OPERATING INSTRUCTIONS

for
MAGNAFLUX® EQUIPMENT
ADH-2000 SERIES

Serial Number ________________

TABLE OF CONTENTS

GENERAL SAFETY INSTRUCTIONS ............................................................................................................ I

SECTION I - 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 ................................................................................................... 2-10
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 ................................................................................................................................... 3-6
Magnetizing Procedures Without Autobath .......................................................................................... 3-9
Magnetizing Procedures With Autobath ............................................................................................. 3-10
Magnetizing Procedures With Automag ............................................................................................. 3-10
Demagnetization.................................................................................................................................. 3-11
Shutdown ............................................................................................................................................ 3-12
Emergency Shutdown ......................................................................................................................... 3-12
SECTION 4 - MAINTENANCE and TROUBLESHOOTING ................................................................... 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 ......................................................................................................... 4-3
Initial Set-up .......................................................................................................................................... 4-3
Circular (Contact) and Longitudinal (Coil) Magnetization Check ........................................................ 4-4
Current Turn On Speed Adjustment...................................................................................................... 4-5
SECTION 5 – TROUBLESHOOTING.......................................................................................................... 5-1
SECTION 6 - DRAWING LIST ..................................................................................................................... 6-1
 GENERAL SAFETY INSTRUCTIONS
This manual provides information on how to 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 to ASTM E-1444. 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 Magnaflux
ADH 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 nondestructive 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 alternating or half wave direct current for magnetization and alternating
current for demagnetization.

The current level is governed by a 2 current control potentiometers (one for CONTACTS and one for COIL).
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 extending the length of the unit, 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 recirculates and
agitates the particle in bath and provides flow to the hand held spray nozzle or the optional autobath nozzles.
Grilles cover the tank and provide a work area 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.

October 2002 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 side of the unit.

October 2002 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

Table 1-1. Electrical Input

Model Input Volts Load Recommended Line Recommended

Series AC Phase* (Amperes) Fuse (Amperes) Wire Size (AWG)
208 1 350 250 2/0
ADH-2045
230 1 300 250 0
380 1 175 125 #3
415 1 160 125 #4
460 1 150 125 #4
575 1 120 100 #6

Table 1-1. Electrical Input

Model Input Volts Load Recommended Line Recommended

Series AC Phase* (Amperes) Fuse (Amperes) Wire Size (AWG)
208 1 na na na
ADH-2066
230 1 650 400 2/0
380 1 375 250 0
415 1 365 250 0
460 1 325 225 #1
575 1 250 200 #1

*Some areas refer to 2 phase instead of 1 phase. The incoming power goes directly to an isolation
transformer so the unit will operate identically on 1 or 2 phase power.

October 2002 1-3

Output Specifications

*All contacts current ratings are based on the maximum current through a
2000amp/100 mv shunt.

Table 1-2. Magnetization and Demagnetization Output

Maximum Current
(Amperes)*

Model RMS (AC) or Current

Series Mode Average (DC) Peak Control Demag

ADH-2045 Contacts AC 4000 5600 Continuously Decaying AC

Contacts HW 5000 8000 Variable In all cases
12” Coil AC 2250 3100 In all cases
12” Coil HW 4000 6400
16” Coil AC 2000 2800
16” Coil HW 3500 5600
1800 2500
20” Coil AC
20” Coil HW 3000 4800
25” Coil AC 1450 2000
25” Coil HW 2200 3500
*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 RMS (AC) or Current

Series Mode Average (DC) Peak Control Demag

ADH-2066 Contacts AC 6000 8400 Continuously Decaying AC

Contacts HW 6000 9600 Variable In all cases
12” Coil AC 2250 3100 In all cases
12” Coil HW 4000 6400
16” Coil AC 2000 2800
16” Coil HW 3500 5600
1800 2500
20” Coil AC
20” Coil HW 3000 4800
25” Coil AC 1450 2000
25” Coil HW 2200 3500

October 2002 1-4

 Table 1-3. Duty Cycle

Model Series Seconds “On” Seconds “Off”

