Magnaflux Universal WE TOUCH with TCODE User manual

Operating Manual
Universal WE TOUCH with TCODE
Multi-Directional Magnetic Wet Bench
Part number 022690

UNIVERSAL WE TOUCH TCODE
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2019-05-03

UNIVERSAL WE TOUCH TCODE (600/900) v.3 Identification
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2019-05-03
Identification
Machine data
Manufacturer
MAGNAFLUX GmbH
Machine type
UNIVERSAL WE TOUCH TCODE (600/900) v.3
Machine number
…
Customer
…
Country of application
…
Order
…
Year of manufacture
2019
Document
Document No.:
MX UWETOUCH_v.3
Version:
3
Issue date:
2019-05-03
© Copyright 1934-2019
MAGNAFLUX GmbH
All rights reserved. Reprinting, even in part,
only permitted with the approval of MAGNAFLUX
GmbH.
Manufacturer
MAGNAFLUX GmbH
Bahnhofstrasse 94-98
73457 Essingen
Germany
P: [phone]
F: [phone]
[email protected]om
www.eu.magnaflux.com

Structure of these operating instructions UNIVERSAL WE TOUCH TCODE (600/900) v.3
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Structure of these operating instructions
Chapter 1
Information for your safety
starting page 9
Chapter 2
Machine description
starting page 17
Operation and application
Chapter 3
Basis of operation
starting page 36
Chapter 4
Machine adjustments
starting page 53
Chapter 5
Workpiece testing
starting page 60
Chapter 6
Conduct during malfunctions
starting page 64
Chapter 7
Machine cleaning
starting page 65
Chapter 8
Machine maintenance
starting page 66
Supplementary instructions and information
Chapter 9
Machine transport
starting page 76
Chapter 10
Setting up the machine and commissioning it
starting page 80
Chapter 11
Take the machine out of operation and disposing of it
starting page 84

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Machine equipment
Individual limits of the machine
Workpiece length
70-600/900 mm (3”-23”/35”)
Workpiece diameter
max. 300 mm (11.8”)
Weight of the workpieces
max. 100 kg (220 lbs)
Activation cycle
Relative ED 60%, absolute ED max.30 s
ON/ 20 s OFF at 50% of nominal power
Power input
approx. 59/69 kVA
Magnetising
X
Magnetising circuit 1
max. 2000 A AC (effective value)
max. 3000 A AC (effective value) as
option
X
Magnetising circuit 2
max. 15.000 AW (amp-turns) AC
(effective value)
Magnetising circuit 1
Magnetising the circuit by axial current
flow or field current flow with inserted
or attached conductor at sleeve 1
Magnetising circuit 2
Longitudinal magnetising by yoke
(coil) magnetising
Spraying
X
Hand-held hose
-
Hand-held shower with push button (option)
-
Large-area shower or spray nozzles/shower heads (option)
-
Nozzles in the 5agnetizing coil (option)
UV lighting
-
UV hand-held lamp
Model: Magnaflux EV6000 (option)
-
UV panel lamp
Model: Magnaflux UV-LED 365-30
(option)
-
UV panel lamp
Model: Magnaflux ST700 (option)
Special equipment
-
Two-handed control (option)
X
Control panel with touch operation
-
T-Code Parameter Memory (option)
-
Dark booth (option)

