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
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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

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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.

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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.

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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.

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Output Specifications:
*All contacts current ratings are based on the maximum current through a 2000 amp/100 mv shunt.
Table 1-2. A/AD/ADH-2000 Series Magnetization and Demagnetization Output
Model
Series Mode
Maximum Current (Amperes)*
Current
Control Demag
RMS (AC) or
Average (DC) Peak
A-2030
Contacts AC
12” Coil AC
16” Coil AC
3000
975
825
4200
1310
1150
Continuously
variable
in all
cases
Decaying AC
in all cases
ADH-2045
Contacts AC
Contacts HW
12” Coil AC
12” Coil HW
16” Coil AC
16” Coil HW
20” Coil AC
20” Coil HW
25” Coil AC
25” Coil HW
4000
5000
1400
1600
1000
1400
800
1100
700
850
5600
7000
2000
2300
1400
2000
1200
1600
1000
1200
Continuously
variable in all
cases
Decaying AC
in all cases
AD-2045
Contacts AC
Contacts FW
12” Coil AC
12” Coil FW
16” Coil AC
16” Coil FW
20” Coil AC
20” Coil FW
25” Coil AC
25” Coil FW
4000
5000
1600
4500
1400
3900
1000
3500
800
3200
5600
7000
2200
6300
2000
5000
1400
4900
1100
4500
Continuously
Variable in all
cases
Decaying AC
in all cases
*Some coils may be capable of handling more current but these levels are based on the duty cycle of the unit.
Table 1-3. A/AD/ADH-2000 Series Duty Cycle
Output Selection Seconds “On” Seconds “Off”
At Maximum Output
0.5
10
At 1000 A. Output
0.5
5

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Dimensions and Capacities
Table 1-4. A/AD/ADH-2000 Series Part Weight Capacity Maximum Load
Description Pounds Kilograms
Using contact pad mounted v-blocks to support part 300 136
Using contact pad mounted v-blocks to support part (with rotating
heads) 70 32
Using rail mounted steady rests to support part 1500 680
Equipped with heavy duty frame option and rail mounted steady rests to
support part 4000 1814
Table 1-5. A/AD/ADH-2000 Series Part
Length Capacity
Table 1-6. A/AD/ADH-2000 Series
Recommended Bath Level
Model No. Length Model No. Gallons Liters
A-2*** 54" (137 cm) A-2*** 20 76
A-2***L 102" (259 cm) A-2***L 34 129
A-2***XL 146" (370 cm) A-2***XL 46 174
Table 1-7. A/AD/ADH-2000 Series Machine Weight
Model No.
Approximate Weight (Dry) Approximate Weight (Crated)
Pounds
Kilograms
Pounds Kilograms
A-2***
1600
726
1875
850
A-2***L
1825
828
2100
952
A-2***XL 1925 873 2200 998

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Table 1-8. A/AD/ADH-2000 Series Overall Dimensions
Description A/AD/ADH-2*** A/AD/ADH-2***L A/AD/ADH-2***XL
Basic Unit (No Hood)
Length
Depth
Height
84½ (215cm)
41(104cm)
60¼(153cm)
132½(336cm)
41(104cm)
60¼(153cm)
176½(448cm)
41(104cm)
60¼(153cm)
Basic Unit (With Optional Hood)
Length
Depth (Hood Opened)
Depth (Hood Closed)
Height (Hood Opened)
Height (Hood Closed)
86(218cm)
50(127cm)
73(185cm)
120(305cm)
89½(227cm)
135(336cm)
50(127cm)
73(185cm)
120(305cm)
89½(227cm)
178(452cm)
50(127cm)
73(185cm)
120(305cm)
89½(227cm)
EQUIPMENT WARRANTY
The Equipment Warranty Statement can be found on our Web site at the following link:
https://www.magnaflux.com/Files/Corporate/Equipment-Warranty-Statement.pdf

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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 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 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.
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:

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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. Ensure that the plug on J8 on SCR firing board (located on the REC stack) has been selected to 50Hz or
60Hz operation (whichever is applicable). 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.
3. 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 the rear headstock side panel has been removed. This is the location for the electrical
connection. Figure 2-2 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.
Air Supply
Connect a 60-100 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.
Figure 2-1
Figure 2-2
Figure 2-3

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Figure 2-4 Figure 2-5
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 into
the outlet located on the operator’s end of machine. Figures 2-6 below shows the pump as it is shipped and
normal operation. Figure 2-7 shows the front cover removed, however, you have to remove the entire cover to
do any maintenance.
Figure 2-6
Figure 2-7

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NOTE: The following procedure should be performed by a qualified maintenance technician.
Ammeter Accuracy Verification
1. With the unit electrically installed, the compressed air supply connected, and the inspection hood
(optional) installed, connect the foot switch to the foot switch receptacle or the optional Dual Palm to
the Dual Palm receptacle on the left side of unit. Refer to Figure 2-8 to locate both receptacles.
Figure 2-8
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 (Magnaflux Accessory Part #622350) as shown in Figures 2-9
and 2-10 on the following page, and specified in Table 4-5, between the headstock and tailstock.
Figure 2-9 Figure 2-10
Dual Palm Receptacle
Foot Switch Receptacle