ADH-2000 SERIES
At Maximum Output 0.5 10
At 1000 A. Output 0.5 5

Dimensions and Capacities

Table 1-4. Part Weight Capacity

Maximum Load

Description Pounds Kilograms

Using contact pad mounted v’s to support part 300 136

Using contact pad mounted v’s to support part (with rotating heads) 70 32

Using rail mounted steadyrests to support part 1500 680

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

Table 1-5. Part Length Capacity Table -16. Recommended Bath Level

Model No. Length Model No. Gallons Liters

ADH-20** 54" (137 cm) ADH-20** 25 95

ADH-20**L 102" (259 cm) ADH-20**L 37 140

ADH-20**XL 146" (370 cm) ADH-20**XL 60 235

October 2002 1-5

 Table 1-7. Machine Weight

Approximate Weight (Dry) Approximate Weight (Crated)

Model No. Pounds Kilograms Pounds Kilograms

ADH-20** 1600 726 1875 850

ADH-20**L 1825 828 2100 952

ADH-20**XL 1925 873 2200 998

Table 1-8. Overall Dimensions

Description ADH-20** ADH-20**L ADH-20**XL

Basic Unit (No Hood)

Length 84½ (215cm) 132½(336cm) 176½(448cm)
Width 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)
Width (Hood Opened) 50(127cm) 50(127cm) 50(127cm)
Width (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)

October 2002 1-6

NOTES

October 2002 1-7

 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 assure 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 accessory), 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. (847- 657- 5300)

Plug the Pump AC power cord into the GFI Pump outlet on the headstock end panel.

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.

September 2002 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 area as follows:

1. Open Safety Disconnect located on the headstock end to gain access to input power terminal block

WARNING Before connecting power to unit through the external fused disconnect switch, be certain the
external disconnect switch is in open position (“OFF”). Failure to heed this warning could result
in serious injury or death to installation personnel. Good electrical practices should always be
used as well as lock out tag out procedures.
2. Extend external power source through the fused disconnect switch on the left of the inspection unit Refer to
Tables 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.

Table 2-2. Recommended Fuse Size

(Amperes) ADH-2045
Voltage Fuse Line Wire Ground
wire

208 250 2/0 Same as

230 250 #1 Line
380 125 #3 Or one size
larger
415 125 #4
460 125 #4
575 100 #6

(Amperes) ADH-2066
Voltage Fuse Line Wire Ground
wire

208 x x Same as
230 x x Line
380 300 2/0 Or one size
larger
415 275 0
460 250 #1
575 200 #1

September 2002 2-2

Air Supply
Connect a 60-100 psig compressed air supply to the Pressure Regulator Valve (7, Figure 2-1). Adjust the pressure
regulating knob until the air pressure gauge indicates 40 psi.

September 2002 2-3

 FIGURE 2-1

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 2-2) 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.

September 2002 2-4

Inspection Hood installation
(Optional Accessory)
1. Support the inspection canopy and align the holes in the canopy frame with holes in the unit frame.

2. Install cap screws and lock washers from inside and secure in place. Tighten fully only after all screws are
installed.

3. Plug the fan assembly cord into the HOOD outlet on the left side of the unit.

Black Light Installation

(Optional Accessory)

1. Secure the black light mounting bracket with three round head machine 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 the 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 each end next to the BLACK LIGHT outlets.

Adjustment of Magnetizing Shot

Duration
The duration of the magnetizing shot is set at 0.5 sec from the factory. Adjustment is as follows:

1) Adjust the topmost small potentiometer behind the communication port cover on the PLC. The range is from .5
to 3 seconds. Use caution not to exceed the duty cycle of the unit when adjusting the timer.

NOTE The following procedure should be performed by a qualified maintenance technician.

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

1. If the unit is using 50hz supply power and it is found to “fire” roughly, ensure that the plug on J8 on each SCR
firing board (located on the REC stacks) has been converted to 50Hz operation.