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Table of contents
1General safety instructions...............................................................................9
1.1 Operating Manual ..................................................................................................... 9
1.2 Hazards when handling the machine...................................................................... 12
1.3 Emergency measures............................................................................................. 12
1.4 Magnetic loads at the workplace ............................................................................ 13
1.5 Mechanical hazards caused by driven machine parts............................................ 14
1.6 Risk of crushing due to heavy workpieces.............................................................. 14
1.7 Skin irritation caused by test substances................................................................ 14
1.8 High fire risk due to oily test liquids ........................................................................ 15
1.9 Obligations of the operating company.................................................................... 15
1.10 Defective protective and safety features................................................................. 16
1.11 Alterations or modifications..................................................................................... 16
1.12 Spare/ wear parts and consumables...................................................................... 16
2Machine description........................................................................................ 17
2.1 Intended use ........................................................................................................... 17
2.1.1 Specification of the workpieces.................................................................... 18
2.1.2 Limits of the machine.................................................................................... 18
2.2 Structure of the machine......................................................................................... 19
2.3 Safety equipment.................................................................................................... 20
2.4 Technical data......................................................................................................... 21
2.4.1 Dimensions and weights............................................................................... 21
2.4.2 Electrical data............................................................................................... 21
2.4.3 Magnetising circuits...................................................................................... 22
2.4.4 Clamping devices for the workpiece............................................................. 23
2.4.5 Workpiece holders........................................................................................ 23
2.4.6 Pneumatics................................................................................................... 23
2.4.7 Test liquid system......................................................................................... 23
2.4.8 UV-LED lamp (sample)................................................................................. 24
2.4.9 Ambient conditions ....................................................................................... 24
2.4.10 Emissions ..................................................................................................... 24
2.5 Operator work stations............................................................................................ 25
2.6 Markings and type plate on the machine................................................................ 25
2.7 Testing liquid system and spraying of the workpiece ............................................. 26
2.8 Pneumatic Maintenance Unit.................................................................................. 29
2.9 Individual test sequence ......................................................................................... 30
2.10 Home position of the machine ................................................................................ 30
2.11 Magnetising the workpiece ..................................................................................... 31
2.11.1 Constant current control............................................................................... 31
2.11.2 Current flow monitoring ................................................................................ 31
2.11.3 Magnetising types in accordance with EN ISO 9934-1................................ 32
2.11.4 Demagnetising of workpieces....................................................................... 33
2.12 Lighting on the workstation..................................................................................... 34
2.13 Visual inspection..................................................................................................... 35
3Basis of operation ........................................................................................... 36
3.1 Option: Two-handed operation ............................................................................... 36
3.2 Pedal switch............................................................................................................ 36
3.3 Touch control panel on the main control panel....................................................... 37
3.3.1 Screen layout................................................................................................ 37
3.3.2 Automatic mode............................................................................................ 38
3.3.3 Automatic T-Code mode............................................................................... 40
3.3.4 “Edit T-Code” screen .................................................................................... 42
3.3.5 Manual operation mode................................................................................ 43
3.3.6 “Options” screen ........................................................................................... 45
3.3.7 Screen “User Administration” ....................................................................... 48
3.3.8 “Commissioning (IBN)” screen ..................................................................... 49
3.4 Switching the machine ON and OFF ...................................................................... 50

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3.4.1 Emergency shut-down..................................................................................50
3.4.2 Before switching the machine ON ................................................................50
3.4.3 Switching the machine ON ...........................................................................50
3.4.4 Reactivating the machine after an emergency stop .....................................51
3.4.5 Switching off the machine.............................................................................51
3.5 Select operating mode ............................................................................................52
4Machine adjustments ......................................................................................53
4.1 Filling the test liquid tank.........................................................................................53
4.2 Overview of setting tasks........................................................................................53
4.3 Set the distance between the sleeves ....................................................................53
4.4 Replacing the magnetising mandrel (central conductor) ........................................55
4.5 Setting the magnetising parameters .......................................................................57
4.6 Manage users..........................................................................................................59
5Inspecting workpieces ....................................................................................60
5.1 Safety instructions...................................................................................................60
5.2 Testing the workpiece in automatic mode...............................................................61
5.3 Manual mode...........................................................................................................62
5.4 Replacing the test liquid..........................................................................................63
6What to do in the event of a fault....................................................................64
7Machine cleaning.............................................................................................65
7.1 Clean the magnetising station.................................................................................65
7.2 Clean the test liquid tank.........................................................................................65
8Maintenance.....................................................................................................66
8.1 Maintenance schedule ............................................................................................66
8.2 Inspection instructions.............................................................................................68
8.2.1 Where available: Checking the EMERGENCY STOP button.......................68
8.2.2 Where available: Checking the two-handed control.....................................68
8.2.3 Measuring the magnetising field strength.....................................................69
8.2.4 Magnetising testing.......................................................................................70
8.2.5 Checking the test liquid concentration..........................................................71
8.2.6 Verifying the test liquid indication capability .................................................72
8.2.7 Checking the UV Intensity ............................................................................73
8.3 Maintenance instructions ........................................................................................74
8.3.1 Drain the compressed air water separator....................................................74
8.3.2 Filling oil into the dosing oiler........................................................................74
8.3.3 Cleaning the magnetising contacts...............................................................75
8.3.4 Cleaning the contacts of the high-current connections.................................75
9Machine transport............................................................................................76
9.1 Transport preparation..............................................................................................76
9.2 Transport in original packaging...............................................................................76
9.3 Unpacking the machine...........................................................................................77
9.4 Machine transport ...................................................................................................77
9.4.1 Transporting the magnetising station with a forklift ......................................78
9.4.2 Transporting the magnetising station with a crane.......................................79
10 Setting up the machine and commissioning it..............................................80
10.1 Setting up the machine ...........................................................................................80
10.2 Connecting the power supply..................................................................................81
10.3 Connecting the test liquid pump..............................................................................82
10.4 Initial commissioning...............................................................................................82

