipped with Optional Palm Buttons, follow steps 13 and 14, keeping in mind that the Palm
Buttons are depressed and held to clamp the part and extend the bath applicator. Once the bath
applicator has started retracting, the Palm Buttons may be released. After mag shot occurs, headstock
retracts to unclamp part.

16. If equipped with Auto-Mag option, check as follows:

a. Toggle Auto-Mag to “on” by momentarily pressing and releasing Auto-Mag push-button.

b. Place part between contacts and depress and hold footswitch. Part will be clamped.

c. When footswitch is released, a mag shot will be “fired”, then heads will unclamp.

d. To deselect Auto-Mag, press and hold Auto-Mag push-button until light goes out (0.3 seconds), then
release.

NOTE: To ensure reliable processing of parts, all above conditions must be met. For corrective action, refer
to Section 4 Troubleshooting.

3-6
PIECE PART SET UP

WARNING: Heavy materials may cause severe damage or injury if dropped; always lock tailstock
and/or coil in desired position before applying current.

WARNING: Use rail mounted steady rests to support heavier parts. See Table 1-4 for part weight
capacities.

Normal Piece Set Up

All controls and indicators are illustrated in Figures 2-9 and 2-12.

WARNING: Lower air pressure setting may be required to prevent damage to small parts.

1. If equipped with Auto-bath, adjust bath applicator ball valve for the desired bath flow.

2. If equipped with Auto-bath, adjust bath extend limit switch for the length of part being inspected.

3. Check that the Pressure Regulator Valves are properly set for the type of part being inspected.

4. Move the coil against the headstock so it will not interfere and lock.

5. Unlock and move tailstock to a position where part can be supported by tailstock and headstock shelves,
or by Optional rail mounted steady rests. Lock tailstock.

6. Align part so that current will flow parallel to direction of expected flaw. This places magnetic field at
right angles to flaw and provides best indications.

7. Move coil to desired position.

8. Position part, depress and release foot switch or Optional Palm Buttons to clamp part in place. On units
equipped with Auto-bath, the automatic cycle will begin if Auto-bath push-button is on.

Remote Operation Set-up

For remote operation, turn off bath applicator ball valve and Auto-bath switch, clamp contact block between
headstock and tailstock; then connect remote cables. Use Optional clamps, prods or cable wraps to magnetize
parts for inspection.

3-7
 Figure 3-2

Central Conductor Set-up

If parts are hollow, tubular, ring-like, or have holes, it is generally better to magnetize them using a central
conductor rather than passing current directly through them. This method also reveals defects on the inside
diameter of the part. Parts are placed over a central conductor that is clamped between the headstock and
tailstock. Circular Magnetization is accomplished by passing current through the central conductor. This is
shown above in Figure 3-2.

MAGNETIZING PROCEDURES

Without Auto-Bath:

All controls and indicators are illustrated in Figures 2-9 and 2-12.

1. Clamp the part as described in PIECE PART SET UP

WARNING: Set current at the appropriate level for the part cross section to avoid overheating.

2. Set the desired current for part being inspected on the appropriate CURRENT CONTROL. Tighten
lock(s).

3-8
3.Press the COIL/CONTACTS push-buttons to select the desired magnetizing circuit.
4. If the hand spray nozzle has not been used in the last 10 minutes, allow bath to circulate through hand
hose for 10-15 seconds to clear any settled bath.

5. If machine is equipped with an Optional black light hood, lower hood to darken work area. Allow time
for your eyes to adjust to the dark (approximately 3 minutes).

6. Use hand spray nozzle to apply bath to the part.

7. As soon as the part (or part section) is thoroughly covered with bath, shut off the hand spray nozzle, and
immediately apply magnetizing current by depressing and releasing MAG push-button or Push Bar.
-Current assurance will light and remain lit for duration of magnetizing shot
-Digital Ammeter will display and retain applied current

NOTE: This technique is called the “wet continuous method.” For long parts, it may be necessary to
inspect in sections, each with a separate bath application and current “shot.” The “wet
residual method,” which applies bath after the current shot, is recommended only for parts with
high magnetic retentivity.

