Magnaflux D-2000 Series User manual

D-20
0
0
0 Series
D-20
0
0
0
S
Revised
N
S
E
R
N
ovember 201
Page | 1-
R
IE
S

5
0
S

D-20
0
GE
N
SE
C
SE
C
SE
C
SE
C
SE
C
SE
C
SE
C
0
0 Series
N
ERAL SA
F
C
TION 1 - E
Q
Scope o
f
Purpose
Equipm
e
Equipm
e
C
TION 2 - IN
General
.
Installati
o
Preparat
C
TION 3 - O
P
Operatin
Daily St
a
Piece P
a
Magneti
z
Demagn
e
Shutdo
w
Emerge
n
C
TION 4 - M
A
General
.
Daily Op
Weekly
O
Monthly
O
Periodic
Operatio
Initial Se
Circular
(
C
TION 5 – T
R
Demagn
e
Trouble
s
C
TION 6 – D
C
TION 7 – H
Hood In
s
Black Li
g
ETY INST
R
Q
UIPMENT
f
this Manu
a
of the Equi
p
e
nt Charact
e
e
nt Specific
a
STALLATI
O
.
..................
o
n...............
ion for Stor
a
P
ERATING
g Controls
a
a
rt Up and
O
a
rt Setup.....
z
ing Proced
u
e
tization.....
w
n................
n
cy Shutdo
w
A
INTENAN
C
.
..................
erator Main
t
O
perator M
a
O
perator M
a
Internal Mai
nal Checko
u
t-up............
(
Contact) a
n
R
OUBLES
H
e
tization Ad
j
s
hooting Gui
d
RAWINGS
&
OOD & BL
A
s
tallation.....
g
ht Installati
o
R
UCTIONS..
SPECIFIC
A
a
l .................
p
ment .........
e
ristics.........
a
tions...........
O
N and ST
O
...................
...................
a
ge or Ship
m
INSTRUCT
I
a
nd Indicato
r
O
peration C
h
...................
u
res............
...................
...................
w
n................
C
E..............
...................
t
enance......
a
intenance ..
a
intenance..
ntenance ...
u
t Procedur
e
...................
n
d Longitudi
n
H
OOTING ...
j
ustment.....
d
e...............
&
SPARE
P
A
CK LIGHT
...................
o
n...............
TABLE
..................
.
A
TIONS......
.
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.
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.
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.
..................
.
O
RAGE......
.
..................
.
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.
m
ent...........
.
I
ONS .........
.
r
s...............
.
h
ecklist .......
.
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.
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.
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e
s...............
.
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.
n
al (Coil) M
a
..................
.
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.
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.
P
ARTS LIS
T
INSTALLA
T
..................
.
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.
OF CONTE
.
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a
gnetization
.
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.
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T
..................
T
ION..........
.
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NTS
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Check .......
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Revised
N
.
................1
.
................1
.
................1
.
................1
.
................1
.
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2
.
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2
.
................
2
.
..............2-
.
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3
.
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3
.
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3
.
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3
.
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3
.
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3
.
..............3-
.
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.
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4
.
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4
.
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4
.
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4
.
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4
.
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4
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4
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4
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4
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5
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7
N
ovember 201
Page | 1-
-2
-3
-3
-3
-3
-4
2
-1
2
-1
2
-1
12
3
-1
3
-1
3
-5
3
-7
3
-8
3
-9
10
10
4
-1
4
-1
4
-1
4
-2
4
-2
4
-2
4
-4
4
-4
4
-5
5
-1
5
-1
5
-3
6
-1
7
-1
7
-1
7
-8