September 2002 2-5

 MAGNETIZING AMPERES X 1000

FIGURE 2-2
CONTROL PANEL
Key

Item 1 Digital Ammeter Item 9 Autobath Select Button (Option)

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 Pushbar ON/OFF Button Item 13 Contacts Select Button
Item 6 Hood White Light Button Item 14 HWDC Select Button
Item 7 Coil Select Button Item 15 Auto-mag Select Button (option)
Item 8 AC Select Button Item 16 Mag Button

September 2002 2-6

Ammeter Accuracy
Verification (refer to figures 2-1and 2-2 and 2-3)
1. With the inspection unit installed, the compressed air supply connected and the inspection unit electrically
wired to an external power source, connect the foot switch or the optional palm buttons to the FOOT SWITCH
outlet on left side of unit.

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

3. Position the digital test meter kit shunt (FIG.2-3 P.2-8)(specified in Table 4-5) between the headstock and tail-
stock.

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 AUTOBATH option, toggle BATH and PUMP push-buttons to off.
If equipped with AUTOMAG option toggle automag to off by pressing and holding the AUTOMAG 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.

11. Select HWDC using the push-button. The push-button is dimly lit when off and brighter when 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 contacts digital ammeter and test kit ammeter should
display close to the same.

Coil Ammeter Accuracy Verification

1. This unit is designed with one meter. The feed back 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 coil mode.

September 2002 2-7

 FIGURE 2-3

This figure depicts a typical test meter set up on a typical wet horizontal unit. All details may not match your
unit or test set exactly.
Item 1 Current Detection Shunt
Item 2 Digital Test Meter Kit

September 2002 2-8

Preparation of Bath

CAUTION Never operate the pump without bath in the tank. Operation of the pump without bath may over-
heat 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 recirculate, followed by a thorough water rinse. If using oil
bath, flush system with light oil (Specification MIL-L-15016) such as Magnaflux Carrier II.(Magnaflux part #
01-2/22-30)

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 9C WA-2B WA-4

Recommended Concentration 1 Part to

Ounces/Gallon 1/6 1/10 1½ 1¼ 1¼ 1_ 100 parts
Grams/Liter 1.25 0.75 11.25 9.4 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 1.2-1.8 N/A N/A

Use Centrifuge Tube Part No. . . 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.

September 2002 2-9

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

4. Place the centrifuge tube in its stand(Magnaflux #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 accessory). Fluorescence in the
liquid or presence of a nonfluorescent 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 1-6 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 autobath valve (if equipped).

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 as well as the tank and hand hose(s) with a dry cleaning
solvent, and dry them with compressed air. Replace the pump, agitator vee and grilles, and close the drain
cock.

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 accessory) and the black light assemblies (optional
accessory). 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 accessory) curtains for added protection.

September 2002 2-10

Long Term Storage and/or Shipment

1. Open the autobath valve (if equipped).

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 the grilles, agitator and pump from the tank. Clean the grilles, agitator vee, pump, hand hoses and
tank with dry cleaning solvent and dry with compressed air. Apply a suitable preservative material to the rail
assembly and the exposed headstock cylinder shaft. Close the drain cock.

4. Open the valve (turn clockwise) at the bottom of the filter/gauge/regulator valve bowl to blow out any
contaminants or accumulated moisture. Close the valve and disconnect the air supply line.

5. Lock the tailstock assembly close to the headstock.

6. Place the CURRENT CONTROLS to the 0 positions.

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 accessory) and the black light assemblies (optional
accessory). Pack and store in a plastic bag or carton on the grilles.

9. Remove the control panel and pack separately.

10. Support the hood (optional accessory) 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.

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

12. 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.

September 2002 2-11

 NOTES

September 2002 2-12

 Section 3
OPERATING INSTRUCTIONS

OPERATING CONTROLS AND

INDICATORS
All controls and indicators are illustrated in Figure 2-2(page 2-6).

CAUTION STOP! Do not operate this machine until you are familiar with all electrical and mechanical
controls. Check controls for proper functioning BEFORE operating unit.

See Figures 2-1(p.2-4) and 2-2(p.2-6)

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 part is clamped, and release; bath cycle begins.

· When bath cycle is finished, a mag shot is fired, then the part is automatically unclamped.

· If 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 “magged”, 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.

August 1, 2000 3-1

Control Cabinet (5). Contains all of the Operator Controls and Pushbuttons. Shown in Fig.2-2 p.2-6.
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 back 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..