8. Depress and release foot switch to unclamp part.

9. Examine part for indications.

With Auto-Mag:

1. Clamp part as in PIECE PART SET UP.

2. Press and release Auto-Mag push-button so light is bright.

3. Depress and hold foot switch and manually bathe the part.

4. When bathing is complete, release foot switch and part will be “magnetized” and released.

3-9
DEMAGNETIZATION

All controls and indicators are illustrated in Figures 2-9 and 2-12.

Demagnetization is generally performed after inspection. A safety feature prevents accidental energizing of
the magnetizing circuit during the demagnetization cycle.

1. If equipped with Auto-bath, press Auto-bath push-button to off. The push-button is dimly lit when off
and brighter when on.

2. Clamp test part between headstock and tailstock in same manner as described in Piece Part Set-up.

3. Set the CURRENT CONTROL to the same or a value slightly higher than setting used to magnetize the
part. Tighten lock.

4. Press and release DEMAG Push button to start demagnetization cycle. DEMAG light will remain lit
during complete cycle.

NOTE: If AC (MOD AC Optional) is selected, DEMAG will be AC demagnetization.

5. After demagnetization of part is complete, DEMAG light will go out.

6. Press and release foot switch or Optional Palm Button to unclamp part.

NOTE: Footswitch is locked out during “demagnetization,” so arc will not damage the machine and the part
being processed.

Demagnetization Using Optional Accessories

All controls and indicators are illustrated in Figure 2-9 and 2-12.

When parts are magnetized for inspection using optional clamps, prods or cable wraps, they can be
demagnetized in the same manner. Use a cable wrap whenever possible. Longitudinal demagnetization with
a cable wrap generally can be accomplished successfully even if the part was magnetized for inspection using
clamps or prods. In all cases, press the CONTACTS push-button on.

3-10
SHUTDOWN

All controls and indicators are illustrated in Figure 2-9 and 2-12.

1. Toggle the PUMP push-button to off.

2. Open valve at bottom of the air filter bowl to blow out any contaminants or accumulated moisture. Close
valve and then shut off air supply to machine.

3. If Optional hood is installed, close curtains.

4. Disconnect power from unit by turning external disconnect switch to OFF.

EMERGENCY SHUTDOWN

To shut off the machine in an emergency, disconnect the power by turning OFF the external disconnect
switch. Lock Out unit as required.

3-11
PAGE LEFT BLANK
INTENTIONALLY
 SECTION 4: MAINTENANCE

GENERAL

The following tables contain periodic visual and Do not remove any cover panels. Inspections or
operational inspections designed to prevent or maintenance requiring removal of cover panels are
discover malfunctions and defective parts. Many of to be performed by a qualified technician. A list of
these checks are based on ASTM E-1444. Authorized Magnaflux Service Centers is located at
Do not operate the inspection unit if it is found to be www.magnaflux.com
in need of repair or unsafe. Report problems to the
designated authority.

DAILY OPERATOR MAINTENANCE

Table 4-1. Daily Operator Checks

Item Action

Bath level See Table 1-6 for proper level.

Particle concentration See Table 2-5 for proper concentration.

Cable and bus bar connec- Check coil, headstock, and tailstock bus bar and cable connections.
tions Tighten as necessary. Check wires and cables for worn or frayed
insulation.

Headstock clamping Check headstock clamping action.

Locking devices Check tailstock and coil lock.

Leaks (bath) Check tank, hoses and nozzle for leakage.

Leaks (pneumatic) Check air cylinder, fittings, hoses, air regulator and speed valve.

Power indicator Check that indicator lights when power is supplied to inspection unit.

Push-buttons Check push-buttons for proper operation. Push-buttons are dimly lit when
off and turn brighter when on.

Digital ammeter and pilot Check ammeter readout and pilot light operations.
light

Automatic current control Check for smooth and proper operation.

Black light assembly Check for missing or broken filter or lamp. Check for damaged cord.

Curtain Repair small cuts and tears with black plastic electrical tape.

Auto-bath and Auto-Mag Check Auto-bath function.

(Optional) Check Auto-Mag function.

4- 1
WEEKLY OPERATOR MAINTENANCE

Table 4-2. Weekly Operator Checks

Item Action

Contact pads and contact When water bath is used, remove oxidation from between the contact pad
plates and contact plate. Use a wire brush.

Ground Fault Interrupt Check for proper operation of Black Light.