5
1

D-20
0
This
insp
e
Rea
d









0
0 Series
manual pr
o
e
ction mac
h
d
these ins
t

Only trai
n
procedu
r

Read thi
s

Wear sa
f

Do not
w

Inspect t

Keep all

A
ccordin
recomm
e
60 cycle
magneti
c
exactly
w
operatin
g

When y
o

This ma
c
is dictat
e
o
vides infor
m
h
ine.
t
ructions c
a
n
ed person
n
r
es as well
a
s
entire ma
n
f
ety glasses
w
ear loose cl
he machine
unauthoriz
e
g to the Am
e
e
ndations, i
n
A.C. field o
v
c
fields. We
a
w
hat they sh
o
g
this equip
m
o
u are finish
e
c
hine was d
e
e
d by this st
a
GEN
E
m
ation on ho
w
a
refully be
f
n
el should o
p
a
s Lock Out/
T
n
ual before
o
that confor
m
othing or je
w
daily for un
s
e
d personne
l
e
rican Conf
e
n
spectors wi
v
er 1.0 gau
s
a
rers should
o
uld avoid,
a
m
ent.
e
d operatin
g
e
signed to h
a
ndard.
E
RAL SA
F
w
to install,
ore operati
p
erate or se
T
ag Out re
q
o
perating thi
m
to ANSI S
w
elry while
o
s
afe conditi
o
l
away from
e
rence of G
o
th pacemak
s
s. There ar
e
discuss pa
c
a
nd whethe
r
g
the machi
n
elp the end
F
ETY INS
T
operate, an
d
n
g or servi
c
rvice this m
a
q
uirements
b
s machine.
tandard Z8
7
o
pe
r
ating or
o
ns; replace
the machin
e
o
vernmenta
ers should
a
e
a variety o
f
c
emaker lim
r
they shoul
d
n
e, turn off a
user compl
y
T
RUCTIO
N
d
maintain
y
c
ing your
m
a
chine. Be f
a
b
efore worki
n
7
.1 while op
e
servicing th
any worn o
e
operating
a
l Industrial
H
a
void expos
u
f
pacemake
itations with
d
be expos
e
ll power.
y
with AST
M
N
S
y
our Magnaf
m
achine.
f
amiliar with
n
g with this
e
rating this
m
is machine.
r broken pa
r
a
rea.
H
ygienists (
A
u
re to D.C.
f
rs with diffe
r
their physi
c
e
d to magne
t
M
E-1444-11
Revised
N
lux magneti
c
your facility
machine.
m
achine.
r
ts (see Sec
A
CGIH)
f
ields over 1
r
ent suscep
t
c
ians and le
a
t
ic fields be
f
. Calibratio
n
N
ovember 201
Page | 1-
c
particle
and local
tion 4).
0 gauss; or
t
ibilities to
a
rn more
f
o
r
e
n
frequency

