Magnaflux D-2000 Series, Operation Manual

Page 1: ...D 2000 Series Revised March 2020 Page 1 0 D 2000 SERIES ...

Page 2: ...tart Up and Operation Checklist 3 7 Piece Part Setup 3 9 Magnetizing Procedures 3 10 Demagnetization 3 11 Shutdown 3 12 Emergency Shutdown 3 12 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 4 Initial Set up 4 4 Circular Contact and Longitudinal...

Page 3: ...cing 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 a...

Page 4: ...pection 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 either 2 separate current control encoders or the HMI Selection of Contacts or Coil operation is provided by push but...

Page 5: ...ional Electric Code 2011 Table 1 1 Electrical Input Model Series Input Volts AC Phase Load Amperes Recommended Line Fuse Amperes Recommended Wire Size AWG D 2060 SEE MOD AC options below 208 230 380 415 460 575 3 3 3 3 3 3 160 160 100 90 80 70 125 125 80 70 60 60 2 2 6 6 6 6 D 2100 SEE MOD AC options below 208 230 380 415 460 575 3 3 3 3 3 3 400 400 245 220 200 160 300 300 200 175 150 125 0 0 2 2 ...

Page 6: ...00 Contacts 12 Coil 16 Coil 20 Coil 25 Coil 10000 5800 5200 5000 4700 Continuously Variable In all cases Reversing Decaying DC D 2100XL4 Contacts 25 Coil Split Coil 10000 8000 6000 Continuously Variable In all cases Reversing Decaying DC D 2100XL5 Contacts 25 Coil Split Coil 10000 7800 6000 Continuously Variable In all cases Reversing Decaying DC Table 1 3 Duty Cycle Model Series Seconds On Second...

Page 7: ...on 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 2060 2 door 20 76 D 2 L 102 259 cm D 2060L 3 door 34 129 D 2 XL 146 370 cm D 2060XL 4 door 46 174 D 2100XL4 243 617 cm D 2060XL2 5 door 58 220 D 2100XL5 278 706 cm Table 1 7 Machine Weight Model No Approximate Weight Dry ...

Page 8: ... 153cm 317 806 cm 41 104cm 60 153cm Basic Unit Optional Hood Length Depth Hood Opened Depth Hood Closed Height Hood Opened Height Hood Closed 86 218cm 50 127cm 73 185cm 120 305cm 89 227cm 135 336cm 50 127cm 73 185cm 120 305cm 89 227cm 178 452cm 50 127cm 73 185cm 120 305cm 89 227cm N A N A EQUIPMENT WARRANTY The Equipment Warranty Statement can be found on our Web site at the following link https w...

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Page 10: ...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 hood 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 adhe...

Page 11: ...ct Refer to Table 1 1 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 connectio...

Page 12: ... as line or larger D 2060 MOD 6AC and D 2100 MOD 6AC Input Volts AC Phase Full Load Amps Line Fuse Amps Wire Size AWG Ground wire 208 230 380 415 460 575 N A 3 3 3 3 3 3 N A 575 350 325 300 200 N A 350 200 200 150 100 N A 2 0 0 0 2 2 Same as line or larger Note 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...

Page 13: ...eumatic 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 ...

Page 14: ...maintenance technician Ammeter Accuracy Verification 1 With the unit electrically installed the compressed air supply connected and the inspection hood optional installed connect the foot switch to the foot switch receptacle or the optional Dual Palm to the Dual Palm receptacle on the left side of the unit Refer to Figure 2 9 to locate both receptacles Figure 2 8 Figure 2 7 Foot Switch Receptacle ...

Page 15: ... 40 psi 6 Turn on disconnect switch Operator HMI and power indicator will light 7 If equipped with the AUTOBATH option toggle AUTOBATH and PUMP buttons to off If equipped with the AUTOMAG option toggle AUTOMAG to off 8 Press the foot switch or the Optional Dual Palm to firmly clamp the shunt in position between the headstock and tailstock 9 Press CONTACTS push button to on 10 Set the amperage usin...