Clean Sump Screen See Instructions page 4.4

MONTHLY OPERATOR MAINTENANCE

Table 4-3. Monthly Operator Checks

Item Action

Tank and grilles Clean if necessary. After cleaning, flush tank and grilles with appropriate
bath solution.

Fans Listen for fan operation and check air flow for restrictions.

Air filter Clean air filter element and bowl.

Check Pump Seal Look for leaks of fluid around/near the pump/motor shaft

PERIODIC INTERNAL MAINTENANCE

NOTE: The following procedures should be WARNING: For cleaning, do not use
performed by a qualified maintenance compressed air greater than 30 psi.
technician. Wear eye protection. Use cleaning
solvents only in well ventilated
WARNING: Turn off and lock out the external areas.
disconnect switch before removing
cover panels. Failure to disconnect
incoming power could result in
severe electrical shock or death.

4- 2
 Table 4-4. Periodic Checks

Item Action

Rectifier stack Blow accumulated dirt from rectifier heat sinks and fan blades. Do not
use cleaning solvents.

Control panel wiring Check wiring for discoloration or burnt insulation, connectors for security.

Lower unit wiring Check wiring for discoloration or burnt insulation, connectors for security.

Transformers Check transformers for discoloration and pungent order.

Connections Check and tighten all connections, bus bars, cables and wires.

Tank and plumbing Check for leaks.

Fans Check that the cooling fan(s) turn freely.

Ammeter and “Mag” shot Check for accuracy every 6 months.

time

Replace Pump Seal See Supplemental pump Instructions.

NOTE: Due to the nature of the material used in Magnetic Particle Inspection, periodic maintenance is
required on the pump seal. Replacement is recommended every 6 months, based on using Magnaflux
materials for an 8 hour day, 5 days a week work schedule. It is recommended to maintain a back-up
pump that can be switched out when the seal needs to be changed in order to decrease the amount of
downtime on the machine.

4-3
Screen Cleaning
To prevent loss of flow from the pump, the screen on the intake of the pump will need to be cleaned on a
weekly basis. To remove the screen, simply push in and twist the brass fitting one quarter turn and pull
off along with a spring and washer. In Figure 4-1 below, this shows the entire assembly assembled.
Figure 4-2 shows the brass fitting removed.

Figure 4-1 Figure 4-2

The spring is shown below in Figure 4-3, and the bib flow on spray nozzle is shown in Figure 4-4.

Figure 4-3 Figure 4-4

4-4
OPERATIONAL CHECKOUT PROCEDURES

The following paragraphs describe the operational checkout procedure for magnetic particle inspection units.
Refer to schematic and wiring diagrams and any referenced illustrations for the location of components
referenced in the procedures. At the conclusion of the operational checkout procedure, place the machine into
service if it has met all the acceptance criteria. If any discrepancies are noted, refer to the troubleshooting
section, and correct all discrepancies before placing the machine into service.

Table 4-5. Test Equipment

Recommended Test Equipment

Tektronix TDS 20128 Two Channel Digital

Storage Oscilloscope, 100 MHz, 1 GS/s

Magnaflux 622350 Digital Test Meter Kit

with Matching Shunt

Steel Test Bar (1" diameter, 12"-18" long,

4140 H.T.)

INITIAL SET-UP

WARNING: Turn off and lock-out the external disconnect switch before opening the rear panel. Failure to
disconnect incoming power could result in severe electrical shock or death.

1. Check that the electrical connections have been made properly.

2. Adjust air supply to 40 psi.

3. Check that the pump drain cock is fully closed. Check bath level and concentration.

4. Turn the external disconnect switch on. The Digital Ammeter and the power indicator should light.

5. Press PUMP push button to turn on the pump. The bath circulating pump motor should start. There
should be no leakage of bath solution. Operate the hand hose nozzle(s) and check for bath discharge.
Release the nozzle lever and check that the bath discharge stops. Press PUMP push button to turn
off the pump.

6. Connect the foot switch or Optional Palm Buttons to the FOOT SWITCH outlet on the headstock end
of the machine.

4-5
7. If an Optional hood has been installed, connect the line plug to the HOOD outlet on the headstock
end of the machine.

8. Connect the black light to the BLACK LIGHT outlet on either end of the machine. The black light
should come to full brilliance in about 10 minutes. To turn off the black light, the plug must be
removed from the BLACK LIGHT outlet.