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10.4.1 Safety instructions ........................................................................................ 82
10.4.2 Preparatory tasks ......................................................................................... 83
10.4.3 Checking functions and magnetising............................................................ 83
11 Decommissioning and disposal .....................................................................84
11.1 Safety instructions for decommissioning ................................................................ 84
11.2 Temporary machine decommissioning................................................................... 84
11.3 Final machine decommissioning............................................................................. 84
11.4 Final machine disposal ........................................................................................... 85

UNIVERSAL WE TOUCH TCODE General safety instructions
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1 General safety instructions
1.1 Operating Manual
The operation manual must be stored at the operating location at all
times! The operating manual must be freely accessible for operating
and maintenance personnel at all times.
You must read the general safety instructions. They form the basis for
safe operation. Specific warnings and safety instructions are provided
before each individual task instruction
Purpose of the operating manual
This operating manual
•describes the function, operation, maintenance and disposal of the
machine and
•provides important information for the safe and efficient use of the entire
system and its individual components.
The operating instructions must be handed over with the machine in case of
a location change or change of ownership.
Location references in the operating manual
All directional and location references given in this manual refer to the main
workstation at the front of the machine.
Location references in the operating manual
[1]
rear
[2]
right
[3]
front
[4]
left

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Action instructions
All tasks of the operating personnel are presented in a numbered list. Follow
the prescribed sequence of actions!
1
Operating action step 1
2
Operating action step 2
→System response to operating action 2
Safety instructions
Safety instructions
•warn of immediate or possible hazards;
•inform about hazard prevention measures;
•describe measures for minimising risk;
•offer important information for safety-conscious behaviour.
Safety instructions are denoted by a pictogram and a signal word.
•The pictogram describes the type of hazard.
•The signal word describes the severity of the hazard
Comply with safety instructions to avoid injury to yourself, to others, and
damage to material assets.
Signal words and symbols in safety instructions
DANGER
Immediate danger to life and health of personnel
(severe injury or death).
WARNING
Possible danger to life and health of personnel (severe
injury or death).
CAUTION
Possibly dangerous situation. Possible danger of injury
to personnel or material damage.
ATTENTION
Possibly dangerous situation. Possible danger of
material damage.
Warning of immediate or possible dangers.
Rule: Requirement for a specific behaviour or activity.
Measures to be absolutely observed!
Prohibition: Prohibits certain activities or conduct.

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Hazard symbols in warning instructions
Danger due to high voltage. Possibility of electric shock
currents and burns. Comply with preventive measures
and safety rules.
Danger due to self-starting machines or components. Do
not remove or render inoperative any safety features.
Danger due to lifted loads. Danger of crushing when
loads are lowered. Danger from falling parts. Do not step
under raised loads.
Danger from powered components. Body parts and
clothing can be caught, pulled in and crushed. Do not
reach into powered components.
Danger of crushing for fingers and hands. Do not
remove any protective covers.
Danger of crushing to the body due to heavy workpieces
and/or powered machine components.
Danger due to hot surfaces. Burn hazard. Components
must only be touched after cool-down period has
elapsed or with hand protection.
Danger due to magnetic fields. Danger of interference
with medical implants. Access is prohibited for personnel
with medical implants.
Hazards due to UV radiation. Possible damage to skin or
eyes. Do not operate UV lamps without filter. Wear
personal protection equipment.
Fire hazard due to flammable substances. Avoid sparks
and naked flame. Keep fire extinguishers at hand.
Danger due to noxious substances. Avoid physical
contact. Read the safety data sheets of these
substances.
Danger of falling. Utilise safety equipment. Use suitable
climbing aids.
Danger of slipping on spilt products or auxiliary
substances. Cordon off area and clean the floor. Use
binding agents where necessary.
Danger due to magnetic fields. Access prohibited for
persons with pacemakers and other medical implants!
Danger due to magnetic fields. Access prohibited for
persons with metallic implants.

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1.2 Hazards when handling the machine
Machine operation may pose hazards and adverse effects
•to the life and limb of operators or third parties,
•to the machine itself,
•and to other material assets.
Familiarity with the safety regulations and user instructions contained in this
manual forms the basis for safe handling and trouble-free operation of this
machine.
Severe injury to personnel and damage to material assets may be caused by
•improper installation and set-up,
•improper use,
•prohibited removal of safety covers or safety features.
Always comply with locally applicable safety regulations!
1.3 Emergency measures
In the event of an emergency, press the emergency stop button (where
available) or disconnect the machine from mains power immediately.
The main switch isolates the machine from mains power.
•The OFF position is marked “0”.
•The ON position is marked “1”.
The machine is isolated from mains power when the main switch is in the
OFF position.
The main switch can be locked in OFF position with a padlock.