5
2

D-20
0
SC
O
This
Mag
PU
R
The
Mag
con
d
1
2
3
Dis
c
fabri
con
s
can
EQ
U
Stat
i
pow
e
reve
The
Coil
Con
t
A
di
g
“sho
late
s
the
t
The
goo
d
Part
s
long
The
reve
0
0 Series
O
PE OF T
H
manual pr
o
naflux D-20
0
R
POSE OF
equipment
netic partic
d
itions, sub-
s
1
.
A
pplicati
o
2
. Establis
h
3
. Inspecti
o
c
ontinuities
m
cation of th
s
idered def
e
readily and
U
IPMENT
C
i
onary mag
n
e
r pack pr
o
rsing 3-pha
s
output curr
e
operation i
s
t
rol Panel,
o
g
ital amme
t
t” is initiate
d
s
the particl
e
t
ank, provid
e
ai
r
-operate
d
d
electrical
c
s
clamped
itudinally wi
t
bath is fill
e
aling flaws i
H
IS MANU
A
o
vides esse
0
0 Series S
t
THE EQU
is used to i
l
e inspectio
s
urface dis
c
o
n of magn
e
h
ment of a s
o
n and eval
u
m
ay exist in
e parts, or,
e
cts if their
e
r
eliably loca
C
HARACT
E
n
etic particl
e
o
vides low-
v
s
e full wave
e
nt levels a
r
s
provided
b
o
r a push ba
r
t
er provides
d
. The wet
b
e
in bath an
d
e
a work sur
f
d
headstoc
k
c
ontact with
t
between t
h
t
h the coil w
e
d with ma
n the part b
e
SECTIO
N
A
L
ntial inform
a
t
ationary M
a
IPMENT
nspect ferr
o
n (MPI) is
ontinuities.
I
e
tic particle
s
uitable mag
n
u
ation of par
t
raw materi
a
they may
e
e
xistence is
te discontin
u
E
RISTICS
e
inspection
v
oltage, hig
direct curre
n
r
e governed
b
y push bu
t
r
, initiates th
a reading
o
b
ath is conta
d
provides f
f
ace, and p
r
k
and adjus
t
t
he part.
h
e headsto
c
hile clampe
d
gnetic parti
c
e
ing tested.
N
1: EQUI
P
a
tion requir
e
a
gnetic Parti
o
magnetic p
a
a non-dest
I
t consists o
f
s
.
n
etic field.
t
icle accum
u
a
l from whi
c
e
xist as cra
c
detrimental
u
ities reveal
units consi
s
h-amperag
e
n
t for dema
g
by 2 separ
a
t
tons on th
e
e timed ma
g
o
f the mag
n
ined in a ta
n
l
ow to the s
r
event parts
t
able lockin
g
c
k and tails
t
d
in the hea
d
c
les.
A
n ul
t
P
MENT S
P
e
d for instal
l
cle Inspecti
o
a
rts by me
a
ructive met
h
f
three basi
c
u
lations.
h parts are
c
ks due to
to the use
f
ing manufa
c
s
t of a proc
e
e
3-phase f
u
g
netization.
a
te current
c
e
Operator
C
g
netizing cu
r
n
etizing cur
r
n
k that runs
pray nozzle
from falling
g
tailstock p
t
ock for cir
c
d
stock and
t
t
raviolet bl
a
P
ECIFICA
T
l
ation, oper
a
o
n Machine
s
a
ns of the
m
hod for re
v
c
operations
made, or, t
h
excessive
s
f
ulness of t
h
c
turing and/
o
e
ssing stati
o
ull wave di
c
ontrol pote
n
C
ontrol Pa
n
rrent “shot.”
r
ent. The r
e
the full len
g
or the Opti
o
into the tan
k
p
rovide the
n
c
ular magn
t
ailstock.
a
ck light ca
u
T
IONS
a
tion, and
m
s
.
m
agnetic pa
r
v
ealing surf
a
:
h
ey may oc
c
s
ervice stre
s
h
e part. Ma
g
o
r service-i
n
o
n and an i
n
rect curren
t
ntiometers.
n
el.
A
push
e
ading is h
e
g
th of the m
a
o
nal
A
utoba
k
.
n
ecessary
c
etization m
a
u
ses the c
o
Revised
N
m
aintenanc
e
r
ticle inspec
a
ce, and, u
c
ur during
p
s
ses. Disco
n
g
netic partic
n
duced defe
c
n
tegral pow
e
t
for magn
e
Selection o
f
button on
t
e
ld until the
a
chine.
A
p
u
a
th nozzles.
c
lamping for
c
a
y also be
o
ated parti
c
N
ovember 201
Page | 1-
e
of standar
d
tion metho
d
u
nder certai
n
p
rocessing
o
n
tinuities ar
e
le inspectio
n
c
ts.
e
r pack. Th
e
e
tization an
d
f
Contacts
o
t
he Operat
o
next curre
n
u
mp re-circ
u
Grilles cov
e
c
e to assur
e
magnetize
d
c
les to glo
w