9. Press LIGHT push button to turn on the hood white light. Press again to turn light off.

4-6
CIRCULAR (CONTACT) AND LONGITUDINAL (COIL) MAGNETIZATION CHECK

1. Move the coil against the headstock so it will not interfere. Lock in place.

2. Unlock and move tailstock to a position where the digital test meter kit shunt, noted in Table 4-5, can be
supported by the tailstock and headstock shelves. Lock tailstock.

3. If equipped with Auto-bath, press the AUTO BATH push-button off. The push-button is dimly lit when
off and bright when on.

4. Position the digital test meter kit shunt between the headstock and tailstock. The terminal with the red
test lead should be closest to the headstock. Lock the tailstock in position. Connect the shunt cable leads
to the shunt terminals and the test meter shunt input as directed in the test kit instructions.

5. Depress the foot switch or Optional Palm Buttons to firmly clamp the shunt in position between the
headstock and tailstock.

6. Electrically connect the digital test meter kit to the unit per instructions furnished with the test meter. The
meter on the digital test meter should light.

7. Press CONTACTS push-button to on.

7. Set the CONTACTS CURRENT CONTROL to the lowest division.

9. Hold the digital test meter as far from the machine as the leads will permit. Depress and release the MAG
push-button (see test meter instructions). The green indicator should light during the “shot,” and the
current should be indicated on both the Digital Ammeter and the digital test meter. Each ammeter
reading should correspond within ± 5% or 50 amps of the machine rating. {MOD AC (Optional) repeat
for AC}.

10. Continue repeating this procedure while increasing the CURRENT CONTROL to the next division after
each “shot.” At all settings, both ammeters should agree within ± 5% or 50 amps of the machine rating.

11. Depress the foot switch or Optional Palm Buttons to unclamp and remove the shunt. Re-clamp with a
non-conductive test bar (2x4 piece of wood).

12. Depress and release the MAG push-button (see test meter instructions). The green LED on the Ammeter
should not light and the meter should hold previous reading. If it does not do this, an electrical short
exists. Refer to Section 5 for Troubleshooting.

13. Press the COIL push-button to on. The push-buttons are dimly lit when off and brighter when on.

14. Set the COIL CURRENT CONTROL to the first division.

4-7
15. Depress and release the MAG push-button. The green indicator should light during the “shot,” and the
current should be indicated on the Digital Ammeter. The data for the coil reading and the contact reading
are from the same shunt, so if the Contact readings are accurate, then the coil meter readings will be
accurate also {MOD AC (Optional) repeat for AC}.

16. Continue repeating this procedure while increasing the CURRENT CONTROL to the next higher
division after each “shot.”

17. Check coil for “Quick Break” at 2000 Amps per Quick Break instructions.

18. At the conclusion of the circular (contact) and longitudinal (coil) magnetization check, proceed with the
circular (contact) and longitudinal (coil) demagnetization check performing only those steps not
previously accomplished. If no further testing is to be done, disconnect the digital test meter and return it
to its carrying case.

4-8
PAGE LEFT BLANK
INTENTIONALLY

4-9
 SECTION 5: TROUBLESHOOTING

Refer to the corresponding wiring diagram as a supplement to the troubleshooting chart when tracing an
electrical problem. Check supplementary drawings for options you may have received with the unit.

DEMAGNETIZATION ADJUSTMENT

Demag Control: Theory of Operation

The PLC control provides 3 functions:

Timing of the demagnetization cycle

Alternation of the output current
Decay of output current (in conjunction with demagnetization capacitor)

1. When DEMAG is selected, the PLC enables the selected firing board(s) to fire a decreasing in
intensity and reversing in polarity mag shot{(Reversing FWDC normally, Decreasing AC with
MD AC (Optional) selected}.
2. Demag balance in the DC mode is adjusted by the lower of the two controls behind the
communication door on the PLC. It is factory set for 30 msec of reverse pulse widths. Adjust
this control very carefully in small increments and check parts residual magnetism often as you
adjust.

Adjustment of Demagnetization

1. With the oscilloscope connected to the shunt, proceed to shoot a mag shot and adjust output current to
2000 amps as indicated on unit ammeter.
2. With scope set to 20 msec/div horiz, check demag pulse trains for equal width forward and reverse
and ajust lower potentiometer on PLC until widths of forward and reverse pulse trains are equal.
Check AC (MOD AC Optional) for decaying AC waveform.
3. Demag cycle time is factory set by PLC program to 16 seconds (approximately 32 switching cycles).
Demag light will go OFF when cycle is finished. Check that pulses decay to zero before cycle is
finished (time between pulses ending and Demag cycle finished depends on CURRENT CONTROL
setting).