Page 16: ...flush system with light oil Specification MIL L 15016 such as Magnaflux Carrier II NOTE All units are tested with the oil bath during the certification process by Magnaflux Look for the tag on the pump housing prior to adding the bath to the system 3 Prepare bath according to the manufacturer s recommendations and any applicable specifications For proper particle agitation DO NOT EXCEED VOLUME REC...

Page 17: ...e the centrifuge tube in its stand Magnaflux Accessory Part Number 1837A and allow the suspension to settle for thirty minutes water bath or sixty minutes oil bath 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 Illumina...

Page 18: ...alve 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 then replace these back on the unit and close the drain cock The tank and spray nozzle can be cleaned using compressed air 4 Open the valve turn counterclockwise at the bottom of the regulator gauge filter...

Page 19: ...ipment 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 ensure 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 identif...

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Page 21: ...ressure Regulator Gauge Item 8 Coil Item 4 Operator Control Cabinet Figure 3 5 Item 9 Tailstock Item 5 Magnetic Current Push button Item 10 Push Bar 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 pa...

Page 22: ...ng shot is set at 0 5 seconds from the factory 1 Select Item 4 in Figure 3 3 to the desired shot time The range is from 0 5 to 2 seconds A shot timer Magnaflux Accessory Part Number 622646 should be used to provide the actual shot time that has been set Figure 3 2 MOD AC Option shown Figure 3 3 1 2 3 4 5 1 2 7 6 8 9 ...

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Page 24: ...t operate this machine until you are familiar with all the electrical and mechanical controls Check controls for proper functioning before operating machine NOTE For a contact shot to be performed the part must be clamped by pressing the foot switch or using the dual touch button optional feature See Figure 3 1 1 a Foot Switch Without Autobath Activates headstock clamping Press once and release pa...

Page 25: ...amage 10 Push Bar 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 inoperable On longer machines a second Push Bar is provided on the tailstock end of the machine for operator convenience See Figures 3 2 3 3 3 4 and 3 5 1 Operator Screen Displays Operator Screen 2 Machine Settings Displa...

Page 26: ... current shot each time is pressed The next mag or demag shot will be dictated by the duty cycle 23 HMI Display Screen Displays the Operator Screen and Machine Settings Screen It also displays the amount of current passed through the circuit Options not Illustrated 1 Tailstock Crank Moves tailstock back and forth along rails 2 Bath Applicator Pressure Regulator Valve Controls the speed of the bath...

Page 27: ...ws 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 3 2 3 3 3 4 and 3 5 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 ...

Page 28: ... clamp part d Press MAG push button while observing Digital Ammeter The current assurance light should not light 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 Press and release foot switch or Optional Dual Palm to clamp te...

Page 29: ...rs are illustrated in Figures 3 2 3 3 3 4 and 3 5 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 p...

Page 30: ... through them This method also reveals defects on the inside diameter of the part The central conductor is placed through a part 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 7 MAGNETIZING PROCEDURES Without Auto Bath All controls and indicators are illustrated in 3 2 3 3 3...

Page 31: ...plication and current shot The wet residual method which applies bath after the current shot is recommended only for parts with high magnetic retention 8 Press and release foot switch to unclamp part 9 Examine part for indications With Auto Mag 1 Clamp part as described in PIECE PART SETUP 2 Press and release Auto Mag button so light is bright 3 Manually bathe the part press and release the foot s...

Page 32: ...d 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 SHUTDOWN All controls and indicators are illustrated in 3 2 3 3 3 4 and 3 5 1 Toggle the PUMP button t...

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Page 34: ... concentration Cable and busbar connections Check coil headstock and tailstock busbar and cable connections 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 sp...

Page 35: ...t and bowl Check Tank Seal Look for leaks of fluid around near the pump motor shaft PERIODIC INTERNAL MAINTENANCE NOTE The following procedures should be performed by a qualified maintenance technician WARNING Turn off and lock out the external disconnect switch before removing cover panels Failure to disconnect incoming power could result in severe electrical shock or death WARNING For cleaning d...

Page 36: ... pump seal Replacement is recommended every 3 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 Screen Cleaning To prevent loss of flow from the pump the screen on the intake of the pump will need to...

Page 37: ...screpancies before placing the machine into service Table 4 5 Test Equipment Recommended Test Equipment Tektronix TDS 2012B 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 ...