5
3
d
d
.
n
o
r
e
n
e
d
o
r
r
n
t
-
r
e
d
w
,

D-20
0
Pert
i
the
M
EQ
U
C
C
Inp
u
The
NE
C
Fac
t
Ta
b
(S
E
opt
(S
E
opt
M
(
O
D
-
D
-
D
-
Out
*All
*So
m
0
0 Series
i
nent data (
e
M
agnaflux
D
U
IPMENT
S
C
ONVENIE
N
C
OMPRES
S
u
t Specifi
c
equipment
c
C
Code Sec
t
t
ors for Resi
s
b
le 1-1. Ele
c
Model
Series
D-2060
E
E MOD AC
ions below)
D-2100
E
E MOD AC
ions below)
M
OD6 AC
O
ptional for
-
2060 and
D-2100)
-
2100XL4
-
2100XL5
put Speci
f
contacts c
u
m
e coils ma
y
e
.g., the uni
D
ata Plate,
S
PECIFIC
A
N
CE OUTL
E
S
ED AIR (
1
/
8
c
ations
c
an be fuse
d
t
ion 630.31
A
s
tance Wel
d
c
trical Inpu
Input Vo
AC
208
230
380
415
460
575
208
230
380
415
460
575
208
230
380
415
460
575
460
460
f
ications
u
rrent ratin
g
y
be capabl
e
t’s serial nu
located on t
h
A
TIONS
E
TS
”
NPT pipe
c
d
based on
A
mpacity o
f
d
ers (NPFA
t
l
ts Pha
s
3
3
3
3
3
3
3
3
3
3
3
3
N/
A
3
3
3
3
3
3
3
g
s are bas
e
e
of handlin
g
mber, elect
r
h
e headsto
c
c
onnection)
less than th
e
f
Supply Co
n
National El
e
s
e L (Am
1
1
1
4
4
2
2
2
1
A
N
5
3
3
3
2
3
3
e
d on the m
g
more curr
e
r
ical specifi
c
c
k end of th
e
2e
a
90-
1
e
maximum
n
ductors an
e
ctric Code
2
o
ad
peres)
1
60
1
60
1
00
90
80
70
4
00
4
00
2
45
2
20
2
00
1
60
N
/A
5
75
3
50
3
25
3
00
2
00
3
50
3
50
aximum cu
e
nt but thes
e
c
ations, and
e
unit.
a
ch 115 volt
s
1
20 psig
amperage
d
d Table 63
0
2
011).
Recomme
n
Fuse (A
m
12
5
12
5
8
0
7
0
6
0
6
0
30
0
30
0
20
0
17
5
15
0
12
5
N/
A
35
0
20
0
20
0
15
0
10
0
25
0
25
0
u
rrent throu
e
levels are
b
duty cycle
s
AC, 10 a
m
d
raw due to
0
.31(A) (2)
D
n
ded Line
m
peres)
5
5
0
0
0
0
0
0
0
5
0
5
A
0
0
0
0
0
0
0
gh a 2000
a
b
ased on th
e
Revised
N
rating) may
m
pere (for Bl
a
the duty cy
c
D
uty Cycle
M
Recomm
e
Size
(
2
2
6
6
6
6
0
0
2
2
4
4
N
2
0
0
2
2
2
2
a
mp/100 m
v
e
duty cycle
N
ovember 201
Page | 1-
be found o
n
a
ck Light)
c
le. Refer t
o
M
ultiplicatio
n
e
nded Wire
(
AWG)
2
2
6
6
6
6
0
0
2
2
4
4
N
/A
2
/0
0
0
2
2
2
/0
2
/0
v
shunt.
of the unit.

5
4
n
o
n

D-20
0
Ta
b
D
-
D
-
Ta
b
D-2
D-2
0
0 Series
b
le 1-2. Ma
g
Model
Series
D-2060
D-2100
-
2100XL4
-
2100XL5
b
le 1-3. Du
t
M
060 SERIE
S
A
t Maximu
m
A
t 1000 A.
O
100 SERIE
S
A
t Maximu
m
A
t 1000 A.
O
g
netization
Mod
e
Conta
c
12” C
o
16” C
o
20” C
o
25” C
o
30” C
o
36” C
o
Conta
c
12” C
o
16” C
o
20” C
o
25” C
o
Conta
c
25” C
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25” C
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odel Serie
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S
m
Output
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and Dema
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c
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aximum C
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Ave
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6
4
4
4
4
1
4
1
6
1
6
Output
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rrent (Am
p
r
age (DC)
6
000
4
600
4
400
4
200
4
000
3
000
3
000
1
0000
5
800
5
200
5
000
4
700
1
0000
8
000
6
000
1
0000
7800
6
000
Seconds
“
0.5
0.5
0.5
0.5
p
eres)*
C
C
C
C
“
On”
Current
Control
C
ontinuousl
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In all cases
C
ontinuousl
y
Variable
In all cases
C
ontinuousl
y
Variable
In all cases
C
ontinuousl
y
Variable
In all cases
S
Revised
N
D
e
y
s
Re
v
Deca
y
y
s
Re
v
Deca
y
y
s
Re
v
Deca
y
y
s
Re
v
Deca
y
S
econds “O
f
10
5
20
5
N
ovember 201
Page | 1-
e
mag
v
ersing
y
ing DC
v
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y
ing DC
v
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ing DC
v
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f
f”
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5
5