· 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 Autobath option).

· Set at 40 psig for normal operation.

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

Palm Buttons (Optional). Used with Autobath in place of foot switch, to activate headstock clamping, bath
application, and Mag Current.

· Press both buttons simultaneously; hold for full extend stroke of bath applicator and release; part is
clamped and cycle begins.

· If BATH push-button is off (dimly lit), the palm buttons will only activate the headstock clamping.

August 1, 2000 3-2

 See Figure 2-2 (P. 2-6)
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 Push-button (5). Activates the push-bar(s) to fire a mag shot.

LIGHT Push-button (6). Turns on/off the white light in the hood (option).

COIL Push-button (7). Selects coil output.

AC Push-button (8). Selects Alternating current output.

AUTOBATH Push-button (9). Enables the Autobath (option) on/off.

DEMAG Push-button (10). Selects a demag cycle. Button is bright when “Demagging” and returns to dim when
demag cycle is complete (approximately 4 seconds).

PUMP Push-button (11). Toggles on/off bath circulating pump motor. NOTE: Do not run pump “dry”!

FAN Push-button (12). Toggles on/off fan in hood (option).

CONTACTS Push-button (13). Selects contacts circuit.

HWDC Push-button (14). Selects Half Wave Direct Current output.

AUTO MAG Push-button (15). Selects Auto mag (option). To select, press and quickly release button. To
deselect, 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 “magged”, then
automatically unclamped.

MAG Push-button (16). Initiates a magnetizing current “shot” each time switch is depressed. Locked out during
demag.

August 1, 2000 3-3

 AUTOBATH (Option) Figure 3-1
Autobath Extended Limit Switch (2). Controls the extend length of the bath applicator.

· Loosen set screws and adjust position for length of part being inspected.

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

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

DAILY START UP AND OPERATION

CHECK LIST
All controls and indicators are illustrated in Figures 2-1, and 2-2.

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

2. Check for proper volume of bath; see EQUIPMENT SPECIFICATIONS, Table 1-6.

3. Press PUMP Push-button to turn on and allow bath to circulate for a minimum of 10 minutes.

August 1, 2000 3-4

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

5. Allow black light to warn up for 5-6 minutes.

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.

CAUTION: Lens on the black light may be extremely hot. Let the unit cool before cleaning or replacing bulb.
7. Set Pressure Regulator Valve to 30 psig.

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

8. If equipped with AUTOBATH (OPTION), toggle the AUTO BATH Pushbutton and the PUMP Push-button
to off. If equipped with AUTO MAG (OPTION), toggle AUTO MAG to off by pressing and holding the
AUTO MAG push-button until light goes dim(approximately .3 sec.), 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. Select AC, or half-wave DC (HW), using the Push-buttons.

13. Set CONTACTS CURRENT CONTROL for 2 divisions.

14. 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 end
of part.

c. Depress and release Foot Switch or optional Palm Buttons to clamp part.
d. Depress Mag Current 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 TROUBLESHOOTING, Section 4.

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

August 1, 2000 3-5

 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.

· The Green Current Assurance Light on the Ammeter should light indicating current flow through the test
bar.

15. Depress and release Foot Switch or optional Palm Buttons to release the part.

16. If equipped with AUTOBATH option, check as follows:

a. Press BATH Push-button and PUMP Push-button to on.

b. If equipped with Foot Switch, follow steps 13 through 21 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 Autobath cycle is complete.

d. If equipped with optional Palm Buttons, follow steps 13 through 21 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.

17. 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(.3 sec.), then
release.

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

PIECE PART SET-UP

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

CAUTION Use rail mounted steady rests to support heavy parts. See EQUIPMENT SPECIFICATIONS
section for maximum weight capability.

August 1, 2000 3-6

Normal Set-Up

All controls and indicators are illustrated in Figures 2-1, and 2-2.

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

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

2. If equipped with autobath, 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 steadyrests. 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 autobath, the automatic cycle will begin if AUTOBATH Push-button is on.

Remote Operation Set-up

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

August 1, 2000 3-7

 Figure 3-2. Central Conductor Operation

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.