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1.4 Magnetic loads at the workplace
WARNING
Magnetising may interfere with the proper function of pacemakers and other
medical implants, e.g. insulin pumps.
Lingering in the vicinity of the machine or within a perimeter of 5 m around
the magnetising station is prohibited for
•persons wearing medical aids and magnetisable implants
•pregnant women
•for persons under the age of 16
High magnetic field strengths during magnetising may cause damage
to health and have negative effects on medical implants.
•Comply with general and location-specific accident prevention
regulations.
•Maintain safety distance during magnetising.
The specified safety distance results from the limit values from
•the German accident prevention regulation DGUV V15 dated June 2001
•and the international guideline for the limitation of exposure to electrical,
magnetic and electromagnetic fields (ICNIRP) dated 2010.
In accordance with the German Accident Prevention Regulation DGUV V15,
the machine for magnetic crack testing is associated with exposure range 1.
Exposure range 1 applies to areas with controlled access, e.g. production
facilities.
Safety distance
Maintain the following safety distance from the magnetising device during
operation (magnetising current active):
•Persons without pacemakers: s=500 mm (1.5’)
•Persons with pacemakers: s=5000 mm (16’)
Areas of elevated exposure
Increased exposure will occur inside the marked areas (safety distance).
tmp-a008-000-00-00-00177
s

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The operating company is required to determine, document and mark areas
of increased exposure. It must be ensured that
•only authorised and trained personnel work in these areas and
•the permitted values for brief and partial bodily exposure are not
exceeded or
•personal protective equipment preventing unacceptable increased
exposure is used.
Important: Magnetic fields penetrate walls!
Recommendation!
Since areas of increased exposure correlate directly with local conditions, we
recommend generally prohibiting access to areas with strong magnetic fields
for
•persons using medical implants, e.g. pacemakers,
•pregnant women,
•persons under the age of 16.
1.5 Mechanical hazards caused by driven machine parts
Electromotive and pneumatically driven machine parts can pull in or
crush fingers and hands.
•The machine is not operated with the protective covers removed.
•Do not reach into the running machine.
•Switch off the main switch before carrying out any maintenance
work in the working area of the machine.
1.6 Risk of crushing due to heavy workpieces
Heavy workpieces can crush hands.
•Do not reach between workpieces and machine components during
loading and unloading.
•Use hand protection.
1.7 Skin irritation caused by test substances
Ingredients of the test substance may cause skin irritation or other
health issues.
•Always comply with the instructions provided in the manufacturer's
safety data sheet when handling test substances.

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1.8 High fire risk due to oily test liquids
Test oils are highly flammable! Fire hazard!
•Only use flame-retardant test oils with a flash point > 100°C.
(>212°F)
When using oily test liquids
•Have suitable fire extinguishers ready;
•always keep magnetising contacts clean;
•ensure compliance with instructions provided by the test liquid
manufacturer!
Dirty or corroded magnetising contacts, e.g. the folding coil, will lead to
excessive transition resistances at the contact points.
Contact points on the workpiece
The magnetising contacts must therefore be cleaned regularly. Maintenance
cycles are strongly dependent on use. Adjust maintenance intervals
according to your own experience.
1.9 Obligations of the operating company
The operating company undertakes to ensure that the machine is only
operated by persons, who
•are familiar with basic requirements regarding work safety and accident
prevention;
•have been trained in the operation of the machine;
•have read and understood this manual.
Contact the manufacturer with any remaining questions you may have.
Personnel training
The machine must only be operated by trained personnel. Personnel in
training must be supervised at all times when working on the machine.
Transport and set-up, supply line connections, commissioning, and
maintenance and repair work must only be performed by qualified personnel
with machine-specific training.

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Personal protection equipment (PPE)
The following PPE is required when operating the machine.
•Safety gloves
•Safety boots
•Skin protecting agents
The operating company is required to make available all necessary PPE.
1.10 Defective protective and safety features
Faulty or dismantled safety features may result in hazardous situations.
Therefore:
1
Switch off machine immediately.
2
Secure against reactivation.
3
If necessary, disconnect from mains power.
1.11 Alterations or modifications
Additions or modifications to the machine without prior written approval of
the manufacturer are not permitted. Please contact the manufacturer if you
are planning any conversions.
1.12 Spare/ wear parts and consumables
The use of spare/ wear parts supplied by third party manufacturers may be
hazardous. Only use OEM parts or parts approved by the manufacturer.
The manufacturer shall not accept any liability for damage caused by non-
approved spare parts, wear parts or consumables.