Troubleshooting Stack

1. Check that green “12V ON” LED is glowing. If not, check for 24VAC input to board
through connection J3-1 and J3-2. If 24VAC is not present at connector, check 24 V
transformer for OUTPUT. Check that red “PHASE LOSS” LED is off. If not, check for
balanced 3 phase voltage input through connector J5-1, 3, and 5. CAUTION: At power line
potential.
2. Check that red “INHIBIT” LED is glowing. Push MAG button, red LED should go out for
duration of mag shot. If not, check thermal overload protectors, which connect J3-4 to J3-6.
Check current command voltage between J3-8 and J3-10. It should read approximately
1.6VDC at minimum output current setting and approximately 4.5VDC at maximum current
setting. If no voltage is present, check that current command POT wiper is intact and that

5-1
 there is approximately 4VDC across POT winding. If there is no voltage across POT, check
for 12VDC as follows:
The 12VDC, +/-0.5V, should be connected to maximum 1POT, and wire #29 connected to
minimum limit 4POT. If no voltage or low voltage, check for 12 volts across J3-6 to J3-8 of
firing board.

Low Mag Current Output at Maximum Current Control Setting, Cannot Get Rate Output
Current

1. Make sure that the 3 phase main input voltages are not sagging under load at full output. A 10%
line voltage sag translates into approximately10% less maximum output current. Also note that
using higher resistance loads than what the unit was calibrated with, will give a lower maximum
output.
2. Use scope to observe SCR peaks as in calibration procedure. Look for missing SCR peak. If you
see one is missing, use amp clamp meter across each of the 6 SCR stack bus bars to see which
SCR is missing. Then check gate pulses to that SCR with scope. If pulses are present, then SCR
is bad. If pulses are not present, then master phase control or wiring from the phase control is
bad.

Unit Does not Demag Properly

1. Check that PLC output 1 flashes at approximately 2 hertz rate during DEMAG.
2. Check that control voltage (Wire 37 to Wire 29) decreases gradually over DEMAG cycle. If not,
check Capacitor 1Cap. on subpanel.
3. If demag passes these steps, then re-do demag adjustment.

5-2
 Table 5-1. TROUBLESHOOTING GUIDE
Trouble Probable Cause Remedy
No line voltage at all. 1. External fused 1. Turn on external fused disconnect switch.
Red POWER ON disconnect switch off.
light not on. 2. Replace fuse. Check for shorts if fuse continues to blow.
2. Fuse in external fused
disconnect switch blown. 3. Replace fuse 4FU. Check for shorts if fuse continues to
blow.
3. Fuse 4FU blown.
4. Replace lamp.

4. POWER ON lamp
burned out.

No convenience outlet Fuse 6FU blown. Replace fuse 6FU. Check for shorts if fuse continues to blow.
power. Internal
power on.

Pump motor does not 1. Fuse 8FU blow.

1. Replace fuse 8FU. Check for shorts if fuse continues to
operate. 2. Relay 2CR not
blow.
functioning.
2. Check 115v on wire 4
NOTE: Pump is external.

Headstock does not 1. Air supply not properly 1. Connect air supply to inlet.
extend to clamp part. connected.

2. Defective foot switch 2. Check Input 0 lamp on PLC. If it doesn’t light when
cable and plug. Footswitch pressed, replace foot switch cable and/or plug.

3. Check that Output lights 4 and 5 on PLC toggle with

3. Defective solenoid Footswitch. If so, replace solenoid valve SOL B coil or
valve SOL B. complete solenoid valve.
4. Replace fuse
3. Fuse 5FU

Current Flow with 1. Insulators worn or 1. Check headstock drawing for insulator locations and
nothing clamped missing repair/replace as needed.

2. Check SCRs
2. SCR(s) shorted

5-3
 Table 5-1. TROUBLESHOOTING GUIDE
Trouble Probable Cause Remedy
Headstock does not 1. Air supply not properly 1. Connect air supply to inlet.
retract to release part. connected.
2. Check per Headstock doesn’t clamp procedure
2. Defective foot switch above.
cable and plug.
3. Replace solenoid valve SOL A coil or complete solenoid
3. Defective solenoid valve.
valve SOL A.