D-20
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Di
m
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Usi
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Usi
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Usi
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Eq
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Ta
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M
o
D-
2
D-
2
D-
2
D-
2
D-
2
Ta
b
D-
2
D-
2
D-
2
D-
2
D-
2
0
0 Series
m
ensions a
b
le 1-4. Pa
r
ng contact p
a
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a
ng rail mount
u
ipped with h
e
b
le 1-5. Pa
r
o
del No.
2
***
2
***L
2
***XL
2
100XL4
2
100XL5
b
le 1-7. Ma
Mod
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2
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2
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2
***XL
2
100XL4
2
100XL5
nd Capaci
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t Weight C
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Des
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a
pacity
Len
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54" (13
102" (2
5
146" (3
7
243” (6
1
278” (7
0
ht
A
P
c
ription
p
port par
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p
port part (wi
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th
7 cm)
5
9 cm)
7
0 cm)
1
7 cm)
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6 cm)
A
pproximat
e
ounds
1600
1825
1925
th rotating h
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Ta
b
Mo
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D-2
D-2
D-2
D-2
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Weight (
D
Kilogr
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72
6
82
8
87
3
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ads)
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s to support
p
b
le 1-6. Re
c
d
el No.
060 (2 door
)
060L (3 do
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060XL (4 d
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060XL2 (5
d
D
ry)
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ms
6
8
3
P
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3
1
p
ar
t
4
c
ommende
d
Ga
)
o
r)
o
or)
d
oor)
Approxim
a
Pounds
1875
2100
2200
6600
7500
Revised
N
Maximum
L
o
unds
K
3
00
70
1
500
4
000
d
Bath Lev
e
llons L
i
20
34
46
58
a
te Weight (
Kilo
8
9
9
3
3
N
ovember 201
Page | 1-
Load
K
ilograms
136
32
680
1814
e
l
i
ters
76
129
174
220
Crated)
o
grams
8
50
9
52
9
98
000
400
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5
6

D-20
0
Tab
l
Basi
c
Le
n
De
p
He
i
Basi
c
Le
n
De
p
De
p
He
i
He
i
0
0 Series
l
e 1-8. Ove
Descript
c
Unit (No H
o
n
gth
p
th
i
ght
c
Unit (Optio
n
n
gth
p
th (Hood
O
p
th (Hood
C
i
ght (Hood
O
i
ght (Hood
C
rall Dimen
s
ion
o
od)
n
al Hood)
O
pened)
C
losed)
O
pened)
C
losed)
s
ions
D-2***
84½ (215c
m
41(104c
m
60¼(153c
m
86(218c
m
50(127c
m
73(185c
m
120(305c
m
89½(227c
m
D-2
*
m
)
m
)
m
)
132½(
3
41(10
4
60¼(1
5
m
)
m
)
m
)
m
)
m
)
135(3
3
50(12
73(18
120(3
0
89½(2
2
*
**L
D
3
36cm)
4
cm)
5
3cm)
17
6
4
6
0
3
6cm)
7cm)
5cm)
0
5cm)
2
7cm)
1
7
5
7
1
2
8
9
D
-2***XL
6
½(448cm)
4
1(104cm)
0
¼(153cm)
7
8(452cm)
5
0(127cm)
7
3(185cm)
2
0(305cm)
9
½(227cm)
D-2100
X
280½(71
2
41(104
c
60¼(15
3
N/
A
Revised
N
X
L4
D
2
½cm)
c
m)
3
cm)
31
7
4
60
¼
A
N
ovember 201
Page | 1-
D
-2100XL5
7
½(806½c
m
4
1(104cm)
¼
(153cm)
N/A

5
7
)

D-2000 Series Revised November 2015
Page | 2-1
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 90-120 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 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 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 [e-mail].
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.