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4. Connect the shunt cable leads to 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; Operator HMI and power indicator will light.
7. If equipped with the AUTOBATH option, toggle AUTOBATH and PUMP buttons to off. If equipped with
the AUTOMAG option, toggle AUTOMAG to off.
8. Press the foot switch or the Optional Dual Palm to firmly clamp the shunt in position between the
headstock and tailstock.
9. Press CONTACTS push-button to on.
10. Set the amperage using the CONTACT current control or use the AMPERAGE SETPOINT on the HMI
to a desired value.
11. Select AC waveform on the HMI and set digital test meter to AC.
12. Press MAG push-button. After the timed “shot,” both the unit’s digital ammeter and test kit ammeter
should display within ±10% or 50 Amps whichever is greater.
13. Repeat steps 10-12 at various setpoints as required.
14. Select DC waveform on the HMI. NOTE: AD-2045 units have FWDC waveform and ADH-2045 units
have HWDC waveform. Set the digital test meter to FWDC or HWDC based on type of unit.
15. Set the amperage using the CONTACT current control or use the AMPERAGE SETPOINT on the HMI
to a desired value.
16. Press MAG push-button. After the timed “shot,” both the unit’s digital ammeter and test kit ammeter
should display within ±10% or 50 Amps whichever is greater.
17. Repeat steps 14-16 at various setpoints as required
Coil Ammeter Accuracy Verification
1. This unit is designed with one meter. The signal 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 all
modes.

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Preparation of Bath
WARNING: Never operate the pump without bath in the tank. Operation of the pump without bath
may overheat 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 re-circulate, followed by a thorough water
rinse. If using oil bath, flush system with light oil (Specification MIL-L-15016) such as Magnaflux
Carrier II.
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 button on the HMI. The button is white when on and brighter when on. Allow the bath to
agitate and circulate through the system.
Table 2-1. Recommended Bath Concentration
Magnaglo® Magnaflux® Water Conditioners
14A MG-410 20B 7C WA-2B WA-4
Recommended Concentration
Ounces/Gallon
Grams/Liter
1/6
1.25
1/10
0.75
1½
11.25
1¼
9.4
1
10.0
1 Part to
100 parts
water
Settling Volume (ml/100 ml bath) 0.15-0.25 0.05-0.15 0.15-0.25 1.1-1.7 N/A N/A
Use Centrifuge Tube Part # 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.
a. Run the suspension through spray nozzle for at least one minute to assure the suspension in the
hose is fresh and agitated.
2. Using the spray nozzle, fill the centrifuge tube with agitated solution to 100 ml.

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3. Centrifuge tube with solution should be demagnetized by one of the following methods:
a. Hold centrifuge tube with solution in the middle of the coil and initiate a demag cycle (1000A or
higher).
OR
b. Run the centrifuge tube with solution through a stand-alone demagnetization unit (S or SB-Series).
4. Place the centrifuge tube in its stand (Magnaflux Accessory Part #1837A), and allow the suspension to
settle for thirty minutes (water bath) or sixty minutes (oil bath) in a vibration-free location.
5. Observe the total level of settled particles. Graduations read directly in milliliters (ml). If a contaminant
layer is present, subtract from the total level to obtain magnetic particle concentration.
6. Illuminate the centrifuge tube and suspension with a black light (Optional). Fluorescence in the liquid
or presence of a non-fluorescent 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 through 5 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 (Optional).
2. Open the drain cock at the rear of the inspection unit, drain all bath solution into a suitable container
and discard the used solution.
3. Remove and clean the grilles, agitator vee; then, replace these back on the unit, and close the drain
cock. The tank and spray nozzle can be cleaned using compressed air.
4. Open the valve 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.

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6. Disconnect the foot switch or Dual Palm (Optional), and the black light (Optional). 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) curtains for added protection.
Long Term Storage and/or Shipment
1. Open the Autobath valve (Optional).
2. Open the drain cock at the rear of the inspection unit, drain all bath solution into a suitable container
and discard the used solution.
3. Remove and clean the grilles, agitator vee; then, replace these back on the unit, and close the drain
cock. The tank and spray nozzle can be cleaned using compressed air.
4. Open the valve at the bottom of the regulator/gauge/filter bowl, and blow out. Then, shut off the air
supply to the machine.
5. Lock the tailstock assembly close to the headstock.
6. Disconnect power from the inspection unit by placing the external disconnect switch in the off position.
Disconnect the conductors from the terminal block. Disconnect the ground conductor from the brass
grounding screw.
7. Disconnect the foot switch or Dual Palm (Optional) and the black light (Optional). Pack and store in a
plastic bag or carton on the grilles.
8. Support the hood (Optional) 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.
9. Remove the mounting screws and shims securing the inspection unit to the floor.
10. 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 ensure safe transportation to the point of delivery. Estimated
shipping dimensions and weight are listed in Tables 1-7 and 1-8. Mark the crate(s) clearly to identify
the contents and denote which side is to be up.

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SECTION 3: OPERATING INSTRUCTIONS
OPERATING CONTROLS AND INDICATORS
Table 3-1. General Bench Key for Figure 3-1
Item 1: Foot Switch Item 6: Headstock
Item 2: Power Indicator Item 7: Spray Nozzle
Item 3: Headstock Pressure Regulator/Gauge
Item 8: Coil
Item 4: Operator Control Cabinet (Figure 3-5) Item 9: Tailstock
Item 5: Magnetic Current Push-button Item 10: Push Bar
NOTE: Adjustment of the pressure regulator for higher or lower pressures will also result in higher or lower
clamping forces. Proper adjustment assures proper clamping force without distorting the test part. Too
low of pressure can cause arcing on the part at high amperage.
Figure 3-1
1
2
3
4
5
6
7
8
9
10

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Adjustment of Magnetizing Shot Duration
NOTE: The duration of the magnetizing shot is set at 0.5 seconds from the factory.
1) Select Item 4 in Figure 3-3 to the desired shot time. The range is from 0.5 to 2 seconds. A shot timer
(Magnaflux Accessory Part Number 622646) should be used to provide the actual shot time that has
been set.
Figure 3-3
1
2
3
Figure 3-2 (A-2030 unit shown)
1
2
4
5
7
6
8
9