Irregular clamping 1. Dirty or defective 1. Clean or replace pressure

action at headstock. pressure regulator.
regulator.
2. Clean air filter.
2. Dirty air filter.

Magnetizing current 1. Incorrect setting POT 0 1. Adjust POT 0 in PLC

shot too long or too in PLC
short.

No output current at Thermo shutdown. Turn off disconnect, wait until unit cools.
Contacts, Coil.

Continuous mag shot Shorted SCR. Call Authorized Service Center.

on coil and/or contact.

Main fuse to unit Shorted SCR Call Authorized Service Center.

blown.

No output current or 1. Loose connection at bus 1. Clean connections and tighten hardware.
irregular current bars or cable joints.
through contacts 2. Replace fuse 5FU. Check for shorts if fuse continues to
2. Fuse 5FU. blow.

3. Swap relays 5CR and 6CR.

3. Defective relay if
occurs on COIL only or 4. Check outputs on PLC and see if Output 6 is on during
CONTACTS only. COIL mag shot and Output 7 is on during CONTACTS shot.
Check harnesses and replace or repair as necessary.

4. Defective harnesses. 5. Call Authorized Service Center

5. Defective SCRs.

No output current or 1. Loose connection at bus 1. Clean connections and tighten hardware.

5-4
 Table 5-1. TROUBLESHOOTING GUIDE
Trouble Probable Cause Remedy
irregular current bars or cable joints.
through Coils. 2. Replace fuse 5FU. Check for shorts if fuse continues to
2. Fuse 5FU blown. blow.
3. AC firing board or relay 7CR.
3. Mod AC(option) NO 3. Swap with 6CR and see if problem switches to
AC CONTACTS.
3. Defective relay 5CR
4. Check harnesses and replace or repair as necessary.

4. Defective harnesses. 5. Call Authorized Service Center

5. Defective SCRs.

Low output current at 1. Impedance of part 1. Check equipment output with a central conductor
higher current control exceeds the equipment (optional accessory). If equipment output is within
settings. capabilities. specifications, part cannot be tested with this equipment.

3. Check line voltage. Correct if possible or try another

line
4. Clean connections and tighten hardware
2. Low line voltage. 5. Adjust per instructions above

3. Loose connection at bus

5. Check SPAN and BIAS adj. on AC firing board.
bars or cable joints.
4. Wrong voltage range on
current controls
5. MOD AC(Optional)
only

Maximum current 1. Defective SCR firing 1. Check inhibit light operation.

output at all settings. board.

2. Check harnesses and repair/replace as necessary.

2. Defective harness. 3. Adjust per instructions above

3. Wrong voltage range on

current controls
4. Contact Authorized Magnaflux Service Center
4. Shorted SCR.

Current assurance Defective Ammeter Replace Ammeter

light defective.

5-5
 Table 5-1. TROUBLESHOOTING GUIDE
Trouble Probable Cause Remedy
Demag does not work 1. SCR is not properly 1. Call Authorized Service Center
or does not balanced.
completely demag. 2. Change 1 cap.
2. Defective 1 Cap.

Contacts push-button 1. Lamp burned out. 1. Replace lamp.

does not light at all.
2. Defective PB switch 2. Replace Switch

Coil push-button does 1. Lamp burned out. 1. Replace lamp.

not light at all.
2. Defective PB switch. 2. Replace Switch

No push-buttons light. 1. Fuse 4FU blown. 1. Replace fuse 4FU. Check for shorts if fuse continues to
blow.

2. No 115v control supply. 2. Check 115Vac voltage between 1 and 2.

White light does not 1. Bulb burned out. 1. Replace bulb.

work
2. Fuse 7FU blown. 2. Replace fuse 7FU. Check for shorts if fuse continues to
blow.

3. Defective switch. 3. Check white light switch and replace if defective.

4. Replace 3CR
4. Defective relay 3CR

Meter does not work. 1. Meter not responding. 1. Connect oscilloscope to terminal 5 & 6 on meter, (AT
50MV/ DIV) At 2,000 amps, wave form should be
approximately 2 divisions (0 to peak). If wave form is
not there, check harness.
2. Replace Meter

2. Meter got wet

Meter does not light. 1. Fuse 4FU blown. 1. Replace fuse 4FU. Check for shorts if fuse continues to
blow.