D-2000 Series Revised November 2015
Page | 2-2
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 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 connection with an ohmmeter. A
reading of 0 ohms denotes an acceptable ground connection.
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.
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.
Figure 2-2
Figure 2-1
Figure 2-3

D-2000 Series Revised November 2015
Page | 2-3
Table 2-1. Recommended Fuse Size
D-2060 and D-2060 MOD 2.5 AC
Input Volts AC Phase Full Load (Amps) Line Fuse (Amps) Wire Size (AWG) Ground wire
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
Same as line
or larger
D-2100 and D-2100 MOD 4.0
Input Volts AC Phase Full Load (Amps) Line Fuse (Amps) Wire Size (AWG) Ground Wire
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
#4
#4
Same 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 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.

D-2000 Series Revised November 2015
Page | 2-4
Air Supply
Connect a 90-120 psig compressed air supply to the air filter. 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.
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
Figure 2-4
Figure 2-5

D-2000 Series Revised November 2015
Page | 2-5
normal operation. Figure 2-8 shows the front cover removed, however, you have to remove the entire cover to
do any maintenance.
Inspection Hood Installation (Optional)
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 2-9 below shows the separate fan and white light assembly. Figure 2-10 shows the hood
assembly.
Figure 2-8
Figure 2-7
Figure 2-10
Figure 2-9

D-2000 Series Revised November 2015
Page | 2-6
Figure 2-11
5. Place the Magnaflux machine on a solid surface and secure it based on Section 1 of this manual. Figure
2-11 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 2-12 and 2-13 below.
NOTE: Grilles have been removed for clarity
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 2-14 above.
Figure 2-12
Figure 2-13
Figure 2-14

D-2000 Series Revised November 2015
Page | 2-7
11. Side and rear curtains are folded on to the top curtain for convenience.
12. Be careful when doing this; the fan frame section and swivel frame section are not mounted to each other.
13. With a person on either side of the hood, carefully lift it onto the unit and insert the frame into the mounting
holes as shown in Figure 2-15 and Figure 2-16 below.
14. Verify the frame slides into the hole.
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 2-17 through 2-20.
Figure 2-15
Figure 2-16

D-2000 Series Revised November 2015
Page | 2-8
Figure 2-17 Figure 2-18
Figure 2-19 Figure 2-20
20. Now open the hood and stretch out the top curtain as show in Figure 2-21 and Figure 2-22 below.
21. Locate the four (4) mounting bolts on the stationary frame as shown in Figures 2-23 through 2-26.
NOTE: Two (2) are under the curtain.
Figure 2-21
Figure 2-22

D-2000 Series Revised November 2015
Page | 2-9
22. Remove nuts and set aside.
Figure 2-23 Figure 2-24
Figure 2-25 Figure 2-26
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.
24. Carefully ensure the white light clears the frames as shown in Figure 2-27 below.
Figure 2-27

D-2000 Series Revised November 2015
Page | 2-10
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 2-28 and 2-29.
27. Removing and re-orienting 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 2-28 Figure 2-29
Figure 2-30
28. String the fan cord along the frame and down to the outlet on the headstock side of the unit.
29. Plug into the twist lock marked for the hood as shown in Figure 2-30 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 2-31.

D-2000 Series Revised November 2015
Page | 2-11
Figure 2-31
31. Now the left and right side curtains can carefully be unfolded as shown in Figure 2-32 below.
32. Bring down the top curtain, carefully working the opening around the fan vent as shown in Figure 2-33.
33. Locate the front curtain and hang it from the front track with hooks as shown in Figure 2-34 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 2-35 on the next page.
Figure 2-32
Figure 2-33

D-2000 Series Revised November 2015
Page | 2-12
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.
Black Light Installation
1. Locate the three mounting bolts as shown in Figure 2-37 for the black light bracket and remove the
hardware. Place the bracket in place securing with the hardware provided as shown in Figure 2-38.
2. Orient the transformer so the light cord comes out towards the front of the unit. Then, slide the ballast
transformer into the slots provided. This is shown in Figure 2-39.
Figure 2-36
Figure 2-37
Figure 2-38
Figure 2-34
Figure 2-35