August 1, 2000 3-8

MAGNETIZING PROCEDURES
WITHOUT AUTOBATH
All controls and indicators are illustrated in Figures 2-1 and 2-2.

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

CAUTION 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. Press the COIL/CONTACTS and AC/HWDC push-buttons to select the desired magnetizing current and
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 area

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 Current 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.

NOTE Footswitch is inoperative while current is flowing, preventing arc damage to machine and part being
processed.

8. Depress and release Foot Switch to unclamp part.

9. Examine part for indications.

August 1, 2000 3-9

MAGNETIZING PROCEDURES WITH AUTOBATH
All controls and indicators are illustrated in Figures 2-1, and 2-2.

1. Press BATH Push-button to on.

CAUTION 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 selected CURRENT CONTROL. Tighten lock(s).

3. Press the appropriate Push-button(s) to select the desired magnetizing current and circuit.

4. If machine is equipped with an optional black light hood, lower hood to darken work area. Allow your eyes
time to adjust to the dark.

5. Clamp the part as described in PIECE PART SET-UP. When the Foot Switch or optional Palm Buttons are
pressed, the part will be clamped, bath will be applied by the autobath nozzles, and the Mag Current will be
energized.

· Green Pilot Light will light and remain lit for duration of magnetizing “shot.”

· Digital Ammeter will display and retain applied current.

6. When cycle is complete, head will unclamp to release part.

7. Examine part for indications.

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 footswitch and manually bathe the part.

4. When bathing is complete, release footswitch and part will be “magged” and released.

August 1, 2000 3-10

DEMAGNETIZATION

All controls and indicators are illustrated in Figures 2-1, and 2-2.

Demagnetization is generally performed after inspection. A safety features prevents accidental energizing of the
magnetizing circuit during the demag cycle. A unique feature of this machine causes the Demag initial current to
be slightly higher than a mag current at the same setting. This eliminates the need to set the CURRENT
CONTROLS to a slightly higher setting to demag most parts.

1. If equipped with autobath, press AUTOBATH 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 part.
Tighten lock.

4. Press and release DEMAG push-button to start demagnetization cycle. Demag Light will remain lit during
complete cycle.

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

5. After demagnetization of part is complete, Demag Light will go out.

6. Press and release Foot Switch or optional Palm Buttons to unclamp part.

Demagnetization Using Optional

Accessories

All controls and indicators are illustrated in Figure 2-1, and 2-2.

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.

August 1, 2000 3-11

SHUTDOWN
All controls and indicators are illustrated in Figure 2-1, and 2-2.

1. Press the PUMP push-button to turn off.

2. Open valve at bottom of filter/gauge regulator valve 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 OFF external disconnect switch.

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.

August 1, 2000 3-12

 NOTES

August 1, 2000 3-13

 Section 4
MAINTENANCE AND TROUBLESHOOTING

GENERAL
Do not remove any cover panels. Inspections or
The following tables contain periodic visual and maintenance requiring removal of cover panels are to
operational inspections designed to prevent or be performed by a qualified technician.
discover malfunctions and defective parts. Many of A list of Authorized Magnaflux Service Centers is in
these checks are based on ASTM E-1444. the rear of this manual.
Do not operate the inspection unit if it is found to be
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 Equipment Specifications for proper level.

Particle concentration See Table 2-5, page 2-7 for proper concentration.

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

Autobath and Auto Mag(if Check Autobath function.

equipped) Check Auto Mag function

October 2002 4-1

WEEKLY OPERATOR MAINTENANCE

Table 4-2. Weekly Operator Checks

Item Action

Air filter Open valve and blow out moisture from air filter bowl.

Ground Fault Interrupt Check for proper operation of Black Light and Pump.
Lead Contact Plates Clean both sides of each plate weekly if using water bath

MONTHLY OPERATOR MAINTENANCE

Table 4-3. Monthly Operator Checks

Item Action

Tank and grilles Clean using dry cleaning solvent. After cleaning, flush parts with appro-
priate bath solution

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

Air filter Clean air filter element and bowl.

PERIODIC INTERNAL MAINTENANCE

NOTE The following procedures should be WARNING For cleaning, do not use com-
performed by a qualified maintenance pressed 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.