5-6
 Table 5-1. TROUBLESHOOTING GUIDE
Trouble Probable Cause Remedy

2. Defective harness. 2. Check harnesses and replace or fix as necessary.

3. Check cables for worn indication. Replace meter if

3. Meter failure from necessary.
surge.
1. AC relay not energizing. AC switch not ON. AC firing
MOD AC not firing 1. Inhibit lamp on AC firing
board bad.
board not OFF during mag
shot.

5-7
PAGE LEFT BLANK
INTENTIONALLY
 SECTION 6: DRAWINGS AND SPARE PARTS LIST

GENERAL

The drawings provided describe major equipment groups, assemblies, sub-assemblies, and detail parts of
the Magnaflux Magnetic Particle Inspection Units. Depending on your options package, certain parts
may have been substituted.

FIGURE AND INDEX NUMBER COLUMN

The first number identifies the corresponding drawing. The number after the hyphen identifies a
component on the associated illustration.

PART NUMBER COLUMN

On each drawing is a bill of material located in the lower right corner. Magnaflux part numbers are used
to identify all parts except common commercial hardware. Commercial hardware is identified with a full
identification in the DESCRIPTION column. Material and coating for commercial hardware is zinc
plated steel except where noted.

DESCRIPTION COLUMN

A brief description is provided for each item. The descriptions to the right indicate assembly-sub-
assembly-part relationship. The Magnaflux part number is included in the description.

UNITS PER ASSEMBLY COLUMN

The quantities listed are for that assembly only. The abbreviation "REF" is used to indicate that the
quantity has been shown in a previous listing. The abbreviation "A/R" (as required) is used when a
precise quantity cannot be specified.

HOW TO ORDER A PART

Contact your local Authorized Magnaflux Service Center or Distributor to order the part. Provide the
model and serial number of the unit, and the part number requested.

6-1
 SPARE PARTS LIST

D-2060
Part Number Description
624286 External Pump (Standard and Extra Long Frame Units)
624316 External Pump (Long Frame Units)
624570 Seal for pump
521328 Relay
519940 Ammeter
519780 Air Solenoid Valve
621076 Grille Assembly (Standard Frame Unit)
621225 Grille Assembly (Long Frame Unit)
621347 Grille Assembly (Extra Long Frame Unit)
623113 Rectifier Stack (includes fans, firing board, SCR’s)
521432 Fan only for Rectifier Stack
622996 Firing board only for Rectifier Stack
521097 SCR only for Rectifier Stack
624724 Maintained Assembly Pushbuttons
624702 Harness for 624724
624716 Momentary Assembly Pushbuttons
624703 Harness for 624716

D-2100
Part Number Description
624286 External Pump (Standard and Extra Long Frame Units)
624316 External Pump (Long Frame Units)
624570 Seal for pump
521328 Relay
519940 Ammeter
519780 Air Solenoid Valve
621076 Grille Assembly (Standard Frame Unit)
621225 Grille Assembly (Long Frame Unit)
621347 Grille Assembly (Extra Long Frame Unit)
621158 Rectifier Stack (includes fans, firing board, SCR’s)
519968 Fan only for Rectifier Stack
622996 Firing board only for Rectifier Stack
521095 SCR only for Rectifier Stack
624724 Maintained Assembly Pushbuttons
624702 Harness for 624724
624716 Momentary Assembly Pushbuttons
624703 Harness for 624716
114184 Braided Lead Contact Pad
PAGE LEFT BLANK
INTENTIONALLY
SECTION 7: HOOD INSTALLATION

7-1
INSTALLATION

1. The hood is wrapped in a protective plastic for shipping.

2. Carefully cut away the wrap without cutting the curtain material.
3. In a separate box the hood fan and white light are located.
4. Figure 7-1 below shows the separate fan and white light assembly. Figure 7-2 shows the
hood assembly.

Figure 7-1

Figure 7-2

7-2
 Figure 7-3
5. Locate the Magnaflux machine on a solid surface and secure it based on Section 1 of this
manual. Figure 7-3 above shows the unit.
6. Once it is secure, remove the accessory boxes containing the foot switch and black lights,
and set aside in a safe place.
7. Verify the hood installation with the electrician prior to installing so as to not have any
conduit interference with the hood.
8. Locate the mounting holes in the rear of the unit frame as shown in Figures 7-4 and 7-5
below.
NOTE: Grills have been removed for clarity.