Page 38: ... 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 button off The 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...

Page 39: ...r use the AMPERAGE SETPOINT on the HMI to a desired value 14 Press and release the MAG push button The green current assurance 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...

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Page 41: ...d through connection J5 3 and J5 11 If 24VAC is not present at connector check 24V Power Supply for OUTPUT 2 Check that red PHASE LOSS LED is off If not check for balanced 3 phase voltage input through connector J7 1 J7 2 and J7 3 If three phase power is not at test points check incoming power to ensure all three phases are present or at Fuses 7FU 8FU and 9FU CAUTION At power line potential 3 Chec...

Page 42: ... power supply 1 Connect air supply to inlet 90psi Note Pressure Regulator setting min 40 psi 2 Check Input I 00 light on PLC If it doesn t light when Footswitch pressed replace foot switch cable and or plug 3 Check that Output O 14 light on PLC toggles with Footswitch If so replace solenoid valve 2SOL or complete solenoid valve 4 Replace fuse 8FU 5 Replace 24VDC power supply Current Flow with noth...

Page 43: ...ctions and tighten hardware 4 Adjust per instructions above in Troubleshooting stack 5 Ensure part is clamped properly Maximum current output at all settings 1 Defective SCR firing board 2 Shorted SCR 1 Replace Firing Board 2 Contact Authorized Magnaflux Service Center Demag does not completely demag part 1 Attempt using Extended Demag on HMI 2 Set Demag Power higher 1 Use Extended Demag cycle on ...

Page 44: ...e for additional troubleshooting options in AC mode 1 Defective AC firing board 2 Replace 6CR 3 See above table for additional troubleshooting options in AC mode MOD AC not firing a mag shot 1 Inhibit lamp on AC Firing Board 2 not OFF during a mag shot 2 Defective AC Firing Board 3 Check Green LED on Firing Board if no light Defective 2T 4 Loss of Phase 1 Relay 6CR is not energizing AC switch not ...

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Page 46: ...al 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 quant...

Page 47: ...for Rectifier Stack 624717 Momentary Assembly Pushbuttons 624928 Harness for 624717 629270 DVM Board for True Amps D 2100 Part Number Description 624316 External Pump Standard and Extra Long Frame Units 624630 External Pump Long Frame Units 624570 Seal for pump 521454 DPDT Relay 624779 4PDT Relay 623956 Air Solenoid Valve 621076 Grille Assembly Standard Frame Unit 621225 Grille Assembly Long Frame...

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Page 49: ...l 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 5 Place 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 set aside in a safe place Fi...

Page 50: ...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 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 uni...

Page 51: ...ext 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 12 Figure 7 11 ...

Page 52: ... out the top curtain as show in Figure 7 13 and Figure 7 14 below 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 13 Figure 7 14 ...

Page 53: ...ly ensure the white light clears the frames as shown in Figure 7 19 below 25 Return and tighten nuts onto 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 27 Removing and reorienting the vent direction is possible by removing the mounting hardware and rotating the vent NOTE Verify white light levels inside booth before changin...

Page 54: ... 29 Plug into 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 buttons on the main control panel as shown in Figure 7 23 below Figure 7 23 31 Now the left and right side curtains can be carefully unfolded as shown in Figure 7 24 below ...

Page 55: ...t 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...

Page 56: ...ring with the hardware provided as shown in Figure 7 28 and Figure 7 29 below 2 Orient the power supply so the light cord comes out toward the front of the unit Secure the power supply to the black light bracket by velcro This is shown in Figure 7 31 below Figure 7 30 3 Plug the transformer cord into the outlet on the side of the unit as shown in Figure 7 31 below Figure 7 28 Figure 7 29 ...

Page 57: ...sed March 2020 www magnaflux com Page 7 9 4 Mount the EV6000 or EV6500 black light onto the peg provided as shown in Figure 7 32 This completes the installation of the hood assembly Figure 7 31 Figure 7 32 ...

Page 58: ...Revised March 2020 www magnaflux com Page 7 10 155 Harlem Avenue Glenview Illinois 60025 USA Telephone 1 847 657 5300 Fax 1 847 657 5388 Web www magnaflux com E mail support magnaflux com ...