October 2002 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 Check for accuracy every 6 months

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 table
and correct all discrepancies before placing the machine into service.

Table 4-5. Test Equipment

Recommended Test Equipment

Tektronix 465 Oscilloscope or equivalent

Magnaflux 600355 Digital Test Meter Kit

with Matching Shunt

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

4140 H.T.)

October 2002 4-3

INITIAL SET-UP
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
inspection unit.

7. If an optional hood has been installed, connect the line plug to the HOOD outlet on the headstock end of
the inspection unit.

8. Connect the black light to the BLACK LIGHT outlet on either end of the inspection unit. The black light
should come up 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.

October 2002 4-4

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 autobath, press the 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.

8. Press AC push-button to on. The push-button is dimly lit when off and brighter when on.

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

10. 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 ± 3% of the machine rating.

11. Continue repeating this procedure while increasing the CURRENT CONTROL to the next division after
each “shot.” At all settings, both ammeters should agree within ± 3% of the machine rating.

12. Press the HWDC push-button to on, and set standard meter as needed.

14. Repeat steps 10, 11, and 12.

17. Depress the foot switch or optional palm buttons to unclamp and remove the shunt.

18. Depress and release the MAG push-button (see test meter instructions). The Ammeter should rest to zero.
If it does not an electrical short exists. Refer to the trouble-shooting table.

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

20. Press AC push-button to on. The push-button is dimly lit when off and brighter when on.

October 2002 4-5

21. Set the COIL CURRENT CONTROL to the first division.
22. 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 feed back for the coil reading and the contact
reading are from the same source. So if the Contact readings are accurate then the coil meter readings will
be accurate also.

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

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

26. Repeat steps 23, and 24.

27. 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.

October 2002 4-6

 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 custom options you may have received with the unit.

A listing of Magnaflux Authorized Service Centers is located in the back of this manual or on our website,
www.magnaflux.com.

Table 5-1. Troubleshooting Guide

Trouble Probable Cause Remedy

No line voltage at all. Red POWER 1. External fused disconnect switch 1. Turn on external fused disconnect
ON light not on. off. switch.

2. Fuse in external fused disconnect 2. Replace fuse. Check for shorts if

switch blown. fuse continues to blow.

3. Fuse 4FU blown. 3. Replace fuse 4FU. Check for

shorts if fuse continues to blow.

4. Replace lamp.
4. POWER ON lamp burned out.

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

Pump motor does not operate. 1. GFI on pump receptacle tripped. 1. Check power cord to pump. Allow
the motor to cool. If GFI retrips,
check for excess current draw. If
GFI continues to trip, motor or
pump is bound up or shorted

2. Replace fuse 8FU. Check for

2. Fuse 8FU blown. shorts if fuse continues to blow.

Headstock does not extend to clamp 1. Air supply not properly con- 1. Connect air supply to inlet.
part. nected.

2. Defective foot switch cable and 2. Check Input 0 lamp on PLC. If it

plug. doesn’t light when Footswitch pressed,
replace foot switch cable and/or plug.

3. Defective solenoid valve SOL B. 3. Check that Output lights 4 and 5

on PLC toggle with Footswitch. If so,
replace solenoid valve SOL B coil or
complete solenoid valve.

October 2002 5-1

 Table 5-1. Troubleshooting Guide

Trouble Probable Cause Remedy

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

2. CONTACT SCR(s) shorted

2. Check SCRs #1 and #3

Headstock does not retract to release 1. Air supply not properly con- 1. Connect air supply to inlet.
part. nected.
2. Check per Headstock doesn’t clamp
2. Defective foot switch cable and procedure above.
plug.
3. Replace solenoid valve SOL A coil
3. Defective solenoid valve SOL A. or complete solenoid valve.

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

headstock. regulator. regulator.

2. Dirty air filter. 2. Clean air filter.

Magnetizing current shot too long or 1. Incorrect setting POT 0 in PLC 1. Adjust POT 0 in PLC
too short.

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

Continuous mag shot on coil and/or Shorted SCR. Call Authorized Service Center.
contact.