Figure 7-4 Figure 7-5

7-3
9. On a solid surface with the assistance of another person, stand on each side of the hood to
support it.
10. Carefully open the hood frame as shown in Figure 7-6 below.

Figure 7-6
11. Side and rear curtains are folded on to the top curtain for convenience.
12. Be careful when doing this as the fan frame section and the swivel frame section are not
mounted to each other.
13. With a person on either side of the hood, carefully lift it on to the unit and insert the
frame in to the mounting holes as shown in Figure 7-7 and Figure 7-8 below.

Figure 7-7 Figure 7-8

7-4
14. Verify the frame slides in to the bottom of the space.
15. Insert bolt and lock nut supplied to secure to the frame (two places).
16. Next, locate shoulder bolt in the swivel frame of the hood (each side of the frame).
17. Remove the lock nut and one washer.
18. Place the shoulder bolt through the hole in the stationary part of the frame.
19. With one washer on the inside and outside, tighten the nut to secure the frames together
as shown in Figures 7-9 through 7-12 below.

Figure 7-9 Figure 7-10

Figure 7-11 Figure 7-12

7-5
20. Now open the hood and stretch out the top curtain as show in Figure 7-13 and Figure 7-
14 below.

Figure 7-13

Figure 7-14
7-6
21. Locate the four (4) mounting bolts on the stationary frame as shown in Figures 7-15
through 7-18 below.
NOTE: Two (2) are under the curtain.
22. Remove nuts and set aside.

Figure 7-15 Figure 7-16

Figure 7-17 Figure 7-18

23. In Figure 7-18 above, locate the four (4) mounting holes on the fan and place the bolts in
it.
NOTE: Orientation of the fan should be with the light closest to the headstock.

7-7
24. Carefully insure the white light clears the frames as shown in Figure 7-19 below.

Figure 7-19
25. Return and tighten nuts on to the mounting studs.
26. Standard mounting has the vent to the tailstock side of the unit as shown in Figures 7-20
and 7-21 below.
27. Removing and re-orientating the vent direction is possible by removing the mounting
hardware and rotating the vent.
NOTE: Verify white light levels inside booth before changing the orientation.

Figure 7-20 Figure 7-21

7-8
 Figure 7-22
28. String the fan cord along the frame and down to the outlet on the headstock side of the
unit.
29. Plug in to the twist lock marked for the hood as shown in Figure 7-22 above
30. If power is available on the unit, the white light and fan operation can be tested by
selecting these push buttons on the main control panel, as shown in Figure 7-23 below.

Figure 7-23

7-9
31. Now the left and right side curtains can carefully be unfolded as shown in Figure 7-24
below.

Figure 7-24
32. Bring down the top curtain, carefully working the opening around the fan vent as shown
in Figure 7-25 below.

Figure 7-25

7-10
33. Locate the front curtain and hang it from the front track with hooks as shown in Figure 7-
26 below. Once the front curtain is installed, pull down the curtain with “Magnaflux” on
it to block white light from entering the inspection booth. This “Magnaflux” curtain is
shown in Figure 7-27 below.

Figure 7-26 Figure 7-27

34. The front curtain can be folded in half for extra ventilation. Fold in half and mount the
lower eyelets on the same hook already supporting the curtain. Verify white light levels
inside the inspection booth are still acceptable if this is done.

Figure 7-28

7-11
35. Locate the three mounting bolts for the black light bracket and remove the hardware.
Place the bracket in place securing with the hardware provided as shown in Figure 7-30
below.

Figure 7-29 Figure 7-30

36. Orientate the transformer so the light cord comes out towards the front of the unit. Then,
slide ballast transformer in to the slots provided. This is shown in Figure 7-31 below.

Figure 7-31

7-12
37. Plug the transformer cord in to the outlet on the side of the unit as shown in Figure 7-32
below.

Figure 7-32

38. Mount the ZB-100F black light on to the peg provided, as shown in Figure 7-33 below.
This completes the installation of the hood assembly.

Figure 7-33

7-13
PAGE LEFT BLANK
INTENTIONALLY

7-14