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2 Machine description
2.1 Intended use
Operational safety of this machine/system can only be guaranteed for the
intended use. The machine/installation is intended solely for materials testing
•of specified workpieces;
•using the magnetic powder process according to
–DIN EN ISO 9934-1:2002-03;
–DIN EN ISO 9934-2:2003-03;
–DIN EN ISO 9934-3:2002-10;
–ASTM E1444, E709, & E3024
•when stationary;
•within the limits specified below.
If there are any questions regarding optimised utilisation of the machine,
please contact the manufacturer.
Feeding the workpieces
The operating company must ensure that workpieces are checked and
fed into the magnetising station properly. The operating company must
supply all required equipment and ensure appropriate measures to
eliminate hazards due to moving or hoisted workpieces.
Use contrary to intended use
Use contrary to intended use can lead to injury or damage. The system must
not be operated
•in potentially explosive environments
•for mechanical or thermal processing of workpieces.
These types of use constitute a misuse of the system.
The operating company is solely responsible for any consequences
•from use other than intended use
•from actions not described in the operating manual.
The manufacturer accepts no liability for consequential damage. If used for
any other than the intended use, all warranty claims against the
manufacturer become null and void.
Work location
The system meets the requirements of the following standards with regards
to electromagnetic compatibility
•DIN EN 61000-6-4 VDE 0839-6-4:2011-09
Interference emission standard for industrial environments
•DIN EN 61000-6-2 VDE 0839-6-2:2006-03
Emission resistance standard for industrial environments
With regards to interference emission, the system is not suitable for use in
residential and small trade environments.

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2.1.1 Specification of the workpieces
Only workpieces complying with the following specification may be tested
with the machine using the magnetic particle inspection method:
Workpieces
Workpieces made of ferromagnetic materials with
a magnetic conductivity of µ>100.
Clamping
length
600/900 mm (23”/35”)
Diameter
max. 300 mm (11.8”) (11.8”)
Weight
max. 100 kg (220 lbs) (220 lbs)
Flammability
Not self-igniting under pressure, friction and heat
Explosiveness
Not self-exploding under pressure, friction and heat
Please contact the customer service department of the manufacturer with
any questions regarding the products to be tested.
2.1.2 Limits of the machine
Field strength in the
workpiece
> 32 A/cm
Magnetising circuit 1
Variably adjustable up to max. 3000 A AC
(effective value) as option
Magnetising circuit 2
max. 15.000 AW (amp-turns) AC (effective value)
Activation cycle
Relative ED 60%, absolute ED max.30 s ON/ 20
s OFF at 50% of nominal power
Throughput/h
Depending on loading/ unloading times,
magnetising times, and assessment times
Permissible
temperature range
for operation
min. 10 °C (50°F), max. 35 °C (95°F)
Service life
A comprehensive safety inspection by the
manufacturer is required after 10 years of
operation. Please contact the manufacturer's
customer service department in good time.
Testing area
Crack indication is restricted or even impossible
•in the case of workpieces that deviate substantially from the specification,
•in the area of the bearing and contact regions of the workpiece,
•if an unsuitable test liquid is used,
•in severely contaminated workpieces.

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2.2 Structure of the machine
Machine components (standard version)
[1]
Magnetising mandrels(central conductor), installed in the left
sleeve
[2]
Coil of the magnetisation yoke in the right sleeve
[3]
Magnetisation yoke right sleeve
[4]
Clamping cylinder right sleeve (If installed)
[5]
Test liquid tank
[6]
Test liquid pump
[7]
Right tailstock
[8]
Pneumatic maintenance unit with pneumatic connection
[9]
Transformer cabinet
[10]
Coil of the magnetisation yoke in the left sleeve
[11]
Clamping cylinder left sleeve
[12]
Control cabinet with operating elements (main control console)

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Magnetising station
Magnetising station
[1]
Clamping cylinder left sleeve
[2]
Coil of the magnetisation yoke in the left sleeve
[3]
Magnetising mandrels magnetising circuits 1 and 2
[4]
Workpiece supports
[5]
Mating contacts for magnetising mandrels
[6]
Coil of the magnetisation yoke in the right sleeve
[7]
Clamping cylinder right sleeve 1
[8]
Clamping cylinder right sleeve 2
[10]
Shower heads for test agent
[11]
Workpiece to be inspected
2.3 Safety equipment
WARNING
Only operate the equipment with all protection and safety features in place
and fully functional.
Check safety and protection features periodically.
The machine is equipped with the following safety and protection features:
•Main switch (mains isolation) on the control cabinet
•Two-hand control for activation of the pneumatic or electro-motor drives