Magnaflux A-2000 Series User manual

A/AD/ADH-2000 Series Revised April 2020
www.magnaflux.com
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A/AD/ADH-2000 SERIES

A/AD/ADH-2000 Series Revised April 2020
www.magnaflux.com
Page | 1-1
TABLE OF CONTENTS
GENERAL SAFETY INSTRUCTIONS..............................................................................................1-2
SECTION 1 - EQUIPMENT SPECIFICATIONS................................................................................1-3
Scope of this Manual.............................................................................................................1-3
Purpose of the Equipment .....................................................................................................1-3
Equipment Characteristics.....................................................................................................1-3
Equipment Specifications ......................................................................................................1-4
Equipment Warranty..............................................................................................................1-7
SECTION 2 - INSTALLATION and STORAGE................................................................................2-1
General..................................................................................................................................2-1
Installation .............................................................................................................................2-1
Preparation for Storage or Shipment.................................................................................... 2-7
SECTION 3 - OPERATING INSTRUCTIONS...................................................................................3-1
Operating Controls and Indicators.........................................................................................3-1
Daily Start Up and Operation Checklist .................................................................................3-7
Piece Part Setup....................................................................................................................3-9
Magnetizing Procedures......................................................................................................3-11
Demagnetization..................................................................................................................3-12
Shutdown.............................................................................................................................3-12
Emergency Shutdown .........................................................................................................3-13
SECTION 4 - MAINTENANCE..........................................................................................................4-1
General..................................................................................................................................4-1
Daily Operator Maintenance..................................................................................................4-1
Weekly Operator Maintenance ..............................................................................................4-2
Monthly Operator Maintenance .............................................................................................4-2
Periodic Internal Maintenance ...............................................................................................4-2
Operational Checkout Procedures ........................................................................................4-4
Initial Set-up...........................................................................................................................4-4
Circular (Contact) and Longitudinal (Coil) Magnetization Check...........................................4-5
SECTION 5 – TROUBLESHOOTING...............................................................................................5-1
Troubleshooting Guide ..........................................................................................................5-1
SECTION 6 – DRAWINGS & SPARE PARTS LIST ........................................................................6-1
SECTION 7 – HOOD & BLACK LIGHT INSTALLATION ................................................................7-1
Hood Installation....................................................................................................................7-1
Black Light Installation...........................................................................................................7-8

A/AD/ADH-2000 Series Revised April 2020
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GENERAL SAFETY INSTRUCTIONS
This manual provides information on how to install, operate, and maintain your Magnaflux
magnetic particle inspection machine.
Read these instructions carefully before operating or servicing your machine.
•Only trained personnel should operate or service this machine. Be familiar with your facility and
local procedures as well as Lock Out/Tag Out requirements before working with this machine.
•Read this entire manual before operating this machine.
•Wear safety glasses that conform to ANSI Standard Z87.1 while operating this machine.
•Do not wear loose clothing or jewelry while operating or servicing this machine.
•Inspect the machine daily for unsafe conditions; replace any worn or broken parts (see Section 4).
•Keep all unauthorized personnel away from the machine operating area.
•According to the American Conference of Governmental Industrial Hygienists (ACGIH)
recommendations, inspectors with
pacemakers should avoid exposure to fields over 1.0 gauss. There
are a variety of pacemakers with different susceptibilities to
magnetic fields. Wearers should discuss
pacemaker limitations with their physicians and learn more exactly what they should avoid, and
whether they should be exposed to magnetic fields before operating this equipment.
•When you are finished operating the machine, turn off all power.
•This machine was designed to help the end user comply with ASTM E-1444, ASTM E-709, and
ASTM E-3024. Calibration frequency is dictated by these standards.

A/AD/ADH-2000 Series Revised April 2020
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SECTION 1: EQUIPMENT SPECIFICATIONS
SCOPE OF THIS MANUAL
This manual provides essential information required for installation, operation, and maintenance of standard
Magnaflux A/AD/ADH-2000 Series Stationary Magnetic Particle Inspection Machines.
PURPOSE OF THE EQUIPMENT
The equipment is used to inspect ferromagnetic parts by means of the magnetic particle inspection
method. Magnetic particle inspection (MPI) is a
non-destructive method for revealing surface, and, under certain
conditions, sub-surface discontinuities. It consists of three basic operations:
1. Application of magnetic particles.
2. Establishment of a suitable magnetic field.
3. Inspection and evaluation of particle accumulations.
Discontinuities may exist in raw material from which parts are made, or, they may occur during processing or
fabrication of the parts, or, they may exist as cracks due to excessive service stresses. Discontinuities are
considered defects if their existence is detrimental to the usefulness of the part. Magnetic particle inspection
can readily and reliably locate discontinuities revealing manufacturing and/or service-induced defects.
EQUIPMENT CHARACTERISTICS
Stationary magnetic particle inspection units consist of a processing station and an integral power pack. The
power pack provides low-voltage, high-amperage single-phase alternating current for magnetization and
decaying AC current for demagnetization.
The output current levels are governed by 2 separate current control potentiometers or the HMI. Selection of
Contacts or Coil operation is provided by push buttons on the Operator Control Panel. A push button on the
Operator Control Panel, or a push bar, initiates the timed magnetizing current “shot.”
A digital ammeter provides a reading of the magnetizing current. The reading is held until the next current “shot”
is
initiated. The wet bath is contained in a tank that runs the full length of the machine. A pump re-circulates and
agitates the particles in the bath and provides flow to the spray nozzle or the Optional Autobath nozzles.
Grilles cover the tank, provide a work surface, and prevent parts from falling into the tank.
The air-operated headstock and adjustable locking tailstock provide the necessary clamping force to assure
good electrical contact with the part.
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 filled with
magnetic particles. An ultraviolet black light causes the coated particles to glow, revealing flaws in the part
being tested.

A/AD/ADH-2000 Series Revised April 2020
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Pertinent data (e.g., the unit’s serial number, electrical specifications, and duty cycle rating) may be found on the
Magnaflux Data Plate, located on the headstock end of the unit.
EQUIPMENT SPECIFICATIONS
CONVENIENCE OUTLETS: 2 each 115 volts AC, 10 ampere (for Black Light)
COMPRESSED AIR (1/8” NPT pipe connection): 60-100 psig
Input Specifications
The equipment can be fused based on less than the maximum amperage draw due to the duty cycle. Refer to
NEC Code Section 630.31
Ampacity of Supply Conductors and Table 630.31(A) (2) Duty Cycle Multiplication
Factors for Resistance Welders (NPFA National Electric Code 2011).
Table 1-1. A/AD/ADH-2000 Series Electrical Input
Model
Series
Input Volts
AC Phase*
Load
(Amperes)
Recommended Line
Fuse (Amperes)
Recommended
Wire Size (AWG)
A-2030
208
230
380
415
460
575
1
1
1
1
1
1
240
200
120
110
100
80
180
150
90
90
80
60
#2
#2
#4
#6
#6
#6
ADH-2045
208
230
380
415
460
575
1
1
1
1
1
1
425
400
260
240
200
N/A
300
300
200
200
150
N/A
0
0
#2
#2
#4
N/A
AD-2045
208
230
380
415
460
575
1
1
1
1
1
1
350
300
175
160
150
120
250
250
125
125
125
100
2/0
#1
#3
#4
#4
#6
*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.