Main fuse to unit blown. Shorted SCR Call Authorized Service Center.

No output current or irregular current 1. Loose connection at bus bars or 1. Clean connections and tighten
through contacts cable joints. hardware.

2. Fuse 5FU. 2. Replace fuse 5FU. Check for

shorts if fuse continues to blow.

3. Defective relay if occurs on HW 3. Swap relays 5CR and 6CR.

only or AC only.
4. Swap relays 7CR and 8CR.
4. Defective relay if occurs on
COIL only or CONTACTS only. 5. Check outputs on PLC and see if
Output 6 is on during COIL mag shot
and Output 7 is on during CONTACTS
5. Defective harnesses. shot.

October 2002 5-2

 Table 5-1. Troubleshooting Guide

Trouble Probable Cause Remedy

6. Check harnesses and replace or
repair as necessary.
6. Defective SCRs.
7. Call Authorized Service Center

No output current or irregular current 1. Loose connection at bus bars or 1. Clean connections and tighten
through Coils. cable joints. hardware.

2. Fuse 5FU blown. 2. Replace fuse 5FU. Check for

shorts if fuse continues to blow.

3. Defective relay 8CR 3. Swap with 7CR and see if problem

switches to CONTACTS.

4. Defective relay 5CR or 6CR. 4. Swap relays and see if problem

switches from AC to HW or HW to
AC.

5. Defective harnesses. 5. Check harnesses and replace or

repair as necessary.

6. Defective SCRs. 6. Call Authorized Service Center

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

2. Low line voltage. 2. Check line voltage. Correct if

possible or try another line.

3. Loose connection at bus bars or 3. Clean connections and tighten

cable joints. hardware.

Maximum current output at all 1. Defective SCR firing board. 1. Swap COIL and CONTACT
settings through Contacts. boards and see if problem moves.

2. Check harnesses and repair/replace

2. Defective harness. as necessary.

3. Shorted red or blue SCR. 3. Contact Authorized Magnaflux

Service Center

October 2002 5-3

 Table 5-1. Troubleshooting Guide

Trouble Probable Cause Remedy

Maximum current output at all 1. Defective SCR firing board. 1. Swap COIL and CONTACTS
settings through Coil. firing boards and see if problem moves.

2. Defective harness. 2. Check harnesses and repair/replace

as necessary.

3. Shorted SCR. 3. Contact Authorized Service Center

Current assurance light defective. Defective Ammeter Replace Ammeter

Demag does not work or does not 1. SCR is not properly balanced. 1. Call Authorized Service Center
completely demag.
2. Call Authorized Service Center
2. Defective Capacitor 1CAP

Contacts push-button does not light at 1. Lamp burned out. 1. Replace lamp.
all.
2. Defective relay 7CR 2. Replace Relay

Coil push-button does not light at all. 1. Lamp burned out. 1. Replace lamp.

2. Defective Relay 8CR. 2. Replace Relay

All push-buttons do not 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 work 1. Bulb burned out. 1. Replace bulb.

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. Defective relay 3CR 4. Replace 3CR

October 2002 5-4

 Table 5-1. Troubleshooting Guide

Trouble Probable Cause Remedy

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 harnesse. If wave form is
good, check pins 3, 4, and 5 on
back of meter as on Table 5-2.
2. Meter got wet
2. Replace Meter

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

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

as necessary.

3. Meter failure from surge. 3. Check cables for worn indication.

Replace meter if necessary.

Table 5-2. Meter Pin Check

PIN 3 PIN 4

AC Shorted to pin 5 Shorted to pin 5

HW Open to pin 5 Open to pin 5

October 2002 5-5

 DRAWING LIST

GENERAL
This drawing list tabulates and describes major equipment groups, assemblies, subassemblies 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-subassembly-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 "AR" (as required) is used when a precise quantity cannot be
specified.

HOW TO USE THIS ILLUSTRATED

PARTS BREAKDOWN
Find the drawing for the major assembly in which the part is used. Locate the Part and its index number on the
illustration. Contact your local Authorized Magnaflux Service Center or Distributor to order the part.

October 2002 6-1

 NOTES

October 2002 6-2