Magnaflux AD-2045 User manual

A-2045 Series
© 2015 Magnaflux
Page 1 Magnaflux-SRVC-IG002
Issued: Apr 2015
Rev. 2
AD-2045 Series
Congratulations on the purchase of your new Magnaflux
AD-2045 Magnetic Particle Inspection Machine! This guide
will help you install and set-up your new Magnaflux machine.
If you have any questions, please contact your local
Magnaflux Authorized Service Center or call Magnaflux
Customer Service at 847-657-5300.

A-2045 Series
© 2015 Magnaflux
Page 2 Magnaflux-SRVC-IG002
Issued: Apr 2015
Rev. 2
1. A minimum of two feet is required at both ends and the rear of the inspection unit to ensure
adequate space for servicing (removing machine panels and accessing the circulating
pump) and ventilation.
2. A firm, reasonably level floor capable of supporting the inspection unit and the materials
awaiting inspection.
3. Adequate space to accommodate a black light inspection canopy (Optional), material stor-
age, material movement and access to the materials.
4. A power source of the proper voltage, frequency and phase (as designated on the Mag-
naflux Data Plate located on headstock end of inspection unit) capable of providing current
per the nameplate. Connect the incoming power to the Incoming Power Connection located
inside the unit on the back side. Attach the Chassis Ground wire to the inside of the unit to
the Chassis Ground Connection Screw. Follow all local electrical codes for wiring. It is high-
ly recommended that an electrical fused disconnect be installed on the headstock side of
the unit—Either on the wall behind the unit or on a pedestal near the unit. See page 3 for
correct fuse sizes.
Operating Manual and
Drawings
The manual is shipped with the unit in electronic format wrapped
in a green bubble wrap mailer within the Accessories Box. In the
manual is an extensive step by step process of how to assemble
the enclosure and attach it to the unit.
Getting Started
Air Pressure
Regulator
Front of Unit: Back of Unit:
120VAC receptacle
for pump
Incoming Power
Connection
Chassis Ground
Connection
Incoming Air Connection
1/8” NPT Thread
Set-Up
continued on Page 3...

A-2045 Series
© 2015 Magnaflux
Page 3 Magnaflux-SRVC-IG002
Issued: Apr 2015
Rev. 2
Model No. Gallons Liters
AD-2045 (2 door) 20 76
AD-2045L (3 door) 34 129
AD-2045XL (4 door) 46 174
AD-2045XL2 (5 door) 58 220
Recommended Bath Level:
When adding 14A particles to a new bath you can use
the following guide to achieve a 0.2 concentration. 1
level scoop of 14A particles per 1 gallon of Carrier II.
NOTE: DO NOT ADD ALL THE PARTILCES ALL AT
ONCE. This will cause particles to accumulate in the
bottom of the tank. Allow particles to mix for 20–30
minutes, then test concentration per instructions.
Duty Cycle:
At full output: 0.5 seconds “ON” – 10 seconds “OFF”
At 1000 amps: 0.5 seconds “ON” – 5 seconds “OFF”
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). 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.
Electrical Input:
Input Volts AC Phase
Full Load
(Amps)
Recommended
Line Fuse (Amps)
Recommended
Wire Size (AWG)
208 1350 250 2/0
230 1300 250 #1
380 1175 125 #3
415 1160 125 #4
460 1150 125 #4
575 1120 100 #6
5. A compressed air supply capable of providing a minimum of 90-120 psig at 5 cubic feet per
minute. Connect the incoming air supply to the Incoming Air Connection on the air filter ex-
ternally on the unit. Adjust the Air Pressure Regulator (located under the control panel) to
40 psig to supply air to the headstock extension cylinder. Follow all local codes for plumb-
ing pneumatics.
6. Fill the tank to the appropriate level as per the Recommended Bath Level.
7. Connect the pump plug to the 120VAC receptacle that is located above the black box on
the headstock side of the unit. Never run the pump dry. The pump On/Off switch is located
continued from Page 2...

A-2045 Series
© 2015 Magnaflux
Page 4 Magnaflux-SRVC-IG002
Issued: Apr 2015
Rev. 2
Pump Care and Maintenance
NOTE: Due to the nature of the material used in Magnetic Particle Inspection, periodic mainte-
nance is required on the 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.
The life of the pump and pump seal can be maximized if contamination is not introduced into
the machine’s inspection bath. Contamination may include but not limited to grinding dust, tool-
ing oil or coolant, metal shavings, wheelabrator/sandblasting residue and paint chips.
Ways to prevent contamination include locating the machine in a dedicated room, providing
positive air pressure inside the Equipment Enclosure (Hood Assembly) , keeping the front cur-
tain of the Equipment Enclosure closed, and thoroughly cleaning parts before they are subject-
ed to testing.
Signs of contamination:
1. Settling time exceeds either 30 minutes (water) or 60 minutes for Carrier II (Oil)
2. 2nd layer (lighter in color) appears in centrifuge tube (Spec. is less than 30%)
3. Oil bath turning a “milky white” color (water/coolant contamination)
Examples of contaminated pumps:

A-2045 Series
© 2015 Magnaflux
Page 5 Magnaflux-SRVC-IG002
Issued: Apr 2015
Rev. 2
Optional Hood Enclosure
with UV Light and Fan Assembly and White Light
Note: Both the UV light and Fan Assembly plug into
receptacles located on the unit. The Fan Assembly
plugs into a 4 prong receptacle on the Headstock end
of the unit and the ON/OFF switches for both the fan
and white light are located on the Operator Control
Panel. The UV light (supplied associated mounting
bracket and transformer) will mount on the tailstock
end of the unit and plug into the 115 outlet located
there.
Enclosure Foot Print:
Open Dimensions Closed Dimensions
Model Length Depth Height Length Depth Height
Standard unit 86″
(218 cm)
50″
(127 cm)
120″
(305 cm)
86″
(218 cm)
73″
(185 cm)
89.5″
(227 cm)
Long unit
(AD-2045L)
135″
(336 cm)
50″
(127 cm)
120″
(305 cm)
135″
(336 cm)
73″
(185 cm)
89.5″
(227 cm)
Extra long unit
(AD-2045XL)
178″
(452 cm)
50″
(127 cm)
120″
(305 cm)
178″
(452 cm)
73″
(185 cm)
89.5″
(227 cm)
Machine Only Footprint:
Model Length Depth Height
Standard unit 84.5″
(215 cm)
41″
(104 cm)
60.25″
(153 cm)
Long unit
(AD-2045L)
132.5″
(336 cm)
41″
(104 cm)
60.25″
(153 cm)
Extra long unit
(AD-2045XL)
176.5″
(448 cm)
41″
(104 cm)
60.25″
(305 cm)