Magnaflux D-2000 Series User manual

D-2000 Series Revised March 2020
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D-2000 SERIES

D-2000 Series Revised March 2020
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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 .................................................................................... 2-8
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 ..................................................................................................... 3-10
Demagnetization ................................................................................................................. 3-11
Shutdown ............................................................................................................................ 3-12
Emergency Shutdown......................................................................................................... 3-12
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 Stack (Firing Board) ................................................................................... 5-1
Troubleshooting Guide.......................................................................................................... 5-2
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 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 with ASTM E-1444. Calibration frequency is
dictated by this standard.

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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 D-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 3-phase full wave direct current for magnetization and
reversing 3-phase full wave direct current for demagnetization.
The output current levels are governed by either 2 separate current control encoders 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-circu-
lates the particle in 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 amperes (for Black Light)
COMPRESSED AIR (1/8” NPT pipe connection) 90-120 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. Electrical Input
Model
Series
Input Volts
AC
Phase
Load
(Amperes)
Recommended Line
Fuse (Amperes)
Recommended Wire
Size (AWG)
D-2060
(SEE MOD AC
options below)
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
D-2100
(SEE MOD AC
options below)
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
MOD6 AC
(Optional for
D-2060 and
D-2100)
208
230
380
415
460
575
N/A
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
D-2100XL4
460
3
350
250
2/0
D-2100XL5
460
3
350
250
2/0
Output Specifications
*All contacts current ratings are based on the maximum current through a 2000 amp/100 mv shunt.
*Some coils may be capable of handling more current but these levels are based on the duty cycle of the unit.

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Table 1-2. Magnetization and Demagnetization Output
Model
Series Mode
Maximum Current (Amperes)* Current
Control Demag
Average (DC)
D-2060
Contacts
12” Coil
16” Coil
20” Coil
25” Coil
30” Coil
36” Coil
6000
4600
4400
4200
4000
3000
3000
Continuously
Variable
In all cases
Reversing
Decaying DC
D-2100
Contacts
12” Coil
16” Coil
20” Coil
25” Coil
10000
5800
5200
5000
4700
Continuously
Variable
In all cases
Reversing
Decaying DC
D-2100XL4
Contacts
25” Coil
Split Coil
10000
8000
6000
Continuously
Variable
In all cases
Reversing
Decaying DC
D-2100XL5
Contacts
25” Coil
Split Coil
10000
7800
6000
Continuously
Variable
In all cases
Reversing
Decaying DC
Table 1-3. Duty Cycle
Model Series Seconds “On” Seconds “Off”
D-2060 SERIES
At Maximum Output
At 1000 A. Output
0.5
0.5
10
5
D-2100 SERIES
At Maximum Output
At 1000 A. Output
0.5
0.5
20
5

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Dimensions and Capacities
Table 1-4. Part Weight Capacity
Description
Maximum Load
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. Part Length Capacity
Table 1-6. Recommended Bath Level
Model No.
Length
Model No.
Gallons
Liters
D-2*** 54" (137 cm) D-2060 (2 door) 20 76
D-2***L
102" (259 cm)
D-2060L (3 door) 34 129
D-2***XL 146" (370 cm) D-2060XL (4 door) 46 174
D-2100XL4 243” (617 cm)
D-2060XL2 (5 door) 58 220
D-2100XL5 278” (706 cm)
Table 1-7. Machine Weight
Model No.
Approximate Weight (Dry)
Approximate Weight (Crated)
Pounds
Kilograms
Pounds
Kilograms
D-2*** 1600 726 1875 850
D-2***L 1825 828 2100 952
D-2***XL 1925 873 2200 998
D-2100XL4 6600 3000
D-2100XL5 7500 3400

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Table 1-8. Overall Dimensions
Description D-2*** D-2***L D-2***XL D-2100XL4 D-2100XL5
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)
280½(712½cm)
41(104cm)
60¼(153cm)
317½(806½cm)
41(104cm)
60¼(153cm)
Basic Unit (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)
N/A N/A
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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PAGE LEFT BLANK
INTENTIONALLY

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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 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.